Honda TRX350TM Rancher Service Manual
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Honda TRX350TM Rancher Service Manual

2000-2003 rancher/rancher 4x4
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Irving Louviere
April 18, 2025

Fuel drains out through the drain line

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Summary of Contents for Honda TRX350TM Rancher

  • Page 2: Table Of Contents

    ELECTRIC STARTER THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE LIGHTS/METERS/SWITCHES TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE ELECTRIC SHIFT PROGRAM CHANGES AT ANY TIME WITHOUT NOTICE AND (ESP: TE/FE models) WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.

  • Page 3: General Information

    1-16 SERVICE RULES Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don’t meet HONDA’s design specifications may cause damage to the motorcycle. Use the special tools designed for this product to avoid damage and incorrect assembly.
  • Page 4 GENERAL INFORMATION The Vehicle Identification Number (VIN) is located on The frame serial number is stamped on the front side the left side frame down tube. of the frame. The engine serial number is stamped on the left side The carburetor identification number is stamped on of the rear crankcase.

  • Page 5: Specifications

    GENERAL INFORMATION SPECIFICATIONS GENERAL: TRX350TM/TE SPECIFICATIONS ITEM DIMENSIONS Overall length 1,983 mm (78.1 in) Overall width 1,143 mm (45.0 in) Overall height 1,119 mm (44.1 in) Wheelbase 1,253 mm (49.3 in) Front tread 851 mm (33.5 in) Rear tread 840 mm (33.1 in) Seat height 812 mm (32.0 in)
  • Page 6 GENERAL INFORMATION GENERAL: TRX350TM/TE (Cont’d) ITEM SPECIFICATIONS CARBURETOR Carburetor type Constant Vacuum (VE type) Throttle bore 32 mm (1.3 in) DRIVE TRAIN Clutch system Centrifugal and Multi-plate, wet Clutch operation system Automatic Transmission Constant mesh, 5-speeds with reverse Primary reduction 2.188...
  • Page 7 GENERAL INFORMATION GENERAL: TRX350FM/FE ITEM SPECIFICATIONS DIMENSIONS Overall length 1,983 mm (78.1 in) Overall width 1,143 mm (45.0 in) Overall height 1,130 mm (44.5 in) Wheelbase 1,246 mm (49.1 in) Front tread 844 mm (33.2 in) Rear tread 860 mm (33.9 in) Seat height 824 mm (32.4 in) Footpeg height...
  • Page 8 GENERAL INFORMATION GENERAL: TRX350FM/FE (Cont’d) SPECIFICATIONS ITEM CARBURETOR Carburetor type Constant Vacuum (VE type) Throttle bore 32 mm (1.3 in) DRIVE TRAIN Clutch system Centrifugal and Multi-plate, wet Clutch operation system Automatic Transmission Constant mesh, 5-speeds with reverse Primary reduction 2.188 (70/32) Secondary reduction...

  • Page 9: Fuel System

    2.0 (2.1 US qt , 1.8 Imp qt) After disassembly 2.5 (2.6 US qt , 2.2 Imp qt) Recommended engine oil Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil or equivalent motor oil API service classification: SG or higher...
  • Page 10 GENERAL INFORMATION Unit: mm (in) CYLINDER/PISTON ITEM STANDARD SERVICE LIMIT Cylinder I.D. 78.500 78.510 (3.0905 3.0909) 78.60 (3.094) Out-of-round 0.10 (0.004) Taper 0.10 (0.004) Warpage 0.10 (0.004) Piston, Piston O.D. at 15 (0.6) from bottom 78.465 78.485 (3.0892 3.0900) 78.43 (3.088) Piston pin, Piston pin hole I.D.
  • Page 11 GENERAL INFORMATION Unit: mm (in) CRANKCASE/TRANSMISSION/CRANKSHAFT STANDARD SERVICE LIMIT ITEM Shift fork I.D. 13.000 13.018 (0.5118 0.5125) 13.04 (0.513) Claw thickness 4.93 5.00 (0.194 0.197) 4.5 (0.18) Shaft O.D. 12.966 12.984 (0.5105 0.5112) 12.96 (0.510) Transmission Gear I.D. 23.000 23.021 (0.9055 0.9063) 23.04 (0.907) 18.000 18.021 (0.7087 0.7095) 18.05 (0.711)
  • Page 12 GENERAL INFORMATION Unit: mm (in) FRONT WHEEL/SUSPENSION/STEERING (TM/TE model) ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 4.0 (0.16) Cold tire pressure Standard 20 kPa (0.20 kgf/cm , 2.9 psi) Minimum 17 kPa (0.17 kgf/cm , 2.5 psi) Maximum 23 kPa (0.23 kgf/cm , 3.3 psi) With cargo 20 kPa (0.20 kgf/cm , 2.9 psi) Tie-rod distance between the ball joints...

  • Page 13: Brake System

    GENERAL INFORMATION Unit: mm (in) BRAKE SYSTEM ITEM STANDARD SERVICE LIMIT Front brake Recommended brake fluid Honda DOT 4 brake fluid Drum I.D. 160.0 (6.30) 161.0 (6.34) Shoe lining thickness 4.0 (0.16) 1.0 (0.04) Brake panel warpage 0.4 (0.02) Waterproof seal lip length 22 (0.9)

  • Page 14: Ignition System

    GENERAL INFORMATION BATTERY/CHARGING SYSTEM ITEM SPECIFICATIONS Battery Capacity 12 V 12 Ah Current leakage 1 mA max. (Equipped with digital meter) 0.1 mA max. (No digital meter) Voltage Fully charged 13.0 13.2 V (20°C/68°F) Needs charging Below 12.3 V Charging current Normal 1.4 A 5 10 h...

  • Page 15: Torque Values

    GENERAL INFORMATION TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft) 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)

  • Page 16: Frame/Body Panels/Exhaust

    GENERAL INFORMATION ENGINE (Cont’d) THREAD TORQUE ITEM Q’TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) LIGHTS/METER/SWITCHES: Gear position switch bolt 12 (1.2) NOTE 1 Oil thermosensor 18 (1.8) ELECTRIC SHIFT PROGRAM (ESP: TE/FE model): Angle sensor bolt 6 (0.6) NOTE 1 Reverse shift switch 13 (1.3) FRAME...
  • Page 17 GENERAL INFORMATION FRAME (Cont’d) THREAD TORQUE ITEM Q’TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) BRAKE SYSTEM: Brake hose oil bolt 34 (3.5 , 25) Wheel cylinder bleed valve 6 (0.6 , 4.3) Front master cylinder reservoir cap screw 2 (0.2 , 1.4) Front brake lever pivot bolt 6 (0.6 , 4.3) 6 (0.6 , 4.3)
  • Page 18 GENERAL INFORMATION TOOLS NOTES: 1. Newly designed tool 2. Equivalent commercially available in U.S.A. 3. Not available in U.S.A. 4. Alternative tool DESCRIPTION TOOL NUMBER REMARKS REF. SECTION Carburetor float level gauge 07401-0010000 Universal bearing puller 07631-0010000 NOTE 2 Flywheel holder 07725-0040000 NOTE 2 Adjustable bearing puller, 24 40 mm...
  • Page 19 GENERAL INFORMATION DESCRIPTION TOOL NUMBER REMARKS REF. SECTION Bearing remover set, 20 mm 07936-3710001 NOTE 3 Remover handle 07936-3710100 11, 12, 13, 15, 16 Remover weight 07936-3710200 NOTE 4: 07936-371020A (U.S.A. only) 11, 12, 13, 15, 16 Bearing remover, 17 mm 07936-3710300 11, 13 Bearing remover, 20 mm...
  • Page 20 GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE LOCATION MATERIAL REMARKS Camshaft cam lobes Molybdenum oil Rocker arm shaft sliding surface solution (a mixture of Valve stem (valve guide sliding surface) 1/2 engine oil and 1/2 Change clutch outer guide inner and outer surfaces molybdenum disulfide Piston pin outer surface grease)
  • Page 21 GENERAL INFORMATION ENGINE (Cont’d) LOCATION MATERIAL REMARKS Oil pipe retaining bolt threads Locking agent Gear position switch special bolt threads Cam chain tensioner slider pivot bolt threads Cam chain tensioner lifter bolt threads Camshaft bearing retainer bolt threads Gearshift drum stopper arm pivot bolt threads Gearshift cam plate bolt threads Gearshift spindle return spring pin threads Gearshift spindle retaining bolt threads...
  • Page 22 GENERAL INFORMATION FRAME LOCATION MATERIAL REMARKS Throttle cable end Multi-purpose grease Throttle lever pivot and dust seal lip (NLGI Rear (parking) brake lever pivot Parking lock arm pivot (screw) Front brake drum (wheel hub) dust seal lips TM/TE only Front axle O-ring Front brake drum (wheel hub) nut threads and seating surface Steering shaft bushing inner surface...
  • Page 23 GENERAL INFORMATION FRAME (Cont’d) LOCATION MATERIAL REMARKS Handlebar grip rubber inside Honda Bond A or Air cleaner case-to-connecting tube (carburetor and air Honda Hand Grip intake duct) mating groove Cement (U.S.A. only) or Air cleaner case-to-crankcase breather tube grommet equivalent...
  • Page 24 GENERAL INFORMATION CABLE & HARNESS ROUTING FUEL TANK BREATHER HOSE COVER HANDLEBAR HANDLEBAR SWITCH WIRE FUEL TANK BREATHER HOSE (Equipped with meter) (Do not pinch it between the handlebar and cover) Reverse side of the front fender: AIR TEMPERATURE SWITCH (U.S.A.
  • Page 25 GENERAL INFORMATION BRAKE HOSE BRAKE BREATHER HOSE DIFFERENTIAL BREATHER HOSE CLIPS (All FM/FE models) BRAKE HOSE BRAKE BREATHER HOSE BRAKE PIPE SPARK PLUG WIRE CLAMPS IGNITION COIL Incorrect: BOOT BAND (REAR SIDE) Correct: View: B View: A BOLT SPEED SENSOR SWINGARM JOINT BOOT WIRE (U.S.A.
  • Page 26 GENERAL INFORMATION OIL PRESSURE INDICATOR NEUTRAL INDICATOR IGNITION SWITCH REVERSE INDICATOR U.S.A. TM/FM models DIGITAL METER: HANDLEBAR SWITCH WIRE U.S.A. TE/FE models and All Canada type (U.S.A. TM/FM models optional) METER WIRE REVERSE SELECTOR CABLE THROTTLE CABLE HANDLEBAR SWITCH WIRE IGNITION SWITCH WIRE FRONT BRAKE HOSE CHOKE CABLE...
  • Page 27 GENERAL INFORMATION See page 1-27 See below OIL COOLER HOSE DIFFERENTIAL BREATHER HOSE (All FM/FE models) BRAKE BREATHER HOSE THROTTLE CABLE CHOKE CABLE REAR (PARKING) MAIN WIRE BRAKE CABLE HARNESS IGNITION CONTROL MODULE (ICM) REVERSE SELECTOR CABLE ANGLE SENSOR (All TE/FE models) AIR TEMPERATURE SWITCH WIRE FAN MOTOR BREATHER HOSE (U.S.A.
  • Page 28 GENERAL INFORMATION SUB-IGNITION CONTROL MODULE Early production of the TE/FE model only: (SUB-ICM) CONNECTORS PLASTIC BANDS IGNITION CONTROL MODULE (ICM) CARRY PIPE SUB-ICM WIRES MOLDING FACE Short Long RUBBER HOUSING 1-26...
  • Page 29 GENERAL INFORMATION AIR INTAKE DUCT BRAKE BREATHER HOSE CARBURETOR AIR VENT HOSE CARBURETOR AIR VENT HOSE FUEL TANK SIDE COVER BRAKE BREATHER HOSE DIFFERENTIAL/FINAL GEAR CASE DIFFERENTIAL/FINAL CLIPS BREATHER HOSE GEAR CASE BREATHER (Carburetor air CLIP: vent hose only) HOSE Main wire harness Breather hoses Reverse selector cable...
  • Page 30 GENERAL INFORMATION Except early TE/FE model production: CLIP: Main wire harness Breather hoses Reverse selector cable THROTTLE CABLE CHOKE CABLE STARTER MOTOR CABLE REVERSE SELECTOR CABLE CARBURETOR HEATER WIRE BATTERY ( ) CABLE GROUND ( ) FUEL HOSE CABLES CARBURETOR AIR VENT HOSE GROUND CABLE STARTER MOTOR CABLE...
  • Page 31 GENERAL INFORMATION Early production of the TE/FE model only: SPEED SENSOR CONNECTOR ALTERNATOR CONNECTOR THERMOSENSOR CONNECTOR TAILLIGHT WIRE CARBURETOR HEATER CONNECTOR GROUND BREATHER HOSES REVERSE SELECTOR ESP ECU CABLE MAIN WIRE HARNESS WIRE BAND: Gear position switch wire REGULATOR/RECTIFIER Speed sensor wire ALTERNATOR WIRE GEAR POSITION SWITCH 8P CONNECTOR...
  • Page 32 GENERAL INFORMATION Except early TE/FE model production: SPEED SENSOR CONNECTOR U.S.A. TM/FM models optional) ALTERNATOR CONNECTOR THERMOSENSOR CONNECTOR TAILLIGHT WIRE CARBURETOR HEATER CONNECTOR GROUND BREATHER HOSES REVERSE SELECTOR ESP ECU CABLE (All TE/FE models) MAIN WIRE HARNESS REGULATOR/RECTIFIER ALTERNATOR WIRE GEAR POSITION SWITCH 8P CONNECTOR (All TE/FE models) REAR (PARKING)
  • Page 33 GENERAL INFORMATION GROUND TERMINAL OIL THERMOSENSOR WIRE SPEED SENSOR ALTERNATOR WIRE GEAR POSITION SWITCH CLIP: Alternator wire Speed sensor wire Oil thermosensor wire Gear position switch wire Reverse selector cable REVERSE SHIFT SWITCH REVERSE SELECTOR CABLE (All TE/FE models) All TE/FE models: SPEED SENSOR WIRE (Optional) OIL THERMOSENSOR WIRE...
  • Page 34 GENERAL INFORMATION FUSE BOX (including diode) STARTER MOTOR CABLE STARTER RELAY SWITCH MAIN WIRE HARNESS BATTERY ( ) CABLE BATTERY BATTERY ( ) CABLE Reverse side of the tool box cover: TAILLIGHT WIRE WIRE GUIDE WIRE GUIDES 1-32...

  • Page 35: 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 hydrocarbons.
  • Page 36 GENERAL INFORMATION EMISSION CONTROL INFORMATION EMISSION CONTROL INFORMATION LABEL LABEL (U.S.A. only) The Vehicle Emission Control Information Label is attached on the right side frame down tube. 1-34...

  • Page 37: Service Information

    2. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION FRONT CARRIER/CARRY PIPE TROUBLESHOOTING FRONT FENDER BODY PANEL LOCATIONS REAR CARRIER SEAT REAR FENDER SIDE COVER TOOL BOX FUEL TANK COVER INNER FENDER REAR MUD GUARD (TM/FM models) OUTER FENDER CENTER MUD GUARD (TE/FE models) HEADLIGHT GRILL 2-10 FRONT MUD GUARD...
  • Page 38 FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS TRX350 TM/FM: (U.S.A. type shown) (10) (12) (13) (12) (11) TRX350 TE/FE: (10) (12) (13) (12) (11) Seat (page 2-4) Front Fender (page 2-7) Side Cover (page 2-4) Rear Carrier (page 2-8) Fuel Tank Cover (page 2-5) Rear Fender (page 2-8) Rear Mud Guard (TM/FM: page 2-5) (10)
  • Page 39 FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL REMOVAL CHART This chart shows removal order of body panels by means of arrow. TRX350 TM/FM: (4) Rear Mud Guard (2) Side Cover (1) Seat (8) Rear Carrier (5) Front Mud Guard (7) Front Fender (3) Fuel Tank Cover (9) Rear Fender (11) Inner Fender...
  • Page 40 FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL Unlock the seat by turning the release lever upward. Pull the seat back and remove it. INSTALLATION Install the seat by inserting the hook between the screw and fuel tank and the prong into the seat retainer of the frame.

