10. ALTERNATOR/STARTER CLUTCH

Transcription

1 10. ALTERNATOR/STARTER CLUTCH SYSTEM COMPONENTS 10-2 SERVICE INFORMATION 10-3 TROUBLESHOOTING 10-3 LEFT CRANKCASE COVER REMOVAL 10-4 STATOR/IGNITION PULSE GENERATOR 10-5 FLYWHEEL/STARTER CLUTCH 10-6 LEFT CRANKCASE COVER INSTALLATION

2 ALTERNATOR/STARTER CLUTCH ALTERNATOR/STARTER CLUTCH SYSTEM COMPONENTS 74 N m (7.5 kgf m, 55 lbf ft) 10-2

3 SERVICE INFORMATION GENERAL ALTERNATOR/STARTER CLUTCH This section covers the removal and installation of the alternator stator, flywheel and starter clutch. These services can be done with the engine installed in the frame. Alternator inspection (page 15-8). Starter motor servicing (page 17-6). SPECIFICATION Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter driven gear boss O.D ( ) (1.795) TORQUE VALUES Starter clutch bolt 16 N m (1.6 kgf m, 12 lbf ft) Apply locking agent to the threads. Flywheel nut 74 N m (7.5 kgf m, 55 lbf ft) Apply engine oil to the threads and seating surface. Alternator stator socket bolt 12 N m (1.2 kgf m, 9 lbf ft) Ignition pulse generator socket bolt 12 N m (1.2 kgf m, 9 lbf ft) Apply locking agent to the threads. Wire guide socket bolt 12 N m (1.2 kgf m, 9 lbf ft) Apply locking agent to the threads. TOOLS Flywheel holder Flywheel puller KM10000 TROUBLESHOOTING Starter motor turns, but engine does not turn Faulty starter clutch Damaged starter motor pinion gear, starter reduction gear or shaft 10-3

4 ALTERNATOR/STARTER CLUTCH LEFT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-11). Remove the drive sprocket cover (page 2-8). Remove the left side cover (page 2-4). Disconnect the alternator 3P connector and ignition pulse generator 2P connector, then release them from the wire clamp. IGNITION PULSE GENERATOR 2P CONNECTOR ALTERNATOR 3P CONNECTOR Remove the gear position switch wire from the left crankcase cover. CLAMP The left crankcase cover (stator) is magnetically attracted to the flywheel, be careful during removal. Loosen the left crankcase cover bolts in a crisscross pattern in several steps. Remove the bolts and left crankcase cover. LEFT CRANKCASE COVER GEAR POSITION SWITCH WIRE Remove the dowel pins and gasket. BOLTS GASKET DOWEL PINS 10-4

5 STATOR/IGNITION PULSE GENERATOR REMOVAL Remove the left crankcase cover (page 10-4). Remove the following from the left crankcase cover: socket bolt and wire guide grommet two socket bolts and ignition pulse generator three socket bolts and alternator stator assembly ALTERNATOR/STARTER CLUTCH ALTERNATOR STATOR WIRE GUIDE GROMMET INSTALLATION SOCKET BOLTS IGNITION PULSE GENERATOR ALTERNATOR STATOR SOCKET BOLT 12 N m (1.2 kgf m, 9 lbf ft) GROMMET WIRE GUIDE SOCKET BOLT 12 N m (1.2 kgf m, 9 lbf ft) ALTERNATOR STATOR WIRE GUIDE IGNITION PULSE GENERATOR SOCKET BOLTS 12 N m (1.2 kgf m, 9 lbf ft) IGNITION PULSE GENERATOR Install the alternator stator assembly onto the left crankcase cover. Install the three socket bolts and tighten them to the specified torque. TORQUE: 12 N m (1.2 kgf m, 9 lbf ft) SOCKET BOLTS ALTERNATOR STATOR 10-5

6 ALTERNATOR/STARTER CLUTCH Apply liquid sealant to the wire grommet seating surface and install it into the cover groove. Apply locking agent to the bolt threads. Install the wire guide and ignition pulse generator onto the cover. Install the bolts and tighten them to the specified torque. TORQUE: 12 N m (1.2 kgf m, 9 lbf ft) Install the left crankcase cover (page 10-11). GROMMET IGNITION PULSE GENERATOR SOCKET BOLTS FLYWHEEL/STARTER CLUTCH REMOVAL Remove the left crankcase cover (page 10-4). Remove the collar, starter reduction gear shaft and reduction gear. WIRE GUIDE COLLAR STARTER REDUCTION GEAR Hold the flywheel with the special tool and loosen the flywheel nut. TOOL: Flywheel holder SHAFT FLYWHEEL HOLDER Remove the flywheel nut and washer. FLYWHEEL NUT WASHER FLYWHEEL NUT 10-6

7 ALTERNATOR/STARTER CLUTCH Remove the flywheel using the special tool. TOOL: Flywheel puller KM10000 FLYWHEEL FLYWHEEL PULLER Be careful not to damage the crankshaft. Remove the woodruff key and needle bearing. NEEDLE BEARING STARTER CLUTCH DISASSEMBLY Check that the starter driven gear turns counterclockwise smoothly and does not turn clockwise. Remove the starter driven gear from the flywheel while turning it counterclockwise. WOODRUFF KEY STARTER DRIVEN GEAR Hold the flywheel using the special tool and remove the starter clutch bolts. BOLTS TOOL: Flywheel holder Remove the starter clutch assembly from the flywheel. FLYWHEEL HOLDER 10-7

8 ALTERNATOR/STARTER CLUTCH INSPECTION Check the starter reduction gear, shaft and collar for wear or damage. REDUCTION GEAR COLLAR SHAFT Remove the starter sprag clutch from the clutch outer. Check the starter sprag clutch for abnormal wear or damage. Check the sprag clutch sliding surface of the clutch outer for abnormal wear or damage. SPRAG CLUTCH CLUTCH OUTER Check the starter driven gear for abnormal wear or damage. Measure the starter driven gear boss O.D. SERVICE LIMIT: mm (1.795 in) 10-8

9 ASSEMBLY ALTERNATOR/STARTER CLUTCH BOLTS 16 N m (1.6 kgf m, 12 lbf ft) DRIVEN GEAR CLUTCH OUTER SPRAG CLUTCH FLYWHEEL Apply engine oil to the starer sprag clutch. Install the sprag clutch into the clutch outer with its flange side facing the flywheel. SPRAG CLUTCH CLUTCH OUTER Install the starter clutch assembly onto the flywheel. FLYWHEEL STARTER CLUTCH ASSEMBLY 10-9

10 ALTERNATOR/STARTER CLUTCH Apply locking agent to the starter clutch bolt threads. Align the bolt holes in the flywheel and starter clutch, and install the bolts. Hold the flywheel with the special tool and tighten the bolts. TOOL: Flywheel holder BOLTS TORQUE: 16 N m (1.6 kgf m, 12 lbf ft) FLYWHEEL HOLDER Apply molybdenum oil solution to the starter driven gear inner surface. Apply engine oil to the starter driven gear sliding surface. Install the starter driven gear into the flywheel while turning it counterclockwise. Make sure that the starter driven gear turns counterclockwise smoothly and does not turn clockwise. STARTER DRIVEN GEAR INSTALLATION Apply engine oil to the needle bearing and install it onto the crankshaft. Install the woodruff key into the crankshaft key groove. Clean any oil from the tapered portions of the crankshaft and flywheel. NEEDLE BEARING WOODRUFF KEY Install the flywheel by aligning the key way with the key on the crankshaft. Align FLYWHEEL 10-10

11 ALTERNATOR/STARTER CLUTCH Apply engine oil to the flywheel nut threads and seating surface. Install the washer and flywheel nut. WASHER FLYWHEEL NUT Hold the flywheel with the special tool and tighten the flywheel nut. FLYWHEEL HOLDER TOOL: Flywheel holder TORQUE: 74 N m (7.5 kgf m, 55 lbf ft) Apply engine oil to the starter reduction gear shaft. Install the starter reduction gear, shaft and collar. Install the left crankcase cover (page 10-11). FLYWHEEL NUT COLLAR STARTER REDUCTION GEAR LEFT CRANKCASE COVER INSTALLATION Be careful not to damage the mating surfaces. Clean any gasket material from the mating surfaces of the left crankcase and cover. Install the dowel pins and a new gasket. GASKET SHAFT DOWEL PINS 10-11

12 ALTERNATOR/STARTER CLUTCH Install the left crankcase cover and bolts, and tighten the bolts in a crisscross pattern in several steps. LEFT CRANKCASE COVER BOLTS Route the wire properly (page 1-16). Route the gear position switch wire onto the left crankcase cover. GEAR POSITION SWITCH WIRE Route the wire properly (page 1-16). Route the wires into the clamp and connect the alternator 3P connector and ignition pulse generator 2P connector. Install the left side cover (page 2-4). Install the drive sprocket cover (page 2-8). IGNITION PULSE GENERATOR 2P CONNECTOR ALTERNATOR 3P CONNECTOR Fill the crankcase with the recommended engine oil (page 3-11). CLAMP 10-12

13 11. CRANKCASE/CRANKSHAFT/TRANSMISSION SYSTEM COMPONENTS 11-2 SERVICE INFORMATION 11-3 TROUBLESHOOTING 11-5 CRANKCASE SEPARATION 11-6 TRANSMISSION 11-8 CRANKSHAFT CRANKCASE BEARING CRANKCASE ASSEMBLY

14 CRANKCASE/CRANKSHAFT/TRANSMISSION CRANKCASE/CRANKSHAFT/TRANSMISSION SYSTEM COMPONENTS 10 N m (1.0 kgf m, 7 lbf ft) 11-2

15 SERVICE INFORMATION GENERAL CRANKCASE/CRANKSHAFT/TRANSMISSION The crankcase halves must be separated to service the transmission and crankshaft. To service these parts, the engine must be removed from the frame (page 6-4). Be careful not to damage the crankcase mating surfaces when servicing. Engine lubricating oil is fed through the oil passages in the crankcase. Clean the oil passages before assembling the crankcase halves. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Crankshaft Connecting rod big end radial clearance ( ) 0.05 (0.002) Connecting rod big end side clearance ( ) 0.80 (0.032) Runout 0.03 (0.001) 0.08 (0.003) Transmission Gear I.D. M ( ) (0.789) M ( ) (0.671) C ( ) (0.809) C2, C ( ) (0.908) Bushing O.D. C ( ) (0.804) C2, C ( ) (0.904) Gear-to-bushing clearance Shift fork, shift fork shaft C ( ) 0.10 (0.004) C ( ) 0.10 (0.004) C ( ) 0.10 (0.004) Bushing I.D. C ( ) (0.671) C2, C ( ) (0.790) Mainshaft O.D. at M ( ) (0.785) at M ( ) (0.667) Countershaft O.D. at C ( ) (0.667) at C ( ) (0.785) at C ( ) (0.785) Bushing-to-shaft clearance C ( ) 0.10 (0.004) C ( ) 0.10 (0.004) C ( ) 0.10 (0.004) Shift fork shaft O.D ( ) 9.93 (0.391) Shift fork I.D ( ) (0.396) Shift fork claw thickness ( ) 4.50 (0.177) TORQUE VALUES Mainshaft bearing setting plate bolt 12 N m (1.2 kgf m, 9 lbf ft) Apply locking agent to the threads. Push plug bolt 10 N m (1.0 kgf m, 7 lbf ft) Apply locking agent to the threads. Gearshift spindle return spring pin 22 N m (2.2 kgf m, 16 lbf ft) Apply locking agent to the threads. 11-3

16 CRANKCASE/CRANKSHAFT/TRANSMISSION TOOLS Sliding hammer weight Bearing driver attachment, Bearing driver attachment, Bearing driver attachment, Bearing driver attachment, Pilot, Pilot, Pilot, Pilot, Driver handle, L Bearing remover head, Bearing remover shaft,

17 TROUBLESHOOTING Excessive noise Worn, sized or chipped transmission gear Worn or damaged transmission bearing Worn or damaged connecting rod bearing Worn connecting rod small end Worn crankshaft bearing Hard to shift Bent shift fork Bent shift fork shaft Damaged shift drum guide groove Damaged shift fork guide pin Transmission jumps out of gear Worn gear dogs or dog holes Worn shift drum guide groove Worn shift fork guide pin Worn gear shifter groove Worn shift fork shaft Bent shift fork shaft CRANKCASE/CRANKSHAFT/TRANSMISSION 11-5

18 CRANKCASE/CRANKSHAFT/TRANSMISSION CRANKCASE SEPARATION Remove the following: engine (page 6-4) cylinder head (page 7-17) cylinder and piston (page 8-4) oil pump (page 4-4) clutch (page 9-8) kickstarter (page 9-21) primary drive gear (page 9-18) gearshift linkage (page 9-15) flywheel (page 10-6) starter motor (page 17-6) gear position switch (page 18-14) two bolts and cam chain guide setting plate cam chain guide cam chain bolt and push plug plate spring and push plug GUIDE CHAIN BOLT BOLTS SPRING PLATE three bolts and crankshaft bearing setting plates PUSH PLUG PLATE SETTING PLATES PUSH PLUG BOLTS right crankcase bolt BOLT 11-6

19 CRANKCASE/CRANKSHAFT/TRANSMISSION Loosen the thirteen left crankcase bolts in a crisscross pattern in 2 or 3 steps, and remove them. BOLTS Do not ply the crankcase halves. Place the crankcase assembly with the right side down. Carefully separate the left crankcase from the right crankcase while tapping them at several locations with a soft hammer. LEFT CRANKCASE RIGHT CRANKCASE Remove the dowel pins. DOWEL PINS Remove the countershaft oil seal from the left crankcase. COUNTERSHAFT OIL SEAL 11-7

20 CRANKCASE/CRANKSHAFT/TRANSMISSION TRANSMISSION DISASSEMBLY Separate the crankcase halves (page 11-6). Remove the shift fork shafts. Remove the shift forks and shift drum. SHIFT FORK SHAFTS SHIFT DRUM Remove the mainshaft and countershaft as an assembly. MAINSHAFT SHIFT FORKS COUNTERSHAFT Disassemble the mainshaft and countershaft. Keep track of the disassembled parts (gears, bushings, washers, and snap rings) by stacking them on a tool or slipping them onto a piece of wire. Clean disassembled parts in solvent thoroughly. COUNTERSHAFT INSPECTION GEAR/BUSHING/SHAFT Check the shifter groove for abnormal wear or damage. Check the gear dogs, dog slots and teeth for abnormal wear or damage. MAINSHAFT SHIFTER GROOVE DOG SLOT GEAR DOG 11-8

21 CRANKCASE/CRANKSHAFT/TRANSMISSION Measure the I.D. of each gear. SERVICE LIMITS: M4: mm (0.789 in) M5: mm (0.671 in) C1: mm (0.809 in) C2, C3: mm (0.908 in) Measure the O.D. of each bushing. SERVICE LIMITS: C1: mm (0.804 in) C2, C3: mm (0.904 in) Calculate the gear-to-bushing clearance. SERVICE LIMITS: C1, C2, C3: 0.10 mm (0.004 in) Measure the I.D. of each bushing. SERVICE LIMITS: C1: mm (0.671 in) C2, C3: mm (0.790 in) Check the spline grooves and sliding surfaces for abnormal wear or damage. Measure the mainshaft and countershaft O.D. SERVICE LIMITS: M4: mm (0.785 in) M5: mm (0.667 in) C1: mm (0.667 in) C2: mm (0.785 in) C3: mm (0.785 in) Calculate the bushing-to-shaft clearance. SERVICE LIMIT: C1, C2, C3: 0.10 mm (0.004 in) C2 M5 C3 M4 C1 SHIFT DRUM/SHIFT FORK/SHAFT Inspect the shift drum journals for scoring, scratches, or evidence of insufficient lubrication. Check the shift drum guide grooves for abnormal wear or damage. JOURNALS GUIDE GROOVES 11-9

22 CRANKCASE/CRANKSHAFT/TRANSMISSION Check the shift forks for deformation or abnormal wear. Measure each shift fork claw thickness. SERVICE LIMIT: 4.50 mm (0.177 in) Measure I.D. of each fork. SERVICE LIMIT: mm (0.396 in) Check the shift fork shafts for damage and straightness. Measure the shift fork shaft O.D. SERVICE LIMIT: 9.93 mm (0.391 in) ASSEMBLY Apply molybdenum oil solution to the gear and bushing sliding surfaces. Assemble all parts into their original positions. Check the gears for freedom of movement or rotation on the shaft. Do not reuse worn snap ring which could easily spin in the groove. Always install the thrust washers and snap ring with the chamfered (rolled) edge facing away from the thrust load. Install the snap ring so its ends aligns with the grooves in the splines. Make sure the snap ring is fully seated in the shaft groove after installing it. CORRECT SNAP RING INCORRECT 11-10

