HOW TO USE THIS MANUAL CONTENTS

Follow the competition Maintenance Sched ule GENERAL INFORMATION

recommendations (Page 3-2) to ensu re that the
vehicle is always in peak operati ng co ndition. LUBRICATION

Sections 1 t hrough 3 apply to the w hole motor- MAINTENANCE

cycle, white sections 4 through 15 describe
parts of the motorcycle, grouped acco rd ing to
FUEL SYSTEM
location.

Find the section you want on this page, then ENGINE REMOVAL/INSTALLATION
turn to the table of contents on page 1 of
that section. CYLINDER HEAD/CYLINDER/PISTON

Most sections start with an assembly or system

illustration and specif icat ions, torque values,
genera l instructions, tools and t ro ubleshoot- CLUTCH/ KICKSTARTER/SHIFT LINKAGE
ing for the section. The subsequent pages give
detailed proced ures for the section.

If you don't know the source of a problem,

see section 16.

~ REAR WHEEL/BRAKE/SUSPENSION
"' i=============
:.! HYDRAULIC BRAKE (After '85)
U ~===================
SUB FRAME/ EXHAUST PIPE

IGNITION SYSTEM

TROUBLESHOOTING

INDEX
 1. GENERAl INFORMATION
GENERAL SAFETY ,-, TORQU E V ALUES ' -6
SERVICE RULES ,-, TOOLS , -B
MOOEL IOENTIFICATION ' -2 CABLE AND HARNESS ROUTING , -'0
SPECIFICATIONS , -4 OPTIONAL PARTS , -, 5

GENERAL SAFETY
11i1B;iillii<i 'MI·iMI!!;
If 'h~ ~nlinr mwt be run"lnl to do some ...·ork, mah sure the Gasoline is utnmely [Iommoble and is aplosivr under
arN is wdJ·ventiloted. Never run the engine In a closed area, analn conditions. Work in Q W#!// Vl!ntilated area with the
The exhaust contains poisonous carbon monoxide gas that engine stapp«!. Do not smoke or allow flames or sparles in
may cause loss oj consciousness and lead 10 death. your working area or where gasoline is stored.

["holed asbestos fibers hD~ bNn found 10 cause res-

"''hP'
Us~ only nltoro,~n to pressurll~ th~ shock QbsorfHr.
piratory disease and Cilncer. Ne~' use 4n air hose or Th~ us~ 0/ an unstab/~ gas may I:IWS~ a rlr~ or uplosion
dry brush 10 clNn brake or clutch o~mbl;es. resulting In s~riow injury.
In the Uniud Slaus, use on OSHA;Jpproved vacuum The r~r shock absorber contains nitrogen gas under
cleaner or alternote method approwd by OSHA de- high pressure. Do not 0110 w fire or heat near the rear
signed to minimize the lunard caused by airborne shock absorber.
asbestos fibers. &fore disposal of the shol:k absorber, re/elm! the
njtrog~n by pressing the Wll~ core, Then remo'/Je the
ra/~ from the shode obsorber.

CAUTION
Used engine oil (or transmission oil in two- strokes) may cause
skin cancer if repeatedly left in contact with the skin jar
prolonged periods. Although this is unlikely unless you handle
wed oil on a daily basis, il is still advisable to th roughly wash
your hands with soap and water as soon as possible after han-
dling used oil.

SERVICE RULES
1. Use genuine HONOA or HONDA-recommended parts and lubricants or their equivalent_ Parts that do not meet HONDA's
design specifications may damage the motorcycle.
2. Use the special tools designed for this product.
3. Use only metr ic tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English
fasteners. The use of incorrect tools and fasteners may damage the motorcycle.
4. Install new gaskets, O·rings, cotter pins, lock plates, etc. when reassembling.
5. When tightening bolts or nuts. begin with larger-diameter or inner bolts first, and tighten to the specified torque diagonally,
in 2-3 steps, unless a particular sequence is specified.
6 . Clean parts in non-flammable or high flash point solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
1. When installing a new oil seal, make sure that the sealing lip is lubr icated with grease. If an oil seal and related parts have
been washed, apply the proper grease to the lip of the oil seal.
8. After reassembly, check all parts for proper installation and operation.

1-1
GENERAL INFORMATION

MODEL IDENTIFICATION
' 86 : ' 86:

' 88 shown; ' 87 through ' 90 similar: After '9' :

1-2
 GENERAL INFORMATION

III FRAME SEFIIAI_NL

(1) The frame serial number is stamped on the left side (2) The engine serial number is stamped on the lower left
of the steering head . side of t he crankcase .

(31 The carburetor identif ication number is on the car-

buretor right side.

1-3
GENERAL INFORMATION

SPECIFICATION
Dimension Overall length '85, ' 86 1,810 mm 71.3 in
After ' 86 1,815 mm 71.5 in
Overall width ' 85 760 mm 29.9 in
After ' 85 745 mm 29.3 in
Overall height '85, ' 86 1 ,070 mm 42 . 1 in
After ' 86 1,OBO mm 42 .5 in
Wheelbase ' 85, '86 1,250 mm 49.2 in
After '86 1,255 mm 49.4 in
Seat height '85 820 mm 32.3 in
'86 800mm 31.5 in
After '86 810 mm 31.9 in
Foot peg height 390 mm 15.4 in
Ground clearance '85, '86 305 mm 12.0 in
After '86 310 mm 12.2 in
Dry weight ' 85 62 kg 136.71b
'86 62. 5 kg 137.81b
'87 -' 91 62 .1 kg 138.2 Ib
After '9 1 63.0 kg 138.9 Ib
Frame Type Semi-double cradle
Front suspension, travel ' 85, '86 Air assist. telescopic fork, travel 260 mm (10.2 in)
After ' 86 Air assist, telescopic fork. travel 275 mm (10.8 inl
Rear suspension, travel '8 5, '86 Pro link, travel 270 mm (l0.6 in)
After ' 86 Pro link, travel 280 mm 111 .0 in)
Front tire size, pressure ' 85 80/ 80-17 41 M , air pressure 100 kPa (LO kg /cm 2, 15 psi)
After '85 70/ 100-17 40M, air pressure 100 kPa (1.0 kg fc m 2 , 15 psi)
Rear tire size, pressure '85 110/ 80-14 53M, air pressure 100 kPa (LO kg fcm 2 , 15 psi)
After '85 90/ 100·14 49M, air pressure 100 kPa 11.0 kg /cm 2 , 15 psi)
Front brake, swept area ' 85 Cable operated leading shoe, lining swept area 59.7 cm 2 19.3 in2)
After ' 85 Single disc brake, swept area 174.2 cm 2 127.0 in 2 )
Rear brake, swept area ' 85 - '9 1 Cable operated leading shoe, lining swept area 53 .4 cm2 18.3 in 2 )
After ' 91 Single disc brake, swept area 131.2 cm 2 120.3 in2)
Fuel capaci ty 5, 1.3 US gal , 1 . 1 Imp gal
Caster angle '8 5, ' 86 26 ° 50'
After ' 86 26 ° 40'
Trail length '8 5, '86 73mm 2 .9 in
After ' 86 79mm 3,1 in
Fork oil capacity ' 85 273 cc 9 .2 US OZ, 9 .6 Imp oz
IStandard ) '86 287 cc 9 . 7 US OZ , 10. 1 Imp oz
'87 308 cc 10.4 US OZ , 10.8 Imp oz
' 88 - ' 91 305 cc 10.3 US OZ, 10 . 7 Imp oz
After ' 91 309 cc 10.4 US OZ , 10.8 Imp oz

1-4
 GENERAL INFORMATION

Engine Type liquid cooled , 2·stroke

Cylinder arrangement Single ' ,5 0 inclined from .... ertical
Bore and stroke 47.0)( 47 .8 mm 1 .85 )( 1.88 in
Displacement 82 .9 cc 5.06 cu in
Compression fat io ' 85 8.2 : 1
' 86 8 .7 : 1
After ' 86 8.4 : 1
Transmission oil capeci- '85, '86 0 .55 , 0.58 US qt, 0.48 Imp qt
ty at disassembly After '86 0 .60 I 0.63 US qt. 0 .53 Imp qt
Transmission oil capaci- ' 85, ' 86 0 . 50 t 0.53 US qt, 0 .44 Imp qt
ty at change After '86 0 . 55 t 0.58 US qt, 0.48 Imp ql
Coolant capacity '85, '86 0 .53 t 0.56 US qt, 0.47 Imp qt
After '86 0.43 I 0.45 US qt, 0 .38 Imp qt
Carburetor Type '85 Piston valve PE67B
'86 Piston valve PE68A
After '86 Piston valve PE68B
Main jet (standard) ' 85 #155
' 85 #128
After ' 86 #125
Slow jet Istandardl ' 85 #42
After ' 85 #52
Air screw initial opening '85 1- 1{2 turns out
After ' 85 2 turns out
Float height 19.0 mm 0.75 in
Throttle bore 30mm 1.2 in
Venturi diameter 28 mm 1. 1 in
Drive train Clutch type Wet , multi-plate type
Transmission 6-speed, constan t mesh
Primary reduc tion 4. 117 : 1
Gear ratio I 2.333 : 1
Gear ratio II 1.722 : 1
Gear ratio III 1.400 : 1
Gear ratio IV 1.174 : 1
Gear ratio V 1.000 : 1
Gear ratio VI 0 .885 : 1
Final reduction 3 .267, drive sproket 15 T , driven sproket 49 T
Gearshift pattern left foot operated return system, l - N - 2-3-4 - 5 - 6
Electrical Ignition COl
Starting system Kickstarter
Spark plug '8 5 CHAMPION: QN-2C
NGK : BASES
After '85 NGK : BA10EG

1-5
GENERAL INFORMATION

TORQUE VALUES
ENGINE

Torque
Item Thread die . mm
Nom kg-m ft- Ib

Cylinder head nuts 8 25 - 29 2.5 - 2.9 18-21

Cylinder mounting nuts 8 25 - 29 2.5 - 2.9 18 - 21
Flywheel nut 12 50- 60 5.0-6.0 36 - 43
Drive gear nut °85 12 45 - 55 4.5 - 5.5 33 - 40
Atter '85 12 50 - 60 5.0-6.0 36 - 43
Oil drain bolt 12 20 - 30 2.0-3.0 14 - 21
left crankcase cover screw s 6 5-" 0.5 - 0 .9 4- 7
Clutch center bolt 10 40 - 50 4.0 - 5.0 29 - 36
Water pump impeller 7 8 - 12 0.8 - 0.2 6- "
Carburetor insulator bolts 6 7 - 11 0.7 - 1.1 5-8
Oil check bolt 6 7-1 1 0.7 - 1.1 5- 8
AT AC ra ck plug °85 8 5- 8 O.S - O.B 4-6
AT AC rack adjusting lock nut °85 5 4- 6 0.4 - 0 .6 3-5
Cylinder coolant drain bolt 6 7 - 11 0 .7 - 1.1 5-8
Drive sprocket bolt 6 10 - 16 1.0 - 1.6 7 - 12
Spark plug 14 12 - 19 1.2 - 1.9 9 - 14
Shift drum center bolt 8 24 - 30 2.4 - 3.0 17 - 21

FRAME

Torque
Item Thread die. mm
Nom kg-m ft-Ib
Steering stem nut °85 22 60 - 90 6.0 - 9.0 43-65
'86-'91 22 90 - 120 9 .0 - 12.0 65 - 90
After '91 24 80 - 120 8.0 - 12.0 60 - 90
Fork upper pinch bolts 8 18-25 1.8 - 2.5 13 - 18
Handlebar holder bolts 8 18 - 25 1.8 - 2.5 13 - 18
Fork lower pinch bolts 8 18 - 25 1.8 - 2.5 13 - 18
Front axle nut 12 55 - 70 5.5 - 7.0 40 - 50
Engine mounting bolts '85, '86 8 30-35 3 .0 -3 .5 22-25
After '86 8 44 - 50 4.4-5 .0 32 - 36
Brake lever pivot nut After '86 6 8 - 12 0.8 - 1.2 6- "
Brake lever pivot bolt After ' 86 6 8 - 12 0.8 - 1.2 6- "
Clutch lever pivot bolt After '86 6 1- 3 0 . 1 - 0 .3 1-2
lock nut After '86 6 8 - 12 0.8-1.2 6-"
Rear axle nut °85 12 55 - 70 5.5 - 7.0 40 - 50
After '85 14 80 - 100 8.0 - 10.0 58 - 72
Wheel bearing retainer After '85 - 15 - 25 1.5 - 2.5 11 - 18
Final driven sprocket socket bolts 8 28 - 34 2.8 - 3.4 20 - 25
Rear brake pedal pivot bolt 8 18 - 25 1.8 - 2.5 13 - 18
Swing arm pivot nut 14 70- 90 7.0 - 9.0 50 - 65
Gearshift pedal bolt 6 8 - 12 0.8 - 1.2 6- "
Kickstarter pedal bolt 6 10 - 14 1.0- 1.4 7-10
Fork cap bolt 2" 15 - 30 1.5 - 3.0 11 - 21
Rear shock absorber mounting bolts (upper) 10 40-50 4.0-5.0 29-36
(lower) 10 38 - 48 3.8 - 4.8 27 - 35
Damper spring lock nut - 60 - 80 6 .0 - 8.0 43 - 60
Compression damping valve After '85 - 18 - 22 1.8 - 2.2 13 - 16

1-6
 GENERAL INFORMATION

FRAME

Torque
Item Thread die . mm
N·m kg-m ft -Ib
Rear shock absorber linkage pivot bolts 10 40 - 50 4.0- 5.0 29 - 36
Wheel spokes B.C. 2.9 2.5 - 5.0 0.25-0.5 1.8 - 3.6
Handle lever holder screws 5 1- 2 0.1-0.2 0 .1-1. 4
Throttle grip housing bolts 6 8 - 12 0.8 - 1.2 6- 9
Seat bolts 6 8 - 12 0.8 - 1.2 6-9
Sub frame bolts 8 18 - 25 1.8 - 2.5 13 - 18
Steering adjustment nut - 1-2 0.1 - 0.2 0.7 - 1.4
Fork socket bolt 8 15 - 25 1.5 - 2.5 11 - 18
Resr brake torque link bolts '85-'9 1 8 18 - 25 1.8 - 2.5 13 - 18
Rear shock piston rod end nut 12 10 - 15 1.0 - 1.5 7- 11
Brake caliper bleeder After ' 85 - 4- 7 0.4 - 0 .7 3- 5
Caliper mounting bolt After '85 8 18 - 25 1.8 - 2.5 13 - 18
Caliper hanger pin After '85 10 15 - 20 1.5 - 2.0 11 - 14
Brake hose joint (master cylinder) After '85 10 30 - 40 3.0 - 4.0 22 - 29
(brake hose) After ' 85 10 12 - 15 1.2 - 1.5 9 - 11
Brake hose banjo bolt fbrake caliper) After '85 10 30 - 40 3.0-4.0 22-29
Caliper slide pin After ' 85 8 20 - 25 2.0 - 2.5 14-18
Front brake disc mount bolt ' 85 -' 91 6 14 - 16 1.4 - 1.6 10 - 12
After '91 6 20-24 2.0 - 2.4 14 - 17
Rear brake caliper pin bolt After '91 8 10 - 15 1.0-1.5 7 - 11
Rear brake caliper pin bolt A After ' 91 12 25 - 30 2.5-3.0 18 - 22
Brake caliper hanger pin plug After '9 1 10 2- 3 0.2 - 0.3 1.4 -2
Rear brake disc mount bolt After '91 6 18 - 22 1.8 - 2.2 13 - 16
Rear master cylinder bolt After '91 6 14 - 16 1.4 - 1.6 7 - 12
Rear fender bolt 6 8 - 12 0.8 - 1.2 6- 9
The torque values listed above are for the most important fasteners . If a torque specification is not listed, use the standards
given below :

STANDARD TORQUE VALUES

Torque Torque
Size Size
N·m kg -m ft-Ib N·m kg-m ft -Ib

4 mm bolt 3- 4 0.3 - 0.4 2- 3 6 mm SH flange bolt 7 - 11 0 .7- 1.1 5- 8

6 mm screw 7- 11 0 .7 - 1.1 5- 8 6 mm flange nut 10- 14 1.0-1.4 7 - 10
6 mm hex . bolt 8- 12 0.8 - 1.2 6- 9 8 mm flange bolt 24 - 30 2.4 - 3 .0 17 -2 1
8 mm hex . bolt 18 - 25 1.8 - 2 .5 13 - 18 10 mm flange bolt 35-45 3 .5 - 4 .5 25 - 33
10 mm hex . bolt 30- 40 3 .0 - 4 .0 22 - 29

1-7
GENERAL INFORMATION

TOOLS 1
'85 fin d Aftef '8 5

SPECIAL

Description Tool No. A lternative Tool No. Aef. page

Universal bearing puller 07631 -0010000 Commercially available in 9-8

U.S. A.
Steering stem socket 07916-3710100 11-24, 11 · 26
Clutch center holder 07923 - 9580000 Not available in U.S.A. 8 · S, 8 · 9
Bearing remover, 7 mm 07931 -KA30000 10-8
Bearing driver. 7 mm 07946 -KA30100 10-8
Bearing remover set, 12 mm 07936 - 1660001 9-6, 10-8
Remover weight 07741 -00 10201 Remover weight 07936 - 3710200 9-6, 10-8
Case puller 07937 - 4300000 9-3, 9-7
Attachment, 28 x 30 mm 07946 - 1870 100 9-7, 10· B,
11·12
Ball race remover ' 85, ' 86 07944 - 1150001 Adjustable bearing puller 07736 - A01000A 11-25
(U.S.A. only)
After ' 86 07953 - 1150001 07953 - 42S000Z 11-25
Ball face remover attachment ' 86 07GMO-GC40100 Adjustable bearing puller 07736 - A01000A 11-25
07953 - MJ10001A 11-25
After' 86 07948 - 46301 00 Bearing remover (U.S.A . only)
attachment
8earing driver 07946 - 6920100 11 -25
Water seal driver 07945 - KA3OO00 Mechanical seal installer GN - AH - 065 - 415 10-9
(U.S.A. only)
Steering stem driver 'S5 ' 86 07946 - GC4000Q Adjustable bearing puller 07736 - AOloo0A 11-26
Attachment 07946 - GC40001A
(U.S.A. only)
Steering slem driver 07946 - MBOOOOO
Sleering stem driver After ' 86 07946 - 4300101 11-26
Spherical bearing driver 07946 - KA302oo 12-32,12-37,
12-38
Spherical bearing driver After ' 87 07946 - KM40701 12-38
Dis/assembly tool B 07964 - MB00200 12-36, 12-37
Needle bearing driver 07946 - KA50000 12-36
Driver 07946 - MJool00 9-7
Assembly bolt 07965 - 1660200 9-9,9-12
Assembly collar 07965 - 1660300
Piston ring slider set '8 5, ' 86 07974 - GC40000
After ' 86 07HMG - GC40000
- Sleeve collar 07974 - GC401oo 12-23
- Piston ring slider ' 85, ' 86 07974 - GC402oo
After ' S6 07HMG - GC402oo
Slider guide, 12 mm 07973 - GC40000 12-28
Snap ring pliers After '85 07914 - 3230001 Commercially 13-8, 13- 12
available in U.S. A . 13-13, 13-14

1-8
 GENERAL INFORMATION

COMMON

Description Tool No . Alternative Tool No. Ref. page

Float level gauge 07401 - 0010000 4-17

Spoke wrench B, 4 .5 x 5.1 mm 07701 - 0020200 Commercially 3- 16
Spoke wrench C, 5.8 x 6.1 mm 07701 - 0020300 available in U.S.A.
Lock nut wrench, 30 x 32 mm 077 1 6 - 0020400 Commercially 11 -24, 11 -27
Extension bar 07716 - 0020500 available in U.S.A.
Universal holder 07725 - 0030000 Universal holder 07725 - 0010101 9 ·3 , 9- 12 ,
10-7, 15-3
Flywheel puller 07733 - 0010000 Flywheel puller 07933 - 0010000 15· 3
Attachment , 24 )( 26 mm 07746 - 0010700 12-38
Attachment , 32 )( 35 mm 07746 - 0010100 12-9 , 12-11
Attachment , 37 )( 40 mm 07746 - 0010200 , 1-25 , 12-9
Attachment , 42 x 47 mm
Attachment, 52 x 55 mm
Pilot, 10 mm '85
07746 -
07746 -
07746 -
0010300
0010400
0040100
.-.
9-7, 11-25

11 - 12
Pilot , 12 mm 07746 - 0040200 10-8 , 12-9
Pilot , 15 mm After '85 07746 - 0040300 12- 10, 12- 11
Pilot , 17 mm 07746 - 0040400 . -7
Pilot , 20
Pilot , 22
Pilot, 25
mm
mm
mm
' 85 07746 -
0774 6 -
07746 -
0040500
0041000
0040600
.-.
. -7

9-7
Driver 0774 9 - 0010000 9-7, 9 -9 ,
10-8
Driver, B 07746 - 0020100 12-27
Attachment, 20 mm I.D. 07746 - 0020400 12-27
Bearing remover expander 07746 - 0050100 11-11 , 12-7,
12-8
Bearing remover cottet, 10 mm 07746 - 0050200 Commercially 11 - 1 1
'85 available in U.S.A .
Bearing remover collet, 12 mm 07746 - 0050300
Bearing remover coUet, 15 mm 07746 - 0050400 12-7
After '85 12-7 , 12-8

Fork seal driver 07747 - 00 10100 11 -21

Fork seal driver attachment 07947 - 3330000
' 85 07747 - 00 10500 1 1-21
'86 07747 - 0010501
After ' 86 07947 - KA20200
Primary gear holder 07724 - 0010200 Not available in U.S.A . 8 -6 , 8-8
Retainer wrench body '86 - '87 07710 - 0010401 12- 7
Retainer wrench C '86 - ' 87 07710 - 0010301 12- 7

1-9
GENERAL INFORMATION

CABLE AND HARNESS ROUTING 0: CORR ECT

X: INCORR ECT
Note the following when routing cables and wire harnesses:

• A loose wire, harness or cable can be a safety hazard. After

clamping, check each wife to be sure it is secure.

• Do not squeeze a wire against a weld or end of its clamp

when 8 weld -on clamp is used.
o X
QOOl
• Secure wires and wife harnesses to the frame with their
respective wire bands at the designated Iceations . Tighten
the bands so that only the insulated surfaces contact the
wires or wire harnesses .

• leave a little slack w hen routing harnesses.

Avoid pulling the harness too tight or leaving excessive slack.

• Protect wires and harnesses with electrical tape or tubes if

they contact a sharp edge or corner.
Clean the attaching surface thoroughly before applying
tape .

• Do not use wires or harnesses with broken insulators.

Repair by wrapping them with protective tape or replace
them.
o x x
• Aoute wire harnesses to avoid sharp edges or corners. Also
avoid the projected ends of bolts and screws.

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

x
• 8e sure grommets are seated in their grooves properly .

• After clamping, check each harness to be certain that it is

not interfering With any moving or sliding parts.
x x
• Wire harnesses routed along the handlebars should not be
pulled taut, have excessive slack, be pinched by, or in-
terfere with adjacent or surrounding parts in all steering
positions .

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

• Do not bend or twist control cables . Damaged control

cables will not operate smoothly and may stick or bind.

1-10
 GENERAL INFORMATION

'85,

(1) CLUTCH CABLE

(2) THROTTLE CABLE

(4) CARBURETOR HOSES

(3) ALTERNATOR
WIRES

(2) THROTTLE CABLE (5) FRONT BRAKE CABLE

(8) SHOCK RESERVOIR

(6) IGN ITION CO I L

171 CO l
UNIT ------:;!ft'I:d ~~~ ~

(1) CLUTCH
CABLE

1-11
GENERAL INFORMATION

'96-'9 1:

(1) THROTTLE
CABLE

(4)

(5) CARBURETOR HOSES

(3) ALTERNATOR
WIRES
121 FUEL MOUNTING RUBBER

(4) BRAKE HOSE

(9) SHOCK RESERVOIR (1) T",Rm"
CABLE '87 -'91 :

(8) IGNITION
COIL
'"A,L .\,,:;W
..:::

(7) CLUTCH CABLE (6) COl UNIT

1-12
 GENERAL INFORMATION

After '9 1:

(1) THROT LE CABLE (2) BREATHER TUBE

(4 ) (3 ) C UTCH CABLE
ENGINE STOP' --+PR F
8unON WIR E
(5) BRAKE HOSE

CABLE

(6 ) IGNITION COil

W\1"\\-~--- (3:) FRONT BRAKE

HOSE

m - - ' 41 CLUTCH CABLE

1-13
GENERAL INFORMATION

After '91 :

1) THROTTLE CABLE

(2) DAMPER HOSE

"KINT BRAKE

(4) CARBURETOR
AIR VENT
TUBe

(5) CRANKCASE
BREATHER
TUBe
~2) HOSE

(6) CARBURETOR OVERFLOW TUBe

1-14
 GENERAL INFORMATION

OPTIONAL PARTS
ITEM REMARKS
FRAME:
Driven sprocket '85: 47T
5IT
(Standard : 49T)
'86-'87: Aluminum, 47T
Aluminum, 51 T
(Standard: 49TI
After '87: Aiuminum,47T
Steel, 49T (For mud and sand tracks)
Aluminum.51T
(Standard: 49T)
Drive chain ' 85 : 116 links: Daido, Takasago
1 1Slinks: Dsido, Takasago
(Standard : 114 Links)
After ' 85 : 116 links: AK420M$
116 links: 420MBK
(Standard: 114 Links)

Fork spring '85 :

Type Spring rate Remarks
0.24 kg/ mm
light duty 2 grooves
(13.4 Ib/ in)
0.26 kg /mm
Standard
(14.6Ibfin)
4 grooves ~GROOVE
0.28 kg/ mm
Heavy duty 6 grooves
(15 .7Ib/inl

' 86:
Type Spring rate Remarks
0 .24 kg/mm
light duty
(13.4lb/ in)
2 coils
~ 2 coits

0.26 kg/ mm
Standard
(14.6 Iblin)
, coil
~ 1 coil

0.28 kg/mm
Heavy duty
05 .7 Iblinl
3 coils
~ 3 coils

'87:
Type Spring rate Remarks
0.24 kg/mm
Light duty 1 groove
t 13.4 Ib/in)
0.26 kg/mm
Standard
(14.6 Ibl in)
No grooves f§i- GROOVE
0 .28 kgl mm
Heavy duty 2 grooves
t15.7 tb/in)

After '87: Ty", Spring rate Remarks

0.26 kg/mm
Light duty 1 groove
(14.6 Ib/in)

Standard
0.29 k.g /mm
No grooves ~GROOVE
(16.3Ib/ in)
0 .3 1 kg/mm
Heavy duty 2 grooves
(17.3 tb/in)

1-15
GENERAL INFORMATION

ITEM REMARKS

Shock spring
Type Spring rate Remarks
3.9 kg/ mm
light duty light green paint
(218 Ib/in)
4 .3 kg/ mm
Standard
(241 Ib/ln)
Pink paint ~ PAINT
4 .7 kg/mm
Heavy duty Gray paint
~263 Ib/;n)

'86:
Type Spring rate Remarks
4.1 kg/ mm
Light duty Red paint
(229 Ib/ in)
4.5 kg/ mm
Standard
(252 Ib/in)
Black paint ~PAINT
4.9 kg/ mm
Heavy duty White paint
(274 Ib/in)

[After '87]
'87 Type Spring rate Remarks
4.0 kg/ mm Red paint
light duty
(224 Ib/in) (Yellow paint]
4.4 kg/ mm Black paint
Standard
(246 Ib/in) (No paint}
~PAINT
4 .8 kg/ mm White paint
Heavy duty
(269 Ib/in) [Blad< paint1

Work stand For maintenance service ...:: ~

Air pressure gauge For adjusting non-standard fork air pressure .

Pin spanner For shock absorber spring

"
~y
length (preload) adjustment (two)
ENGINE : Oversize piston
'85 : 0 .2 5 mm, 0.50 mm (2 sizes)
The cylinder must be rebored , and an oversize piston and piston rings fitted if
worn or seized . Use the corre ct oversize piston rings with an oversize piston .

NOTE:

;M
Pilton POllan M.nufklUf"'1I
ov..-';a T~If\C. After reboring . remove all burrs from each port edge and chamfer as indicated
0 .25mm 41.195 • 1210 mm below .
(0.0 1 inl 0.8581-1.8581 inl 1.2mm
I - 2R
O.SOmm 41 .445 41460 mm 1.2 mm

~
(0.02 inl 11.8619-18685 inl
o
Oo.ammao
03
. mm ~ 0.5R mm

-'
1.2 mm 0.3mm

1-16
 GENERAL INFORMATION

ITEM REMARKS

Before reborlng the cylinder, follow the contour of the exhaust port bridge with your
fingers so that the original radius can be restored after boring .
Radius the bridge carefully by hand with a cutting stone.

CAUTION
. Failure to radius this bridge
could cause Q seized piston.
A
1-3mm

)
U
r
8
.
\
EXHAUST PORT
Be care!ul no/ /0 damage the
cylinder ""II when radi-
using the bnage.
r-0.05-0.08 - BRIDGE

mm

~A~I-3mm~~
A-A'
Alter '85: There are no oversize pistons for these models. The engine uses sleeveless, aluminum
cylinders Icalled NS plated cylinder} with 8 special costing on the piston sliding surfaces.

CARBURETOR :
Main jet ' 85:

' 86:
#140 /I 170 (in increments of 2 or 3)
Standard: "155
#118-#138 lin increments of 2 or 3) (8 sizes)
J/,(5~; ~
M.ri<
Standard: #128
After '86: #115-#135 (in increments of 2 or 3) IS sizes)
Standard: #125

Jet needle ' 85 : standard: lOA (TAPER ANGLE 3 ° 30' 0.0. 2 .505 mm)

Jet needles for the CRBOR carburetors are available in eight different profiles which
combine any of three straight diameters with any of three taper angles.

@JlIIJ!JIn I
I i I : ~

TAPER ANGLE
NEEDLE 0 .0.
NUMBER

GENERAL FLOW JET NEEDLE 0.0 . TAPER SPECIFIC FLOW

CHARACTERISTICS NUMBER (mm) ANGLE CHARACTERISTICS

10H 2.525 3°00' leaner at l /B to 3/4 throttle.

leaner than the
standard needle lOB 2.525 3°30' Leaner only at 1/8 to 112 throttle.
lOG 2.505 3°00' Leaner only at 112 to 3 /4 throttle.
IOF 2.485 4 D
oo' Richer at 1/8 to 3/4 throttle.
Aicher than the
standard needle
IOC 2.485 3°30' Richer only at l I B to 1/2 throttle.
100 2.505 4°00' Richer onlv at 1/ 2 to 3 /4 thronle.
Leaner at 1/8 to 1/2 thronle, then
Combination of leaner IOE 2 .525 4°00'
richer at 1/ 2 to 3 /4 thronle .
and richer than the
standard needle Richer at 1/ 8 to 1/ 2 throttle, then
IOJ 2.485 3°00'
leaner at 112 to 3 /4 throttle.

1-17
GENERAL INFORMATION

ITEM REMARKS

After '85: F1 343H I 1 °34 '

Standard: (TAPER ANGLE: II 2045' 0.0. 2.435 mm)
24NAAC
Jet needles for the CRSOA carburetors are available in two different profiles with
three straight diameters.
TAPER ANGLE I: ,° 34 ,

illIF ::-:I :
NEEDLE 0.0.
,
: I ~ TAPER ANGLE II : 2°45'
NUMBER

GENERAL FLOW JET NEEDLE 0.0. SPECIFIC FLOW

CHARACTERISTICS NUMBER (mm) CHARACTERISTICS

Leaner than the stock F1345H Leaner only at 1/8 to

2.4S5
standard needle 24NAAE 1/4 throttle.
Richer t han the stock F1341H Richer only at 1/8 to
2.415
standard needle 24NAAA 1/4 throttle.

Slow jet '85: #38 - #48 (in increments of 2 or 3)

Standard: #42
'86: #48 - #58 lin increments of 2 or 3)
Standard: #52
After ' 86: #50, #55
Standard: #52

Throttle valve spring

'8 5: Standard spring rate: 0.56 kg /mm (with no mark)
Optional spring rate: 0.7 kgfmm (with red paint mark)

1-18
 2. LUBRICATION
SERVICE INFORMATION 2·' TRANSMISSION OIL 2·2
TROUBLESHOOTING 2·' LUBRICATION POINTS 2·4

SERVICE INFORMATION
GENERAL

• This section describes inspection and replacement of transmission oil.

• The Honda CRBO R has a two-stroke engine that requires a 32 : 1 gasoline-oil mixture.

CAUTION
Used engine oil (or transmission oil in two-strokes) may cause skin cancer if repeatedly le!t in contact with the skin jor prolonged
periods. A Ithough this is unlikely unless you handle used oil an Q daily basis, it is stiff advisable 10 rhroughly wash y ou hands with
soap and water as soon as possible ojter handling used oil.

SPECIF ICA Tl ONS

Recommended oil Honda HP2 2-Stroke Oil 132 : I) or an equivalent.

Mixing ratio (Fuel: Oil) 32 : 1
Transmission oil capacity '85, ' 86: 0 .55 lit (0.58 US qt, 0.48 Imp qti at disassemblv
0.50 lit (0.53 US qt, 0. 44 Imp qt) 8t change
After '86: 0.60 lit (0.63 US qt , 0 . 53 Imp qt) 8t disassembly
0.55 lit (0.58 US qt. 0 .48 Imp qt) 8t change

Recommended transmission oil Honda GN4 4-Stroke Oil SAE 1OW - 40 or equivalent .
API Service Classification : SF or SG .

Recommended transmission oi l viscosity: SAE 10W-40

NOTE
Viscosity selection should be based on the average atmos·
pheric temperature in your riding area. Change to the
proper viscosity oil whenever the average atmospheric
tem perature changes substantial ly.

TROUBLESHOOTING
Engine does not have sufficient power o 20 )0 4O'C
- Deter iorated fuel-oil mixture.

Engine st alls frequently

- Deteriorated fuel-oil mixture.

Spllk plug is fouled

- Deterioratad fuel -oil mixture
- Incorrect fue l ·to-oi l mixture ratio.

Transmission 011 level too low

- Worn right crankshaft seal .

2-1
LUBRICATION

TRANSMISSION OIL

If th~ M,f"~ must In running to do gom~ work, make sure the

0"0 Is well l'entilaUd. Ne~er run the engine in on enclosed orea.
The exhaust contains poisonous carbon monoxide gas thol can
cause loss 0/ consciousness ond may lead to dcath.

CAUTION
Used transmission oil may cause ski" canetr if repeatedly left in
contact with the skin jor prolonged ~riods. A/though Ihir Is
unlikely unlns you handle used oil on Q daily basis, it is still ad-
visable to thoroughly wash your hands with soap and water as
soon as possible ojter handling used oil.

INSPECTING & AOolNG TRANSMISSION OIL

1) Run the engine for three minutes, then shut it off.

21 Wait three minutes after shuning off the engine to allow the
011 to properly distribute itself in the clutch and transmis-
sion.
3) Support the CR in an upright position on 8 level surface.
4 ) Remove the oil filler cap and check bolt from the right
crankcase cover. A small amount of oil should flow out of
the check bolt hole .
Allow any excess oil to flow out of the check bolt hole.
5) If no oil flows out of the check bolt hole. add oil slowly
through the oil filler hole until oil starts to flow out of the
check bolt hole. Install the oil check bolt and filler cap.

RECOMMENDED Oil: Honda GN4 4-Stroka Oil.