  • Page 41: Fuel Tank Cover

    FRAME/BODY PANELS/EXHAUST SYSTEM FUEL TANK COVER Remove the seat (page 2-4). Remove the following: four trim clips fuel tank breather hose and fuel fill cap fuel tank cover (release six tabs by sliding cover rearward) Install the fuel fill cap. Installation is in the reverse order of removal.

  • Page 42: Center Mud Guard (Te/Fe Models)

    FRAME/BODY PANELS/EXHAUST SYSTEM CENTER MUD GUARD (TE/FE models) RIGHT SIDE: Remove the following: recoil starter cover (release boss and tabs) two bolts and footpeg five trim clips socket bolt center mud guard LEFT SIDE: Remove the following: two bolts and footpeg seven trim clips center mud guard Installation is in the reverse order of removal.

  • Page 43: Front Fender

    FRAME/BODY PANELS/EXHAUST SYSTEM FRONT CARRIER/CARRY PIPE Early T E/ F E Remove the two plastic bands to remove the sub- model production ignition control module (ICM) from the carry pipe. only: Remove the following: two 6 mm bolts and two collars Be caref ul not to four 8 mm bolts and front carrier scratch the f ront...

  • Page 44: Rear Fender

    FRAME/BODY PANELS/EXHAUST SYSTEM REAR CARRIER Remove the following: two 6 mm bolts and two collars six 8 mm bolts and rear carrier Installation is in the reverse order of removal. REAR FENDER Remove the rear carrier. TRIM CLIPS Remove the battery (page 17-4). TM/FM models: Release the main wire harness from the clamp.

  • Page 45: Inner Fender

    FRAME/BODY PANELS/EXHAUST SYSTEM TOOL BOX Remove the rear fender (page 2-8). Disconnect the taillight connectors and release the wire from the wire clip on the frame pipe. Remove the two screws and the tool box. Installation is in the reverse order of removal. SCREWS INNER FENDER Remove the following:...
  • Page 46 FRAME/BODY PANELS/EXHAUST SYSTEM HEADLIGHT GRILL Remove the headlights (page 20-3). Remove the following: headlight wire (from two wire guides of grill) two screws and wire clamp four trim clips headlight grill Installation is in the reverse order of removal. Route the headlight wire properly (page 1-22). EXHAUST SYSTEM REMOVAL MUFFLER...
  • Page 47 FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY INSTALLATION Install new joint and muffler gaskets. Install the exhaust pipe and muffler in the reverse order of removal by loosely tightening all fasteners. Tighten the joint nuts first, then tighten the mounting nuts and the band bolts. TORQUE: Muffler band bolt: 23 N·m (2.3 kgf·m , 17 lbf·ft)
  • Page 48 MEMO...

  • Page 49: Brake Fluid

    2.0 (2.1 US qt , 1.8 Imp qt) After disassembly 2.5 (2.6 US qt , 2.2 Imp qt) Recommended engine oil Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil or equivalent motor oil API service classification: SG or higher JASO T 903 standard: MA...
  • Page 50 MAINTENANCE ITEM SPECIFICATIONS Recommended brake fluid Honda DOT 4 brake fluid Front brake shoe lining thickness Standard: 4.0 mm (0.16 in) /Service limit: 1.0 mm (0.04 in) Front brake lever free play 25 30 mm (1 1-3/16 in) Rear (parking) brake lever free play...

  • Page 51: Maintenance Schedule

    BEARING STEERING SYSTEM 3-19 Should be serviced by your Honda dealer, unless the owner has proper tools and service data and is mechanically qualified. In the interest of safety, we recommend these items be serviced only by your Honda dealer.

  • Page 52: Table Of Contents

    BEARING STEERING SYSTEM 3-19 Should be serviced by your Honda dealer, unless the owner has proper tools and service data and is mechanically qualified. In the interest of safety, we recommend these items be serviced only by your Honda dealer.

  • Page 53: Throttle Operation

    MAINTENANCE FUEL HOSE Remove the seat (page 2-4). Check the fuel hose for deterioration, damage or leakage. Replace the fuel hose if necessary. THROTTLE OPERATION Check for any deterioration or damage to the throttle cable. Check the throttle lever for smooth operation.
  • Page 54 MAINTENANCE CARBURETOR CHOKE This model’s choke system uses a fuel enriching circuit controlled by a starting enrichment (SE) valve. The SE valve opens the enriching circuit via a cable when the choke knob on the handlebar is pulled up. Check for smooth choke knob operation and lubricate the choke if required.

  • Page 55: Air Cleaner Housing Drain Tube

    Squeeze out the solvent thoroughly, and allow the element to dry. Apply approximately 20 g (0.7 oz) of Pro Honda Foam Filter Oil or equivalent oil from the inside of the element. Place the element into a plastic bag and spread the oil evenly by hand.

  • Page 56: Spark Plug

    MAINTENANCE SPARK PLUG Disconnect the spark plug cap and clean around the spark plug base. Clean around the spark plug base with compressed air before removing the plug, and be sure that no debris is allowed to enter the combustion chamber. Remove the spark plug.
  • Page 57 MAINTENANCE Rotate the crankshaft using the recoil starter knob to align the ‘‘T’’ mark on the flywheel with the index mark on the rear crankcase cover. Make sure the piston is at TDC (Top Dead Center) on the compression stroke. This position can be obtained by confirming that there is slack in the rocker arm.
  • Page 58 RECOMMENDED ENGINE OIL: Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil or equivalent motor oil API service classification: SG or higher JASO T 903 standard: MA...

  • Page 59: Engine Oil Change & Filter

    MAINTENANCE OIL CHANGE Pour the engine oil after replacing the oil filter (See below). Change the oil with the engine warm to assure complete and rapid draining. Start the engine and let it idle for a few minutes. Stop the engine and remove the oil filler cap. Remove the drain bolt and drain the engine oil.

  • Page 60: Engine Idle Speed

    MAINTENANCE ENGINE IDLE SPEED Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specifications. The engine must be warm for accurate adjustment. Ten minutes of stop-and-go riding is sufficient. Warm up the engine, shift the transmission into neutral and place the vehicle on a level surface.
  • Page 61 MAINTENANCE OIL CHANGE Place the vehicle on a level surface. Remove the oil filler cap and drain bolt to drain the oil. When the oil is completely drained, install the drain bolt with a new sealing washer. TORQUE: 12 N·m (1.2 kgf·m , 9 lbf·ft) Fill the final gear case with the recommended oil (page 3-12).

  • Page 62: Front Brake

    MAINTENANCE BRAKE FLUID FRONT BRAKE Do not mix different types of fluid, as they are not compatible with each other. Do not allow foreign material to enter the system when filling the reservoir. Avoid spilling fluid on painted, plastic or rubber parts.
  • Page 63 MAINTENANCE BRAKE SYSTEM FRONT BRAKE Measure the free play (distance the brake lever moves before the brake starts to take hold) at the end of the front brake lever. FREE PLAY: 25 30 mm (1 1-3/16 in) If the free play is excessive and the brake shoe lining is not worn beyond the recommended limit, adjust the brake shoe lining-to-drum clearance.

  • Page 64: Reverse Lock System

    MAINTENANCE Make sure the Adjust the brake lever free play by turning the cutout in the upper adjusting nut at the brake arm. adjusting nut is seated on the brake arm joint. Measure the rear brake pedal free play at the end of the pedal.

  • Page 65: Skid Plates

    MAINTENANCE SKID PLATES Check the skid plates for cracks, damage or looseness. Tighten any loose fasteners. Replace the skid plate as required. CLUTCH SYSTEM Loosen the lock nut and turn the adjusting screw one full turn clockwise. Slowly turn the adjusting screw counterclockwise until resistance is felt, then turn the adjusting screw 1/4 turn clockwise.

  • Page 66: Spark Arrester

    MAINTENANCE SPARK ARRESTER Remove the bolt. Block the end of the muffler with a shop towel. Start the engine with the transmission in neutral, and purge accumulated carbon from the muffler by momentarily revving the engine several times. Stop the engine and allow the exhaust system to cool.

  • Page 67: Steering System

    MAINTENANCE STEERING SHAFT HOLDER BEARING Make sure the Raise the front wheels off the ground and support cables do not the vehicle securely. interf ere with the Check that the handlebar moves freely from side to rotation of the side. handlebar If the handlebar moves unevenly, binds, or has horizontal movement, inspect the steering shaft...
  • Page 68 LUBRICATION SYSTEM...

  • Page 69: Lubrication System

    2.0 (2.1 US qt , 1.8 Imp qt) After disassembly 2.5 (2.6 US qt , 2.2 Imp qt) Recommended engine oil Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil or equivalent motor oil API service classification: SG or higher JASO T 903 standard: MA...

  • Page 70: Oil Cooler

    LUBRICATION SYSTEM OIL COOLER INSPECTION Check the oil cooler air passage for clogging or damage. Straighten bent fins with a small, flat blade screwdriver and remove insects, mud or other obstructions with compressed air. Check for any oil leakage from the oil cooler and hose joints.
  • Page 71 LUBRICATION SYSTEM DISASSEMBLY Remove the following: three screws and fan cover nut and cooling fan collar three screws and fan motor ASSEMBLY Set the fan motor into the shroud by aligning the tube joint with the groove and install it with the three screws as shown.

  • Page 72: Oil Pump

    LUBRICATION SYSTEM OIL PUMP REMOVAL Remove the front crankcase cover (page 9-3). Remove the following: two bolts and retainer feed oil pipe (long) O-rings bolt scavenge oil pipe (short) O-rings three bolts oil pump RELIEF VALVE CHECK Remove the following: cotter pin stopper plate spring...
  • Page 73 LUBRICATION SYSTEM Check the spring and valve for wear or damage. Install the valve, spring and stopper plate into the oil pump, then insert a new cotter pin from the pump body side (outside) and secure it. DISASSEMBLY Remove the bolt and separate the pump base from the pump spacer.
  • Page 74 LUBRICATION SYSTEM INSPECTION Measure at several places and use the largest reading to compare the service limit. If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly. Install the inner and outer rotors into the pump base and pump body.
  • Page 75 LUBRICATION SYSTEM ASSEMBLY PUMP BASE (Scavenge side) DOWEL PINS STOPPER PLATE PUMP SHAFT SPRING RELIEF VALVE DRIVE PIN COTTER PIN SCAVENGE OUTER ROTOR DRIVE PIN SCAVENGE INNER ROTOR THRUST WASHER PUMP SPACER FEED OUTER ROTOR FEED INNER ROTOR PUMP BODY (Feed side) Install the following into the pump body: outer rotor inner rotor...
  • Page 76 LUBRICATION SYSTEM Be sure that there are no gap between the mating surfaces and tighten the bolt. INSTALLATION Set the pump assembly onto the crankcase by aligning the pump shaft end with the balancer groove and tighten the three bolts securely. Coat new O-rings with engine oil and install them onto the scavenge oil pipe.
  • Page 77 MEMO...
  • Page 78 FUEL SYSTEM 4 N·m (0.4 kgf·m , 2.9 lbf·ft)

  • Page 79: Air Cleaner Housing

    5. FUEL SYSTEM SERVICE INFORMATION CARBURETOR ASSEMBLY TROUBLESHOOTING CARBURETOR INSTALLATION 5-14 AIR CLEANER HOUSING PILOT SCREW ADJUSTMENT 5-15 CARBURETOR REMOVAL HIGH ALTITUDE ADJUSTMENT 5-16 CARBURETOR DISASSEMBLY/ FUEL TANK 5-17 INSPECTION SERVICE INFORMATION GENERAL Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion.
  • Page 80 FUEL SYSTEM TROUBLESHOOTING Engine cranks but won’t start Engine stalls, hard to start, rough idling No fuel in tank Restricted fuel line No fuel to carburetor Fuel mixture too lean/rich Clogged fuel strainer Contaminated/deteriorated fuel Clogged fuel line Clogged jets Clogged fuel tank breather tube Intake air leak Misadjusted fuel level...
  • Page 81 FUEL SYSTEM AIR CLEANER HOUSING INTAKE DUCT REMOVAL/INSTALLATION Remove the following: fuel tank cover (page 2-5) left side cover (page 2-4) Remove the air vent and breather tubes from the air intake duct. BREATHER TUBES Disconnect the crankcase breather hose. Loosen the connecting tube band and intake duct band screws.
  • Page 82 FUEL SYSTEM CARBURETOR REMOVAL Remove the following: side covers (page 2-4) air cleaner housing (page 5-3) Place and approved fuel container under the drain tube. Loosen the drain screw and drain the carburetor. Release the carburetor heater wire from the clip and disconnect its connector.
  • Page 83 FUEL SYSTEM CARBURETOR DISASSEMBLY/ INSPECTION Check the SE valve face for scores, scratches or wear. Check the SE valve seat at the tip of the valve for stepped wear. Check the seal ring for wear or damage. Remove the following from the carburetor body: air vent tubes drain tubes carburetor heater...
  • Page 84 FUEL SYSTEM Apply vacuum to the vacuum tube. The vacuum should be maintained. Air should not flow through the valve ports when the vacuum is applied, and should flow when the vacuum is not applied. VACUUM CHAMBER Remove the four screws with the tube clamp and the vacuum chamber cover while holding it.
  • Page 85 FUEL SYSTEM Check the jet needle for stepped wear. Check the vacuum piston for wear or damage. Check the diaphragm for pin hole, deterioration or damage. Check the vacuum piston for smooth operation up and down in the carburetor body. Air will leak out of the vacuum chamber if the diaphragm is damaged in any way, even with just a pin hole.
  • Page 86 FUEL SYSTEM T ap the f loat pin Remove the following: gently with baffle plate suitable pin float pin ( O.D. 2 mm) float float valve Check the float for damage or fuel in the float. Check the float valve and valve seat for scoring, scratches, clogging or damage.

  • Page 87: Carburetor Cleaning

    FUEL SYSTEM CARBURETOR CLEANING Remove the following: air cut-off valve diaphragm/vacuum piston. main jet, needle jet holder and needle jet slow jet starter jet pilot screw Cleaning the air Blow open all air and fuel passages in the and f uel passages carburetor body with compressed air.
  • Page 88 FUEL SYSTEM FLOAT AND JETS Damage to the Install the pilot screw with the spring, washer and a pilot screw seat new O-ring and return it to its original position as will occur if the noted during removal. pilot screw is Perform the pilot screw adjustment if a new pilot tightened against screw is installed.
  • Page 89 FUEL SYSTEM Install a new O-ring into the float chamber groove securely. Install the float chamber and tighten the four screws. PRIMER KNOB Install the primer knob with the spring and tighten the two screws, being careful not to pinch the diaphragm.
  • Page 90 FUEL SYSTEM Be caref ul not to Install the diaphragm/vacuum piston into the damage the jet carburetor body by aligning the tab of the needle. diaphragm with the air passage, then insert the jet needle into the needle jet. Lift the bottom of the piston with your finger to set the diaphragm rib into the groove in the carburetor body.
  • Page 91 FUEL SYSTEM Install the air cut-off valve and secure it with the screw. Turn the throttle stop screw to align the butterfly throttle valve with the edge of the outside by-pass hole in the carburetor body, If the throttle stop screw was removed.
  • Page 92 FUEL SYSTEM CARBURETOR INSTALLATION Connect the throttle cable to the throttle drum and install the cable adjuster into the carburetor body. Connect the choke cable by screwing the SE valve nut, being careful not to damage the SE valve. Install the carburetor into the insulator by aligning the lug with the groove, and tighten the band screw.

  • Page 93: Pilot Screw Adjustment

    FUEL SYSTEM PILOT SCREW ADJUSTMENT IDLE DROP PROCEDURE 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 will accurately indicate a 50 rpm change.