23 CRANKCASE/CRANKSHAFT/TRANSMISSION MAINSHAFT : Gear and bushing sliding surfaces M4 GEAR (26T) SPLINE WASHER SNAP RING M1 GEAR (13T) MAINSHAFT THRUST WASHER M3 GEAR (23T) M2 GEAR (19T) THRUST WASHER M5 GEAR (28T) SPLINE WASHER SNAP RING THRUST WASHER THRUST WASHER M4 GEAR (26T) M3 GEAR (23T) M5 GEAR (28T) M2 GEAR (19T) 11-11

24 CRANKCASE/CRANKSHAFT/TRANSMISSION COUNTERSHAFT : Gear and bushing sliding surfaces C4 GEAR (28T) SPLINE WASHER C3 BUSHING C3 GEAR (30T) THRUST WASHER C1 GEAR (40T) THRUST WASHER SNAP RING C1 BUSHING THRUST WASHER THRUST WASHER C2 BUSHING THRUST WASHERS SNAP RING COUNTERSHAFT SPLINE WASHER C2 GEAR (34T) THRUST WASHER C5 GEAR (26T) THRUST WASHERS THRUST WASHER C1 BUSHING C3 BUSHING C2 BUSHING C4 GEAR (28T) C5 GEAR (26T) C1 GEAR (40T) C3 GEAR (30T) C2 GEAR (34T) 11-12

25 Apply molybdenum oil solution to the gear shifter grooves. Apply clean engine oil to the gear teeth and engage the mainshaft and countershaft gears. CRANKCASE/CRANKSHAFT/TRANSMISSION Install the mainshaft and countershaft assemblies as a set into the left crankcase. MAINSHAFT COUNTERSHAFT Each shift fork has an identification marks; R/L for right and left shift forks, and C for center shift fork. "C" MARK "R/L" MARKS Install the shift forks into the shifter gear grooves with the marks facing up (left crankcase side). Apply engine oil to the shift drum journals and guide grooves in the and install the shift drum. Install the shift fork guide pins into the shift drum guide grooves. SHIFT DRUM SHIFT FORKS 11-13

26 CRANKCASE/CRANKSHAFT/TRANSMISSION Apply engine oil to the shift fork shafts and insert them through the shift forks into the right crankcase. Assemble the crankcase (page 11-17). SHIFT FORK SHAFTS CRANKSHAFT REMOVAL Remove the crankshaft from the right crankcase. CRANKSHAFT INSPECTION Set the crankshaft in a stand or V-blocks and measure the runout using a dial indicator. SERVICE LIMIT: 0.08 mm (0.003 in) 47.5 mm (1.87 in) 43.0 mm (1.69 in) Measure the side clearance between the connecting rod big end and crank weight with a feeler gauge. SERVICE LIMIT: 0.80 mm (0.032 in) 11-14

27 Measure the radial clearance at the connecting rod big end in an X and Y directions. SERVICE LIMIT: 0.05 mm (0.002 in) CRANKCASE/CRANKSHAFT/TRANSMISSION X Y Turn the outer race of the crankshaft bearing with your finger. The bearing should turn smoothly and quietly. Also check that bearing inner races fit tightly in the crankshaft. Replace crankshaft if the outer race does not turn smoothly, quietly or if the inner race fits loosely in the crankshaft. BEARING INSTALLATION Apply 1-2 cc of molybdenum oil solution to the connecting rod big end bearing. Install the crankshaft into the right crankcase. CRANKSHAFT CRANKCASE BEARING INSPECTION Remove the following: transmission (page 11-8) crankshaft (page 11-14) Turn the inner race of each crankcase bearing with your finger. The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the crankcase. Replace any bearing if the inner race does not turn smoothly, quietly or if the outer race fits loosely in the crankcase

28 CRANKCASE/CRANKSHAFT/TRANSMISSION RIGHT CRANKCASE BEARING REPLACEMENT CRANKSHAFT BEARING Remove the crankcase bearing inner race. Press the crankshaft bearing out of the crankcase. CRANKSHAFT BEARING Lubricate a new bearing with molybdenum oil solution. Press a new crankcase bearing into the crankcase using the special tools. TOOLS: Driver Attachment, 52 x 55 mm Pilot, Install a new crankcase bearing inner race. INNER RACE ATTACHMENT DRIVER BEARING TRANSMISSION BEARING Remove the bolts and mainshaft bearing setting plates from the crankcase. Drive the mainshaft and countershaft bearings out of the crankcase. BOLTS/ PLATES PILOT MAINSHAFT BEARING Apply engine oil to new bearings. Drive the bearings in the crankcase with the marked side facing up, using the special tools. TOOLS: Driver Attachment, 37 x 40 mm (mainshaft side) Attachment, 42 x 47 mm (countershaft side) Pilot, 17 mm COUNTERSHAFT BEARING DRIVER BEARING PILOT ATTACHMENT 11-16

29 CRANKCASE/CRANKSHAFT/TRANSMISSION Apply locking agent to the setting plate bolt threads. Install the mainshaft bearing setting plates and bolts, and tighten the bolts. TORQUE: 12 N m (1.2 kgf m, 9 lbf ft) BOLTS LEFT CRANKCASE BEARING REPLACEMENT Drive the countershaft bearing out of the crankcase. Remove the mainshaft bearing from the crankcase using the special tools. TOOLS: Remover head, 12 mm Remover shaft, 12 mm Remover weight MAINSHAFT BEARING PLATES BEARING REMOVER Apply engine oil to new bearings. Drive the bearings in the crankcase with the marked side facing up, using the special tools. TOOLS: Mainshaft bearing: Driver Attachment, 32 x 35 mm Pilot, 12 mm Countershaft bearing: Driver Attachment, 42 x 47 mm Pilot, 20 mm CRANKCASE ASSEMBLY Apply grease to new countershaft oil seal lips and install them into the left crankcase. COUNTERSHAFT BEARING ATTACHMENT COUNTERSHAFT OIL SEAL DRIVER BEARING PILOT GEARSHIFT SPINDLE OIL SEAL 11-17

30 CRANKCASE/CRANKSHAFT/TRANSMISSION Clean the left and right crankcase mating surfaces thoroughly, being careful not to damage them. Apply liquid sealant to the mating surface (shadowed area) of the left crankcase except the oil passage area as shown. Install the two dowel pins. DOWEL PINS Install the left crankcase over the right crankcase. LEFT CRANKCASE RIGHT CRANKCASE Install the thirteen left crankcase bolts, and tighten them in a crisscross pattern in 2 or 3 steps. BOLTS 11-18

31 CRANKCASE/CRANKSHAFT/TRANSMISSION Install the right crankcase bolt and tighten it. BOLT When installing the retainer plate, pull the crankshaft and hook the plate tab to the crankshaft bearing groove as shown. Install the bearing retainer plates and bolts. Tighten the bolts securely. PLATES PLATE Hook BOLT Apply molybdenum oil solution to the push plug entire surface. Install the push plug and spring by aligning the tapered surfaces of the plug and crankshaft bearing outer race. BOLTS PUSH PLUG CRANKSHAFT SPRING Apply locking agent to the push plug bolt threads. Install the push plug plate and bolt, and tighten the bolt. TORQUE: 10 N m (1.0 kgf m, 7 lbf ft) BOLT OUTER RACE PLATE 11-19

32 CRANKCASE/CRANKSHAFT/TRANSMISSION Install the cam chain and cam chain guide. Install the setting plate with the two bolts and tighten the bolts. Install the following: gear position switch (page 18-14) starter motor (page 17-11) flywheel (page 10-10) gearshift linkage (page 9-16) primary drive gear (page 9-18) kickstarter (page 9-21) clutch (page 9-12) oil pump (page 4-6) cylinder and piston (page 8-8) cylinder head (page 7-25) engine (page 6-6) GUIDE CHAIN BOLTS PLATE 11-20

33 12. FRONT WHEEL/BRAKE/SUSPENSION/STEERING SYSTEM COMPONENTS 12-2 SERVICE INFORMATION 12-4 TROUBLESHOOTING 12-6 HANDLEBAR 12-7 FRONT WHEEL (DRUM BRAKE TYPE) FRONT DRUM BRAKE (Type 1, 3, 4, 6) FORK STEERING STEM FRONT WHEEL (DISC BRAKE TYPE)

34 FRONT WHEEL/BRAKE/SUSPENSION/STEERING FRONT WHEEL/BRAKE/SUSPENSION/STEERING SYSTEM COMPONENTS DRUM BRAKE TYPE 12 N m (1.2 kgf m, 9 lbf ft) 23 N m (2.3 kgf m, 17 lbf ft) 34 N m (3.5 kgf m, 25 lbf ft) 52 N m (5.3 kgf m, 38 lbf ft) 12-2

35 DISC BRAKE TYPE FRONT WHEEL/BRAKE/SUSPENSION/STEERING 12 N m (1.2 kgf m, 9 lbf ft) 23 N m (2.3 kgf m, 17 lbf ft) 34 N m (3.5 kgf m, 25 lbf ft) 30 N m (3.1 kgf m, 22 lbf ft) 52 N m (5.3 kgf m, 38 lbf ft) 12-3

36 FRONT WHEEL/BRAKE/SUSPENSION/STEERING SERVICE INFORMATION GENERAL Frequent inhalation of brake shoe dust, regardless of material composition could be hazardous to your health. Avoid breathing dust particles. Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Raise the front wheel off the ground by supporting the frame securely when servicing the front wheel, suspension and steering stem. A hoist or equivalent is required to support the motorcycle. Disc brake type: A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. Drum brake type: A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a contaminated drum with a high quality brake degreasing agent. After the front wheel installation, check the brake operation by applying the brake lever. For hydraulic brake system (Type 2, 5), see Hydraulic Disc Brake section (page 14-2). SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire tread depth To indicator Cold tire Driver only 200 kpa (2.00 kgf/cm 2, 29 psi) pressure Driver and passenger 200 kpa (2.00 kgf/cm 2, 29 psi) Axle runout 0.2 (0.01) Wheel rim Radial 1.0 (0.04) runout Axial 1.0 (0.04) Wheel hub-to-rim distance (Type 3, 6) 6.5 ± 1 (0.3 ± 0.04) Front brake Lever freeplay ( ) (Type 1, 3, 4, 6) Drum I.D ( ) 131 (5.2) Fork Spring free length 485 (19.1) 453 (17.8) Tube runout 0.20 (0.008) Recommended fork fluid Fork fluid Fluid level 147 (5.8) Fluid capacity 159 ± 2.5 cm 3 (5.4 ± 0.08 US oz, 5.6 ± 0.09 lmp oz) TORQUE VALUES Front axle nut 52 N m (5.3 kgf m, 38 lbf ft) U-nut Front brake disc bolt (Type 2,5) 42 N m (4.3 kgf m, 31 lbf ft) ALOC bolt: replace with a new one. Front spoke (Type 3, 6) 3.7 N m (0.38 kgf m, 2.7 lbf ft) Front brake arm nut (Type 1, 3, 4, 6) 10 N m (1.0 kgf m, 7 lbf ft) Handlebar holder bolt 12 N m (1.2 kgf m, 9 lbf ft) Clutch lever pivot bolt 1 N m (0.1 kgf m, 0.7 lbf ft) Clutch lever pivot nut 5.9 N m (0.6 kgf m, 4.4 lbf ft) Rearview mirror lock nut 34 N m (3.5 kgf m, 25 lbf ft) Fork socket bolt 20 N m (2.0 kgf m, 15 lbf ft) Apply locking agent to the threads. Fork cap 22 N m (2.2 kgf m, 16 lbf ft) Bottom bridge pinch bolt 34 N m (3.5 kgf m, 25 lbf ft) Top bridge pinch bolt 23 N m (2.3 kgf m, 17 lbf ft) Brake caliper mounting bolt 30 N m (3.1 kgf m, 22 lbf ft) ALOC bolt: replace with a new one. Steering bearing adjustment nut For tightening sequence; See page Steering stem nut For tightening sequence; See page

37 TOOLS FRONT WHEEL/BRAKE/SUSPENSION/STEERING Spoke wrench, Bearing driver attachment, Bearing driver attachment, Pilot, Bearing remover shaft, 9 200L Remover head, Oil seal remover Driver handle, L Lock nut wrench, Ball race remover, L Inner driver, L GC

38 FRONT WHEEL/BRAKE/SUSPENSION/STEERING TROUBLESHOOTING Hard steering Steering bearing adjustment nut too tight Worn or damaged steering head bearings Worn or damaged steering head bearing races Damaged steering stem Insufficient tire pressure Faulty front tire Steers to one side or does not track straight Bent fork leg Damaged or loose steering head bearings Worn wheel bearings Bent front axle Wheel installed incorrectly Bent frame Worn swingarm pivot components (page 13-20) Front wheel wobbles Bent rim Worn or damaged wheel bearings Faulty front tire Loose or broken spokes (spoke wheel type) Loose axle fasteners Wheel turns hard Faulty wheel bearings Bent front axle Brake drag (page 14-4) Soft suspension Weak fork springs Low fluid level in fork Wrong type of fluid in fork Low tire pressure Stiff suspension Bent fork tubes Fork slider binds High fluid level in fork Incorrect fluid weight (high viscosity) Clogged fork fluid passage High tire pressure Front suspension noise Loose fork fasteners Worn fork tube or guide bushing Low fluid level in fork 12-6

39 HANDLEBAR The right rearview mirror lock nut has left-hand threads. REMOVAL Remove the following: four wire bands rearview mirrors FRONT WHEEL/BRAKE/SUSPENSION/STEERING MIRRORS BANDS screw and right side handlebar weight WEIGHT SCREW Disc brake type only. brake light switch connectors two bolts, holder and master cylinder (keep the reservoir upright to prevent air from entering the hydraulic system) Disc brake type only: HOLDER MASTER CYLINDER CONNECTORS BOLTS two screws (and separate the right handlebar switch) SWITCH SCREWS 12-7

40 FRONT WHEEL/BRAKE/SUSPENSION/STEERING throttle cable (disconnect from the throttle grip) right handlebar switch throttle grip SWITCH GRIP THROTTLE CABLE Drum brake type only. brake lever bracket bolt (only loosen) Drum brake type only: BOLT screw and left side handlebar weight handlebar grip GRIP WEIGHT SCREW clutch switch connectors two screws (and separate the left handlebar switch) SWITCH CONNECTORS SCREWS 12-8

41 FRONT WHEEL/BRAKE/SUSPENSION/STEERING choke cable (disconnect from the choke lever) left handlebar switch choke lever SWITCH LEVER CABLE clutch cable (by sliding the dust cover off and loosening the lock nut and adjuster) clutch lever bracket bolt (only loosen) clutch lever bracket BOLT LEVER BRACKET LOCK NUT ADJUSTER CLUTCH CABLE DUST COVER two screws and handlebar cover COVER SCREWS four bolts, handlebar cover stay and handlebar holders handlebar STAY HANDLEBAR Drum brake type only. Remove the front brake lever bracket from the handlebar. BOLTS HOLDERS 12-9

42 FRONT WHEEL/BRAKE/SUSPENSION/STEERING INSTALLATION Route the cables, hose and wires properly (page 1-16). Drum brake type only. Align the punch mark on the handlebar with the with the top edge of the lower holder. Set the front brake lever bracket to the handlebar. Install the handlebar, handlebar cover stay and holders with the punch marks facing forward. Tighten the front bolts first, then tighten the rear bolts. TORQUE: 12 N m (1.2 kgf m, 9 lbf ft) STAY HANDLEBAR PUNCH MARKS Align HOLDERS Install the handlebar cover and tighten the two screws. COVER SCREWS Set the clutch lever bracket to the handlebar. Align the slit of clutch lever bracket with the punch mark on the handlebar, and tighten the bracket bolt. Apply grease to the cable end and cable rolling area. Connect the clutch cable and adjust it (page 3-22). BOLT LEVER BRACKET Align CLUTCH CABLE Install the choke lever onto the handlebar. Apply grease to the cable end and cable rolling area. Connect the throttle cable to the throttle grip pipe. Connect the choke cable to the choke lever. SWITCH LEVER Align the locating pin with the hole in the handlebar. Install the left handlebar switch by setting the switch housing ends into the choke lever groove. Align CABLE 12-10

43 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the screws and tighten the front screw first, then tighten the rear screw. Connect the clutch switch connectors. SWITCH CONNECTORS SCREWS Allow the adhesive to dry for an hour before using. Clean the inside surface of the left handlebar grip and the outside surface of the handlebar. Apply Honda Bond A or equivalent to the inside surface of the handlebar grip and to the outside surface of the handlebar. Wait 3 5 minutes and install the grip. Rotate the grip for even application of the adhesive. HANDLEBAR GRIP LEFT HANDLEBAR Install the left handlebar weight and tighten the screw. WEIGHT SCREW Drum brake type only. Align the slit of brake lever bracket with the punch mark on the handlebar, and tighten the bracket bolt. Drum brake type only: LEVER BRACKET Align BOLT 12-11