SAE 10 W - 40 or equivalent.
API Service Classification :
SF or SG

6) Repeat steps 1 - 4 .
7) After Inspecting the oil level or adding oil . tighten the oil
check bolt and fill er cap securely.

TORaUE 1011 check boh) :

7 - 11 N·m (0.7-1.1 kg-m. 5 - 8 ft·lb)

REPLACING TRANSMISSION OIL

NOTE
Transmission oil should be changed at least every 3 race s or
7.5 hours of running to ensura consistent performance and
m llKlmum service life of both transmi ssion and clutch
components.
Warm·up the engine before draining the oil.
This ensures complete and rapid draining.

1) Run the engine for three minutes. then shut it off.

2) SuPport the CR in an uptight position on a level surface.
3) Remo ve the oil filler cap from the right crank case cover.

2-2
 LUBR ICATION

4) Place an oil drain pan under the engine to catch the oil.
Then remove the drain bolt.
S) After the oil has drained completely. install the drain bolt
with 8 new sealing washer.

TORQUE: 20-30 N·m (2.0 - 3.0 kg-m. 14-22 ft-Ibl

6) Add the recommended oil.

CAPACITY : at all change

' 86, '86: 0 .60 lit (0.53 US qt, 0 .44 Imp qtl
After ' 86: 0.55 lit )0.58 US qt. 0 .48 Imp qtl
RECOMMENDED OIL: Honda GN4 4-Stroke Oil.
SAE 10 W- 40 or equivalent.
API Service Clas.ification:
SF or SG

NOTE
Use this specified capacity only as 8 guide: add oil until it
flows out of the oil check bolt hole, allow it to stop flow ing
out, then reinstall and tighten the oil check bolt and sealing
washer.

Use only high detergent, premium quality motorcycle engine

oil certified to meet or exceed U.S. automobile manufacturer' s
requirements for Service Classification SF or SG.

7) Reinstall the oil filler cap. Check the oil level by following
the steps in Inspecting & Adding Transmission oil.

2-3
LUBRICATION

LUBRICATION POINTS Apply a paste grease with 40% or more molybdenum

disulfide to the· mark components.
Unless otherwise specified, use general purpose grease.
NOTE
Apply oil or gresse to the other sliding surfaces not shown
here. Some sources of MOS2 paste grease with 40% or more
molybdenum are:
CONTROL CABLE LUBRICATION Molykote* G-n Paste manuf actured by Sow Corning,
U.S.A.
Periodically disconnect the throttle and clutch cables at Honda Moly 60 (U.S.A. only)
their upper ends. Clean the cable end mount in the throttle Rocol ASP manufactured by Rocol limited. U.K .
and dutch lever, then oil the cable ends and reinstall. If the Rocol Paste manufactured by Sumico Lubricant. Japan.
cable is binding, it must be replaced. Any other manufacture's paste grease equivalent to the
above may also be used.

' 85 -'91: _ !i<iM;

(4)·SHOCK UPPER AND
LOWER MOUNT/ OUST
(3)· SWINGAAM PIVOTI SEALS/SPHERICAL
DUST SEAlS/COLLARSI BEARING

(21 "SHOCK LINK AND

NEEDLE BEA RINGS
('86 - '91)

SHOCK ARM PIVOTS!

DUST SEALSINEEDLE
BEARINGS/ SPHERICAL
(5) BRAKE FLUID

..
(6) THROTTLE/
BRAKE ('S51!C LUTCH

-,
(7) THROTTLE GRI P
_ !i<iM;

BEARING
, ,
(1) 1CHAIN LUBe I , , , ::::::::..-_--- (S) CLUTCH! BRAKE
DRI VE N -:::;; LEVER PI VOT BOLTS

_ !i<iM;
- - -- -, ,.(9) STEERING ST EM BEARINGS!
" OUST SEA L
,,

,
'85' -~
(lO)ATAC
!l91 BR AKE PANEL \ VALVE SHAFT/
COLLAR/ DUST LINK PIVOT
SEAL
Gill
11) HONDA
SS-8
Suspension
Fluid or an
equivalent

,, (14) KI CK STARTER '85>-.. !i<iM;

(18) WHEEL BEARINGS! ARM JOIN T
(12) BRAKE CAM
DUST SEALS
(HI BRAKE PEIDA ILJ , 03) WHEEL BEARINGS!
BRAKE TORQUE \ DUST SEALS
(1 5) FQOTPEG
ROD PIVOT
, PI VOT
I

_ f;;;;m
• [MULT IPURPOSE GREASE NLGl No.2 l
(MOLYBDENUM DISULFID E A D D ITI V E ~ (16) SIDE STAN D
'S6 shown; 'S5 similar.
PI VOT

2-4
 LUBRICATION

After '9 1:

!4) • SHOCK UPPER AND

LOWER MOUNT/DUST
SEALS! SPHERICAL
BEARING (61 THROTTLE!
-~
(31 'SWINGARM PIVOT!
,,
I CLUTCH
/ ' CABLES
:,
DUST SEALS/COLLARS!
NEEDLE BEARINGS
,,
\
,,
,,
,
,,,
15) ;,K.~~:~'~/// _~
!2) • SHOCK LINK AND
,
SHOCK ARM PIVOTS/
DUST SEALS/NEEDLE
BEARINGS/SPHERICAL
BEARING ,
,,
,,
,,
,,
,
\•,
\
\
,,
,
I
,
I
,,,
,

,,
I
a~------- 17)

,,""",I---'\I:jt:~
--- --- --- ., THROTTLE GRIP

--- -----18) CLUTCH /BRAKE

LEVER PIVOT BOLTS

!') I CHAIN LUBE j

DRIVE CHAIN
'::=::---::~:''''/~='NG STEM
8EARINGS!

..
DUST SEAL

. (10) Honda
SS-8
Suspension
Fluid or an
equivalent

,
,/
{16 1 WHEEL BEARINGS/
DUST SEALS
/
,,
112) KICK STARTER
ARM JOINT
-.;;;;..
\

(11) WHEEL BEARINGS!

,,,
DUST SEALS
(13) FOOTPEG
(15) BRAKE PEDAL , PIVOT
PIVOT I
~..w;;..
(14) SIDE STAND
PIVOT 1'92 only)

• [MULTIPURPOSE GREASE NLG 1 No.2]

(MOLYBDENUM DISULFIDE ADDITIVE)

2-5
 3. MAINTENANCE
SERVICE INFORMATION 3-1 DRIVE CHAIN SLIDER 3-9
COMPETITION MAINTENANCE BRAKE SYSTEM 3-9
SCHEDULE 3-2 3-13
CLUTCH SYSTEM
THROTTLE OPERATION 3-4 CONTROL CABLES 3-14
AIR CLEANER 3-5
SPARK PLUG
TRANSMISSION OIL
3-6
3-6
EXPANSION CHAMBER
SUSPENSION
WHEELSITIRES
3-14
3-15
3-16
I-
COOLING SYSTEM 3-7 NUTS, BOLTS, FASTENERS 3-17
RADIATOR COOLANT 3-7 STEERING HEAD BEARINGS 3-17
DRIVE AND DRIVEN SPROCKETS 3-7
DRIVE CHAIN 3-7

SERVICE INFORMATION
SPECIFICATIONS
< ENGINE>
ITEM STANDARD SERVI CE LIMIT
Transmission oil capacity 8t ' 85, ' 86 0 .50' 10.53 US Qt, 0 .44 Imp Qt) --
oil change
After '86 0 .55' 10.58 US qt, 0 .48 Imp qt)
Recommended Ifensmission oil HONDA GN4 4- STROKE Oil. SAE 10 W-40 or
equivalent. API Service clesailicltion: SF or 5G
- -
Clutch lever free play 10 - 20 mm (3/B - 3/4 in) --
Thronls grip free play 3 6 mm O /B 1/4 inl
Recommended spark plug
' 85
Champion: QN· 2C
NGK: BA9ES
-
Alter '85 NGK: BA10EG --
Spark plug gap
' 85
Champion: 0 .6
NGK :
0 .7 mm 10.02 4 0.028 inl
0.7 - 0.8 mm 10 .028 - 0.031 inl --
After ' 85 NGK : 0.5 - 0.6 mm (0.020 - 0 .024 In) - -
<CHASSIS>
ITEM STANDARD SERVICE UMIT
Fork oil capacity ' 85 273 cc 19 .2 US Ol, 9.6 Imp Ol) --
' 8. 287 cc IS.7 US oz, 10.1 Imp 01)

' 87 308 cc ( 10.4 US Ol , 10.8 Imp oz)

' SS - ' 91 305 cc (10. 3 US oz. 10. 7 Imp Ol)

After'Sl 30S cc
Fork air pressure o kPa (0 kg /eml. 0 psn 41 kPa (0.4 kg/em'. 6 psi!
Brake lining thic kness -- 1.0 mm (0.04 in)
Drive chain slack 30 - 35 mm (1 -1/4 - 1-1/2 in) --
Brake lever ('S5t/pedal free plav '8S '91 20 30 mm (3/4 1- 1/4 in)
Tire siles Front " S SO/80-17-41 M
Alter ' 85 70/100-17-40M - -
Rear '8S 1 10/80-14- 53M
After ' 85 90/ 100-14-4SM
lire pressures Front 100 kPa (1.0 kg/em', 15 psi)
Rear 100 kPa (1 .0 kg/em', , 5 psi) --
I 3-1
 •
I
MAIN TE NANCE

TORQUE VALUES 1
Rear axle nut ' 85: 55 - 70 N·m 15.5 - 7.0 kg -m, 40 - 50 ft-Ib)
After '85: 80 - 100 N·m 18.0 - 10.0 kg-m, 58 - 72 ft-Ib) I
Spoke nipple 2.5 - 5.0 N·m to.25 - 0 .5 kg -m , 1.8 - 3.6 ft-Ib) I
Rim lock 10 - 15 N·m 11.0- 1.5 kg -m , 7- 11 ft-Ib)

TOOL
Common

Spoke Wrench e, 4 .5 x 5.1 mm '85: 07701 - 0020200 or commercially available in U,S.A .

Spoke Wrench C, 5 .8 )( 6 . 1 mm After ' 85: 0770 1- 0020300 or commercially available in U.S .A .

COMPETITION MAINTENANCE SCHEDULE

' 85 -'91 :
This maintenance schedule is deSigned to keep the CABOR in top running condition, when used in motocross competition .
Because the CRBOR has no odometer, the replacement interval for lubricants and parts is determined by "hours of running ."
Ke ep an accurate log of how long the engine runs 8ach time you practice or ra ce.

I: Inspect and clean, adjust, lubricate or replace as necessary. R: Replace C: Clean l : lubricate

~Y
Each race

"
about 2.5
.,
Every 3 races

about 7.5
.,
Every 9 races

about 22.5
NOTE Rei. pages
ITEM hours hours hoors
THROTTLE OPERATION 1 3·'
AIR CLEANER C 3·5
SPARK PlUG 1 R 3·6
TRANSMISSION OIL R 3·6
RADIATOR COOLANT I Every 2 years R 3·'
COOLING SYSTEM I 3·'
CYLINDER HEAD OECARBONIZING C 6-4
PISTON AND PISTON RING R 6·8
PISTON PIN AND CONNECTING ROO
R 6·.
SMALL END BEARING
DRIVE CHAI N I, L R 3·'
DRIVE CHAIN SLIDER 1 3·.
DRI VE SPROCKET 1 3·'
DRIVEN SPROCKET I 3·'
BRAKE FLUID 1'86 - ' 91) 1 Every 2 years R 3- 10
PAD WEARfBRAKE SHOES ('86 ' 91 ) 1 3- 11 , 12· 14
BRAKE SHOES 1' 85) 1 11·14, 12· 14
BRAKE SYSTEM 1 3·.
CLUTCH SYSTEM 1 3· 13
CONTROL CABLES I, L 3-1'
EXPANSION CHAMBER 1 3· 14
SUSPENSION 1 3- 15
SWINGARM/SHOCK LINKAGE 1'88 - '911 L 12·35
FORK Oil R 11· 21
WHEELSmRES 1 3- 16
NUTS, BOLTS AND fASTENERS 1 3- 17
STEERING HEAD BEARINGS 1 3· 17
..
NOTE : ThiS maIntenance scrn,dule IS based upon average ndlng COnditionS. Machines subtected 10 severe use reqUlra more frequent serviCing .

3-2 1
I MAINTENANCE

AFTER '91:
Perform the Pre-ride Inspection at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean R: Replace L: lubricate

~Y
Each race Every 3 races Every 9 faces
NOTE ••
about 2.5
••
llbout 7 .5
••
about 22.5
Rei. pages
ITEM
hours hours hours
THROTILE OPERATION 1 3-'
AIR FILTER NOTE 1 C 3-'
SPARK PLUG 1 R 3-.
RADIATOR COOLANT NOTE 2 1 3-7
COOLING SYSTEM
CYLINDER HEAD DECARBONIZING
PISTON AND PISTON RINGS
1
C
R
.-.
3-7

.-8
PISTON PIN AND CONNECTING ROD
SMALL END BEARING
TRANSMISSION OIL R
R .-.
3-.
DRIVE CHAIN I. L R 3-7
DRIVE CHAIN SLIDER 1 3-'
DRIVE SPROCKET 1 3-7
DRIVEN SPROCKET 1 3-7
BRAKE FLUID NOTE 2 1 3-10,3-12
BRAKE PADS WEAR 1 3· 11,3- 13
BRAKE SYSTEM 1 3-'
CLUTCH SYSTEM 1 3- 13
CONTROL CABLES I, L 3-14
EXPANSION CHAMBER/SILENCER 1 3-14

SUSPENSION 1 3-15
SWINGARM /SHOCK LINKAGE L 12-35, 12-37
FORK OIL R 11-21
NUTS, BOLTS, FASTENERS 1 3- 17
WHEELSfTlRES 1 3-16
STEERING HEAD BEARINGS 1 3-17
--
ThIS maintenance schedule IS based upon average tiding condition . Machine subjected to severe use reqUire more frequent sarvlclng.
NOTE
1. Clean alter every moto for dusty riding condition.
2. Replace every 2 years. Replacement requires mechanicel skill .

3-3
MAINTENANCE

ADDITIONAL ITEMS REQUIRING FREQUENT REPLA CEMENT

Item Cause Remark

Cylinder nead gasket Compression leak Replace whenever disassembled

w Reed velve Damage or fatigu e
~ Clutch disc Wear or discolofelian
'zw" Cylinder blSl gasket
Right crankcase cover gaskel
Leakage
Damage
Replace whenever disassembled
Replace wl'ltlnever disilssembled
Radiator hoses Deteriolation or damage
Front/rear tire Wear Minimum cleat height : 8 mm IS/ 161nl
Front brake pads IAft er '851 Weer M inimum thickness: 1 mm (0 .04 int
Front ('85)l r88r brake lining "85 -'91) Wear Minimum thickness: 2 mm 10.08 Inl
Reaf brake torque . rm bushing 1' 85 - ' 911 Weer
Rear brake panel bu shing ('85 - '91) Wear
Re af brake pads IAfter ' 91 ) Wear Minimum thickness: 1 mm (0.04 in)
f
Subfleme mounting bolts Fatigue or damage I
Chain guide plate Wear or damage
Side cover Damage I
w
~
Front number plate Damage I
< Front/rear fender Damage
~
~ Clutch level/holder Plav or damage I
Brake holdar !'85)/lever Plav or damage I
Handlebar Bent or cracked
Throttle housing Damage
Grip rubber Damage
Geershift pedal Damage
Brake pedal Damage
Chain &dju,ter/bolt Damage
Air cleaner element Damage
Exhaust chamber spring/hook Fatigue or damage

THROTTLE OPERATION (1) THROTTLE GR IP FREE PLAY

3-6 mm 11/8- 1/4 in)
Inspect the throttle cable for deterioration , damage, or kinks
and replace t he cable as required.

Measure throttle grip free play at the throttle grip flange .

THROTT LE GR IP FREE PLAY:

3-6 mm( 1!B-1 /4Inl

'85
Throttle grip free play (After '85 : Minor adjustments) can be ADJUSTER
adjusted with the adjuster at the handlebar. (1 1 DECREASE PLAY
Slide the rubber cover off t he lever mount and loosen the lock
nut. Turn the adjuster to obtain 3- 6 mm 0 /8-1 /4 inl of free
play.
Then t ighten the lock nut and slide the rubber cOlier back .
Replace the throttle cable with a new one if the adjuster or
cable is damaged.

3-4
 MAINTENANCE

Aft., ' 85
Major adjustments can be made at the carburetor end of the
cable.
Turn the adjuster at the throttle grip in all the way,
Pull the rubber cap UP. loosen the lock nut, and tUrn the
adjuster.
Tighten the lock nut and reinstall the rubber cup,
Check that the throttle grip turns smoothly and returns com-
pletely .

AIR ClEANER
Remove the seat.
Open the air cleaner case cover (After '85 : air deaner cover) .
Re move the air cleaner element wing nut (After '85 : bolt) and
element Issembly.
Remove the element from the element holder.

Wash the element in non-flammable or high flash point solvent

and allow it to dry thoroughly.
Than wash the element in hot soapy water and allow it to dry
thoroughly .

Soak the element in clean Honda Foam Filter Oil or an

equivalent and squeeze out the excess.

NOTE
Use Honda Foam Filter Oil or an equivalent when riding on a
• dusty track .
Apply Honda Foam Filter Oil or an equivalent to all surfaces
of the element and rub it gently with both hands to saturate
the oil in the element. Squeeze out excess oil and wipe ex-
cess oil from the element surfaces with a dry cloth.

3-5
MAINTENANCE

111 AIR CLEANI,R E;l.MENT

Apply 8 thin coating of grease to the sealing surface of the
element.
Assemble the element and element holder.

Install the element and holder assembly with the tab on the
element facing upward.
Install the seat.

NOTE
The rubber shield on the front of the air cleaner 1' 85) or the
mud guard in front of the air cleaner (After '85) are for use
only during wet or muddy conditions, and should be remov -
ed while track conditions are generall y dry (page 14-4).

SPARK PLUG
Remove the spark plug, then visually inspect it for damage.
Discard it if the insulator is cricked or chipped.
Adjust the gap by carefully bending the side electrode to the
required specifications then rei nsta ll .
'86,
STANDARD SPARK PLUG cr===~11I GAP
Champion: ON-2C
NGK : BR9ES
SPARK PLUG GAP
Champion : 0.6-0.7 mm 10.024-0.028 inl
NGK : 0.7-0.8 mm (0.028-0.031 inl
After '85:
STANDARD SPARK PLUG
NGK: BR10EG •
SPARK PLUG GAP
NGK : 0.5-0.6 mm (0.020-0.024 Inl !
TRANSMISSION Oil
Aun the engine for three m inutes, then shut it off.
Wait three minutes after shutting off the engine to allow the oil
to properlv distribute itself In the clutch and transmission .

Support the CA in an upright position on a level surface .

Remove the oil filler cap and check bolt from the right
c rankcase covet, and check the oil level (See page 2-21.

3-6
 MAINTENANCE

COOLING SYSTEM
Remove the radiator shroud.
Inspect the hoses for cracks and deterioration.
Replace. if necessary.
Check that all cooling system items are secure and not leak ing .
Use low pressure water and a soft brush to rinse off any dirt
tnat may be stuck on the radiator core.

RADIATOR COOLANT
Check the coolant level with the engine cold, it should be up
to the filler neck . Add coolant as required .

IJ
DRIVE AND DRIVEN SPROCKETS
(11 GOOD (2) REPLACE
Inspect the sprocket teeth for excessive wear or damage.
Replace if necessary .

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

DRIVE CHAIN
NOTE
• Perform aU chain service with the engine off.

Stop the engine.

Place the motorcycte on the side stand and shift the trans-
mission into neutral.

Check the drive chain slack at a point midway between the

sprockets. Move the chain up and down by hand measure the
amount of slack.

DRIVE CHAIN SLACK : 30-35 mm "·1/4-1-1 /2 in)

3-7
MAINTENANCE

If the drive chain requires &djustment, adjust 85 follows :

Loosen the rear 1)(le nut and adjuster lock nuts.

Turn the adjusting nuts equallv on both sides to increase or

decrease chain slack.

CAUTION

Be sure the indo: mark aligns with the .same graduQtion on

both sides of the swingarm.

Tighten the rear 8xle nut.

TORQUE
'85: 60-70 N'm (5.5-7.0 kg-m, 40- 51 ft -Ibl
After '85: 80-100 N·m (8.0-10.0 kg-m, 58-72 ft ·lb)

Tighten the adjusting nuts.

Check the rear brake pedal free play (page 3·11).

When the drive chain is dirty. it should be removed and

cleaned prior to lubrication.

NOTE
For maximum service life, the drive chain should be cleaned
and lubricated before each outing.

Carefully remove the master link clip with pliers.

121W~ ?I
141
Remove the master link and the drive chain. CHAIN
Clean the drive chain in kerosene and allow it to dry. LUBRICANT
Inspect the chain for possible wear or damage : replace any
chain that has damaged rollers, loose fitting links, or otherwise (3) LUBRICATE
appears unserviceable.

Measure the drive chain distance between 8 span of 21 pins

from pin center to pin center with the chain held taut and any
kinks straightened.
SERVICE LIMIT: 259 mm (10.2 in)
SE RVICE LIMIT: 259 mm (10.2 in)

Replace if necessary.

CAUTION
000000 .,000000 o
Never install a new drille chain on worn sprockets or a
worn chain on new sprockets. Both chain and sprockets Measure a span of 21 pins
must be in good condition, or the new replaced chain or
sprockets will wear rapidly.

3-8
 MAINTENANCE

Install the drive chain with the master link clip closed end (1) CLIP
facing the direction of the chain's travel.

DRIVE CHAIN SLIDER

Inspect the chain slider and slider guide for wear or damage.

SERVICE LIMITS :
Chain slider !from upper surfacel :
3 mm (0 .1 inl
Slider guide (from upper surface) :
'S5, '86: 6 mm 10.2 inl
'87 : 5 mm (0.2 in)
After 'S7: 3 mm (0.1 in)

Inspect the chain guide slider for wear or damage .

Replace the chain guide slider if the c hain is visible through the
wear inspection window in the chain guide.

BRAKE SYSTEM (1) FREE PLAY

'85:
FRONT

Measure the front brake lever free play at the tip of the brake
lever.

FREE PLAY: 20-30 mm (3/4-1 ·114 inl

3-9
MAINTENANCE

Minor adjustments are made with the upper adjuster.

Slide the cover down the cable. Loosen the lock nut and turn
the adjuster to obtain the specified free play. (3) INCREASE PLAY

Tighten the lock nut and ,Iide the coyer into place.

Major adjustments are made with the lower adjuster.

Loosen the cable clamp.
Turn the upper adjurter aU the way in and back out one turn .
Loosen the lower adjuster lock nut and turn the lower ad-
juner to obtain the specified free play.

Tighten the lock nut and the cable clamp,

After '8S:
FRO NT

Check the front brake fluid reservoir level. If the level is near
the lower level mark , remove the colier and diaphragm. Fill
the reservoir with DOT 3 Of' 4 brake fluid to about 3 mm
(0.12 in) below the casting ledge.

If the level was low, check the entire system for leaks.

CAUT ION
Do not remOP8 the cover until the hondlebar /un been
turned so that the reservoir is leveL
A Iloid operating the brake If!IJer with the cap removed.
Brake fluid will squirt out if the ieller is pUlled.
Do not mix different types of fluid, as they are not com-
patible with each other.
Avoid spilling fluid on painted, plilstic or rubber parts.
PlIlee a rag over these parts whenever the system is serviced.

Refer to section 13 for brake bleeding procedures.

3-10
 MAINTENANCE

Inspect the brake hose and fittings for deterioration, cracks

and signs of leakage. Tighten any loose fittings.
Replace sealing washers as necessary.

Replace hose and fittings as required .

After '85: 111

PAD WEAR

Check the brake pads for wear .

Replace the brake pads if either pad is worn to a thickness of
, mm (0.04 in ) or worn to the bottom of the groove (Page
13-4),

CAUTION
• Always rep/Dce the brake pads as Q ser.

Aft ar '85 :
LEVER FREE PLAY (1 ) ADJUSTER

Free play must be adjusted to provide 0 .1-1.4 mm (0.004- ~ 30 m

0.055 in) clearance between the end of the adjuster and the
front brake master cylinder piston. /-______ ___-_-Tin'
-_-~- -"
11 .25

CAUTION
• Do not adjus/ distance "A" TO less than O. J mm (0.004 in).

If the brake lever free play exceeds 30 mm (1.25 in) with the "A"
10.004inl
0 .1 mm

clearance between the adjuster and the front brake master

cylinder pinon below 1.4 mm (0.06 int. there is probabl y air (2) OCK NUT
in the brake system and it must be bled (Page 13-3).

' 8 5-'91 :
REAR
Adjust the brake pedal height by loosening the lock nut and
turning the pedal height adjusting bolt.
Tighten the lock nut.

Measure the rear brake pedal free play.

FREE PLAY : 20-30 mm (3/4-1 -1/4 in)

(3) FREE
PLAY

3-11
MAINTENANCE

Adjust the free play bV turning the adjusting nut.

(21 fE".REASE
PLAY

If the slot in the brake arm aligns with the" 6" mark on the
brake panel when the brake pedal is depressed fully, check the
brake shoes for excessive wear. (Section 121
If the amount of wear is within the service limit, relocate the
brake arm on the camshaft one serration backward.

After '91: t 1) RESERVOIR 121 RESERVOIR CAP

REAR

Check the rear brake fluid reservoir level. If the level is neaf the
lower level mark, remove the cap and fill the reservoir with
DOT 4 brake fluid to the upper level mark .

