Honda TRX400EX FOURTRAX 1999 Service Manual
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Honda TRX400EX FOURTRAX 1999 Service Manual

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  • Page 4 Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGl#2 or equivalent). Example: Molykotea G-n paste, manufactured by Dow Corning, U S A . Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease.
  • Page 5 GENERAL INFORMATION LUBRICATION & SEAL POINTS 1-16 GENERAL SAFETY CABLE & HARNESS ROUTING 1-18 SERVICE RULES EMISSION CONTROL SYSTEMS 1-23 MODEL IDENTIFICATION EMISSION CONTROL INFORMATION SPECIFICATIONS LABEL 1-24 1-11 TORQUE VALUES 1-14 TOOLS GENERAL SAFETY USED ENGINE OIL CARBON MONOXIDE the engine must be running to do some work, make sure the area is well ventilated.
  • Page 6 CHILDREN. SERVICE RULES 1 . Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don't meet HONDAs design specifications may cause damage to the motorcycle. Use the special tools designed for this product to avoid damage and incorrect assembly.

  • Page 7: Model Identification

    GENERAL INFORMATION MODEL IDENTIFICATION VEHICLE IDENTIF' I CATION NUMBER The Vehicle Identification Number (VIN) located on the left side frame down tube. FRAME The engine serial number is stamped on the lower left The frame serial number is stamped o n the front side of the crankcase.
  • Page 8 GENERAL INFORMATION SPECIFICATIONS GENERAL ITEM SPECIFICATIONS DIMENSIONS Overall length 1,835 mm (72.2 in) Overall width 1,150 mm (45.3 in) Overall height 1,110 rnm (43.7 in) Wheelbase 1,230 mm (48.4 in) Seat height 810 mm (31.9 in) 353 mm (13.9 in) Ground clearance 110 mm (4.3 in) Dry weight...
  • Page 9 GENERAL INFORMATION GENERAL ITEM SPECIFICATIONS CARBURETOR Carburetor type Piston valve Throttle bore 38 mm (1.5 in) Clutch system Multi-plate, wet Clutch operation system Cable operating Transmission Constant mesh, 5-speeds Primary reduction 2.826 (23/65) Final reduction 2.533 (15/38) Gear ratio 2.916 (12/35) 1.937 (16/31) 1.473 (19/28) 1.181 (22/26)
  • Page 10 1.85 liters (1.95 US qt, 1.63 Imp qt) After disassem bly 2.2 liters (2.3 US qt, 1.9 Imp qt) Recommended engine oil Honda GN4 or HP4 4-stroke oil or equivalent motor oil API service classification SF or SG Viscosity: SAE 1OW-40 or 2OW-50...
  • Page 11 GENERAL INFORMATION ITEM STANDARD SERVICE LIMIT Cylinder I.D. 85.000 85.010 (3.3465 3.3468) 85.10 (3.350) Out of round 0.05 (0.002) Taper 0.05 (0.002) 0.10 (0.004) Piston, Piston O.D. at 15 (0.6) from bottom 84.960 84.985 (3.3449 3.3459) 84.880 (3.3417) Piston pin O.D. 19.994 20.000 (0.7872 0.7874)
  • Page 12 GENERAL INFORMATION STANDARD SERVICE LIMIT ITEM 0.12 0.018) Big end side clearance 0.05 0.45 (0.002 (0.02) Big end radial clearance 0.006 - 0.018 (0.0002 0.0007) 0.05 (0.002)
  • Page 13 ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 4.0 (0.16) Cold tire pressure Standard 10.275 4 . 0 osil Minimum psi) (0.235 Maximum (0.315 4 . 6 psi) Tie-rod distance between the ball joints 370.2 (14.57) Toe-in: (0.7 0.6) 4th from softest Dosition Shock absorber spring adiuster standard position ITEM STANDARD...
  • Page 14 SPECIFICATIONS ITEM 12 V - 8 A h Capacity 0.1 mA max. Current leakage 13.0- 13.2 V Voltage Fully charged Needs charaina Below 12.3 V 0.9 A x 5 Charging current Normal 10 h Quick 4.0 A x 1.0 h Capacity 147 W/5,000 rpm Alternator...
  • Page 15 GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE TORQUE FASTENER TYPE FASTENER TYPE 5 mm bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9) 6 mm bolt and nut 10 (1.0,7) 6 mm screw 9 (0.9. 6.5) 8 mm bolt and nut 22 (2.2, 16) 6 mm flange bolt 9 (0.9.
  • Page 16 ENGINE (Cont'd) THREAD TORQUE REMARKS ITEM DIA. (mm) CRANKCASE/TRANSMlSSlON/CRANKSHAFT: NOTE 1 12 (1.2, Mainshaft bearing setting plate bolt LIGHTSISWITCHES 13 (1.3,9) Neutral switch FRAME THREAD TORQUE REMARKS ITEM DIA. WAME/BODY PANELS/EXHAUST SYSTEM: 42 (4.3.31) NOTE 4 30 (3.1, 22) Skid plate bolt 32 (3.3, 24) Muffler mounting bolt 23 (2.3, 17)
  • Page 17 GENERAL INFORMATION THREAD ITEM HYDRAULIC BRAKE: Caliper bleed valve (0.6, 4.3) Front brake caliper pad pin plug 3 (0.3, 2.2) Front brake caliper pad pin 18 11.8. 13) Rear brake caliper pad pin 18 (1.8, 13) Brake hose oil bolt 34 (3.5, 25) Brake pipe joint nut (1.7,...
  • Page 18 GENERAL INFORMATION TOOLS NOTES: 1. Equivalent commercially available in U.S.A. 2. Not available in U.S.A. 3. Alternative tool REF. SECTION REMARKS TOOL NUMBER DESCRIPTION 07401 -0010000 NOTE 1 07631-0010000 Jniversal bearing puller NOTE 2 07724-0010100 NOTE 1 07724 0050002 NOTE 1 07725 0040000 NOTE 3...

  • Page 19: Table Of Contents

    GENERAL INFORMATION DESCRIPTION TOOL NUMBER REMARKS REF. SECTION Crankcase assembly tool 07965 V M O O O O O NOTE assembly collar 07965 assemblv shaft 07965 NOTE 3: 07931 07931 -threaded adaptor 07965 NOTE 3: Assembly collar 07965 VMOOl O O 12.13 Valve guide reamer, 5.5 mm 07984...
  • Page 20 GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE LOCATION MATERIAL REMARKS Camshaft journals and cam lobes Molybdenum oil solution Rocker arm slipper surfaces and 112 molybdenum Sub-rocker arm slipper surfaces Valve stem (valve guide sliding surface) disulfide grease) Clutch outer guide inner and outer surfaces Piston pin outer surface Connecting rod small end inner surface Transmission gear rotating surfaces...
  • Page 21 Throttle cable outer inside Cable lubricant Clutch cable outer inside Brake lock cable outer inside Handlebar grip rubber inside Honda Bond A or Honda Hand Grip Cement (U.S.A. only) or equivalent Front brake lever-to-master piston contacting area Silicone grease Front brake lever pivot...
  • Page 22 GENERAL INFORMATION CABLE & HARNESS ROUTING THROTTLE CABLE BRAKE LOCK CABLE WIRE BRAKE HOSE ANDLEBAR SWITCH CLUTCH CABLE OIL TANK BREATHER TUBE NEUTRAL INDICATOR CONNECTORS IGNITION SWITCH CONNECTORS 1-18...
  • Page 23 GENERAL INFORMATION 1-19...
  • Page 24 GENERAL INFORMATION 1-20...
  • Page 25 GENERAL INFORMATION NEUTRAL SWITCH DIODE CARBURETOR DRAIN TUBE CARBURETOR AIR VENT TUBE FUEL TUBE 1-21...
  • Page 26 GENERAL INFORMATION MASTER CYLINDER RESERVOIR HOSE 1-22...

  • Page 27: Emission Control Systems

    Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocar- bons.
  • Page 28 GENERAL INFORMATION EMISSION CONTROL INFORMATION VEHICLE EMISSION CONTROL INFORMATION LABEL LABEL The Vehicle Emission Control Information Label is attached o n the right side frame down tube. 1-24...
  • Page 29 2. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION FUEL TANK & HEAT PROTECTOR TROUBLESHOOTING SKID PLATE FRONT FENDER EXHAUST SYSTEM SIDE COVER SERVICE INFORMATION GENERAL Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. before Serious burns may result the exhaust system is not allowed to cool components are removed or serviced.

  • Page 30: Front Fender

    CAUTION: The rear fender may be deformed if it contacts the muffler while the exhaust system is hot. REMOVAL Unlock the seat by turning the lock lever upward. Raise the seatlfender assembly up and remove it. not allow the assembly to INSTALLATION contact the muffler when the...
  • Page 31 SIDE COVER TABS TRIM CLIP Remove the seathear fender (page 2-2). Remove the screw and two trim clips. Release the side cover from the three tabs of the front fender by sliding it forward and remove the side cover. Installation is in the reverse order removal.
  • Page 32 FUEL TANK & HEAT PROTECTOR BOLTS Remove the front fender (page 2-2). FUEL TANK Turn the fuel valve OFF. Disconnect the fuel tube from the fuel valve. Unhook the mounting straps. Remove the two mounting bolts and the fuel tank. TANK UNDER HEAT PROTECTOR Remove the carburetor air vent tube from the tube holder in the heat protector.
  • Page 33 Remove the five screws, nut and the mud guard. Remove the washer bolt from the footpeg bottom and the inner mud guard stay. Remove the bolt and washer and the outer mud guard stay from the stay hole in the footpeg. Remove the two socket bolts and washers and the footpeg.

  • Page 34: Exhaust System

    EXHAUST SYSTEM REMOVAL Do not service the exhaust system while it is hot. Remove the seatkear fender (page 2-2). MUFFLER Loosen the muffler band bolts. Remove the upper and lower muffler mounting bolts and washers (between the muffler and frame). Remove the muffler.
  • Page 35 0.10 mm (0.004 in) Exhaust 0.12 mm (0.005 in) Recommended engine oil Honda GN4 or HP4 4-stroke oil or eauivalent motor oil Viscosity: SAE IOW-40 or 2OW-50 After draining 1.8 liters (1.9 US qt, 1.6 Imp qt) Engine oil capacity After drainingtfilter change 1.85 IiterS (1.95 US qt, 1.63 Imp qt)
  • Page 36 40 mm (1-114 Drive chain slack DOT 4 brake fluid Recommended brake fluid Clutch lever free play 20 mm (318 Cold tire pressure Standard 27 kPa (0.275 kgf/cm2,4.0 psi) Minimum 23 kPa 10.235 kof/cm?. 3.4 Maximum 31 kPa (0.315 kgf/cmZ, 4.6 psi) Tire size Front AT22 x 7-10...