44 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the throttle grip onto the handlebar. Apply grease to the cable end and cable rolling area. Connect the throttle cable to the throttle grip pipe. Install the right handlebar switch by aligning the locating pin with the hole on the handlebar. SWITCH Align GRIP THROTTLE CABLE Install the screws and tighten the front screw first, then tighten the rear screw. SWITCH SCREWS Disc brake type only. Install the brake master cylinder and holder with the "UP" mark facing up. Align the edge of the master cylinder with the punch mark on the handlebar and tighten the upper bolt first, then tighten the lower bolt. Disc Brake type: only: HOLDER MASTER CYLINDER "UP" Connect the brake light switch connectors. Align CONNECTORS BOLTS Install right handlebar weight and tighten the screw. WEIGHT SCREW 12-12

45 FRONT WHEEL/BRAKE/SUSPENSION/STEERING The right rearview mirror has left-hand threads. Install each rearview mirror and tighten the lock nut to the specified torque. TORQUE: 34 N m (3.5 kgf m, 25 lbf ft) Secure the wires with the wire bands. Check the following: throttle operation (page 3-6) choke operation (page 3-6) MIRRORS BANDS FRONT WHEEL (DISC BRAKE TYPE) REMOVAL Remove the screw and disconnect the speedometer cable/o-ring. Do not operate the brake lever after removing the wheel. To do so will cause difficulty in fitting the brake disc between the brake pads. Remove the nut cap and loosen the axle nut. Raise the front wheel off the ground and support the motorcycle securely. Remove the axle nut. Pull the axle out and remove the front wheel. CAP NUT SCREW CABLE/O-RING Remove the side collar and side collar cover. SIDE COLLAR COVER SIDE COLLAR INSPECTION AXLE Set the axle in V-blocks. Turn the axle and measure the runout using a dial indicator. Actual runout is 1/2 of the total indicator reading. SERVICE LIMIT: 0.2 mm (0.01 in) 12-13

46 FRONT WHEEL/BRAKE/SUSPENSION/STEERING WHEEL RIM Check the rim runout by placing the wheel in a turning stand. Spin the wheel slowly and read the runout using a dial indicator. Actual runout is 1/2 of the total indicator reading. SERVICE LIMITS: Axial: 1.0 mm (0.04 in) Radial: 1.0 mm (0.04 in) Replace the bearings in pairs. WHEEL BEARING Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if they do not turn smoothly, quietly, or if they fit loosely in the hub. DISASSEMBLY Remove the following: speedometer gearbox SPEEDOMETER GEAR dust seal speedometer gear retainer RETAINER DUST SEAL 12-14

47 FRONT WHEEL/BRAKE/SUSPENSION/STEERING four bolts and brake disc dust seal BRAKE DISC BOLTS Install the remover head into the bearing. From the opposite side of the wheel, install the remover shaft and drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing. TOOLS: Bearing remover head, 12 mm Bearing remover shaft DUST SEAL REMOVER SHAFT ASSEMBLY REMOVER HEAD DISC BOLTS 42 N m (4.3 kgf m, 31 lbf ft) DUST SEAL BEARING (6301U) BEARING (6301U) BRAKE DISC DUST SEAL DISTANCE COLLAR SPEEDOMETER GEAR RETAINER 12-15

48 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Pack new bearing cavities with grease. Drive in a new right side (brake disc side) bearing squarely with the sealed side facing up until it is fully seated. Install the distance collar. Drive in a new left side (gear box side) bearing squarely with the sealed side facing up. TOOLS: Driver Attachment, 37 x 40 mm Pilot, 12 mm BEARING DRIVER ATTACHMENT PILOT Do not get grease on the brake disc or stopping power will be reduced. Install the brake disc with the stamp facing out. Install new disc bolts and tighten them in a crisscross pattern in several steps. TORQUE: 42 N m (4.3 kgf m, 31 lbf ft) BRAKE DISC BOLTS Apply grease to the lips of a new dust seal. Install the dust seal as specified mm ( in) DUST SEAL Install the gear retainer, aligning the locating tabs with the grooves in the hub. Apply grease to the lips of a new dust seal. Install the dust seal so that it is flush with the wheel hub. RETAINER DUST SEAL Align Apply 3 g of grease to the speedometer gear teeth and g to inner surface, and install the washers and gear. SPEEDOMETER GEAR Install the gear box so the tabs on the retainer and slots on the gear are aligned. TABS 12-16

49 INSTALLATION Install the side collar cover and side collar. FRONT WHEEL/BRAKE/SUSPENSION/STEERING SIDE COLLAR COVER SIDE COLLAR Be careful not to damage the brake pads. Place the wheel between the fork legs while inserting the brake disc between the pads in the caliper so the groove in the gear box is aligned with the stopper. Insert the axle from the right side and temporary tighten the axle nut. Align AXLE Coat a new O-ring with grease and install it into the cable groove. Connect the speedometer cable by aligning the groove with the blade. O-RING Align Install the speedometer cable setting screw and tighten it. Tighten the axle nut. TORQUE: 52 N m (5.3 kgf m, 38 lbf ft) Install the nut cap securely. With the front brake applied, pump the suspension up and down several times and check brake operation. NUT CAP SCREW CABLE 12-17

50 FRONT WHEEL/BRAKE/SUSPENSION/STEERING FRONT WHEEL (DRUM BRAKE TYPE) REMOVAL Remove the screw and disconnect the speedometer cable. Disconnect the brake cable by removing the adjusting nut, and remove the brake cable and joint pin. Remove the nut cap and loosen the axle nut. Raise the front wheel off the ground and support the motorcycle securely. Remove the axle nut. Pull the axle out and remove the front wheel. Remove the brake panel. SCREW ADJUSTING NUT SPEEDOMETER CABLE CAP JOINT PIN AXLE NUT BRAKE CABLE Remove the side collar and side collar cover. INSPECTION AXLE Set the axle in V-blocks. Turn the axle and measure the runout using a dial indicator. Actual runout is 1/2 of the total indicator reading. SERVICE LIMIT: 0.2 mm (0.01 in) COLLAR COLLAR COVER 12-18

51 WHEEL RIM Check the rim runout by placing the wheel in a turning stand. Spin the wheel slowly and read the runout using a dial indicator. Actual runout is 1/2 of the total indicator reading. SERVICE LIMITS: Axial: 1.0 mm (0.04 in) Radial: 1.0 mm (0.04 in) FRONT WHEEL/BRAKE/SUSPENSION/STEERING Replace the bearings in pairs. WHEEL BEARING Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if they do not turn smoothly, quietly, or if they fit loosely in the hub. DISASSEMBLY For brake panel service, refer to front drum brake (page 12-22). Remove the dust seal. DUST SEAL Install the remover head into the bearing. From the opposite side of the wheel, install the remover shaft and drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing. TOOLS: Bearing remover head, 12 mm Bearing remover shaft REMOVER SHAFT REMOVER HEAD 12-19

52 FRONT WHEEL/BRAKE/SUSPENSION/STEERING ASSEMBLY BEARING (6301U) DISTANCE COLLAR DUST SEAL BEARING (6301U) WHEEL CENTER ADJUSTMENT (type 3, 6) Adjust the hub position so that the distance from the left end surface of the hub center to the side of rim is 6.5 ± 1 mm (0.3 ± 0.04 in) as shown. Tighten the spokes in 2 or 3 progressive steps. TOOL: Spoke wrench, 5.8 x 6.1 mm TORQUE: 3.7 N m (0.38 kgf m, 2.7 lbf ft) Check the rim runout (page 12-19). WHEEL ASSEMBLY Pack new bearing cavities with grease. Drive in a new left side (brake drum side) bearing squarely with the sealed side facing up until it is fully seated. Install the distance collar. Drive in a new right side bearing squarely with the sealed side facing up. TOOLS: Driver Attachment, 37 x 40 mm Pilot, 12 mm BEARING 6.5 ± 1 mm (0.3 ± 0.04 in) DRIVER BASE POINT ATTACHMENT PILOT 12-20

53 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Apply grease to the lips of a new dust seal. Install the dust seal as specified mm ( in) DUST SEAL Do not get grease on the brake drum and shoe linings or stopping power will be reduced. INSTALLATION Install the brake panel by aligning the speedometer gear tabs with the grooves in the hub. BRAKE PANEL Align Install the side collar and side collar cover. Install the wheel between the fork legs and align the groove of the brake panel with the boss on the left fork leg. Insert the front axle through the fork and wheel from the right side. Install the axle nut and tighten it. TORQUE: 52 N m (5.3 kgf m, 38 lbf ft) COLLAR BRAKE PANEL COLLAR COVER AXLE NUT Align 12-21

54 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Apply grease to a speedometer cable seal lips. Connect the speedometer cable by tightening the screw. Install the brake cable into the brake panel and connect it with the joint pin and adjusting nut. Install the nut cap securely. Adjust the brake lever freeplay and check the brake operation (page 3-19). SCREW SPEEDOMETER CABLE CAP ADJUSTING NUT JOINT PIN BRAKE CABLE FRONT DRUM BRAKE (Type 1, 3, 4, 6) REMOVAL Remove the wheel and the brake panel (page 12-18). INSPECTION Measure the front brake drum I.D. SERVICE LIMIT: 131 mm (5.2 in) DISASSEMBLY Always replace the brake shoes in pairs. Expand the brake shoes and remove them from the brake panel. Remove the shoe springs from the brake shoes. SHOES SPRINGS 12-22

55 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Remove the following: dust seal speedometer gear washer GEAR AND WASHER DUST SEAL nut and bolt brake arm NUT BRAKE ARM wear indicator return spring brake cam felt seal BOLT BRAKE CAM INDICATOR FELT SEAL SPRING 12-23

56 FRONT WHEEL/BRAKE/SUSPENSION/STEERING ASSEMBLY BRAKE SHOES *1: 3 g to gear teeth/ g to inner surface *2: Gear oil DUST SEAL SPEEDOMETER GEAR *1 WASHER SHOE SPRINGS WEAR INDICATOR BRAKE ARM BRAKE CAM *2 FELT SEAL RETURN SPRING BOLT BRAKE ARM NUT 10 N m (1.0 kgf m, 7 lbf ft) Apply grease to the brake cam sliding surface and install it into the brake panel. Apply gear oil to the felt seal and install it onto the brake panel. Install the return spring by inserting the spring end into the hole in the brake panel. Install the wear indicator by aligning the wide tooth with the wide groove in the brake cam. SPRING INDICATOR Align HOLE FELT SEAL 12-24

57 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the brake arm by aligning the punch marks. Install the bolt from the opposite side of the punch mark and tighten the nut. TORQUE: 10 N m (1.0 kgf m, 7 lbf ft) NUT Align SPRING Hook the return spring onto the brake arm. BRAKE ARM Apply 3 g of grease to the speedometer gear teeth and g to inner surface. Install the washer and gear. BOLT GEAR WASHER Apply grease to the lips of a new dust seal. Install the dust seal so that it is flush with the brake panel. Apply g of grease to the anchor pin and brake cam sliding surfaces. DUST SEAL Assemble the brake shoes and springs in the direction as shown. Install the shoe assembly onto the brake panel so the spring ends are facing up (wheel side). Wipe any excess grease from the brake cam and anchor pin. Install the front wheel (page 12-21). SHOES Up SPRINGS 12-25

58 FRONT WHEEL/BRAKE/SUSPENSION/STEERING FORK Disc brake type only: Support the caliper so it does not hang from the brake hose. Do not twist the brake hose. REMOVAL Remove the following: front wheel (disc brake type; page 12-13) (drum brake type; page 12-18) front fender (page 2-5) Remove the two bolts and brake caliper from the right fork leg. Disc brake type only: BOLTS When the fork is ready to be disassembled, loosen the fork cap, but do not remove it. Loosen the top bridge pinch bolt/nut. CALIPER FORK CAP PINCH BOLT NUT Loosen the bottom bridge pinch bolts while supporting the fork leg. Pull the fork leg down and remove it out of the fork bridges. FORK DISASSEMBLY Hold the fork slider in a vise with soft jaws or shop towels. Loosen the socket bolt, but do not remove it yet. PINCH BOLT SOCKET BOLT 12-26

59 The fork cap is under spring pressure; use care when loosening it. Remove the following: fork cap O-ring FRONT WHEEL/BRAKE/SUSPENSION/STEERING FORK CAP O-RING fork spring Pour out the fork fluid by pumping the fork tube up and down several times. FORK SPRING socket bolt sealing washer SEALING WASHER SOCKET BOLT fork piston rebound spring REBOUND SPRING FORK PISTON 12-27

60 FRONT WHEEL/BRAKE/SUSPENSION/STEERING fork tube oil lock piece FORK TUBE OIL LOCK PIECE dust seal stopper ring DUST SEAL STOPPER RING oil seal TOOL: Oil seal remover OIL SEAL OIL SEAL REMOVER INSPECTION FORK SPRING Measure the fork spring free length. SERVICE LIMIT: 453 mm (17.8 in) 12-28

61 FRONT WHEEL/BRAKE/SUSPENSION/STEERING FORK TUBE/SLIDER/PISTON Check the fork tube, slider, oil lock piece and fork piston for score marks, and excessive or abnormal wear. Check the fork piston ring for wear or damage. Check the rebound spring for fatigue or damage. Replace any damaged component if necessary. FORK SLIDER OIL LOCK PIECE FORK TUBE REBOUND SPRING PISTON RING FORK PISTON Set the fork tube in V-blocks and measure the fork tube runout with a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.20 mm (0.008 in) ASSEMBLY DUST SEAL FORK TUBE FORK CAP 22 N m (2.2 kgf m, 16 lbf ft) STOPPER RING PISTON RING OIL SEAL O-RING FORK SLIDER SEALING WASHER FORK PISTON FORK SPRING SOCKET BOLT 20 N m (2.0 kgf m, 15 lbf ft) OIL LOCK PIECE REBOUND SPRING 12-29

62 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Wrap vinyl tape around the fork tube top end to avoid damaging the oil seal lip. Apply fork fluid to a new oil seal lip. Install the oil seal with the marking facing up. Drive the oil seal until the stopper ring groove is visible. TOOLS: Driver Attachment, DRIVER HANDLE OIL SEAL Install the stopper ring into the groove in the fork slider, being careful not to scratch the fork tube sliding surface. Coat the lips of a new dust seal with fork fluid and install it. ATTACHMENT STOPPER RING DUST SEAL Before assembly, wash all parts with a high-flash or non-flammable solvent and wipe them off completely. Install the rebound spring and fork piston into the fork tube. FORK TUBE REBOUND SPRING FORK PISTON Install the following: rebound spring (onto the fork piston) fork piston (into the fork tube) oil lock piece (onto the fork piston) Install the fork tube into the fork slider. REBOUND SPRING OIL LOCK PIECE FORK PISTON FORK TUBE 12-30

63 Apply locking agent to the fork socket bolt threads. Install the socket bolt with a new sealing washer. FRONT WHEEL/BRAKE/SUSPENSION/STEERING WASHER SOCKET BOLT Pour the specified amount of the fork fluid into the fork tube. FLUID CAPACITY: 159 ± 2.5 cm 3 (5.4 ± 0.08 US oz, 5.6 ± 0.09 lmp oz) Slowly pump the fork tube several times to remove any trapped air from the lower portion of the fork tube. Compress the fork tube fully. Measure the oil level from the top of the fork tube. FLUID LEVEL: 147 mm (5.8 in) 147 mm (5.8 in) Pull the fork tube up and install the fork spring with the tightly wound coil side facing down. Down Tighten the fork cap after installing the fork tube into the fork bridges. Coat a new O-ring with fork fluid and install it into the fork cap groove. Hold the fork cap securely and install it into the fork tube, being careful not to cross-thread the cap. FORK CAP O-RING 12-31

64 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Hold the fork slider in a vise with soft jaws or shop towels. Tighten the socket bolt to the specified torque. TORQUE: 20 N m (2.0 kgf m, 15 lbf ft) INSTALLATION Install the fork tube into the bottom and top bridges. Align the top of the fork tube with the upper surface of the top bridge. Tighten the bottom bridge pinch bolts. TORQUE: 34 N m (3.5 kgf m, 25 lbf ft) Tighten the top bridge pinch bolts and nuts. TORQUE: 23 N m (2.3 kgf m, 17 lbf ft) Tighten the fork cap to the specified torque if it was removed. TORQUE: 22 N m (2.2 kgf m, 16 lbf ft) Install the following: front fender (page 2-5) front wheel (disc brake type; page 12-17) (drum brake type; page 12-21) SOCKET BOLT Align FORK CAP PINCH BOLTS TOP BRIDGE FORK CAP NUT Disc brake type only: Install the brake caliper with new mounting bolts and tighten the bolts. TORQUE: 30 N m (3.1 kgf m, 22 lbf ft) Disc brake type only: BOLTS CALIPER 12-32