If the level was low, check brake pad wear and the entire
~~~1i33) UPPER LEVEL MARK
system for leaks.
- I / ~ __
f)~~1141 LOWER LEVEL MARK
CAUTION
Do not remove the cover unless the resen'oir is level because
fluid may spill OUl,
Do no/ mix different types oj fluid. as they are no/ compatible
with each other.
M\
A void spilling fluid on painted, plastic or rubber parts. Place a
rag over these parts whenever the system is serviced.

Refer to section 13 for brake bleeding procedures.

Inspect the brake hose and fittings for deterioration, cracks or

signs of leakage. Tighten any loose fittings. Replace sealing
washars as necessary .

Replace hoses and f ittings as required .

3-12
 MAINTENANCE

After '9 1:
REAR BRAKE PAD WEAR

Check the brake pads for wear.

Replace the brake pads if either pad is worn to the bottom of
the wear line {page t 3 ·6).

After ' 91:

BRAKE PEDAL HEIGHT ADJUSTMENT

Adjust the brake pedal to the desired height by loosening the

lock nut and turning the pedal height adjusting bolt.
Tighten the lock nut.

CLUTCH SYSTEM
(1) FREE PLAY
Measure the clutch lever free play at the lever end.

FREE PLAY : 10-20 mm (318-314 in )

Minor adjustments are made with the upper adjuster:

Sl ide the cover down the cable.
(3) INCREASE PLAY
- Loosen the lock nut and turn the adjuster to obtain the
specified free play.
- Tighten the lock nut and install the cOlier .

Check clutch operation.

3-13
MAI NTENANCE

Major adjustments are made with the lower adjuster:

Turn the upper adjuster in all the way and back out 1 turn .
Loosen the lock nut and turn the lower adjuster to obtain
the specified free play.
T ighten the lock nut and check. clutch operation.

CONTROL CABLES
Periodically, disconnect the throttle, brake and clutch cables
at their upper ends,
Thoroughly lubricate the pivot points with a commercially
available cable lubricant .

EXPANSION CHAMBER
Check the expansion chamber for cracks or deformation.
Check the expansion chamber spring for damage or 10S$ of
tension.

Check the ATAe chamber for cracks or deformation ('85).

After '86 (1) UPPER MOUNTING SCREW

(2) MU''''.'"

\
GLASS WOOL REPLACEMENT

Remove the seat and right side cover Ipage 14-4 ).

Remove the muffler mounting bolt and muffler .

loosen the upper mounting screw a linle and remove the

lower mounting batt .

NOTE
• 00 not over-loosen the upper mounting screw.

(3) LOWER MOUNTING BOLT

3-14
 MAINTENANCE

Pull out the inner pipe. (1 ) UPPER MOUNTING SCRIEW r""""!Ir

When the inner pipe does not remove easily, tap the upper
mounting screw carefully by plastic hammer as shown .

Remo ve the glass wool.

Remove the carbon deposit from the inner pipe using the wire {I I INNER PIPE
brush.

NOTE
• Be careful not to damage the glass wool during installation.

Install the inner pipe to the silencer body with bolt hole and
screw aligned.
Install the washer and lower mounting bolt.
Tighten the upper mounting screw and lower mounting bolt.
(21 GLASS WOOL

TORQUE : 3.5-5.0 N· m 10 .35- 0 .5 kg -m, 2.5 - 3 .6 ft· lbl

Install the muffler (pages 14- 5 and 14-6).

Install the right side cover and the seat (page 14-3).

SUSPENSION
FRONT

Check the action of the front suspension by compressing the

fork several times.

Check the entire fork assembly for signs of leaks or damage.

Replace any components which cannot be repaired.

Tighten all nuts and bolts to the specified torque values {page
1-61_ •
. (2) AIR VALVE
See Section 11 (page 11 -211 for fork oil change.
Remo ve the air valve caps . CAP

Check the air pressure when the fork is cold and the front
wheel suspended off the ground.

STANDARD AIR PRESSURE: 0 psi (O kPa., 0 kg/cm ')

MAXIMUM AIR PRESSURE : 6 psi {41 kPa. 0.4 kg /em' l

Reinstall the air valve caps.

Release any built -up pressure in this same way before each
ride.

3-15
MAINTENANCE

RE A R

Check the action of the rear suspension by compressing the

rear damper several times.
Look for proper operation as the rear end is compressed and as
it extends.

Check that the shock rod is not bent and no oi l is leaki ng from
0) SHOCK
the seal or hose fitt ings.

Check that the shock link is not damaged.

Push and pull on the rear wheel to check fo r play in the sw-
ingarrn pivot. Replace bearings as necessary.

WHEElS/ TIRES
Check the ti re for cuts, damage or excessive wear.

TIRE PRESSURE (front ; rear) :

100 kPa 11 .0 kg /cm 2 • 14 psi)

Inspect the wheel rims and spokes for damage. (1' SPOKE WRENCH B ('85' '\
Tighten any loose spokes and rim locks. 07701 - 0020200 OR
COMMERCIALLY A VA ILABLE IN U.S.A. 't
TORQUE :
Spoke : 2.5-5.0 N-m (
(0.25-0.5 kg-m. 1.8-3.6 It-Ibl
Rim lock : 10-15 N'm
0 .0- 1.5 kg-m. 7- 11 ft·lb)

Check wheel runou t (pages 11- 1 0, , 2-6).

r
RIM LOCK
(2 ) SPOKE WREN CH C (A fter '85)
07701 - 0020300 OR
COMMERCIALLY A VAILABLE IN U.S.A.

3-16
 MAINTENANCE

NUTS, BOLTS, FASTENERS

Check that all chassis nuts and bolts are tightened to their cor~
rect torque values (page 1 -6).

Check all cotter pins and safety clips to be sure they are
secured properly.

STEERING HEAD BEARINGS

NOTE
Check that the control cables do not interfere with the
rotation of the handlebar.

Place the motorcycle on a box or workstand so the fron t

wheel is off the ground.

From the front of the motorcycle, hold the fork sliders at the
axle and push them in and out. If there is any play, adjust the
steering head bearing by turning the steering head adjusting
nut (page 11-26).

Turn the handlebar from left to right. If the fork binds or turns
roughly, th e bearing races may be damaged. Inspect and
repla ce as necessary (page 11-24).

3-17
FUEL SYSTEM

After '87 :

After '87:

After '81:

'86, 'S7:

After '87 :

After '85:

4-0
 4. FUEL SYSTEM
SERVICE INFORMA TION 4-1 FLOAT, FLOAT VALVE ANO JETS 4-14
TROUBLESHOOTIN G 4-2 CHOKE VALVE 4-16
OPTIONAL PA RTS , '85 4-3 CARBURETOR ASSEMBLY 4-16
, After '85 4-4 FLOAT LEVEL ADJUSTMENT 4-17
CA RBURETOR THEORY 4-5 CARBURETOR INSTALLATION 4-17
MINOR CARBURETOR ADJUSTMENT 4-7 THROTTLE VALVE ASSEMBLY 4-17
MAJOR CARBURETOR REED VALVE 4-19
ADJUSTMENT , '85 4-7
FUEL LINE AND FUEL FILTER 4-20
: After '85 4-9
FUEL TANK 4-21
TUNING FOR SPECIAL CONDITIONS 4-10
AIR CLEANER CASE , '85 4-23
THROTTLE VALVE DISASSEMBLY 4-11
, After '85 4-24
CARBURETOR REMOVAL 4-12

SERVICE INFORMATION
GENERAL
• Use caution when working with gasoline. A lways work in a well ·ventilated area and away from sparks or flames.
• The float bowl has a drain plug that can be loosened to drain residual fuel.
• When disassembling fuel system parts, note the locations of the O·rlngs. Replace them during assembly.
• The carburetor used on the CASOR is tuned for average load, climatic, end barometric conditions. However, to fine tune
the engine's power output, it's essential that the carburetor be adjusted for specific racing conditions .
See pages 4 -7 thro ugh 4·10.

Gaso/jn~ is eXlremely fklmmable and ;$ expJosi~ under certain c<?ndilions. Work in a ~II ~nf;Io't!d areo with the enpne
stopped. Do not smoke or allow flames or sparks in the work area or where tasoline is stored.

CAUTION
• Do not bend or /Wisl control cables Damaged control cables will not operate smoothly and may slick or bind.

SPECIF ICATIONS
Fuel tank capacity 5 r (1.3 US gal, 1.1 Imp gal)
Fuel Premium or leaded gasoline (Octane rati ng 92- 100)
Oil Honda HP2 2-Stroke oil (32 : 1) or an equivalent
Mixing ratio (Fuel : Oil) 32: 1
Carburetor :

' 85 '86, '87 After '87

Identification mark PE678 PE68A PE68B
Type Piston va lve ~ ~

Venturi d iameter 28 mm (1.1 in) ~ ~

Float level 19 mm (0.8 in) ~ ~

Air screw opening ' -1/2 turns out 2 turns out ~

Jet needle lOA 4th groove F 1343"H24NAAC, 2nd groove ~

Main jet #155 #128('861 I #125 ('87) #125

Slow jet #42 #52 ~

4-1
FUEL SYSTEM

TORQUE VALUE
I
Sub frame bolt 18-25 N·m .8- 2.5 kg.m. 13- 18 ft-Ib)

TOOL

Common
Float level gauge 0740 1-00 10000

TROUBLESHOOTING
Engine cranks bot won't start Lean mixture
No fuel in tank. Carburetor fuel jets clogged .
No fuel to carburetor. Fuel cap vent clogged or blocked.
Too much fuel getting into cylinder. Fuel fitter clogged.
No spark at plug (ignition malfunction), Fuel line kinked or restricted.
Air cleaner clogged. Float val ve faulty .
Deteriorated premix, Float level too low.
Air vent tube clogged.
Engine stalls, or runs poorly Advanced ignition timing.
Ignition malfunction. Air leaks.
low compre"ion. Worn crankshaft $eal !alternator side).
Rich mixture.
Lean mixture. Rich mixture
A ir cleaner clogged. Choke is on.
Air leaking into carburetor insulator. Faulty float valve.
Fuel contaminated. Float level too high .
Carburetor air jets clogged.
Dirty air cleaner.
Retarded ignition timing.
Worn crankshaft seal (clutch si de).

4-2
 FUEL SYSTEM

OPTIONAL PARTS
'85:
ITEM REMARKS

Carburetor tuning parts

Main jet # 140 - #170 (in increments of 2 or 3)
Standard: #155

1,/,,55, ~uiiUi\il
Mark

Jet needle .Standard: lOA (Taper angle: 3°30': straight diameter: 2.505 mm)

Jet needles for the CABOR carburetor are available in eight different profiles which combine
any of three straight diameters with any of three taper angles.

NEEDLE
, ! :>
4IflIIIIlJICl I
0 .0.
I
TAPER ANGLE
NUMBER

JET NEEDLE NUMBER

GENERAL FLOW 0.0. TAPER SPECIFIC FLOW
NUM- PART (mm) ANG LE CHARACTERISTICS
CHARACTER ISTleS
BER NUMBER
'DH 16207-GC4-701 2.525 3°00' Leaner at 1/8 to 3/4 throttle.
Leaner than the 16201-GC4-701 2.525 3°30' Leaner only at 1/8 to 1/2 throttle.
standard needle
'DB
'DG 16206-GC4- 731 2.505 3°()(), Leaner only at 1/2 to 3/4 throttle.
'OF 16205-GC4- 731 2.485 4" 00' Richer at 1/8 to 3/4 throttle.
Richer than the
standard needle
lOe 16202-GC4-731 2.485 3"30' Richer only at 1/8 to 1/2 throttle.
'DO 16203-GC4-731 2.505 400' Richer only at 1/2 to 3/4 throttle.
Leaner at 1/8 to 1/2 throttle, then
Combination of leaner 'DE 16204-GC4-731 2.525 4"00'
richer at 1/2 to 3/4 throttle.
and richer than the
Richer at 1/8 to 1/2 throttle, then
standard needle 'OJ 16208-GC4-731 2.485 3"00'
leaner at 1/2 to 3/4 throttle.

Slow jet #38, #40, #45, #48

Standard: #42

Throttle valve spring Spring rate: 0.7 kg/ mm (with red paint mark)
Standard spring rate: 0.56 kg/ mm (with no mark)

4-3
FUEL SYSTEM

OPTIONAL PARTS
After '85

ITEM REMARKS

CARBURETOR: '86:
Main jet # 118 - # 138 (in increments of 2 or 3) (8 sizes)
Standard: # 128

1/.(28, D,iiiijjjjiiJ
Mark

After '86:
#' 115 -# 135 (in increments of 2 or 3) m sizes)
Standard: #125

Mark
1 A25; ~iUijllill1
Jet needle Standard: F1343H ( ' ''34'
24NAAC (TAPER ANGLE: II 2"45,0.0. 2.435 mm)
Jet needles for the CRBOR carburetors are available in two different profiles with three
straight diameters.
TAPER ANGLE I : 1" 34'

~: :!
NEEDLE
/

:
0.0.
,
t
•! ~
TAPER ANGLE II: 2°45'
NUMBER

GENERAL FLOW JET NEEOLE SPECIFIC FLOW

0.0. (mm)
CHARACTERISTICS NUMBER CHARACTERISTICS
leaner than the stock F1345H leaner only at 1/8 to
24NAAE 2.455
standard needle 1/4 throttle.
Richer than the stock F1341 H Richer only at 1/ 8 to
2.415
standard needle 24NAAA 1/ 4 throttle.

Slow jet '86: #48-#58 (in increments of 2 or 3)

Standard: #52
After '86: #50, #55
Standard: #52

4-4
 FUEL SYSTEM

CARBURETOR THEORY '85

FLOAT CfjAMBER

The float valve and float maintain a constant fuel level in the
float chamber.

• The float level affects the mixture throughout the entire

range.
Although it is possible to alter the fuel mixture by
changing the float level , it is not recommended . FLClATVALVE

) FLOAT
VALVE

STARTING CIR CU IT (1) CHOKE VALVE

(2) ORIFICE
When the choke lIalve is opened, fuel is metered by the starter
jet and is mixed with air from t he primary air passage. The
mixture enters the venturi at the orifice shown.

• Th is circuit is only used when starting a cold engine.

(4) PRIMARY AIR "=~~ 131 STARTER JET

PASSAGE

SLOW JET CIRCUIT (1) PILOT OUTLET

Fuel is metered by the slow jet and is mixed with air that has (2) BYPASS
been metered by the air screw. The mixture enters the venturi
through the bypass and slow jet circuits.

• Th is circuit affects idle-to-' /8 throttle.

- The mixture can be al t ered by changing t he slow jet or
t he air screw adjustment.

(4) SLOW (3) AI R SCREW

4-5
FUEL SYSTEM

MA IN JET CIR CU IT '85 (1 NOZZLE

AIR JET
As the throttle valve is raised, fuel is metered by t he needle
jet, jet needle, and t he throttle valve cutaway. The fuel is
m ixed with air from the air jet and enters the vent uri at the
nozzle.
131 NE IEDL.E ':~¢I~~\
• This beginning portion of the main jet circuit affects 1/8-
to-3/4 throttle.
- In the 1/8-to-112 throttle range, the mixture can be
altered by changing the throttle valve.
- In the 1/8-to-3/4 throttle range, the mixture can be
altered by adjusting the jet needle. 141 JET NEIEDL.E

NOZZLE

(11 NEEDLE
I:::::=~~+TI ~S~l;;;J--'131 JET
AlA

JET

(4) JET
NEEDLE

• T his final portion of the main jet circuit affecu 3/4-ta·f ull '85
(1) NOZZLE
throttle.
"L~J'I (2) AI A JET
- The mixture can be altered by changing the main jet .
¢>

(41 MAIN JET (3) MAIN JET HOLDER

After

AIR JET

131 MAIN--\m~
JET

4-6
 FUEL SYSTEM

CARBURETOR OPERATION
(AI Main
The operation of the carburetor is broken into throttle open-
ing segments; each of the metering units is responsible for one
segment.
There is always overlap from one segment to the next, so any IBI Jet-==-;d~I='IC=I=;P==PO'~"~'O~"~'====:-===-:::=o>
change will always affect the next segment up or down. Be-
cause of this, making carburetor adjustments for altitude or Ie) Jet neftlle (Straight lection)
temperature should be done in a methodical manner. See page
4-7. (After '85: 4·9) Slow jet and AI, ,craw
314 Full
closad opened

MINOR CARBURETOR ADJUSTMENT

(Idle mixture and idle speed)

Idle mixture can be adjusted by turning the air screw: turning

it in richens the mixture, while turning it out leans the mix-
ture.

To adjust: turn the air screw in until it seats lightly, then back
it out to the standard setting.

STANDARD: '85 : ' -1/2 turns out

After '85 : 2 turns out
Start the engine. When the engine is warm enough to run
without the choke, make fine adjustments in the air screw set-
ting until the engine revs up smoothly. For best results, con-
firm that the engine revs up smoothly when accelerating out
of a turn . Adjust the idle speed , if desired , with the thro ttle
stop screw .

Readjust as necessary .

MAJOR CARBURETOR ADJUSTMENT

'85:
(For temperature and altitude)
STANDARD SeTI INGS:
1) Check that the carburetor is adjusted to the standard set· Float level 19 mm (0.75 in)
Air screw opening ,., /2 turns out
tings.
Slow jet # 42
Th ro ttle valve # 6 .0
NOTE
Jet needle IDA
The standard settings are ideal for a motorcycle with an Needle clip position 4th groove from top
unmodified engine running under the following conditions: Main jet # 155

NOTE
• 32·to·' premix ratio with Honda 2-stroke injector oil, or
For the following recommendations to be
its equivalent.
act:urate, you must use these standard set-
• Altitude - sea level.
t ings as a baseline.
• Temperature - 20° C (6B° F).

4-7
FUEL SYSTEM

NOTE
VI 1,1 ,
If you are using a different pre-mix ratio or engine is modi- a::
1.08

,. -S~ -
O '~
fied, you must adjust the mixture accordingly to prevent t ,
engine damage. " 1.0.

,-
~ 'OO
Z 0,\18
2) Find your correction factor. 0 0 .96
_
I-
O.M
,
0.9
. ,ooo.n
0.., (Oft)
5DDm(I600I1 )
13200 tt l
EXAMPLE : 1000 meters (1600 ttl altitude with an air
c
b:: 0.9D (2) EXAMPLE 200(1", I~f"

temperature of 3S C (95°F). The correction factor is 0 .94. <r ,~

JDOIl", 19800 ttl
a:: 0.96
,
8 . . '". . . . 1!)C JOe
~" 68" F lla"f

(4) Temperature

3) Using your correction factor , select the correct main jet.

EXAMPLE : For a correction factor of 0 .94, multiply the

jet size by that number.

Mai n jet # 155 x 0.94 - # 145

4) Find your factO!' on the Jet Needle/Air Screw Chart and 111 JET NEEDLE/AIR SCREW CHART
adjust the jet needle clip position and air screw opening
as shown. 151 161
(2) CORRECTION 1.06 - 1.01 - 0.98 -
1.06 0.94
FACTORS 1.02 0.98 0.'"
or above or below
EXAMPLE: For a correction factor of 0.94, raise the
needle clip one position and turn out the air screw one 191
PI
extra turn. (3) JET NEEDLE Co_, (8) SAME
Rail.
CLIP POSITION clip clip
Jet needle clip setting 1 groove 1 groove
4th groove from
(11) (13)
top minus 1 .. 3rd groove (10) (14)
(41 AIR SCREW
I turn 'n
turn
(12)
SAME
'n
turn
1 turn
OPENING
i.
Air scrlN'l opening i.
'"' '"
' · 1/2 + 1 turn a: 2-1/2 turns out

5) Start the engine and let it warm up for a few minutes. Adjust the idle speed, if desired, as necessary . Test ride the motor-
cycle . Does it perform poorly in any of t he speed rangesl If so, make adjustments as required.

NOTE: The correction factors wi ll get you very close to the ideal jetting. However, because of differences in pressure and
humidity, you may need to fine tune the carburetor for race day conditions.

• J ust off idle:

Engine blubbers (rich) - turn out the air screw 1/4 turn.
Engine surges (lean) - turn in the air screw 1/4 turn .

• On the top end:

Engine blubbers (rich) - go to next smallest main jet.
Engine surges (leanl- go to next largest main jet.

4 -8
 FUEL SYSTEM

CAUTION: To prevent engine damage, always adjust the main jet (top end) before adjusting the jet needle (mid-range),
Always jet one number on the rich side to help prevent engine damage if riding conditions change .

• In the mid-range:
Engine blubbers (rich) - raise the needle clip one position.
Engine surges (lean) - lower the needle clip one position.

6) Test ride 8gain snd readjust as required.

NOTE: If you used the correction factors correctly. it should't be necessary to adjust more than one increment, richer or
leaner. If a very large adjustment is required, there may be something wrong elsewhere. Check for worn crankshaft seals,
air leaKs, blocked exhaust or fuel system, or a dirty air cleaner element.

MAJOR CARBURETOR ADJUSTMENT

After '85:
STANDARD SETTINGS:
(For temperature and altitude)
Float level - 19 mm (0.75 in)
1) Check that the carburetor is adjusted to the standard set·
Air screw opening - 2 turns out
tings.
Slow jet - # 52
Throttle valve - # 6.0
NOTE Jet needle - Fl343H24NAAC
The standard settings are ideal for a motorcycle with an Needle clip position - 2nd groove from top
unmodified engine running under the following conditions:
Main jet - # 128 ('86)

NOTE
- #125 IAfter ' 86)

• 32-to·' premix ratio with Honda 2-stroke injector oil, or , Fo, the following recommendations to be
its equivalent.
accurate, you must use these standard set-
• Altitude - sea level.
tings as a baseline.
• Temperature _ 20°C (68° F) .

NOTE
<n 1.10
-g•
.-
If you are using a different premix ratio or engine is modi· "" ~
fied, you must adjust the mixture accordingly to prevent O'~
t;'~
,~ "E
engine damage.
~:: ,
§
~,
Z 0.98
2) Find your correction factor. 0_ 0 .118

~ o.n
o.~

. Om 10 ft l
500m 11 &OOft i
10Q()n, 1J200 h i
EXAMP LE : 1000 meters (1600 ttl altitude with an air ~ 0.110 (2) EXAMPLE 2000 '" 1660D 1< 1
temperature of 35°C (9SoF) . The correction factor is 0.94. '" OM
a:
0
0.86

.1 .1 .1 , 3000 m 19800 I!I

."" ,.,
---
<.>
'"
-lo"C
14" F
0"

", ~"
~"
M' ,
",. ,
M' ,
~"
1000' F

(4) Temperature

3) Using your correction factor, select the correct main jet .

EXAMPLE: For a correction factor of 0.94, mult iply the

standard jet size by that number.

Main jet # 128 x 0.94 '" # 120

4-9
FUEL SYSTEM

41 Find your factor on the Jet Needle/Air Screw Chart and 111 JET NEE OLE/AIR SCREW CHART
adjust the jet needle clip position and air screw opening
as snown. 121CORRECTION
151 1.06- 1.02 - 0.98 -
161
La< 0.94
EXAMPLE : For a correction factor of 0 .94, raise ,h, FACTORS
or abo ....
1.02 0.98 0 .94
or below
needle clip one position and turn out the air screw one
171 191
extra turn. (3) JET NEEDLE Lo~, R.ill
IBI SAME clip
CL IP POSI TI ON clip
Jet needle clip setting '11.00..- 1111"OOWl
2nd groove from
top minus 1 ,. 1st groove 111) 1131
110) 1141
(121

Air screw opening

141 AIR SCREW
OPENING ,.
1 turn
'",.
turn SAME '"
turn
0",
1 turn
0",

2 turns out + 1 turn out - 3 turns out

5) Start the engine and let it warm up for a few minutes. Adjust the idle speed, if desired, as necessary. Test ride the motor-
cycle, Does it perform poorly in any of the speed ranges? If so, make adjustments as required.

NOTE : The correctio n factors will get you very close to the ideal jetting. However, because of differences in pressure and
humidity, you may need to fine tune the carburetor for race day conditions,

• Just off idle :

Engine blubbers (rich) - turn out the air screw 1/4 turn.
Engine surges (lean) - turn in the air screw 1/4 turn.

• On the top end :

Engine blubbers (rich) - go to next smallest main jet.
Engine surges (lean) - go to next largest main jet.
CAUTION : To prevent engine damage, always adjust the mein jet (top end) before adjusting the jet needle (mid-range.'
Always jet one number on the rich side to allow for changes in riding conditions and to prevent possible engine damage .

• In the mid·range :
Engine blubbers (rich) - raise the needle clip one position.
Engine surges Uean)- lower the needle clip one position.

6) Test ride again and readjust as required.

NOTE: If you used the correction factors corr tly , it should't be necessary to adiust more than one increment, richer or
leaner. If a very large adjustment is required , t re may be something wrong elsewhere. Check for worn crankshaft seals,
air leaks, blocked exhaust or fuel system, or a dir yair cleaner element.

TUNING FOR SPECIAL CONDITIONS

Once you have adjusted the carburetor for temperature and altitude, it shou ld not need major readjustment unless the race
conditions change drastically. Exclusive of the correction factors, there are some unique atmospheric conditions or race
day situations that may require additional adjustments. They are as follows:

MAIN JET • Go richer on the main jet, by one number, when: the track has a very long straightaway, steep climbs,
a high percentage of sand , or the track is muddy .
• Go leaner on the main jet, bV one number, when: it is very humid or raining, or it is very hot- above
45°C (113° F).

JET NEEDLES • Under normal circumstances, the standard jet needle can be adjusted to fit most situations. However, a
peculiar condition may require replacement of the standard jet needle. But before replacing the standard
needle, complete all the carburetor adjustments (Pages 4·7 through 4-9, After '85: Pages 4·9 th rough
4- 10). If mid-range performance is still not satisfactory, try one o f the optional jet needles: See page 4-3
(After '85: 4-4) .

4-10
 FUEL SYSTEM

THROTTLE VALVE DISASSEMBLY

Remove the carburetor top and pull out the throttle valve.

After '9 1:

Loosen the connecting tube and insulator clamps.

Turn the fuel valve OFF, and disconnect the fue l line.
Remove the carbure t or top and pull out the throttle valve.

'85:
Compress the throttle valve spring and remove -t he throttle
cable.

Remove the spring seat, throttle valve spring, carburetor top

and rubber cap.

After '85:
Compress the throttle valve spring and spring seat and remove
the thrott le cable.

Remo ve the spring seat, throttle valve spring, carbureto r top

with adjuster and rubber cap.

Remove the retainer. (1 ) JET EEDLE

Remove the jet needle with clip attached.

!21 RETAINER

4-11
FUEL SYSTEM

Inspect the throttle valve for wear or scratches. OJ THROTTLE VALVE

I
Inspect the jet needle for damage.

(3) RETAINER

\~
(2) JET NEEDLE

CARBURETOR REMOVAL
'85:

(l)THROTTLE
STOP SCREW

e
~
~~
'" N (3) NEEDLE

~
~ ,I . JET (9) DRAIN PLUG

IS)JET
NEEDLE
? F1 15)SLDW_~~
~
I!i JET
_
t;)
i
(4) NEEDLE
JET HOLDER

(7) THROTTLE AI
(6) MA IN JET
VALVE

4-12
I
 FUEL SYSTEM

Aft,r '85:

0) THROTTLE
STOP SCREW

(3) DRAIN

~ PLUG
(4) NEEDLE
JET

(8) JET
~ (6) SLOW....-'~
NEEDLE ~ JET

(7) THROTTLE ~ (5) MAIN JET

VA LVE

Unscrew the carburetor top and pull the throttle valve out.

Turn the fuel valve OFF and disconnect the fuel line .

Loosen the connecting tube and insulator clamps.

Remolle the carburetor.

1'i4W!ii!d
Keep gasoline 4WOy from fIomes or sparks. Wipe up spilled
gasoline at ona.

Drain the residual gas into a suitable conta iner by removing

the d rain plug.
Reinstall the drain plug.

4-13
FUEL SYSTEM

flOAT, flOAT VALVE AND JETS (1) AlA V ENT TUBE (2) OVERF LOW TUBe

Remove the air vent and overflow tubes from ihe carburetor.
Remove the flolt chamber by removing the two screws.
\

CHAMBER

Remove the float pin , float and float valve. (11 FLOAT (21 FLClAT PIN

Check the float v81v8 and seat for wear or dam,ga. (1) JET .A'" c."
Replace the valve if it', worn or damaged.
Check the float for deformation.
Replace the float if it's deformed,

Remove the jet baHle .

'86: (2) MAIN JET

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

Remove the slow jet .

Remove the throttle stop and air screws. EmITD:~ HIJLDER

NOTE
Before removing the throttle stop and air screws, record
the number of rotations until they seat lightly. so they
can be returned to their original positions.
(5) THROTTLE
STOP SCREW R SCREW

4-14
 FUEL SYSTEM

Aftar '85:
Remove the main let and needle jet.
Remove the slow jet.
Remove the throttle stop and air screws.

NOTE
Before removing the throttle stop and air screws, record
the number of rotations until they slat lightly. so they
can be returned to their origin.1 positions.

Inspect the pilot screw and jets for signs of wear or damage. '85 0) NEEDLE
JET HOLDER
121 SLOW
JET
(6) THROTTLE

I
STOP SCREW

I
.- ----
(5) AIR SCREW
~

(3) MAIN JET _

- ,..- - ...
After '86

(1) THROTTLE
STOP SCREW

~;,
/ (4) NEEDLE
(5) AIR SC REW

Remove the choke valve.

Clean and blow open all jets and openings with compressed
air.

4-15
FUEL SYSTEM

CHOKE VAlVE
Remove the choke valve by loosening the valve nut.

Inspect the choke valve and spring for signs of wear or (1) SP ING
damage .

/
(2) CHOKE VALVE

CARBURETOR ASSEMBLY '85 • _ _~-'" MAIN JET

Install the choke valve.

'85:
Install the needle jet, needle jet holder and lock nut and lock (1) NEED \~~~~~~;~
the needle Jet holder.

Aft, r '85:
Install the needle jet.

After '85 (2) MAIN JET

_........
Install the main jet and slow jet.
(1) NEEDLE
Inst811 the throttle stop screw and air screw to original position
recorded on page 4-14. (After '85: 4-15)

STANDARD AIR SCREW OPENING

'85 : 1·1/2 turns out
Aft,r '85 : 2 turns out

(4) THROTTLE
STOP SCREW (3) AI R SCREW

4-16
 FUEL SYSTEM

Install the jet baffle.

Install the float valve, float and float pin .

Check operation of the float .

flOAT LEVEL ADJUSTMENT

Measure the float level with the float level gauge as shown.

To adjust the float level , bend the float arm carefully until
the float t ip just contacts the float valve.

FLOAT LEVEL : 19.0 mm (0.75 in)

Install the float chamber, overflow and air vent tubes.

CARBURETOR INSTALLATION
Carburetor installation is essentially the reverse order of
removal.

NOTE
A lign the Jug on the carburetor with the groove of t he
carburetor insulator.

Route the carburetor overfl ow and air vent tubes properly

as shown.
After installing the carburetor, make the following adjust-
ments :
Throttle grip free play (Page 3-4).
A ir screw adjustment (Page 4-7). (1) CARBURETOR T UBES

THROTTLE VALVE ASSEMBLY ' BS After '85 e

~ ~ ~
Install the clip on the iet needle. E(2) CLIP (5) CLI P

STANDARD CLIP POSITION '85: 4th Groove

Aft ar ' 85 : 2nd Groove (lIStan~
4th groove
141SIOnl-
2nd groove

(3) JET NEEDLE 161 ":~,,

4-17
FUE~ SYSTEM

Install the jet needle and clip retainer into the throttle valve. 111 JETNEEDI.E

121E[~~El____===-________~

'86:
Slip the rubber cap. carburetor top. spring, and spring seat
over the throttle cable .

Aft,r ' 85:

Slip the rubber cap. carburetor tOp with adjuster, throttle
valve spring and spring sut over the throttle cable.

Compress the throttle valve spring and spring seat and insert
the cable into the slot of the throttle valve.

4-18
 FUEL SYSTEM

In5tall the throttle valvI! assembly into the carburetor aligning

the slot in the valvl! with the locating pin in the carburetor.

TIghten the carburetor top securely.

Inspect and adjust throttle grip free play (Page 3·4).

After ' 91
Install the throttle valve 8ssembly into the carburetor aligning
the slot in the valve with the locBting pin in the carburetor.
Tighten the carburetor top securely.
Tighten the connecting tube and insulator ctamps.
Connect the fuel line.

REED VALVE
Remove the carburetor (Page 4·12).
Remove the four insulator flange bolts and insulator.

Remove the reed valvl! from the cylinder. ( 1) REED VALVE

4-19
FUEL SYSTEM

INSPECTION STOPPER

Check the reed valve assembly for damage or fat igue and
replace if necessary, Replace the lIalve with a new one if the
Jelt rubber is cracked or damaged, or if there is clearance be-
tween the reed and seat.

CAUTION
Do not damage or distort the reed stoppers.
Do not disassemble or bend the reed stoppers as this TTIilY
cOUJe improper engine per/omlance. The reed vallie must
not bt disassembled. If the stopper, reed or seal is faulty,
replllee the assembly.

After '85 {l' STOPPER

INSTALLATION

Inst.llation of the reed valve is enenti.lIy the reverse order

of removii.

NOTE
After installation, check for air leaks around the reed cage
and Insulator.

FUEL LINE AND FUEL FILTER

Drain the fuel from the fuel unk . Disconnect the fue l line .
Repllce the fuel line if it is cracked or damaged.

4-20
 FUEL SYSTEM

Remove the fuel valve from the fuel tank by removing the two
bolts.

,
Wash the filter portion of the fuel valve in high flash point sol- FUEL FILTER
vent and reinstall the removed pan-s .

Do not overtighten the fuel v alve mounting bolts.

Clean the fuel filter and valve in non-flammable or high flash

point solvent.
Check the D -ring for damage and replace with a new one if
necessary.

Reinstall the removed parts.

FUEL TANK
Remove the seat.
11 (3) BAND

~<
Turn the fuel valve OFF, and disconnect the fuel line.

Remove the three radiator shroud mounting bolts and the

shroud,

Remove the fuel tank mounting bolts, band and fuel tank.

li1hW@'
Keep gasoline away from flames or sparks. Wipe up spilled
gasoline 01 once.

Check that fuel flows freely from the fuel valve.

Remove the fuel valve and clean the strainer if fuel flow is
restricted.

Installation is the reverse of removal.

4-21
FUEL SYSTEM

'85-'87:

(1) BREATHER TUBE

(2) FUEL TANK CAP

[7,--- - - - - - - ,
, '85: .
1__ __J

VALVE

(4) LINE

Aft" '87:
(1) BREATHER TUBE
(2) FUEL TANK CAP

(3) L VALVE

(4) LINE

NOTE
. After assembly. make SUfe there ar, no fuel leaks,

4-22
 FUEL SYSTEM

AIR CLEANER CASE

Remove the sub-frame (Page 14·3)
Remove the air cleaner mounting bolt and air cleaner case .
Service the air cleaner element (Page 3- 5)

Check the carburetor connecting tube to see if it is seating pro-

perlv at the air cleaner.
If dirt penetration is detected, disassemble, clean thoroughly
and apply silicone sealer 10 the carburetor.

Connect the tube where it attaches to the air cleaner csse

before assembly.

Check. the air cleaner case for damage or cracks.

'86, '87 shown; '85 similar:

(3) ELEMENT HOLDER

121 AI .CLE'AN I" CASE

(1) SILICONE SEAL

Use silicone seal where
the carburetor connector
tube meets the air (6) AIR CLEANER ELEMENT

CAUTION
The Qir cleQner element is mode
of several different mQteriQ/s
bonded together; to prevent
damaging the element, handle it
carefully.

(9) CARBURETOR (8) FRONT MUD GUARD ('86-'87:)

CONNECT ING CAUTION
TUBE
Install the front mud guard
whenever the motorcycle is to
be operQted in wet tTack con-
ditions.

(7) MUD GUARD

4-23
FUEL SYSTEM

Aft., '87:

(2) MUD GUARD (4) WASHER

~ (5) WING BOLT

(1) SILICONE SEAL

Use silicone seal where
the carburetor connector (6) AIR CLEANER ELEMENT
tube meets the air CAUTION
cleaner case.
The air cleaner element is nwde
of several different moterials
bonded together; to prel'ent
damaging the element. handle it
carefully.

(9) CARBURETOR (81 AIR CLEANER CASE

CONNECTING
TUBE

(7) MUD GUARD

4 -24
ENGINE REMOVAL/ INSTALLATION

'85 :

0.7-1.0 N'm (0.0'7-(). )0 kg·m, 0.5-0.7 ft- Ib)

70-90 N'm
I/.,';:.".Okg·m, 50-65 ft· lb)

30-35 N·m
(3.0-3.5 kg.m,
22-25 ft·lb)

5-0
 ENGINE REMOVAL/INSTALLATION

After '85:

,
~
After '86 :
~~~
, '-4.

After '87 :

0.7-1.0 N'm (0.07--0. 1 kg-m, 0.5--0.7 ft-tb)

/70--90 N'm (7.0-9.0 kg-m,

50-65 ft·lb)

86:
30-35 N·m
(3.0 - 3.5 kg-m, 22 - 25 ft-Ib)
After '86 :
44 -50 N-m
(4 .4 -5.0 kg-m, 32-36 ft-Ib)

5-1
5. ENGINE REMOVAL/ INSTALLATION
SERVICE INFORMATION 5·2 ENGINE INSTALLATION 5·4
ENGINE REMOVAL 5-3

SERVICE INfORMATION
GENERAL

• During removal and installation, support the motorcycle on the optional work stand or other suitable device .
• Parts requiring engine removal for servicing:
Crankshaft Ie:!> Section 91
Transmission I~ Section 9 )
Shift drum and shift fo rks (~ Section 9)

SPECIFICATIONS

Engine dry weigh t ' 85: 14.6 kg (32 . 19 Ib)

'86: 14 .4 kg (31.75Ib)
T ransm ission oil After '86: 14.3 kg (3 1,5 1 1bl
Honda 4 -Stroke oil SAE 10W - 40 or equivalent (see Page 2- 1)
Transmission oil capacity ' 85, ' 86: 0.55 lit I1B .6 US OZ, O.4Blmp qt) after disassembly
0.50 lit (1 7 .0 US oZ. 0 .44 Imp qtl at oil change
After ' 86 : 0.60 lit 10.63 US qt, 0 .53 Imp qti after disassembly
0.55 lit (0.58 US qt, 0. 48 Imp qtl at oil change
Coolant capacity ' 85, ' 86: 0.53 lit 117. 9 US qt. 0.4 6 Imp qt) after disassembly
0 .47 lit 05.9 US qt, 0 .41 Imp qt) at coolant change
After ' 86 : 0 .43 lit (0. 4 5 US qt, 0.38 Imp qtl after disassembly
0 .37 lit (0.39 US qt, 0. 33 Imp qt ) at coolant change

TORQUE VALUES

Engine mounting bolts ' 85, ' 86: 30 - 35 N·m (3.0 - 3 .5 kg-m , 22 - 25 ft·lb)
After ' 86 : 44 - 50 N·m (4.4 - 5 .0 kg-m , 32 - 36 h ·lb)
Swingarm pivot bolt 70- 90 N·m (7.0 - 9.0 kg·m , 50-65 ft·lbl
Rad iator hose clam ps 0 .7- 1.0 N·m (0.07-0.1 kg·m, 0 .5-0.7 ft·lbj
Sub frame bolts 18-25 N·m (1 .8- 2.5 kg·m, 13- 18 ft·lb)

5-2
 ENGINE REMOVAL/INSTALLATION

ENGINE REMOVAl
'85:
Drain the transmission oil (Page 2-2).
Drain the coolant (Page 10-51.
Remove the following:
- seat and fuel tank Wage 4-21).
- expansion chamber (Page 14-5),
- exhaust head pipe (Page 7-21.

After '86:
Drain the transmission oil (Page 2·2).
Drain the coolant (Page 10-5).
Remove the following:
- seat and fuel tank (Page 4-2 1).
- right side cover.
- expansion chamber (Page 14-5).

Disconnect the clutch cable by loosening the upper and lower

adjusters.
Disconnect the spark plug cap.
Disconnect the radiator hoses from the cylinder head and
right crankcase cover.

Disconnect the alternator wire connectors and remove the

wire bands.
Remove the carburetor (Page 4-121.
'85:
Remove the drive chain {Page 3-SI,
After '85:
Remove the left crankcase cover (Page 15-3).

5-3
ENGINE REMOVAL/ INSTALLAT ION

Afte, 'S5:
Hold the drive sprocket with the drive chain and remove the
fixing bolts, plate and sprocket.

NOTE
If the sprocket needs to be replaced, replace both the
sprocket and fixing plate as a matched set.
Replace drive, driven sprockets and the drive chain as a
set.

'85:
Remove the engine mounting bolts.
Remove the swingarm pivot nut and pull out the pivot bolt
until it is just clear of the engine while depressing the brake
pedal.
Remove the engine.

Aft,r '86:
Remove the engine mounting nuts.
Remove the swingarm pivot nut and pull out the pivot bolt
until it is just clear of the engine while depressing the brake
pedal.
Remove the engine from the fra me.

ENGINE INSTALLATION 0) WASHERS

Installat ion is essentially the reverse order of removal.

Add the recommended amount of coolant and transmission
oil up to the correct level (Page 10-5, 2-21 _

NOTE
Use the correct bolts in their proper positions.
Tighten the bolts to the specified torque values.
•
Route the wires and cables properly (Pages 1 -l ' through
' -14,.
' 8 5: 30-35 N·m
• Install the head pipe properly (Page 7-3).

5-4
 ENGINE REMOVAL/INSTALLATION

After installing the engine, perform the follow ing inspections

and adjustmenu :
Transmission oilleyel (Page 2·2).
Throttle grip free play (Page 3·4) .
Clutch cable free play {Page 3· '31 .
Check thet exhaust gas is not leaking past the expansion
chamber connections.

5-5
CYLINDER HEAD/CYLINDER/ PISTON

'85:

12-19 N'm
(1.2-1 . 9 ky-m, 9- 14 ft·lb)

25-29 N·m
(2.5-29
. k9-m , 18-2 1 ft-fbl

7-11 N·m
(0.7
/ - 1 ' 1 kg-m. 5-8 ft -Ib'

5-8 N·m
(0.5-0.8 kg-m
4-6 ft-Ib) ,

'<---~ ~---
." _~.0;?jcYl 25-29 kg-m , 18-21 ft -Ibl
.N·m
12.5-29

5-8 N'm
. k g-m . 4-6 ft-Ib)
(0.5-08

6-0
 CYLINDER HEAD/ CYLINDER/ PISTON

After '85:

a
Aftar '87:

~ 12_19N. ml1 ' 2 - 1.9 kg-m • 9 - 14ft-lb)

25 - 29 N·m
!2.5-2 .9 kg-m . 18 - 2 1 ft-Ib i
Aft er '91 :

After ' 91 :

6-1
6. CYLINDER HEAD/CYLINDER/PISTON
SERVICE INFORMAT ION 6-2 PISTON REMOVAL 6-7
TROUBLESH OOTIN G 6-3 PISTON INSTALLATION 6-9
CYLINOER HEA D 6-4 CYLINDER INSTALLATION 6-10
CYLINDER REMOVAL 6-6

SERVICE INFORMATION
GENERAL

• This section covers maintenance of the cylinder head, cylinder and piston. These services can be done with the engine
installed in the frame .
• Before disassembling, clean the engine thoroughly to keep dirt from entering the engine.
• Remove all gasket material from the mating surfaces.
• Do not use ill screwdriver to remove the cylinder head.
• Clean all parts before inspecting.
• Colt all contacting surfaces with clean engine oil before assembly.
• Under racing conditions, the piston and rings (After '85: ring) should be replaced after 7.5 hours of running. T he piston pin
IIld small end connecting rod bearing should be replaced after 22 hours of running.