  • Page 37: Note

    In the interest of safety, we recommend these items be serviced only by your Honda dealer. NOTES 1. Service more frequently if the A N is ridden in dusty areas, sand or snow. 2. Service more frequently if the ATV is ridden in very wet or muddy conditions.

  • Page 38: Fuel Line

    MAINTENANCE FUEL LINE Remove the front fender (page 2-2). Check the fuel line for deterioration, damage or leak- age. Replace the fuel line if necessary. Check for any deterioration or damage to the throttle cable. Check that the throttle lever for smooth opera- tion.

  • Page 39: Air Cleaner

    MAINTENANCE AIR CLEANER RETAINING CLIPS NOTE: If the vehicle is used in dusty areas, sand or snow, more freauent inwections are rewired. Remove the seathear fender assembly (page 2-2). Release the six retaining clips from the air cleaner housing covet and remove the cover. COVER Loosen the air cleaner element band screw.

  • Page 40: Spark Plug

    MAINTENANCE Apply approximately 20 g (0.7 oz) of Pro Honda Foam Filter Oil or equivalent oil from the inside of the ele- ment. PRO HONDA FILTER Place the element into a plastic bag and spread the oil evenly by hand.

  • Page 41: Valve Clearance

    MAINTENANCE Check the insulator for cracks or damage, and the CENTER ELECTRODE electrodes for wear, fouling or discoloration. Replace INSULATOR the plug if necessary (recommended spark plug: page 3-1). S IDE E L E C T R O ~ Clean the spark plug electrodes with a wire type brush or special plug cleaner.
  • Page 42 MAINTENANCE Rotate the crankshaft only counterclockwise to align the T mark on the flywheel with the index notch in the left crankcase cover. Make sure the piston is TDC (Top Dead Center) on the compression stroke. This position can be obtained by confirming that there is slack in the sub-rocker arm.

  • Page 43: Engine Oil

    If the oil level is near or below the lower level mark, and the recommended engine oil up to the upper level mark. RECOMMENDED ENGINE Honda GN4 or HP4 4-stroke oil or equivalent motor oil API service classification SF or SG Viscosity: SAE 1OW-40 or 2OW-50 -20 -10 40 "C...

  • Page 44: Oil Change

    MAINTENANCE A t Crankcase Oil Check Bolt OIL CHECK BOLT AND SEALING WASHER NOTE The crankcase oil level check bolt is useful when checking the lubrication; the oil pump adjusts the oil level so that the crankcase is always kept at the proper level.
  • Page 45 MAINTENANCE Pour the recommended oil (page into the oil tank up to the upper level mark on the dipstick. NOTE: The engine takes about 1.85 liters (1.95 US qt, 1.63 Imp qt) at oil and filter change. Because only a por- tion of that oil is held in the oil tank, you cannot add the full amount initially.

  • Page 46: Engine Idle Speed

    MAINTENANCE ENGINE OIL STRAINER SCREEN IN OIL TANK Engine and exhaust system parts become very h o t and remain h o t for some time after the engine is run. Wear insulated gloves. Drain the engine oil (page 3-10). Disconnect the oil pipe from the lower side of the oil tank by loosening the flare nut.

  • Page 47: Drive Chain

    Inspect and replace the sprockets necessary. LUBRICATION Lubricate the drive chain with Pro Honda Chain Lube or equivalent chain lubricant designed for specifically for use on O-ring chains. Some commercially available chain lubricants may contain solvents which could damage the O-rings.

  • Page 48: Drive Chain Slider

    MAINTENANCE SPROCKET INSPECTION WORN Inspect the drive and driven sprocket teeth for dam- age or wear. Replace if necessary. Never use worn chain on new sprockets. Both chain and sprockets must be in good condition, or the new replacement parts will wear rapidly. Check the attachment bolt and nuts on the drive and driven sprockets.

  • Page 49: Rear Brake

    MAINTENANCE REAR BRAKE RESERVOIR CAP Place the vehicle on level surface. Remove the seathear fender assembly (page 2-2). Check the fluid level in the rear brake reservoir. If the level is near the "LOWER" level line, remove the reservoir cap, set plate and diaphragm, and fill the reservoir with DOT 4 brake fluid from a sealed container to the "UPPER"...
  • Page 50 MAINTENANCE BRAKE LOCK CABLE ADJUSTMENT LOCK NUT ,ADJUSTING BOLT Slide the dust cover the lever bracket. lock cable adjust the clutch lever free play to more than 30 adjustment may be required if the and turn the adjuster all the way in. parking brake does not hold Loosen the lock nut at the brake arm on the caliper...

  • Page 51: Clutch System

    MAINTENANCE HIGHER POSITION: If adjusting the brake pedal t o the lower position, make sure that the clearance between the lower end of the push rod and the brake pedal does not fall below 1 mm (0.04 in). adjusting to the higher position, make sure that a the push rod thread is vis- portion of the lower end ible inside the joint.
  • Page 52 MAINTENANCE Major adjustments are made with the lower adjusting nut at the engine. Loosen the lock nut and turn the adjusting nut. After adjustment is complete, tighten the lock nut securely while holding the adjusting nut. Check the clutch operation. the free play cannot be obtained, or the clutch slips during test ride, disassemble and inspect the clutch (section...

  • Page 53: Spark Arrester

    MAINTENANCE SPARK ARRESTER Wait until the exhaust system has cooled before removing or installing the arrester. Touching the h o t exhaust may result in severe burns. Remove the three bolts and the spark arrester with the gasket. B O L T S Use a brush to remove carbon deposits from the screen mesh, being careful not to damage the screen mesh.

  • Page 54: Steering Shaft Holder Bearing

    MAINTENANCE STEERING SHAFT HOLDER BEARING Raise the front wheels off the ground and support the Make sure the vehicle securely. cables do not Check that the handlebar moves freely from side to interfere with the side. rotation If the handlebar moves unevenly, binds, or has hori- handlebar zontal movement, inspect the steering shaft holder bushing and bearings (section 12).
  • Page 55 MEMO...
  • Page 57 1.85 liters (1.95 qt, 1.63 Imp qt) After disassembly 2.2 liters (2.3 US qt. 1.9 Irnp qt) Recommended engine oil Honda GN4 or HP4 4-stroke oil or equivalent motor oil API service classification SE. SF or SG Viscosity: SAE 1OW-40 Tip clearance 0.15 (0.006)
  • Page 58 LUBRICATION SYSTEM OIL PUMP & STRAINER REMOVAL Remove the right crankcase cover (page 9-21, Remove the clutch outer (page 9-5). Remove the three mounting bolts and the oil pump. Remove the gasket and two dowel pins. RELIEF VALVE CHECK Remove the following: cotter pin stopper plate spring...
  • Page 59 LUBRICATION SYSTEM DISASSEMBLY Remove the two bolts and separate the pump base from the pump spacer. Remove the following: - drive pin - thrust washer - inner rotor outer rotor WASH SHAFT AND PIN PUMP BODY Separate the pump body from the pump spacer. Remove the following: - pump shaft - drive pin...
  • Page 60 LUBRICATION SYSTEM -.-- BASE SIDE: Measure the pump body clearance. SERVICE LIMIT 0.25 mm 10.010 in) Measure the pump side clearance. BASE SIDE: SERVICE LIMIT 0.12 mm (0.005 in) OIL STRAINER CLEANING Remove the bolt and pull the strainer out of the crankcase.
  • Page 61 LUBRICATION SYSTEM ASSEMBLY DOWEL PINS PUMP BODY DY OUTER ROTOR BODY INNER ROTOR PUMP SHAFT PUMP SPACER THRUST WASHER RELIEF VALVE STOPPER PLATE BASE INNER ROTOR Install the following into the pump body: - outer rotor with the punch mark facing the pump spacer inner rotor - drive pin and shaft with the stepped end facing...
  • Page 62 LUBRICATION SYSTEM BOLTS Be sure that there are no gap between the mating surfaces and tighten the two bolts. TORQUE: 13 N.m (1.3 k9f.m. 9 IbfW INSTALLATION Install the two dowel pins and a new gasket. Set the pump assembly onto the crankcase and tight- en the three bolts securely.
  • Page 63 LUBRICATION SYSTEM Drain the engine oil (page OIL COOLER Disconnect the oil pipes from the oil cooler by removing the joint bolts and remove the O-rings. Remove the two mounting bolts and the oil cooler. Installation is in the reverse order of removal Replace the 0- rings with new ones and coat...
  • Page 64 FUEL SYSTEM...

  • Page 65: Fuel System

    FUEL SYSTEM CARBURETOR INSTALLATION 5-12 SERVICE INFORMATION TROUBLESHOOTING PILOT SCREW ADJUSTMENT 5-13 HIGH ALTITUDE ADJUSTMENT 5-14 CARBURETOR REMOVAL CARBURETOR DISASSEMBLY/ AIR CLEANER HOUSING 5-15 INSPECTION CARBURETOR ASSEMBLY SERVICE INFORMATION GENERAL KEEP OF REACH CHILDREN. Gasoline is extremely flammable and is explosive under certain conditions. If the engine must be running to do some work make sure the area is well-ventilated.

  • Page 66: Pilot Screw Wrench

    FUEL SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Carburetor identification number Main jet Slow jet 3rd groove from top Jet needle clip position Pilot screw opening See page 5-13 18.5 (0.73 Float level 1,400 Throttle lever free Dlav 8 mm 5/16 TOOL Carburetor float level gauge 07401 0010000 Pilot screw wrench...

  • Page 67: Carburetor Removal

    FUEL SYSTEM CARBURETOR REMOVAL AIR VENTTUBE CARBURETOR Remove the fuel tank (page 2-41. Place and approved fuel container under the drain tube. Loosen the drain screw and drain the carbure- tor. Remove the air vent tube from the heat protector and the fuel t u b e f r o m t h e heat protector rubber.
  • Page 68 FUEL SYSTEM Apply vacuum to the vacuum port. The vacuum should maintained. Air should not flow through the valve ports when the vacuum is applied, and should flow when the vacu- um is not applied. THROTTLE VALVE SCREWSAND Remove the three screws, clamp and top cover. Remove the O-ring from the body groove.
  • Page 69 FUEL SYSTEM Check the jet needle for stepped wear or damage. Check the throttle valve for scoring, scratches or damage. ACCELERATOR PUMP Remove the three screws while holding the accelera- tor pump cover. Remove the pump cover, spring and the diaphragm, SPRING being careful not to damage it.
  • Page 70 FUEL SYSTEM Remove the baffle plate and the diaphragm shaft boot. Check the boot for deterioration or damage. FLOAT FLOATVALVE Remove the float pin, float and float valve. After ' 0 0 Remove the float pin by gently tapping with a suitable pin driver (O.D.