65 STEERING STEM REMOVAL Remove the following: front wheel (disc brake type; page 12-13) (drum brake type; page 12-18) front fender (page 2-5) headlight case (page 2-3) speedometer (page 18-6) handlebar (page 12-7) Disconnect the connectors from the wire harness. FRONT WHEEL/BRAKE/SUSPENSION/STEERING CONNECTORS Remove the two bolts and headlight stay. BOLTS HEADLIGHT STAY Loosen the steering stem nut and top bridge pinch bolts. STEM NUT Loosen the bottom bridge pinch bolts while supporting the fork leg. Pull the fork leg down and remove it out of the fork bridges. Remove the following: bottom bridge pinch bolts and headlight cover stay stem nut and washer top bridge headlight back plate Remove the stem nut and washer. Remove the top bridge and headlight back plate. STEM NUT/WASHER BACK PLATE FORK PINCH BOLTS TOP BRIDGE STAY PINCH BOLT 12-33

66 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Loosen the steering bearing adjustment nut. TOOL: Stem socket wrench While holding the steering stem, remove the adjustment nut. Remove the following: steering stem upper inner race upper steering bearing lower steering bearing ADJUSTMENT NUT SOCKET WRENCH UPPER INNER RACE UPPER BEARING Always replace the bearings and races as a set. Remove the upper and lower outer races using the special tool. TOOL: Ball race remover STEM LOWER BEARING BALL RACE REMOVER BALL RACE REMOVER 12-34

67 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the stem nut onto the stem to prevent the threads from being damaged when removing the inner race. Remove the lower inner race with a chisel or equivalent tool, being careful not to damage the stem. Remove the dust seal and washer. DUST SEAL AND WASHER NUT INNER RACE INSTALLATION Route the wires, hose and cables properly (page 1-16). DUST SEAL UPPER INNER RACE ADJUSTMENT NUT WASHER STEERING STEM UPPER OUTER RACE UPPER STEERING BEARING (21) LOWER OUTER RACE LOWER STEERING BEARING (21) grease with extreme pressure agent (recommended: EXCELIGHT EP2 manufactured by KYODO YUSHI, japan or Shell ALVANIA EP2 or equivalent) LOWER INNER RACE 12-35

68 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Use multi-purpose grease with extreme pressure agent for the steering bearings and dust seals: Excelite EP2 (Kyodo Yushi) or Alvania EP2 (Shell) or equivalent Apply grease to the lips of a new lower dust seal. Install the washer and lower dust seal onto the steering stem. Press a new lower bearing inner race using the special tool. TOOL: Inner driver GC40000 INNER DRIVER DUST SEAL INNER RACE WASHER Drive in new upper and lower bearing outer races into the steering head pipe. DRIVER TOOLS: Driver Bearing driver attachment, ATTACHMENT UPPER OUTER RACE LOWER OUTER RACE ATTACHMENT DRIVER Apply 3 g (0.1 oz) of grease to each new bearing and fill it up. Attach the lower steering bearing balls onto the stem. Attach the upper steering balls onto the upper outer race. Insert the steering stem into the steering head pipe, and install the following while holding the stem. upper inner race adjustment nut (and temporarily tighten it) UPPER INNER RACE UPPER BEARING (21 BALLS) STEM LOWER BEARING (21 BALLS) 12-36

69 FRONT WHEEL/BRAKE/SUSPENSION/STEERING 1. Tighten the adjustment nut to the initial torque. TOOL: Stem socket wrench SOCKET WRENCH TORQUE: 25 N m (2.5 kgf m, 18 lbf ft) ADJUSTMENT NUT 2. Turn the steering stem left and right, lock-to-lock several times to seat the bearings. Completely loosen the adjustment nut. ADJUSTMENT NUT 3. Retighten the adjustment nut to the specified torque. TORQUE: 3.0 N m (0.30 kgf m, 2.2 lbf ft) SOCKET WRENCH ADJUSTMENT NUT Install the following: headlight back plate top bridge stem nut and washer bottom bridge pinch bolts and headlight cover stay Temporarily install the fork legs into the bottom and top bridges. STEM NUT/WASHER BACK PLATE FORK TOP BRIDGE STAY PINCH BOLT 12-37

70 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Tighten the stem nut. TORQUE: 74 N m (7.5 kgf m, 55 lbf ft) Move the steering stem lock-to-lock and make sure the steering stem moves smoothly without play or binding. STEM NUT Align the top of the fork tube with the upper surface of the top bridge. Tighten the bottom bridge pinch bolts. TORQUE: 34 N m (3.5 kgf m, 25 lbf ft) Tighten the top bridge pinch bolts and nuts. TORQUE: 23 N m (2.3 kgf m, 17 lbf ft) Align TOP BRIDGE PINCH BOLTS NUTS Install the headlight stay by setting its boss into grommet of bottom bridge. Tighten the two bolts. BOLTS HEADLIGHT STAY 12-38

71 Route the wire harness properly (page 1-16). FRONT WHEEL/BRAKE/SUSPENSION/STEERING Connect the following: ignition switch 2P connector right handlebar switch 2P connector left handlebar switch 3P connector right handlebar switch Brown wire connector left handlebar switch Black, Light blue and Orange wire connectors lighting switch Blue/white wire connector front brake light switch Green/yellow wire connector clutch switch Green connector Install the following: handlebar (page 12-7) speedometer (page 18-6) headlight case (page 18-17) CONNECTORS 12-39

72 MEMO

73 13. REAR WHEEL/BRAKE/SUSPENSION SYSTEM COMPONENTS 13-2 SERVICE INFORMATION 13-4 TROUBLESHOOTING 13-6 REAR WHEEL 13-7 REAR DRUM BRAKE BRAKE PEDAL/CENTERSTAND SHOCK ABSORBER SWINGARM

74 REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL/BRAKE/SUSPENSION SYSTEM COMPONENTS 29 N m (3.0 kgf m, 21 lbf ft) 59 N m (6.0 kgf m, 44 lbf ft) 34 N m (3.5 kgf m, 25 lbf ft) 22 N m (2.2 kgf m, 16 lbf ft) 59 N m (6.0 kgf m, 44 lbf ft) 13-2

75 REAR WHEEL/BRAKE/SUSPENSION 13-3

76 REAR WHEEL/BRAKE/SUSPENSION SERVICE INFORMATION GENERAL Frequent inhalation of brake shoe dust, regardless of material composition could be hazardous to your health. Avoid breathing dust particles. Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a contaminated drum with a high quality brake degreasing agent. Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points. For drive chain information, see Maintenance section (page 3-14). SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire tread depth To indicator Cold tire pressure Driver only 225 kpa (2.25 kgf/cm 2, 33 psi) Driver and passenger 225 kpa (2.25 kgf/cm 2, 33 psi) Axle runout 0.2 (0.01) Wheel rim Radial 1.0 (0.04) runout Axial 1.0 (0.04) Wheel hub-to-rim distance (Type 3, 6) 2.0 ± 1 (0.08 ± 0.04) Drive chain Size/link 428H/112 Slack ( ) Rear brake Pedal freeplay ( ) Drum I.D ( ) 131 (5.2) TORQUE VALUES Rear brake arm nut 10 N m (1.0 kgf m, 7 lbf ft) U-nut Driven sprocket bolt 34 N m (3.5 kgf m, 25 lbf ft) Rear axle nut 59 N m (6.0 kgf m, 44 lbf ft) U-nut Shock absorber upper mounting bolt 29 N m (3.0 kgf m, 21 lbf ft) Shock absorber lower mounting bolt 34 N m (3.5 kgf m, 25 lbf ft) Rear brake stopper arm nut 22 N m (2.2 kgf m, 16 lbf ft) Rear spoke (Type 3, 6) 3.7 N m (0.38 kgf m, 2.7 lbf ft) Swingarm pivot nut 59 N m (6.0 kgf m, 44 lbf ft) U-nut 13-4

77 TOOLS REAR WHEEL/BRAKE/SUSPENSION Spoke wrench, Bearing driver attachment, Bearing driver attachment, Bearing driver attachment, Pilot, Pilot, Bearing remover shaft, 9 200L Remover head, Driver handle, L

78 REAR WHEEL/BRAKE/SUSPENSION TROUBLESHOOTING Rear wheel wobbles Bent rim Worn or damaged rear wheel bearings Faulty rear tire Worn or damaged swingarm bushings Bent frame or swingarm Axle fastener not tightened properly Loose or broken spokes (spoke wheel type) Wheel turns hard Faulty wheel bearings Bent axle Drive chain too tight (page 3-14) Brake drag (page 14-4) Soft suspension Incorrect suspension adjustment Weak shock absorber springs Oil leakage from damper unit Low tire pressure Stiff suspension Incorrect suspension adjustment Bent shock absorber damper rod Damaged suspension or swingarm pivot bushings Bent swingarm pivot or frame High tire pressure Steers to one side or does not track straight Drive chain adjusters not adjusted equally Bent axle Bent frame Worn swingarm pivot components Rear suspension noise Loose suspension fasteners Worn or damaged suspension pivot bushings Faulty shock absorber 13-6

79 REAR WHEEL REMOVAL Place the motorcycle on its centerstand. Disconnect the brake rod by removing the adjusting nut, and remove the spring and joint pin. REAR WHEEL/BRAKE/SUSPENSION JOINT PIN ROD SPRING ADJUSTING NUT Disconnect the stopper arm from the brake panel by removing the following. cotter pin nut washer rubber seat joint bolt NUT WASHER COTTER PIN STOPPER ARM Loosen the axle nut. Loosen the both drive chain adjuster lock nuts and adjusting bolts so the wheel can be moved all the way forward. Move the wheel forward for maximum chain slack. Remove the axle nut and washer. Derail the drive chain from the driven sprocket. Remove the following: axle both adjusters and adjuster plates collar rear wheel Remove the brake panel assembly from the wheel hub. BOLT ADJUSTER PLATE LOCK NUT COLLAR ADJUSTING BOLT RUBBER SEAT AXLE NUT AXLE WASHER ADJUSTER BRAKE PANEL 13-7

80 REAR WHEEL/BRAKE/SUSPENSION Remove the side collar from the driven flange. SIDE COLLAR INSPECTION AXLE Set the axle in V-blocks. Turn the axle and measure the runout using a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.2 mm (0.01 in) Replace the bearings in pairs. WHEEL BEARING Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub or driven flange. Remove and discard the bearings if they do not turn smoothly, quietly, or if they fit loosely in the hub or driven flange. Replace the bearings if necessary (page 13-9). WHEEL RIM Check the wheel rim runout by placing the wheel in a turning stand. Spin the wheel slowly by hand, and read the runout using a dial indicator. Actual runout is 1/2 of the total indicator reading. SERVICE LIMITS: Radial: 1.0 mm (0.04 in) Axial: 1.0 mm (0.04 in) 13-8

81 If you will replace the driven sprocket, bend down the lock plates and loosen the four bolts. DISASSEMBLY Remove the driven flange assembly from the wheel. REAR WHEEL/BRAKE/SUSPENSION LOCK PLATE DUST SEAL DRIVEN FLANGE ASSEMBLY LOCK PLATE Replace the rubber dampers as a set. Remove the O-ring and the rubber dampers. Check the rubber dampers for deterioration or damage. RUBBER DAMPERS O-RING Remove the sleeve. SLEEVE Remove the following: four bolts/nuts lock plates driven sprocket dust seal LOCK PLATE DUST SEAL DRIVEN SPROCKET LOCK PLATE BOLTS/ NUTS 13-9

82 REAR WHEEL/BRAKE/SUSPENSION Drive the bearing out of the driven flange. BEARING Install the bearing remover head into the wheel bearing. From the opposite side of the wheel, install the bearing remover shaft and drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing. REMOVER HEAD TOOLS: Bearing remover head, 15 mm Bearing remover shaft ASSEMBLY BEARING REMOVER SHAFT BEARING (6302U) BEARING (6202U) SLEEVE LOCK PLATE DAMPER RUBBERS BOLTS DRIVEN FLANGE 34 N m (3.5 kgf m, 25 lbf ft) LOCK PLATE DRIVEN SPROCKET NUT DISTANCE COLLAR DUST SEAL O-RING BEARING (6004UU) SIDE COLLAR 13-10

83 REAR WHEEL/BRAKE/SUSPENSION WHEEL CENTER ADJUSTMENT (Type 3, 6) Adjust the hub position so that the distance from the left end surface of the hub center to the side of rim is 2.0 ± 1 mm (0.08 ± 0.04 in) as shown. Tighten the spokes in 2 or 3 progressive steps. TOOL: Spoke wrench, 5.8 x 6.1 mm ± 1 mm (0.08 ± 0.04 in) TORQUE: 3.7 N m (0.38 kgf m, 2.7 lbf ft) Check the rim runout (page 13-8). WHEEL ASSEMBLY Pack new bearing cavities with grease. Drive in a new right side (brake drum side) bearing squarely with the sealed side facing up until it is fully seated. Install the distance collar. Drive in a new left side bearing with the sealed side facing up. TOOLS: Driver Attachment, (brake drum side) Attachment, (left side) Pilot, 15 mm Pack new bearing cavities with grease. Drive in a new driven flange bearing squarely with the sealed side facing up until it is fully seated. TOOLS: Driver Attachment, 42 x 47 mm Pilot, 25 mm ATTACHMENT DRIVER BEARING PILOT DRIVER BEARING ATTACHMENT PILOT Apply grease to the lips of a new dust seal. Install the dust seal so that it is flush with the wheel hub. Install the following: driven sprocket lock plates four bolts four nuts Temporary tighten the bolts. LOCK PLATE DUST SEAL DRIVEN SPROCKET LOCK PLATE BOLTS 13-11

84 REAR WHEEL/BRAKE/SUSPENSION Install the sleeve into the new driven frange bearing. SLEEVE Install the rubber dampers as shown. Coat a new O-ring with grease and install it into the groove. RUBBER DAMPERS O-RING Install the driven flange assembly to the wheel hub. Tighten the sprocket bolts in a crisscross pattern in several steps if they were removed. LOCK PLATE TORQUE: 34 N m (3.5 kgf m, 25 lbf ft) Bend up the lock plate tabs against the bolts as shown so that the bolts cannot be loosed. INSTALLATION DRIVEN FLANGE ASSEMBLY LOCK PLATE BOLTS/ NUTS Install the left side collar. SIDE COLLAR 13-12

85 Do not get grease on the brake drum and shoe linings. Install the brake panel assembly into the wheel hub. REAR WHEEL/BRAKE/SUSPENSION BRAKE PANEL Place the rear wheel in the swingarm and install the drive chain onto the final driven sprocket. Install the both adjusters and adjuster plates to the swingarm. Insert the axle from the left side through the swingarm, collar and rear wheel. Install the axle nut and washer. ADJUSTER PLATE COLLAR AXLE NUT AXLE WASHER Connect the stopper arm to the brake panel with the joint bolt. Install the rubber seat, washer and nut and tighten the nut to the specified torque. TORQUE: 22 N m (2.2 kgf m, 16 lbf ft) Install a new cotter pin into the joint bolt. NUT WASHER ADJUSTER COTTER PIN Install the joint pin into the brake arm. Install the spring onto the brake rod. Push down the brake pedal and install the brake rod into the joint pin. Install the adjusting nut. Adjust the drive chain slack (page 3-15). Adjust the brake pedal freeplay (page 3-20). BOLT JOINT PIN STOPPER ARM RUBBER SEAT ROD ADJUSTING NUT SPRING 13-13

86 REAR WHEEL/BRAKE/SUSPENSION REAR DRUM BRAKE REMOVAL Remove the rear wheel and the brake panel (page 13-7). INSPECTION Measure the rear brake drum I.D. SERVICE LIMIT: 131 mm (5.2 in) Always replace the brake shoes in pairs. DISASSEMBLY Expand the brake shoes and remove them from the brake panel. Remove the shoe springs from the brake shoes. PANEL SHOES SPRINGS Remove the following: nut and bolt brake arm NUT BRAKE ARM BOLT 13-14

87 REAR WHEEL/BRAKE/SUSPENSION wear indicator brake cam felt seal BRAKE CAM ASSEMBLY INDICATOR FELT SEAL *: Gear oil BRAKE CAM WEAR INDICATOR SPRINGS BOLT BRAKE SHOES BRAKE ARM * FELT SEAL NUT 10 N m (1.0 kgf m, 7 lbf ft) BRAKE PANEL Apply g of grease to the brake cam sliding surface and install it into the brake panel. BRAKE CAM 13-15