SPECIF ICATIONS
mm (in)
ITEM STANDA RD SE RVICE LIMIT
Cylinder head warpage -- 0 .1010.0041
Cylinder '8S 47.000-47 .015 (1.8504-1.8 510) 47.05 (1.852)
1.0.
After '85 46.980-46.995 (1.8496-1.8502) 47.03 (1.851)
Taper 0.1010.0041
Out of round 0.1010.0041
Warpage acron top - - 0.10 (0.004)
Pilton, piston Piston 0.0. 46.945-46.960 (1.8482 1.84881 46.90 (1.846)
pin, piston ring Piston pin boss ('85) 14.40-14.55 (0.567-0.573) 14.8 (0.583) .
'8S 13.002-13.008 (0.51 19-0.5 121) 13.0 2 (0.513)
Piston pin bore
After '85 14.002 14.008 (0.5513 0.5515) 14.02 (0. 559)
'8S 12.994-13.000 (0.511 6-0.5 11 8) 12.97 (0.51 1)
Piston pin 0 .0 .
After '85 13.994- 14.000 (0.5509-0.5511) 13.97 (0.550)
Piston·to·pin clearance 0.002-0.014 (0.0001-0.0006) 0.02 (0.001)
Piston ring end gap 0.20- 0.40 (0.008-0.01 61 O.SO 10.0201
Cylinder-to.piston clearance 0.04-0.07 (0.002-0.003) 0.10 (0.0041
Connecting rod small end 1.0. 18.005-18.017 (0.7089-0.7093) 18.03 (0.7 10)

TORQUE VA LUES

Cylinder head nuts 25-29 N·m (2.5-2.9 kg.m, 18-21 ft-tbJ

Cylinder nuts 25-29 N·m (2 .5-2.9 kg-m,18-21 ft-tb)
ATAC tdjuster lock nut ('85) 4- 6 N'm (0.4-0.6 kg·m, 3- 5 ft·lb)
Rack hole plug ('85) 5-8 N·m (0.5-0.8 kg·m, 4- 6 ft· lb)
ATAC adjuster holder ('85) 5-8 N·m (0.5-0.8 kg-m, 4- 6 ft-Ib)
Spark plug 12-19N·m (1.2- 1.9kg·m, 9-14ft-lb)
Carburetor insulator bolt 7 - 11 N·m 10 .7 - 1.1 kg-m, 5 - 8 ft-tbl

6-2
 CYLINDER HEAD/ CYLINDER/ PISTON

TROUBLESHOOTING
Low compression, hard starting or poor perfor- Abnormal noi,. - pilton
mlnee It low speed Worn or cracked piston.
Blown cylinder head gasket and/or base gasket. Worn cylinder and piston.
Loose spark plug. Worn piston pin or piston pin hole.
Worn, stuck or broken piston rings. (After '85 : piston ring) Worn connecting rod smlll end bearing.
Worn or damaged cylinder and piston.
Faulty reed lIalve. Abnormal noise - piston rings
Worn crankshaft seals. Worn, stuck or broken piston rings. lAtter '85: piston ringl
• Worn or damaged cyl inder .
High compression, overheating or knocking
Excessive carbon buildup in combust ion chamber Contaminated coolant
or on piston top. • Leak ing cylinder head gasket.

6-3
CYLINDER HEAD/CYLINDER/ PISTON

CYLINDER HEAD
REMOVAL

Drain the radiator coolant (Page 10-5) ,

Loosen the radiator hose clamps and remove the radiator hoses
from the cylinder head.
Remove the spark plug cap and spark plug.

Remove the four cylinder head nuts and the cylinder head.

COMBUSTION CHAMB ER DECARBONIZING

Remove the carbon deposits from the combustion chamber.

Clean the head gasket surface of all gasket material.

NOTE
Be careful not to scratch the cylinder mating surface or
the combustion chamber.

INSPECTION

Check the cylinder head for warpage with a straight edge and
a feeler gauge in the directions shown.

SERVICE LIMIT : 0.10 mm (0.004 in)

6-4
 CYLINDER HEAD/CYLINDER/PISTON

INSTALLATION

Clean the cylinder head mating surface, taking care not to drop
any gasket material into the cylinder bore and liquid cooling
passages. Placing small portions of a clean paper towel in each
liquid passage and a clean shop towel in the cylinder will help
prevent this gasket debris from entering these areas.
A light blast of compressed air across the top of the cylinder
prior to removing the paper towel portions and shop towel will
aid in this procedure.

Install a new gasket onto the cylinder with its tab facing the
carburetor.

Place the cylinder head onto the cylinder with its arrow
facing forward.

Install the four nuts and tighten to the specified torque in

2-3 steps.

TORQUE: 25-29 N'm (2.S-2.9 kll,m. 18-21 ft·lb)

Install the spark plug and plug cap.

Connect the radiator hoses to the cylinder head .
Pour the recommended coolant mixture up to the correct
level {Page 10-5).

6-5
CY LIND ER H EAD/ CY LINDER /PISTON

CYLINDER REMOVAL (l)CYLI

r
(4) EXHAUST
Remove the following:
MAN IFOLD
- expansion chamber 1'85: Page 14-5, After '85: Page 14-6). (After '85)
- head pipe ('S5: Page 7·2).
- ATAC rack ('85: Page 7·4).
- carburetor (Page 4-12).
reed vallie (Page 4-19).
- cylinder head (Page 6-4\.
- radiator-te-water pump hose.
- exhaust manifold (After '85).

Loosen the clutch cable lower adjuster.

Remove the cylinder mounting nuts and remolle the cylinder.

CAUTION
• Do not pry or strike the cylinder.

Remove the dowel pins and gasket.

,
)

CYLINDER INSPECT ION

Clean carbon deposits from the exhaust port area.

CAUTION

• Do not damage the cylinder bore.

Clean the head and cylinder gasket surfaces of all gasket

material.

6-6
 CYLINDER HEAD/CYLINDER/ PISTDN

Use a straight edge and feeler gauge to check the head gasket
surface on the cylinder for warpage. If warpage is beyond the
service limit, resurface or replace the cylinder.
SERVICE LIMIT : 0.10 mm (0.004 in)
Check that the cyl inder studs are tight. If any are loose,
remove them, clean their threads with contact cleaner, then
reinstall them using Honda Anaerobic Thread lock, or an
equivalent.
Measure the cylinder 10 15-20 mm (0.6-0.8 in) from top
in X and Y directions.
Use the largest figure measured to determine the cylinder
bore.
SERVICE LIMIT '85 : 47.05 mm (1.852 in)
After '85 ; 47.03 rnm (1.851 in)
'85 :
Rebore the cylinder if it is worn or seized.

After boring, refer to page 1 - 16 for specifications on restor·

ing the radius of the exhaust port bridge.

CAUTION

Failure to radius this bridge may lead to a broken ring and

a seized piston.

There are two oversize pistons and piston rings; 0.25 and 0.50
mm.

OVERSIZE CYLINDER BORE

0.25 mm 47.250-47.265 mm
(0.01 in) (1.8602-1.8608 in)

0.50 mm 47.500-47.516 mm
(0.02 in) (1.8700-1.8707 in)

Check that the cylinder head studs are tight. If any are loose,
remove them. clean their threads with contact cleaner, then
reinstall them using Honda Anaerobic Thread Lock, or its
equivalent.

After '85:
There is not an oversize piston fo r these models, since the
engine uses a sleeveless aluminum cylinder with a special
coating on the piston sliding surfaces (Nikasil plated cylinder).

PISTON REMOVAL
(1) PISTON PIN
Place a clean shop towel over the crankcase bore.
Remove the piston pin clip and press the piston pin out of
the piston.

Remove the piston.

NOTE :
Do not allow any pressure to be placed on the connecting
rod when pressing the piston pin out.
Under racing conditions, t he piston and rings (After '85:
ring) should be replaced after about 7.5 hours of running.
And the piston pin and connecting rod small end bearing
should be replaced after about 22.5 hours of running.

6-7
CYLINDER HEAD/CYLINDER /PISTON

Measure the piston 0.0. 10 mm (3/B in) from the bottom of

the skirt and at a fight angle to the piston pin hole.

SERVICE LtMIT: 46.90 mm 11.846 in)

If the 0.0. is under t he service limit , replace the piston with a

new one. 10 mm

Calculate the piston·to-cylinder clearance.

SERVICE LIMIT: 0.10 mm (0.004 inl

'85 : '85 ~4
Measure the piston pin boss inside width as shown.
;/ ~
SERVICE LIMIT : 14.8 mm (0.58 in )
If the width is over the service limit, replace the piston with a
new one.
-..
~
-.'
4!!!it
"-
Measure the piston pin bore. \

SERVICE LIMIT '85 : 13.02 mm (0.513 in)

After '85 : 14.02 mm (0.552 in) -
~

Check the piston pin for wear and excessive discoloration.

NOTE
Excessive discoloration may indicate that the pin is sticking
or binding in the piston or connecting rod. Check the
pinon pin bore and connecting rod bore for signs of bind-
ing.

Measure the 0.0.

SERVICE LIMIT '85 : 12.97 mm (0.511 in)
After '85 : 13.97 mm to.550 in)
-- --
Calculate the piston pin-to-piston clearance.

SERVICE LIMIT: 0.02 mm (0.001 in)

PISTON RING REMO VAL

Spread each piston ring and remove by lifting it up at a point

opposit e the gap.

CAUTI O N

Do not darruzge the piston ring! (A/reT '85: the piston ring)
by spreading the ends (AfteT '85: the end) too faT.

6-8
 CYLINDER HEAD/CYLINDER /PISTON

PISTON RING END GAP INSPECTION

Set the piston ring in the cylinder square to the bore 35 shown
and measure the ring end gap wit h a feeter gauge . If the gap
exceeds the service limit, replace the ring.

SERVICE LIMIT : 0.50 mm (0.020 in )

If the end gap is still over the service limit with a new ring, the
cylinder must be reoored and fitted with a new oversiZe piston
and rings. (After '85: the cylinder must be replaced.)

CONNECTING ROD INSPECTION

Install the bearing and piston pin in the connecting rod imaH
end and check for excessive play.

If it feels loose, measure the connecting rod small end LD.

SERVICE LIMIT: 18.03 mm to.710 in)

If not over the service limit, replace the piston pin and small
end bearing.
If over the service limit, the crankshaft assembly will have to
be replaced.

PISTON INSTAllATION (1) MARK

"T" OR " Au
'85:
Clean the piston ring grooves.
Install the piston rings on the piston with the marks facing up.

After '85:
Clean the piston ring groove. (1) MARK
Install the piston ring on the piston with the mark facing up. UN"

6-9
CYLINDER HEAD/CYLINDER/PISTON

Apply clean 2'stroke oil to t he small end bearing and piston

pin.
Install the piston on the connecting rod with the small end
bearing and piston pin.

NOTE
Install the piston with the "I N" mark toward the intake
side.

CYLINDER INSTALLATION
Clean the cylinder gasket surface being careful not to drop any
gasket material into the crankcase.

Check that the cylinder hold down studs are tight. If any
ilIre loose, remove them, clean their threads with contact
cleaner, then reinstal l using Honda Anaerobic Thread Lock,
or its equivalent.

Place a new cylinder base gasket on the crankcase.

Install the dowel pins, , 111 DOI;:'EL

Align each ring end gap with the piston ring pins (After '85 :
pin) in the ring land.

6-10
 CYLINDER HEAD/CYLINDER/ PISTON

Apply a thin coat of 2-stroke oil to the cylinder wall and

pi5ton rings.

Slowly lower the cylinder over the piston while compressing

the piston rings (After '85: the piston ring). Take care not to
catch the rings (After '85: the ring) on a port.

Place the clutch cable holder onto the ri ght rear cylinder
mounting stud.

Tighten the four cylinder mounting nuts in a criss cross pat-

tern in 2 to 3 steps to the specified torque .

TORQUE : 25-29 N'm 12.5 - 2.9 kg-m. 18 -2 1 ft·lbl

Install the following:

new gasket and exhaust manifold (After '85).
radiator-Ie-water pump hose.
cylinder head (Page 6-51,
read valve (Page 4-20),
carburetor (Page 4-17),
ATAe rack ('85: Page 7·4).
head pipe ('85: Page 7-3).
expansion chamber ('85: Page 14·5, After '85: Page 14·6) .
Adjust clutch lever free play {Paga 3 · 13).

Perform the following inspections:

Check for compression leaks.
listen for abnormal engine noises.
Check for carburetor insulalor air leaks.

Fill the radiator with coolant (Page 10-4).

6-11
ATACSYSTEM

25- 29 N·m
(2.5-2.9 kg·m. 18-21 ft·lb)

5- 8 N'm
(0.5-0.8 kg-m, 4-6 ft-I b)

5-8 N·m
(0.5-0.8 kg-m,
4-6 ft·lb)

4-6 N·m

10.4-0.6
3--4 h-Ib)',-m, ------:t~?~~~
WJ' ~~.1'(i

7-0
 7. '85 : ATAe SYSTEM
SERVICE INFORMATION 7-' GOVERNOR / RACK/CAM 7-4
TROUBLESHOOTING 7-' ATAC VALVE ADJUSTMENT 7-6
HEAD PIPE 7 -2

SERVICE INFORMATION
GENERAL

• This section covers maintenance of the A T AC (Automatically-controlled TorQue Ampl if ication Chamber) sYltem .
• The ATAC system should be adjusted whenever the related parts (rack, expansion chamber, governor and/or water pump
shaft) are replaced. (Page 7·6)

TORQUE VALUES

Adjuster lock nut: 4- 6 N·m (0.4-0.6 kg-m, 3- 5 ft -Ib)

Rack hole plug: 5- 8 N·m (0.5-0.8 kg-m, 4-6 ft·lb)
Adjuster holder: 5-8 N'm (0.5-0.8 kg-m. 4-6 fHb)

TROUBLESHOOTING
Poor performance at low speed
Butterfly valve does not open fully.
- Improperly adjusted ATAC system,
- Faulty governor.
- Worn AT AC governor cam.
- Bent valve shaft.
Excessive carbon build-up in sub chamber.
Damaged AT AC-chamber.

Poor performance at h igh speed

Butterfly valve does not c lose fully .
Improperly adjusted AT AC-chamber.
- Faulty governor.
- Broken rack spring.
- Worn rack and/or pin ion.
Damaged butterfly valve.
Worn exhaust pipe seal.

7-1
ATACK SYSTEM

HEAD PIPE
ATAC CHAMBER REMOVAL

Remove the two bolts and the AT AC chamber from the

head pipe.

ATAC CHAMBER INSPECTION

Check the ATAC chamber for cracks or deformation, and

replace it if nectssary.
Remove any carbon deposits from the AT AC chamber.

HEAD PIPE REMOVAL

Remove the expansion chamber (Page 14-5),

Remove the three bolu and the head pipe.

/
(2) HEAD PIPE

HEAD PIPE INSPECTION RII-rTOR" Y VA LVE

Remove all carbon deposits from the head pipe.

Check the butterfly valve for smooth operation by turning

the valve shaft.

Check that the valve closes fully. If it does not, check for and
remove any deposits that may be obstructing the vatlle seating
area.
If the valve still won't close properly. replace the head pipe,

7-2
 ATACK SYSTEM

HEAD PIPE INSTALLATION

Set a new gasket onto the cylinder.

Hold the butterfly valve vertically and inrert the pinion into
the cylinder.

NOTE
Be sure the pinion teeth engage the rltCk teeth properly
before tighten ing the head pipe bolts.
The right crankcase cover must be installed when installing
the head pipe, otherwise the butterfly valve w ill not stay
in posit ion.

Install the head pipe in poSition wit h the butterfly valve fully
open !vertical) tighten the head pipe mounting bolts.
(2) HEAD PIPE
If the butterfly valve does not fully open after installat ion,
adjust the ATAC system (Page 7·6).

NOTE
If the butterfly valve is out of position by 45° degrees or
more reset the head p ipe.

Install the expansion chamber (Page 14·5). (3) BUTTERFLY VALVE

ATAC CHAMBER INSTALLATION

Install a new gasket onto the head pipe.

Install the ATAC chamber onto the head p ipe using the two
bolts.

7-3
I
ATACK SYSTEM

GOYERNOR/RACK/ CAM
GOVERNOR D ISASSEMB LY

Remove the right crankcase cover (Page 8-3) .

While pressing down on the spring end of the governor rocker
arm, loosen and remove the screws and rocker arm.

Remove the governor spring and spring seats. (1) SPRING SPRING

Remove the governor and steel balls.

RAC K/CAM REMOVAL 111 HA"Klll

Remove the head pipe (Page 7·2) .

Remove the rack hole plug and sealing washer.
Remove the spring and pull out the rack using a magnet.

131 PLUG ~.
iEALING WASHER

7-4
 ATACK SYSTEM

Check the spring and rack for wear or damage, and replace
them if necessary.

Remove the right crankcase cover (Page 8·3).

Pull out the cl ip from the governor camshaft and remove the
lower cam.

Remove the cylinder (Page 6·6) .

Remove the upper cam and bushing.
Check the cams, camshaft and bushing for wear or damage,
replace if necessary.

CAM/RACK INSTALLATION

Clean all disassembled parts.

Install the upper cam and bushing into the crankcase.
Install the cylinder (Page 6· 10).
Install the lower cam and clip.

";":_ J

7-5
ATACK SYSTEM
Slide the rack into the cylinder with the head pipe angle Band
rack angle A parallel. Use II screwdriver to adjsut t he position
of the rack groove, IS necessary .
Install the spring, sealing washer and plug.

TORQUE : 8-12 N'm (0.8-1.2 kg-m, 6-9 ft·lb)

Install the head pipe (Page 7·3) and expansion chamber

(Page 14-6) .

GOVERNOR ASSEMBLY
Install the steel balls (governor weights) in the water pump
drive geaf.

Install the governor housing.

Install the spring selts and governor spring.

NOTE
Note the direction of the spring seats.
• Align the rocker arm ends with the bosses of the governor.

Position the governor rocker arm in place; press down against

the spring and install the screws .

Reinstall the right crankcase cover (Page S.4).

AlAe VAlVE ADJUSTMENT 111 SCREW

Remove the expansion chamber (Page 14- 51 and ATAe

chamber IPage 7-2 ).
Remolle the right crankcase cover !Page 8·3).
Inspect the butterfly lIallle. It should be tully closed .
If t he butterfly vallie is stilt open. loosen t he lock nut and
screw out the adjusting screw until the valve is fullv closed.

(2) LOCK NUT

(3) BUTTERFLY VALVE

7-6
 ATACK SYSTEM

Turn in the adjusting screw until you feel the screw end
touching the upper cam, then turn the screw in 1/2 turn fur-
ther and tighten the lock nut securely.

(2) ADJUSTlNG:~~#;~f'
Inst/lll the right crankcase cover (Page 8-4).
After installing the right crankcase cover, check that the
butterfly valve is V1!rtical. Adjust the butterfly position as
necessary.

Install the exhaust chamber and ATAC chamber.

7-7
CLUTCH/KICKSTARTER/SHIFT LINKAGE

After '85 :

45-55 N'm
(4.5-5.5 kgom. 33-40 ft·lb)
After '85 :

:----1 o

8-0
 8. CLUTCH/KICKSTARTER/SHIFT LINKAGE
SERVICE INFORMATION 8-1 CLUTCH 8-5
TROUBLESHOOTING 8-2 SHIFT LINKAGE 8-10
RIGHT CRANKCASE COVER 8-3 KICKSTARTER 8-13

SERVICE INFORMATION
GENERAL

• The clutch, kickstarter and shift linkage can be serviced with the engine in the frame.
• Remove all gasket material from the crankcase mating surfaces.
• Do not allow dirt in the engine .
• Be careful not to damttgl! the case mating surfaces during disassembly .
• Clean all parts before inspecting. Coat all contacting surfaces with clean transmission oil before assembly.

SPECIFICATIONS
mmHnl D
ITEM STANDARD SERV ICE LIMIT
Clutch lever free play 10-20 13/8 3/41
Clutch spring free length '85, '86 37.50.48) 36.5 (1.44)
After '86 36.4 0.43 ) 35.4 (1.39)
Clutch plate warpage
. - - 0.15 10.0061
Clutch disc thickness 2.80-2.90 (0.110- 0.114) 2.7 10.111
'85 20.000-20.021 fO.1874 - 0.78821 20_04 10,7891
Clutch outer 1.0. (0.8661 0.8670)
After '85 22.000-22.021 22.04 10.8581
Kickstarter shaft 0 .0. 16.978- 16.989 (0.6684-0.6689) 16.96 (0.668)
Kickstarter pinion gear LO. 19.020- 19.041 (0.7488-0.7496) 19.05 (0.750)
1.0. 17.016- 18.995 (0.7473-0.7478) 17.06 (0.672)
Kickstarter pinion bushing (0.7473 0.7478)
0.0. 18.982 18.995 18.96 (0.747)
Countershaft 0.0. 14.982-15.000 10.5898-0_59061 14.96 10.5891
Kickstarter idler gear
Gear 1.0. 15.032-15.050 (0.5918-0.5925) 15.08 10.5941
Mainshaft 0.0. at clutch outer ('85) 19,964 19.985 (0.7860 0.7868) 19.95 10.7851
Mainshaft 0.0. at clutch outer guide (After '85) 16.966-16.984 (0.6680- 0.6686) 16.95 10_6671
height 30.40-30.50 O. 197-L200J 30.35 11. 195)
Clutch outer guide (After '85) 0.0. 21.964-21.985 10.8647-0.8655) 21.95 (0.8541
1.0. 17.000- 17.018 (0.6692 0.6699) 17.03 10.6701

TORQUE VALUES

Primary drive gear nut '85: 45-55 N·m 14.5-5.5 kg·m, 33--40 ft·lb)
After '85: SO- SO N·m (S.0-6.0 kg·m, 36--43 ft·lb)
Clutch center bolt 40-50 N·m (4.0-5.0 kg·m, 29-36 ft·lb)

TOOLS

Special
Clutch center holder 07923 -9580000
Primary gear holder 07724-0010200

8-1
CLUTCH/ KICKSTARTERISHIFT LINKAGE

TROUBLESHOOTING
Clutch slips when accelerating
No free play.
Discs worn.
Spring weak.

Clutch operation feels rough

• Outer drum slots rough .

Clutch will not disengage - motorcycle c rHps with clutch disenpged

Too much free play.
• Plates warped.

Excessi"e lever pressure

Clutch cable kinked, damaged or dirty .
Ufter mechanism damaged.
Clutch cable not routed properly.

8-2
 CLUTCH/KI CKSTARTERI SHIFT LINKAGE

RIGHT CRANKCASE COYER

REMOVAL

'85:
Drain the radiator coolant (Page 10-4).
Drain the transmission olt (Page 2·2).
Remove the brake pedal (Page 12-1 71 .
Disconnect the radiator hoses from the water pump.
Remove the kickstarter lever.
Disconnect the clutch cable,
Remove the right crankcase cover mounting bolts and remove
the right crankcase cover.
Remove the gasket and dowel pins.

Aft.r '85:
Drain the radiator coolant (Page 10-4).
Drain the transmission oil (Page 2·2).
Remove the brake pedal (Page 12·' 7),
Disconnect the radiator hoses from the water pump.
Remove the kickstarter lever.

',
Remove the len right crankcase covar mounting bolts.
Remove the right crankcase cover while d isconnecting t he
4;:-
'.
if
clutch cable.

Remove the gasket and dowel pins,

OISASSEMBLY

'85:
Remove the clutch lifter rod and clutch arm.
Visually inspect the D-ring for damage and check the clutch
arm for bending or damage.

8-3
 -
CLUTCH/ KICKSTARTER/SHIFT LINKAGE

Aft., '85: After '85

Remove the clutch lifter rod and clutch arm.
Visually inspect the oil seal for damage and check the clutch
arm for damage.

ASSEMBLY

Install the clutch arm lind clutch lifter rod on the right crank-
C~ cover. 1"!1~
y
21"'!C~L~
UTCH ARM

INSTALLATION

Clean the gasket surface and install the dowel pins and a new
gasket on the right crankcase .

Remove the water pump cover from the right crankcase cover.

Connect the clutch cable (After '85).

Install the right crankcase cover.

Rotate the water pump impeller bv hand to be sure that the

gears are meshing as you install the right crankcase cover.

NOTE
• Tighten the bolts in II crisscross pattern in 2·3 steps.

Install the water pump cover.

Connect the clutch cable ('85).

InstaU the kickstarter lever and brake pedal (Page 12· 17).
Connect the radiator hoses to the water pump.
Fill the cooling system with coolant (Page 104).
Fill the transmission with the recommended oil (Page 2·2).
Adjust the clutch lever free play (Page 3· 13) .

8-4
 CLUTCH/ KICKSTARTER / SHIFT LINKAGE

CLUTCH
CLUTCH REMOVAL

Remove the right crankcase cover (Page 8·3).

Remove the clutch lifter plate bolts, clutch lifter plate, clutch
springs and clutch release bearing.

NOTE
• Loosen the bolts in a crisscross pattern in 2 to 3 steps.

Hold the clutch center with a clutch center holder tool and
remove t he clutch bolt and washer.

Remove the clutch center, clutch discs, clutch plates and pres-
sure plate.

Remove the thrust washer.

8-5
CLUTCH/ KICKSTARTERI SHIFT LINKAGE

Hold the primary drive gear using the gear holder and remove
the drive gear nUl.

Remolle the clutch outer together with the water pump gear.
Remolle the primary drive gear.
Remove the dutch outer guide (After '85).

INSPECTION

Measure the free length of each clutch spring.

SERVICE LIMIT
' 85. '86: 36.5 mm (1 .44 in)
Aftef '86: 35.4 mm (1.39 Inl
Replace the clutch springs as a set if any of them are shorter
than the service limit.

Replace the clutch discs if they show signs of scoring or dis·

coloration.

Measure the thickness of each disc.

SERVICE LIMIT: 2.7 mm (0.11 in)

Replace the discs if they are thinner than the service limit.

8-6
 CLUTCH/ KICKSTARTERI SHIFT LINKAGE

Check for plate warpage on a surface plate, using a feeler

gauge.

SERV ICE LIMIT : 0.15 mm (0.006 in )

Check the slots in the outer drum for nicks, cuts or indenta- (1)
tions made by the friction discs.

Measure the 1.0. of the clutch outer bushing.

SE RVIC E LIMIT '85 : 20.04 mm (0.789 in)

After '85 : 22.04 mm (0.868 in)

'85:
Measure where Ihe clutch outer spins on the mainshaft.

SERV ICE LIMIT: 19.95 mm (0.785 in)

After '85:
Measure the mainshaft 0.0. at the clutch outer guide.

SERVICE LIMIT : 16.95 mm (0.661 in)

Measure the 1.0., 0.0. and height of clutch outer guide.

SERVICE LIMIT 1.0. : 17.03 mm (0.670 in)

0.0. : 21 .95 mm (0.864 in)
height: 30,35 mm ( 1.195 in)

8-7
CLUTCH/ KICKSTARTER/ SHIFT LINKAGE

CLUTCH INSTALLATION

Install the primary drive gear.

Install (After '85: the clutch outer guide,) the clutch outer
and water pump gear.

Install the gear holder and tighten the drive gear nut.

TORQUE
'85: 45-55 N·m (4.5-5.5 kg·m, 33-40 ft-Ibl
After '85: 50-60 N·m (5,D-6.0 kg-m, 36-43 ft-Ib)

Install the thrust washer onto the mainshaft.

Coat the discs and plates with etean transmission oi1. '85
(2) CLUTC H PLATE (4)
Install the following parts in the clutch outer: 0) CLUTCH DISC (5)
- pressure plate.
- clutch discs and clutch plates.
- clutch center.
- clutch outer guide (After '85) .

(4) PRESSURE
(3) CLUTCH CENTER PLATE

8-8
 CLUTCH/ KICKSTARTER I SHIFT LINKAGE

After '85

(1) CLUTCH OUTER GU I DE

Install the clutch lock washer and bolt with washer's "OUT"
mark facing o ut.

Hold the clutch with the clutch holder and tighten the clutch
bolt.

TORQUE : 40-50 N·m 14.0- 5.0 kg-rn, 29- 36 ft-Ibl

Install the clutch springs, lifter plate and release bearing.

Tighten the bolts in a crisscross pattern in 2 t o 3 steps.
Install the righ t crankcase cover !Page 8·4).

8-9
CLUTCH/ KICKSTARTERISHI FT liNKAGE

SHIFT LINKAGE
REMOVAL
Remove the clutch assembly (Page 8·5).
Remove the gearshift lever.

Remove t he gearshift spind le and collar.

Remove the two attaching bolts end remove the shift guide
plate together with the drum shifter.

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

8-10
 CLUTCH/ KICKSTARTER/ SHIFT LINKAGE

Remove the drum center bolt, drum cam and dowel pin from
the shift drum.

DRUM SHIFTER DISASSEMBLY/ ASSEMBLY (2) DRUM SHIFTER

Remove the pawls and remove the pins and springs.

Remove the drum shifter from the stopper guide plate.

Assemblv is the reverse order of disassembly.

(3) PIN S (4) STOPPER GUIDE PLATE

INSPECTION

Inspect the stopper arm and spring for damage.

Inspect the return spring for damage and inspect t he gearshift
shaft for wear or bending.

(2) RETURN SPRIN G

!1) GEARSHIFT SHAFT

141 SPRING

(3) DRUM STOPPE R ARM

8-11
CLUTCH/ KICKSTARTERI SHIFT LINKAGE

INSTALLATION

Install the dowel pin in its hole in the shift drum.

Install the drum cam by aligning the hole in the drum cam
with the dowel pin in the shift drum.

Tighten the drum center bolt.

Install the stopper arm spring, washer and stopper arm and
tighten the stopper arm bolt.

(4) SPR ING

Install the drum shifter and the guide plate, and tighten two
shift guide plate bolts,

Install the collar onto the drum shifter pin.

(3) COLLAR (4) STIOP!~~:!.!!:~~E

Install the gearshift shaft by aligning the slot of the gearshift

shaft arm with the pin of the drum Shifter, and the return
spring with the pin oolt.

131 GEARSHI F1·~~~A~R~M SLOT

8-12
 CLUTCH/K ICKSTARTERI SHIFT LINKAGE

Install the gearshift lever.

Install the cl utch assembly (Page 8-8) and insta ll the right
crankcase cover (Page 8·4).

KICKSTARTER
REMO VA L

Remove the right crankcase cover (Page 8-3) and the clutch
(Page 8-51,

Remo ve the kickstarter idler gear.

Remo ve the kickstarter return spring hook from the hole in

the right crankcase and remove the kickstarter assembly.

Bend down the lock washer tab and remove the ratchet
guide plate bolt.

Remove the lock washer and the ratchet guide plate .