  • Page 71: Carburetor Cleaning

    FUEL SYSTEM Remove the pilot screw, spring, washer and O-ring. Check each jet for wear or damage. Check the pilot screw for wear or damage. Clean the jets with cleaning solvent and blow open with compressed air. CARBURETOR CLEANING Remove the following: air cut-off valve thronle valve accelerator pump...
  • Page 72 FUEL SYSTEM FLOAT AND JETS NEEDLEJET Install the pilot screw with the spring, washer and a new O-ring and return it to its original position as noted during removal. Perform the pilot screw adjustment if new pilot screw installed. CAUTION: will Damage t o the pilot screw seat occur...
  • Page 73 FUEL SYSTEM Install a new O-ring into the float chamber groove securely. Install the float chamber, being careful not to pinch the boot and tighten the four screws. ACCELERATOR PUMP Insert the diaphragm shaft into the float chamber through the boot and set the diaphragm rib into the groove properly.
  • Page 74 FUEL SYSTEM Set the thrust washer between the valve arm and car- buretor body (throttle drum side). Insert the link arm shaft through the throttle link arm, spring, carburetor body, washer and valve arm while hanging the spring ends as shown. Align the screw holes in the valve arm and shaft and tighten the screw with the washer.
  • Page 75 FUEL SYSTEM Install the throttle stop screw with the washer and spring by screwing clockwise. Secure the with the screw by aligning its hole stay and boss. STAY Turn the throttle stop screw to align the butterfly throttle valve with the edge of the outside by-pass hole in the carburetor.

  • Page 76: Carburetor Installation

    FUEL SYSTEM CARBURETOR INSTALLATION Install the throttle cable outer to the carburetor body and connect the cable inner to the throttle drum. Install the throttle linkage cover by aligning the tab with the slit in the carburetor and secure it with the screws.

  • Page 77: Pilot Screw Adjustment

    PILOT SCREW ADJUSTMENT IDLE DROP PROCEDURE NOTE: The pilot screw is factory pre-set and no adjustment is necessary unless the pilot screw is replaced. Use a tachometer with graduations of 50 rpm or smaller that w i l l accurately indicate a 50 rpm change.

  • Page 78: High Altitude Adjustment

    HIGH ALTITUDE ADJUSTMENT Between Below 3,000 8,000 Main jet turns in from Pilot screw The carburetor must be adjusted for high altitude rid- ing (between 3,000 8,000 ft/l,OOO - 2,500 STANDARD SETTING: Below 5,000 11,500 ml HIGH ALTITUDE SETTING: Between 3,000 8,000 ft 2,500 ml (1.000...

  • Page 79: Air Cleaner Housing

    FUEL SYSTEM AIR CLEANER HOUSING REMOVAL/INSTALLATION Remove the seat/rear fender assembly (page 2-2). Disconnect the crankcase breather tube and remove the crankcase breather storage tank f r o m the air cleaner connecting tube. Remove the mounting bolt. Loosen the connecting tube band and intake duct band screws.
  • Page 80 ENGINE REMOVAL/INSTALLATION 74 N.m 17.5 kgfm, 54 IbfW 26 N.m (i.7...
  • Page 81 6. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION ENGINE INSTALLATION ENGINE REMOVAL SERVICE INFORMATION GENERAL Afloor jack or other adjustable support is required to support and maneuver the engine. When removing and installing the engine, tape the frame around the engine beforehand for frame protection. The following components require engine removal for service: -transmission (including shift fork, drum and shift spindle) (section 111 Other components can be serviced with the engine installed in the frame.

  • Page 82: Engine Removal

    ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil (page 3-91 Remove the following: tank and heat protector (page -carburetor assembly (page 5-3) -exhaust system (page 2-6). Loosen the rear axle for maximum drive chain slack (page 3-13). Remove the two bolts, sprocket cover, sprocket pro- tector and clamp.
  • Page 83 ENGINE REMOVAL/INSTALLATION Disconnect the starter motor cable by removing the terminal nut. Disconnect the crankcase breather tube from the engine. Release the brake lock cable from the cable guide by removing the mounting bolt. Loosen the clutch cable lock nut. Remove the holder bolts and cable holder and disconnect the clutch cable from the clutch arm.

  • Page 84: Engine Installation

    ENGINE REMOVAL/INSTALLATION Remove the swingarm pivot nut and bolt. Remove the engine out of the frame to the right. ENGINE INSTALLATION Install the engine into the frame from the right side in the reverse order of removal. NOTE: Before installing, make sure that the pivot collars are installed into the swingarm pivots.
  • Page 85 ENGINE REMOVAL/INSTALLATION Install the removed parts from engine removal proce- dure (page 6-2 to 6-3) in the reverse order or removal. TORQUE: Gearshift pedal pinch bolt: 20 N m 12.0 NOTE: Route the wires, cables and tubes properly (page 1-18). When installing the gearshift pedal, align the punch marks on the pedal and spindle.
  • Page 86 CYLINDER HEAD/VALVE 17 IbfW...
  • Page 87 7. CYLINDER HEAD/VALVE SERVICE INFORMATION VALVE GUIDE REPLACEMENT 7-12 TROUBLESHOOTING VALVE SEAT INSPECTION/REFACING 7-13 CYLINDER COMPRESSION CYLINDER HEAD ASSEMBLY/ INSTALLATION 7-16 CYLINDER HEAD COVER/CAMSHAFT REMOVAL CYLINDER HEAD REMOVAL/ INSTALLATION 7-18 DISASSEMBLY SERVICE INFORMATION GENERAL This section covers service of the camshaft. rocker arms, cylinder head and valves. These parts can be serviced with the engine installed in the frame.
  • Page 88 CYLINDER HEADNALVE TORQUE VALUES 54 N.m (5.5 kgfm, 40 IbfW Upper engine hanger nut 44 N m (4.5 kgfm, 33 Ibf.ft) Apply oil to the threads and seating surface Cylinder head nut 20 N m (2.0 kgf.m, 14 IbfW Apply locking agent to the threads Cam sprocket bolt 4 N m (0.4 kgfm, 2.9 IbfW Cam chain tensioner plug...

  • Page 89: Cylinder Compression

    CYLINDER HE A WVALVE CYLINDER COMPRESSION Warm up the engine to normal operating temperature. Stop the engine, disconnect the spark plug cap and remove the spark plug. Install the compression gauge with the gauge attach- ment into the spark plug hole. TOOL Compression gauge attachment 07908 equivalent com-...
  • Page 90 CYLINDER HEAD/VALVE Remove the upper engine hanger nut, bolt and spacers. Remove the timing hole cap, crankshaft hole cap and valve adjusting hole caps (page Rotate the crankshaft counterclockwise and align the The crankshaff "T" mark on the flywheel with the index notch in the should be turned left crankcase cover.
  • Page 91 CYLINDER HEADlVALVE Loosen the cam chain tensioner lifter plug. Remove the t w o bolts, cam chain tensioner lifter and gasket Remove the cam sprocket bolt. Becarefulnotto Rotate the crankshaft counterclockwise one turn and let the sprocket remove the other cam sprocket bolt. bolts fallinto the crankcase, Remove the cam sprocket from the camshaft flange.
  • Page 92 CYLINDER HEAD/VALVE CYLINDER HEAD COVER DISASSEMBLY Hold the cylinder head cover securely and loosen the sub-rocker arm shafts, being careful not to damage the mating surface of the cylinder head cover. Remove the shafts, sealing washers, sub-rocker arms and wave washers. Hold the cylinder head cover securely and loosen the rocker arm shafts, being careful to damage the...
  • Page 93 CYLINDER HEAD/VALVE Measure each cam lobe height, SERVICE LIMIT I N 30.57 E X 30.37 mm (1.196 in) ROCKER ARMlSHAFT Check the rocker arms and shafts for wear or damage. If the rocker arm slipper surface is worn or damaged, check the camshaft cam lobe and oil passages.
  • Page 94 CYLINDER HEAD/VALVE Remove the following: - thrust washer RSE DECOMPRESSOF one-way clutch (clutch outer, rollers and springs) reverse decompressor cam -stopper pin decompressor cam - spring ONE WAY CLUTCH INSPECTION Check the one-way clutch outer, rollers and springs WASHER for wear or damage. Check both cams for wear or damage.
  • Page 95 CYLINDER HEAD/VALVE CYLINDER HEAD REMOVAL/ DISASSEMBLY Remove the following: - exhaust system (page 2-6) - carburetor (page - cylinder head cover and camshaft (page 7-3) - spark plug Remove the four cap nuts and washers, being careful not to drop them into the crankcase. not strike the Remove the cylinder head.
  • Page 96 CYLINDER HEADNALVE Remove the following: - spring retainer inner and outer valve springs -valve - stem seal - valve spring seat NOTE: Mark all parts during disassembly so they can be Remove the carbon deposits from the combustion chamber and clean off the gasket surface, being care- ful not to damage the gasket and valve seat surfaces.
  • Page 97 CYLINDER HEADlVALVE VALVE STEMlVALVE GUIDE Check that the valve moves smoothly in the guide. Check the valve for bending, burning or abnormal wear. Measure each valve stem O.D. and record it. SERVICE LIMITS: IN: 5.46 mm (0.215 in) E X 5.44 mm 10.214 in) Ream the valve guide to remove any carbon build-up before measuring the guide.