88 REAR WHEEL/BRAKE/SUSPENSION Apply gear oil to the felt seal and install it onto the brake panel. Install the wear indicator by aligning the wide tooth with the wide groove in the brake cam. BRAKE CAM Align INDICATOR FELT SEAL Install the brake arm by aligning the punch marks. Install the bolt from the punch mark side and tighten the nut. BRAKE ARM TORQUE: 10 N m (1.0 kgf m, 7 lbf ft) NUT Align BOLT Apply g of grease to the anchor pin and brake cam sliding surfaces. Assemble the brake shoes and springs in the direction as shown. Install the shoe assembly onto the brake panel so the spring ends are facing up (wheel side). Wipe any excess grease from the brake cam and anchor pin. Install the rear wheel (page 13-12). SHOES PANEL SPRINGS BRAKE PEDAL/CENTERSTAND REMOVAL Place the motorcycle on its sidestand. Retract the centerstand. Disconnect the brake rod by removing the adjusting nut, and remove the spring and joint pin. JOINT PIN ROD ADJUSTING NUT SPRING 13-16

89 REAR WHEEL/BRAKE/SUSPENSION Remove the following: centerstand return spring RETURN SPRING centerstand return spring plate PLATE brake light switch rod brake pedal return spring cotter pin pivot shaft and washer brake pedal centerstand PIVOT SHAFT WASHER COTTER PIN RETURN SPRING ROD BRAKE PEDAL CENTERSTAND cotter pin and washer brake rod COTTER PIN WASHER PEDAL BRAKE ROD 13-17

90 REAR WHEEL/BRAKE/SUSPENSION INSTALLATION Connect the brake rod to the brake pedal, then install the washer and a new cotter pin as shown. COTTER PIN WASHER PEDAL BRAKE ROD Apply grease to the pivot shaft sliding surface. Place the centerstand and brake pedal in the frame. Insert the pivot shaft from the left side through the frame, centerstand and brake pedal. PIVOT SHAFT CENTERSTAND Install the washer and new cotter pin into the pivot shaft. Install the following as shown: brake pedal return spring brake light switch rod PIVOT SHAFT WASHER COTTER PIN ROD RETURN SPRING Install the centerstand return spring plate by setting its hole and boss of the frame. PLATE 13-18

91 REAR WHEEL/BRAKE/SUSPENSION Install the centerstand return spring. Install the joint pin into the brake arm. Install the spring onto the brake rod. Push down the brake pedal and install the brake rod into the joint pin. Install the adjusting nut. Adjust the brake pedal freeplay (page 3-20). RETURN SPRING JOINT PIN ROD SPRING SHOCK ABSORBER Do not disassemble the shock absorber. Replace the shock absorber as an assembly. REMOVAL/INSTALLATION Place the motorcycle on its centerstand and support the swingarm. Remove the following: rear carrier (page 2-6) upper mounting bolt, washer and collar lower mounting bolt shock absorber Installation is in the reverse order of removal. TORQUE: Lower mounting bolt 34 N m (3.5 kgf m, 25 lbf ft) Upper mounting bolt 29 N m (3.0 kgf m, 21 lbf ft) INSPECTION Visually inspect the shock absorber for wear or damage. Check the following: damper rod for bending or damage damper unit for leakage or other damage bushings for wear or damage Check for smooth damper operation. UPPER MOUNTING BOLT SHOCK ABSORBER ADJUSTING NUT WASHER/COLLAR SHOCK ABSORBER LOWER MOUNTING BOLT 13-19

92 REAR WHEEL/BRAKE/SUSPENSION SWINGARM REMOVAL Place the motorcycle on its centerstand. Remove the following: muffler (page 2-9) rear wheel (page 13-7) two bolts and drive chain cover CHAIN COVER BOLTS Remove the shock absorber lower mounting bolts. Release the both shock absorber lower mounts from the swingarm. SHOCK ABSORBER LOWER MOUNTING BOLT Remove the swingarm pivot bolt/washer and swingarm. BOLTS WASHER DISASSEMBLY Remove the chain slider by releasing the bosses from the holes of the swingarm. BOSSES HOLES CHAIN SLIDER 13-20

93 REAR WHEEL/BRAKE/SUSPENSION Remove the following: cotter pin nut washer spring washer joint bolt brake panel stopper arm COTTER PIN, NUT AND WASHERS ARM BOLT INSPECTION Check the pivot bushings for wear, deterioration or damage. BUSHINGS Check the chain slider for wear or damage. The chain slider must be replaced if it is worn to the wear limit groove. LIMIT GROOVE 13-21

94 REAR WHEEL/BRAKE/SUSPENSION Note the installation direction of the stopper arm. ASSEMBLY Install the following: brake panel stopper arm joint bolt spring washer washer nut Tighten the nut to the specified torque. TORQUE: 22 N m (2.2 kgf m, 16 lbf ft) Install a new cotter pin into the joint bolt. Install the chain slider by setting the bosses into the holes in the swingarm securely. NUT 22 N m (2.2 kgf m, 16 lbf ft) WASHER SPRING WASHER BOLT CHAIN SLIDER COTTER PIN INSTALLATION SWINGARM Apply grease to the swingarm pivot bolt. Set the swingarm into the frame through the drive chain and insert the pivot bolt with washer from the left side. BOLT STOPPER ARM SWINGARM WASHER 13-22

95 REAR WHEEL/BRAKE/SUSPENSION Align the shock absorber lower mounts side hole and thread hole of the swingarm, then temporary tighten the shock absorber lower mounting bolts. SHOCK ABSORBER LOWER MOUNTING BOLT Install the chain cover, aligning the locating tab of the cover with the slit in the swingarm. Align CHAIN COVER Install the two bolts and tighten them. Install the rear wheel (page 13-12). Install the muffler (page 2-10). Tighten the shock absorber lower mounting bolts to the specified torque. TORQUE: 34 N m (3.5 kgf m, 25 lbf ft) LOWER MOUNTING BOLT BOLTS 13-23

96 MEMO

97 14. HYDRAULIC DISC BRAKE SYSTEM COMPONENTS 14-2 SERVICE INFORMATION 14-3 TROUBLESHOOTING 14-4 BRAKE PADS/DISC 14-7 MASTER CYLINDER BRAKE CALIPER BRAKE FLUID REPLACEMENT/ AIR BLEEDING

98 HYDRAULIC DISC BRAKE HYDRAULIC DISC BRAKE SYSTEM COMPONENTS 34 N m (3.5 kgf m, 25 lbf ft) 34 N m (3.5 kgf m, 25 lbf ft) 30 N m (3.1 kgf m, 22 lbf ft) 14-2

99 SERVICE INFORMATION GENERAL HYDRAULIC DISC BRAKE Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles. Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Spilled brake fluid will severely damage the plastic parts and painted surface. It is also harmful to some rubber parts. Be careful whenever you remove the reservoir cap; make sure the master cylinder reservoir is horizontal first. A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. Always use fresh DOT 3 or DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid as they may not be compatible. Never allow contaminants (dirt, water, etc.) to get into an open reservoir. Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled. Always check brake operation before riding the motorcycle. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Specified brake fluid DOT 3 or DOT 4 Brake pad wear indicator To the groove Brake disc thickness ( ) 3.5 (0.14) Brake disc runout 0.10 (0.004) TORQUE VALUES Caliper bleed valve 8 N m (0.8 kgf m, 5.9 lbf ft) Master cylinder reservoir cap screw 1.5 N m (0.15 kgf m, 1.1 lbf ft) Brake caliper mounting bolt 30 N m (3.1 kgf m, 22 lbf ft) ALOC bolt: replace with a new one. Front brake light switch screw 1.0 N m (0.10 kgf m, 0.7 lbf ft) Brake lever pivot bolt 1.0 N m (0.10 kgf m, 0.7 lbf ft) Brake lever pivot nut 6.0 N m (0.6 kgf m, 4.4 lbf ft) Brake hose oil bolt 34 N m (3.5 kgf m, 25 lbf ft) Brake caliper slide pin 18 N m (1.8 kgf m, 13 lbf ft) Apply locking agent to the threads. Pad pin 18 N m (1.8 kgf m, 13 lbf ft) Pad pin plug 2.5 N m (0.25 kgf m, 1.8 lbf ft) Rear view mirror lock nut 34 N m (3.5 kgf m, 25 lbf ft) TOOL Snap ring pliers SA

100 HYDRAULIC DISC BRAKE TROUBLESHOOTING Brake lever soft or spongy Air in hydraulic system Leaking hydraulic system Contaminated brake pads/disc Worn caliper piston seal Worn master cylinder piston cups Worn brake pads/disc Contaminated caliper Contaminated master cylinder Caliper not sliding properly Low brake fluid level Clogged fluid passage Warped/deformed brake disc Sticking/worn caliper piston Sticking/worn master cylinder piston Bent brake lever Brake lever hard Clogged/restricted brake system Sticking/worn caliper piston Caliper not sliding properly Sticking/worn master cylinder piston Bent brake lever Brake drags Contaminated brake pads/disc Misaligned wheel Badly worn brake pads/disc Warped/deformed brake disc Caliper not sliding properly Clogged/restricted fluid passage Sticking caliper piston 14-4

101 BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE FLUID DRAINING Turn the handlebar until the master cylinder reservoir is level before removing the reservoir cap. Remove the screws, reservoir cap, set plate and diaphragm. HYDRAULIC DISC BRAKE SCREWS RESERVOIR CAP SET PLATE DIAPHRAGM Connect a bleed hose to the bleed valve. Loosen the bleed valve and pump the brake lever until no more fluid flows out of the bleed valve. Tighten the bleed valve. BLEED HOSE Follow the manufacturer s operating instructions. If air enters the bleeder from around the bleed valve threads, seal the threads with teflon tape. BRAKE FLUID FILLING/AIR BLEEDING Close the bleed valve. Fill the reservoir with DOT 3 or DOT 4 brake fluid from a sealed container. Connect a commercially available brake bleeder to the bleed valve. Operate the brake bleeder and loosen the bleed valve. Check the fluid level often while bleeding the brake to prevent air from being pumped into the system. Perform the bleeding procedure until the system is completely flushed/bled. Close the bleed valve and operate the brake lever. If it still feels spongy, bleed the system again. BLEED VALVE BRAKE BLEEDER BLEED VALVE 14-5

102 HYDRAULIC DISC BRAKE Do not release the lever until the bleed valve has been closed. If a brake bleeder is not available, use the following procedure: Connect a bleed hose to the bleed valve. Pressurize the system with the brake lever until lever resistance is felt. 1. Squeeze the brake lever, open the bleed valve 1/4 turn and then close it. 2. Release the brake lever slowly and wait several seconds after it reaches the end of its travel. 3. Repeat the steps 1 and 2 until there are no air bubbles in the bleed hose. After bleeding the system completely, tighten the bleed valve. TORQUE: 8 N m (0.8 kgf m, 5.9 lbf ft) Fill the reservoir to the upper level line with DOT 3 or DOT 4 brake fluid. BRAKE LEVER UPPER LINE (CASING LEDGE) Install the diaphragm, set plate and reservoir cap and tighten the screws. TORQUE: 1.5 N m (0.15 kgf m, 1.1 lbf ft) SCREWS RESERVOIR CAP SET PLATE DIAPHRAGM 14-6

103 BRAKE PADS/DISC Check the brake fluid level in the master cylinder reservoir as this operation causes the fluid level to rise. BRAKE PADS REPLACEMENT Push the caliper pistons all the way in to allow installation of new brake pads. HYDRAULIC DISC BRAKE Remove the pad pin plugs. PAD PIN PLUGS Loosen the pad pins. Remove the caliper mounting bolts and brake caliper. BRAKE CALIPER BOLTS PAD PINS Pull the pad pins out of the caliper while pushing in the pads against the pad spring. PAD PINS 14-7

104 HYDRAULIC DISC BRAKE Remove the brake pads. BRAKE PADS Make sure the pad spring is installed in position. Always replace the brake pads in pairs to ensure even disc pressure. Install new brake pads into the caliper so their ends are positioned onto the bracket as shown. BRAKE PADS PAD SPRING Install the pad pin by pushing the pads against the pad spring to align the pad pin holes of the pads and caliper. PAD PINS 14-8

105 HYDRAULIC DISC BRAKE Install the brake caliper and new mounting bolts. Tighten the brake caliper mounting bolts. TORQUE: 30 N m (3.1 kgf m, 22 lbf ft) Tighten the pad pins. TORQUE: 18 N m (1.8 kgf m, 13 lbf ft) Operate the brake lever to seat the caliper pistons against the pads. BRAKE CALIPER BOLTS PAD PINS Install and tighten the pad pin plugs. TORQUE: 2.5 N m (0.25 kgf m, 1.8 lbf ft) PAD PIN PLUG BRAKE DISC INSPECTION Visually inspect the brake disc for damage or crack. Measure the brake disc thickness at several points. SERVICE LIMIT: 3.5 mm (0.14 in) Measure the brake disc runout with a dial indicator. SERVICE LIMIT: 0.10 mm (0.004 in) Check the wheel bearings for excessive play, if the warpage exceeds the service limit. Replace the brake disc if the wheel bearings are normal. Refer to Front Wheel/Brake/Suspension/Steering section for brake disc replacement (page 12-13). 14-9

106 HYDRAULIC DISC BRAKE MASTER CYLINDER DISASSEMBLY The right rearview mirror lock nut has left-hand threads. Drain the brake fluid from the hydraulic system (page 14-5). Remove the following: brake light switch connectors rearview mirror MIRROR CONNECTORS When removing the oil bolt, cover the end of the hose to prevent contamination. oil bolt and sealing washers brake hose two bolts holder master cylinder MASTER CYLINDER WASHERS HOLDER OIL BOLT HOSE BOLTS pivot nut and bolt brake lever BOLT LEVER NUT screw and brake light switch piston boot SCREW SWITCH BOOT 14-10

107 HYDRAULIC DISC BRAKE snap ring TOOL: Snap ring pliers SA50001 PLIERS SNAP RING master piston spring Clean the master cylinder, reservoir and master piston in clean brake fluid. MASTER PISTON SPRING INSPECTION Check the master cylinder and piston for scoring, scratches or damage. Check the piston cups and boot for wear, deterioration or damage. Check the spring for fatigue or damage

108 HYDRAULIC DISC BRAKE ASSEMBLY SCREWS 1.5 N m (0.15 kgf m, 1.1 lbf ft) SNAP RING BOOT MASTER PISTON SPRING PIVOT BOLT 1.0 N m (0.10 kgf m, 0.7 lbf ft) MASTER CYLINDER PISTON CUPS BRAKE LIGHT SWITCH BRAKE LEVER Do not allow the piston cup lips to turn inside out. PIVOT NUT 6.0 N m (0.6 kgf m, 4.4 lbf ft) Coat the master piston and piston cups with clean brake fluid. Install the spring onto the master piston. Install the master piston/spring into the master cylinder. SCREW 1.0 N m (0.10 kgf m, 0.7 lbf ft) SPRING MASTER PISTON CUPS Make sure the snap ring is firmly seated in the groove. Install the snap ring into the groove in the master cylinder with the chamfered side facing the piston. TOOL: Snap ring pliers SA50001 PLIERS SNAP RING 14-12

109 HYDRAULIC DISC BRAKE Install the boot into the master cylinder and the piston groove. Apply silicone grease to the brake lever contacting surface of the piston. BOOT Apply silicone grease to the brake lever pivot sliding surface. Install the brake lever and pivot bolt, and tighten it while holding the pivot bolt. TORQUE: 1.0 N m (0.10 kgf m, 0.7 lbf ft) Install the pivot nut and tighten it. TORQUE: 6.0 N m (0.6 kgf m, 4.4 lbf ft) BOLT LEVER NUT Install the brake light switch by aligning the locating pin with the hole and tighten the screw. TORQUE: 1.0 N m (0.10 kgf m, 0.7 lbf ft) SCREW SWITCH BOOT Align the edge of the master cylinder with the punch mark on the handlebar. Rest the hose joint against the stopper. Install the master cylinder and holder with the UP mark facing up. Tighten the upper bolt first, then tighten the lower bolt. Connect the brake hose to the master cylinder with the oil bolt and new sealing washers. Tighten the oil bolt. MASTER CYLINDER Align WASHERS OIL BOLT BOLTS TORQUE: 34 N m (3.5 kgf m, 25 lbf ft) HOSE HOLDER ("UP") 14-13