  • Page 94: High Altitude Adjustment

    FUEL SYSTEM HIGH ALTITUDE ADJUSTMENT Below Between 5,000 ft (1,500 m) 3,000 8,000 ft (1,000 2,500 m) Main jet Pilot screw 3/4 turns in Factory preset opening from factory preset The carburetor must be adjusted for high altitude riding (between 3,000 8,000 ft/1,000 2,500 m). STANDARD SETTING: Below 5,000 ft (1,500 m) HIGH ALTITUDE SETTING:...
  • Page 95 FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Remove the following: fuel tank cover (page 2-5) side covers (page 2-4) FUEL TANK Remove the air vent and breather tubes from the air intake duct. Loosen the intake duct band screw. Remove the trim clip and the intake duct from the air cleaner housing.
  • Page 96 FUEL SYSTEM Remove the O-ring. Clean the strainer screen with non-flammable or high flash point solvent. Install a new O-ring onto the fuel valve. Install the fuel valve into the fuel tank and tighten the bolts with the collars. Install the fuel tank. 5-18...
  • Page 97 MEMO...
  • Page 98 ENGINE REMOVAL/INSTALLATION 54 N·m (5.5 kgf·m , 40 lbf·ft) 54 N·m (5.5 kgf·m , 40 lbf·ft) 32 N·m (3.3 kgf·m , 24 lbf·ft)
  • Page 99 6. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION ENGINE INSTALLATION ENGINE REMOVAL SERVICE INFORMATION GENERAL When removing and installing the engine, tape the frame around the engine beforehand for frame protection. The following components require engine removal for service: alternator and starter clutch (section 10) transmission (including shift fork and shift drum) (section 11) crankshaft and balancer (section 11) Other components without above can be serviced with the engine installed in the frame.
  • Page 100 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil (page 3-11). Remove the following: front fender (page 2-7) fuel tank and heat guard (page 5-17) exhaust system (page 2-10) carburetor assembly (page 5-4) brake pedal (page 14-19) T M/ F M model Remove the pinch bolt and the gearshift pedal.
  • Page 101 ENGINE REMOVAL/INSTALLATION Remove the wire band (early TE/FE model production only) and release the two wire clips. Early production of the TE/FE models: BAND CLIPS CLIPS Remove the bolt and stay and disconnect the re- verse selector cable from the selector arm. T E/ F E model Remove the three wire bands from the frame down only:...
  • Page 102 ENGINE REMOVAL/INSTALLATION Remove the propeller shaft from the engine (FM/FE only; page 15-8). Loosen the band screw and remove the boot band. Remove the joint boot from the engine. Remove the following: upper hanger bolts and nut hanger bracket and mounting rubbers left and right lower hanger nuts Support the bottom of the engine securely.

  • Page 103: Engine Installation

    ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION Install the engine into the frame in the reverse order of removal. Apply molybdenum disulfide grease to the out- put shaft spline. Note the installation direction of the hanger bolts, mounting rubbers (large I.D. side facing in) and dust seals (lips side facing out) and position of the spacers and mounting rubbers.

  • Page 104: Cylinder Head/Valve

    CYLINDER HEAD/VALVE 30 N·m (3.1 kgf·m , 22 lbf·ft) 39 N·m (4.0 kgf·m , 29 lbf·ft) 32 N·m (3.3 kgf·m , 24 lbf·ft) 18 N·m (1.8 kgf·m , 13 lbf·ft) 54 N·m (5.5 kgf·m , 40 lbf·ft) 12 N·m (1.2 kgf·m , 9 lbf·ft)
  • Page 105 7. CYLINDER HEAD/VALVE SERVICE INFORMATION VALVE SEAT INSPECTION/REFACING TROUBLESHOOTING CYLINDER HEAD ASSEMBLY 7-11 CYLINDER COMPRESSION CYLINDER HEAD INSTALLATION 7-13 CYLINDER HEAD REMOVAL CAMSHAFT REMOVAL 7-15 CYLINDER HEAD DISASSEMBLY CAMSHAFT INSTALLATION 7-17 VALVE GUIDE REPLACEMENT SERVICE INFORMATION GENERAL This section covers service of the cylinder head, rocker arms, valves and camshaft. To service the camshaft, the engine must be removed from the frame.

  • Page 106: Cylinder/Piston

    CYLINDER HEAD/VALVE TORQUE VALUES Rocker arm shaft retaining bolt 7 N·m (0.7 kgf·m , 5.1 lbf·ft) Cylinder head cap nut 39 N·m (4.0 kgf·m , 29 lbf·ft) Apply oil to the threads and seating surface Rocker arm holder bolt 30 N·m (3.1 kgf·m , 22 lbf·ft) Apply oil to the threads and seating surface Cam chain tensioner slider pivot bolt 12 N·m (1.2 kgf·m , 9 lbf·ft)

  • Page 107: Cylinder Head Removal

    CYLINDER HEAD/VALVE 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 into the spark plug hole. Shift the transmission in neutral and close the choke knob (OFF).
  • Page 108 CYLINDER HEAD/VALVE CYLINDER HEAD AND ROCKER ARM HOLDER Remove the following: exhaust system (page 2-10) carburetor assembly (page 5-4) timing hole cap Rotate the crankshaft clockwise using the recoil starter knob to align the T mark on the flywheel with the index mark on the rear crankcase cover. Make sure the piston is TDC (Top Dead Center) on the compression stroke.

  • Page 109: Cylinder Head

    CYLINDER HEAD/VALVE two dowel pins gasket CYLINDER HEAD DISASSEMBLY CYLINDER HEAD Remove the spark plug. T o prevent loss of Remove the valve spring cotters using the valve tension, do not spring compressor. compress the valve springs TOOL: more than Valve spring compressor 07757-0010000 necessary to...
  • Page 110 CYLINDER HEAD/VALVE INSPECTION ROCKER ARM/SHAFT Check the rocker arms and shafts for wear or damage. If the rocker arm follower is worn or damaged, check the push rod and oil passages. Measure each rocker arm shaft O.D. SERVICE LIMIT: 11.92 mm (0.469 in) Measure each rocker arm I.D.
  • Page 111 CYLINDER HEAD/VALVE VALVE SPRING Measure the valve spring free length. SERVICE LIMITS: Inner: 36.94 mm (1.454 in) Outer: 40.42 mm (1.591 in) VALVE/VALVE GUIDE Check that the valve moves smoothly in the guide. Check the valve for bending, burning or abnormal wear.

  • Page 112: Valve Guide Replacement

    CYLINDER HEAD/VALVE VALVE GUIDE REPLACEMENT Chill new valve guides in the freezer section of a refrigerator for about an hour. Be sure to wear Heat the cylinder head to 130 140°C (275 290°F) heavy gloves to with a hot plate or oven. Do not heat the cylinder avoid burns when head beyond 150°C (300°F).
  • Page 113 CYLINDER HEAD/VALVE T he valve cannot Remove the valve and inspect the valve seat face. be ground. If the The valve seat contact should be within the speci- valve f ace is fied width and even all around the circumference. burned or badly worn or if it STANDARD:...
  • Page 114 CYLINDER HEAD/VALVE If the contact area is too high on the valve, the seat CONTACT TOO HIGH OLD SEAT must be lowered using a 32° flat cutter. WIDTH If the contact area is too low on the valve, the seat must be raised using a 60°...

  • Page 115: Cylinder Head Assembly

    CYLINDER HEAD/VALVE Using a 45° seat cutter, cut the seat to the proper width. SEAT WIDTH VALVE SEAT WIDTH: 1.2 mm (0.05 in) Make sure that all pitting and irregularities are removed. 45° Excessive lapping After cutting the seat, apply lapping compound to pressure may the valve face, and lap the valve using light pres- def orm or damage...
  • Page 116 CYLINDER HEAD/VALVE CYLINDER HEAD Blow through the oil passage (stud bolt hole) 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. Insert the valve into the guide while turning it slowly to avoid damage to the stem seal.
  • Page 117 CYLINDER HEAD/VALVE ROCKER ARM HOLDER Apply molybdenum oil solution to the rocker arm and shaft sliding surfaces. Set the rocker arms into the rocker arm holder and install the rocker arm shaft through the holder and arms. Turn the rocker arm shaft and align the bolt holes in the shaft and holder, and install the retaining bolt.
  • Page 118 CYLINDER HEAD/VALVE Apply engine oil to rocker arm followers and adjusting screw tips. Install the rocker arm holder onto the cylinder head. Install the following and tighten them in a crisscross pattern in 2 or 3 steps: four cap nuts with new sealing washers (apply engine oil) rocker arm holder bolt (apply engine oil) two cylinder head bolts...

  • Page 119: Head Cover

    CYLINDER HEAD/VALVE HEAD COVER Clean the mating surfaces of the head cover and cylinder head. Blow through the oil passage in the head cover with compressed air. Install the following: new gasket new O-ring (coat with engine oil) Install the cylinder head cover and tighten the four bolts.
  • Page 120 CYLINDER HEAD/VALVE Remove the following: tensioner pivot bolt tensioner slider washer retainer bolt bearing retainer camshaft cam chain INSPECTION CAMSHAFT Check the cam surfaces for scoring, scratches or evidence of insufficient lubrication. Check the sprocket teeth for wear or damage. Turn the outer race of each bearing with your finger.

  • Page 121: Camshaft Installation

    CYLINDER HEAD/VALVE CAM CHAIN TENSIONER Check the slipper surface of the tensioner slider for wear or damage. Check the tensioner lifter operation: the tensioner shaft should not go into the body when it is pushed. When stopper block is pressed in, the tensioner shaft should be pushed into the body.
  • Page 122 CYLINDER HEAD/VALVE Turn the crankshaft so that the key groove is facing up and parallel with the cylinder stud bolt (This position is TDC). Do not turn the Install the cam chain over the cam sprocket and crankshaf t while insert the camshaft into the crankcase.
  • Page 123 MEMO...
  • Page 124 CYLINDER/PISTON 12 N·m (1.2 kgf·m , 9 lbf·ft)
  • Page 125 8. CYLINDER/PISTON SERVICE INFORMATION CYLINDER/PISTON REMOVAL TROUBLESHOOTING CYLINDER/PISTON INSTALLATION 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. Be careful not to damage the mating surfaces when removing the cylinder. Do not strike the cylinder too hard during removal.

  • Page 126: Cylinder Removal

    CYLINDER/PISTON CYLINDER/PISTON REMOVAL CYLINDER REMOVAL Remove the cylinder head (section 7). Do not strike the Remove the following: cylinder too hard cylinder and do not damage the mating surf ace with a screwdriver. gasket dowel pins PISTON REMOVAL Place a clean shop towel over the crankcase to prevent the clip from falling into the crankcase.

  • Page 127: Inspection

    CYLINDER/PISTON Clean carbon deposits from the ring grooves with a ring that will be discarded. Never use a wire brush; it will scratch the groove. INSPECTION CYLINDER Inspect the cylinder bore for scratch or wear. Measure the cylinder I.D. at three levels in an X and Y axis.
  • Page 128 CYLINDER/PISTON PISTON/PISTON RING Inspect the piston rings for movement by rotating the rings. The rings should be able to move in their grooves without catching. Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the ring-to-ring groove clearance.

  • Page 129: Piston Ring Installation

    CYLINDER/PISTON Measure the connecting rod small end I.D. SERVICE LIMIT: 17.10 mm (0.673 in) Calculate the connecting rod-to-piston pin clearance. SERVICE LIMIT: 0.06 mm (0.002 in) CYLINDER STUD BOLT REPLACEMENT Remove the stud bolts from the cylinder. Install new stud bolts in their proper positions and tighten them.

  • Page 130: Cylinder Installation

    CYLINDER/PISTON PISTON INSTALLATION ‘ ‘ ‘ ‘ ’ ’ ’ ’ Place a clean shop towel over the crankcase to prevent the clip from falling into the crankcase. Apply molybdenum oil solution to the piston pin outer surface. Apply engine oil to the piston pin hole and connecting rod inner surface.
  • Page 131 CYLINDER/PISTON Apply engine oil to the cylinder wall, piston and piston ring outer surfaces. Be caref ul not to Install the cylinder over the piston while damage the piston compressing the piston rings with your fingers. rings and cylinder wall. Make sure that the cylinder touches the crankcase evenly.

  • Page 132: Clutch/Gearshift Linkage

    CLUTCH/GEARSHIFT LINKAGE 22 N·m (2.2 kgf·m , 16 lbf·ft) 12 N·m (1.2 kgf·m , 9 lbf·ft) 118 N·m (12.0 kgf·m , 87 lbf·ft) TE/FE model : 23 N·m (2.3 kgf·m , 17 lbf·ft) 108 N·m (11.0 kgf·m , 80 lbf·ft)
  • Page 133 9. CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION GEARSHIFT LINKAGE 9-15 TROUBLESHOOTING GEARSHIFT SPINDLE AND REVERSE STOPPER ARM 9-17 FRONT CRANKCASE COVER REMOVAL FRONT CRANKCASE COVER CENTRIFUGAL CLUTCH INSTALLATION 9-18 CHANGE CLUTCH SERVICE INFORMATION GENERAL This section covers service of the clutch (centrifugal clutch and change clutch) and gearshift linkage. To service the reverse stopper shaft and gearshift spindle, the engine must be removed from the frame.
  • Page 134 CLUTCH/GEARSHIFT LINKAGE TOOLS Clutch holder 07GMB-HA7010B Clutch puller 07933-HB3000A Driver, 22 mm I.D. 07746-0020100 Attachment, 20 mm I.D. 07746-0020400 Clutch center holder 07JMB-MN50301 or Holder plate 07HGB-001010B (U.S.A. only) or 07HGB-001010A (U.S.A. only) with Holder collar A 07HGB-001020B (U.S.A. only) or 07HGB-001020A (U.S.A.
  • Page 135 CLUTCH/GEARSHIFT LINKAGE FRONT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-11). F M/ F E model Remove the following: only: shift control motor reduction gears (page 21-23) propeller shaft from the engine (page 15-8) Remove the following: four screws and left engine side cover two joint bolts and oil cooler hoses O-rings oil level dipstick...