8-13
CLUTCH/K ICKSTARTERI SHI FT LINKAGE

DISASSEMBLY (1) RATCHET (2) SPRING (3) PINION GEAR

~~
~
Remove the snap ring and collar from the shaft.
Then slide off all the remaining components. 191 WASHE R

~~~
,~ W

(4) BUSHING

(5) RETURN SPRING

P
(7) COLLAR (6) KICKSTARTER SHAFT

INSPECTION (3) KICKSTARTER

SHAFT '"
Measure the kickstarter shaft 0.0.

SERVICE LIMIT: 16.96 mm (0.668 in)

Measure the pinion gear bushing 0.0. and I.D.

SERVICE LIMIT:
0 .0 .: 18.96 mm (0.747 in)
I.D.: 17.06 mm (0.672 in)
11) PINION (2) PINION
Inspect the pinion gear and pawl for damage. GEAR BUSH ING
Measure the pinion gear I,D.

SERVICE LIMIT : 19.05 mm (0.750 in)

Measure the kick starter idler gear I.D.

SERVICE LIMIT : 15.08 mm (0.594 In)

(1) KICKSTARTER
IDLER GEAR

Measure the 0.0. of the countershaft end.

SERVICE LIMIT: 14.96 mm 10.589 in)

8-14
 CLUTCH/K ICKSTARTERISHIFT LINKAGE

ASSEMBLY

Install the thrust washer, bushing, and the pinion gear onto the (2) THRUST
kickstarter shaft.
WAS~

b!il~~~ljl!!3:I~KST.ARAR PINION GEAR

Install the thrust washer, return spring and collar onto the kick (1) THRUST (2) COLLAR
starter shaft.

Eij]ETURNSPRING
Install the ratchet onto the kickstarter shaft aligning the III RATCHET (2) PUNCH MARKS
punch mark on the ratchet with the one on the shaft.

Install the thrust \pring onto the starter shaft. (1) THRUST SPRING

8-15
CLUTCH/ KICKSTARTER I SHIFT LINKAGE

INSTAL LAT ION

Position the ratchet guide plate onto the right crankcase

aligning its slot with the locating pin on the crankcase.
Install the lock washer and bolt, aligning the look washer tab
with the slot in the ratchet guide plate and tighten the boh.
Bend up the lock washer tab against the bolt head as shown.

InstaU the kickstarter assembly in the crankcase with the

drive ratchet resting against the ratchet guide plate.

Hook the return spring in the hole of the right crankcase as

shown.

Install the idler gear onto the countershaft.

Install the clutch assembly !Page 8-8) and the right crankcase
cover (Page 8·4).

8-16
CRANKCASefTRANSMISSION/CRANKSHAFT

9-0
 9. CRANKCASE/TRANSMISSION/ CRANKSHAFT
SERVICE INFORMATION 9 -1 CRANKSHAFT REMOVAL 9-7
TROUBL ESHOOT ING 9 -2 CRANKSHAFT INSTALLATION 9-7
CRANKCASE SEPA RATION 9 -3 TRANSMISSION ASSEMBLY 9-1 0
TRANSMI SSION DI SASSEMBLY 9-4 CRAN KCASE ASSEMBLY 9-11

SERVICE INFORMATION
GENERAL

The crankcase halves must be separated to repair the transmission and crankshaft. Remove the following parts before sepa-
rating the crankcase.

Clutch (Section 8) Cylinder head (Section 6) .

Kickstarter shaft (Section 8). Cylinder (Section 6),
Sh ift shaft (Section 8). Piston (Sect ion 6).
Alternator (Section 15).

SPECI FICATIONS

ITEM STANDARD SERVICE LIMIT

mm Un) IJ
Shih fork 1.0 . 11 .027- 11.042 (0.4341 - 0 .434 7) 11.06 (0.435)
Shift fork pawl thickness 4 .93 - 5.00 (0.194-0.1971 4.88 10.1921
Shift fork shaft 0.0. 10.969-10.980 (0.4318- 0.4323) 10.95 (0.431 )
MS, M6 gears 17.016- 17.034 (0.6699- 0.6706) 17.10 (0.673)
CI gear 16.516- 16.534 (0.6501 0 .6509) 16.60 10.6541
Gear 1.0 .
C2 gear 20.020 20.041 (0.7881-0.7890) 20.10 (0.791 )
C3, C4 gears 19.020 19.041 (0.7488-0.7496) 19.10 (0.7521
1.0. 17.0 16 17.034 (0.6699 0.6706) 17.10 (0.6731
C2 gear bushing
0.0. 19.984- 19.995 (0.7868-0.7872) 19.92 (0.7841
At clutch outer ('S5) 19.964 19.985 (0.7860-0.7868) 19.95 (0.7B51
Mainshaft 0.0.
At M5. M6 16.966 16.984 (0.6679 0.6686) 16.95 10.6671
At C1 16.466- 16.484 (0.6483 0.6489) 16.45 10.64BI
At C3, C4 18.959- 18.980 (0.7464- 0.7472) 18.94 10.7461
Countershaft 0.0.
At C2 ('85 '87) 16.978 16.989 (0.6684 0.6689) 16.96 10.66BI
At C2 (After '87) 16.981 16.992 (0.6685 0.6690) 16.96 (0.668)
At starter idler 14.982 15.000 (0.5898-0.5906) 14.96 (0.589)
Connecting rod big end radial ' B5 0.009- 0.023 (0.0004--0.0009) 0.030 (0.001)
clearance After ' 85 0.013- 0.027 (0.0005-0.0011 ) 0.034 10.0011
Connecting rod big end side clearance 0.15 - 0.55 (0.0059-0.02 17) 0.7 (0.031
Crankshaft journal runout 0.020- 0.035 (0.0008--0.0014) 0.10 10.0041

9-1
CRANKCASEITRANSMISSION/CRANKSHAFT

TOOLS

Special
Bearing remover, 12 mm 07936-1660 100
Remover weight 07741 - 0010201 or 07936-3710200
Case puller 07937- 4300000
Assembly bolt 07965-1660200
Assembly collar 07965-1660300
Driver attachment, 28 x 30 mm 07946-1870100
Driver 07946-MJ00100
Universal bearing puller 07631-0010000 or commercially available in U.S.A.

Common
Attachment, 37 x 40 mm (After '85) 07746-0010200
Attachment, 42 x 47 mm 07746-0010300
Attachment, 52 x 55 mm 07746-0010400
Pilot, 17 mm 07746- 0040400
Pilot. 20 mm 07746- 0040500
Pilot, 22 mm 07746-004 1000
Pilot, 25 mm 07746- 0040600
Driver 07749-0010000
Universal holder ('S5) 07725- 0030000 or 07725-0010101

TROUBLESHOOTING
Engine vibration
• E)(cessive crankshaft runout .

Engine noise
Worn crankpin bearing.
Worn crankshaft bearing(s).
Worn transmission bearing(s) .

Transmission jumps out of gear

Worn gear dogs and holes.
Bent or damaged shift fork.
Bent shift fork shaft .
Damaged shift drum stopper.

Hard to shift
Clutch not adjusted properly.
Bent shift fork .
Bent shift fork shaft.
Bent or damaged shift spindle pawl.
Worn or damaged shift drum cam grooves.

9-2
 CRANKCASEITRANSMISSION/C RANKSHAFT

CRANKCASE SEPARATION
'85 :

Hold the drive sprocket with a universal holder and remove

the fixing plate bolts, plate and sprocket.

NOTE
If the sprocket needs to be replaced, replace both the
sprocket and fixing plate as a matched set.
Replace drive and driven $prockets, and the drive chain
as a set.

Remove the ten left crankcase bolts.

Remove the crankcase breather tube from the left crankcase.

Set up the crankcase pu ller on the left crankcase,

Separate the left and right crankcase halves.

NOTE
Separate the right and left crankcases from each other
while tapping them at several locations with a soft hammer.

M~:ll~!\n'ER TUBE
CAUTION
• Do not pry the crankcase halves apart with a screwdriver.

Remove the gasket and dowel pins.

9-3
CRAN KCASEiT RANSM ISSION/C RAN KSHAFT

TRANSMISSION DISASSEMBLY
Remove the shift fork shafts.

Remove the shift forks.

Remove the shift drum.

Re molle and disassemble the mainshaft and countershaft

gear sets.

TRANSMI SS ION GEA R/SHA FT

INSPECTI ON

Inspect each gear for wear or damage and replace if necessary.

Check the gear teeth and engagement dogs for wear or damage.
Check the mainshaft and countershaft splines and sliding
surfaces fo r wear or damage.
Measure each gear 1.0.

SERVICE LIMITS :
MS, M8 : 17.10 mm (0.673 in)
Cl : 16.60 mm (0.654 in)
C2 : 20.10 mm (0.791 in )
C3, C4: 19.10 mm (0.752 i n)

9-4
 CRANKCASEITRANSMISSION /CRANKSHAFT

Measure the 1.0. and 0 .0 . of the C2 gear bush ing.

SERVICE LIMIT :
1.0.: 17.10 mm (0.613 in)
0 .0 .: 19.92 mm (0.184 in)

Measure the 0 . 0 . of the mainshaft and countersh aft.

SERVICE LIMITS :
CLUTCH OUTER ('S5) : 19.95mm (0.785 in) (21
M5, M6 GEAR : 16.95 mm (0.661 in)
C1 GEAR : 16.45 mm (0.648 in)
C3, C4GEAR : 18.94mm(0.746in)
C2 GEAR : 16.96 mm (0.668 in)
STARTER IDLER : 14.96 mm (0.589 inl

SHIFT FORKISHIFT FORK SHAFTI

SHIFT DRUM INSPE CTION

Check that the shift forks are not bent, worn or damaged .
Measure the shift fork I.D.

SERVICE LIMIT : 11.06 mm (0.435 inl

Measure the shift fork pawl thickness.

SERVICE LIMIT : 4.88 mm (0.192 in)

Check that the shift fork shafts are not bent, worn ,
or damaged.
Measure the O.D. of the shafts.

SERVICE LIMIT : 10.94 mm (0.431 in)

9-5
CRANKCASEfTRANSMISSION/C RANKSHAFT

Inspect the shift drum grooves.

Replace the drum if the grooves are damaged or worn exces-

sively.

TRANSMISSION BEARING INSPECTION

Turn the inner race of each bearing with your finger. The
bearings shouk1 turn smoothly and gently. Replace the bearings
if the races do not turn smoothly.

TRANSMISSION BEARING REPLACEMENT

Remove the mainshaft bearing and coontershaft needle bearing

from the right crankcase.

121

Remove the countershaft oil seal fro m the right crankcase. (1) REMOVER WEIGHT
Remove the mainshaft and countershaft bearings from the
left crankcase.

(4) COUNTEASHAFT
BEARING

9-6
 CRANKCASE/T RANSMISS ION /CRANKSHAFT

Install new bearings with the following tools.

Mainshaft right bearing: (,85)

Driver 07749-00 10000
Attachment, 42 x 47 mm 07746-00 10300
Pilot, 20 mm 07146-0040500
Mainshaft right bearing: (After '85)
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot. 17 mm 07746-0040400
Mainshaft left bearing:
Driver 01749-00 10000
Attachment, 28 x 30 mm 07940- 1870100
Countershaft right needle bearing:
Driver 07946-MJOO 100
Hydraulic press
Countershaft left bearing:
Driver 07749-00 10000
Attachment, 42 x 47 mm 0774.6-00 10300
Pilot, 17 mm 07746-0040400
Shift drum bearing :
Driver 07749-00 10000
Attachment, 42 x 47 mm 07746-00 10300
Pilot, 25 mm 07746-0040600

Install a new countershaft oil seal on the left crankcase.

CRANKSHAFT REMOVAL
Attach the crankcase puller on the right crankcase.

CAU TI ON
• Do not drive the crankshaft out.

Remove and discard both t he right and left crankshaft oil

seals.
121 RIGHT CR,''''CASE.'!!
(3) CASE PULLER
07937-4300000

9-7
CRANKCASEITRANSMISSION/CRANKSHAFT

If the crankshaft bearing is removed with the crankshaft, (1) BEAR ING PULLER
remove it from the crankshaft and discard it. 07631 -00 10000
OR COMMERCIALLY
AVAILABLE IN U.S.A.

CRANKSHAFT INSPECTION

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

using a d ial indicator.
Actual runout is 1/2 the total indicator reading .

SERVICE LIMIT : 0.10 mm (0.004 in)

.. ~

Measure the connecting rod big end radial clearance,

SERVICE LIMIT '85 : 0.03 mm (0.001 in)

After '85 : 0.034 mrn (0.001 In)
x
y

Measur. the connecting rocl big end side clearance,

SERVICE LIMIT : 0.7 mm (0.03 Inl

If the clearance is beyond the service limit, replace the crank·

shaft.

9-8
 CRANKCASEfTRANSMISSION/CRANKSHAFT

CRANKSHAFT BEARING INSPECTION

Turn the inner race of each bearing with your finger . The
bearings should turn smoothly and gently, Replace the bearings
if the races do not turn smoothly.

CRANKSHAFT BEARING REPLACEMENT

RemOlle the right and left crankshaft bearings.

Drive new bearings into the right and left crankcase. 07749-0010000

.52x55mm
07746-00 10400
PILOT , 22 mm 07746-0041000

CRANKSHAFT INSTAlLATION
Install the crankshaft into the right crankcase using the crank·
case assembling tool.

9-9
CRANKCASE/T RANSMISSION/CRANKSHAFT

Install the right crankshaft oil seal so that it is flush with the
outer edge of the crankcase as shown.

TRANSMISSION ASSEMBLY
Assemble the transmission gears and shafts.

Coat each gear with clean transmission oil and check for
smooth movement.

(4) Note the thrust washer direction.

Cl C5

@.@~©

9-10
 CRANKCASEfTRANSMISSION/CRA NKSHA FT

Engage the mainshaft and countershaft gears and place the

gears into the right crankcase.

Install the shift drum and shift forks.

CAUTION
Install the shift forks with thei, mlll'h facing toward the
right crankcase.

Slide the shift fork shafts through the shift forks, and into
..
the crankcase.
After installation, check for smooth operation.

CRANKCASE ASSEMBLY
Clean the crankcase gasket surfaces.

NOTE
Be careful not to damage the gasket surfaces.
Gaskets will come off easier if soaked in solvent. Be careful
not to get dirt in the bearings. Place the crankcase in II pan
and pour in enough soll/ent to soak the gasket.

9-11
CRANKCASEfT RANSMISSION/CRANKSHAFT

Install the gasket and dowel pins in the left crankcase.

Install the crankcase breather tube onto the left crankcase,

Place the left crankcase onto the right crankcase.
-
(1) ASSEM BLY BOLT
ASSEMBL Y ~O LL '\F 07965- 1660300

Assemble the right and left crankcase with the crankcase

ISsembly tool. (3) OIL
/ " SEAL
Periodically. tap the end of the mainshaft with 8 soft hammer
to help the crankcase halvllS go to together evenly.

Install the left crankshaft oil seal with the same tool so that
it is 3 mm (1/8 in) from the outer edge of the crankcase as
shown.

Install and tighten the crankcase bolts.

NOTE
• Tighten the bolts in • crisscross pattern in 2 to 3 naps.

'85:

Install the drive sprocket and fixing plate on the countershaft

and tighten the bolts.

07125 - 0030000 OR

9-12
COOLING SYSTEM

FRONT

8- N'm
{O. 8- 1.2 kg·m. 6-9 ft.lbJ

10-0
 COOLING SYSTEM

After '85:

After '81:

FRONT

N·m
(0.8- 1.2 kg·m. 6-9 ft·lbl

10-1
10. COOLING SYSTEM
SERVICE INFORMATION 10-2 COOLING SYSTEM INSPECTION 10-5
TROUBLESHOOTING 10-3 COOLANT REPLACEMENT 10-5
RADIATOR AND HOSE INSPECTION 10-4 RADIATOR 10-6
RADIATOR CAP INSPECTION 10-4 WATER PUMP 10-6

SERVICE INFORMATION
GENERAL

: !Ii.
Walt until the engine is cool !Hfore slowly umo~ing the rodioror cop. Remall/ng the CIlP while the engine is hot and the coolant is
under pressure may cause serious scoldln,.
Radiator cooltJnt is toxic. Keep it awa)' from tJ~S. mouth, skin and clothes.
- 1/ any coolant gets in your e)'n, rinse them with wattr and consult Q doctor immediatdy.
_ 1/ any coolant is swal/owtd, lnduu l1omltlng, gargle and consult a physic/an immediately.
- If any coolant gtts an )'Our skin or clothes, rinse thoroughly with plenty of water.
KEEP OUT OF REACH OF CHILDREN.
Kup out 0/ reach of pels. Some peU QU attracted to the smoll and tastt 0/ coolant and elm die ilthey drink il.

• To service the water pump seal, rem ove the right crankcase cover.
• All cooling system services can be done with the engine in the frame.
• Do not remove the radiator cap when the engine is hot. The engine must be cool before servicing the cooling system to
avoid the poSSibility of being scalded .
• Avoid spilling coolant on painted surfaces. After servicing the system, check for leaks.

SPECIFICATIONS

Recommended coolant Use only a high qualit y ethylene glycol based anti-freeze contain'
ing corrosion protection inhibitors specifically recommended for
use in aluminum engines. A SO/ 50 mixture of anti-freeze and
water is recommended for most operating conditions. (See anti·
freeze container label for other mixture ratios).
Coolant capacity '85 , ' 86 : 0 . 53 tit 10 .56 US qt . 0 .47 Imp qtl at disassembly
0.47 lit 10.50 US qt . 0 .41 Imp qtl at coolant change
After ' 86 ' 0.43 lit 10.45 US qt . 0 .38 Imp qtl at disassembly
0 .37 lit 10 .39 US qt , 0 .33 Imp qU at coolant change
Radiator cap relief pressure 110 140kPa ( 1.1 - 1.4kg/cm 2 ,15.6 - 19.9psil

TOROUE VALUES
Rad iator hose clamps 0.7- 1.0 N·m to.07-0. 1 kg·m, 0 .5-0.7 ft·lb)
Water pump impeller 8- 12 N·m (0 .8 - 1.2 kg·m, 6-9 ft-Ib)

TOOLS

Special
Water seal driver 07945- KA30000 o r GN - AH - 065 - 415 (U .S.A. only )
8earing remover, 12 mm 07936- 1660100
Remover weight 07741 - 0010201 or 07936- 3710200
Bear ing remover, 7 mm 07931 - KA30000
Bearing dr iver, 7 mm 07946- KA30100
Driver attachment, 28 It 30 mm 07946- 1870100
Common
Universal holder 0'/725 - 0030000 or 07725- 0010101
Driver 07749- 0010000
Pilot , 12 mm 07746- 0040200
Pilot, 25 mm 07746- 0040600
Attachment, 28 x 30 mm 07946- 1870100

10-2
 COOLING SYSTEM

TROUBLESHOOTING
Engine temperature too high
Faulty radiator cap.
Insuff iCient cool an\.
Passages blocked in rad ia tor . hoses Of water jacke\.

Coolant leakl
Fault y pump oil seal.
. Deter iorated water seal.

10-3
COOLI NG SYSTEM

RADIATOR AND HOSE INSPECTION

Remolle the radiator shroud by remolling the three bolts.
Remove the radiator grill.

Check the air passages for blockage or damage.

Straighten bent fins.
Remove insects, mud or any obstruction with compressed air
Of low water pressure.
Replace the radiator If the air flow is renricted Oller more
than 20 % of the rad iating surface.

Inspect all the radiator hoses for cracks or deterioration, and

replace if necessary.
8e sure all hose damps are t ight.

RADIATOR CAP INSPECTION

Pressure test the rad iator cap. Replace it if it does not hold
pressure, or if relief pressure is too high or too low. It must
hold specified pressure for at least six seconds.

NOTE
Before installing the cap on the tester, apply water to
seal ing surfaces.

RADIATOR CAP RELIEF PRESSURE :

110-140 kPl 11.1-1.4 kg/cm 2 • 15.6-19.9 psi)

10-4
 COOLING SYSTEM

COOLING SYSTEM INSPECTION

Pressur ize the radiator, engine and hoses, and check for leaks.
CAUTION

ExceSlive pressure can damage the radilJror. Do not exceed

140kl'a(J.4 kg/cm2, J9.9psiJ

Repair or replace componen ts if the system w ill not hold

specified pressure for at least six seconds.

COOLANT REPLACEMENT
"W!;Ii!!i!ij
Engine must be cool before servicing the cooling system, or
you could be scalded
c~._ _ __ _ _ _ _ _ _ _ __ _

Remove the radiator cap with the vehicle uprig ht .

Remove the coolant drain bolt at the cylinder and water

pump. and drain the coolant.

'W·i;ldWN
Wail until the engine is cool be/ore slowly remolting the
radialor cap. Remol'ing the cap while the engine ;s hOI and the
coolant is under pressure may cause suious scalding.
Radiator coolant Is toxic. Keep;1 away fr om eyes, mouth. skin
and clothes.
- If any coolant gels in your eyes, rinse them with wattr and
consult a doctor ;mmediattfy.
- If any coolant Is swallowed, Imluce ~'omiting, gargle and
consilit a ph)'sician immediately,
- If any coolant gets on your skin or clothes, rinse thoroughly
with plenty of water,
KEEP O U T OF REACH OF CHnDREN,
Keep our of the reach pets. Some pets are attracted to the sm oll
and teste of coolant and can die if th e)' drink it.

Check that the drain bolt sealing washers are in good condi·
t ion, and reinsta ll the drain bolts.

Pour the recommended coolant mixture (Page 1()'2) slowly

through the ladiator filler hole up t o the filler neck .

CAPACITY:
'85, '86: 0.47 lit (0 .50 US qt, 0 .41 Imp qtl at coolant
c hange .
After '86: 0 .37 lit (0.39 US qt, 0 .33 Imp qtl at coolant
change.

0
Lean the machine approx imately 20 r ight and left several
times to bleed air trapped in the cooling system. If the cool·
ant level drops, add the coolant and repeat the air bleeding
procedure.

Insta ll the radiator cap securely.

10-5
COOLING SYSTEM

RADIATOR
REMOVAL

Drain the radiator coolant.

Remove the radiator shroud by removing the mounting bolts.

Remove the radiator mounting bolts.

Loosen the hose clamps and ramove the radiator hoses and !1)
radiator.

INSTALLATION
Installation is essentially the reverse order of removal.
Pour the recommended 50/50 coolant mixture up to the
filler neck (Page 10-4).

After installation, check the radiator and radiator hoses for

leak. (Page 10-3).

WATER PUMP
WATER SEAL INSPECTION

Inspect the lei Hale hole for sigm of coolant leakage.

If leakage is evident, disassemble the water pump and replace
the water 5eal.

WATER PUMP DISASSEMBLY

Drain the radiator coolant (Page 10-4).

Remove the water pump cover by remolling the four botts.

Remove the gasket and dowel p in.

10-6
 COOLING SYSTEM

Remove the leh crankcase cover.

Hold the flywheel with a universal holder and remove the

impeller and copper washer.

Remove the right crankcase cover (Page 8 -3 ).

'85: Remove the ATAC governor (Page 7-4).

Remove the water pump shaft from the right crankcase cover.

Check the water pump shaft for damage or wear and replace
if necessary.

Check the water seal for damage or wear.

Check the water pump tell -tale hole for signs of a water seal
leak .

Replace the water seal if necessary.

Check the water pump shaft bearings in the right crankcase

cover alld right crankcase for excessive play or damage .
Replace the bearing(5) if necessary .

10-7
COOLING SYSTEM

WATER PU MP BEA RING REPLAC EMENT (1) REMOVER WE IGHT

07741-001020 1 OR 07!l36-,!~~
Remove the bearing from the right crankcase cover using the
bearing remover as shown.

Check the oil seal for wear or damage, replace if necessary.

Install a new bearing into the right crankcase cover.

121
PILOT,1~2;.;;,
m;;m;..._ _ _ _ _O;;;7;;7.;4,;;6-."0040200

Remove the bearing from the right crankcase using the bearing
remover as shown .

Install a new bearing into the right crankcase cover.

10-8
 COOLING SYSTEM

WATER SEAL REPLACEMENT

Remo ve the water pump bearing from the right crankcase

cover (Page 10-7).
Drive out the water seal and oil seal together.

NOTE

Replace the bearing and oil seal with new ones whenever
the water seal is replaced.

Drive in a new water seal using the special tool using care not
to damage the seal.

Apply grease to a new oil seal lip and install it into the right
crankcase cover using the same tool.
Install a new water pump bearing into the right crankcase
cover {page 10-7 1.

To install the water seal, use tool GN-AH - 065-415

(U.S.A. ONLY):

Remove the water pump bearing from the right crankcase

cover.
Slide the water pump seal onto the bolt and against the guide 111 (2) WATER SEAL
plate of the special tool as shown. WATE R SEAL / ___r-
Apply a thin coal of sealant to the outer surface of the metal DRIVER SET
casing of the seal. 07945- KA30000

NOTE
Some water pump seals may be precoated with sealant
PUMP INSTALLER
from the factory.

Position the seal and tool in the right crankcase cover.

Place the installer cup and nut onto the bolt from the back side

~
of the cover.
Torque the nut to 42.5 - 44.8 N·m 1380 - 400 Ib-in,
31.5 - 33.3Ib-ftl.
NUT
Remove the tool and inspect the installation .
COVEA
Apply grease to the lip of a new oil seal and install it into the
right crankcase cover using the following tools:
Pilot 25 mm 07746 - 0 040600
Driver 07749 - 00 10000

WAT ER PUMP ASSEMB LY

Install the water pump shaft into the right crankcase cover.

'85: Install the ATAC governor (Page 7-6),

Install the right crankcase cover (Page 8-3),

10-9
COOLING SYSTEM

Install a new copper washer onto the water pump shaft.

Install the impeller onto the water pump shaft.

Hold the flywheel with the universal holder and tighten the
impeller.

TORQUE : 8-12 N·m (0.8- 1.2 kg-m, 6- 9 ft-Ib)

'85 and After

Instal l a new gasket onto the water pump cover.

'85:
Install the water pump cover onto the right crankcase cover
by aligning the dowel pin of the water pump cOlier with the
hole of the right crankcase cover.

Aft.r '85:
Install the water pump cover onto the right crankcase cover by
aligning the dowel pins of the right crankcase cover with the
holes of the water pump cover.

T ighten the pump cover using the four bolts.

Fil l the cooling system (Page 10-4).

Install the radiator cap. start the engine and check for leaks.

10-10
FRONT WHEELIBRAKE/SUSPENSION/STEERING

'85:

t __
r, /
---1S-25 N-m (1.8-2.5 kg-m. 13- 18 ft·lbl

60-90 N·m (6.0-9.0 kg-m. 43-65 ft-Ib)

18-25 N-m (1.8-2.5 kg-m, 13- 18 ft·lb)

~_ _ _ _ 1_2 N·m (0. 1-0.2 kg-m, O.7-1.4ft-lb)

18-25 N·m fl,8-2.5 kg-m, 13- 18 ft·lb)

55-70 N-m
(5.5-7.0 kg-m,
40-50 ft-Ib)

l
11-0
 FRONT WHEEL/BRAKE/SUSPENSION /STEERING

Afte r '85:
___ 18 - 25 N·m 11.8 - 2.5 kg-m , 13 - 18 ft-Ib)

18 - 25 N'm n .8 - 2.5
120 N·m (9.0 - 12.0 kg -m , 65 - 90 ft-Ib)
After '9 1:
80 - 120 N·m 18.0 - 12.0 kg-m, 60 - 90 ft-Ib)
After ' 86 :
------; 0 I
1 -2~~~~~~~~~~~~F~------~I
ID.I - O. 2 kg·m, 0 .7 - 1.4
41]' Afte r ' 8 6:

oiiiiI
e ~

ID
18 - 25 N·m
11.8 - 2.5 kg-m , 13- 18 ft-Ib )

After '91 :

55 - 70
15.5 - 7.0 kg -m. 40 - 50 ft-Ib)

11 -1
11. FRONT WHEEL/BRAKE/ SUSPENSION/STEERING
SERVICE INFORMATION 11 -2 FRONT BRAKE: '85 11-14
TROUBLESHOOTING 11 -4 FRONT HYDRAULIC BRAKE : Alter '85 11-16
HANDLEBAR 11-5 FORK 11 -16
FRONT WHEEL 11-9 STEERING STEM 11 -23

SERVICE INFORMATION
GENERAL
• This section co~er$ maintenance of the front wheel, fork and steering system .
• OPtional fork springs ate available, Aefer to General Information, Section 1 for details.
• Recommended Fork Oil: Honda ssa Suspension Fluid or an equivalent .
• A workstand or box is required to support the motorcycle.
• For optimum fork performance, the fork should be completely disassembled and cleaned after the first three hours of
riding. Thereafter it should be disassembled and gleaned on a regular basis to ensure consistent performance and
maximum service life from the internal parts.
• Refer to Section 13 about hydraulic brake system (After '85) ,

i.
Inhaled asbestos fibers hallt been found to couse respiratory diseose and cancer. use an air to cletm ·
brake or clutch assemblies. In the United States, use an OSHA~pprolltd IJQcuum cleoner or alternate approved by
OSHA design,ed to minimize the hazard coused by airborne asbestos fibers.
SPECIFICATIONS
mm (in )

ITEM STANDARD SERVICE LIMIT

Front axle runout -- 0 .2 (0 .01)

Front wheel rim runout Radial 2 .0 (0 . 10)
Axial -- 2 .0 (0 . 101
Front brake drum 1.0 . (' 85) 95 (3 .71 96 (3.8 )
Front brake lining thickness ('85) 3 (0 . 12) 1.0 (0 .04)
Fork spring ' 85 558 .7 (22.00) 547 .5 (21.56)
free length ' 86 562 .7 (22 . 15) 557 . 1 (21 .931
'87 538 .5 (21 .20) 533.1 (29 .99)
After '87 486.4 (19 . 15) 476.7 (18.771
Fork tube runout 0 .2 (0.01 )
Fork oil capacity ' 85 273 cc (9.2 US oz, 9 .6 Imp oz) --
' 86 287 cc (9.7 US OZ, 10.1 Imp oz) --
'87 308 cc (10.4 US OZ, 10.81mp OZ ) --
' 88 - ' 9 1 305 cc (10.3 US oz. 10.7 Imp OZ ) --
After '9 1 309 cc (10.4 US oz. 10.8 Imp 02) --
Fork oil level ' 85, '86 135 (5.31) --
' 87 142 (5.59) --
' 88- ' 91 146 (5.75) --
After '91 132 (5 .201 --
Fork air pressure o kg /cm 2 (0 psi) Maximum pressure
40 kPa (0.4 kg /cm 2 , 6 psi )

11-2
 FRONT WHEEL/BRAKE/SUSPENSION/STEERING

TOR QUE V ALUES

Steering stem nut '85: 60 - 90 N·m (6.0 - 9.0 kg-m, 43 - 65 ft-Ib)

'86 - '91 90 - 120 N·m 19.0-12.0 kg -m, 65 - 90 it-fbI
After '91: SO - 120 N·m 18.0 - 1 2.0 kg-m, 60-90 ft-fbl
Handlebar holder bolt 1S - 25N·m (1.8 - 2.5kg-m, 13 - 18ft-lbl
Fork bridge upper pinch bolts 18 - 25 N·m 11.8-2. 5 kg -m, 13 - 1 8 It-Ibl
Fork bridge lower pinch bolts 18 - 25 N·m (1.S - 2.5 kg-m, 13-18 ft-Ibl
Fork cap 15 - 30 N·m (1 . 5 - 3.0 kg-m, 1 1-22 ft-Ibl
Fork socket bolt 15 - 25 N·m (1 .5 - 2.5 kg-m, 1 1 - 18 It-Ibl
Axle nut 55 - 70 N·m (5 .5 - 7.0 kg-m, 40-50 It-Ibl
Steering head adjustment nut 1- 2 N·m 10.1 - 0.2 kg-m, 0.7 - 1.4 ft- fbl
Wheel spokes 2.5 - 5.0 N·m (0.25 - 0.5 kg -m, 1.S - 3.6 ft -Ib)
Aim lock 10 - 15N·mI1.0- 1.5kg-m, 7- 1 1 ft-Ib)
Front brake disc mount bolt '86 - '91: 14 - 16 N·m 11 .4 - 1.6 kg-m, 10-12 ft-Ib)
Ahar '91: 20 - 24 N·m (2 .0 - 2.4 kg-m, 14- 1 7 ft·lbl

TOOLS

Special
Steering stem socket 07916 - 3710100
Ball race remover '85 , ' 86 : 07944 - 1150001 or 07736 - A010001A (U.S .A . onlyl with commer -
cially available, slide hammer.
After '86: 07953 - 1150001 or 07953 - 425000Z
Steering stem driver ' 85, ' 86: 07946 - GC40000 or 07736 - A01000A (U.S .A. only) with commer-
cially available , slide hammer.
After '86 : 07946-4300101
Ball race remover attachment ' 86: 07GMD - GC40100 or 07736 - A01000A (U.S.A . only ) with commer -
cially available , slide hammer.
After '86: 07HMG - GC40200 or 07953 - MJ10001A (U.S.A. only)
Bearing driver '86 : 07946 - 6920100
Driver attachment . 28 )( 30 mm 07946 - 1870100
Attachment 07946 - GC40001A
Steering stem driver 07946 - M800000
Common
Driver 07749 - 0010000
Fork seal driver 07747 - 0010100
Fork seal driver attachment '85 : 07747 - 001 0500}- 07947 - 3330000
'S6 : 07747-0010501 or
After 'S6: 07947 - KA20200
Bearing remover expander 07746 - 00501003-
Bearing remover collet. 10 mm '85: 07746-0050200 Of commercially available in U.S.A.
12 mm After '85: 07746 - 0050300
Pilot , 10 mm ' 85 : 07746-0040100
12 mm After '85 : 07746-0040200
Attachment, 32 x 35 mm Aller ' S5 : 07746 - 0010100
Attachment. 37)( 40 mm 07746 - 0010200
Attachment, 42 )( 47 mrn 07746 - 0010300
lock nut wrench , 30 )( 32 mm
Extension bar
g;;~~ = gg;~~ggJ- or commerciall y available in U.S.A .

Attachment 07946 - GC4000A (U.S.A . only )

Steering stem driver 07946 - M800000

11-3
FRONT WHEEL/BRAKE/SUSPENSION/STEERING

TROUBLESHOOTING
Hard steering Hard suspension
Steering head bearing adjustment too tight . High fork oil level (too much oil).
Faulty steering stem bearings. Fork oil viscosity too thick .
Damaged steering stem bearing. Fork tube(5) bent andlor fork sliders are damaged.
Insufficient tire pressure. Sliders are hitting the lower fork clamp on full
compression - drop the fork tubes 5 mm and
Steers to one side or does not track straight retest.
Bent forks.
NOTE: This will only occur if the fork tubes
Bent front axle, wheel installed incorrectly. have been raised in the fork clamps an excessive
Bent frame or swingarm. amount (over 10 mm).
Misaligned rear wheel.
Front suspension noise
Front wheel wobbling Slider binding.
Bent rim .
Insufficient fluid in forks.
Worn front wheel bearings .
Fork damper piston bolts are loose.
Bent spokes.
Faulty tire. '85 : Improper brake performance
Axle not tightened properl y. Incorrect adjustment of lever .
Contaminated brake shoes .
Soft suspension
Worn brake shoes.
Low fork oil level (insufficient oil).
Fork oi l viscosity too thin . Worn brake cam.
Worn brake drum.
Weak fork springs - if free length is OK, go to
Improperly engaged brake arm serrations.
optional stiffer spring.

11 -4
 FRONT WHEEL/BRAKE/SUSPENSION/STEERING

HANDLEBAR (1) ENGINE BUTTON 121 THROTIlE

SWITCH G
' 85 :
REMOVAL

Remove the throttle grip from the handlebar.

Disconnect tke front brake and clutd-l cables.
Disconnect the engine button switch wires.

Unfasten the number plate tab.

Remove the nandlebar holder bolu and the handlebar.

After '85:
REMOVAL

Remove the mounting bolt and unhook the holding tab.

Remove the front number plate.

Remove the w ire band securing the engine stop button wire
and remove the engine button swit ch.
Remove the grip from the handlebar.
Disconnect the clutch cable and remove the clutch lever
bracket.

Remove the front brake master cylinder keeping it upright (1)

to prevent air from entering the syste m.

Remove the throttle housing and d isconnect the throttle

cable from the throttle grip.

121 T;:;;;rrnL_E HOUSING

Remo ve the handlebar holder bolts, upper holders and handle·

bar.

11-5
FRONT WHEEL/ BRAKE/SUSPENSION /STEERING

'85:
INSTALLATION

Install the handlebar; align the punch mark on the handlebar

with the top of the lower holders.
Place the upper holders on the handlebar with the punch
marks facing the front.

Tighten the forward bolts first, then tighten the rear bolts.

TORQUE : 18-25 N·m

{1.8-2.5 klJ"m. 13-18 ft·lb)

Install the brake lever bracket by aligning the slit of the lever
bracket with the punch mark on the handlebar.

Connect the brake cable to the brake lever,

Apply oil to the sliding surface of the throttle grip and handle -
ban.

11-6
 FRONT WHEEL/BRAKE/SUSPENSION/STEERING

Connect the throttle cable to the throttle grip. 111 CABLE G.':!.~.i
Install the cable guide into the throttle housing.

Install the throttle housing.

THROTTLE HOUSING

Align the end of the throttle grip housing with the punch mark 111 TS
on the handlebar and tighten the forward bolt first, then the
rear bolt.

(2) PUNCH MAR K

Install the clutch lever bracket by aligning the slit of the

bracket with the punch mark.

Connect the clutch cable to the clutch lever.

Install the grip onto the handlebar (Page 11 - 9 ).

Install the engine stop button and the ground w ire using th e
screw.

11-7
FRONT WHEELfBRAKEfSUSPENSIONfSTEERING

After '85:
INSTALLATION

Install the handlebar.

Align the punch marks on the handlebar with the top of the
lower holders.

Place the upper holders on the handlebar with the punc h

marks facing forward.

Tighten the forward handlebar holder bolts first. then tighten

the fear bolts.

TORQUE : 18-25 N·m (1.8-2.5 kg-m, 13- 18 fHbj

Set the front brake master cylinder on the handlebar.

Install the master cylinder holder with the " UP " mark up and
align the end of the holder with the punch mark on the
handlebar.
Tighten the master cylinder holder bolts.

NOTE
• Tighten the upper bolt first. then the lower bolt.

TORQUE : 8- 12 N'm (0.8-1 .2 kg-m, 6- 9 ft-Ibl

Apply a thin coat of oil to the sliding surfaces of the throttle

grip and throttle housing.

Connect the throttle cable end to the throttle grip.

Install the throttle grip by aligning the slit of the housing with
the punch mark on the handlebar.

T ighten the upper screw firs t then tigh ten the lower screw
securely.

(2) PUNCH MARK

11-8
 FRONT WHEEL/ BRAKE/SUSPENSION /STEERING

Install the clutch lever bracket by aligning the slit of the

bracket with the punch ·mark.

Connect the clutch cable to the clutch lever.

Apply Honda Bond A. Honda Hand Grip Cement (U.S.A.

only) or an equivalent to the inside surface of the grips and to
the dean surface of the left handlebar and throttle pipe.
Wait 3-5 minutes and install the grips. Rotate the grips for
even application of the adhesive.

NOTE
• Allow the adhesive to dry for an hour before using.

Install the engine button switch and the ground wire.

Install the front number plate.

FRONT WHEEL
'85:
REMOVAL

Raise the front wheel off the ground by placing a box or

workstand under the engine.

Remolle the brake cable clamp.

Disconnect the brake cable from the brake arm.

•
Remove the axle nut, axle and the front wheel.
Remove the front brake panel from the hub. . (3)
-
After '85:
REMOVA L

Raise the front wheel off the ground by placing a box or

work stand under the engine.

Loosen the axle shaft nut and remove the front axle.
Remove the front wheel.

NOTE
• Don't operate the brake lever with the front w heel removed .

11-9
FRONT WHEEL/BRAKE/SUSPENSION/STEERING

FRONT AXLE RUNOUT

Set the axle in V blocks and measure the runout.

Actual runout is 1/2 the total indicator reading.

SERVICE LIMIT ; 0.2 mm (O.01 in)

WHEEL BEARING INSPECTION

Turn the inner race of each bearing with your finger. The
bearings should turn smoothly and quietly. Also check that
the bearing outer race fits tightly in the hub.

Remolle and discard the bearings if the races do not turn

smoothly, quietly, or if they fit loosely in the hub.

NOTE
• Replace hub bearings in pairs.

For replacement of bearings, see page 1 1- 10. ~After '85:

11-11)

WHEEL RIM RUNOUT

Check the wheel rim for runout by placing the wheet in II

truing stand. Spin the wheel by hand and read the runout
using 8 dial indicator.

SERVICE LIMIT:.
RADIAL : 2.0 mm (O.10 in)
AXIAL: 2.0 mm (0.10 in)

DISASSEMBLY 'B5:

Remove the collar and dust seal from the hub.

11-10
 FRONT WHEEL/ BRAKE/ SUSPENSION /STEERING

Remove the wheel bearings and spacer. BEARING REMOVER mm

07746- 0050200 OR COMMERC IAl l Y
I

~
BEARING RE ••a,
07746-0050100 OR COMMERCIALLY
AVAILABLE IN U.S.A.
' - --

After '85:
DISASSEMBLY

Remove the right side collar and dust seal.

Remove the leh side collar and dust seal.

Remove the brake disc mounting bolts and disc.

Remove the wheel hub cover from the d isc.

Remove the wheel bearings and distance collar from the wheel ~ii" BEAAI,,'iG REMOVE R CO LLET. 1 mm
hub. 07746- 0050300 OR COMMERCIA LLY
IN .
NOTE
Never reinstall old beari ngs ; once the bearings have been
removed, tliay must be replaced with new ones.

Remove the tire, tube, rim band, and the rim lock.
Remove the spokes and rim from the hub.

(2) I
07746-0050100 OR COMMERCIAL LY

ASSEMBLY '85:
0) DUST SEAL

~
Pack all bearing cavities with grease.

rel;li!ii!d
Do not get greau on the brake drum or slopping powt!r (2) 8EARING~
will be ~du ced.

131 SPACE R (4) BEA RING

11-11
FRONT WHEEL/BRAKE/SUSPENSION/STEE RING

Drive the right bearing into the hub. Place the spacer into the 07749-0010000
hub and drive the left bearing into the hub.

NOTE
Make sure that the sealed side of the bearing is facing out.

Drive the left bearing in squarely.

! ILOT, 10 m~ J
....-277~OO401.22J

Apply grease to the lip of a new dust seal.

Install the dust seal and collar into wheel hub.

ASSEMBLY After '85:

(2) OUST SEAL

11IAXa-~ (3) SPACE R

(4) HUB COVER
1111

C> ~
/
/ k- (5) DUST SEAL
16' LEFT SIDE COLLAR

IB'BEL,~~ /
NOTE
(9) RIM LOCK
~~o (7) DISK

. Assemble the wheel hub and rim so the seal end of the hub
is 20.5 mm (0.8 1 in) above the rim as shown. (1) RIM
Tighten the spokes in progressive steps.
TOROUE :
U
2O.5mm
Spoke nippl .. : 2.5-5.0 N·m (0.81 in)
(0.25-0.5 kg-m, 1.8-3.6 ft-Ib)
Check the runout as shown on page 11 · ' 0, and adjust as
required. (2) WHEEL
HUB
Instell the rim band, rim lock, tube and tire.