110 HYDRAULIC DISC BRAKE The right rearview mirror lock nut has left-hand threads. Install the rearview mirror. Tighten the rear view mirror lock nut to the specified torque. TORQUE: 34 N m (3.5 kgf m, 25 lbf ft) Connect the brake light switch connectors. Fill and bleed the hydraulic system (page 14-5). MIRROR CONNECTORS BRAKE CALIPER When removing the oil bolt, cover the end of the hose to prevent contamination. REMOVAL Drain the brake fluid from the hydraulic system (page 14-5). Disconnect the brake hose from the brake caliper by removing the oil bolt and sealing washers. Remove the brake pads and brake caliper (page 14-7). BRAKE HOSE OIL BOLT BRAKE CALIPER DISASSEMBLY Remove the following: caliper bracket pin boots SEALING WASHERS BRACKET BOOTS Place a shop towel over the piston. Do not use high pressure air or bring the nozzle too close to the inlet. Position the caliper body with the piston facing down and apply small squirts of air pressure to the fluid inlet to remove the piston

111 Be careful not to damage the piston sliding surface. Push the dust and piston seals in and lift them out. Clean the seal grooves, caliper cylinders and piston with clean brake fluid. HYDRAULIC DISC BRAKE PISTON SEAL INSPECTION Check the caliper cylinders and pistons for scoring, scratches or damage. DUST SEAL CALIPER PISTONS 14-15

112 HYDRAULIC DISC BRAKE ASSEMBLY BLEED VALVE 8 N m (0.8 kgf m, 5.9 lbf ft) PAD PIN PLUGS 2.5 N m (0.25 kgf m, 1.8 lbf ft) BOOT *: Apply 0.02 g PISTON SEALS * DUST SEALS * PAD PINS 18 N m (1.8 kgf m, 13 lbf ft) BOOT CALIPER BODY CALIPER BRACKET PAD SPRING CALIPER PISTONS BRAKE PADS Coat new dust seals with 0.02 g of clean brake fluid and install them into the seal grooves in the caliper. Coat new pistons with clean brake fluid and install them into the caliper. Coat the caliper piston with clean brake fluid and install them into the caliper cylinders with the open side toward the pads. SEALS CALIPER PISTONS Check the pin boots and replace them if they are hard, deteriorated or damaged. Install the boot into the caliper. Apply silicone grease to the inside of the boots and install the caliper bracket over the caliper body. Make sure the boot ribs are seated into the boot grooves in the slide pins properly. BRACKET BOOTS 14-16

113 INSTALLATION Install the brake pads and brake caliper (page 14-7). Connect the brake hose to the brake caliper with the oil bolt and new sealing washers. Set the hose eyelet joint into the stopper groove and tighten the oil bolt. TORQUE: 34 N m (3.5 kgf m, 25 lbf ft) Fill and bleed the hydraulic system (page 14-5). BRAKE HOSE OIL BOLT HYDRAULIC DISC BRAKE GROOVE BRAKE CALIPER SEALING WASHERS 14-17

114 MEMO

115 15. BATTERY/CHARGING SYSTEM COMPONENT LOCATION 15-2 SYSTEM DIAGRAM 15-2 SERVICE INFORMATION 15-3 TROUBLESHOOTING 15-4 BATTERY 15-5 CHARGING SYSTEM INSPECTION 15-7 REGULATOR/RECTIFIER 15-8 ALTERNATOR CHARGING COIL

116 BATTERY/CHARGING SYSTEM BATTERY/CHARGING SYSTEM COMPONENT LOCATION REGULATOR/RECTIFIER IGNITION SWITCH BATTERY ALTERNATOR SUB FUSE (15 A) MAIN FUSE (20 A) SYSTEM DIAGRAM To SWITCHES Bl R/Bl R/Bl R/W SUB FUSE 15 A IGNITION SWITCH R/W Y Y Y Y Y Y R/W G R MAIN FUSE 20 A Bl: Black G: Green R: Red Y: Yellow W: White ALTERNATOR REGULATOR/RECTIFIER BATTERY 15-2

117 SERVICE INFORMATION GENERAL BATTERY/CHARGING SYSTEM The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. If electrolyte gets on your skin, flush with water. If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately. Electrolyte is poisonous. If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a physician immediately. KEEP OUT OF REACH OF CHILDREN. Always turn OFF the ignition switch before disconnecting any electrical component. Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present. For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum service life, charge the stored battery every two weeks. For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal. The battery can be damaged if overcharged or undercharged, or if left to discharge for long period. These same conditions contribute to shortening the "life span" of the battery. Even under normal use, the performance of the battery deteriorates after 2 3 years. Battery voltage may recover after battery charging, but under heavy load, the battery voltage will drop quickly and eventually die out. For this reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in the battery itself, which may appear to be an overcharging symptom. If one of the battery cells is shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes down quickly. Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is frequently under heavy load, such as having the headlight and taillight ON for long periods of time without riding the motorcycle. The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every two weeks to prevent sulfation from occurring. Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance, always charge the battery. Also, the battery life is lengthened when it is initially charged. When checking the charging system, always follow the steps in the troubleshooting (page 15-4). Alternator stator removal/installation (page 10-5). Ignition switch servicing (page 18-9). BATTERY TESTING Refer to the instruction of the Operation Manual for the recommended battery tester for details about battery testing. The recommended battery tester puts a "load" on the battery so that the actual battery condition can be measured. Recommended battery tester: BM210 or BATTERY MATE or equivalent SPECIFICATIONS ITEM SPECIFICATIONS Battery Capacity 12 V 7 Ah Current leakage 1 ma max. Specific gravity Fully charged (20 C/68 F) Needs charging Below Voltage Fully charged V (20 C/68 F) Needs charging Below 12.3 V Charging current Normal 0.6 A/5 10 h Quick 3 A/1 h Alternator Capacity 0.16 kw/5,000 min -1 (rpm) Charging coil resistance (20 C/68 F) Ω TORQUE VALUE Battery holder bolt 1.8 N m (0.18 kgf m, 1.3 lbf ft) 15-3

118 BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. Battery Test Remove the battery (page 15-5). Check the battery condition using the recommended battery tester. RECOMMENDED BATTERY TESTER: BM210 or BATTERY MATE or equivalent Is the battery in good condition? YES GO TO STEP 2. NO Faulty battery 2. Current Leakage Test Install the battery (page 15-5). Check the battery current leakage test (Leak test;(page 15-7)). Is the current leakage below 1 ma? YES GO TO STEP 4. NO GO TO STEP Current Leakage Test Without Regulator/Rectifier Disconnect the regulator/rectifier connector and recheck the battery current leakage. Is the current leakage below 1 ma? YES Faulty regulator/rectifier NO Shorted wire harness Faulty ignition switch 4. Charging Voltage Inspection Measure and record the battery voltage using a digital multimeter (page 15-6). Start the engine. Measure the charging voltage (page 15-7). Compare the measurements to the results of the following calculation. STANDARD: Measured BV < Measured CV < 15.5 V BV = Battery Voltage CV = Charging Voltage Is the measured charging voltage within the standard voltage? YES Intermittent failure (system is normal.) NO GO TO STEP Alternator Charging Coil Inspection Measure the alternator charging coil resistance (page 15-8). STANDARD: Ω (20 C/68 F) Is the alternator charging coil resistance within the standard value? YES GO TO STEP 6. NO Faulty charging coil 6. REGULATOR/RECTIFIER SYSTEM INSPECTION Perform the regulator/rectifier system inspection (page 15-8). Are the measurements correct? YES Faulty regulator/rectifier NO Open circuit in related wire Loose or poor contacts of related terminal Shorted wire harness 15-4

119 BATTERY Connect the positive (+) terminal first, and then the negative ( ) cable. REMOVAL/INSTALLATION Remove the left side cover (page 2-4). Turn the ignition switch to OFF. Remove the bolt, nut and battery negative ( ) cable from the battery. Remove the bolt, nut and battery positive (+) cable from the battery. Remove the battery holder bolt and open the battery stay. Remove the battery by disconnecting the battery breather hose. Install the battery in the reverse order of removal. Make sure that the battery breather hose is correctly positioned, and not kinked, trapped or bent in such away as to obstruct the passage of the air. If the hose is blocked, the battery s internal pressure will not be relieved, the breather may come off, or the battery crack as a result. NUTS HOSE TORQUE: BATTERY HOLDER BOLT: 1.8 N m (0.18 kgf m, 1.3 lbf ft) NEGATIVE ( ) CABLE BATTERY/CHARGING SYSTEM POSITIVE (+) CABLE BATTERY STAY TERMINAL BOLT HOLDER BOLT BATTERY INSPECTION remove the battery (page 15-5). Check for cracked or broken case or plates. Check the plates for sulfation. Check each cell s electrolyte level. If low, remove the caps and add distilled water to bring the level to the upper level line. Replace the battery if damaged or sulfated. In order to obtain an accurate test reading when checking the charging system, the battery must be fully charged and in good condition. Perform the following inspections and tests before attempting to troubleshooting charging system problems. DISTILLED WATER UPPER LEVEL LINE CAPS 15-5

120 BATTERY/CHARGING SYSTEM SPECIFIC GRAVITY The battery electrolyte contains sulfuric acid. Avoid contact with skin, eyes or clothing. The specific gravity must be checked with a hydro meter. Test each cell by drawing electrolyte into the hydrometer. SPECIFIC GRAVITY (20 C/68 F): Fully charged: Under charged: Below HYDROMETER ELECTROLYTE If the difference in specific gravity between cells exceeds 0.01, re-charge the battery. If the difference in specific gravity is excessive, replace the battery. There is a charging in specific gravity of approximately per 10 C change in temperature. Be sure to consider this when taking measurements. Reading of the hydrometer s fluid level should be taken horizontally. SPECIFIC GRAVITY CAPS ELECTROLYTE TEMPERATURE ( C) VOLTAGE INSPECTION Remove the left side cover (page 2-4). Measure the battery voltage using a commercially available digital multimeter. VOLTAGE (20 C/68 F):Fully charged: V Under charged: Below 12.3 V When measuring the battery voltage after charging, leave it for least 30 minutes, or the accurate results cannot be obtained because the battery voltage fluctuates just after charging. (-) (+) Turn power ON/ OFF at the charger, not at the battery terminals to prevent sparks. BATTERY CHARGING Remove the battery (page 15-5). Connect the charger positive (+) cable to the battery positive (+) terminal. Connect the charger negative ( ) cable to the battery negative ( ) terminal. CHARGING CURRENT/TIME: Normal: 0.6 A/5 10 h Quick: 3 A/1 h CHARGER 15-6 Quick-charging should only be done in an emergency; slow charging is preferred. For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or extending the charging time may damage the battery. BATTERY

121 CHARGING SYSTEM INSPECTION CURRENT LEAKAGE INSPECTION Remove the left side cover (page 2-4). Turn the ignition switch to OFF and disconnect the battery negative ( ) cable from the battery. Connect the ammeter (+) probe to the battery negative ( ) cable and the ammeter ( ) probe to the battery negative ( ) terminal. With the ignition switch turned to OFF, check for current leakage. BATTERY/CHARGING SYSTEM (+) PROBE (-) PROBE When measuring current using a tester, set it to a high range, and then bring the range down to an appropriate level. Current flow higher than the range selected may blow out the fuse in the tester. While measuring current, do not turn the ignition switch to ON. A sudden surge of current may blow out the fuse in the tester. (-) CABLE CURRENT LEAKAGE: 1 ma max. If the current leakage exceeds the specified value, a shorted circuit is likely. Locate the short by disconnecting connections one by one and measuring the current. CHARGING VOLTAGE INSPECTION Be sure the battery is in good condition before performing this test. Remove the left side cover (page 2-4). Warm up the engine to normal operating temperature and stop it. Connect the multimeter between the battery positive (+) and negative ( ) terminals. (-) (+) To prevent a short, make absolutely certain which are the positive (+) and negative ( ) terminals or cables. Do not disconnect the battery or any cable in the charging system without first switching off the ignition switch. Failure to follow this precaution can damage the tester or electrical components. Restart the engine and turn the headlight on. Measure the voltage on the multimeter when the engine runs at 5,000 min 1 (rpm). STANDARD: Measured BV < Measured CV < 15.5 V BV = Battery voltage CV = Charging voltage 15-7

122 BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER SYSTEM INSPECTION Remove the fuel tank (page 2-5). Disconnect the regulator/rectifier 6P connector, and check it for loose contact or corroded terminals. Check the following at the wire harness side connector terminals. Item Terminal Specification Battery Red/White (+) Battery voltage should charging line and Green ( ) exist at all times. Ground line Green and Continuity should exist ground at all times. 6P CONNECTOR Charging coil line inspection (page 15-8). REMOVAL/INSTALLATION Remove the fuel tank (page 2-5). Disconnect the regulator/rectifier 6P connector. Remove the two bolts and regulator/rectifier. Installation is in the reverse order of removal. BOLTS 6P CONNECTOR ALTERNATOR CHARGING COIL INSPECTION Remove the left side cover (page 2-4). Disconnect the alternator 3P connector, and check it for loose contact or corroded terminals. Measure the resistance between the Yellow wire terminals of the alternator side connector. STANDARD: Ω (20 C/68 F) Check for continuity between each Yellow wire terminal of the alternator side connector and ground. There should be no continuity. If resistance is out of specification or if any wire has continuity to ground, replace the alternator stator (page 10-5). REGULATOR/ RECTIFIER 3P CONNECTOR 15-8

123 16. IGNITION SYSTEM COMPONENT LOCATION 16-2 SYSTEM DIAGRAM 16-2 SERVICE INFORMATION 16-3 TROUBLESHOOTING 16-4 IGNITION SYSTEM INSPECTION 16-5 IGNITION TIMING 16-7 IGNITION COIL 16-8 ICM (IGNITION CONTROL MODULE)

124 IGNITION SYSTEM IGNITION SYSTEM COMPONENT LOCATION IGNITION SWITCH ICM BATTERY IGNITION COIL SPARK PLUG IGNITION PULSE GENERATOR MAIN FUSE (20 A) SYSTEM DIAGRAM R/Bl IGNITION SWITCH R/W R MAIN FUSE 20 A IGNITION COIL Bl/Y G G G Bu/Y Bu/Y G Bl/Y R/Bl R Bl: Black Bu: Blue G: Green R: Red Y: Yellow W: White SPARK PLUG IGNITION PULSE GENERATOR ICM BATTERY 16-2

125 SERVICE INFORMATION GENERAL IGNITION SYSTEM The Ignition Control Module (ICM) may be damaged if dropped. Also if the connector is disconnected when current is flowing, the excessive voltage may damage the ICM. Always turn the ignition switch to OFF before servicing. Use spark plug with the correct heat range. Using spark plug with an incorrect heat range can damage the engine. When servicing the ignition system, always follow the steps in the troubleshooting chart (page 16-4). The ignition timing cannot be adjusted since the ICM is factory preset. A faulty ignition system is often related to poor connections. Check those connections before proceeding. Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spark plug. Ignition pulse generator removal/installation (page 10-5). Ignition switch servicing (page 18-9). SPECIFICATION ITEM SPECIFICATION Spark plug Standard CPR7EA-9 (NGK) For extended high speed riding CPR8EA-9 (NGK) Spark plug gap mm ( in) Ignition coil primary peak voltage 100 V minimum Ignition pulse generator peak voltage 0.7 V minimum Ignition timing ("F" mark) 8 BTDC at idle TORQUE VALUE Timing hole cap 10 N m (1.0 kgf m, 7 lbf ft) TOOLS Peak voltage adaptor 07HGJ

126 IGNITION SYSTEM TROUBLESHOOTING Inspect the following before diagnosing the system. Faulty spark plug Loose spark plug cap or spark plug wire connection Water got into the spark plug cap (Leaking the ignition coil secondary voltage) No spark at plug Unusual condition Ignition coil primary Low peak voltage. voltage Ignition pulse generator No peak voltage. Peak voltage is normal, but no spark at the plug. Low peak voltage. No peak voltage. Probable cause (check in numerical order) 1. The multimeter impedance is too low; below 10 MΩ/DCV. 2. Cranking speed is too slow. (Battery is undercharged.) 3. The sampling time of the tester and measured pulse were not synchronized. (System is normal if measured voltage is over the standard voltage at least once.) 4. Poorly connected connectors or an open circuit in the ignition system. 5. Faulty ignition coil. 6. Faulty ICM (in case when above No. 1 through 5 are normal). 1. Incorrect peak voltage adaptor connections. (System is normal if measured voltage is over the specifications with reverse connections.) 2. Battery is undercharged. (Voltage drops largely when the engine is started.) 3. Faulty ignition switch. 4. Loose or poorly connected ICM connector. 5. No voltage at the Red/black wire of the ICM. 6. Open circuit or poor connection in the Green wire of the ICM. 7. Faulty peak voltage adapter. 8. Faulty ignition pulse generator. (Measure the peak voltage.) 9. Faulty ICM (in case when above No. 1 through 8 are normal). 1. Faulty spark plug or leaking ignition coil secondary current. 2. Faulty ignition coil. 1. The multimeter impedance is too low; below 10 MΩ/DCV. 2. Cranking speed is too slow. (Battery is undercharged.) 3. The sampling time of the tester and measured pulse were not synchronized. (System is normal if measured voltage is over the standard voltage at least once.) 4. Faulty ignition pulse generator (in case when above No. 1 through 3 are normal). 1. Faulty peak voltage adapter. 2. Faulty ignition pulse generator. 16-4