  • Page 98: Valve Guide Replacement

    CYLINDER HEAD/VALVE VALVE GUIDE REPLACEMENT Chill new valve guides in the freezer section of refrigerator for about an hour. Heat the cylinder head to 130 140°C (275 290°F) with hot plate or oven. Do not heat the cylinder head beyond 150" (300°F). Use temperature indicator sticks, available from welding supply stores, to be sure the cylinder head is heated to the proper tem- perature.
  • Page 99 CYLINDER HEADNALVE VALVE SEAT INSPECTION/REFACING INSPECTION Clean all intake and exhaust valves thoroughly t o remove carbon deposits. Apply a light coating of Prussian Blue t o each valve seat. Tap the valve against the valve seat several times without rotating the valve, t o check for proper valve seat contact.
  • Page 100 CYLINDER HEAD/VALVE NOTE: Follow the refacing manufacturer's operating instructions. Be careful not to grind the seat more than neces- sary. If the contact area is too high on the valve, the seat CONTACT TOO HIGH OLD SEAT 32" flat cutter. must be lowered using WIDTH If the contact area is too low on the valve, the seat...
  • Page 101 CYLINDER HEAD/VALVE Using a 60" interior cutter, remove 114 of the existing valve seat material. OLD SEAT WIDTH TOOLS: Interior cutter, 30 mm 07780-0014000 Cutter holder, 5.5 mm 07781 -0010101 in U S A . or equivalent commercially available Using a 45" seat cutter, cut the seat to the proper width.
  • Page 102 CYLINDER HEAD/VALVE CYLINDER HEAD ASSEMBLY/ INSTALLATION COTTER Blow through the oil passage in the cylinder head with compressed air. Install the valve spring seats. Install new stem seals. Lubricate the valve stem sliding surface with molyb- denum oil solution. to avoid damage to the stem seal. Install the inner and outer valve springs with the tightly wound coils facing the combustion chamber.
  • Page 103 CYLINDER HEADlVALVE Install the valve spring cotters using the valve spring Grease the cot- ease compressor. TOOL Valve spring compressor CAUTION: To prevent loss tension, do n o t compress the valve springs more than necessary t o install the cot- ters.
  • Page 104 CYLINDER HEADWALVE Route the cam cnain tnrough the cylhoer head and instal. the cylinoer head onto the cylinder. Apply oil to the cylinder head nut threads and seating surfaces. Install the cylinder head nuts with the washers and tighten them in a crisscross pattern in 2 or 3 steps. Note the position of the large washer.
  • Page 105 CYLINDER HEADNALVE Install the cam sprocket onto the cam chain so that the index lines on the sprocket with the upper surface of the cylinder head. Install the camshaft onto the cylinder head through cam sprocket. Install the cam sprocket onto the camshaft flange securely.
  • Page 106 CYLINDER HEAD/VALVE Make a tensioner shaft stopper tool of a thin piece of steel (0.8 m m thick) using the diagram. Turn the tensioner shaft clockwise with the stopper tool to retract the tensioner, then insert the stopper fully to hold the tensioner in the fully retracted posi- tion.
  • Page 107 CYLINDER HEAD/VALVE CYLINDER HEAD COVER ASSEMBLY IN. ROCKER ARM SUB-ROCKER ARM "A"/ COPPER W A S H T WAVE WASHER ROCKER ARM EXHAUST SUB-ROCKER ARM SHAFTS COPPER WASHERS ROCKER ARM "IN"/ WAVE WASHER SUB-ROCKER ARM "IN"/ AKE SUB - ROCKER COPPER ARM SHAFTS WASHERS...
  • Page 108 CYLINDER HEAD/VALVE Install the rocker arms in the cylinder head cover as shown. Install the rocker arm shafts with new sealing washers. Apply locking agent to the 3 threads of the rocker arm shafts and tighten the shafts. WASHER TORQUE: 27 N m 12.8 kgfm. 20 Ibf4t) Install the sub-rocker arms and wave washers in the cylinder head cover as shown, noting each identifica- tion mark as shown.
  • Page 109 CYLINDER HEAD/VALVE CYLINDER HEAD COVER INSTALLATION Apply molybdenum oil solution to the slipper surfaces of the rocker arms and sub-rocker arms. Clean the mating surfaces of the cylinder head and head cover. Pour engine oil into the oil pocket in the cylinder head. Rotate the crankshaft counterclockwise and align the The crankshaff "T"...
  • Page 110 CYLINDER HEADlVALVE Install the valve adjusting hole caps. Install the cylinder head cover onto the cylinder head. Install the 8 mm and 6 rnrn cylinder head cover bolts and tighten them in a crisscross pattern i n 2 or 3 steps.
  • Page 111 MEMO...
  • Page 112 44 N m (4.5 kgfm,...
  • Page 113 8. CYLINDER/PISTON SERVICE INFORMATION TROUBLESHOOTING SERVICE INFORMATION GENERAL The cylinder and piston can be serviced with the engine installed in the frame. Take care not to damage the cylinder wall and piston. Do not damage mating surfaces by using a screwdriver when removing the cylinder. Camshaft lubricating oil is fed through the oil passage in the cylinder.
  • Page 114 TROUBLESHOOTING Compression too low, hard starting or poor performance speed Leaking cylinder head gasket Worn. stuck or broken piston ring Worn or damaged cylinder and piston Compression too high, overheating or knocking Excessive carbon built-up on piston head or combustion chamber Excessive smoke Worn cylinder, piston or piston rings...

  • Page 115: Cylinder Removal

    CYLINDER REMOVAL Remove the cylinder head (section 7). Remove the 6 mm cylinder bolts. Remove the cam chain guide (front). Remove the four 10 mm cylinder bolts and washers. Do not strike the Remove the cylinder. cylinder too hard and do not dam- age the mating surface with a screwdriver.
  • Page 116 PISTON Spread each piston ring and remove by lifting up at a point opposite the gap. CAUTION: Do not damage the piston ring by spreading the ends too far. Clean carbon deposits from the piston. CAUTION from Clean carbon deposits the ring grooves with a ring that wi// be discarded.
  • Page 117 Check the top of the cylinder for warpage with a straight edge and feeler gauge across the studs and bolt holes as shown. SERVICE LIMIT 0.10 mm (0.004 in) Inspect the piston rings for movement by rotating the rings. The rings should be able t o move in their grooves without catching.
  • Page 118 Measure piston pin hole I.D. in an X and Y axis. Take the maximum reading to determine the I.D. SERVICE LIMIT 20.060 mm (0.7898 in) O.D. Measure the piston pin at three points. SERVICE LIMIT: 19.964 mm (0.7860 in) Calculate the piston-to-piston pin clearance. SERVICE LIMIT 0.096 mm (0.0038 in1 Measure the connecting rod small end SERVICE LIMIT: 20.067 mm (0.7900 in)

  • Page 119: Piston Ring Installation

    PISTON RING INSTALLATION Carefully install the piston rings into the piston ring grooves with the markings facing up. SECOND RING CAUTION: OIL RING Be careful not to damage the piston and rings during NOTE: Do not confuse the top and second rings. To install the oil ring, install the spacer first, then install the side rails.

  • Page 120: Cylinder Installation

    NOTE: Make sure that the piston pin clips are seated securely. Do not align the piston pin clip end gap with the piston cutout. CYLINDER INSTALLATION Clean the gasket surfaces of the cylinder and crank- case thoroughly, being careful not to damage it, and careful not to allow gasket material into the crank- case.
  • Page 121 Apply oil to the cylinder wall, piston and piston ring outer surfaces. Route the cam chain through the cylinder and install the cylinder over the piston while compressing the piston rings with your fingers. CAUTION: Be careful not to damage the piston rings and cylin- der wall.
  • Page 122 108 N m (1...
  • Page 123 9. CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION PRIMARY DRIVE GEAR 9-10 GEARSHIFT LINKAGE 9-1 1 TROUBLESHOOTING RIGHT CRANKCASE COVER REMOVAL RIGHT CRANKCASE COVER INSTALLATION 9-12 CLUTCH SERVICE INFORMATION GENERAL The clutch and gearshift linkage can be serviced with the engine installed in the frame. Engine oil viscosity and level and the use of oil additives have an effect on clutch operation.
  • Page 124 TROUBLESHOOTING Clutch lever too hard Damaged, kinked or dirty clutch cable Improperly routed clutch cable Damaged clutch lifter mechanism Faulty clutch lifter plate bearing Clutch will not disengage or motorcycle creeps with clutch disengaged much clutch lever free play Warped clutch plates Faulty clutch lifter Improper oil viscosity or oil additive used Clutch slips...
  • Page 125 RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-10), Remove the rear brake pedal (page 14-20). Remove the two bolts and clutch cable holder, and disconnect the clutch cable from the clutch lifter arm. Remove the bolts, oil pipes O-rings and dowel pins from the right crankcase cover.
  • Page 126 DOWEL-PINS Remove the gasket and dowel pins. Remove the O-ring and oil pump driven sprocket from the oil pump. CLUTCH LIFTER ARM RETUR Remove the clutch lifter arm and return spring from the right crankcase cover. Check the lifter arm spindle for wear or damage. Check the return spring for fatigue or damage.
  • Page 127 CLUTCH DISASSEMBLY Remove the right crankcase cover (page Loosen the clutch spring bolts in a crisscross p2w-m in several steps. Remove the bolts and springs. Remove the pressure plate and lifter piece. Remove the clutch discs and plates. Unstake the clutch center lock nut. Be carefulnor to damage the threads.
  • Page 128 Remove the lock washer, plain washer and clutch center. Remove the thrust washer, clutch outer and clutch outer guide. BEARING INSPECTION LIFTER BEARING Turn the inner race of the lifter bearing with your fin- ger. The bearing should turn smoothly and quietly. Also check that the outer race of the bearing fits tightly in the pressure plate.
  • Page 129 CLUTCH DISC Check the clutch discs for signs of scoring or discol- Replace the oration. clutch discs and Measure the clutch disc thickness. plates as a set. SERVICE LIMIT 2.69 mm 10.106 in) CLUTCH PLATE Check the plates for discoloration. Replace the Check the plate warpage o n a surface plate using a clutchdiscsand...
  • Page 130 Measure the mainshaft O.D. a t the clutch outer guide. SERVICE LIMIT 21.91 ASSEMBLY Coat the clutch outer guide with molybdenum oil solution and install it onto the mainshaft with the flange side facing the crankcase. Install the clutch outer and thrust washer. Install the clutch center and plain washer.
  • Page 131 Install the lock washer with the "OUTSIDE" mark fac- ing out. Apply oil to the threads and seating surface of a new clutch center lock nut and install it onto the mainshaft. Hold the clutch center with the special tool and tighten the lock nut.
  • Page 132 Apply oil to the clutch lifter piece whole surface and lifter bearing. Install the clutch lifter piece and pressure plate. Install the clutch springs and bolts. Tighten the bolts in a crisscross pattern in several steps. Install the right crankcase cover (page 9-12). PRIMARY DRIVE GEAR REMOVAL Remove the right crankcase cover (page...
  • Page 133 Apply oil to the primary drive gear nut threads and seating surface. Install the washer and primary drive gear nut. 4-21. Remove the oil pump (page Install the clutch outer onto the mainshaft. Install the special tool between the primary drive and driven gears as shown and tighten the primary drive gear nut.
  • Page 135 10. ALTERNATOR/STARTER CLUTCH FLYWHEEL REMOVAL SERVICE INFORMATION 10-1 10-5 STARTER CLUTCH 10-6 TROUBLESHOOTING 10-1 ALTERNATOR STATOR 10-2 FLYWHEEL INSTALLATION 10-8 ITEM STANDARD SERVICE LIMIT TORQUE VALUES 127 N m (13.0 kgf.m, 94 Ibf.ft) Apply oil to the threads and seating surface. Flywheel bolt Apply locking agent to the threads.