TORQUE :
Rim lock : 10-15 N·m
U
(1,0-1,5 kg-m, 7-11 ft-Jb)

11-12
 FRONT WHEELIBRAKE/SUSPENSION/STEERING

Pack all bearing cavities with grease. 07749-00 10000

1J!1i;iliii!fi
Do not get greose on the brab disc or slopping po~' will
be reduced.

Drive in the right bearing first and press the spacer into place.
Drive in the left bearing squarely making sure that it is fully
seated and that the sealed side is facing out.

Install the brake disc onto the wheel hub.

Tighten the brake d isc nuts.

TORQUE : ' 86 - ' 91 : 14 - 16 N'm

(1.4-1.6 kg-m. 10 - 12 ft -Ibl
After ' 91 : 20-24 N-m
12.0 - 2.4 kg-m , 14 - 17 ft ·lbl
Cfean the brake disc with a high qualitY degreasing agent.

Pack the dust seal lip with grease and install the left side dust
seal.

Install the left side collar.

Pack the dust seal lip with grease and install the right side dust
seal.

Insta ll the right side collar.

INSTALLATION '85:

Position the front wheel between the fork legs, aligning the
groove in the brake panel with the tab of the left fork leg.

11-13
FRONT WHEEL/BRAKE/SUSPENSION/STEERING

Install the axle from the right side, through the right fork leg.
wheel hub. and left fork leg.

Install the axle nut and tighten to the specified torque.

TORQUE: 55-70 N-m

(5.5-7.0 kg-m, 40-50 ft.lb)

Connect the brake cable and adjust the brake lever free play
(Page 3-9).
Install the front brake cable clamp.

After '85:
INSTALLATION

Fit the caliper over the disc, taking care not to damage the
brake pads.

Clean the axle shaft.

Instill the axle shaft and tighten the axle nut.

TORQUE : 55-70 N'm

(5.5-7.0 kg·m. 40-50 ft·lb)

FRONT BRAKE '85:

REMOVAL

Remove the front wheel and front brake panel (Page 11- 9) .

BRAKE DRUM INSPECTION

Measure the I.D. of the brake drum.

SERVICE LIMIT : 96 mm (3.8 in)

BRAKE LINING INSPECTION

Check the brake shoe spr ings for fatigue or damage and check
the brake cam for wear or cracks.
Measure the brake lin ing thickness.

SERVICE LIMIT : 1.0 mm (0.04 in)

- •

11-14
 FRONT WHEE LIBRAKE/SUSPENSION /STEERING

BRAK E PANEL DISASSEMB LY

Spread the brake shoes apart and lift them off the anchor
pivot and brake cam.

RemO'le the brake arm and brake cam.

Remove the dust seal.

BR AK E PANE L ASSEMBLY
121 SHOE (3) BRAKE PANEL
(1) BRAKE SPR I NGS
SHOES

i
(4) BR AKE
_ _ (7) BRAKE ARM

Install a new dust seal into the brake panel.

Apply a small amount of grease to the brake cam and insert (1)
it into the brake panel.

Apply a small amount of grease to the brake shoe anchor pin.

tM.I;iii@i
Contaminated bra~ Iininls reduu slopping pawt'. Kef!p
rr~ oft the brake lininp.
Wipe excess grt!(J~ off the brake com.

11-15
FRONT WHEELfBRAKEfSUSPENSION fSTEERING

Install tha thrust washer onto the brake cam.

Align the punch marks on the brake arm and brake cam and
install the brake arm. Tighten the brake arm bolt.

Install new brake shoes onto the brake panel . SHOES

INSTALLATION

Place the brake panel assembly into the wheel.

Install the front wheel (Page 11·13 ).

FRONT HYDRAULIC BRAKE After '85 :

• Refer to section 13.

FORK (1) UPPER PI

REMOVAL

Remove the front wheel (Page 11 ·9 ).

l oose the upper and lower fork pinch bohs.

11-16
 FRONT WHEELIBRAKEI SUSPENSIDNI STEERING

Pull and twist the fork tube down and out.

DISASSEMBLY 0) A IR VALVE {21 CAP

Ramolle the lIallle cap.
Release the air from each f()(k tube.

IM1;Wii!<'
Be sure to releou fork air pressure before dfsossembling
\
10 pre~nt ports from becoming projectiles.

Remolle the fork cap and fork spring.

I"'&-W!ii!<i
The fork cop u undel spring pressure. Use CDre when
removin, and wear eye and face protection.

Pour out all the fork fluid by pumping the fork slowly several 111
t imes.

Hold the fork tube in a vice with soft jaws or wrap the tube.

Remolle the socket bolt. •

NOTE
Temporarily install the fork spring and fork cap if diffi·
cult'{ is encountered removing the bolt.

Remove the fork p iston and rebound spring from the fork
tube.

11-17
FRONT WHEEl/BRAKE/SUSPENSION /STEERING

Remove the dust seal and snap ri ng.

Pull the fork tube out until it stops, the slider bushing COn-
tacts the fork tube bushing and prevents if from coming apart.
Then move it in and out, tapping the fork tube bushing
lightly against the slider bushing until the fork tube separates •
from the slider. The slider bushing will be forced out by the
fork tube bushing.
Remove the oil lock piece from inside the slider.

Remove the oil seal, back-up ring and slider bushing from the (2) SLlI)ER BUSHING
fork tube.

NOT E
Do not remOlle the fork tube bushing unless it is necessary
to replace it with a new one.

(3) BACK·U P (41 FORK BUSHI NG

FORK SPRING INSPE CTION

Measure the fork spring free length.

SERVICE LIMIT
'85: 547.5 mm 121.56 in)
' 86: 557,1 mm (21 .93 in) r-III1I1I1I1I1I1UlIIIIIIII ............... ------------
mFV,."",jJjjjj"mtflfnffl1llllllll
'87 : 533.1 mm (29.99
After '81: 476.1 mm (18.71
in)
in)

Replace the spring if it shorter than the service limit.

- ..

11-18
 FRONT WHEEL/ BRAKE/SUSPENSION/STEERING

FORK PISTON/ FORK TUBE/ SLIDER INSPECTION (1) PISTON

RING --~.~..
~ (3) SLIDER
Cheke the slider and fork tube for score marks, scratches,
or abnormal wear, replacing those parts which are worn or
damaged.
Cheke the piston r ing for wear or damage.

121 FORK.--""
PISTON

(4) FORK
TUBE

Set the fork tube in V blocks and read the runout.

Actual runout is 1/ 2 of the total indicator reading.

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

Check the bushings for excessive wear or scratches. (1) BUSHING

If copper appears on more than 3/4 of the entire surface,
replace the bushings.

(2) COPPER
SURFACES

11-19
FRONT WHEEL/ BRAKE/SUSPENSION/STEERING

ASSEMBLY

Wash all removed parts in solvent and wipe them off thorough·
IV before assemblv.

'8~ ' B1 :
191 DUST
_ / ' SEAL

111 AIR VALVE CAP JING

(4) PISTON
~
@r( 10) SNAP
RING
01 L SEAL

Aft~r7
@l)--1 1I1

~12)
j(2 ) FORK '85:
BACK·UP RING

(13) FORK SLIDER

~CAP/AIR
BUSHING
if,

~51 ~~~:VE ,1
LU
(14) FORK SLIDER

161 REfOUND
SPR ING
..,
n_~_--(15) SOCKET

(3) FORK
SPRING r
(8) OIL LOCK
PIECE
~
(7) FORK TtlSE BUSHING
BOLT

Aft er '87 :
(6) PISTON RING
III AlA VALVE CAP ' \ : FORK PISTON ~(11) DUST SEAL
"tt 0 - (12) SNAP RING
(2) FORK CAP~
@)---1131 OIL SEAL
o ~"41 BACK·UP RING

(3) FORK SPRI NG

(15) FORK SLIDER
BUSHING

(4) TSV ROD

r
" ' j I B I REBOUND SPRING A (16) FORK
SLIDER

BUSHIN~
!
(5) TSV ROO SPR ING
191 FORK TUBE
(10) OIL LOCK PIECE.

4. (17) SOCKET BOLT

11-20
 FRONT WHEEL/ BRAKE/ SUSPENSION/ STEERING

Install the rebound spring on the fork piston, then slip it into (1 ) FORK PI S;TON (2) OIL LOCK PIECE
the fork tube.

Place the oil lock piece on the end of the piston.

(3) K TUBE

Insert the fork tube into the slider.

Place the fork slider in a vise with soft jaws or wrap the
tube with a shop towel .
Apply a locking agent to the threads of the socket bolt and
tighten the socket bolt.

NOTE
To tighten the socket bolt. it may be necessary to tem po-
rarily install the fork spring and tighten the fork cap.

TORQUE : 15-25 N'm

11 .5-2.5 kg·m, 11-18 ft ·lbl

Place the slider bushing over the fork tube until it rests on the flj FORK- SEA L DRI V ER
slider. 07747-00 10100
Us ing the fork seal driver and attachment, dr ive the bushing
into place.
Instati the back-up ring.
Coat the lip of a new oil seal with the recommended fork oil
or 07947 - 3330000
r .---- I I)
-OUST SEAL

121
SNAP
(See below) .
RING

~
Place the oil $8al over the fork tube with its markings facing up
and drive it into place using the fork seal driver and attachment 13)
until the snap ring groove is visible. OIL SEAL
Install the snap ring and dust seal.
14)
FORK SEAL DRIVER ATTACHMENT (2) FORK SEf>.l DRIVER BACK· UP
ATTACHMENT RING
'85: 07747 -00 10S00}-
' 86 : 07747 - 001050 1 or 07947 - 3330000
After '86 : 07947 - KA20200
Pour in the specified amount of fork oil.

RECOMMENDED Oil: Honda SSB Suspension Fluid or an

equivalent .
CAPACITY lat disassembly)
' 85: 273 cc (9 .2 US OZ, 9 .6 Imp ozi
' 8 6: 287 cc 19 .7 US OZ, 10. 1 Imp od
' 87 : 308 cc (10 .4 US OZ, 10.71 Imp ozl
'88 - '9 1: 305 cc 110 .3 US OZ, 10.7 1 Imp oz)
After ' 91 : 309 cc 110.4 US OZ , 10.S lmp ozl

11-21
FRONT WHEEL/BRAKE/SUSPENSION /STEERING

Compress the fork and measure the oil lel/el from the top of
the tube.

NOTE
• Be sure the oil lellel is the same in both fork tubes.
STANDARD OIL LEVEL (1) OIL CO".C
' 85, ' 86 : 135 mm (5 .31 in)
' 87 : 142 mm (5 .59 inl
'88 - ' 91: 146 mm 15.75 in)
Aftef ' 91 : 132 mm (5.20 in)
MAXIMUM lEVEL
'85, 'S6: 135 mm 15.31 in) (21 OIL
' S7: 142 mm 15.59 in}
' 88 - '91 : 111 mm 14.37 inl
After '91 : 103 mm 14.06 in) '85-' 87:
MINIMUM OIL lEVEL
(1) FORK SPRING
'85, '86: 160 mm 16 .30 inl

~
' 87 : 167 mm (6.57 inl
'88 -'91 : 158 mm 16.22 inl
After ' 91 : 150 mm 15.91 inl
I
Wipe off any excess oil from the fork spring, then install it I
into the fork tube.

~
NOTE
Note the spring direction; the closely wound coils must
face toward the bottom. ('85-'S7)
{21 DOWN

INSTALLATION

Innall the fork tubes into the neMing stem while rot8ting
them by hanc:!.

'85-' S7:
Align the groove in the fork tube with the upper surface of the
fork bridge as shown.

After '87:
Align the jOint of the fork cap and the top of the fork tube
with the upper surface of t he fork bridge as shown.

11-22
 FRONT WHEEL/ BRAKE/SUSPENSION /STEERING

Tighten the fork upper and lower pinch bolt5.

TORQUE :
UPPER/ LOWER PINCH BOLT:
18-25 N'm (1 .8-2.5 kg·m, 13-18 ft-Ibl

Tighten the fork cap.

TORQUE : 15-30 N' m

(1.5-3.0 kg-m, 11-21 ft-Ibl

Install the front wheel (Page ' 1- 13). AIR PRESSURE

Check the fork air pressure with the air pressure gauge. GAUGE

STANDARD FORK AIR PRESSURE :

o kPa (0 kg/em 1, 0 psi)

STEERING STEM
REMOVAL

Remove the following:

- front wheel (Pq 11 -9).
- handlebar (Page 11 -51-
- front number plate.

- front fender by removing the three bolts.

11-23
FRONT WHEEUBRAKEISUSPENSIONI STEERING

- steering stem nut. (1) EXTENSION BAR 07716-0020500

- fork bridge. LOCK NUT WRENCH, 30 x 32 mm 07716-0020400
- forks (Page 11 -161. OR AVAILABLE IN U.S.A.

(21 STEM

_ steering head bearing adjustment nut. (1) EXTENSION BAR 07716-0020500

OR COMME IN U,S.A .

• (2) SOCKET"WRENCH 07916-3.!.,01 00

'85, ' 86:

' 85, ' 86 : ,.,.:::.;:.:,... BALLS (21 PIECES)
Remolle the steering stem, top cone race and steel balls (2 1
pieces) .

NOTE
The steel ball bearings Bre loose; be careful not to drop
them.

~
Inspect the bearings, top cone face and ball r8 ce for wear or
damage .
LOWER ROLLER
BEARING STEM

After ' S6 :
Remove the steering stem and upper rolier bearing.
Inspect the upper roller bearing for wear or damage.

Inspect the lower roller bearing and outer race for damage or
excessive play.
Replace if necessary.

~TL1)~-RCILLlE~~~'NG STEE'''''G STEM

11-24
 FRONT WHEEL/BRAKE/SUSPENSION /STEERING

BEARING REPLACEMENT (1) OUST

Install t he steering stem nut onto the steering stem to prevent
damage to the screw.
(21 NUT
Remove the lower bearing and dust seal using a punch or
driver.

Replace the dust seal with new one whenever it is removed.

Remove the steering stem nut.

(3) LOWER IN G

Remove the top ball race first using the special tool. (1) BALL -
'B5
(21 STEERING STEM
BALL RACE REMOVER 07944 - 1150001
or 07736 - A01000A tU .S,A . only) with a commercially
available . lIder hammer.

' 85:
Then remove t he lower bearing out er face using the special
tool.

STEERING STEM DRIVER 07946 - GC40000

or ADJUSTABLE BEARING PULLER 07736 - A01000A
(U.S.A . only) with 8 commercially available slide hammer.

Aftar '85 : AI", 'B5 . ,

Then remove the lower bearing outer race using the special DRIVER
tool.

'86: I~
--(~
BEARING DRIVER 07946 - 6920100
BAll RACE REMOVER ATTACHMENT
~ :':
"~ ~--- '
,:
07GMO - GC40100

After '86 :
BAll RACE REMOVER 07953-1150001
BAll RACE REMOVER ATTACHMENT
07948 - 4630100 or
07953 - MJ 1000 1A
(U .S.A . onlyl

Drive in a new top ball race and lower bearing outer race into
the steerin g head .

' 85, ' 86:

DRIVER 07749 - 0010000
TOP: ATTACHMENT 37 x 40 mm
07746 - 0010200
BOTTOM: ATTACHMENT 4 2 x 47 mm
07746 - 0010300

After '86:
DRIVER 07749 - 0010000
TOP, BOTTOM : ATTACHMENT 42 x 47 mm
07746 - 0010300

11-25
FRONT WHEEL/BRAKE/SUSPENSION/STEERING

Apply grease to the dust seal and install it onto the steering 11' STEERING OT<;::;;''''
stem.

Drive the lower bearing onto the steering stem using the steer·
Ing stem driver.

' 85, '86:

STEERING STEM DRIVER 07946 - GC40000
or ATIACHMENT 07946 - GC4000A
(U .S.A . only)
STEERING STEM DRIVER 07946 - MBODOOO
After '86:
STEERING STEM DRIVER 07946 - 4300101

' 85, ' 86:

IN STAL LATION ~1) TOP CONE ~2 1 PIECES)

'85, '86 :
Apply grease to the lower roller bearing and top ball race.

Install the steel balls 12 1 pieces).

Install the steering stem and top cone ra ce.

LOWER ROl.LeFle E • .,HINuSTEM

Afte r
After' 86 : III
Apply grease to the lower roller bearing and upper roller
bearing .

Install the steering stem.

STE~R"'G STEM

Install the steering head bearing adjustment nut and tighten it

to the specified torque.

TORQUE : 1-2 N'm (0.1- 0 .2 kg..m, 9-17 in·lbl

Turn the steering stem lock·to·lock 4 or 5 times to seat the

bearings and tighten the adjustment nut again.
Repeat the bearing tightening and steering stem turning
sequence twice.
If the nut does not tighten after turning the steering stem the
first or second time, remOl/e the nut and inspect it and the
steering stem threads for dirt 0( burrs.

11-26
J
 FRONT WHEEL/ BRAKE/ SUSPENSION/STEERING

Install the top bridge and forks. "i::II-;-LO~C:;'K

:;-:N;:-U~Tc;W~R~E~N~C"H"'."'3"'
O-x-:3~
2 mm 077 16-0020400
Tighten the steering stem nut. OR Y AVA I IN U.S.A.

TORQUE:
' 85: 60-90 N· m 16.0 - 9 .0 kg-m . 43 - 65 ft ·lbl
' S6 -' S1 : 90-120 N·m (9.0 - 12.0 kg-m. 65 - 90 ft·Jbl
After ' 91 : 80 - 120 N·m (8.0-12 .0 kg-m. 60 - 90 ft-Ib)
Install the removed parts in the reverse order of removal.

12) I
COMM ERCIALLY AVAILABLE IN U.S.A.

11-27
I
REAR WHEE L/BRAKE/SUSPENSION

'85

40- 50 N'm 14.0-5.0 kg-m, 29-36 ft-Ibl

70-90 N'm
(7.0-9.0 kg-m,
51--65 ft· lb)

65-70 N·m
(5.5-1.0 kg-m.
40--51 ft·lb)

38-48N-m
(3.8-4.8 kg-m,
27-35 ft-Ibl

40-50
(4.0-5.0 kg-m,
29- 36 ft-Ib)

N ·m 40-50 N'm
(1 .8-2.5 kg-m. (4.0-5.0 kg·m.
13-18 ft·lbl 29-36 ft·lbJ

12-0
 REAR WHEEL/ BRAKE/SUSPENSION

'86-'9 1 :

40-50 N'm
(4.0-5.0 kg-m. 40-50 N'm (4.0-5.0 kg-m, 29-36 ft·lb)
ft·lbl

70-90 N'm
(7.0-9.0 kg-m,
51-65 ft -fbl

80- 100 N-m

(8.0- 10.0 kg -m,
58-72 ft-Ib)

N·m
, (3.8-4 .8 kg-m,
27-35 ft·l b)

40- 50 N·m
(4.0- 5.0 kg-m, 29-36 ft-lb)

18-25 N-m N·m

(1.8-2.5 kg-m, (4.0-5.0 kg-m,
13-18 ft-Ibl 29-36 ft-Ib)

12-1
REAR WHEEL/BRAKE/SUSPENSION

After '91:

40 - 50 N·m
(4.0 - 5.0 kg-m,
29 - 36 ft-fbl

70 - 90 N·m
(7.0-9.0 kg-m,
51-65 ft-Ibl

80 - N·m
(8.0-10.0 kg -m
58 - 72 ft-Ib)
40 "-"50 N·m
14.0 - 5.0 kg-m,
29-36 ft -Jb)

1 N·m 40- 50 N·m

0,8 - 2.5 kg-m, {4.0- 5.0 kg-m,
13 - 18 ft-Ibl 29 - 36 tHb)

12-2
 12. REAR WHEEL/BRAKE/SUSPENSION
SERVICE INFORMATION 12-3 REAR HYDRAULIC BRAKE: Alter '91 12-18
TROUBLESHOOTING 12-4 SHOCK ABSORBER 12-19
REAR WHEEl 12-5 SWINGARM 12-35
REAR BRAKE: ' B5 - ' 91 12-14 SHOCK LINKAGE 12-37

SERVICE INFORMATION
GENERAL

• Optional driven sprockets, drive chain and reBr shock springs are available. Refer to General Information, Section t.
• Recommended shock oil: Honda SSB Suspension fluid or an equivalent.
• A box or a workstand is required to support the motorcycle.
• Use genuine bolts for the feaf suspension linkage and shock absorber privot and mounting; ordinary bolts lack adequate
strength for these applications. Also take note of the installation direction of these bolts since they must be installed
correctly.
• For optimum suspension performance and linkage component service life, the sw ingarm pivot bearings /bushings and
shock linkage pivot bearings falong with related collars, seals and bushings) should be disassembled, cleaned, inspected
for wear and lubricated with multipurpose grease NLGl No.2 (molydisulfide additive~ each 3 races or 7.5 hours of running.
• Refer to Section 13 about hydraulic system (After '91 I.

inila/"d asbestos f ibers have bun found to couse respiratory disease ond concer. Never use on oir hose or dry brush to clean
broke or clutch assemblies. In the United Stares, use an OSHA-approved vacuum cleaner or o/terlUJte method opproved by
OSHA designed to minimize the hozard caused by airborne asbestos fibers.
Use only nitrogen 10 pressurize the shock absorber. The use of an unstable gas 11IIJy cause 0 fire or explosion resulting
serious injury. Th e rear shock absorber contains nitrogen gas under high pressure. Do not allow fire or heat near the rear
shock absorber.
Be/ore disposal of the shock absorber, release the nitrogen by pressing the vo/ve core. Then I't!molle the volve from the shock
absorber.

SPECIFICATIONS
mm(in)

ITEM STANDARD SERVICE LIMIT

Rear axle runout 0.2 (0.0l)

Rear wheel rim runout Radial -- 2.0 {0.101
Axial -- 2.0 (0.10)
Rear brake drum 1.0. '8 5 - ' 91 85.0 (3.35) 86.0 (3.39)
Rear brake lining thickness '85-'91 3.0 (0 . 12) 1.5 (0.06)
Rear shock absorber spring ' 85, ' 86 24 3 (9 .6 ) 240.6 (9.51
free length After '86 239 (9.41 236.6 (9.3)

12-3
REAR WHEEL/BRAKE/SUSPENSION
TORQUE VALUES
Final driven sprocket bolts 28- 34 N·m (2.8-3.4 kg-m, 20-25 ft-Ib)
Rear axle nut '85: 55-70 N-m (5.5-7_0 kg-m, 40-51 ft-Ib)
After 'S5: 80-100 N·m (S.0-10_0 kg-m, 58-72 ft-fb)
Rear brake pedal pivot bolt lS-25 N·m (1.S-2.5 kg-m, 13- 18 ft-Ib)
Rear shock absorber upper mount bolt .40-50 N'm (4.0-5.0 kg-m, 29-36 ft-Ib)
Rear shock absorber lower mount bolt 3S-48 N·m (3.8-4.8 kg-m, 27-35 ft-Ib)
Shock absorber linkage pivot bolts 40-50 N·m (4.0-5.0 kg-m, 29-36 ft-Ib)
Swingarm pivot nut 70-90 N·m p.0- 9.0 kg-m, 51-65 ft-Ib)
Brake torque link bolts 'S5 - 91 : 1 B-25 N·m (1.S - 2_5 kg -m , 13 - 18 ft-Ib)
Rear shock piston rod end nut 10-15 N 'm (t .0-1.5 kg·m, 7-11 h-jb)
Damper spring lock nut 60-SO N·m (6.0-8_0 kg-m, 43-60 ft- fb)
Compression damping valve After '85: 1S- 22 N-m (1_8-2.2 kg-m, 13-16 ft -Ib)
Wheel spokes 2_5-5_0 N-m (0.25-0.5 kg-m, 1_8-3.6 ft·lb)
Rim locks 10-15 N'm (1.0-1.5 kg-m, 7-11 ft-Ib)
Wheel bearing retainer After '85 15-25 N'm (1.5-2.5 kg -m. 11 - 18 ft-Ib)
Rear brake disc mount bolt After '91: 18 - 22 N-m 11.8 - 2.2 kg-m, 13 - 1 6 ft -Ib)
TOOLS
Special
Piston ring slider set '85, '86: 07974-GC40000
After '86: 07HMG-GC40oo0
-Piston ring slider '85, '86: 07974-GC402oo
After '86: 07HMG-GC40200
-Sleeve collar 07974-GC401oo
Slider guide, 12 mm 07973 - GC40000
Spherical bearing driver 07946- KA30200
Needle bearing driver (After '85) 07946- KA50000
Dis/asse mblv tool B 07964-MB00200
Common
Bearing remover expander 07746-0050100
Bearing remover collet, 12 mm '85: 07746-0050300 lor commercially available in U.S.A_
15 mm After '85 : 0 7746-0050400T
Attachment, 24 x 26 mm 07746-0010700
Attachment, 32 )( 35 mm 07746-00 10100
Attachment, 37 )( 40 mm 'B5: 07746-0010200
PHot, 12mm '85: 07746-0040200
15mm After '85: 07746-0040300
Driver 07749-0010000
Driver, 8 07746-0020100
Attachment, 20 mm 1.0. 07746 - 0020400
Retainer wrench body '86 - 'S7 : 07710-0010401
Retainer wrench C '86 - 'S7: 077 10 - 0010301

TROUBLESHOOTING
Wobble or vibration in motorcycle Hard suspension
Bent rim. Spring preload is improper for rider's weight -
Loose wheel bearing(s). see the Owner's Manual.
Loose or bent spokes. Bent shock damper rod.
Damaged tire. Damaged swingarm pivot bearings.
Axle not tightened properly. Bent frame or swingarm.
Damaged swingarm pivot bearings.
Suspension noise
Chain adjusters not adjusted equally.
Faulty rear damper.
Bent frame or swingarm.
• Loose fasteners.
• Damaged swingarm pivot beari ngs.
Soft suspension
Spring preload adjustment is improper for rider's '85 - '91: Poor brake performance
weight - See Owner's Manual. Improper brake adjustment.
Weak shock spring - it tree length is OK, go t o Worn brake linings.
optional stiffer shock spring_ See Owner's Brake linings oily, greasy or dirty_
Manual first tor the correct sequence of steps to Worn brake cam.
determine if a different spring is required_ Worn brake drum_
Brake arm serrations improperly engaged.
Worn brake shoes at cam contact area.

12-4
 REAR WHEEL/BRAKE/SUSPENSION

REAR WHEEL
REMO VA L
' 85 -' 91 :
Raise the rear wheel off the ground with a box or work stand
under the engi ne.
Remove the axle nut.

Loosen the drive chain adjusting nuts; move the rear wheel
felWard, and remove the drive chain.

Remove the rear brake adjusting nut and cable.

Disconnect the brake torque link from the brake panel bV
removing the nut and bolt.
Remove the axle and wheel.
' (3) BRAKE AOWsTlNG
•• -
BRAKE CABLE

Remove the brake panel from the wheel hub.

After '91 ;
Loosen the lock nuts and the drive chain adjusting bolts .

Remove the axle nut and 8)Cle .

Push the wheel forward and remove the drive chain from the
driven sprocket and remove the rear wheel.

NOTE
Do not depress the brake pedal while the rear wheel is
removed. The caliper piston will move out and make
reassemblv difficult.

INSPECTION

AX LE

Pl ace the rear axle in V-blocks and measure the runout.

Actual runout is 1/ 2 the total indicat or reading.

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

12-5
REAR WHEEL/BRAKE/S USPENSION

WHEEL BE A RI NGS

Turn the inner race of each bearing wi th your finger. The

bearings should turn smoothly and quietly. Also check that
the bearing outer race fits tightly in the hub.

Remove and discard the bearings if the races do not turn

smoothly, quietly, or if they fit loosely in the hUb.

NOTE
. Replace hub bearings in pairs.

For repla cemen t of bearings, see page 12-7.

WHE EL RIM RU NOUT

Measure the rear wheel rim runout with a dial indicato r.

SERVICE LIMIT :
RADIAL : 2.0 mm (O.lO in)
AXIAL : 2.0mm {O. 10 in)

DRI V EN SPR OCKET

Check the condition of the fina l drillen sprocket teeth.

Replace the sprocket if it is worn or damaged. (1) GOOD (2) REP LACE

NOTE
If the driven sprocket is worn or damaged, the drive chain
end the drive sprocket must be inspected end replaced if
necessary.

' 85 -'91:
DISASS EMBLY

Remove the side collar and dust seal.

12-6
 REAR WHEEL/ BRAKE/SUSPENSION

Remove the bolts and nuts attaching the final driven sprocket
and remove the sprocket.

' 86 - '8 7:
Remove the bearing retainer using the retainer wrench and
attachment.

(1 ) RETAINER C 07710-0010301
RETAINER WRENCH BODY 07710- 0010401

' S5
'85 -' 91 :
Remove the wheel bearings and spacer from the wheel hub
(1) BEARING R,~~~~~~~~~
07746-0050100 OR
with the bearing remover. AVAILA BLE IN

12 mm
07746- 0050300 OR COMMERCIALLY
AVAILABLE IN U.S.A.

' 86 -'91 :

12-7
REAR WHEEL/BRAKE/SUSPENSION

After '91 :
DISA SS EM BLY

Remove the side collar and dust seal.

Remove the brake disc.

Remove the side coltar and dust seal .

Aemo ..... the bolts and nuts attaching the f inal driven sprocket
and remove the sprocket.

Remove the wheel bearings and spacer from the wheel hub (1) BEARING REMOVER EXPANDER
,
with the bearing remover. 07746 - 0050100 OR COMMERCIALLY

(2) BEARING COLLET, 15 mm

07746 - 0050400 OR COMMERCIALLY
AVAILABLE IN U.S.A.

12-8
 REAR WHEEL/ BRAKE/SUSPENSION

'85 -'91 :
ASSEMBLY
'86 - ' 91 :

28- 34 N·m
~~ 12.8-3.4 _,·m. 20-25 ft-lb)
~

NOTE
(11~

r~
Assemble the wheel hub and rim so the outer end of the
hub is 24.25 mm (0.954 inl above the rim as shown. 24.25mm
10.954 inl
Tighten the spokes in progressive steps.

TORQUE : 2.5- 5.0 N·m

I. =+_12) WHEEL
(0.25-0.5 kg-m, 1,8-3.6 ft-fbJ HUB
I
Check the runout as shown on page' 2-6, and adjust as
required .

Insta ll the rim band, rim lock, tube and tire. L.

TOROUE : 10-15 N·m
11,0-1.5 kg-m. 7- 11 ft·fbl

Pack all bearing cavities with grease.

Dr ive in the right bearing.
Place the spacer into the hub and drive in the left bearing.

NOTE
Innall the bearings with the sealed ends facing out .
• Drive the bearings squarely.

12)
07746-0010100 07746-00 10200
PILOT, 12 mm PILOT, 12 mm
07746- 0040200 01746-0040200

12-9
REAR WHEEL/ BRAKE/SUSPENSION

32x35mm 32K35mm
07746-0010100 07746--0010100
PILOT, 15mm PILOT,15mm
07746-0040300
'86 - '81:
Grease the bearing retainer and tighten it into the hub using
the retainer wrench and attachment.

TOROUE : 15-25 N-m 11 .5-2.5 kg·m, 11-18 ft·lbl

Peen the edge of the retainer in the places shown.

'85-'91 :
Install the driven sprocket on the wheel hub and tighten the
soCket bolts and nuts.

TORQUE : 28-34 N·m 12.8-3.4 kg-m, 20-25 ft-lb)

Apply grease to the tip of a new dust seal.

Install the dust seal and side collar.

12-10
 REAR WHEEl/BRAKE/SUSPENSION

After '91 :
111 DISC
ASSEMBLY

121 SPACER

18- 22 N·m
/1.8 - 2.2 kg-m.
13 - 16 ft-Ib)

28 - 34 N·m
12.8-3.4 kg-m.
20-25 ft-Jbl

(3) SPROCKET

NOTE (2) TIRE

(1) RIM
Assemble the wheel hub and rim so the outsr end of the hub
is 24 .25 mm (0. 954 in) above the rim 85 shown .

Tighten the spokes in progressive steps. (3) WHEEL

HUB
TORQUE: 2 .5-5.0 N·m
(0 .25-0.6 kg-m, 1.8 - 3 .6 ft·lb)

Check the runout 85 shown on page 12-6, and adjust as

required .

Instatl the rim band, rim lock, tube and tire.

TORQUE : 10 - 15 N·m
11.0-1.5 kg-m. 7-11 ft ·lbl (1) DRIVER

Pack all bearing cavities with grease .

Drive in the right bearing.

NOTE
Install the bearings with the seated ends fac ing out .
• Drive the bearings squarelv.

mm
PILOT, 15 mm 07746 -0040300

12-11
REAR WH EEL/BRAKE/SUSPENSION

Place t he spacer into the hub.

Drive in t he left bearing . (1) DRI VER

NOTE

Install the bearings with the sealed ends faCing out.

o Drive the bearings squarely.

Install the driven sprocket on t he w heel hub and tighten the

socket bolts and nuts.

TORQUE : 28 - 34 N·m (2 .8 - 3 .4 kg-m , 2 0 -2 5 ft -Ib l

Apply grease to the lip of a new dust seal.

Install the dust seal and side coliar .

Install the brake disc on the wheel hub and tighten the mount -
ing bolts to the specified torque.

TORQUE : 18 - 22 N·m (1.8 - 2 .2 kg-m . 13 - 16 ft -tbl

12-12
 REAR WHEEL/BRAKE/SUSPENSION

'85-'91:

INSTA LLATI ON

Install the brake panel into the wheel hub.

Position the wheel inside the swingarm.
Insert the rear axle through the washer, left chain adjuster.
rear wheel hub, brake panel and right chain adjuster. Install
the right washer and axle nut looselV.
Connect the brake cable to the brake arm.
Connect the brake torque link to the brake panel using the
bolt and nut and tighten the nut.
r
TORQUE : 18-25 N· m 11 .8-2.5 kg-m. 13- 18 ft-Ibl
(4) BRAKE "'''R"

'86 -' 91
-

Install the drive chain using the master link and retaining clip (1 ) RETAINING CLIP
wi t h the clip closed end facing the d irection shown.

Adjust the drive chain slack {Page 3-71.

Tighten the axle nut.

TORQUE
'85: 55-70 N·m (5.5-7.0 kg.m, 40-51 ft-Ib)
'85-'9 1: 80-100 N'm 10.8 - 10.0 kg -m , 58-72 ft -Ibl

Adjust the rear brake pedal free play {Page 3-11 I. ~ (2) ~ MASTER LIN K

After '9 1:
INSTALLATION

Install the rear brake caliper aligning the caliper slide raillpage
13-17J.
Position the wheel inside the swing arm.
Insert the reafaxle through the washer, left chain adjuster,
rear wheel hub and right chain adjuster. Install the right
washer and axle nut looselV .

ADJUSTE R
I

12-13
REAR WHEEL/ BRAKE/SUSPENSION

Install the drive chain using the maste r link and ratlini ng clip (1) RETAINING CUP
with t he clip closed end facing the direction shown.

Adjust the drive chain slack (Page 3-71.

Tighten the axle nut.

TORQUE : 80 - 100 N·m (8 .0 - 10.0 kg-m , 58 - 72 ft -Ibl

~ (2) MASTER LI NK

REAR BRAKE '85-'91:

REMOVA L

Remove the rear wheel and brake panel (Page 12-51.

INSPECTION

BRAKE DRU M

Measure I.D. of the brake d ru m.

SERVICE LIMIT : 86.0 mm (3.39 In)

BRA KE LI NIN G 11 1 SHOE

Check the brake shoe spring for fatigue or damage and t he
brake cam for wear or cracks,
Measure the brake lining thickness.

SERVICE LIMIT : 1.5 mm (0.06 In)

DISASSEMBLY SP RIN G

Pry the brake spring off the brake shoe anchor pin and remove
the spring and brake shoes.

Remove the brake arm and cam.

Remove t he brake cam dust $881.
Remove the dust seal and brake panel collar.
Remove the brake torq ue link p ivot collers and O-rings.

12-14
 REAR WHEEL/BRAKE/SUSPENSION

ASSEMBLY
(6) BRAKE SHOES
(5) BR AK E
CAM

(4) DUST SEAL

(3) WASHER

(2) RETURN
SPRING
\'LO--
. --~
181 BRAKE PANEL
COLLAR
(9) O-R ING

)::.~ cy~.!Y''--- 1101 TORQUE LI N K

""'l,=~~~ COLLAR

(1 1) a -RINGS

(12) DUST SEAL

(1) BRAKE ARM

(13) DUST CAP

ApplV grease to the brake panel collar and install it into t he

brake panel.

Install new D-rings over the brake torque link collars and install
them into the pivot hole .

• o
Install the brake cam dust seal into the brake panel.
Apply a small amount of grease to the brake cam and anchor
pin and install the cam into t he brake panel.

111

12-15
REAR WHEEL/BRAKE/SUSPENSION

Install the brake arm return spring and washer.

(31 RETURN SPR ING

Install the brake arm onto the brake cam aligning the punch (2) BRAKE ARM
marks.
T ighten the arm using the bolt and nut. /

BOLT

Position the brake shoes into place and install the brake shoe (1) SHOE ING
spring.

'31k';ii!ii!i'
Gr~ on the brake linings reduces slopping pOWf!r. Keep
fTea~ 011 the linings.

Apply grease to the lip of the dust seal and install it onto the
brake panel. Install the du st cap.

INSTALLATION

Install the brake panel and tear wheel (Page 12-13),

12-16
 REAR WHEEL/ BRAKE/SUSPENSION

' 85 - ' 91 :

BRAKE PED A L RE MOVA L

Remove the rear brake adjusting nut.

Remove the brake pedal pivot bolt and return spring and
remove the brake pedal.

After '91 :
BRAK E PEDAL REMOVAL

Remove the brake pedal pivot bolt and return spring .

Remove the cotter pin and joint pin.
Remove the brake pedal.

'8 5 - '9 1:

INSTA LLATION

Apply grease to the brake torque link pivot collars and a-rings.
Install the collars and O-rings into the torque l ink pivot hole .

12-17
REAR WHEEL/BRAKE/SUSPENSION

Instali the pedal return spring between the pedal and the
frame.
Posit ion the brake torque link and pedal into place.
Apply grease to the brake pedal pillot bolt.
Install and tighten the pivot bolt.

TORQUE : 18-25 N·m (1.S-2.S kg-m. 13- 18 ft·lb)

After '91:
INSTALLATION

InSIBlithe brake pedal to the master cylinder by inserting the

joint pin and cotter pin .

Install the return spring.

Apply grease to the sliding surface of the pivot bolt .
Install and tighten the pivot bolt.

TORQUE: 18-25 N·m 11.8-2.5 kg-m. 13 - 18 ft-Ibl

REAR HYDRAULIC BRAKE After '91:

• Refer to section 13.

12-18
 REAR WHEEL/BRAKE/S USPENSION

' BS
SHOCK
'85-'9 1:
ABSORBER (1) UPPER MCIU.'T'!~~~
REMOVA L

Remove the subframe (Page 14-3',

Loo$8n the reservoir bands and remove the reservoir from

the frame.

RemOlle the rear shock upper mounting bolt.

(2) BANDS

Remove the shock lower mounting bolt.

After '9 1: II1l1iilluJip~p~E;A;-;;;mMmiGBcilT:----;-;::-----1

REMOVAL

Remove the subframe (Page 14-3).

Remove the fuel tank (Page 4 -21 I.
Loosen the reservoir band and remove the reservoir from the BAND
frame .

Remove the rear shock upper mounting bolt.

12-19
REAR WHEEL/ BRAKE/SUSPENSION

Remove the shock lower mounting bolt.

SPRING REMOVAL/INSPECTION

Hold the lower shock mount in a vise with soft jaws or ill shop
towel. Loosen the lock nut and adjusting nut.

111 PIN SP',NNEFis

_ 89201 - GC4- 810_ __---=1
<----=89202- GC4- 810 AND

Remolle the lower spring seat and spring.

Measure the free length of the spring.

SERVICE LIMIT : '85, '86: 240.6 rnm (9.47 inl

After '86: 236.6 mm 19.31 in)

12-20
 REAR WHEEL/ BRAKE /SUSPENSION
'85
DAMPER INSPECTION

Visually inspect the damper unit reservoir hose and reservoir

for oil leaks or damage. Replace the damper unit if necessary.

After '85

DAMPER DI SASSEMBLY (1) RESER VOI R

Release the nitrogen from the reservoir by depresSing the

valve core. Do not remove the valve untit pressure is released . /
. 'Ii.
Point the I'a/l.'e away from } 'Ol/ /0 prel't'nt debris gellillg I" ),ollr
e)'es.

NOTE
(2) VALVE
Release the nitrogen pressure before draining the oil from
the damper .

Loosen the hose joint lock nut, then separate the reservoir,
hose and damper.

Drain the oil from the hose and damper. Pump the damper
rod in and out several times to drain most o f the oi l from the
damper.

Drain the oi l from th e reservoir.

12-21
REAR WHEEL/ BRAKE/SUSPENSION

Remove the damper end plate and tape or tie it to the anti-
bottoming rubber bumper.

Push in the damper seal until you have good access to the
circlip.
You' ll need two small screwdrivers to remove the drclip ,

The circiip groove in the damper is ramped towards the

inside to give the circlip a square shoulder on which to seat
securely.
To remove the circlip. first push one end of the circlip out
of in groove, then slip the second screwdriver between the
circUp and the damper to act as a ramp. Now, use the other
screwdriver to pult the circlip completely out.

Pull the piston rod assembly out of the damper.

PISTON RING REPLACEMENT (2 ) Q-RIN GS

If the piston ring is damaged, cut the piston ring and remove
it from the piston.
Replace the O-rings with new ones.

RING

12-22
Place the slider guide attachment over the piston and press a
new piston ring into place wi th the slider sleeve.

PISTON RING SLIDER SET

' 85, '86 07974 - GC40000
After '86 07HMG - GC40000
- PISTON RING SLIDER SET
'85, '86 07974 - GC40200
After '86 07HMG - GC40200
- SLEEVE COLLAR 07974 - GC40100

PISTON ROO DISASSEMBLY

Place the piston rod lower mount in a vise with shop towel
or soft jaws, being careful not to distort the lower mount.
~ _ _- (2) PISTON
Remove the piston rod end nut that is staked onto the piston ROD
md.

NOTE
Do not reuse the end nut.
Remove all burrs from the end of the damper rod after
removing the end nut, taking care not to damage the
,
damping force adjusting needle at the end of the piston rod .

Turn the rebound damping adjuster clockwise fully to prevent '85: d ie, 12 x 1.25 mm
metal chips from entering the damper rod. After '85 : die, 10)( 1.25 mm
Remove burrs from the piston rod end with fingers and chase
the threads with a die.
Clean the piston rod with solvent after chasing the threads.

NOTE
• Make sure that burrs are not stuck inside the damper rod.

'85, ' 86
'85, ' 86: (1) VALVE STOPPER
Remove the piston washer, damping valves, piston and valve (2) PISTON
stopper from the damper rod.

\,
(3) PISTON
WASHER

(4) DAMPING VALVES

12-23
REAR WHEEL/ BRAKE/SUSPENSION
A fte r '86
After '86:
Remo ve the piston washer, damping valves, valve collar end
valve stopper from the damper rod.

NOTE
Slip 8 piece of thin wire through the removed valves to en-
sure correct reassembly order.
Keep away from air-borne dust and abra sives.
Thoroughly clean the valves in solvent and blow them dry
wi th compressed air before they ere to be reassembled .
Be careful not 10 get solvent on the D·rings and seats .

(5) DAMPING VALVES

'85, '86
Wrap the top threads of the piston rod with tape.
(11
' 85, 'S6:
Remove the rebound spring and ro d guide case from the piston
rod .

(31 REIBOl"O SPRING

Af1er '86
After ' S6 : (2 1 ROD GUIDE CASE
Remove the rod guide case from the piston rod .
(11 TAPE

Remove the end plate, stopper rubber and spr ing seat stopper (1) STOPPER RUBBER (2) SPRING SEAT STOPPER
from the piston rod.
j
\ \ __ ~l

1
(3) END PLATE

12-24
 REAR WHEEL/ BRAKE /SUSPENSION

Remove the dUlt seal from the rod guide cue by prying it out 111 DUSTS~
carefully.

Remove the a-ring from the rod guide case.

121 (3) ROD GUIDe CASE

'85. ' 86
' 85, 'S6 : (1 ) SNAP RING

/
Remove the snap ring and rebound seat .

After '86 :
Remove the rebound rubber and rebound seat.

121 REEIOLIND SEAT (21 REBOUND SEAT

Remove the oil seal and back-up ring. 111 OIL

' 85, ' 86

ROD GUIDE CASE INSPECTION
/ -"
(1 ) DUST SEAL
121 ROD GUIDE
Replace the oil seal and dust seal whenever the piston rod is
d isassembled . fI /'.,.
,.
,. CASE
(3) SNAP
RING

/~(J~ I
Visually inspect the rod guide case metal.
If the metal is worn so that the copper surface appears, replace