127 IGNITION SYSTEM INSPECTION IGNITION SYSTEM If there is no spark at the plug, check all connections for loose or poor contact before measuring the peak voltage. Use a commercially available digital multimeter with an impedance of 10 MΩ/DCV minimum. The display value differs depending upon the internal impedance of the multimeter. If using the Imrie diagnostic tester (model 625), follow the manufacturer s instructions. Connect the peak voltage adaptor to the digital multimeter, or use the Imrie diagnostic tester. DIGITAL MULTIMETER TOOL: Imrie diagnostic tester (model 625) or Peak voltage adaptor 07HGJ with commercially available digital multimeter (impedance 10 MW/DCV minimum) IGNITION COIL PRIMARY PEAK VOLTAGE INSPECTION PEAK VOLTAGE ADAPTOR Check all system connections before this inspection. Poor connected connectors can cause incorrect readings. Check that the cylinder compression is normal and the spark plug is installed correctly in the cylinder head. Disconnect the spark plug cap from the spark plug. Connect a known good spark plug to the spark plug cap and ground it to the cylinder head as done in a spark test. KNOWN GOOD SPARK PLUG 16-5

128 IGNITION SYSTEM With the connector connected, connect the Imrie diagnostic tester or peak voltage adaptor probes to the ignition coil primary wire terminal and body ground. TOOL: Imrie diagnostic tester (model 625) or Peak voltage adaptor 07HGJ with commercially available digital multimeter (impedance 10 MΩ/DCV minimum) CONNECTION: Black/yellow ( ) Body ground (+) Shift the transmission into neutral. Turn the ignition switch to ON. Crank the engine with the starter motor and read ignition coil primary peak voltage. PEAK VOLTAGE: 100 V minimum If the peak voltage is lower than the standard value, follow the checks described in the troubleshooting chart (page 16-4). IGNITION PULSE GENERATOR PEAK VOLTAGE ( ) PROBE (+) PROBE IGNITION COIL CONNECTOR PEAK VOLTAGE ADAPTOR 16-6 Check that the cylinder compression is normal and the spark plug is installed correctly in the cylinder head. Remove the ICM (page 16-8). Connect the Imrie diagnostic tester or adaptor probes to the wire harness side 4P connector terminals. TOOL: Imrie diagnostic tester (model 625) or Peak voltage adaptor 07HGJ with commercially available digital multimeter (impedance 10 MΩ/DCV minimum) CONNECTION: Blue/yellow (+) Green ( ) Shift the transmission into neutral. Turn the ignition switch to ON. Crank the engine with the starter motor and read the ignition pulse generator peak voltage. PEAK VOLTAGE: 0.7 V minimum If the peak voltage measured at the ICM 4P connector is abnormal, measure the peak voltage at the ignition pulse generator side. Remove the left side cover (page 2-4). Disconnect the ignition pulse generator 2P connector and connect the tester probes to the ignition pulse generator side 2P connector terminals. CONNECTION: Blue/yellow (+) Green ( ) In the same manner as at the ICM connector, measure the peak voltage and compare it to the voltage measured at the ICM connector. If the peak voltage measured at the ICM is abnormal and the one measured at the ignition pulse generator is normal, the wire harness has an open or short circuit, or loose connection. If both peak voltages are abnormal, follow the checks described in the troubleshooting chart (page 16-4). Green ( ) Blue/yellow (+) 2P CONNECTOR ICM 4P CONNECTOR

129 IGNITION TIMING Warm up the engine. Stop the engine and remove the timing hole cap and O- ring. IGNITION SYSTEM TIMING HOLE CAP O-RING Read the instructions for timing light operation. Connect a timing light to the spark plug wire. Start the engine, let it idle and check the ignition timing. TIMING LIGHT The ignition timing is correct if the "F" mark on the flywheel aligns with the index notch on the left crankcase cover. INDEX NOTCH "F" MARK Coat a new O-ring with engine oil and install it onto the timing hole cap. Install the timing hole cap and tighten it. TORQUE: 10 N m (1.0 kgf m, 7 lbf ft) TIMING HOLE CAP O-RING 16-7

130 IGNITION SYSTEM IGNITION COIL REMOVAL/INSTALLATION Remove the fuel tank (page 2-5). Disconnect the ignition coil primary wire connector. CONNECTOR Remove the plug cap from the spark plug and release the plug wire from the wire holder and the clamp. HOLDER PLUG CAP Route the spark plug wire properly (page 1-16). Remove the two bolts, ground terminal and ignition coil. Installation is in the reverse order of removal. BOLTS ICM (IGNITION CONTROL MODULE) REMOVAL/INSTALLATION Remove the right side cover (page 2-4). Release the ICM from the stays of the frame. Disconnect the ICM 4P connector and remove the ICM. Installation is in the reverse order of removal. IGNITION COIL ICM GROUND TERMINAL 4P CONNECTOR STAYS 16-8

131 POWER/GROUND LINE INSPECTION Remove the ICM (page 16-8). Turn the ignition switch "ON". Measure the voltage between the ICM 4P connector of the wire harness side. CONNECTION: Red/Black (+) Green ( ) There should be battery voltage with the ignition switch "ON". If there is no voltage with the ignition switch "ON", check the following: Wire harness between the battery and ICM Ignition switch Main fuse 20 A Turn the ignition switch "OFF". Disconnect the ICM 4P connector. Check for continuity between the ICM 4P connector of the wire harness side. CONNECTION: Green Body ground There should be continuity at all time. If there is no continuity, check the open circuit in green wire. IGNITION SYSTEM 4P CONNECTOR 16-9

132 MEMO

133 17. ELECTRIC STARTER COMPONENT LOCATION 17-2 SYSTEM DIAGRAM 17-2 SERVICE INFORMATION 17-3 STARTER MOTOR 17-6 STARTER RELAY NEUTRAL DIODE TROUBLESHOOTING

134 ELECTRIC STARTER ELECTRIC STARTER COMPONENT LOCATION CLUTCH SWITCH STARTER SWITCH BATTERY STARTER RELAY SWITCH IGNITION SWITCH MAIN FUSE (20 A) DIODE SYSTEM DIAGRAM GEAR POSITION SWITCH STARTER MOTOR SUB FUSE (15 A) STARTER RELAY SWITCH R G/R Y/R BATTERY R MAIN FUSE 20 A R/W IGNITION SWITCH R/Bl STARTER MOTOR Y/R Bl STARTER SWITCH Lg/R R/Bl SUB FUSE 15 A 2 3 Bl: Black G: Green Lg: Light green R: Red Y: Yellow W: White G/R DIODE G/R CLUTCH SWITCH G Lg/R 1 N 5 4 GEAR POSITION SWITCH 17-2

135 SERVICE INFORMATION GENERAL ELECTRIC STARTER If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damaged. Always turn the ignition switch to OFF before servicing the starter motor. The motor could suddenly start, causing serious injury. The starter motor can be serviced with the engine in the frame. When checking the starter system, always follow the steps in the troubleshooting (page 17-4). A weak battery may be unable to turn the starter motor quick enough, or supply adequate ignition current. Starter clutch servicing (page 10-6) Ignition switch servicing (page 18-9) Starter switch inspection (page 18-11) Clutch switch inspection (page 18-12) Gear position switch servicing (page 18-13) SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter motor brush length ( ) 3.5 (0.14) TORQUE VALUE Starter motor case bolt 4.9 N m (0.50 kgf m, 3.6 lbf ft) 17-3

136 ELECTRIC STARTER TROUBLESHOOTING NOTE: The starter motor should operate when the transmission is in neutral or when the clutch lever is squeezed. Starter motor does not turn 1. Fuse Inspection Check for blown main fuse (20 A) or sub-fuse (15 A). Is the fuse blown? YES Replace the fuse. NO GO TO STEP Battery Inspection Make sure the battery is fully charged and in good condition. Is the battery in good condition? YES GO TO STEP 3. NO Charge or replace the battery (page 15-5). 3. Battery Cable Inspection Check the battery cables for loose or poorly connected terminal, and for an open circuit. Is the battery cable in good condition? YES GO TO STEP 4. NO Loose or poorly connected battery cables. Open circuit in the battery cable. 4. Starter Motor Cable Inspection Check the starter motor cable for loose or poorly connected terminal, and for an open circuit. Is the starter motor cable in good condition? YES GO TO STEP 5. NO Loose or poorly connected starter motor cable. Open circuit in the starter motor cable. 5. Starter Relay Switch Operation Inspection Check the operation of the starter relay switch (page 17-12). Does the starter relay switch click? YES GO TO STEP 6. NO GO TO STEP Starter Motor Inspection Connect the starter motor terminal to the battery positive (+) terminal directly. (A large amount of current flows, so do not use a thin wire.) Does the starter motor turn? YES Faulty starter relay switch. NO Faulty starter motor. 7. Relay Coil Ground Line Inspection Check the ground line of the starter relay switch (page 17-12). Is the ground line normal? YES GO TO STEP 8. NO Faulty neutral diode (page 17-14). Faulty gear position switch (page 18-13). Faulty clutch switch (page 18-12). Loose or poor contact of the related connector terminal. Open circuit in the wire harness. 17-4

137 8. Relay Coil Power Input Line Inspection Check the power input line of the starter relay switch (page 17-12). Is the power input line normal? YES GO TO STEP 9. NO Faulty ignition switch (page 18-9). Faulty starter switch (page 18-11). Loose or poor contact of the related connector terminal. Open circuit in the wire harness. 9. Starter Relay Switch Inspection Check the function of the starter relay switch (page 17-13). Does the starter relay switch function properly? NO Faulty starter relay switch. YES Loose or poor contact of the starter relay switch connector. ELECTRIC STARTER Starter motor turns, but the engine turns slowly Low battery voltage Poorly connected battery cable Poorly connected starter motor cable Faulty starter motor Poorly connected ground cable terminal Starter motor turns, but engine does not turn Faulty starter clutch Damaged or faulty starter gear train Starter relay switch clicks, but engine does not turn Crankshaft does not turn due to engine problems 17-5

138 ELECTRIC STARTER STARTER MOTOR REMOVAL Disconnect the negative ( ) cable from the battery (page 15-5). Slide the rubber cap off the starter motor terminal, and remove the starter motor terminal nut and starter motor cable. Remove the mounting bolts, battery ( ) cable and starter motor from the crankcase. MOTOR CABLE RUBBER CAP NUT ( ) CABLE Remove the O-ring from the starter motor. BOLTS STARTER MOTOR DISASSEMBLY/INSPECTION Remove the following: motor case bolts O-rings setting plates O-RING BOLTS, SETTING PLATES, O-RING If the shims are installed, record the location and number of them. front cover seal ring shim(s) SHIM FRONT COVER SEAL RING 17-6

139 ELECTRIC STARTER rear cover seal ring armature SEAL RING Check the oil seal and bushing in the front cover for deterioration, wear or damage. ARMATURE REAR COVER BUSHING Do not use emery or sand paper on the commutator. Check the commutator bars of the armature for discoloration. OIL SEAL COMMUTATOR BARS Check for continuity between pairs of commutator bars. There should be continuity. CONTINUITY: 17-7

140 ELECTRIC STARTER Check for continuity between each commutator bar and the armature shaft. There should be no continuity. NO CONTINUITY: Check for continuity between the insulated brush and cable terminal. There should be continuity. CONTINUITY: Check for continuity between the insulated brush and rear cover as shown. There should be no continuity. Remove the brushes from the brush holder. NO CONTINUITY: Measure the brush length. SERVICE LIMIT: 3.5 mm (0.14 in) Remove the brush holder. BRUSH HOLDER 17-8

141 ELECTRIC STARTER Remove the following: nut insulators O-ring cable terminal Insulator plate CABLE TERMINAL INSULATOR PLATE NUT O-RING INSULATORS Check the bushing in the rear cover for wear or damage. BUSHING ASSEMBLY INSULATOR PLATE NUT INSULATORS CABLE TERMINAL O-RING BRUSH HOLDER REAR COVER ARMATURE SHIM(S) SEAL RING MOTOR CASE SETTING PLATES SEAL RING MOTOR CASE BOLTS 4.9 N m (0.50 kgf m, 3.6 lbf ft) O-RINGS FRONT COVER 17-9

142 ELECTRIC STARTER Install the following: Insulator plate cable terminal new O-ring insulators nut CABLE TERMINAL INSULATOR PLATE NUT Install the brush holder into the rear cover by aligning the cutouts with the insulator plate. Install the brushes into the brush holder. O-RING INSULATORS Align BRUSH HOLDER Install the armature into the rear cover while pushing the brushes into the brush holder. BRUSHES REAR COVER ARMATURE Install a new seal ring onto the motor case. While holding the armature tightly to prevent the magnet of the motor case from pulling the armature against it, install the motor case over the armature and into the rear cover. REAR COVER SEAL RING The coil may be damaged if the magnet pulls the armature and hits the case. MOTOR CASE 17-10

143 ELECTRIC STARTER Install the same number of shims in the same locations as noted during disassembly if they are installed. Install a new seal ring onto the motor case. Install the front cover. SHIM FRONT COVER SEAL RING Align the index lines on the motor case, rear cover and front cover. Install the motor case bolts with the setting plates and new O-rings and tighten them to the specified torque. TORQUE: 4.9 N m (0.50 kgf m, 3.6 lbf ft) Align O-RINGS SETTING PLATES INSTALLATION Coat a new O-ring with clean engine oil and install it into the starter motor groove. CASE BOLTS O-RING 17-11

144 ELECTRIC STARTER Install the starter motor into the left crankcase cover and onto the crankcase. MOTOR CABLE RUBBER CAP Route the wire harness properly (page 1-16). Install the mounting bolts with the battery ( ) cable, and tighten the bolts. Install the starter motor cable and terminal nut onto the motor terminal and tighten the nut as specified. Install the rubber cap over the motor terminal properly. Connect the negative ( ) cable to the battery (page 15-5). NUT ( ) CABLE BOLTS STARTER MOTOR BATTERY NEGATIVE ( ) CABLE 45º STARTER MOTOR CABLE STARTER RELAY OPERATION INSPECTION Remove the left side cover (page 2-4). Shift the transmission into neutral. Turn the ignition switch to ON and push the starter switch. The coil is normal if the starter relay switch clicks. If you don't hear the switch click, inspect the relay switch circuits (page 17-12). Install the left side cover (page 2-4). STARTER RELAY SWITCH CIRCUIT INSPECTION Remove the left side cover (page 2-4). Disconnect the starter relay switch 2P (Black) connector, and check it for loose contact or corroded terminals. GROUND LINE Check for continuity between the Green/red wire terminal of the wire harness side connector and ground. If there is continuity when the transmission is in neutral or when the clutch lever is squeezed, the ground line is normal. 2P CONNECTOR 17-12

145 ELECTRIC STARTER POWER INPUT LINE Turn the ignition switch to ON. Measure the voltage between the Yellow/red wire terminal (+) of the wire harness side connector and ground ( ). If the battery voltage appears only when the starter switch is pushed, the power input line is normal. FUNCTION INSPECTION Remove the starter relay switch (page 17-13). Connect an ohmmeter to the starter relay switch cable terminals. Connect the fully charged 12 V battery to the 2P black connector terminals. CONNECTIONS: Battery (+) terminal Yellow/red Battery ( ) terminal Green/red There should be continuity between the cable terminals while the battery is connected, and no continuity when the battery is disconnected. Install the starter relay switch (page 17-13). REMOVAL/INSTALLATION Remove the left side cover (page 2-4). Disconnect the negative ( ) cable from the battery (page 15-5). Disconnect the starter relay switch 2P (Black) connector. Release the starter relay switch from the stays of the frame. STARTER RELAY SWITCH BATTERY STAYS Route the wire harness properly (page 1-16). Remove the rubber covers from the starter relay switch. Remove the nuts, battery cable, starter motor cable and starter relay switch. Installation is in the reverse order of removal. 2P CONNECTOR STARTER RELAY SWITCH NUTS CABLES COVERS 17-13

146 ELECTRIC STARTER NEUTRAL DIODE INSPECTION Remove the fuel tank (page 2-5). Remove the neutral diode from the wire harness. NEUTRAL DIODE Check for continuity between the diode terminals. When there is continuity, a small resistance value will register. If there is continuity in one direction, the neutral diode is normal. Install the neutral diode in the reverse order of removal. A A B B NEUTRAL DIODE 17-14