  • Page 136: Alternator Stator

    ALTERNATOR STATOR LEFT CRANKCASE COVER REMOVAL Remove the four bolts and the starter idle gear cover. Remove the gasket and dowel pins. Remove the spacer, starter idle gear and shaft from the left crankcase cover. Remove the seatlrear fender (page 2-2). Disconnect the alternator connectors.
  • Page 137 Remove the nut, seven bolts and the left crankcase cover. Remove the gasket and dowel pins. Remove the starter reduction gear shaft and gear. STATOR REMOVAL/INSTALLATION ,GROMMET Remove the bolt and wire clamp. Remove the two ignition pulse generator bolts and wire clamp.

  • Page 138: Left Crankcase Cover

    LEFT CRANKCASE COVER INSTALLATION Install the starter reduction gear and shaft. Coat new O-ring with oil and install it into the starter motor groove..Install the dowel pins and a new gasket Install the left crankcase cover, being careful not to pinch the neutral switch wire.
  • Page 139 Route the alternator wire properly (page 1-18). Connect the alternator connectors. Install the seatlrear fender (page 2-21. Install the starter idle gear shaft, gear and spacer in the left crankcase cover. Install the dowel pins and new gasket. Install the starter idle gear cover and tighten the four bolts securely.

  • Page 140: Starter Clutch

    Remove the flywheel using the special tool. TOOL Rotor puller 07733- 0020001or 07933 3950000 Remove the 3.7 mm washer and starter drive gear. key. STARTER CLUTCH REMOVAL Remove the flywheel (page 10-5). Remove the starter driven gear while turning it coun- terclockwise.
  • Page 141 INSPECTION F GFAR Check the starter idle gear and reduction gear for wear or damage. Check the starter clutch outer and sprag clutch for abnormal wear or damage. Check the starter driven gear teeth for wear or damage. Measure the starter driven gear boss SERVICE LIMIT 51.67 mm (2.034 in) INSTALLATION Install the sprag clutch into the starter clutch outer...
  • Page 142 Apply locking agent t o the starter clutch bolt threads. Install the starter clutch assembly onto the flywheel and install the bolts. Hold the flywheel with the special tool and tighten the bolts. TOOL Flywheel holder equivalent commercially available in U S A . TORQUE: 30 N.m 22 Ibf.ft) (3.1 kgf.m,...
  • Page 143 Apply oil to the flywheel bolt threads and seating sur- face, and install the special washer and bolt. Hold the flywheel with the special tool and tighten the bolt. TOOL Flywheel holder equivalent commercially available in U.S.A. TORQUE: 127 N m 113.0 kgfm, 94 Ibf4t) Install the left crankcase cover (page 10-41, 10-9...
  • Page 144 11-0...
  • Page 145 CRANKCASE/TRANSMISSION/CRANKSHAFT 1 1. SERVICE- INFORMATION 11-9 11-2 CRANKCASE BEARING REPLACEMENT 11-12 TROUBLESHOOTING 11-3 CRANKCASE ASSEMBLY 11-15 CRANKCASE SEPARATION 11-4 TRANSMISSION SERVICE IN FORMATI0 N GENERAL The crankcase halves must be separated to service the transmission and crankshaft. To service these parts, the engine must be removed from the frame (section 6).
  • Page 146 TOOLS Bearing remover set, 15 mm 07936- KCIOOOO not available in U.S.A. bearing remover, 15 07936 remover shaft 07936- KClOlOO not available in U S A . remover head 07936 - sliding weight 07741 -0010201 or 07936-371020A or 07936-3710200 Bearing remover, 17 07936 3710300 Remover handle...

  • Page 147: Crankcase Separation

    CRANKCASEITRANSMISSIONICRANKSHAFT CRANKCASE SEPARATION Remove the following: -engine (section 6) -cylinder head (section 7) -cylinder and piston (section clutch, gearshift linkage, primary drive gear (section 9) pump (section 4 1 - flywheel (section 101 -starter motor (section 18) bolt, tensioner sliderlcollar and washer - cam chain cam chain drive sprocket - two right crankcase bolts...
  • Page 148 Remove the gasket and dowel pins. GASKET TRANSMISSION DISASSEMBLY Separate the crankcase (page 11-3). Pull the gearshift plate away from the shift drum and remove the gearshift spindle. FORK SHAF Pull the shift fork shaft out of the left crankcase and shift forks.
  • Page 149 INSPECTION Check the gear dogs and teeth for abnormal wear or damage. Measure the gear I.D. SERVICE LIMITS: M 4 25.08 mm (0.987 in1 Measure the gear bushing O.D. SERVICE LIMITS: M4, M5: 24.90 mm (0.980 27.94 mm (1.100 Calculate the gear-to-bushing clearance. SERVICE LIMIT 0.10 mm (0.004 in) Measure the gear bushing I.D.
  • Page 150 . .- . SHIFT FORK Check the shift fork guide pins for abnormal wear or damage. Measure the shift fork SERVICE LIMIT 13.05 mm (0.514 in) Measure the shift fork claw thickness. SERVICE LIMIT 5.5 (0.22 SHIFT FORK SHAFT Check the shift fork shaft for damage or bending Measure the shift fork shaft O.D.
  • Page 151 MAINSHAFT THRUST WASHER SPLINE WASHER SPLINE WASHER M 4 GEAR (22T) THRUST WASHER WASHER AND SNAP RING DIRECTION: THRUST WASHER GEAR BUSING C3 GEAR (28T) SPLINE WASHER COUNTERSHAFT WASHER AND SNAP RING DIRECTION: THRUST WAS HER THRUST WASHER Gear bushing rotating 11-7...
  • Page 152 Check the gears for freedom of movement or rotation on the shaft. Engage the mainshaft and countershaft gears. Apply oil to the countershaft oil seal lip. Install the mainshaft and countershaft assemblies as to install a set into the left crankcase. the thrust washers.
  • Page 153 FORK Coat the shift fork shaft with oil. Install the shift fork shaft through the shift forks and into the left crankcase. Apply oil to the gearshift spindle oil seal lip Install the gearshift spindle by aligning the return spring ends with the spring pin bolt while pulling the gearshift plate.
  • Page 154 If the left crankshaft bearing is left on the crankshaft, remove it using the bearing puller with a suitable protector. TOOL Universal bearing puller 07631 0010000 or equivalent commercially available in U.S.A. NOTE: Always replace the left crankshaft bearing with a new one when the crankshaft is removed.
  • Page 155 BALANCER Check the balancer gear for wear or damage. INSTALLATION Apply oil to a new crankshaft bearing. Drive the crankshaft bearing into the left crankcase with the marking side facing up. TOOLS Driver 07749-0010000 Attachment, 72 x 75 mm 07746 0010600 Pilot.

  • Page 156: Bearing Remover, 15 Mm

    cob. Assemble the special tools onto the crankshah. Draw tne crankshatt into the bearing 'nner race. TOOLS: Crankcase assembly tool 07965 not available in U.S.A. -Assembly collar 07965 Assembly shaft 07965 07931 07931 Threaded adaptor 07965 07931 CAUTION: Be careful n o t t o let the connecting r o d press against the crankcase mating surface while drawing the crankshaft.
  • Page 157 Apply oil to new bearings. Drive the mainshaft, crankshaft and balancer bear- ings in with the marking side facing up using the spe- cial tools. TOOLS: Mainshaft bearing: 07749 0010000 Driver Attachment, 42 x 47 mm 07746-0010300 07746 0041000 Pilot, 22 mm Crankshaft bearing: Driver 07749...
  • Page 158 Remove the mainshaft bearing using the special tools. TOOLS: Mainshaft bearing: Bearing remover, 17 mm 07936-3710300 Remover handle 07936-3710100 Sliding weight 07936 07936-3710200 evenly using a heat Heat the crankcase 80°C (176°F) gun and remove the balancer bearing. Always wear insulated gloves when handling the crankcase after has been heated.

  • Page 159: Crankcase Assembly

    CRANKCASE ASSEMBLY Clean the left and right crankcase mating surfaces thoroughly, being careful not to damage them. Install the dowel pins and a new gasket. Make sure a l l t h e p a r t s are i n s t a l l e d in t h e left crankcase.
  • Page 160 Install the cam chain drive sprocket onto the crank- shaft, b y aligning the wide groove w i t h the wide tooth. Install the cam chain onto the drive sprocket and through the crankcase. Apply locking agent the cam chain tensioner bolt threads.
  • Page 161 MEMO...
  • Page 162 FRONT WHEELlSUSPENSlONlSTEERlNG (4.5 kgfm, 42 N m (4.3 kgfm, 9 N m (3.0 33 IbfW (6.5 kgfm, 12-0...
  • Page 163 12. FRONT WHEEL/SUSPENSION/STEERING 12-1 TIRES 12-9 SERVICE INFORMATION 12-2 SUSPENSION ARM 12-12 TROUBLESHOOTING HANDLEBAR 12-3 FRONT SHOCK ABSORBER 12-16 THROTTLE HOUSING 12-5 STEERING SHAFT AND TIE-ROD 12-17 FRONT WHEEL AND HUB 12-6 SERVICE INFORMATION GENERAL contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high qualify brake degreasing agent ITEM STANDARD...