~~~~ UP I V I J
o
the rod guide case with a new one.
141

(5) OIL
SEAL
I U
(6) REBOUND / (2) ROD GUIDE
SEAT m D -RING CASE

12-25
REAR WHEEL/ BRAKE/SUSPENSION
After '86
PISTON RO~ INSPECTION (1) DUST SEAL

Inspect the piston rod sliding surface for damage or distortion.

~- (2)
GUIDE CASE
(3) O-RING
Small scratches can be removed with No. 2000 sand paper. (4 ) Oil SEAL GUIDE

NOTE (J--
• Remove only small scratches and dress the area evenly.

PISTON ROD ASSEMBLY

(5) BACK-UP RIN~(J ..

(6) Oil SEAL / .,()

Before assembly, wash all parts with solvent and blow dry
17) REBOUND SEAT /
with compressed air.
Check that there is no dust or lint on any parts.
(8 ) REBOUND RUBBER ~~~~::~J
NOTE
Because solvent can damage the rubber m aterial many 0 -
rings and seals Bfe made of, use added cafe to avoid getting
solvent on t hese parts.
Never 8558mble valves which you might have damaged or (1) SLiOING
gotten dirty disassembled. Clean them with solven t SURFACE
thoroughly, and blow them dry with compressed air before
reassembly .
The valve arrangement and number of valves may differ
from those shown.

After '86:

After '85:
o
,o
o
t
•

12-26
 REAR WHE EL/ BRAKE/SUSPENSION
'85, '86 After '86
'85, '86:
Install the back-up fing in the rod guide case with its
chamfered edge facing down .

Press a new oil seal into the rod guide case until it s8ats on the
back-up ring with its flat side down .

A fte r '86:
InstaU the oil seal guide in the rod guide case.
Install the back-up ring.

Press a new oil seal into the rod guide case until it seats flat
face side down.
(31 OIL SEAL GUIDE

'8 5, '86
Install the rebound seat into the rod guide case with its radius-
ed edge facing down . I' ) RING

'85. '86:
Install the snap ring .

After '86:
Install the rebound rubber.

)2 ) H."UlINU SEAT

Press the dust seal onto the rod guide case. 07746-0020 100

NOTE
• Install the dust seal squarely onto the rod ~ide case .

(21 ATTACHMENT,
07746 - 0020400

\ (4) ROD GUIDE CASE

)3)
/"

Install a new O' ring onto the rod g.Jide case. (1) DUST SEAL

(2) )NG

12-27
REAR WHEEL/ BRAKE/SUSPENSION

Install the spring seat stopper, stopper rubber and end plate
over the piston rod .

Install the special toot onto the piston rod.

Install the rod guide case carefully over the piston rod .

NOTE
Be careful not to damage the dust seal lip or turn the lip in-
side out.

Remove the special tool.

Check the rod guide case movement by sliding it fully up and

down by hand .
'85, '86
' 05, '86: VALVE STOPPER
Install the rebound spring.
\ 13) COr.~RESS"ON VALVES

~\

,
Install the valve stopper onto the piston rod with its polished (4) PISTON
surface down.

Install the compression valves, piston and rebound valves onto

the piston rod.
11 )
SPRING

After '86:
15)
~VA~~L'VJ'~E'~S'o_ _~. I
InSlall the valve stopper onto the piston rod with its polished
surface down . (6) WASHER--

Install the valve collar. compression valves, piston and re o

!
bound valves onto the piston rod.
(1 ) VALVE STOPPER
(2) VALVE COLLOR

j (31 PISTON

NOTE
Note the installation direction of the piston and val\185.
Be careful not to bind the \lal\les when installing the piston o
~J,g
onto the piston rod . Also check that they are concentric
with the piston rod. 141 COMPRESSION VALVES/
(5) REBOUND VALVES ............... / '
Install the washer onto the damper rod with its polished
(6) WASHER
surface down.

Place the piston rod in a vise, and install a new end nut .

NOTE
To prevent damage to the lower mount, use a shop towel or
a vise having soft jaws .

Tighten the new end not to the specified torQue.

TORQUE : 10- 15 N·m 11.0- 1.5 kg-m. 7 - 11 ft -Ibl

12-28
 REAR WHEEL/ BRAKE/SUSPENSION

Turn the rebound damping adjuster counterclockwise fully 11) LOCKING T AB

to lower the adjusting needle. /'. 131 A DJUSTING
NEEDLE
Bend the locking tabs of the nut against the damper rod ilS
shown. : (( O)J \>, .
1'85: And stake the end of the damper rod at four places to
"
~
121 STAK1J ri I
secure the end nut, taking care not to damage the adjusti'ng ~
.-'
needle.) Aft.r '85:
1
~
NOTE
. Stake the damper rod SO that it is well peened over into
the end nut.

Install the piston O-rings and piston ring Wage 12·22).

Coat the inside of the damper case with clean shock oil and (1) CIRC LIP (2) END PLATE
insert the damper rod assembly.
Install the cirdip into the groove of the damper case.

Dr ive the end plate into the shock body.

(31 DAN'PER CASE

After '85: (' I

SERVICING THE RESERVO IR

Remove the compression damping valve from the reservoir to

drain the shock oil.
Turn the reservoir upside down to allow all the shock oil to
drain. Then, flush out the reservoir using clean shock oil.
Allow all the oil to drain.

' 86
' 86:
'---
Remove the spring, spring guides and bottom valve as an (1) DAMPING VALVE
assemblv from the damping valve.
(2) SPRING GUIDES

~
Disassemble and clean them with clean shock oil.

~! ZRESE~'R
(4) BOnOM VA LV E
(5) SPR IN G

12-29
REAR WHEEL/ BRAKE/SUSPENSION
After '86
Aft er '86:
Remove t~e spring. washers, spring guides and bottom valve
8S an assemblv from the damping valve.
~
Disassemble and clean them with clean shock. oil. ( 1) RESER VOR

IS) SPRING GUIDES

L! -7'
121 WASHERS

~
(3) SPRING . / ~
(4 ) DAMPING VALVE ---"'" ..

Fill the reservoir with fresh shock oil.

RECOMMENDED OIL : Honda SSB Suspension Fluid or an
equivalent
Reinstall the bottom valve, spring guides and spring.

Tighten the compression damping valve.

TORQUE : 18-22 N·m (1,8-2.2 kg.m. 13-16 ft·lb)

DAMPER ASSEMBLY

Hold the shock body in a vise w ith soft jaws or a shop towel
as shown .
Pull out the damper rod all the way .
Fill the damper with shock oiL

RECOMMENDED Oil: Honda sse Suspension Fluid or an

equivalent

Install a new O-ring onto the hose joint threads and connect
the hose to the damper body .
T ighten the hose joint.
Dip the reservoir-end of the hose into a container filled with
shock oil.

Very slowly compress the damper rod until bubbles disappear, 111 PUMP VERY SLOWLY
then slowly pull the rod out. Repeat this until all air has
been bled from the hose and shock.

Remove the hose from the oil and keep the shock upright and
the open hose end elevated to avoid losing any shock oil.

12-30
 REAR WHEEL/BRAKE/SUSPENSION

Reinstall the valve core into the Shrader valve on the bottom of
the reservoir and charge it slowly with 14 psi to inflate the
diaphragm inside the reservoir .

Fill the reservoir with the shock oiL

Top off the reservoir with shock oil to the top of the threads;
this excess oil will be forced out when you install the hose
fitting.

Install 8 new O' ring onto the hose joint threads and connect
the hose to the reservoir.
Tighten the hose joint lock nut.

Wipe off any excess oil and check for oil leaks.

Release the 14 psi that was in the reservoir.

Fill the reservoir with 14 kg/cm 1 (199 psi) of nitrogen. ) VALVE

: i
The shock absorber is jilted with a gas-filled resuvolr. Use only
nitrogen gas to pressurize the shock obsorbtr. The uu 0/ an
unstable gas can cause a/lre or explosion resulting in serious in-
jury. fI
InS1allthe .... al .... e cap.
"'-
(2) VALV E CAP

Install the spring and lower spring seat.

Turn the lower shock mount so that the rebound adjuster is

on the same side of the shock as the reservoir hose outlet.

12-31
REAR WHEEL/ BRAKE /SUSPENSION

T ighten the spring adjuster nut until the spring length is as (1) LOCK NUT
specified.
A : DECREASE THE SPRING LENGTH (2) ADJUSTING
B: INCREASE THE SPRING LENGTH
NOTE SPRI NG LENGTH
• One turn of the adjuster nut changes the spring length by
1.5 mm (0.06 in).
STANDARD SPRING LENGTH
'85: 234 .5 mm 19.23 Inl
'8 6: 240. 7 mm (9.48 in t
'87: 236.3 mm (9.30 in )
After '87 : 235.3 mm 19.26 int
Use this standard spring preload length just as a baseline. See
'85- '87:
the Owner's Manual for detailed instructions on ad justing
preload for rider weight and setting damping for r id ing condi-
" )
tions and rider skill.

Tighten the lock nut.

TORQUE : 60-80 N'm (6.0-8.0 kg·m , 43- 60 ft-Ibl

UPPER MOUNT BEARING REPLACEMENT
'85- 'S7:
Check the spherical bearing for wear or damage.
Aft, r '87:
Check the needle bearing for wear or damage.
If it ;s worn or damaged, tt must be replaced.
'85-'87: (4 )

,
Remove the upper coliars, dust seals and circlips.
After '87: '85-'87:
Remove the dust seals.
NOTE
Drive the spherical bearing down to make a clearance be·
tween the circlip and bearing surface; then, push the circlip
out and up from the circlip groove with a small screwdriver .
Remove the other circlip the same way.

Press out the bearing from the shock absorber. 11) SPHERICAL BEARING DRIVER
Press in a new bearing into t he shock absorber. 07946 - KA30200

12-32
 REAR WHEEL/ BRAKE /SUSPENSION

'85- '87:
Install the circlips.
Apply Multi·purpose grease NlGl No. 2 (MoS~ Additive) or
equivalent to the dust seals and upper collars, then install them
as shown.

(2) DUST SEALS

After '87:
After ' 87:
Install the dust seals.
Apply Multi-purpose grease NlGl No.2 (MOSl Additive) or
equivalent to the mount collar, then install it.

INSTALLATION

Set the shock absorber onto the shock arm by facing the
rebound adjuster to the left.

T ighten the lower mounting bolt to the specified torq ue.

TO ROUE : 38-48 N·m (3.8-4.8 kg·m, 27- 35 ft-Ib)

Install and torque the shock absorber upper mounting bolt. 11) UPPER MO'U~T"jG

TORQUE : 40-50 N·m (4.0-5.0 kg-m, 29-36 ft-Ib)

Aoute the hose as shown.

12-33
REAR WHEEL/ BRAKE/SUSPENSION

RESERVO IR INSTALLATION

'85 -'91:
Clamp the reservoir onto the frame with the reservoir bands as
shown.

Install the sub frame (Page 14-3).

'85: '86 - '91:

After '9 1:
RESERVO IR INSTALLATION (1) BOSS (2) RESERVOIR

Install the reservoir by aligning the boss with hole in the

bracket.

(3) BRACKET

Clamp the reservoir onto the frame with the reservoir band as
shown.

Install the sub frame (Page 14-3).

Install the fuel tank (Page 4-2 1).

12-34
 REAR WHEEL/ BRAKE/SUSPENSION

SWINGARM
REMOVAL

Remove the following:

- rear wheel (Page 12-5).
- shock arm-to-swingarm pivot bolt.

,,-
t
BOLT

Remove the swingarm pivot nut. pull out the pivot bolt and (l) SW INGAAM
remove the swingarm.
\

Remove the drive chain slider and chain guide. (1) DUST SEALS 121
Remove the dUst seals and pivot collars.

,.
' ~r~
~ r
(3) CHA I N GUIDE

INSPECTI ON (1) BUSHING

Inspect the swingarm for deformation or cracks.

'85 :
Check the pivot bushings, collars and dust seals for wear or
damage.

12-35
REAR WHEEL/BRAKE/SUSPENSION

After ' 85: (1) NEED LE BEARINGS

Inspect the dust seals, collars and needle bearings.
, ,
Replace them jf they have score marks, scratches
wear.
Of excessive ,
-'
,

.. (2) COLLARS

."""r,.,..--~"
131 DUST S L "'-'
r/

PIVOT BEARING REPLACEMENT After '85: (1) NEEDLE DRIVER

07946-KA50000
Press out the needle bearings with 8 beari ng driller.

NOTE
• Be carefu l to center the d is/assembly tool B correctly.

I
121

Pack new needle bearings with grease,

Carefully press the needle bearing into the proper position in (1) NEEDLE BEARING DRI V ER
the 5wingarm pivot as shown.

NOTE
• Install the bearings with their marks facing out.
10mm
(0.3 i")

1
INSTALLATION

Install the swingarm in the reverse order of disassembly.

Apply Multi·purpose grease NlG1 No.2 (MOS2 Additive) or

equivalent to the swingarm bushings, collars and dust seats.
Torque the 5wingarm pivot bolt.

TOROUE : 70-90 N·m

17.0-9.0 kg-m, 51--65 ft·tb)

12-36
 REAR WHEEl/BRAKE/SUSPENSION

SHOCK LINKAGE
REMOVAL
Raise the rear wheel off the ground with a work stand or box
under the engine .
Remove the shock absorber lower mounting bolt.

Remove the shock arm bolt (Swingarm side).

Remove the shock link boh (Frame side),
Remove the shock arm and shock link, then disconnect the
shock arm from the shock link.

INSPECTION

Inspect the shock linkage dust seals, collars, bushings and

0,,..._-o---,/,-,1I_D7UZ::LS
needle bearings,
Replace them if they have excessive or abnormal wear.

NOTE
o
Be earful not to lose the needle rollers of the shock linkage
pivot needle bearings . Each needle beering has 24 needle
roll ers.
If the needle rollers are out of place, inspect them for wear
or damage and install using molybdenum disulfide grease .
121

NEEDLE BEARING REPLACEMENT

Drive out one bushing with a drift .

Then press out the needle bearing and bushing with the special
tool.

12-37
REAR WHEEL/BRAKE/SUSPENSION

NOTE
• Install the bearings with the marks facing out.

orille one bushing into the shock arm or link .

Press the new needle boaring and the other bushing into tho
shock Irm or link with the special tools.

SPHERI CAL BEARING REPLACEMENT

Remove the side collars and dust seals,

Remove the circtips.

Press the spherical bearing out of the shock arm. '85-'87: After '87:
Press a new spherical bearing into the shock arm. (1) SPHERICAL BEl~ING SPHERICAL BEARING
Installtha circlips. DRIVER 07946-KA30200 DRIVER
Install new dust seals and side coliars. 07946-KM40701

I NSTALLATION
,,,,.,,,..._ _ _-'.:1'.:.1;;;DUST SEALS
Apply Multi-purpose grease NlGl No, 2 (MaSl Additive) or
equivalent to the shock linkage collars, bearings and dust seat O:;:::---~
lips .

NOTE
o
Make sure that the needle rollers afe in position before
installing t he pivot collars.

.\~ ,,..:..,-,~
Install the shock link to the frame and tighten the bolt. (2) COLLARS ~ ...... ~I
(3) BEARINGS •
TORQUE: 40-50 N·m 14.0-5.0 kg- m. 29-36 ft·fbl

12-38
 REAR WHEEL/BRAKE/SUSPENSION

Temporarily install the shock arm to the shock link then con-
nect it to the swingarm.
Tighten the shock arm bolts to the specified torque.

TORQUe (Swingarm side) :

40-50 N·m {4.0-S.0 kg·m, 29-36 ft·lbl

TORQUE (Shock link side):

40-50 N'm (4.0-5.0 kg-m, 29-36 ft·lb)

Connect the shock absorber lower mount to the shock arm and
tighten the bolt to the specified torque.

TORQUE: 38-48 N'm (3.8-4.8 kg-m, 27-35 ft-lb)

12-39
HYDRAULIC BRA KE

Front
Aft ar '85:
After '86 :
8 - 12 N·m (0.8
6 - 9 ft-Ib)
1.2 kg-m,
8

, (O, a 12T'
12 N·m 6 9 ft-lb)

~ 30 - 40 N·m
IMJ /3.0-4.0 kg-m,
!:"',~;" 22 - 29 ft-Ib)
d@
15-20N'm '1 - 14ft-lb)
(15~~

- 1.5 kg-m, 9 - 11 ft-fbl

12 - 15 N·m
~ 11.2

30 - 40 N·m 22 _ 29 ft -Ib)
- 13. 0 - 40'.-m,
.

•
~~
ReBr
Afte r ' 91 :
la~25 N·m
It 8 - 2.5 kg-m.
13-' 8 ft -Ib)
8
~ 1 ~14
I, 11~.5~2~2
.5 - .~
0","g-m, ft -Ibl

-,...---.:", 1 4 - 1 6 N·m
2- 3 k m /1.4 - 1.6 kg-m,
W.2 - 0.3 g- . 7 - 12 ft-Ib)
1.4 - 2 ft -Ib)