147 18. LIGHTS/METERS/SWITCHES COMPONENT LOCATION 18-2 SERVICE INFORMATION 18-3 HEADLIGHT 18-4 BRAKE/TAILLIGHT 18-5 TURN SIGNAL LIGHT 18-5 SPEEDOMETER 18-6 TACHOMETER 18-8 HANDLEBAR SWITCH CLUTCH SWITCH BRAKE LIGHT SWITCH GEAR POSITION SWITCH FUEL GAUGE/FUEL LEVEL SENSOR HORN TURN SIGNAL RELAY IGNITION SWITCH

148 LIGHTS/METERS/SWITCHES LIGHTS/METERS/SWITCHES COMPONENT LOCATION DISC BRAKE TYPE SHOWN: FRONT BRAKE LIGHT SWITCH LEFT HANDLEBAR SWITCHES IGNITION SWITCH RIGHT HANDLEBAR SWITCHES SPEEDOMETER FUEL LEVEL SENSOR TURN SIGNAL RELAY CLUTCH SWITCH HORN GEAR POSITION SWITCH REAR BRAKE LIGHT SWITCH 18-2

149 SERVICE INFORMATION GENERAL Be sure to install the dust cover after replacing the bulb. Check the battery condition before performing any inspection that requires proper battery voltage. A continuity test can be made with the switches installed on the motorcycle. The following color codes are used throughout this section. Bl: Black G: Green Lg: Light green R: Red Bu: Blue Gr: Gray O: Orange W: White Br: Brown Lb: Light blue P: Pink Y: Yellow LIGHTS/METERS/SWITCHES SPECIFICATIONS ITEM SPECIFICATION Bulbs Headlight (Hi/low beam) 12 V - 35/35 W Position light 12 V - 3 W Brake/tail light 12 V - 21/5 W Turn signal light 12 V - 10 W x 4 Instrument light 12 V W x 3 Turn signal indicator 12 V W x 2 High beam indicator 12 V W Gear position indicator LED x 5 Neutral indicator 12 V W Fuse Main 20 A Sub 15 A Fuel level sensor resistance Full 4 10 Ω (20 C/68 F) Empty Ω TORQUE VALUES Fuel level sensor mounting nut 10 N m (1.0 kgf m, 7 lbf ft) Ignition switch mounting bolt 24 N m (2.4 kgf m, 18 lbf ft) ALOC bolt: replace with a new one. TOOLS Peak voltage adaptor 07HGJ

150 LIGHTS/METERS/SWITCHES HEADLIGHT REMOVAL/INSTALLATION Remove the headlight case (page 2-3). Disconnect the headlight wire connectors (Blue, White, Green, Brown). Remove the two bolts and headlight from the headlight stay. Install the headlight by aligning the tabs and slots of the headlight stay. Install the two bolts and tighten it. HEADLIGHT STAY HEADLIGHT Align Route the wire harness properly (page 1-16). Connect the headlight wire connectors (Blue, White, Green, Brown). Install the headlight case (page 2-3). Check the headlight aim (page 3-21) HEADLIGHT BULB REPLACEMENT Remove the headlight case (page 2-3). Remove the dust cover. Unhook the retainer and remove the bulb socket. WIRE CONNECTORS BOLTS RETAINER Push the bulb in, turn it counterclockwise and remove it. If you touch the bulb with your bare hands, clean it with cloth moistened with alcohol to prevent early bulb failure. Install the new bulb in the reverse order of removal. DUST COVER SOCKET SOCKET BULB 18-4

151 POSITION LIGHT BULB REPLACEMENT Remove the headlight case (page 2-3). Pull the position light bulb socket out of the headlight. Pull the bulb out of the socket and replace it with a new one. Install the bulb socket into the headlight securely. Install the headlight case (page 2-3). LIGHTS/METERS/SWITCHES SOCKET BULB BRAKE/TAILLIGHT BULB REPLACEMENT Remove the seat (page 2-4). Turn the bulb socket clockwise and remove it. Push the bulb in, turn it counterclockwise and remove it from the bulb socket. Install the new bulb in the reverse order of removal. BULB TURN SIGNAL LIGHT BULB REPLACEMENT Remove the screw and turn signal light lens. Push the bulb in, turn it counterclockwise and remove it from the turn signal light unit. Replace the bulb with a new one. Install the removed parts in the reverse order of removal. SCREW SOCKET LENS BULB 18-5

152 LIGHTS/METERS/SWITCHES SPEEDOMETER POWER/GROUND LINE INSPECTION Remove the headlight (page 18-4). Disconnect the speedometer 3P connector of the speedometer wire harness. Turn the ignition switch to " " and measure the voltage between the main wire harness side connector terminal. CONNECTION: Black (+) Green ( ) There should be battery voltage. Turn the ignition switch to " ". Check for continuity between the wire harness side connector terminal and ground. CONNECTION: Green Body ground There should be continuity. REMOVAL/INSTALLATION Remove the headlight (page 18-4). Disconnect the following connectors: 6P connector 3P connector Brown wire connector Light blue wire connector Orange wire connector Yellow/green wire connector 3P CONNECTOR CONNECTORS Route the wire harness properly (page 1-16). Disconnect the speedometer cable. Remove the two nuts, washers and speedometer. Install the speedometer in the reverse order of removal. SPEEDOMETER NUTS/ WASHER SPEEDOMETER CABLE 18-6

153 DISASSEMBLY/ASSEMBLY Remove the following: two screw and lower cover screw, O-ring and knob screws and speedometer sub harness screws and meter case screws/washers, fuel meter, speedometer and tachometer Assembly is in the reverse order of disassembly. LIGHTS/METERS/SWITCHES TACHOMETER UPPER CASE SPEEDOMETER FUEL METER SPEEDOMETER SUB HARNESS O-RING KNOB METER CASE SCREWS LOWER COVER PLUG SCREWS/WASHERS Br, G Y/G Bl Y/W G Br, G G Bl SB, G Bu, G GEAR POSITION INDICATER Br, G Lg, Bl O, G 18-7

154 LIGHTS/METERS/SWITCHES BULB REPLACEMENT Remove the speedometer lower cover (page 18-7). Pull the bulb socket out of the speedometer case. Pull the bulb out of the socket and replace it with a new one. Install the removed parts in the reverse order of removal. SOCKET TACHOMETER INSPECTION Check that the speedometer power/ground lines are normal (page 18-6). Connect the peak voltage adaptor to the digital multimeter, or use the Imrie diagnostic tester. TOOL: Imrie diagnostic tester (model 625) or Peak voltage adaptor 07HGJ with commercially available digital multimeter (impedance 10 MW/DCV minimum) BULB DIGITAL MULTIMETER Use a commercially available digital multimeter with an impedance of 10 MΩ/DCV minimum. The display value differs depending upon the internal impedance of the multimeter. If using the Imrie diagnostic tester (model 625), follow the manufacturer s instructions. Connect the peak voltage adaptor or Imrie diagnostic tester probes to the wire harness side connector terminals. CONNECTION: Yellow/green (+) Green ( ) Start the engine and measure the peak voltage. PEAK VOLTAGE: 100 V minimum If the measured value is normal, check the Black, Green and Yellow/green wires in the meter harness for open circuit. If the meter harness is normal, replace the tachometer (page 18-6). If the value is 0 V, check the Yellow/green wire for continuity between the speedometer and ICM. PEAK VOLTAGE ADAPTOR GREEN WIRE CONNECTOR (YELLOW/GREEN) 18-8

155 IGNITION SWITCH INSPECTION Remove the headlight (page 18-4). Disconnect the ignition switch 2P connector. Check for continuity between the ignition switch side connector terminals in each switch position. Continuity should exist between the color coded wires as follows: 2P CONNECTER LIGHTS/METERS/SWITCHES IGNITION SWITCH BAT 1 BAT 2 COLOR R/Bl R/W IGNITION SWITCH Route the wire harness properly (page 1-16) Replace the mounting bolts with new ones. REMOVAL/INSTALLATION Remove the following: headlight case (page 2-3) handlebar cover (page 12-9) Disconnect the ignition switch 2P connector. Remove the two bolts and pull the speedometer forward. Remove the two ignition switch mounting bolts and ignition switch from the top bridge. Installation is in the reverse order of removal. TORQUE: IGNITION SWITCH MOUNTING BOLT: 4.2 N m (0.43 kgf m, 3.1 lbf ft) BOLTS IGNITION SWITCH MOUNTING BOLTS 2P CONNECTOR 18-9

156 LIGHTS/METERS/SWITCHES HANDLEBAR SWITCH LEFT HANDLEBAR SWITCH INSPECTION Remove the headlight (page 18-4). Disconnect the left handlebar switch 3P connector, and Light blue, Orange, Black and Blue/white wire connectors. CONNECTORS Check for continuity between the wire terminals of the switch side connectors in each switch position. Continuity should exist between the color coded wire terminals as follows: PASSING SWITCH DIMMER SWITCH TURN SIGNAL LIGHT SWITCH PASSING SWITCH FREE PUSH BAT H1 HORN SWITCH DIMMER SWITCH HL HI LO (N) COLOR Bl Bu COLOR Bu/W Bu W HORN SWITCH TURN SIGNAL LIGHT SWITCH BAT HO R WR L FREE PUSH N COLOR Bl Lg COLOR Lb Gr O 18-10

157 RIGHT HANDLEBAR SWITCH INSPECTION Remove the headlight (page 18-4). Disconnect the right handlebar switch 2P connector, and Brown and Blue/white wire connectors. LIGHTS/METERS/SWITCHES RIGHT HANDLEBAR SWITCH 2P CONNECTOR Check for continuity between the wire terminals of the switch side connectors in each switch position. Continuity should exist between the color coded wire terminals as follows: WIRE CONNECTORS (BLUE/WHITE) WIRE CONNECTORS (BROWN) LIGHTING SWITCH STARTER SWITCH STARTER SWITCH ST FREE PUSH BAT COLOR Y/R Bl LIGHTING SWITCH BAT TL HL COLOR Bl Br Bl/W 18-11

158 LIGHTS/METERS/SWITCHES CLUTCH SWITCH INSPECTION Disconnect the clutch switch connectors and check for continuity between the switch terminals. There should be continuity with the clutch lever squeezed and no continuity with the lever released. BRAKE LIGHT SWITCH FRONT DRUM BRAKE TYPE (Type 1, 3, 4, 6) Remove the headlight case (page 2-3). Disconnect the front brake light switch (Green/Yellow and Black) wire connectors and check for continuity between the switch side connectors. There should be continuity with the front brake lever squeezed and no continuity with the lever released. BRAKE LEVER WIRE CONNECTORS DISC BRAKE TYPE (Type 2, 5) Disconnect the front brake light switch connectors and check for continuity between the switch terminals. There should be continuity with the front brake lever squeezed and no continuity with the lever released. FRONT BRAKE LIGHT SWITCH 18-12

159 REAR Remove the left side cover (page 2-4). Disconnect the rear brake light switch 2P connector and check for continuity between the switch side connector terminals. There should be continuity with the rear brake pedal depressed and no continuity with the pedal released. 2P CONNECTOR LIGHTS/METERS/SWITCHES GEAR POSITION SWITCH INSPECTION Turn the ignition switch "ON", and shift the transmission into each gear position. Check the operation of gear position and neutral indicator lights at each gear position. If all the indicator bulbs are normal but the gear position indicator does not light, check as follows: GEAR POSITION INDICATORS NEUTRAL INDICATOR Remove the left side cover (page 2-4). Disconnect the gear position switch 6P connector. Check for continuity at the switch side connector terminals. There should be continuity in each gear position as follows: Gear position Neutral 1st 2nd 3rd 4th 5th Connection Light green/red ground Light green/pink ground Light green/brown ground Light green/green ground Light green/yellow ground Light green/black ground 6P CONNECTOR 18-13

160 LIGHTS/METERS/SWITCHES REMOVAL Drain the engine oil (page 3-11). Remove the following: left side cover (page 2-4) drive sprocket cover (page 2-8) Disconnect the gear position switch 6P connector and release the gear position switch wire from the clamp. 6P CONNECTOR GEAR POSITION SWITCH WIRE CLAMP Remove the gear position switch wire from the left crankcase cover. Remove the upper side bolt and gear position switch from the collar. Remove the O-ring from the gear position switch. GEAR POSITION SWITCH WIRE O-RING BOLT Remove the bolt and collar from the left crankcase. Remove the O-ring from the collar. GEAR POSITION SWITCH COLLAR O-RING INSTALLATION Coat a new O-ring with engine oil and install it into the collar groove. Install the collar to the left crankcase. COLLAR BOLT O-RING 18-14

161 LIGHTS/METERS/SWITCHES Coat a new O-ring with engine oil and install it into the gear position switch groove. Install the gear position switch by aligning the spring pin with the slot in the shift drum. SLOT SPRING PIN GEAR POSITION SWITCH O-RING Route the wire harness properly (page 1-16). Install the two bolts and tighten them. Route the gear position switch wire into the left crankcase cover as shown. GEAR POSITION SWITCH WIRE GEAR POSITION SWITCH BOLTS Route the wire harness properly (page 1-16). Secure the gear position switch wire with the clamp and connect the gear position switch 6P connector. Install the following: drive sprocket cover (page 2-8) left side cover (page 2-4) 6P CONNECTOR GEAR POSITION SWITCH WIRE Fill the crankcase with the recommended engine oil (page 3-11). CLAMP FUEL GAUGE/FUEL LEVEL SENSOR SYSTEM INSPECTION Check that the speedometer power/ground lines are normal (page 18-6). Remove the fuel tank (page 2-5). FUEL LEVEL SENSOR 2P CONNECTOR 18-15

162 LIGHTS/METERS/SWITCHES With the fuel level sensor 2P connector disconnected, turn the ignition switch to " " and check the fuel gauge. The gauge needle should move to "E". Turn the ignition switch to " " and connect the wire harness side connector terminals with a jumper wire. Turn the ignition switch to " " and check the fuel gauge. The gauge needle should move to "F". If the fuel gauge needle moves properly, check the fuel level sensor (page 18-16). If the fuel gauge needle does not move properly, check the Yellow/white wire in the wire harness, and Black, Green and Yellow/white wire in the meter harness. If the wires are normal, replace the fuel gauge (page 18-6). FUEL LEVEL SENSOR REMOVAL Remove the fuel tank (page 2-5). Remove the four nuts. FUEL GAUGE NUTS Be careful not to damage the float arm. Remove the rubber gasket and fuel level sensor. FUEL LEVEL SENSOR Be careful not to damage the float arm. FUEL LEVEL SENSOR INSTALLATION Coat a new rubber gasket with engine oil and install it onto the fuel tank. Install the fuel level sensor. RUBBER GASKET FUEL LEVEL SENSOR RUBBER GASKET 18-16

163 LIGHTS/METERS/SWITCHES Install the four nuts and tighten them. TORQUE: 10 N m (1.0 kgf m, 7 lbf ft) Install the fuel tank (page 2-5). NUTS FUEL LEVEL SENSOR INSPECTION Remove the fuel level sensor (page 18-16). Measure the resistance between the fuel level sensor connector terminals in each float position. FLOAT POSITION FULL EMPTY Resistance (20 C/68 F) 4 10 Ω Ω FULL Install the fuel sensor (page 18-16). EMPTY HORN Route the wire harness properly (page 1-16) REMOVAL/INSTALLATION LEFT SIDE Disconnect the wire connectors from the horn. Remove the bolt and horn. Installation is in the reverse order of removal. CONNECTORS BOLT HORN 18-17

164 LIGHTS/METERS/SWITCHES Route the wire harness properly (page 1-16) RIGHT SIDE Disconnect the wire connectors from the horn. Remove the bolt and horn. Install the horn and tighten the bolt. Connect the wire connectors with their drain holes facing down. BOLT HORN CONNECTORS The inspect procedure is same for both sides. INSPECTION Disconnect the wire connectors from the horn. Connect the fully charged 12 V battery to the horn terminals. The horn is normal if it sounds when the 12 V battery is connected across the horn terminals. DRAIN HOLES LEFT SIDE SHOWN: CONNECTORS TURN SIGNAL RELAY SYSTEM INSPECTION Remove the left side cover (page 2-4). Disconnect the 2P connector from the turn signal relay and connect the 2P connector terminals with a jumper wire. Turn the ignition switch to " " and operate the turn signal light switch. If the turn signal lights come on, replace the turn signal relay with a new one. If the turn signal lights do not come on, check the following: turn signal light bulb turn signal light switch (page 18-10) wire harness for open circuit TURN SIGNAL RELAY 2P CONNECTOR 18-18