  • Page 136: Centrifugal Clutch

    CLUTCH/GEARSHIFT LINKAGE CENTRIFUGAL CLUTCH REMOVAL Remove the front crankcase cover (page 9-3). Be caref ul not to Unstake the clutch lock nut. damage the crankshaf t threads. Set the special tool into the grooves in the drive plate and hold it, and loosen the lock nut. TOOLS: Clutch holder 07GMB-HA7010B...
  • Page 137 CLUTCH/GEARSHIFT LINKAGE INSPECTION ONE-WAY CLUTCH Check the one-way clutch sprag for abnormal wear, damage or irregular movement. Check the drive plate boss and clutch drum inner contact surfaces for abnormal wear or damage. CLUTCH DRUM AND LINING Check the weight contact surface for scratches or abnormal wear.
  • Page 138 CLUTCH/GEARSHIFT LINKAGE CLUTCH SPRING Be caref ul not to Remove the E-clips using a screwdriver while damage the clutch compressing the outer plate. weights while compressing. Remove the following: outer plate clutch spring inner plate Measure the height of the clutch spring. SERVICE LIMIT: 2.73 mm (0.107 in) WEIGHT SPRING...
  • Page 139 CLUTCH/GEARSHIFT LINKAGE ASSEMBLY Install with the Install the clutch weights and springs onto the drive spring’s open ends plate as shown. f acing in. Install the following: inner plate with flange side facing up clutch spring with concavity side facing down outer plate with locating pins facing up...
  • Page 140 CLUTCH/GEARSHIFT LINKAGE Be caref ul not to Install the E-clips into the spindle grooves with its damage the clutch gap facing towards the locating pin by using the weights while pliers while compressing the outer plate. compressing. Apply engine oil to the sprag clutch whole surface and the sprag clutch contacting surface of the ‘...
  • Page 141 CLUTCH/GEARSHIFT LINKAGE Be caref ul not to Stake the lock nut into the crankshaft groove. damage the crankshaf t threads. Install the front crankcase cover (page 9-18). CHANGE CLUTCH REMOVAL Remove the centrifugal clutch assembly (page 9-4). Remove the following: washer and lifter lever lifter bearing and bearing holder Loosen in a...
  • Page 142 CLUTCH/GEARSHIFT LINKAGE Remove the following as an assembly: clutch center spring seat judder spring clutch discs clutch plates pressure plate Remove the following from the mainshaft: thrust washer clutch outer outer guide Remove the following: two bolts and retainer feed oil pipe O-rings primary drive gear washer...
  • Page 143 CLUTCH/GEARSHIFT LINKAGE LIFTER CAM Check the lifter lever for wear or damage. Check the cam plate, ball retainer and adjusting plate for abnormal wear or damage. CLUTCH SPRING Replace the clutch Measure the clutch spring free length. springs as a set SERVICE LIMIT: TM/FM: 27.0 mm (1.06 in)
  • Page 144 CLUTCH/GEARSHIFT LINKAGE CLUTCH PLATE Replace the clutch Check the plates for discoloration. discs and plates Check the spring seat and judder spring for as a set. distortion, wear or damage. Check the plate warpage on a surface plate using a feeler gauge.
  • Page 145 CLUTCH/GEARSHIFT LINKAGE MAINSHAFT AND CRANKSHAFT Measure the mainshaft O.D. at the clutch outer guide. SERVICE LIMIT: 21.93 mm (0.863 in) Measure the crankshaft O.D. at the primary drive gear. SERVICE LIMIT: 26.93 mm (1.060 in) ASSEMBLY Apply engine oil to the primary drive gear inner surface.
  • Page 146 CLUTCH/GEARSHIFT LINKAGE Coat the clutch discs with clean engine oil. Assemble the following and install them onto the mainshaft: pressure plate Install the discs six discs (large I.D. disc A is installed onto and plate outside end only on TE/FE models) alternately, five plates starting with the...
  • Page 147 CLUTCH/GEARSHIFT LINKAGE Install the clutch springs and lifter plate with the ‘‘OUT’’ mark facing out and tighten the clutch bolts ‘ ‘ ‘ ‘ ’ ’ ’ ’ in a crisscross pattern in several steps. Install the following: bearing holder and lifter bearing lifter lever by aligning wide groove (indicated by punch mark) with wide tooth of spindle washer...
  • Page 148 CLUTCH/GEARSHIFT LINKAGE GEARSHIFT PLATE Check the gearshift plate for wear or damage. Check the return spring and reset spring for fatigue or damage. INSTALLATION Install the following: dowel pin (into shift drum) washer (between spring and crankcase) return spring bolt/stopper arm (apply locking agent to threads) TORQUE: 12 N·m (1.2 kgf·m , 9 lbf·ft) Lower the stopper...
  • Page 149 CLUTCH/GEARSHIFT LINKAGE GEARSHIFT SPINDLE AND REVERSE STOPPER ARM Remove the rear crankcase cover (page 10-7). REMOVAL GEARSHIFT SPINDLE Remove the following: retaining bolt gearshift spindle spindle arm REVERSE STOPPER ARM Pull the stopper arm shaft out of the crankcase while holding the arm to release it from the shift drum.
  • Page 150 CLUTCH/GEARSHIFT LINKAGE INSTALLATION REVERSE STOPPER ARM Apply engine oil to the shaft journal. Set the spring end onto the arm groove. Install the shaft of the stopper arm into the hole in the crankcase securely while pressing the spring against the crankcase bottom and set the arm to the shift drum.
  • Page 151 CLUTCH/GEARSHIFT LINKAGE Install the joint pipes into the oil pump. Coat new O-rings with engine oil and install them onto the joint pipe. Install the spring onto the ball retainer and install them onto the lifter cam. Install the ball retainer/lifter cam into the lifter bearing and onto the lifter lever.
  • Page 152 CLUTCH/GEARSHIFT LINKAGE Install the two dowel pins and the front crankcase cover, being careful not to damage the oil seal lips. Install the twelve bolts with the engine side cover stay and tighten them in a crisscross pattern in several steps. Install the oil level dipstick.
  • Page 153 MEMO...

  • Page 154: Alternator/Starter Clutch

    ALTERNATOR/STARTER CLUTCH 108 N·m (11.0 kgf·m , 80 lbf·ft) 10-0...

  • Page 155: Alternator Stator

    10. ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION 10-1 ALTERNATOR STATOR 10-5 TROUBLESHOOTING 10-1 FLYWHEEL/STARTER CLUTCH 10-7 RECOIL STARTER 10-2 SERVICE INFORMATION GENERAL The recoil starter can be removed with the engine installed in the frame. To service the alternator stator, flywheel and starter clutch, the engine must be removed from the frame (these items can be serviced by removing the swingarm if no additional engine work is needed).
  • Page 156 ALTERNATOR/STARTER CLUTCH RECOIL STARTER REMOVAL Remove the air cleaner housing (page 5-3). Remove the wire clip from the recoil starter housing. Remove the three mounting bolts and the recoil starter assembly. DISASSEMBLY Remove the following: bolt ratchet cover ratchet guide and spring seat spring ratchet and pin Check each part for wear or damage.
  • Page 157 ALTERNATOR/STARTER CLUTCH Remove the starter rope from the drive pulley. Check the starter rope for wear or damage. Check the starter spring for damage or break. W ear eye Remove the spring and replace it if it is broken. protection and use ASSEMBLY care when removing.
  • Page 158 ALTERNATOR/STARTER CLUTCH Route the rope end through the housing hole while the pulley remains held in place. Route the rope end through the starter grip and stopper, then tie it in a square knot. Press the knot in the stopper and install the stopper into the starter grip securely.
  • Page 159 ALTERNATOR/STARTER CLUTCH ALTERNATOR STATOR ALTERNATOR COVER REMOVAL Remove the engine from the frame (section 6). Remove the recoil starter (page 10-3). Hold the recoil starter driven pulley using a screw- driver and loosen the bolt. Remove the bolt, O-ring and the driven pulley. T he cover ( stator) Remove the seven bolts, clamp and the alternator is magnetically...
  • Page 160 ALTERNATOR/STARTER CLUTCH ALTERNATOR COVER INSTALLATION Install the dowel pins and a new gasket. T he cover ( stator) Install the alternator cover. is magnetically Install the seven bolts with the clamp and tighten attached to the them. f lywheel, be Secure the alternator wire with the clamp.
  • Page 161 ALTERNATOR/STARTER CLUTCH FLYWHEEL/STARTER CLUTCH REAR CRANKCASE COVER REMOVAL Remove the following: alternator cover (page 10-5) starter motor (page 19-4) speed sensor bolts speed sensor, sensor base and O-rings nut, washer and reverse selector arm twelve cover bolts, wire guide and side cover stay thermosensor connector Remove the rear crankcase cover.
  • Page 162 ALTERNATOR/STARTER CLUTCH STARTER CLUTCH REMOVAL/ INSPECTION Make sure that the starter driven gear turns clock- wise smoothly and does not turn counterclockwise. Remove the driven gear while turning it clockwise. Hold the flywheel with the special tool and remove the starter clutch bolts. TOOL: Flywheel holder 07725-0040000 or...
  • Page 163 ALTERNATOR/STARTER CLUTCH Check the starter driven gear teeth and needle bearing for wear or damage. Measure the starter driven gear boss O.D. SERVICE LIMIT: 45.65 mm (1.797 in) STARTER CLUTCH INSTALLATION Lubricate the sprag clutch with engine oil and install it into the starter clutch outer with the flange side facing the flywheel side.
  • Page 164 ALTERNATOR/STARTER CLUTCH Lubricate the needle bearing with molybdenum oil solution. Install the washer and needle bearing onto the crankshaft. Clean any oil from the tapered portions of the crankshaft and flywheel. Install the woodruff key into the crankshaft key groove. Install the flywheel on the crankshaft, aligning the key way with the woodruff key.
  • Page 165 ALTERNATOR/STARTER CLUTCH Install the two dowel pins and thrust washer. Shift the transmission into neutral to align the groove in the shift drum with the lug on the crankcase. WASHER Align the long end of the gear position switch pin with the ‘‘N’’...

  • Page 166: Crankcase/Transmission

    CRANKCASE/TRANSMISSION/CRANKSHAFT 11-0...
  • Page 167 11. CRANKCASE/TRANSMISSION/CRANKSHAFT SERVICE INFORMATION 11-1 CRANKSHAFT/BALANCER 11-10 TROUBLESHOOTING 11-2 CRANKCASE BEARING REPLACEMENT 11-12 CRANKCASE SEPARATION 11-3 CRANKCASE ASSEMBLY 11-16 TRANSMISSION 11-4 SERVICE INFORMATION 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 168 CRANKCASE/TRANSMISSION/CRANKSHAFT TOOLS Universal bearing puller 07631-0010000 or equivalent commercially available in U.S.A. Bearing remover set, 15 mm 07936-KC10000 not available in U.S.A. bearing remover, 15 mm 07936-KC10500 remover head 07936-KC10200 remover shaft 07936-KC10100 not available in U.S.A. remover weight 07936-371020A or 07936-3710200 Bearing remover, 17 mm 07936-3710300 Remover handle...
  • Page 169 CRANKCASE/TRANSMISSION/CRANKSHAFT CRANKCASE SEPARATION DRIVE AND DRIVEN GEARS Remove the following: engine (section 6) cylinder head (section 7) cylinder and piston (section 8) clutch and gearshift linkage (section 9) oil pump (section 4) flywheel and starter clutch (section 10) camshaft (section 7) output shaft drive and driven gears Loosen the seven rear crankcase bolts in a crisscross pattern in several steps and remove...
  • Page 170 CRANKCASE/TRANSMISSION/CRANKSHAFT TRANSMISSION DISASSEMBLY Separate the crankcase (page 11-3). Remove the following: washer and sub-gearshift spindle output shaft and washer shift fork shaft shift drum shift forks shaft and reverse idle gear mainshaft and countershaft as an assembly For crankcase bearing replacement, see page 11-12. Disassemble the mainshaft and countershaft.
  • Page 171 CRANKCASE/TRANSMISSION/CRANKSHAFT INSPECTION GEAR/BUSHING/SHAFT Check the gear shifter groove for abnormal wear or damage. Check the gear dogs and teeth for abnormal wear or damage. Measure the gear I.D. SERVICE LIMITS: 23.04 mm (0.907 in) 18.05 mm (0.711 in) C1, C2, C3, CR: 25.05 mm (0.986 in) Reverse idle: 13.04 mm (0.513 in)
  • Page 172 CRANKCASE/TRANSMISSION/CRANKSHAFT OUTPUT SHAFT/JOINT SHAFT/GEAR Check the teeth and splines for abnormal wear or damage. SHIFT DRUM Check the shift drum guide grooves for abnormal wear or damage. Check the shift drum journals for scoring, scratches or evidence of insufficient lubrication. SHIFT FORK Check the shift fork guide pins for abnormal wear or damage.
  • Page 173 CRANKCASE/TRANSMISSION/CRANKSHAFT SUB-GEARSHIFT SPINDLE Check the spindle for damage or bending. Check the spindle arm for wear or damage. ASSEMBLY Clean all parts in solvent and dry them thoroughly. Apply engine oil to the gear teeth, sliding surface, shifter grooves and bushings. Assemble the mainshaft and countershaft.
  • Page 174 CRANKCASE/TRANSMISSION/CRANKSHAFT MAINSHAFT REVERSE IDLE GEAR (13/23T) WASHER IDLE GEAR SHAFT M5 GEAR (25T) M5 BUSHING WASHER M1 GEAR (11T) M3 GEAR (21T) SNAP RING M2 GEAR (15T) SPLINE WASHER M4 GEAR (29T) MAINSHAFT M4 BUSHING WASHER Washer and snap ring direction: Always install the thrust washer and snap ring with the chamfered (rolled) edge facing away from the thrust load.
  • Page 175 CRANKCASE/TRANSMISSION/CRANKSHAFT Check the gears for freedom of movement or rota- tion on the shaft. Apply engine oil to the mainshaft and countershaft journals. Engage the mainshaft and countershaft gears. If removed, install the crankshaft and balancer (page 11-11). Be sure to install Install the mainshaft and countershaft assemblies the thrust washers.
  • Page 176 CRANKCASE/TRANSMISSION/CRANKSHAFT Install the output shaft into the crankcase with the washer. Install the sub-gearshift spindle and the washer. Assemble the crankcase halves (page 11-16). CRANKSHAFT/BALANCER REMOVAL Separate the crankcase (page 11-3). Remove the transmission (page 11-4). Be caref ul not to Remove the crankshaft and balancer from the rear damage the crankcase using a hydraulic press.
  • Page 177 CRANKCASE/TRANSMISSION/CRANKSHAFT Measure the side clearance between the con- necting rod big end and crank weight with a feeler gauge. SERVICE LIMIT: 0.8 mm (0.03 in) Measure the radial clearance at the connecting rod big end. SERVICE LIMIT: 0.05 mm (0.002 in) BALANCER Check the balancer gear for wear or damage.
  • Page 178 CRANKCASE/TRANSMISSION/CRANKSHAFT Engage the balancer and crankshaft by aligning the CRANKSHAFT index lines on the side surfaces of the balancer drive and driven gears and install the crankshaft and balancer together into the rear crankcase. Align BALANCER Be caref ul not to Assemble the special tools onto the crankshaft.
  • Page 179 CRANKCASE/TRANSMISSION/CRANKSHAFT Remove the bolts and shift drum bearing and mainshaft bearing setting plates. Drive the crankshaft, output shaft, shift drum, mainshaft and countershaft bearings out of the front crankcase. Apply engine oil to new bearings. Drive the bearings in with the marking side facing out using the special tools.
  • Page 180 CRANKCASE/TRANSMISSION/CRANKSHAFT REAR CRANKCASE Remove the mainshaft bearing with the special tools. TOOLS: Bearing remover set, 07936-KC10000 15 mm not available in U.S.A. Bearing remover, 07936-KC10500 15 mm remover head 07936-KC10200 remover shaft 07936-KC10100 not available in U.S.A. Remover weight 07936-371020A or 07936-3710200 Drive the countershaft and balancer bearings out of the rear crankcase.
  • Page 181 CRANKCASE/TRANSMISSION/CRANKSHAFT FRONT CRANKCASE COVER Remove the crankshaft end bearing with the special tools. TOOLS: Bearing remover set, 07936-KC10000 15 mm not available in U.S.A. Bearing remover, 07936-KC10500 15 mm remover head 07936-KC10200 remover shaft 07936-KC10100 not available in U.S.A. Remover weight 07936-371020A or 07936-3710200 Remove the output joint shaft (FM/FE) and sub-...
  • Page 182 CRANKCASE/TRANSMISSION/CRANKSHAFT CRANKCASE ASSEMBLY Clean the front and rear crankcase mating surfaces thoroughly, being careful not to damage them. Blow through the oil passages in the crankcases with compressed air. Wash the strainer screen thoroughly in high flash point solvent until all accumulated dirt has been removed.
  • Page 183 CRANKCASE/TRANSMISSION/CRANKSHAFT Install the seven rear crankcase bolts with the stay and tighten them in a crisscross pattern in 2 or 3 steps. Install the output shaft driven gear and the drive DRIVE GEAR gear with the spline side facing out. Install the following: camshaft (section 7) flywheel and starter clutch (section 10)
  • Page 184 FRONT WHEEL/SUSPENSION/STEERING FE model shown: 32 N·m (3.3 kgf·m , 24 lbf·ft) 30 N·m (3.1 kgf·m , 22 lbf·ft) 39 N·m (4.0 kgf·m , 29 lbf·ft) 30 N·m (3.1 kgf·m , 22 lbf·ft) 44 N·m (4.5 kgf·m , 33 lbf·ft) 54 N·m (5.5 kgf·m , 40 lbf·ft) 44 N·m (4.5 kgf·m , 33 lbf·ft)

  • Page 185: Wheel Hub And Knuckle

    Adjust toe whenever the tie-rod, knuckle or steering shaft are replaced or removed (page 3-19). Do not twist or bend the brake hose and pipe when servicing. Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points. Refer to section 14 for brake system information.
  • Page 186 FRONT WHEEL/SUSPENSION/STEERING TORQUE VALUES Handlebar lower holder nut 39 N·m (4.0 kgf·m , 29 lbf·ft) Lock nut Front master cylinder holder bolt 12 N·m (1.2 kgf·m , 9 lbf·ft) Throttle housing cover screw 2 N·m (0.2 kgf·m , 1.4 lbf·ft) Front wheel nut 64 N·m (6.5 kgf·m , 47 lbf·ft) Front wheel hub nut...
  • Page 187 FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR REMOVAL U.S.A. T M/ F M Disonnect the ignition switch 4P and indicator 6P models: connectors, and open the two wire clips on the frame and steering shaft holder. Remove the following: fuel tank breather tube cover cap two screws handlebar cover Except U.S.A.
  • Page 188 FRONT WHEEL/SUSPENSION/STEERING choke knob (loosening the lock nut) two wire bands two screws holder rear (parking) brake lever bracket two screws (TM/FM models) three screws (TE/FE models) handlebar switch bolts grip ends handlebar grips 12-4...
  • Page 189 Install the four bolts and tighten the forward bolts first, then tighten the rear bolts. Apply Honda Bond A or Honda Hand Grip Cement (U.S.A. only) to the inside surface of the handlebar grip and to the clean surface of the handlebar.
  • Page 190 FRONT WHEEL/SUSPENSION/STEERING T M/ F M models: Install the brake lever bracket and holder with the punch mark facing up. Align the right edge of the bracket with the outside punch mark on the handlebar, and tighten the upper screw first, then the lower screw. T E/ F E models: Loosely install the handlebar switch housing with the three screws.