  • Page 164: Assembly Collar

    FRONT WHEEL/SUSPENSION/STEERlNG TOOLS Driver 07749-0010000 Attachment, 32 x 35 mm 07746 0010100 Attachment, 37 x 40 mm 07746 0010200 Attachment, 42 x 47 mm 07746-0010300 07746 0040300 Pilot, 15 mm 07746 0040400 Pilot, 17 mm 07746 0040500 Pilot, 20 mm 07746 0050100 Bearing remover shaft...
  • Page 165 FRONT WHEEL/SUSPENSlON/STEERlNG HANDLEBAR REMOVAL Remove the fuel tank breather tube from the handle- bar cover. Remove the handlebar cover attaching bolt, being careful not to let the bolt fall into the steering shaft. Remove the cover by releasing its ends off the han- dlebar carefully.
  • Page 166 Install the upper holders with the punch marks facing forward. Install the four bolts and tighten the forward bolts first, then tighten the rear bolts. Apply Honda Bond A or Honda Hand Grip Cement grip and to the clean surface of the handlebar. Wait 3 minutes and install the grip.
  • Page 167 FRONT WHEELISUSPENSIONISTEERING Install the clutch lever bracket and holder with the "UP" mark facing up. Align the slit of the lever bracket with the punch mark on the handlebar, and tighten the upper bolt first, then the lower bolt. Connect the clutch switch to the connectors and install it into the clutch lever bracket.

  • Page 168: Wheel Removal

    FRONT WHEELISUSPENSIONISTEERING Slide the boot off the throttle cable adjuster Loosen the cable adjuster. Bend down the lock washer tab and remove the pivot nut, lock washer, throttle arm and return spring, then the throttle lever with the plastic washer. Disconnect the throttle cable from the throttle arm.
  • Page 169 FRONT WHEEL/SUSPENSlON/STEERlNG cotter pin hub nut - wheel hubldisc -three bolts and brake disc side collars - dust seals. DUST Turn the inner race each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub.
  • Page 170 FRONT WHEEL/SUSPENSION/STEERING HUB ASSEMBLY DRIVER Drive in a new inner bearing (brake disc side1 squarely with the marking side facing up until it fully seated. Install the distance collar with the large dia. facing the inner bearing. Drive in a new outer bearing squarely with the mark- ing side facing up until is fully seated.

  • Page 171: Wheel Installation

    FRONT WHEEL/SUSPENSION/STEERlNG WHEEL INSTALLATION Install the wheel onto the hub with the tire valve fac- ing out and the arrow mark facing in the normal rotating direction. NOTE: Do not interchange the left and right tires. Install the wheel nuts with the tapered side facing inward and tighten them.
  • Page 172 FRONT WHEEL/SUSPENSION/STEERlNG Place the proper size adaptor onto the threaded shaft BREAKER ARM ASSEMBLY and then put the wheel over the threaded shaft and adaptor. Lube the bead area with water, pressing down on the tire sidewalllbead area in several places to allow the water to run into and around the bead.

  • Page 173: Tire Repair

    FRONT WHEELlSUSPENSlONlSTEERlNG TIRE REPAIR NOTE: Use the manufacturer’s instructions for the tire repair kit you are using. If your kit does not have instruc- tions, use the procedures provided here. Check the tire for puncturing objects. Chalk mark the punctured area and remove the punc- turing object.
  • Page 174 FRONT WHEELISUSPENSIONISTEERING Apply cement over the area marked and allow it to dry. Remove the lining from the patch and center it over the injury. Press the patch against the injury using a special NOTE: Allow cement to dry until tacky before applying patch.
  • Page 175 FRONT WHEEL/SUSPENSION/STEERlNG Release the ball joints of the upper and lower arms off the knuckle, using the special tool according to the following instructions. TOOL Ball joint remover Apply grease to the ball joint remover at the point PRESSURE BOLT shown.
  • Page 176 FRONT WHEEL/SUSPENSION/STEERlNG bolt and brake hose clamp from the upper arm upper arm pivot nuts, bolts and upper arm -shock absorber lower mounting nut and bolt lower arm pivot nuts, bolts and lower arm Remove the pivot collars and dust seals. INSPECTION Check the pivot collars, dust seals and spherical bear- ings for wear or damage.
  • Page 177 FRONT WHEELlSUSPENSlONlSTEERlNG PIVOT BEARING REPLACEMENT Remove the stopper rings. Press the spherical bearing out of the arm pivot. TOOL Spherical bearing driver not available in U.S.A. or Install a new stopper ring into the groove in the arm pivot properly. BEARING DRIVER Press a new bearing into the arm pivot until it con-...
  • Page 178 FRONT WHEEL/SUSPENSlON/STEERING Install the knuckle onto the upper and lower arms with the joint nuts, washer and clamp. Tighten each nut to the specified torque and further tighten until its grooves align with the cotter pin hole. TORQUE: Install new cotter pins. Install the following: - tie-rod into knuckle (page 12-7) - wheel hub and front wheel (page 12-81,...
  • Page 179 FRONT WHEEL/SUSPENSION/STEERlNG Check the bushings for wear or damage. Check the damper unit for leakage or other damage. Replace the shock absorber assembly if necessary. INSTALLATION Apply molybdenum disulfide paste to the lower bushing of the shock absorber. Coat new dust seal lips with molybdenum disuifide paste and install them into the lower pivot.
  • Page 180 FRONT WHEELlSUSPENSlONlSTEERlNG Remove the cotter pins f r o m the tie-rod ball joint studs. Remove the joint nuts by holding the joint stud flat surfaces. Remove the tie-rods from the knuckles and steering shaft. Remove the cotter p n and tne steering shaft end Remove the steerlng snaft and shaft co lar from tne frame.
  • Page 181 FRONT WHEEL/SUSPENSION/STEERlNG Check the steering shaft for distortion or damage. Turn the inner race of each bearing with your finger. The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the frame. Remove and discard the bearing if the race do not turn smoothly and quietly, if fits loosely in the frame.
  • Page 182 FRONT WHEELISUSPENSIONISTEERING TIE-ROD ASSEMBLY When the tie-rod ball joints will be replaced, install the ball joints and lock nuts as shown. Adjust the tie-rod length so that the distance between each lock nut and thread end is 6.5 mm (0.26 in). (A difference between both ends distances is 3 mm (0.1 in) max.
  • Page 183 FRONT WHEELlSUSPENSlONlSTEERlNG Install the tie-roo into the steer ng shaft and knuckles with the flat lwrench holding point1 side facing the knuckle. Install the joint nuts and tighten them by holding the joint stud flat surfaces. TORQUE 44 N.m 14.5 kgf.m, 33 IbfW If the ball joints were replaced, tighten the lock nuts following procedure: Rotate both ball joints with the tie-rod axis until they...
  • Page 184 REAR WHEEL/SUSPENSION 59 N.m (6.0 kgfm, 43 Ibf4tl 108 N m (11.0 kgf.m, 80 Ibf4t) (14.0 kgfm, 101 IbfW 64 N.m (6.5 kgf.m. 47 Ibf.ft) 13-0...
  • Page 185 13. REAR WHEEL/SUSPENSION 13-1 REAR SHOCK ABSORBER 13-9 SERVICE INFORMATION 13-2 SHOCK LINKAGE 13-11 TROUBLESHOOTING 13-3 13-13 REAR WHEEL REAR AXLE 13-3 SERVICE INFORMATION GENERAL A contaminated brake disc or Dad reduces stODpino Dower. Discard contaminated Dads and clean a contaminated disc with a high quality brake degreasing agent.
  • Page 186 REAR WHEEL/SUSPENSION TOOLS Driver 07749 0010000 Attachment, 24 x 26 mm 07746 0010700 Attachment, 62 x 66 mm 07746 0010500 Attachment, 35 mm 07746 0030400 Pilot, 17 mm 07746-0040400 Pilot, 40 mm 07746 0040900 Lock nut wrench, 56 mm 07916 HA20000 or 07916- HA2010A (U.S.A.

  • Page 187: Rear Wheel

    REAR WHEELlSUSPENSlON REAR WHEEL REMOVAL Loosen the wheel nuts. rear wheels off the ground. Remove the nuts and wheel. For tire removallinstallation and repair, refer to sec- INSTALLATION Install the tire onto the hub with the tire valve facing TAPERED SIDE out.
  • Page 188 REAR WHEELlSUSPENSlON Remove the wheels (page 13-31, Remove the cotter pin and the hub nut. Remove the right wheel hub. Remove the stopper ring, outer and inner lock nuts from the axle. Remove the skid plate (page Remove the brake disclhub by sliding it outward. Remove the O-ring from the inside of the disc hub.
  • Page 189 REAR WHEELlSUSPENSlON Remove the O-ring. Remove the nuts, bolts and driven sprocket. SPROCKET Remove the snap ring from the bearing holder. Remove the caliper stay and stopper bushing. Remove the O-rings from the bearing holder and stay groove. SNAP KING Remove the axle bearing holder to the left by tapping it lightlyfrom the right side.
  • Page 190 REAR WHEEL/SUSPENSION 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 holder. Remove and discard the bearings if the races do not Replace the axle turn smoothly and quietly or if they fit loosely in the bearings...
  • Page 191 REAR WHEELlSUSPENSlON Drive in a new right bearing (brake disc side) squarely with the marking side facing up until it is fully seated. Install the distance collar. Drive in a new left bearing squarely with the marking side facing up until it is fully seated. TOOLS Driver 07749-0010000...
  • Page 192 REAR WHEELlSUSPENSlON Install the driven sprocket with the chamfered side of the bolt holes facing in. Coat a new O-ring with oil and install between the driven sprocket flange and axle. 'ROCKET Install the axle into the swingarm through the drive chain until is fully seated.