  • Page 191: Front Wheel

    FRONT WHEEL/SUSPENSION/STEERING THROTTLE HOUSING DISASSEMBLY Remove the following: three screws throttle housing cover gasket 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.
  • Page 192 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION Install the wheel with the arrow mark facing in the normal rotating direction. Do not interchange the left and right tires. Install the wheel nuts with the tapered side facing inward and tighten them. TORQUE: 64 N·m (6.5 kgf·m , 47 lbf·ft) FRONT TAPERED SIDE TIRES...

  • Page 193: Tire Repair

    FRONT WHEEL/SUSPENSION/STEERING Tighten the press head bolt until the reference REFERENCE MARK TOP EDGE OF mark on the press block is aligned with the top PRESS HEAD edge of the press head. If the rest of the bead cannot be pushed down into the center of the rim by hand, loosen the press head bolt and the lever nut.
  • Page 194 FRONT WHEEL/SUSPENSION/STEERING Insert and center a rubber plug through the eye of the inserting needle. Apply cement to the rubber plug. Push the inserting needle with plug into the injury until the plug is slightly above the tire. Be caref ul not to Twist the needle and remove it from the tire;...
  • Page 195 FRONT WHEEL/SUSPENSION/STEERING WHEEL HUB AND KNUCKLE REMOVAL Remove the wheel (page 12-7). Remove the following: cotter pin hub nut Do not get grease brake drum/hub on the brake shoes or stopping power For waterproof seal inspection, see section 14. will be reduced. Do not twist the brake hose.
  • Page 196 FRONT WHEEL/SUSPENSION/STEERING Release the ball joints, using the special tool according to the following instructions. TOOL: Ball joint remover, 28 mm 07MAC-SL00200 Apply grease to the ball joint remover at the point Apply grease here PRESSURE BOLT shown. This will ease installation of the tool and prevent damage to the pressure bolt threads.

  • Page 197: Bearing Replacement

    FRONT WHEEL/SUSPENSION/STEERING INSPECTION Turn the inner race of each bearing in the brake drum/hub (TM/TE models) and knuckle (FM/FE models) with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub or knuckle. Inspect the knuckle for damage or cracks.
  • Page 198 FRONT WHEEL/SUSPENSION/STEERING Drive in a new inner bearing (brake drum side) squarely with the marking side facing up until it is fully seated. Install the distance collar. Support the center Drive in a new outer bearing squarely with the boss of the hub to marking side facing up until it is fully seated.
  • Page 199 FRONT WHEEL/SUSPENSION/STEERING Apply grease to a new outer dust seal lips and install it using the same tools until it is flush with the knuckle end. Apply grease to a new inner dust seal lips and install it until it is fully seated being careful not to damage the lips.
  • Page 200 FRONT WHEEL/SUSPENSION/STEERING Install the brake panel onto the knuckle and tighten the four bolts. T M/ T E model Coat a new O-ring with grease and install it into the only: axle groove. Make sure that the waterproof seal on the brake drum is packed with the multi-purpose grease (NLGI 3) (page 14-9).

  • Page 201: Ball Joint Replacement

    FRONT WHEEL/SUSPENSION/STEERING BALL JOINT REPLACEMENT UPPER ARM Remove the snap ring from the ball joint. Set the upper arm and special tools with ‘‘A’’ mark side of the remover/installer facing to the ball joint as shown. Press the ball joint out of the upper arm. TOOLS: Ball joint remover/installer 07WMF-HN00100...
  • Page 202 FRONT WHEEL/SUSPENSION/STEERING Set the knuckle and special tools with ‘‘A’’ mark side of the remover/installer facing to the ball joint, in a vise as shown. Press the ball joint out of the knuckle. TOOLS: Ball joint remover/installer 07JMF-HC50110 Attachment, 28 30 mm 07946-1870100 Set the knuckle and special tools with ‘‘B’’...
  • Page 203 FRONT WHEEL/SUSPENSION/STEERING STEERING SHAFT AND TIE-ROD REMOVAL W hen removing Remove the following: the tie-rod only, it front fender (page 2-7) can be removed inner fenders (page 2-9) without removing handlebar cover (U.S.A. TM/FM models)/meter the f ront f ender. cover and combination meter (Except U.S.A.
  • Page 204 FRONT WHEEL/SUSPENSION/STEERING cotter pin (from steering shaft end) shaft end nut and washer shaft arm steering shaft INSPECTION Inspect the tie-rod for distortion or damage. Inspect the ball joint boots for tears or other damage by moving the ball joint studs. They should move freely and smoothly.
  • Page 205 FRONT WHEEL/SUSPENSION/STEERING Turn the inner race of the bearing with your finger. The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the frame. BEARING REPLACEMENT Remove the upper and lower dust seals. Remove the snap ring.
  • Page 206 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION ‘ ‘ ‘ ‘ ’ ’ ’ ’ Install the bushing ring onto the shaft bushing. Apply grease to the shaft bushing inner surface. Install the shaft bushing onto the steering shaft with the ‘‘UP’’ mark facing up. Install the steering shaft into the shaft bearing.
  • Page 207 FRONT WHEEL/SUSPENSION/STEERING If the tie-rod ball joints were replaced, tighten the lock nuts as follows: Rotate both ball joints with the tie-rod axis until they stop against the ball joint studs. Hold them in that position and tighten the ball joint lock nuts. TORQUE: 54 N·m (5.5 kgf·m , 40 lbf·ft) Install new cotter pins into the ball joint studs.
  • Page 208 FRONT WHEEL/SUSPENSION/STEERING INSPECTION Remove the lower pivot collar and dust seals. Check the pivot collar for wear or damage. 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.
  • Page 209 MEMO...
  • Page 210 REAR WHEEL/SUSPENSION 44 N·m (4.5 kgf·m , 33 lbf·ft) 118 N·m (12.0 kgf·m , 87 lbf·ft) 4 N·m (0.4 kgf·m , 2.9 lbf·ft) 118 N·m (12.0 kgf·m , 87 lbf·ft) 44 N·m (4.5 kgf·m , 33 lbf·ft) 44 N·m (4.5 kgf·m , 33 lbf·ft) 13-0...
  • Page 211 A jack or other support is required to support the vehicle. Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points. When using the lock nut wrench, use a deflecting beam type torque wrench 20 inches long. The lock nut wrench increases the torque wrench’s leverage, so the torque wrench reading will be less than the torque actually applied to the...
  • Page 212 REAR WHEEL/SUSPENSION TOOLS Bearing remover, 17 mm 07936-3710300 Remover handle 07936-3710100 Remover weight 07936-371020A or 07936-3710200 Driver 07949-3710001 Attachment, 22 24 mm 07746-0010800 Attachment, 28 30 mm 07946-1870100 Attachment, 37 40 mm 07746-0010200 Pilot, 17 mm 07746-0040400 Pilot, 20 mm 07746-0040500 Lock nut wrench 07908-4690003...

  • Page 213: Rear Wheel

    REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL Loosen the wheel nuts. Support the vehicle with a support block to raise the rear wheels off the ground. Remove the nuts and wheel. For tire removal/installation and repair, refer to section 12. INSTALLATION Install the wheel with the arrow mark facing in the normal rotating direction.
  • Page 214 REAR WHEEL/SUSPENSION INSTALLATION Set the shock absorber into the frame and swing- arm, then install the upper bolts from the left side and the lower bolt from the right side. Install a new upper mounting nuts and tighten the nut and bolt. TORQUE: Upper/Lower: 44 N·m (4.5 kgf·m , 33 lbf·ft) SWINGARM...
  • Page 215 REAR WHEEL/SUSPENSION Remove left and right pivot caps. Loosen the joint boot band screw. Loosen the right pivot lock nut and remove it. TOOL: Lock nut wrench 07908-4690003 Remove the right and left pivot bolts and release the joint boot off the swingarm, then remove the swingarm.
  • Page 216 REAR WHEEL/SUSPENSION INSPECTION Both bearings, Remove the dust seals. outer races and Check the dust seals for wear or damage. grease holders Turn the inner race of each bearing with your finger. must be replaced The bearings should turn smoothly and quietly. as a set if any part Also check that the bearing outer race fits tightly in is damaged or...
  • Page 217 REAR WHEEL/SUSPENSION Install the grease holder into the swingarm pivot. Drive in a new bearing squarely until it is fully seated. TOOLS: Driver 07749-0010000 Attachment, 37 40 mm 07746-0010200 Pilot, 17 mm 07746-0040400 Pack 3 g (0.1 oz) of grease into each bearing cavity and grease holder.
  • Page 218 REAR WHEEL/SUSPENSION Tighten the right pivot lock nut while holding the pivot bolt. TOOL: Lock nut wrench 07908-4690003 Ref er to torque TORQUE: Actual: 118 N·m (12.0 kgf·m , 87 lbf·ft) wrench reading Indicated: 107 N·m (10.9 kgf·m , 79 lbf·ft) inf ormation on page 13-1 ‘‘Service...
  • Page 219 REAR WHEEL/SUSPENSION Route the breather tubes properly (page 1-22) and secure them with the clamps. Install the final drive and rear axle (page 16-16). 13-9...
  • Page 220 BRAKE SYSTEM FM/FE model shown: 20 N·m (2.0 kgf·m , 14 lbf·ft) 34 N·m (3.5 kgf·m , 25 lbf·ft) 16 N·m (1.6 kgf·m , 12 lbf·ft) 137 N·m (14.0 kgf·m , 101 lbf·ft) 78 N·m (8.0 kgf·m , 58 lbf·ft) 29 N·m (3.0 kgf·m , 22 lbf·ft) 14-0...
  • Page 221 Always check brake operation before riding the vehicle. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Front brake Recommended brake fluid Honda DOT 4 brake fluid Drum I.D. 160.0 (6.30) 161.0 (6.34) Shoe lining thickness 4.0 (0.16) 1.0 (0.04) Brake panel warpage 0.4 (0.02)
  • Page 222 BRAKE SYSTEM TORQUE VALUES Brake hose oil bolt 34 N·m (3.5 kgf·m , 25 lbf·ft) Wheel cylinder bleed valve 6 N·m (0.6 kgf·m , 4.3 lbf·ft) Front master cylinder reservoir cap screw 2 N·m (0.2 kgf·m , 1.4 lbf·ft) Front brake lever pivot bolt 6 N·m (0.6 kgf·m , 4.3 lbf·ft) 6 N·m (0.6 kgf·m , 4.3 lbf·ft) Front master cylinder holder bolt...
  • Page 223 BRAKE SYSTEM BRAKE FLUID REPLACEMENT/AIR BLEEDING Do not allow foreign material to enter the system when filling the reservoir. Avoid spilling fluid on painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. Use only DOT 4 brake fluid from a sealed container.
  • Page 224 BRAKE SYSTEM Connect a bleed hose to the bleed valve and bleed the system as follows: Squeeze the brake lever, open the bleed valve 1/4 turn and then close it. Do not release the brake lever until the bleed valve has been closed. Release the brake lever slowly and wait several seconds after it reaches the end of its travel.
  • Page 225 BRAKE SYSTEM snap ring TOOL: Snap ring pliers 07914-SA50001 master piston spring Clean the master cylinder, reservoir and master piston in clean brake fluid. INSPECTION Check the piston cups for wear, deterioration or damage. Check the spring for damage. Check the master cylinder and piston for scoring, scratches or damage.

  • Page 226: Brake Drum Removal

    BRAKE SYSTEM Install the boot into the master cylinder and the groove in the piston. Apply silicone grease to the brake lever contacting surface of the piston. Apply silicone grease to the brake lever pivot. Install the brake lever and pivot bolt, and tighten it. TORQUE: 6 N·m (0.6 kgf·m , 4.3 lbf·ft) Install the pivot nut and tighten it.
  • Page 227 BRAKE SYSTEM BRAKE DRUM Measure the drum I.D. SERVICE LIMIT: 161.0 mm (6.34 in) For waterproof seal and brake panel inspection, see page 14-8. BRAKE SHOE REPLACEMENT Always replace the brake shoes in pairs. Turn each retaining pin 90° while pressing the pin holder to remove them.
  • Page 228 BRAKE SYSTEM BRAKE PANEL AND WATERPROOF Do not get BRAKE PANEL SEAL INSPECTION grease on the shoe linings. BRAKE PANEL Clean any grease from the brake panel thoroughly. HUB NUT Check the brake panel at the waterproof seal lip contact area for abnormal scratches or wear. T M/ T E models: Install a suitable steel plate and collar onto the axle and tighten the hub nut securely.

  • Page 229: Brake Drum Installation

    BRAKE SYSTEM Apply water to a new waterproof seal entire. BRAKE DRUM Press the drum Place the waterproof seal on a clean surface plate, onto the seal and press the brake drum into the waterproof seal, SURFACE Apply water evenly, so the lips making sure that the clearances between the drum PLATE will not be...

  • Page 230: Front Wheel Cylinder And Panel

    BRAKE SYSTEM F M/ F E models: Apply molybdenum disulfide grease to the drive shaft spline. Install the wheel hub onto the drive shaft, if it was removed. Apply grease to the hub nut threads and seating surface. Install the hub nut and tighten it to the specified torque and further tighten until its grooves align with the cotter pin hole.
  • Page 231 BRAKE SYSTEM four bolts (discard them) brake panel O-ring Do not reuse the panel bolts because their threads are specially dry-coated for waterproofing. Loosen the pipe joint nuts and remove the brake pipe. Remove the nuts, washers and bolts and the wheel cylinder A and B.
  • Page 232 BRAKE SYSTEM INSPECTION PISTON Check the piston cup and boot for wear, deterioration or damage. CYLINDER Check the cylinder bore and piston for scoring, scratches of damage. Check the adjuster for wear or damage. BOOT Check the lock spring for fatigue or damage. LOCK SPRING ADJUSTER Measure the wheel cylinder I.D.
  • Page 233 BRAKE SYSTEM Coat the piston and cups with clean brake fluid. Do not allow the Install the piston into the wheel cylinder. piston cup lips to turn inside out. Apply silicone grease to the boot grooves in the piston and cylinder body. Install the piston boot onto the cylinder and piston grooves securely.

  • Page 234: Rear Brake Shoes And Drum

    BRAKE SYSTEM Install the brake panel onto the knuckle with new panel bolts. TORQUE: 29 N·m (3.0 kgf·m , 22 lbf·ft) Connect the brake hose to the wheel cylinder with the oil bolt and new sealing washers by aligning the hose joint with the stopper groove. Tighten the oil bolt.
  • Page 235 BRAKE SYSTEM INSPECTION Measure the brake drum I.D. SERVICE LIMIT: 161.0 mm (6.34 in) Check the dust seals in the wheel hub and drum cover for wear or damage. DISASSEMBLY Always replace the Remove the following: brake shoes in cotter pins pairs.
  • Page 236 BRAKE SYSTEM nut and bolt brake arm wear indicator spring brake cam felt seal dust seal ASSEMBLY Apply grease to the lips of a new brake cam dust seal and install it with the flat side facing toward the brake arm until it is fully seated. Apply grease to the brake cam spindle and install it.
  • Page 237 BRAKE SYSTEM Install the brake cables into the cable holders on the brake panel (upper holder for parking brake cable and lower holder for pedal brake cable). Install the cable springs onto the cables and the joint pins into the brake arm. Connect the brake cables to the brake arm with the adjusting nuts.
  • Page 238 BRAKE SYSTEM Apply grease to the seal lips of a new drum cover dust seal and install it using the special tool. TOOL: Oil seal driver 07965-MC70100 Install the drum cover and tighten the six bolts. Apply molybdenum disulfide grease to the seal lips of a new hub dust seal and install it with the flat side facing in until it is fully seated.
  • Page 239 BRAKE SYSTEM REAR BRAKE PEDAL REMOVAL Remove the right rear mud guard (page 2-5). Disconnect the pedal brake cable from the brake arm (page 14-15). Remove the following: spring brake cable cotter pin washer brake pedal dust seals INSTALLATION Apply grease to the lips of the new dust seals and install them with the flat side facing to the pedal.
  • Page 240 FRONT DRIVING MECHANISM (FM/FE model) 44 N·m (4.5 kgf·m , 33 lbf·ft) 44 N·m (4.5 kgf·m , 33 lbf·ft) 22 N·m (2.2 kgf·m , 16 lbf·ft) 78 N·m (8.0 kgf·m , 58 lbf·ft) 29 N·m (3.0 kgf·m , 22 lbf·ft) 22 N·m (2.2 kgf·m , 16 lbf·ft) 15-0...
  • Page 241 15. FRONT DRIVING MECHANISM (FM/FE models) SERVICE INFORMATION 15-1 CASE BEARING REPLACEMENT 15-17 TROUBLESHOOTING 15-2 DIFFERENTIAL ASSEMBLY 15-19 FRONT DRIVE SHAFT 15-3 DIFFERENTIAL INSTALLATION 15-23 DIFFERENTIAL REMOVAL 15-8 DIFFERENTIAL DISASSEMBLY/ INSPECTION 15-9 SERVICE INFORMATION GENERAL The differential assembly and propeller shaft must be removed together. Perform the gear contact pattern and backlash inspection whenever you replace the bearings, gears or gear case.
  • Page 242 FRONT DRIVING MECHANISM (FM/FE models) TOOLS Driver 07749-0010000 Attachment, 22 24 mm 07746-0010800 Attachment, 52 55 mm 07746-0010400 Pilot, 14 mm 07746-0041200 Pilot, 28 mm 07746-0041100 Driver, 22 mm I.D. 07746-0020100 Driver, 40 mm I.D. 07746-0030100 Attachment, 15 mm I.D. 07746-0020200 Attachment, 20 mm I.D.
  • Page 243 FRONT DRIVING MECHANISM (FM/FE models) FRONT DRIVE SHAFT REMOVAL Remove the front wheel (page 12-7). Remove the cotter pin and loosen the hub nut. Remove the cotter pins and loosen the ball joint nuts. Release the ball joints, using the special tool according to the instructions on page 12-12.
  • Page 244 FRONT DRIVING MECHANISM (FM/FE models) DISASSEMBLY/INSPECTION Check the boots for cuts or other damage. Check the drive shaft joints for excessive play or noise by moving the joints in a circular direction. If the outboard joint seems to be worn or damaged, the drive shaft must be replaced.
  • Page 245 FRONT DRIVING MECHANISM (FM/FE models) Replace their Check the following for wear or damage. components as an bearing cage assembly. race steel balls inboard joint Remove the following: boot band C and A outboard boot ASSEMBLY 15-5...
  • Page 246 FRONT DRIVING MECHANISM (FM/FE models) Each boot has an identification mark; ‘‘BJ68L’’ for ‘ ‘ ‘ ‘ ’ ’ ’ ’ ‘ ‘ ‘ ‘ ’ ’ ’ ’ the outboard and ‘‘BJ68’’ for the inboard. Note the installation direction of the boot bands. Forward direction Pack the outboard joint with 30 50 g of molybde- num disulfide grease.
  • Page 247 FRONT DRIVING MECHANISM (FM/FE models) Adjust the length of the drive shaft to the figure given below. DRIVE SHAFT LENGTH: Left/Right: 344.8 354.8 mm (13.57 13.97 in) Install the boot bands C onto the boots. See page 15-6 f or Install new boot band A onto the outboard boot and band installation the band B onto the inboard boot.
  • Page 248 FRONT DRIVING MECHANISM (FM/FE models) Install the brake panel assembly over the drive shaft and onto the suspension arms. Install and tighten each joint nut to the specified torque and further tighten until its grooves align with the cotter pin hole. TORQUE: 29 N·m (3.0 kgf·m , 22 lbf·ft) Install new cotter pins.
  • Page 249 FRONT DRIVING MECHANISM (FM/FE models) two 8 mm bolts mounting bracket Move the differential forward for maximum clear- ance between the propeller shaft joint and engine. Pull the propeller shaft joint forward, then separate it from the engine (output shaft joint). Separate the other drive shaft from the differential as you remove it.
  • Page 250 FRONT DRIVING MECHANISM (FM/FE models) DIFFERENTIAL Turn the pinion joint and check that the gear turns smoothly and quietly without binding. If the gears do not turn smoothly or quietly, the gears and/or bearing may be damaged or faulty. They must be checked after disassembly; replace them if necessary.

  • Page 251: Bearing Inspection

    FRONT DRIVING MECHANISM (FM/FE models) Twenty-three different thickness shims are available from the thinnest (0.50 mm thickness: A) shim to the thickest (1.60 mm thickness: W) in intervals of 0.05 mm. Ring gear shims: A: (thinnest): 0.50 mm (0.020 in) K: (standard): 1.00 mm (0.039 in) W: (thickest):...
  • Page 252 FRONT DRIVING MECHANISM (FM/FE models) GEAR TOOTH CONTACT PATTERN CHECK K eep dust and dirt Clean sealing material off the mating surfaces of out of the case and the differential case and cover, being careful not to cover. damage them. Apply thin coat of Prussian Blue to the pinion gear teeth for a tooth contact pattern check.
  • Page 253 FRONT DRIVING MECHANISM (FM/FE models) Replace the pinion shim with a thicker one if the contact pattern is too high, toward the face. Replace the pinion shim with a thinner one if the contact pattern is too low, toward the flank. The pattern will shift about 0.5 1.0 mm (0.02 0.04 in) when the thickness of the shim is changed...
  • Page 254 FRONT DRIVING MECHANISM (FM/FE models) DIFFERENTIAL DISASSEMBLY Remove the six bolts, then place the differential assembly with the housing side down, and remove the ring gear. Remove the following: differential cap cone spring shim left face cam six cam followers A and six cam followers B right face cam DIFFERENTIAL COMPONENTS If the dif f erential...
  • Page 255 FRONT DRIVING MECHANISM (FM/FE models) DIFFERENTIAL HOUSING/FACE CAM/ CAM FOLLOWER Check the sliding surface and grooves of the housing for damage or discoloration. Replace the cam Check the shim, face cams and followers for f ollowers as a set damage. ( 12 pieces).
  • Page 256 FRONT DRIVING MECHANISM (FM/FE models) PINION GEAR REMOVAL Remove the pinion joint from the differential by pulling it to force the stopper ring at the pinion gear shaft past the groove in the pinion joint. Remove the oil seal, O-ring and stopper ring. Be caref ul that Unstake the pinion bearing lock nut with a drill or metal particles do...
  • Page 257 FRONT DRIVING MECHANISM (FM/FE models) PINION GEAR BEARING AND SHIM REPLACEMENT Pull the pinion bearing from the shaft with a commercially available bearing puller. Remove the pinion shim. Install the shim and bearing onto the pinion gear. When the gear set, ring gear bearing, differential housing and/or gear case has been replaced, use a 2.00 mm (0.79 in) thick shim for initial reference.
  • Page 258 FRONT DRIVING MECHANISM (FM/FE models) Drive the bearings into the case and cover. TOOLS: Driver 07749-0010000 Attachment, 52 55 mm 07746-0010400 Pilot, 28 mm 07746-0041100 Apply grease to new dust seal lips and install them into the case and cover. TOOL: Attachment, 20 mm I.D.

  • Page 259: Differential Assembly

    FRONT DRIVING MECHANISM (FM/FE models) Heat the gear case to 80 °C (176 °F). Remove the needle bearing and tool assembly from the freezer and drive the bearing into the gear case using the special tools. Only strike the driver once. If you strike it more than once, the ring may slip out of the groove.
  • Page 260 FRONT DRIVING MECHANISM (FM/FE models) PINION GEAR INSTALLATION Drive the pinion assembly into the gear case. TOOL: Driver, 40 mm I.D. 07746-0030100 Keep the driver centered with the bearing outer race during installation. Install a new lock nut and tighten it. TOOL: Lock nut wrench, 34 44 mm...
  • Page 261 FRONT DRIVING MECHANISM (FM/FE models) Coat a new O-ring with grease and install it into the groove in the pinion gear shaft. Apply molybdenum disulfide grease to the pinion gear shaft spline and install the pinion joint until the stopper ring seats in the groove. Make sure that the stopper ring is seated properly by pulling on the pinion joint lightly.
  • Page 262 FRONT DRIVING MECHANISM (FM/FE model) Install the ring gear onto the differential assembly with new ring gear bolts. Tighten the six bolts in a crisscross pattern in several steps. TORQUE: 49 N·m (5.0 kgf·m , 36 lbf·ft) If the differential assembly is replaced, remove the two socket bolts and discard them after installing the ring gear.
  • Page 263 FRONT DRIVING MECHANISM (FM/FE models) It is important to Apply locking agent to the threads of the two 10 turn the pinion mm bolts. while tightening Install the bolts and tighten them several steps until the bolts. If the the cover evenly touches the case. Then, while ring gear shim is rotating the pinion gear, tighten the bolts to the too thick, the...
  • Page 264 FRONT DRIVING MECHANISM (FM/FE models) Install the boot over the propeller shaft joint securely and secure it with the boot band. Install the drive shaft into the differential (page 15- Set the mounting bracket over the front mounting boss of the differential and onto the frame, then install the two mounting bolts and tighten them.
  • Page 265 MEMO...
  • Page 266 REAR DRIVING MECHANISM 137 N·m (14.0 kgf·m , 101 lbf·ft) 44 N·m (4.5 kgf·m , 33 lbf·ft) 54 N·m (5.5 kgf·m , 40 lbf·ft) 54 N·m (5.5 kgf·m , 40 lbf·ft) 32 N·m (3.3 kgf·m , 24 lbf·ft) 44 N·m (4.5 kgf·m , 33 lbf·ft) 16-0...
  • Page 267 16. REAR DRIVING MECHANISM SERVICE INFORMATION 16-1 CASE BEARING REPLACEMENT 16-11 TROUBLESHOOTING 16-2 FINAL DRIVE ASSEMBLY 16-13 REAR AXLE REMOVAL 16-3 FINAL DRIVE INSTALLATION 16-16 FINAL DRIVE REMOVAL 16-5 REAR AXLE INSTALLATION 16-17 FINAL DRIVE DISASSEMBLY/ INSPECTION 16-6 SERVICE INFORMATION GENERAL Perform the gear contact pattern and backlash inspection whenever you replace the bearings, gears or gear case.
  • Page 268 REAR DRIVING MECHANISM TOOLS Driver 07749-0010000 Attachment, 22 24 mm 07746-0010800 Attachment, 52 55 mm 07746-0010400 Attachment, 62 68 mm 07746-0010500 Pilot, 14 mm 07746-0041200 Pilot, 28 mm 07746-0041100 Pilot, 35 mm 07746-0040800 Pilot, 40 mm 07746-0040900 Pilot, 32 35 mm 07MAD-PR90200 Driver, 40 mm I.D.

  • Page 269: Rear Axle Removal

    REAR DRIVING MECHANISM REAR AXLE REMOVAL Remove the following: rear wheels (page 13-3) rear brake drum (page 14-14) breather tube adjusting nuts joint pins springs brake cables four nuts (discard them) Do not get grease brake panel assembly onto the shoe O-ring linings.
  • Page 270 REAR DRIVING MECHANISM INSPECTION Set the axle in V-blocks and measure the axle runout with a dial indicator. Axle runout is 1/2 the total indicator reading. SERVICE LIMIT: 3.0 mm (0.12 in) AXLE BEARING Remove the dust seals from the axle housing and brake panel.
  • Page 271 REAR DRIVING MECHANISM BRAKE PANEL Remove the snap ring. Drive the axle bearings out of the brake panel. Support the Drive the outer bearing (brake drum side) squarely bearing housing with the sealed side facing down until it is fully section of the seated, then the inner bearing with the sealed side brake panel when...
  • Page 272 REAR DRIVING MECHANISM Remove the spring and drive shaft from the swingarm. INSPECTION DRIVE SHAFT Check the splines of the drive shaft for wear or damage. If the splines are damaged, check the pinion and universal joint splines also. For universal joint removal, see page 13-4 ‘‘Swingarm’’...
  • Page 273 REAR DRIVING MECHANISM If the backlash is excessive, replace the ring gear right side shim with a thinner one. If the backlash is too small, replace the ring gear right side shim with a thicker one. Backlash changed by about 0.06 mm (0.002 in) when thickness of the shim is changed by 0.12 mm (0.005 in).
  • Page 274 REAR DRIVING MECHANISM Remove the ring gear and shims. BEARING INSPECTION Turn the inner race of each bearing in the gear case and case cover with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the case or cover.
  • Page 275 REAR DRIVING MECHANISM It is important to Install the case cover and tighten the bolts in turn the pinion several steps until the cover evenly touches the while tightening gear case. Then, while rotating the pinion gear, the bolts. If the tighten the bolts to the specified torque in a ring gear shim is crisscross pattern in several steps.
  • Page 276 REAR DRIVING MECHANISM PINION GEAR REMOVAL Remove the oil seal from the gear case. Be caref ul that Unstake the pinion bearing lock nut with a drill or metal particles do grinder. not enter the bearing and the threads of the case are not damaged.
  • Page 277 REAR DRIVING MECHANISM Install the shim and bearing onto the pinion gear. When the gear set, ring gear bearing, and/or gear case has been replaced, use a 2.00 mm (0.79 in) thick shim for initial reference. Drive the bearing with the marking side facing up. TOOLS: Driver, 40 mm I.D.
  • Page 278 REAR DRIVING MECHANISM Apply grease to new oil seal lips. Install each oil seal with the flat side facing out until it is flush with the case or cover. TOOL: Driver 07749-0010000 Attachment, 52 55 mm 07746-0010400 PINION NEEDLE BEARING Remove the stopper ring by rotating it until the end of the stopper ring appears in the access hole.
  • Page 279 REAR DRIVING MECHANISM FINAL DRIVE ASSEMBLY GEAR CASE OIL SEAL RING GEAR BEARING SHIM RING GEAR STOPPER RING RING GEAR BEARING SHIM PINION NEEDLE BEARING PINION GEAR SHIM CASE COVER PINION BEARING OIL SEAL OIL SEAL LOCK NUT PINION GEAR INSTALLATION Drive the pinion assembly into the gear case.
  • Page 280 REAR DRIVING MECHANISM Install a new lock nut and tighten it. TOOL: Lock nut wrench, 30 64 mm 07916-MB00002 Ref er to torque TORQUE: Actual: 98 N·m (10.0 kgf·m , 72 lbf·ft) wrench reading Indicated: 89 N·m (9.1 kgf·m , 66 lbf·ft) inf ormation on page 16-1 ‘‘Service...