  • Page 193: Rear Shock Absorber

    REAR WHEELlSUSPENSlON Thelocknuts Turn the outer lock nut clockwise until the stopper ring groove is covered with the outer lock nut and apply locking agent to the lock bolt threads as shown. threads. Turn the outer lock nut counterclockwise until the ring groove is visible and install the stopper ring into the groove.
  • Page 194 REAR WHEEL/SUSPENSION BEARING REPLACEMENT Remove the dust seals. Press the needle bearing out of the shock absorber. TOOL Needle bearing remover 07946 Apply grease to new needle bearing rollers. Carefully press the needle bearina into the shock Press mark- absorber until the depth from the outer surface is 5.5 ing side 22 in).
  • Page 195 REAR WHEELlSUSPENSlON SHOCK LINKAGE REMOVAL NOTE: The linkage can be serviced with the skid plate installed, although it is easier to service if the skid plate is removed (page 2-51, Support the vehicle with a support block to raise the rear wheels off the ground.
  • Page 196 REAR WHEEL/SUSPENSION Apply grease to new needle bearing rollers. Carefully press the needle bearing into the shock arm Press the mark- and shock link until the depth from the outer surface ing side is 5.5 mm (0.22 in). bearing TOOLS: Driver 0010000 Attachment, 24...
  • Page 197 REAR WHEEL/SUSPENSION REMOVAL Remove the rear axle (page Support the swingarm and remove the following: -screw and brake hose clamp - bolt and brake hosellock cable clamp -shock absorber lower mounting nut and bolt -shock link-to-swingarm nut and bolt swingarm pivot nut and bolt swingarm from the frame -dust seal caps and outer dust seals -under cover and chain slider if necessary.
  • Page 198 REAR WHEEL/SUSPENSION NEEDLE BEARING Apply grease to new needle bearing rollers. Carefully press the needle bearing and thrust bush- Press the ing into the swingarm pivot until the bushing is fully marking side the bearing. seated. TOOL Needle bearing remover 07946 Pack grease into new inner dust seal lip cavities.
  • Page 199 REAR WHEELlSUSPENSlON Install the brake hoselcable clamp with the bolt t o CLAMP secure the brake lock cable. Install the brake hose clamp with the screw. Install the rear axle (page 13-6). BRAKE HOSE...
  • Page 200 HYDRAULIC DISC BRAKE (3.5 kgfm, 25 IbfW (3.5 kgfm, 25 Ibf.ft) 14-0...
  • Page 201 HYDRAULIC DISC BRAKE 14-1 FRONT BRAKE CALIPER 14-10 SERVICE INFORMATION 14-2 REAR MASTER CYLINDER 14-13 TROUBLESHOOTING REAR BRAKE CALIPER 14-16 BRAKE FLUID REPLACEMENT/ AIR BLEEDING BRAKE PEDAL 14-20 BRAKE PAD/DISC 14-5 FRONT MASTER CYLINDER SERVICE INFORMATION GENERAL A confarninafed brake disc or p a d reduces stopping power. contaminated disc with a high quality brake degreasing agent.
  • Page 202 HYDRAULIC DISC BRAKE TOOL Snap ring pliers 07914- SA50001 TROUBLESHOOTING Brake leverlpedal soft or spongy Air in hydraulic system Leaking hydraulic system Contaminated brake padldisc Worn caliper piston seals Worn master cylinder piston cups Worn brake padldisc Contaminated caliper Contaminated master cylinder Caliper not sliding properly Low brake fluid level Clogged fluid passage...
  • Page 203 HYDRAULIC DISC BRAKE BRAKE FLUID REPLACEMENT/ AIR BLEEDING contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a cont- aminated disc with a high quality brake degreasing agent. CAUTION not allow foreign material to enter the system when filling the reservoir.
  • Page 204 HYDRAULIC DISC BRAKE not appear in the bleed tube. NOTE: If air is entering the bleeder from around the bleed valve threads, seal the threads with teflon tape. Close the bleed valve and operate the brake lever or pedal. If it still feels spongy, bleed the system again. If a brake bleeder is not available.
  • Page 205 HYDRAULIC DISC BRAKE BRAKE PAD/DISC FRONT BRAKE PAD REPLACEMENT Remove the front wheel (page 12-6). Always replace the brake pads in Remove the pad pin plugs and loosen the pad pins. pairs to ensure Release the brake hose from the clamp. even discpres- Remove the mounting bolts and front brake caliper.
  • Page 206 HYDRAULIC DISC BRAKE REAR BRAKE PAD REPLACEMENT Straighten the lock plate tabs and loosen the pad Alwaysreplace pins. the brake pads in pairs to ensure even discpres- Remove the mounting bolts and rear brake caliper. sure. Push the caliper piston all the way in to allow instal- lation of new brake pads.

  • Page 207: Brake Disc Inspection

    HYDRAULIC DISC BRAKE BRAKE DISC INSPECTION Visually inspect the disc for damage or cracks. Measure the brake disc thickness at several points. SERVICE LIMIT Front: 2.5 mm (0.10 in1 Rear: 3.5 mm (0.14 in) Replace the brake disc if the smallest measurement less than service limit.
  • Page 208 HYDRAULIC DISC BRAKE -snap ring SNAP RING TOOL 07914 Snap ring pliers master piston -spring Clean the master cylinder, reservoir and master pis- ton in clean brake fluid. INSPECTION Check the piston cups for wear, deterioration or dam- age. Check the master cylinder and piston for scoring, scratches or damage.
  • Page 209 HYDRAULIC DISC BRAKE Coat the master piston and piston cups with clean brake fluid. Install the spring onto the master piston. Install the sorina and master Diston into the master cylinder. PISTON CAUTION: Do not allow the oiston to turn inside out. C U D Install the snap ring into the groove in the master cylinder, using the special tool.

  • Page 210: Front Brake Caliper

    HYDRAULIC DISC BRAKE FRONT BRAKE CALIPER CAUTION Avoid spilling fluid on painted, plastic or rubber parts. Place a rag over these parts whenever the sys- tem is serviced. DISASSEMBLY Remove the front wheel (page 12-61. Drain the brake fluid from the front brake hydraulic system (page 14-3).
  • Page 211 HYDRAULIC DISC BRAKE INSPECTION Check the caliper cylinder and piston f o r scoring, scratches or damage. Measure the caliper cylinder I.D. SERVICE LIMIT: 34.02 mm (1.340 in) Measure the caliper piston O.D. SERVICE LIMIT 33.87 mm (1.333 ASSEMBLY BLEED VALVE PAD PIN PLUGS CALIPER BODY PISTON SEAL...
  • Page 212 HYDRAULIC DISC BRAKE Install the pad spring as shown. the pin boots are hard or deteriorated, replace them with new ones. Install the bracket pin boot into the caliper body and pack silicone grease to the inside of the boot. Apply silicone grease to the grease groove in the slide pin.

  • Page 213: Rear Master Cylinder

    HYDRAULIC DISC BRAKE REAR MASTER CYLINDER CAUTION: Avoid spilling fluid on painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. When removing the oil bolt, cover the end of the hose prevent contamination. DISASSEMBLY Drain the brake fluid from the rear brake hydraulic system (page 14-3).
  • Page 214 HYDRAULIC DISC BRAKE INSPECTION Check the piston cups for wear, deterioration or dam- age. Check the spring for damage. Check the master cylinder and piston for scoring, scratches or damage. Measure the maser cylinder I.D. SERVICE LIMIT 12.75 10.502 in) Measure the master piston O.D.
  • Page 215 HYDRAULIC DISC BRAKE Install the push rod into the master cylinder and the snap ring into the groove in the master cylinder, using the special tool. TOOL Snap ring pliers 07914 CAUTION: Be certain the snap ring is firmly seated in the groove.

  • Page 216: Rear Brake Caliper

    HYDRAULIC DISC BRAKE Connect the push rod t o the brake pedal with the joint pin and secure with a new cotter pin. Fill and bleed the rear hydraulic system (page 14-3). REAR BRAKE CALIPER CAUTION: Avoid spilling fluid painted, plastic rubber parts.
  • Page 217 HYDRAULIC DISC BRAKE CAUTION: Be careful not to damage the piston sliding surface. Push the dust seal and piston seal in and lift them Remove the O-ring. Clean the seal grooves, caliper cylinder and piston with clean brake fluid. INSPECTION CABLE LOCK BRAKE Remove the shaft boot and the brake shaft.
  • Page 218 HYDRAULIC DISC BRAKE ASSEMBLY WASHER CALIPER BRACKET WASHER SLIDE PIN BRAKE PADS BOOT PISTON SEAL PAD SPRING WEAR REFERENCE PLATE PARKING BRAKE BASE BRAKE SHAFT BLEED VALVE LOCK NU? ADJUSTING BOLT Coat a new O-ring with clean brake fluid and install into the caliper.
  • Page 219 HYDRAULIC DISC BRAKE Install the caliper bracket over the caliper body with the spring washer (between the slide pin and bracket) and thread the slide pin into the bracket, being care- ful not to damage the pin boot. Make sure that the boots are seated securely into the pin grooves.

  • Page 220: Brake Pedal

    HYDRAULIC DISC BRAKE Apply grease to the lock cable end. Install the lock cable into the stay and connect it to the brake arm. Turn the brake shaft clockwise approximately from fully seated position and install the brake arm onto the brake shaft by aligning the punch marks on the arm and shaft.
  • Page 221 HYDRAULIC DISC BRAKE Secure the pedal with the washer and cotter pin. Hook the return spring to the pedal. Connect the push rod to the pedal with the joint and secure the joint pin with new cotter pin. COTTERPIN 14-21...
  • Page 222 FUSE (15A) Black Green Pink 15-0...
  • Page 223 SYSTEM 15-1 CHARGING SYSTEM INSPECTION 15-5 SERVICE INFORMATION 15-3 15-6 TROUBLESHOOTING 15-4 ALTERNATOR CHARGING COIL 15-7 SERVICE INFORMATION GENERAL battery gives explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. 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.
  • Page 224 Battery charging This model comes with maintenance free battery. Remember the following about MF batteries. Use only the electrolyte that comes with the battery. Use all of the electrolyte. Seal the battery properly. -Never open the seals again. CAUTION: For battery charging, do not exceed the charging current and time specified the battery.
  • Page 225 SYSTEM TROUBLESHOOTING Battery is damaged or weak 1. Remove the battery (page 15-4). Incorrect Faulty battery Check the batterv condition usin(l the rec- ommended battery tester. RECOMMENDED BATTERY TESTER: BM-210-AH, BM-210. or EATERY MATE Disconnect the regulatorlrectifier 6P connector Install the battery (page 15-41. Incorrect and rechecn the batten, current leakage.

  • Page 226: Battery Charging

    CABLE HOLDER CABLE With the ignition switch OFF, disconnect the negative cable first, then the positive cable. Remove the two bolts, battery holder and battery from the battery box. Install the battery in the reverse order of removal. NOTE: Connect the positive cable first, then the nega- tive cable.