  • Page 281: Final Gear Case Assembly

    REAR DRIVING MECHANISM Remove the ring gear. Be sure to wear If the clearance exceeds the standard value, heat heavy gloves to the case cover to approximately 80°C (176°F) and avoid burns when remove the stop pin by tapping the cover. handling the heated case cover.
  • Page 282 REAR DRIVING MECHANISM It is important to Apply locking agent to the threads of the two 10 turn the pinion mm bolts. while tightening Install the bolts and tighten them several steps until the bolts. If the the cover evenly touches the case. Then, while ring gear shim is rotating the pinion gear, tighten the bolts to the too thick, the...

  • Page 283: Rear Axle Installation

    REAR DRIVING MECHANISM REAR AXLE INSTALLATION Apply molybdenum disulfide grease to the center spline of the axle. Install the axle into the final gear case from right side until it is fully seated. Coat a new O-ring with grease and install it into the gear case groove.
  • Page 284 REAR DRIVING MECHANISM Apply molybdenum disulfide grease to the seal lips of a new hub dust seal and install it with the flat side facing in until it is fully seated. Apply molybdenum disulfide grease to the left spline of the axle and install the wheel hub. Install the hub nut and tighten it to the specified torque and further tighten until its grooves align with the cotter pin hole.
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  • Page 286: Battery/Charging System

    BATTERY/CHARGING SYSTEM TE/FE model shown: BATTERY MAIN FUSE 30 A REGULATOR/RECTIFIER ALTERNATOR 17-0...
  • Page 287 17. BATTERY/CHARGING SYSTEM SERVICE INFORMATION 17-1 CHARGING SYSTEM INSPECTION 17-5 TROUBLESHOOTING 17-3 REGULATOR/RECTIFIER 17-6 BATTERY 17-4 ALTERNATOR CHARGING COIL 17-6 SERVICE INFORMATION GENERAL The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. The battery contains sulfuric acid (electrolyte).
  • Page 288 BATTERY/CHARGING SYSTEM BATTERY CHARGING This model comes with a maintenance free (MF) 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 For battery charging, do not exceed the charging current and time specified on the battery.
  • Page 289 BATTERY/CHARGING SYSTEM TROUBLESHOOTING Battery is damaged or weak Remove the battery (page 17-4). Incorrect Faulty battery Check the battery condition using the recom- mended battery tester. RECOMMENDED BATTERY TESTER: BM-210-AH, BM-210, or BATTERY MATE or equivalent Correct Install the battery (page 17-4). Incorrect Disconnect the regulator/rectifier 5P (black) Check the battery current leakage (Leak test:...

  • Page 290: Battery Charging

    BATTERY/CHARGING SYSTEM BATTERY TRIM CRIPS REMOVAL/INSTALLATION Remove the seat (page 2-4). Remove the two trim clips. Pull the maintenance lid and release the tabs from the slits to remove it. With the ignition switch OFF, disconnect the negative ( ) cable first, then disconnect the positive ( ) cable.

  • Page 291: Charging System Inspection

    BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION Remove the seat (page 2-4). CURRENT LEAKAGE TEST Turn the ignition switch OFF, and disconnect the negative ( ) cable from the battery. Connect the ammeter ( ) probe to the negative ( ) cable and the ammeter ( ) probe to the battery ( ) terminal.

  • Page 292: Alternator Charging Coil

    BATTERY/CHARGING SYSTEM ALTERNATOR CHARGING COIL INSPECTION Disconnect the alternator 5P (white) connector. Measure the resistance between the Yellow wire terminals of the alternator side connector. STANDARD: 0.1 1.0 (20°C/68°F) Check for continuity between each Yellow wire terminal of the alternator side connector and ground.
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  • Page 294: Ignition System

    IGNITION SYSTEM TE/FE model shown: IGNITION SWITCH ENGINE STOP SWITCH BATTERY IGNITION COIL FUSE 10 A/30 A IGNITION CONTROL MODULE (ICM) SPARK PLUG GEAR POSITION SWITCH IGNITION PULSE GENERATOR Early TE/FE model production only: BI ···· Black R ····· Red Y ·····...

  • Page 295: Ignition Coil

    18. IGNITION SYSTEM SERVICE INFORMATION 18-1 IGNITION COIL 18-4 TROUBLESHOOTING 18-2 IGNITION TIMING 18-5 IGNITION SYSTEM INSPECTION 18-3 SERVICE INFORMATION GENERAL Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present. When servicing the ignition system, always follow the steps in the troubleshooting on page 18-2.
  • Page 296 IGNITION SYSTEM TROUBLESHOOTING Inspect the following before diagnosing the system. 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) No spark at spark plug UNUSUAL CONDITION PROBABLE CAUSE (Check in numerical order) Ignition coil...
  • Page 297 IGNITION SYSTEM IGNITION SYSTEM INSPECTION If not spark jumps at the plug, check all connections for loose or poor contact before measuring each peak voltage. Use recommended digital multimeter or a commercially available digital multimeter (impedance 10 M /DCV minimum). The display value differs depending upon the internal impedance of the multimeter.
  • Page 298 IGNITION SYSTEM IGNITION PULSE GENERATOR PEAK VOLTAGE Check that the cylinder compression is normal and the spark plug is installed correctly in the cylinder head. Disconnect the ignition control module (ICM) 8P (gray) connector. Connect the peak voltage tester or adaptor probes to the connector terminals of the wire harness side.
  • Page 299 IGNITION SYSTEM Disconnect the connectors. Remove the ignition coil from the stay of the frame. Install a new ignition coil in the reverse order of removal. IGNITION TIMING Remove the recoil starter cover (page 2-5). Start the engine and warm it up operating temperature.

  • Page 300: Electric Starter

    ELECTRIC STARTER TE/FE model shown: STARTER SWITCH FUSE BOX (FUSE 15A/30A AND DIODE) IGNITION SWITCH BATTERY STARTER RELAY SWITCH GEAR POSITION SWITCH STARTER MOTOR 19-0...

  • Page 301: Starter Motor

    19. ELECTRIC STARTER SERVICE INFORMATION 19-1 STARTER RELAY SWITCH 19-9 TROUBLESHOOTING 19-2 DIODE 19-10 STARTER MOTOR 19-4 SERVICE INFORMATION GENERAL Always turn the ignition switch 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 flow chart (page 19-2).
  • Page 302 ELECTRIC STARTER TROUBLESHOOTING The starter motor should operate only when the transmission is in neutral with the ignition switch ON. Starter motor will not turn Check for a blown fuse (15 A). Check that the battery is fully charged and in good condition. Check for loose or poorly connected battery Abnormal Poorly connected battery cable...
  • Page 303 ELECTRIC STARTER (From previous page) Check the starter relay voltage (page 19-10). Abnormal Faulty ignition switch Faulty starter switch Loose or poor connector contact Open circuit in wire harness Normal Check the starter relay switch operation (page 19- Abnormal Faulty starter relay switch 10).
  • Page 304 ELECTRIC STARTER STARTER MOTOR BOLTS STARTER MOTOR CABLE REMOVAL Remove the air cleaner housing (page 5-3). When the ignition switch OFF, remove the negative cable at the battery before servicing the starter motor. Release the rubber cap and remove the terminal nut to disconnect the starter motor cable.
  • Page 305 ELECTRIC STARTER rear cover shims seal ring armature Check the bushing in the rear cover for wear or damage. Check the dust seal and needle bearing in the front cover for deterioration, wear or damage. Check the commutator bars of the armature for discoloration.
  • Page 306 ELECTRIC STARTER Check for continuity between pairs of commutator bars. There should be continuity. 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.
  • Page 307 ELECTRIC STARTER Remove the following: washer insulator washers brush holder assembly O-ring Remove the brushes from the brush holder. Measure the brush length. SERVICE LIMIT: 9.0 mm (0.35 in) ASSEMBLY REAR COVER MOTOR CASE ARMATURE BRUSH HOLDER SEAL RING SEAL RING FRONT COVER 19-7...
  • Page 308 ELECTRIC STARTER Install the brushes into the brush holder. 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 T he coil may be Install the armature into the motor case while damaged if the...

  • Page 309: Starter Relay Switch

    ELECTRIC STARTER Align the index lines on the front cover and motor case. Install the set plates and new O-rings onto the motor case bolts. Install the motor case bolts and tighten them. INSTALLATION Coat a new O-ring with engine oil and install it into the starter motor groove.
  • Page 310 ELECTRIC STARTER GROUND LINE Disconnect the starter relay 2P (white) connector. Check for continuity between the Light green/red wire terminal of the harness side connector and ground. If there is continuity when the transmission is in neutral, the ground circuit is normal. STARTER RELAY VOLTAGE Measure the voltage between the Yellow/red wire terminal ( ) of the harness side 2P connector and...
  • Page 311 ELECTRIC STARTER 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 diode is normal. 19-11...

  • Page 312: Lights/Meters/Switches

    LIGHTS/METERS/SWITCHES TE/FE model shown: HANDLEBAR SWITCH COMBINATION METER (U.S.A. TM/FM models-optional) IGNITION SWITCH OIL THERMOSENSOR COOLING FAN MOTOR (U.S.A. TM model-optional) SPEED SENSOR (U.S.A. TM/FM models-optional) GEAR POSITION SWITCH 20-0...

  • Page 313: Handlebar Switch

    20. LIGHTS/METERS/SWITCHES SERVICE INFORMATION 20-1 GEAR POSITION SWITCH 20-7 BULB REPLACEMENT 20-2 CARBURETOR HEATER 20-8 HEADLIGHT 20-3 COMBINATION METER/SPEED SENSOR (Except U.S.A. TM/FM models) 20-9 ACCESSORY SOCKET 20-4 OIL COOLING SYSTEM/ IGNITION SWITCH 20-5 TEMPERATURE INDICATOR 20-11 HANDLEBAR SWITCH 20-5 SERVICE INFORMATION GENERAL All plastic connectors have locking tabs that must be released before disconnecting, and must be aligned when...

  • Page 314: Bulb Replacement

    LIGHTS/METERS/SWITCHES BULB REPLACEMENT SCREW HEADLIGHT SLIT T M/ T E models: Remove the screw and the cover cap by releasing the tabs from the slits in the headlight cover. Remove the dust cover from the headlight. While pushing the bulb socket in, turn it counter- clockwise to remove it.
  • Page 315 LIGHTS/METERS/SWITCHES Turn the bulb socket counterclockwise and remove Pull the bulb out of the socket and replace it with a SOCKET new one. Make sure that the seal rubber is installed in position and is in good condition. Route the taillight Install the removed parts in the reverse order of wire properly.

  • Page 316: Accessory Socket

    LIGHTS/METERS/SWITCHES HEADLIGHT AIM Adjust the headlight beam vertically by loosening the adjusting bolt and moving the headlight back and forth. Tighten the mounting bolts. An improperly adjusted headlight may blind oncoming drivers, or it may fail to light the road for a safe distance.
  • Page 317 LIGHTS/METERS/SWITCHES IGNITION SWITCH INSPECTION Disconnect the ignition switch 4P (white) connector. Check for continuity between the switch side connector terminals in each switch position. Continuity should exist between the color coded wires as follows: Color Red/black Pink Black Position REPLACEMENT Disconnect the ignition switch connector.
  • Page 318 LIGHTS/METERS/SWITCHES Check for continuity between the switch side connector terminals in each switch position. Continuity should exist between the color coded wires as follows: ENGINE STOP SWITCH Color BI/G BI/W Position LIGHTING SWITCH DIMMER SWITCH • Color Color Bu/Bl BI/Br •...
  • Page 319 LIGHTS/METERS/SWITCHES GEAR POSITION SWITCH TM/FM models: INSPECTION T M/ F M model Remove the right side cover (page 2-4). only: T E/ F E model Remove the alternator connector, then the gear only: position switch connector from the frame. Disconnect the gear position switch connector. Check for continuity between each terminal of the switch side connector and ground.

  • Page 320: Carburetor Heater

    LIGHTS/METERS/SWITCHES CARBURETOR HEATER INSPECTION (Except U.S.A. TM model) Remove the right side cover (page 2-4). Disconnect the carburetor heater 2P (white) connector. Measure the voltage between the Brown/black ( ) and Yellow ( ) wire terminals at the harness side connectors.
  • Page 321 LIGHTS/METERS/SWITCHES If the carburetor heater resistance is normal, check for continuity between the switch side connector terminals of the temperature switch 2P connector. Above: 20°C (68°F) : No Continuity Below: 7°C (45°F) : Continuity If there is abnormal, replace the air temperature switch.
  • Page 322 LIGHTS/METERS/SWITCHES SPEEDOMETER/SPEED SENSOR SYSTEM INSPECTION Check that the hour meter or odometer/trip meter function properly. If they do not function, perform the power/ ground line inspection (page 20-9). If they function, check the following. Remove the right side cover (page 2-4). Disconnect the speed sensor 3P (white) connector.
  • Page 323 LIGHTS/METERS/SWITCHES SPEED SENSOR REPLACEMENT Remove the right side cover (page 2-4). Disconnect the speed sensor 3P (white) connector and release the sensor wire from the clips. Remove the following: two bolts speed sensor sensor insulator O-rings Coat new O-rings with engine oil and install them onto the crankcase cover and a new speed sensor.
  • Page 324 LIGHTS/METERS/SWITCHES Fan motor does not start, then oil temperature indicator does not come on Disconnect the ignition control module (ICM) 8P connector. Check for continuity between the 8P connector Light blue terminal and oil thermosensor connector terminal (Blue). There should be continuity. If there is no continuity, check for open circuit in Light blue and Blue wires between the ICM and thermosensor.
  • Page 325 LIGHTS/METERS/SWITCHES Fan motor does not stop Remove the right inner fender (page 2-9). Disconnect the fan motor Green-White connector and ignition control module (ICM) White wire FAN MOTOR WIRE connector. CONNECTOR Check for continuity between the White wire terminal and ground. There should be no continuity.
  • Page 326 LIGHTS/METERS/SWITCHES OIL THERMOSENSOR INSPECTION Disconnect the connector and remove the thermosensor. Suspend the thermosensor in a pan of engine oil THERMOMETER on an electric heating element and measure the resistance through the sensor as the oil heats up. Soak the thermosensor in oil up to its threads with at least 40 mm (1.57 in) from the bottom of the pan to the bottom of the sensor.
  • Page 327 MEMO...

  • Page 328: Electric Shift Program

    ELECTRIC SHIFT PROGRAM (ESP: TE/FE model) UPSHIFT SWITCH IGNITION SWITCH DOWNSHIFT SWITCH FUSE BOX BATTERY SHIFT CONTROL MOTOR ELECTRONIC CONTROL UNIT VEHICLE SPEED SENSOR ANGLE SENSOR GEAR POSITION SWITCH IGNITION PULSE GENERATOR REVERSE SHIFT SWITCH 21-0...
  • Page 329 21. ELECTRIC SHIFT PROGRAM (ESP: TE/FE models) SERVICE INFORMATION 21-1 CONTROL MOTOR AND REDUCTION GEARS 21-22 TROUBLESHOOTING (’00 ’02) 21-2 GEARSHIFT SWITCH 21-24 (After ’02) 21-8 REVERSE SHIFT SWITCH 21-25 ANGLE SENSOR 21-20 SERVICE INFORMATION GENERAL When checking the Electric Shift Program (ESP) system, always follow the steps in the troubleshooting flow chart (page 21-3).
  • Page 330 ELECTRIC SHIFT PROGRAM (ESP: TE/FE models) TROUBLESHOOTING (’00 ’02) TROUBLESHOOTING FEATURE When the ECU detects a system abnormality, it has a built-in self-diagnostic function that stops the Electronic Shift (ES) activity or resets the system entirely (just as when the ignition switch is turned from ‘‘OFF’’ to ‘‘ON’’). The ECU does not have the capability to inform the operator of the cause of the abnormality, except that the ES function stops immediately when the ECU detects a failure condition.
  • Page 331 ELECTRIC SHIFT PROGRAM (ESP: TE/FE models) FLOWCHARTS Turn the ignition switch to ‘‘OFF’’ unless otherwise specified. Inspect the following before diagnosing the system Make sure the battery is fully charged and in good condition Make sure the clutch is adjusted properly. Check for a blown fuse When the ECU is found to be faulty, recheck the connectors before replacing it.
  • Page 332 ELECTRIC SHIFT PROGRAM (ESP: TE/FE models) (From previous page: Continuity) Measure the resistance of the angle sensor at the Out of range Disconnect the angle sensor 3P (white) con- control unit 22P connector (page 21-20). nector and perform the same inspections at the angle sensor terminals.
  • Page 333 ELECTRIC SHIFT PROGRAM (ESP: TE/FE models) (From previous page: Normal) Measure the input voltage of the gearshift switch Abnormal Open or short circuit in related wire at the 10P connector (page 21-24). Loose or poor contact of related terminal Faulty ECU Normal Check for continuity of the gear position switch at Abnormal...
  • Page 334 ELECTRIC SHIFT PROGRAM (ESP: TE/FE models) Electric shift malfunction during vehicle operation Check that the speedometer functions properly and the engine operates normally before troubleshooting. If the speedometer does not function properly, perform the meter and vehicle speed sensor inspection (see section 20). Perform the previous troubleshooting ‘‘Electric shift does not operate’’...
  • Page 335 ELECTRIC SHIFT PROGRAM (ESP: TE/FE models) Electric shift does not operate when engaging the reverse gear Shift the gear manually using the gear change Abnormal Faulty transmission or gearshift linkage tool. (section 9 and 11) Normal Check for continuity of the reverse shift switch at Abnormal Faulty reverse shift switch the 8P (white) connector (page 21-25).
  • Page 336 ELECTRIC SHIFT PROGRAM (ESP) TROUBLESHOOTING (After ’02) BEFORE TROUBLESHOOTING When the Electric Control Unit (ECU) detects a system abnormality, it has a built-in self-diagnostic function that stops the Electric Shift (ES) system or resets the systems entirely (just as when the ignition switch is turned from ‘‘OFF’’ to ‘‘ON’’). If the ECU detects an ES system failure, the ECU stops the ES system function and records a problem code.
  • Page 337 ELECTRIC SHIFT PROGRAM (ESP) If the code number could not be checked (the indicator did not blink), repeat steps 2 and 4. If a failure is still not indicated (i. e., the ‘‘N’’ does not blink), the problem is as follows: Electric shift does not operate (page 21-10) and/or Faulty gear indicator (e.
  • Page 338 ELECTRIC SHIFT PROGRAM (ESP) ELECTRIC SHIFT DOES NOT OPETRATE Inspect the following before diagnosing the system. Make sure the battery is fully charged and in good condition. Make sure the clutch is adjusted properly. Blown main (30 A), motor (30 A) or sub fuse, ignition (10 A) Turn the ignition switch ‘‘OFF’’.
  • Page 339 ELECTRIC SHIFT PROGRAM (ESP) Disconnect the combination meter connector Abnormal Open circuit in White/Pink wire (14P). Loose or poor contact of related circuit Check for continuity of the White/Pink wire between the ECU connector and the combination meter connector terminals. CONNECTION: White/Pink ( ) White/Pink STANDARD: Continuity...
  • Page 340 ELECTRIC SHIFT PROGRAM (ESP) Problem Code 1: ECU (writing and recording circuit) Delete the problem code number. Blinks Replace the ECU with a new one and Check the ES system failure (the gear indicator troubleshoot again blinks) when turning the ignition switch from ‘‘OFF’’...
  • Page 341 ELECTRIC SHIFT PROGRAM (ESP) Problem Code 3, 8, 9: Angle Sensor System Check the connections of the ECU, angle sensor Abnormal Loose or poor contact of related circuit and related circuit. Normal Turn the ignition switch to ‘‘OFF’’. Disconnect the angle sensor connector (3P). Disconnect the ECU connector (22P/Brown).
  • Page 342 ELECTRIC SHIFT PROGRAM (ESP) Connect the angle sensor connector (3P). Abnormal Replace the ECU with a new one and Connect the ECU test harnesses between the troubleshoot again main wire harness and the ECU. TOOL: ECU test harness, 22P 07YMZ 0010100 With the ignition switch turned to ‘‘ON’’, measure the voltage between the Black/Red and the Blue/ Green terminals.
  • Page 343 ELECTRIC SHIFT PROGRAM (ESP) Problem Codes 4 or 12: Gear Position Switch System Check the connections of the ECU, gear position Abnormal Loose or poor contact of related circuit switch and related circuit. Normal Turn the ignition switch to ‘‘OFF’’. Abnormal Disconnect the gear position switch Disconnect the ECU connector (22P/Brown).
  • Page 344 ELECTRIC SHIFT PROGRAM (ESP) Problem Code 5: ECU Motor Driver Circuit Check the connections of the ECU, motor and Abnormal Loose or poor contact of related circuits related circuit. Normal Disconnect the ECU connector (5P/Brown). Abnormal Loose or poor contact of related circuits Measure the voltage between the Red/Yellow Blown fuse terminal and body ground.
  • Page 345 ELECTRIC SHIFT PROGRAM (ESP) Does not Connect a fully charged battery to the motor 2P Faulty motor turn connector terminals. Motor turns Check the ES system failure (the gear indicator Blinks Replace the ECU with a new one and blinks) when turning the ignition switch from troubleshoot again ‘‘OFF’’...
  • Page 346 ELECTRIC SHIFT PROGRAM (ESP) Problem Code 10: Ignition Pulse Generator System Check the connection of the ECU, ignition pulse Abnormal Loose or poor contact of related circuit generator and related circuit. Normal Check the connections of the ground cables. Abnormal Loose or poor contact of ground cable(s) Normal Disconnect the ECU connector (22P/Brown) and...
  • Page 347 ELECTRIC SHIFT PROGRAM (ESP) Problem Code 11: Vehicle Speed Sensor System Check the vehicle speed indicator during low Abnormal Check the combination meter (page 20-2) speed driving. Normal Check the connection of the Pink/Green and Black Abnormal Loose or poor contact of related terminals /Blue wires between the ECU and the vehicle speed sensor.
  • Page 348 ELECTRIC SHIFT PROGRAM (ESP: TE/FE models) ANGLE SENSOR SYSTEM INSPECTION 1. Total resistance: Turn the ignition switch to ‘‘OFF’’. Disconnect the ECU 22P (gray: ’00 ’02, brown: After ’02) connector. Measure and record the resistance between the Black/red and Blue/green terminals of the harness side control unit connector.
  • Page 349 ELECTRIC SHIFT PROGRAM (ESP: TE/FE models) Connect the control unit 22P (gray: ’00 ’02, brown: After ’02) connector. Measure the input voltage between the Black/red ( ) and Blue/green ( ) terminals of the angle sensor 3P connector with the ignition switch turned to ‘‘ON’’.

  • Page 350: Control Motor And Reduction Gears

    ELECTRIC SHIFT PROGRAM (ESP: TE/FE models) CONTROL MOTOR AND REDUCTION GEARS REDUCTION GEARS O-RING CONTROL MOTOR DOWEL PIN O-RING SENSOR COVER GEAR COVER ANGLE SENSOR MOTOR Replace the control motor as an assembly. REMOVAL Remove the sensor cover (page 21-21). Remove the three wire bands from the fame down tube and release the motor wire from the wire clip on the frame cross member.
  • Page 351 ELECTRIC SHIFT PROGRAM (ESP: TE/FE models) INSTALLATION Coat a new O-ring with engine oil and install it into the groove in the motor. Install the control motor and tighten the mounting bolts. Route the wires Connect the motor 2P connector and secure the properly ( page motor and angle sensor wires with the wire clip 1-22).

  • Page 352: Gearshift Switch

    ELECTRIC SHIFT PROGRAM (ESP: TE/FE models) Install the following: gear cover control motor (page 21-23) angle sensor (page 21-21) GEARSHIFT SWITCH SYSTEM INSPECTION Disconnect the ECU 22P (gray) connector. Check for continuity between the terminals of the connector in each switch position. Continuity should exist between the color coded wires as follows: Color...
  • Page 353 ELECTRIC SHIFT PROGRAM (ESP: TE/FE models) REVERSE SHIFT SWITCH INSPECTION Remove the seat (page 2-4). Remove the alternator 5P and gear position/reverse shift switch 8P connectors from the frame. Disconnect the gear position/reverse shift switch 8P (white) connector and check for continuity between the Gray/red terminal of the switch side connector and ground.
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  • Page 355: Wiring Diagrams

    22. WIRING DIAGRAMS USA TM MODEL 22-1 USA TE/FE After 02 MODELS 22-5 USA FM MODEL 22-2 CANDADA TE/FE 00-02 22-6 MODELS CANADA TM/FM MODEL 22-3 CANDADA TE/FE After 02 22-7 MODELS USA TE/FE 00-02 MODELS 22-4 22-0...
  • Page 356 WIRING DIAGRAMS USA TM model 22-1...
  • Page 357 WIRING DIAGRAMS USA FM model 22-2...
  • Page 358 WIRING DIAGRAMS Canada TM/FM models 22-3...
  • Page 359 WIRING DIAGRAMS USA TE/FE 00-02 models 22-4...
  • Page 360 WIRING DIAGRAMS USA TE/FE After 02 models 22-5...
  • Page 361 WIRING DIAGRAMS Canada TE/FE 00-02 models 22-6...
  • Page 362 WIRING DIAGRAMS Canada TE/FE After 02 models 22-7...

  • Page 363: Technical Features

    23. TECHNICAL FEATURES DRY SUMP MECHANISM OF INTEGRAL ELECTRIC SHIFT PROGRAM OIL TANK IN CRANKCASE 23-1 (ESP: TE/FE models) 23-6 A.P.SURETRAC TORQUE BIASING LIMITED SLIP DIFFERENTIAL 23-3 DRY SUMP MECHANISM OF INTEGRAL OIL TANK IN CRANKCASE This engine was designed and manufactured to reduce the overall height of the engine body and to reduce the size of the entire lubrication system.
  • Page 364 TECHNICAL FEATURES OIL MANAGEMENT SYSTEM DRAWING: OIL TANK: OIL SUPPLY AND DRAIN PART DETAIL (FRONT CRANKCASE): Pour Overflow OIL TANK SECTION OIL TANK WALL SCAVENGE SIDE SUPPLY HOLE FEED SIDE SUPPLY HOLE Return from oil cooler STRAINER DRAIN BOLT To oil pump (feed side) Drain If the engine is not operated for a long time, the engine oil will drain to the bottom of the crankcase from the oil tank section through the crankcase mating surface.
  • Page 365 TECHNICAL FEATURES A.P. SURETRAC TORQUE BIASING FRONT DIFFERENTIAL CONSTRUCTION In this mechanism, torque is transmitted through the differential using a cam and follower principle. The differential is groove-fitted in the differential case (which receives torque from a ring gear) so that the cam followers can move to the left and right.
  • Page 366 TECHNICAL FEATURES CONVENTIONAL TYPE Torque transmission: Ring Gear Differential Case Pinion Shaft Pinions Side Gears Drive Shafts Tires Absorption of differential rotation: Self-turning pinion absorb difference in rotation of the side gears (left and right tires). Differential limit: Initial torque The cone springs in a multi-disc clutch imparts axial load in the thrust direction, producing initial torque.
  • Page 367 TECHNICAL FEATURES DIFFERENTIAL OPERATION Figure 1 shows the conditions when one wheel wants to spin, that is, tries to rotate faster than the differential case. The torque generates a force applied to the flank of the follower dog from the differential case spline, which is then shared between the two face cams by forces on the inclined faces.
  • Page 368 TECHNICAL FEATURES ELECTRIC SHIFT PROGRAM (ESP: TE/FE models) Electric Shift Program (ESP) is designed to make gear shift operation easier by replacing conventional foot-operated shift change with a switch located near the operators hand. GEARSHIFT SWITCH FUSE BOX BATTERY IGNITION SWITCH ELECTORONIC CONTOROL UNIT SPEED SENSOR...
  • Page 369 TECHNICAL FEATURES COMPONENT DIAGRAM GEARSHIFT COMBINATION CONTROL MOTOR IGNITION PULSE GENERATOR SWITCH METER REVERSE SHIFT SWITCH SHIFT DRUM IGNITION SWITCH BATTERY GEAR POSITION SWITCH ANGLE SENSOR TRANSMISSION CLUTCH SPEED SENSOR Shift Position Indicator The shift position indicator incorporated in the combination meter indicates the current shift position, as it receives the signal from the gear position switch.
  • Page 370 TECHNICAL FEATURES Angle Sensor The angle sensor, installed on the front crankcase cover, converts the direction of rotation, rotating angle and rotating speed of the sub-gearshifts spindle into a voltage change and speed change and outputs them to the Electronic Control Unit. Gear Position Switch The gear position switch, installed inside the rear crankcase cover, sends gear position signals to the Electronic Control Unit.

  • Page 371: Troubleshooting

    24. TROUBLESHOOTING ENGINE DOES NOT START OR IS POOR PERFORMANCE AT HIGH SPEED 24-4 HARD TO START 24-1 POOR HANDLING 24-4 ENGINE LACKS POWER 24-2 POOR PERFORMANCE AT LOW AND IDLE SPEED 24-3 ENGINE DOES NOT START OR IS HARD TO START Possible cause Check fuel flow to carburetor Not reaching carburetor...
  • Page 372 TROUBLESHOOTING ENGINE LACKS POWER Possible cause Raise wheel off the ground and spin Wheel does not spin Brake dragging by hand freely Worn or damaged axle or wheel bearing Wheel spins freely Check tire pressure Pressure low Faulty tire valve Punctured tire Pressure normal Check for slipping clutch...
  • Page 373 TROUBLESHOOTING From previous page Possible cause Remove cylinder head cover and Valve train not lubricated Clogged oil passage inspect lubrication properly Clogged oil orifice Valve train lubricated praperly Accelerate or run at high speed Engine knocks Worn piston and cylinder Use of poor quality fuel Excessive carbon build-up in Engine does not knock...
  • Page 374 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED Possible cause Disconnect fuel tube at carburetor Fuel flow restricted Restricted fuel tube Restricted fuel tank breather tube Faulty fuel valve Fuel flows freely Clogged fuel strainer Check carburetor for clogging Clogged Carburetor not serviced frequently enough Not clogged Check valve timing...

  • Page 375: Table Of Contents

    25. INDEX ACCESSORY SOCKET ..........20-4 ENGINE OIL FILTER ..........3-11 AIR CLEANER ............3-6 ENGINE REMOVAL ..........6-2 AIR CLEANER HOUSING ......... 5-3 EXHAUST SYSTEM ..........2-10 AIR CLEANER HOUSING DRAIN HOSE ....

  • Page 376: Table Of Contents

    INDEX SERVICE INFORMATION FRONT WHEEL/SUSPENSION/STEERING .... . 12-2 ALTERNATOR/STARTER CLUTCH ......10-1 FUEL SYSTEM ............5-2 BATTERY/CHARGING SYSTEM ......17-1 IGNITION SYSTEM ..........18-2 BRAKE SYSTEM ............14-1 LUBRICATION SYSTEM .......... . 4-1 CLUTCH/GEARSHIFT LINKAGE ......

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