  • Page 227: Charging System Inspection

    CHARGING SYSTEM INSPECTION CURRENT LEAKAGE TEST OFF, Turn the ignition switch and disconnect the neg- ative cable from the battery. Connect the ammeter probe to the negative cable and the ammeter probe to the battery ter- minal. With the ignition switch OFF, check for current leak- age.
  • Page 228 Connect the tachometer NOTE: Read the instructions for tachometer operation. Restart the engine, turn the headlight on and shift it to High beam. Measure the voltage on the multitester when the engine runs at 5,000 rpm. STANDARD: Measured battery voltage (page 15-4lc Measured charging voltage45.5 V a t 5,000 rpm WIRE HARNESS INSPECTION Disconnect the regulatorlrectifier...
  • Page 229 Remove the two bolts and regulatorlrectifier from the removal. ALTERNATOR CHARGING COIL CONNECTOR INSPECTION Remove the seathear fender (page 2-2). Disconnect the alternator 4P connector. and pi1 Measure the resistance between the yt wire terminals of the alternator side connector. STANDARD: 0.1 1.0 0 (20°C/68"Fl Check for continuity between the yellow wire termi-...
  • Page 230 IGNITION SYSTEM IGNITION SWITCH ENGINE STOP SWITCH IGNITION CONTROL MODULE IGNITION COIL IGNITION PULSE GENERATOR IGNITION CONTROL MODULE (I C M) Yellow Green SPARK White IGNITION IGNITION EXCITER Black PULSE Blue 16-0...
  • Page 231 16. IGNITION SYSTEM 16-1 IGNITION COIL 16-6 SERVICE INFORMATION IGNITION CONTROL MODULE (ICM) 16-2 16-6 TROUBLESHOOTING IGNITION SYSTEM INSPECTION 16-3 IGNITION TIMING 16-7 SERVICE INFORMATION GENERAL CAUTION: Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni- tion switch is and current is uresent.
  • Page 232 IGNITION SYSTEM TROUBLESHOOTING Faulty spark plug Loose spark plug cap or spark plug wire connections -Water got into the spark plug cap (Leaking the ignition coil secondary voltage) If there is no spark at cylinder, temporarily exchange the ignition coil with a good one and perform the spark test. If there is spark, the exchanged ignition coil is faulty.
  • Page 233 IGNITION SYSTEM IGNITION SYSTEM INSPECTION DIGITAL MULTIMETER NOTE: no spark jumps at the plugs, check all connec- tions for loose or poor contact before measuring each peakvoltage. Use a commercially available digital multimeter (impedance 10 MOIDCV minimum). The display value differs depending upon the internal impedance of the multimeter.
  • Page 234 IGNITION SYSTEM EXCITER COIL PEAK VOLTAGE ICM CONNECTORS NOTE: Check that the cylinder compression is normal and the spark plug is installed correctly in the cylinder head. Disconnect the ignition control module (ICM) connec- tors. Connect the peak voltage tester or adaptor probes to the connector terminals of the wire harness side.
  • Page 235 IGNITION SYSTEM IGNITION PULSE GENERATOR PEAK VOLTAGE NOTE Check that the cylinder compression is normal and the spark plug is installed correctly in the cylinder head. Disconnect the ignition control module (ICM) 4P con- nector. Connect the peak voltage tester or adaptor probes to the connector terminals of the wire harness side.
  • Page 236 IGNITION SYSTEM IGNITION COIL TERMINALS REPLACEMENT Remove the left side cover (page Disconnect the primary coil connector. Remove the spark plug cap from the plug. Remove the two bolts, ground wire terminals and the ignition coil from the frame. coil Install a new ignition in the reverse order of removal.

  • Page 237: Ignition Timing

    IGNITION SYSTEM IGNITION TIMING If the engine must be running t o d o some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust contains poiso- loss nous carbon monoxide gas that may cause consciousness and lead t o death.
  • Page 238 ELECTRIC STARTER IGNITION SWITCH IGNITION SWITCH FUSE (15A) NEUTRAL INDICATOR DIODE Yellow Green R BI Black Light green CLUTCH RELAY SWITCH MOTOR...

  • Page 239: Electric Starter

    17. ELECTRIC STARTER 17-1 STARTER RELAY SWITCH 17-9 SERVICE INFORMATION 17-2 CLUTCH DIODE 17-10 TROUBLESHOOTING STARTER MOTOR SERVICE INFORMATION GENERAL turn the ignition switch before servicing the starter motor. The motor could suddenly start, causing rwi- Always ITEM STANDARD SERVICE LIMIT 17-1...
  • Page 240 ELECTRIC STARTER TROUBLESHOOTING Starter motor will not turn Check for a blown fuse (15 A). Check that the battery is fully charged and in good condition Abnormal Poorlv connected batterv cable Open'circuit in battery cable Normal Check for loose or poorly connected starter Abnormal Poorly connected terminals or connectors relav switch terminals and connectors.
  • Page 241 ELECTRIC STARTER From page 17-2 Check the starter relay voltage (page 17-10). Abnormal Faulty ignition switch Blownfuse Faulty engine stop switch Faulty starter switch Nor'mal Loose or poor connector contact Open circuit in wire harness Check the starter relay Abnormal Faulty starter relay switch 17-10).

  • Page 242: Starter Motor

    ELECTRIC STARTER STARTER MOTOR REMOVAL the ignition switch OFF before servicing Always turn the starter motor. The motor could suddenly start, causing serious injury. Remove the rubber cap, terminal nut and starter motor cable. Remove the two mounting bolts, cable guide and the starter motor from the crankcase and left crankcase cover.
  • Page 243 ELECTRIC STARTER SHIMS REAR COVER Remove the rear cover, shims and seal ring. Record Remove the armature from the motor case. ofshims. Check the bearing and oil seal in the front cover for wear or damage. Check the commutator bars of the armature for dis- coloration.
  • Page 244 ELECTRIC STARTER Check for continuity between each commutator bar and the armature shaft. There should be no continuity. Check for continuity between the insulated brush and cable terminal. There should be continuity. Check for continuity between the cable terminal and motor case.
  • Page 245 ELECTRIC STARTER Remove the brushes from the brush holder. Measure the brush length. SERVICE LIMIT 8.5 10.33 in) ASSEMBLY FRONT COVER TOR CASE ARMATURE WASHER INSULATOR REAR COVER Install the brushes into the brush holder. 17-7...
  • Page 246 ELECTRIC STARTER Install the brush holder assembly into the rear cover by aligning the tab of the holder with the groove in the rear cover. Install the following: new O-ring insulator washers -washer Install the armature into the motor case while hold- ing the armature tightly to keep the magnet of the case from pulling the armature against it CAUTION:...
  • Page 247 ELECTRIC STARTER INSTALLATION Coat a new O-ring with oil and install it into the starter motor groove. Install the starter motor into the left crankcase cover and onto the crankcase. Install the cable guide and mounting bolts, and tighten the bolts securely. Install the starter motor cable and terminal nut onto the motor terminal and tighten the nut securely.
  • Page 248 ELECTRIC STARTER STARTER RELAY VOLTAGE Disconnect the yellowlred wire connector of the starter relay switch. Measure the voltage between the wire harness side connector terminal and ground the battery voltage appears only when the starter switch is pushed with the ignition switch the cir- cuit normal.
  • Page 249 MEMO...
  • Page 250 HANDLEBAR SWITCH NEUTRAL INDICATOR 18-0...
  • Page 251 LIGHTS/SWITCHES 18-4 SERVICE INFORMATION 18-1 HANDLEBAR SWITCH BULB REPLACEMENT 18-2 CLUTCH SWITCH 18-4 18-3 NEUTRAL SWITCH 18-5 IGNITION SWITCH SERVICE INFORMATION GENERAL continuity test can be made with the switches installed on the vehicle. released before disconnecting, and must be aligned when reconnecting.
  • Page 252 BULB REPLACEMENT DUST COVER HEADLIGHT Remove the front fender (page Remove the dust cover from the headlight. Remove the bulb socket by turning counterclock- wise while pushing it in. Replace the headlight bulb with new one. Installation is in the reverse order of removal. NOTE: Align the bulb tab with the headlight groove.

  • Page 253: Ignition Switch

    Pull the taillight bulb out of the socket. Install a new bulb and the socket in the reverse order of removal. NEUTRAL INDICATOR LENS, Remove the indicator lens from the bulb socket. Remove the neutral indicator from the front fender. Pull the indicator bulb out of the socket, Install a new bulb, the lens and socket in the reverse order of removal.

  • Page 254: Handlebar Switch

    HANDLEBAR SWITCH INSPECTION Disconnect the handlebar switch 6P connector. Check for continuity between the connector terminals in each switch position. Continuity should exist between the color coded wires as follows: ENGINE STOP SWITCH Color Blackfwhite Green Position LIGHTING DIMMER STARTER ENGINE STOP LIGHTING SWITCH DIMMER SWITCH...

  • Page 255: Neutral Switch

    INSPECTION Remove the clutch switch and check for continuity between the switch terminals. There should be n o continuity w i t h the switch plunger pushed in, and continuity with the switch plunger released. NEUTRAL SWITCH INSPECTION Disconnect the neutral switch wire connector. Check for continuity between the switch terminal and engine ground.
  • Page 256 MEMO...
  • Page 259 TROUBLESHOOTING ENGINE LACKS POWER Possible cause Wheels does not spin freely Brake dragging 1. Raise wheel off the ground and spin by hand Worn or damaged wheel bearings Drive chain too tight Wheel spins freely Pressure low Faulty tire valve 2.
  • Page 260 TROUBLESHOOTING From page 20-2 Possible cause Clogged oil passage Valve train not lubricated Clogged oil orifice and inspect lubrication properly Valve train lubricated properly Overheating Excessive carbon build-up in Check for engine overheating combustion chamber Use of poor quality fuel Not overheating Clutch slipping Lean fuel mixture...
  • Page 261 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED Possible cause 1. Disconnect fuel tube a t Fuel flow restricted Restricted fuel tube carburetor Restricted fuel tank breather tube Faulty fuel valve Fuel flows freely Clogged fuel strainer Clogged Check carburetor for clogging enough Not clogged Incorrect...
  • Page 262 INDEX ..................IGNITION COIL .............. IGNITION CONTROL MODULE (ICM) ..............IGNITION SWITCH 18-3 AIR CLEANER HOUSING DRAIN TUBE ............IGNITION SYSTEM INSPECTION ............... IGNITION TIMING ALTERNATOR STATOR ..................LUBRICATION & SEAL POINTS 1-16 ............
  • Page 263 INDEX ..........THROTTLE HOUSING 12-5 .......... THROTTLE OPERATION ..............TIRES 12-9 ..............TOOLS 1-14 ........TORQUE VALUES ............TRANSMISSION TROUBLESHOOTING ....10-1 ................CRANKSHAFT 11-2 ....CYLINDER HEADNALVE CY LINDE R/PISTON ........ELECTRIC STARTER ENGINE DOES NOT START OR IS HARD ..........

This manual is also suitable for:

Trx400ex fourtrax 2000Trx400ex fourtrax 2001

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