30 - 40 N·m
~~~~~~-l:ll -·((3.U~'-2'9':·~ft_lb) kg-rn,

13-0
 13. After '85: HYDRAULIC BRAKE
SERVICE INFORMATION 13- 1 FRONT MASTER CYLINDER 13-8
TROUBLESHOOTING 13-2 FRONT BRAKE CALIPER 13-9
BRAKE FLUIO REPLACEMENT/ REAR BRAKE MASTER CYLINDER
AIR BLEEOING 13-3 After ' 91 13- 12
BRAKE PAO/OISC 13-4 REAR BRAKE CALIPER After '91 13- 15

SERVICE INFORMATION
GENERAL

• Use only recommended brake fluid from a sealed container.

• Bleed the hydraulic system if it has been disassembled or if the brake feels spongy.
• Do not allow foreign material to enter the syst em when filling the teservoir.
• Brake fluid will damage painted, plastic , and rubber parts. Whenever handing brake fluid, protect the painted, plastic, and
rubber parts by covering them with a shop towel. If fluid does get on these parts, wipe it off immediately with a clean
cloth .
• Always check brake operation before riding the motorcycle.

SPECIFICATIONS
mm(inl
ITEM STANDARD SERVICE LIMIT

'wm dl.e I 3.0 10.12) 2.510.10)

Front brake pad thickness 4.910.19) 1.010.04)
Front disc runout -- 0.15 (0.05)
Front master cylinder LD . 11.000 - 11.043 10.433-0.435) 11.05 (0. 4 35)
Front master piston 0 .0. - 10.92 ·0.430) 10.B4
F,ool "lip., , I ,I.D. j 11.190 - 1.1 92) 30.29 11.193 )
"001 "lip.' pl"on O.D. 30.15 - 30.200.187 - 1.189) 30.1411.1S7)
Rear disc thickness (After ' 91) 3.0 (0. 12) 2.510.10)
Rear brake pad thickness (After ' 91 ) 6.4 (0.25) 1.0 10.04)
Rear disc runout (After ' 91 ) - 0.1510.05)
R." I ,I.D. IAft., '91) 12.700 - 12.743 . 017) 12.76
R." 'piston 0.0. (After '91 ) 1 2.657 1 2.684 10.4983 0.4994) 12.64 (0.498)
Rear caliper I.D. (After ' 91 ) 27 .00 27.050.063 1.065) 27 ,06 11.065)
Rear caliper piston 0 .0 . (After ' 91 ) ;- : 11 1. - 1.0617) 26.91 11.059)

TORGUE VALUES
Front brake caliper bolt 18 - 25 N ·m (1.B - 2.5 kg-m, 13-18 ft-Ib)
Caliper hanger pin 15 - 20 N·m /1.5 - 2.0 kg·m, 1 1- 14 ft-Ib)
Caliper slide pin 20 - 25 N·m (2.0- 2.5 kg-m, 14 - 18 ft-Ib)
Brake caliper bleeder 4 - 7 N·m (0.4 - 0.7 kg-m, 3- 5 ft-Ib)
Front master cylinder holder 8 - 12 N·m (0.8 - 1.2 kg-m, 6 - 9 ft -Ib)
Brake lever pivot nut After ' 86 : 8 - 12 N·m (0.8 - 1,2 kg-m, 6 - 9 ft-Ib)
Brake hose joint (master cylinder) 30 - 40 N·m (3.0-4.0 kg -m, 22 - 29 ft-Ib)
(brake hose ) 12 - 15 N·m /1.2 - 1.5kg-m, 9-11 ft-Ib)
Brake hose banjo bolt (caliper) 30 - 40 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
Front brake disc mount bolt '85 - ' 9 1: 14 - 16 N'm (1.4 - 1.6 kg-m, 10 - 12 ft-Ib)
After '91 : 20 - 24 N·m (2.0-2.4 kg-m, 14 - 1 7 ft-Ib)
Rear brake caliper pin bolt After '91 : 10 - 15N·m(1.0- 1.5kg-m, 7-11 ft-Ib)
Rear brake caliper pin bolt A After '91 : 25 - 30 N·m (2.5 - 3.0 kg-m, 18 - 22 ft-Ib)
Brake caliper hanger pin plug After ' 91 : 2 - 3 N' m (0.2 - 0.3 kg-m, 1.4-2 ft-Ib)
Rear brake disc mount bolt After ' 91: 18 - 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-Ib)

13-1
HYDRAULIC BRAKE

TOOL

Spacial
Snap ring pliers 07914-3230001 or Equivalent commercially allailable in U.S.A.

TROUBLESHOOTING
Brake lellif soft or spongy Brake chatter or squeal
Air in hydraulic system Pads contaminated
Low fluid level • Disc or wheel misaligned
Hydraulic system leaking
Brake chattar or squeal
Brake lellif too hard Pads contaminated
Sticking p iston Excessive disc runout
Clogged hydraul ic system Caliper installed incorrectlV
Pads glued or worn excessively Disc or wheel misaligned

Brakls drag
Hydraulic system sticking
Sticking piston
Incorrect pedal adjustment (After '9 1 I
Disc or wheel misaligned

13-2
 HYDRAULIC BRAKE

BRAKE FLUID REPLACEMENT! FRONT:

REAR {After '9 11:

AIR BlEEDING
Check the fluid level with the master cylinder parallel to the
ground.

CAUTION
A void spilling jluid on pointed. plastic. or rubber parIs. Place u
shop lo .....el over these parts whenever Ihe system is serviced.

BRAKE FLUID DRAINING

Connect a bleed hose t o the bleed valve. MA" TE:R CYLINDER
Loosen the caliper bleed valve and pump the brake lever or
pedal. Stop operating the brake lever or pedal w hen fluid stops
flo wing out of the bleed valve.

A contaminaud brake disc or pad reduus stopping po .....er.

DLH:ard contaminaUd pads and clean a contaminaud disc wjth
quality blab cleaning agent.

BRAKE FLUID FILLING/A IR BLEEDING

Close the bleed valve and fill up the brake fluid from a sealed
container.

FRONT (After '8 5) and REAR (After ' 91 1

Fill the master cylinder and reservoir to upper line with reserv-
ed brake flu id.
FRONT : DOT 3 or DOT 4 .
REAR: DOT 4 only.

' 86 - '91 and Alt ar ' 91 :

Connect the Mityvac Brake Bleeder No. 6860 or equivalent t o
the bleed valve.

NOTE
Check the fluid level ot ten while bleeding the brakes to pre-
vent air from being pumped into the system.
Use only reserved brake flu id from a sealed container.
00 not mix brake flu id types and never reuse the con -
taminated flu id which has been pumped out during brake
bleeding, because this will impair the efficiency of the brake
system.
When using a brake bleeding tool, follow the manufac-
turer's operating instruction s. J(1i MITYVAC BRAKE BLEEDER OR FO'U"JAI_""
I
Pump the brake bleeder and loosen the bleed valve.
A dd fluid when the fluid level in the master cylinder is low .
Repeat the above procedures until no air bubbles appear in the
plastic hose .

NOTE
If air is entering the bleeder from around the bleed valva
threads, seal the threads with teflon tape .

. "
13-3
HYDRAULIC BRAKE

If the brake bleeder is not available, perform the following

precedure.

Pump up the system pressure with the lever until there are no
air bubbles in the fluid flowing out of the reservoir small hole
and lever resistance is felt .

1) Squeeze the brake lever, then open the bleed valve 1/2
turn and close the valv8.

NOTE
Do not release the brake lever un tit the bleed valve has
been closed,

2) Release the brake lever slowly and wait several seconds

after it reaches the end of its travel.

Repeat steps 1 and 2 until bubbles cease to appear in the fluid

at the end of the hose.

Tighten the bleed valve,

TORQUE : 4-7 N'm (0.4-0.7 kg·m, 3-5 ft·lb) FRONT: REAR IAfter '9 1)

(1 ) CASTING LEDGE
FRONT
Reinstall the diaphragm and master cylinder cover.

REAR
Reinstall the reservoir cap securely.

BRAKE PAD/ DISC

FRONT

t4\2Miiii!d
A contamilJQ(ed brake disc or pad reduces stopping power.
Discard contamifllJted pads and clean a contam[lJQled disc
with a quolilY brake degreosing agent.

PAD REPLACEMENT

NOTE
Always replace the brake pads in pairs to assure even disc
pressure.

Loosen the hanger pins.

Remove the caliper mounting bolts and caliper from the left
fork leg.

13-4
 HYDRAULIC BRAKE

Pull the hanger pins out of the caliper.

Remove the brake pads.

Push the caliper piston into the caliper all the way.

CAU TION
Check that the jluid level in Ihe master cylinder doesn'l
ol'erjlow when pushing the piston in.

Position the pad spring in the caliper as shown.

Install the new pads in the caliper.

NOTE
Place the pads with the metal backing toward the caliper
piston.

Install the hanger pins.

Carefully spread the pads apart so that they will clear the disc
upon installation onto the fork leg.

13-5
HYDRAULIC BRAKE

Install the caliper so that the brake d isc is positioned between

the pads, making sure not to damage the pads and tighten the
caliper bolu.

TORQUE : 18- 25 N'm 11 ,8- 2.5 kg-m, 13-18 ft-Ib)

Tighten t he hanger pins.

TORQUE : 15-20 N·m (1 ,5- 2.0 kg-m, 11- 14 ft-lb)

After '91 :
REAR
The brake pads can be replaced with the caliper inst alled .

NOTE
A lways replace the brake pads in pairs to anure even d isc
pressure,

Remove t he hanger pin plug and loosen the hanger pin (5 mm

HEX).

Pull the hanger pin out of the caliper.

Remove the brake pads .

'~:;;<;:
A'1( ~
(2) HANGER PIN

13-6
 HYDRAULIC BRAKE

Install new pads.

Install the hanger pin bV pushing the pads against the caliper to
depress the pad spring.
Tighten it to the spacified torque.

TORQUE: 15 - 20 N·m 11 .5 - 2 .0 kg -m. 11 - 14 ft·lb)

Install the hanger pin plug.

Tighten it to the specified torque .

TORQUE : 2-3 N ·m (0.2 - 0.3 kg -m . 1 .4 - 2 .2 ft-Ibl

DISC THI CK NESS

Measure the thickness of the disc.

SERVICE LIMIT : FRONT: 2 .5 mm (0. 10 in)

REA R IAfter '91) : 2 .5 mm 10. 10 in l

Replace the disc jf it is t h inner than the service limit.

BRAKE DISC WA RPAGE

Remove the front brake disc (page 11 -11) and rear brake disc
(page 12-8).

Measure the brake disc for warpage on a surface plate.

SERVICE LIMIT : 0.15 mm (0.006 in)

Replace the disc if warpage is greater than the service l imit.

13-7
HYDRAULIC BRAKE

FRONT MASTER CYLINDER

DISASSEMBLY

Drain brake fluid from the hydraulic system.

Remove the brakel''1er from the master cylinder.
Disconnect the brake hose,

CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts.
P/Qce a rag over these parts whenever the system is ser·
viced.

NOTE
When remolling the brake hose bolt, cOlier the end of the
hose to prevent contamination . Secure the hose to prevent
flu id leakage.

Remove the master cylinder.

Remove the piston boot and the circtip from the master
cylinder body.

(2) SNAP RING PLIERS 07914 -323000 1 OR

EOUI VALENT COMMERCIALLY
AVAILABLE IN U.S.A.

Remove the piston and spring. (1) CUPS

(2) WASHER
Clean the inside of the master cylinder and reservoir with
clean brake fluid . (3) BOOT

IS)
(4) CIRCLIP

INSPECTION

Measure the master cylinder 1.0.

SERVICE LIMIT : 11 .05 mm (0.435 In)

Check the master cylinder for scores, scratches or nicks.

13-8
 HYDRAULIC BRAKE

Measure the master piston 0.0. PISTON

SERVice LIMIT : 10.84 mm 10.427 in)

Check the primary and secondary cups for damage before

assembly,

ASSEMBLY

CAUTION
Handle the master cylinder piston, cylinder and spring
as a set.

Assemble the master cylinder. Coat all paru with clean brake
fluid before assembly.
Dip the piston cups in brake fluid before assembly.
W<SlU CYliNDER
CAUTION (2) PRIMARY CUP
When installing the cups, do not allow the lips to rum in-
side out. Be cerrain the circlip ;s sealed firmly in the
groove,

Install the washer, circlip and boot.

\
I I
(31 SECONDARY CUP

14 1 WASHER

QJ
151S00T

/
Place the master cylinder on the handlebar and install the
holder and two mounting bolu with holder's " UP" mark
(SISPii'ING
fac ing up,
Align the end of the holder with the punch mark on the
handlebar and tighten the upper bolt first, then tighten the
(7) PISTON
/
(6) CIACliP
lower boh.
Connect the brake hose joint and brake hose.

TORQUE : III
BRAKE HOSE JOINT (MASTER CYLINDER)
30-40 N'm (3.0-4.0 kg-m, 22-29 ft -Ib)
BRAKE HOSE
12-15 N'm t1.2-1 .5 kg-m, 9--11 ft-Ib}

Install the brake lever.

TORQUE : IAfter ' 86)
BRAKE LEVER PIVOT NUT
8 - 12 N·m 10.8 - 1.2 kg.m, 6 - 9 ft-Ibl
Install the cover.

Fill the master cylinder to the proper level and bleed the brake
system according to page 13-3.

FRONT BRAKE CALIPER

REMOVAL

Place a clean container under the caliper and disconnect the

brake hose from the caliper.

CAUTION
. A void spilling brake fluid on painted surfaces.

loosen the hanger pins and slide pin.

Remove the caliper mounting bolts and caliper.

13-9
HYDRAULIC BRAKE

DISASSEMBLY

Remove the following :

- hanger pins .
- pads al"ld pad spring.
- slide pin and c.liper bracket.
- caliper pivot boots.
- piston from the caliper,

If necessary, applv compressed air to the caliper fluid Inlet to

get the piston out . Place a shop fag under the caliper to
ClJshion the piston when it is expelled. Use the air in short
spurts.

r£9';iiiWO,
• Do not bring th~ air nozzle too close to ,he inJe"

Examine the pinons and caliper for scoring, scratches or other

damage and replace if necessary,

Push the piston boot and oil seal in, lift them out and d iscard
them.
Cle,n the boot and seal grooves with brake fluid.

CAUTION
Be careful not to damage the piston sliding surfaces when
removing the piston boot and oil seal.

PISTON INSPECTION (1) PISTON

Check the pistons for scoring, scratche, or other damage,

Mllsure the pinon diameter with a micrometer.

SERVICE LIMIT: 30.14 mm 11.1871n)

13-10
 HYDRAULI C BRAKE

CYLINDER INSPECTION

Check the caliper cylinder bore for scoring, scratches or other

faults. Measure the caliper cylinder bore.

SE RVICE LI MIT: 30.29 mm (1. 193 In)

ASSEMBLY

The piston boot and oil seal must be replaced with new ones
whenever they are removed.
Coat the seal and boot with silicone grease or brake fluid be-
fore assembly.

Install new oil seat and piston boot.

Install the piston with its opened end toward the pads.

NOTE
Use care not to turn the oil seal or the piston boot inside out
when installing.

Install the boot making sure that it is seated properly in the (1) PAD SPRING
caliper grooves.

Install the pad spring and pads (Page 13-51 .

(2) BOOTS

Apply silicone grease to the caliper bracket pin and slide pin (1) BRACKET
and assemble the caliper and bracket. PIN

Install the hanger pins.

(4)

13-11
HYDRAULIC BRAKE

Install the caliper on the fork lag and tig hten the caliper bolts.

TORQUE : 18- 25 N·m {1.B- 2.S kg-m. 13- 18 ft ·lbl

Tighten the slide pin.

TORQUE : 20-25 N'm 12.0-2.6 kg-m, 14-18 ft·lbl

Tighten the hanger pins .

TORQUE : 15-20 N-m 11 .6- 2,0 kg-m, 11 - 14 ft·lbl

Connect the brake hose and tighten the banjo bolt.

TORQUE : 30-40 N·m (3.0-4.0 kg-m, 22- 29 ft-Ib)

Fill the master cylinder and bleed the brake system (Page
13-3).

REAR BRAKE MASTER CYLINDER

After '91:
REMOVAL
Drain the rear brake hydraulic system (page 13-3).
Remove the brake hose bolt and disconnect the brake hose.
Remove the brake pedal from the f rame (page 12-171-
Remove the rear master cylinder mounting bolts and fel f
master cylinder from the frame .

Remove the snap ring. SNAP

TOOL :
Snap ring pliers 07914- 3 230001 or
Equivale nt tool
commercially available
in U.S .A.

Disconnect the reservoir hose from the rear master cylinder.

13-12
 HYDRAULIC BRAKE

DISA SSEMBLY 111 HU"",,H BOOT

Remove the rubber boot.

Remove the snap ring and push rod from the master cyli nder
body.

CAUTION
Be aware that the push ,od w;1I pop OUi when removing the
snap ring.

TOOL:
Snap ring pliers 07914 - 3230001 or
Equivalent tool
commercially available
In U.S.A .

Remove the master piston and spring.

It may be necessary to apply a small amount of air pressure to (3) RUBBER

the fluid outlet to remove the mast er piston and spring. BOOT

Do not bring the ai, not.:.Ie too close to the inlet. (6) MASTER PISTON /
0 ~ A.....
(5) SNAP RING /~
(4) PUSH ROO JOINT

INSPECTION

Check the inside of the master cylinder for scores, scratches

or nics.
Measure the inside diameter of the master cylinder bore.

SERVICE LIMIT: 12.76 mm (0.502 inl

Measure the master piston 0.0.

SERVICE LIMIT: 12.64 mm (0.498 in)

Check the primary and secondary cups for damage before

assembly .

13-13
HYDRAULIC BRAKE

ASSEMBLY (1) SPRING

Clean th e master cylinder with compressed air.

Dip the piston cups in clean brake fluid before assembly . / 121 PUSH ROO
Install the spring and msster piston together.
, __ / 131 RUBBER
NOTE
The master cylinder piston, cups and spring must be install-
ad as 8 set.
~~

161 MASTER PISTON ~0

(5ISNA~G
1. BOOT

CAUTION
When installing the cups. do no/ aI/ow lhe lips /0 turn inside 141 PUSH JOINT
out.

Install the push rod and washer into the master cylinder .
Install the snap ring.

TOOL:
Snap ring pliers 07914-3230001 or
Equivalent t ool
commercially available
in U.S.A .
CAUTION
When installing the snap ring, be certain (he snap ring seated
firmly in the groo\le.

Install the rubber boot .

INSTALLATION

C08t the new O-ring with brake fluid and install the new O·ring
to the reservoir hose joint cap.

Connect the reservoir hose to the master cylinder with a new

snap ring.

TOOL:
Snap ring pliers 07914 - 3230001 or
Equivalent tool
commercialiV available
in U .S.A .

13-14
 HYDRAULIC BRAKE

Install t he master cylinder to t he fr ame.

Connect the rear brake pedal to the master cylinder push rod.
Install the rear brake pedal (page 12-18).
Tighten the rear brak e master cylinder mounting bolts.

TORQUE: 14 - 16 N,m " .4 - 1.6 kg·m. 10- 12 ft -Ibl

Connect the rear brake hose eyelet joint with the hose bolt and
two new sealing washers .

CAUTION
Align the eyelet jOin! with the notch in the rooster cylinder first.
then tighten the bolt.
A/lef ilUtaf/ing the broke hose 10 the master cylinder. make
sure it does not interfere with the movement 0/ (he shock ab-
sorber. 111 REAR BR!:KE CALIPER

TORQUE: 30 - 40 N·m (3 .0 - 4 .0 kg-m. 22 - 29 ft -Ibl

Fill and bleed the f ear brake hydraulic system (page 13· 3) .

REAR BRAKE CALIPER After '91:

REMOVAL

Drain the rear brake fluid from t he hydraulic system (page

13-31-
Remove the rear wheel (page 12-5).
Slide the rear brake caliper rearward and pull it off of the
swingarm .
( 1 ) CALIPER GUARD PLATE
If the caliper is to be disassembled , remove the rear brake pads
(page 13·6).

Place a clean container under the caliper and disconnect the

brake hose from the caliper .
Remo ve the brake caliper guard plate .

12) HOSE

DI SASSEMBLY (2 ) CALIPER
/11 RO(lTS
Separates the c aliper and caliper bracke t .
Remo ve the pivot boot s and piston.
Remove the pad spring.

) PAD SPRING

13-15
HYDRAULIC BRAKE

If necessary, apply compressed air to the c aliper fluid inlet to

get the piaton out . Place 8 shop r&g under the caliper to
cushion the piston when it is expelled. Use the air in short
spurts.

Do flot brl'" tht flQu lt 100 dose 10 the inlet .

Examine the piston and caliper for scoring, scratches or other

damage and replece if necessary .

Push the piston and dust sBals in, lift them out and discard (1) DUST SEAL
them.
Clean the piston and dust seal grooves with brake f luid .

CAUTION
Be ca~ul not to damage the piston sliding sur/aces when
removing the seals.

INSPECTION

Check the piston for scoring, scratch es or other damage .

Measure the piston diameter with 8 micrometer.

SERVICE LIMIT; 26 .91 mm /1 .059 in)

Check the cylinder bore for scoring, scra tches or other faults.
Measure the caliper c ylinder bore.

SERVICE LIMIT; 27 .06 mm 11.065 in'

ASSEMBLY

The piston and dust seals must be replaced with new ones
(1' DUST SEAL
(5) BOOT

...
whenever they are removed . Coat the seals with brake flu id
and Install them with small diameters f acing in.
Install the piston w ith the dished ends toward tha pads . I
o
/121 PISTON SEAL

I~
(4) PAD SPRING
0_ I 131 PISTON

13-16
 HYDRAULIC BRAKE

Install the pivot boots making sure the they are seated in the
caliper grooves properly.
Install the pad spring.

Apply silicone grease to the caliper pivot pins and assemble

the caliper and bracket.

) PAD SPRING

INSTALLATION (1) CALIPER GUARD PLATE

Connect the brake hose with the new two sealing washers and
the brake hose bolt.

TORQUE: 30 - 40 N·m 13.0 - 4 .0 kg-m, 22-29 ft -Ibl

Install the caliper guard plate.

(3) BRAKE HOSE SOL T

Install the rear brake caliper onto the swingarm slide rail.
BRI,"E CALIPER
Install the rear wheel (page 12-13). 111 SWING'_RM
Install the rear brake pads (page 13-7).
Fill the rear brake hydraulic system and bleed it (page 13-31.

(3) RAil

13-17
SUB FRAME/ EXHAUST PIPE

'85-'S7:

'S7:

8-12
(0.8-1.2 kg-m. 6-9 ft-Ib)

18- 25 N'm
(1.8-2.5 kg-m. 13-18 tt-"'I __~/

14-0
 SUB FRAME/ EXHAUST PIPE

After '87:

8- 12
(0.8- 1. 2 kg-m, 6-9 ft·lb)

18- 25 N·m
(1.8- 2.5 kg-m, 13- 18 ft·lb) ,~~s~~~~:

14-1
14. SUB FRAME/EXHAUST PIPE
SERVICE INFORMATION 14-2 REAR FENDER 14-4
SUBFRAME 14-3 EXHAUST PIPE 14-5

SERVICE INFORMATION
GENERAL

• This section describes removal/installation of the rear subframe and exhaust p ipe.
• Aear shock absorber service can be done after the subframe is removed.

IJ'2 i;iii@i
• Do nor service the exhaust system whilt it is hOI.

TOROUE VALUES

Seat bolt 8-12 N-m (0.8-1.2 kg-m, 6-9 ft ·lb)

Subframe bolt 18-25 N'm 11.8-2.5 kg-m. 13- 18 ft·lb)

14-2
 SUB FRAME/EXHAUST PIPE

SUB FRAME 111

REMOVAL

Remove the seat by removing the three bohs.

Loosen the air cleaner connecting tube band.

Remove the rear sub frame's four mounting bolts.

Pull the subframe assembly back, taking care not to damage

the mud guard.

INSTALLATION

Position the 5ubframe onto the frame while aligning the air
cleaner connecting tube with the carburetor and the muffler
with the expansion chamber.

Install and tighten the sub frame mounting bolts.

TORQUE : 18-25 N·m {1.B-2.5 kg.m. 13- 18ft-lbl

Tighten the air cleaner connecting tube band.

14-3
SUB FRAME/ EXHAUST PIPE

'85:

Align the seat hook with the screw on the fuel tank and
install the seat.
Tighten the three seat mounting bolts.

NOTE
The air cleaner front rubber is for rainy conditions only .
Otherwise. remove it.

After 'SS: (1)

Align the front seat hook with the screw on the fuel tank,
Ilign the back seat hook with the hook on the main frame and
inst,lI the 58at.
Tighten the three seat mounting bohs.

NOTe
Tha front mud guard is for rainy conditions only. Otherwise,
remove it .

REAR FENDER (1) LEFT SIDe COV ER

REMOVAL/ INSTA L LATION

Remove the seat (Page 14-31.
Remolle the left side cover.

Remove the muffler mounting bolt. 111 REAR FENDER

Remove the two fender mounting bolts and the fender.

Install the rear fender in the reverse order of removal.

TORQUE : 8- 12 N'm (0.8-1.2 kg·m, 6- 9 ft·lbl

(2) FENDER MCIU:'~II.~~~Dii

14-4
 SUB FRAME/EXHAUST PIPE

EXHAUST PIPE '85:

IJ#j;iiilbd
• Do not serpice lhe exhiJus/ system while it Is hot.

EXPANSION CHAMBER REMOVAL

Remove the expansion chamber by removing the mounting

bolt and spring.

MUFFLER REMOVAL 111 MOUNTING BOLTS

Remove the right frame side cover.

Remove the muffler mounting bolts and the muffler.

INSTALLATION

Install the exhaust muffler and expansion chamber in the

reverse order of removal.

NOTE
Slide the exhaust pipe rubber seal over the joint and secure 'd~I~2~1,.;,:::;:;;,:~~~
it with the spring band. •

(1) MUFFLER

(2) EXHAUST PIPE SEAL

,/
(3) SPRING
BAND

(4) HEAT SHIELD

(5) EXPANSION
CHAMBER

(7) SPRING

14-5
SUB FRAME/EXHAUST PIPE

EXHAUST PIPE AFTER '85

IM.I;iliiiM
• Do not Itrriu th~ uhaus, syl/em whl/I! It is hOI.

EXPANSION CHAMBER REMOVAL

Remove the expansion chamber by removing the mounting

bolt and spring.

MUFFLER REMOVAL MoUN·TIN G SOL T

Remove the muffler mounting bolt and the muffler.

INSTALLATION

Install the exhaust muHler and expansion chamber in the

reverse order of removal.

NOTE
~~--~~----~~----­
• Slide the exhaust pipe rubber seal over the joint.

(1) MUFFLER
(2) EXHAUST PIPE SEAL

(5) EXPANSION CHAMBER

.~
~ (3) SPRING

After '87:

(4) SEA L

14-6
IGNITION SYSTEM

' 85

(1) STOP BUTTON

(2) COl UNIT

(3) CO IL

141 PLUG

(6) ALTERNATOR

(5) PULSE GENERATOR

15-0
 IGNITION SYSTEM

After '85

111 ENGINE STOP BUTTON

(2) UNIT

IGNITION COIL

(4) PLUG

(5) GENERATOR

15-1
15. IGNITION SYSTEM
SERVICE INFORMATION 15-2 IGNITION TIMING 15-7
TROUBLESHOOTING 15-2 COl UNIT 15-7
A LTERNATOR 15-3 ENGINE STOP BUTTON 15-8
PULSE GENERATOR 15-5 WIRING DIAGRAM 15-9
IGNITION COIL 15-5

SERVICE INFORMATION
GEN ERA L

Do not remove the pulse generator or exciter coils from the stator base.

SPECIFICATIONS

'B5 After '85

Recommended spark plugs Champion: QN -2C
NG K : BR1 0EG
NGK: SA9ES
Spark plug gap Champion : 0.6-0.7 mm (0.024-0.028 in)
NGK: 0.5-0.6 m m (0.020- 0.024 in)
NGK: 0.7-0.8 mm (0.028-0.031 in)
Alternator exiter coil resistance 350 450 n 290 350 n
Pulse generator resistance 180- 240 n 150-240 n
Ignition primary coil res istance 0.1- 0.3 n 0.2-0.4 n ('86)
0.4-0.6 n (After '86)
Ignition secondary coil resistance 3.7 k-4.5 kn (without cap) 4.6- 7.0 kn ('S61
10.4-15.6 kn (After '86)
TORQUE VALUE

Flywheel nut 50-60 N·m (5.0-6.0 kg-m, 36- 43 ft- Ibl

TOOLS

Common
Flywheel puller 07733-0010000 or 07933- 00 10000
Universal holder 07725- 0030000 or 07725-00 10101

TROUBLESHOOTING
No spark at plug Engine starts but runs poorl y
Faulty spark plug. Ignition primary circuit.
Poorly connected , broken or shorted wires. Faulty ignition coil.
Between alternator and CO l unit. - l oose or bare wire.
Between COl unit and ignition coil. - l oose connector.
~etween CO l unit and ignition switch. Secondary circuit .
Between ignition coil and plug. Fau lty ignition coil.
Faulty ignition coil. Faulty plug.
Faulty COl unit. Faulty high tension wire.
Faulty alternator . Defect ive spark plug cap.
Faulty engine stop switch. Ignition timing.
Faulty alternator.
l oose or improperly insulated stator.
Faulty CO l unit.

15-2
 IGNITION SYSTEM

ALTERNATOR
INSPECTION

Remove the seat and fue l tank.

Disconnect the alternator wire connectors and measure the

resistance between the wires.

RESISTAN CE
'85: IG- RI 350-450 0
After '85: (G- BI/R) 290-350 0

REMOVA L

Remove the seat and fuel tank,

Remove the left crankcase cover screws and cover.

Hold the flywheel using the universal holder and remove

the flywheel nut and a washer.

Remove the flywheel with the puller.

15-3
IGNITION SYSTEM

Disconnl!Ct the alternator wires.

Remove the wire bands.

Remove the stator mounting bolts. and the stator.

INSTALLATION

Install the stltor using the two mounting bolts.

Connect the alternator w ires .

InstaU the fl ywheel on10 the crankshaft aligning its keyway

with the woodruff key on the crankshaft.
Hold the flywheel with the universal holder and tighten the
flywheel nut.

TORQUE : 60-60 N'm 15.0-6.0 kg-m. 36-43 ft-Ib)

(2) UNIVERSAL HOLDE
07725-0010101

15-4
 IGNITION SYSTEM

Make sure that the seal on the left crankcase cover is in good
condition and install the crankcase cover using the four
screws.

PULSE GENERATOR
INSPECTION

Remove the seat and fuel tank .

Disconnect the pulse generator wire connector and measure
the resistance between the terminals.

RESISTANCE (Bu - GIWI

' 8 5: 180 - 240 n
Afte r ' 85: 150-240 0

REMOVA L/INSTALLATION

Remove the left crankcase cover and flywheel (Page 15-3).

Disconnect the pulse generator wire connector.

Remove the pulse generator mount ing bolts, and the pulse
generator.

Install the pulse generator in the reverse order of removal.

IGNITION COIL
CONTINUITY TEST

Remove the seat and fuel tank .

Disconnect the spark plug cap, and primary and ground
leads.

Check for continuity between primary and ground terminals.

PRIMARY COIL RESISTANCE : 0,1-0. 3 n

15-5
IGNITION SYSTEM

Aft.r '85 :
Remove the seat and fuel tank.
Disconnect the spark plug cap and primary lead.

Check for continuity between primary and ground.

PRIMARY COIL RESISTANCE : '86: 0.2 - 0.40

After ' 86: 0.4 - 0.6 n

Remo ve the spark plug cap by turning it countercl ockwise.

Measure the secondary coil resistance.

SECONDARY COil RESISTANCE (WiD CAP):

'85: 3.7 - 4.5 kG
'86: 4.6-7.0 kO
After '86: 10.4 - 15.6 kO

REMOVAL/INSTALLATION

'85:
Remove the seat and fuel tank.
Disconnect the primary and ground leads, and spark plug cap.

Remove the ignition coil mounting bolt.

Remove the ignition coil.

Installat ion is the reverse order of remollal.

Connect the BI/ Y wire to the Black marked terminal and G

wire to the Green marked terminal.

Install the fuel tank and seat.

After '85 :
Remove the seat and fuel tank.
Disconnect the primary lead and spark plug cap.

Remove the ignition coil mounting bolts and ignition coi l.

Instaliation is the reverse order of removal.

Connect the BI/Y wire of the ignition coil to the BI/Y wire of
COl unit.
Install the fuel tank and seat.

15-6
 IGNITION SYSTEM

IGNITION TIMING
NOTE
The Capacitive Discharge Ignition (COl) does not require
regular adjustment . If you feel there is an ignit ion problem,
check the timing . If it is incorrect, check the COl unit
and alternator. Replace any faulty paru.
The timing is non-adjustable.

Remove the left crankcase cover.

Connect a stroboscopic t iming light according to the manufac-

turer's instructions, and start the engine.

At 5,000 r pm, the crankcase index mark (an inverted triangle

at the 12 o'clock position) should align between the two " F"
marks on the rotor .

If the timing is incorrect , check the alternator (Page 15-31,

pulse generalor (Page 15· 5) and COl unit (Page 15-7),

COl UNIT
REMO VA L

Remove the seat and fuel tank.

Disconnect the COl unit connectors.

' 85 :
Remove the COl unit mounting bolt and COl unit.

After '86 :
Remove the COl unit from the mounting rubber.

INSTALLATION

Install the COl unit in the reverse order of removal .

Install the seat and f uel tank.

NOTE
After ' 8 5
The COl unit is semiconductorized component which in-
cludes ignition t iming advance, retard systam and other
calculating circuits. It is difficult to check the COl unit only.

In the case that the ignit ion timing is too far advanced or the
spark is weak and all related systems indicated below are in
good condition , replace the COl unit and recheck the ignition
timing.
- Spark plug.
- Connection of all connectors.
- Engine stop switch IPage 1 5·8) .
- Ignition coil IPage 15-5).
- Alternator e)(citer coil (Page 15-31.
- Pulse generator IPage 15·5).

15-7
IGNITION SYSTEM

ENGINE STOP BUTTON

Disconnect the engine stop button connectors.
Check the engine st op button for continuity.
Continuity should exist w hen the button is pressed.

15-8
 .,; :E
'" -
:"'"
z:

--
COl UNIT en
,
ENGINE STOP BUTTON R
G__
b ___
--d R --cc::::r- R
G -c::Jd- G
E ____ .t I:'
0=

en
~Dp
o L IG
C - - -~_, d t~
0/.. E=: S ~~9--~-::
"'"
:E
G 81M
BI/ Y
G
BI/W-:b'l ,
--- '1I 'I
- ~ I I,
I
II
I

BI IY

~
I
I
I

t.:
I
:J BI:~BI:J.C~II _ J]
BI /Y
"' - %8u
W G R

IGNITION COil ~ EXCITER COi l

ALTERNATOR

PLUG

ENGINE STOP BUTTON

Bu .....Blue
IG E
BI . . . . Bln Cl
OUT G . . . . .Green z
R ... ... Red ....
n -n o
...
PUSHED IN W ... . . White
z
~
Y .... Yellow
COLOR 81/W G en
<
,
U1 ~
m
(g ~
... .;

...o
U1
o

ENGINE STOP BUTTON

COl UNIT

Bl/RC - -2] Bl/R~/RC ----I

'"I
.;
~ I!
Z
en
f-- G G -=<l-- G _ -<

m
,0 en
o -<
E '" Bu
G/WC
- -dBu::(~):iBu
- G/W G/W
--"
, ::
m
s:
o G Bl /W

,,
U Bl /Y
'G'1]l
BI/W '
' ,
-- -, I,
'

Bl / Y
I "I
"
'0
"
"

, ""
"

:1 t
'"
- _d BI/W=rBl/ W
G~G
.=..:!J
___ J
, o
Bl / Y
G/w!iu IBi/R
lJG
IGNITION COIL
_____ __ •I 'I
,,
'I'
PULSE A COIL
----li EXCITER COIL

- _ _ _ _ _ _ _ 'J

1
G

ALTERNATOR
V
L..

BI SLACK
Y YELLOW

ENGINE STOP BUTTON

Bu BLUE
G GREEN
IG E
R RED
OUT II WHITE
PUSHED IN 0
COLOR BI/ II G ~ 0030Z-GC4-6000
 ..~
COl UNIT

F -- - - --=--j - - - - - - - .,
..-
ENGINE STOP BUnON
=

m
---=:J
D
• 'G
o G BI/W

IGNITION COIL ,'I',, COil

,

ALTERNATOR

BI BLACK
PLuG
V YELLOW
Boo BLUE
ENGINE STOP BUTTON
G GREEN
IG E R ...... REO
OUT W WHITE i5
z
PUSH ( =<
o
....;0
COLOR BI/W G ~ z
C1I
,
....;0 0030Z - GS2 - 0000 '"~
-<
m
....;0
s:
 16. TROUBLESHOOTING
ENGINE DOES NOT START OR IS POOR PERFORMANCE AT
HARD TO START 16-1 HIGH SPEED 18·4
ENGINE LACKS POWER 16-2 POOR HANDLING 18·4
POOR PERFORMANCE AT LOW
AND IDLE SPEEDS 16-3

ENGINE DOES NOT START OR IS HARD TO START

CHECK POSSIBLE CAUSES

~_ _ _ _ _ _ _ __• (1) No fuel in fuel tank .

1. Check if fuel is getting to the
carburetor INO FUEL TO
CARBURETO R (2) Clogged fuel line or fuel filter.
(3) Clogged fuel valve.
FUEL TO CARBU RETOR (4) Clogged fuel tank cap breather
tube .
(5) Clogged float valve.

2. Try spark test [~W~E~A~K~O~R~N~O?}SP~A~R~K}I------_. (1) Fau lty spark p lug.

(2) loose spark plug cap or wiring.
SPARK JUMPS (3) Faulty engine stop switch,
if plug sparks when blackJ
white wire is disconnected .
(4) Faulty uciler coil.
(5) Faulty pulse generator .
(6) Faulty ignition coil.
(7) Pulse generator air gap.
(8) loose terminals, connectors,
faulty wiring.
19) Faulty COl .

3. Test cylinder compression LOW COMPR ESSION • (1) Stuck piston ring.
121 Faulty reed valve.
NORMAL 131 Worn cylinder and piston rings.
141 Damaged cylinder head gasket.
151 Cyl inder head flaw.
16) Compression leak into
crankcase.

4. Start by following normal starting

procedure
ENGINE STARTS
[. BUT SOON STOPS .
[r--------------• 121
(1) Choke not on .
Air leak ing through
carburetor insulator.
ENGINE DOES NOT F IRE 131 Improper ignition timing.
141 Crankcase leak.
5. Remove spark plug [ WET PLUG [ .. (1) Carburetor flooded.
121 Carburetor choke on.
131 Throttle valve exceuively
open.

6. Start with choke applied

16-1
TROUBLESHOOTING

ENGINE LACKS POWER

CHECK POSSIBLE CAUSES

1. Raise wheels off ground and spin vwIIHiiEflEflL:-oDcioEESS'NiCoiiTr:sSiP'IINNll-- -- --- 11 ) Brake dragging.
by hand r
. FREELY . (2) Wor n or damaged wheel
bearing.
WHEEL SPINS FREELY (3) Wheel bearing needs
lubrication.
(4) Drive chain too tight.

2. Check tire pressure [~P~R~E~SS~U~R~E~T~O~O~L~O~w~I------_. !1) Punctured tire.

(2) Faulty tire valve.
PRESSURE NORMAL

3. Try rapid acceleration from iEE:r;Nj(G"'NNEE'SiPPEEE

EDD[D"O"EEiS;NNOOT
Tl----~ (1) Clutch slipping.
low to second CHANGE WHE N CLUTCH IS (2) Worn clutch disc.
REL EASE D (3) Warped clutch plate.
ENGINE SPEED IS LOWERED
WHEN CLUTCH IS RELEASED

4 . Lightly accelerate engine ENGINE SPEED DOES NOT 111 Carburetor choke is on.
INCRE ASE SUFF ICIENTLY 12) Clogged air cleaner.
ENGINE SPEED INCREASES 13) Restricted fuel flow.
l4i Clogged fuel tank breather
tube.
15) Clogged muffler.
16) AT AC valve does not close
fully. ('S5)
171 Clogged ATAC sub chamber.('S5)
5. Check ignition timing IINCO RRECT I • (1 ) Faulty alternator .
12) Faulty pulse generator.
131 Faulty COl unit.
[CORr CT [

6. Test cylinder compression

using kick starter
ILOW COMPRESSION I • (1) Faulty reed valve .
12) Worn cylinder and piston
rings.
[NTAL [ 13) Leaking head gasket.
14) Cylinder head, cyl inder or
crankcase flaws.

7. Check carburetor for clogging ICLOGGED I • 111 Carburetor not serviced

frequently enough.
[NOT CLOGGEO [ 12) Dirt getting past air
I
8 . Remove spark plug IFOULEO OR DISCOLORED I , I' )
cleaner.
Plug not serviced frequently
enough.
NOT FOULED OR DISCOLORED 12) Use of plug with improper
heat range.
13) Incorrect fuel·oil
mixture.

16-2
 TROUBL ESHOOTING

9. Check if engine overheats I~O~V!E!R~H~E~A~T~S~I---------~•• (1) Excessive carbon build-up

in combustion chamber.
ENGINE DOES NOT (2) Use of improper quality of
OVERHEAT fuel.
(3) Clutch slipping.
(4) Fuel/ai r mixture too lean.

10. Accelerate or run at high speed [~E~N~G~I~N~ECK~N~O~c~K~s~If---------•• (1) Worn piston and cylinder.
(2) Fuel air mixture too lean.
[ ENGINE OOES NOT KNOCK [ (3) Use of improper grade of fuel.
(4) Excessive carbon build-up
in combustion chamber.
(5) Ignition timing too advanced
(Faulty COl unitl.

POOR PERFORMANCE AT LOW AND IDLE SPEEDS

CHECK POSSIB L E CAUSES

1. Check ignition timing [I~IN~C~O§R~R~E~C~TQ-I----------.. (1) Faulty alternator.

(2) Faulty pulse generator.
ICorEcTI (3) Improper ignition timing
(Faulty COl unit ).

2. Check carburetor air screw [~IN~C~O~R~R~E~C~TG-I----------.. (1) Fuel-air mixture too lean
adjustment {Turn the air screw outl.
(2) Fuel-air mixture too rich
IcorEcTI (Turn the air screw in).

3. Check if air is leaking past [I~l~E~A~K~I~N~GD-I-----------·

.. (') Deteriorated insulator
manifold or reed valve gasket.
(2) Loose carburetor insulator
clamps.

4. Try spark test [WEAK OR INTERMITIENTSPARK ~(1) Faulty, carbon or wet fouled
spark plug.
GOOD SPARK 121 Broken or shorted spark plug
wire.
(3) Faulty ignition coil.
1'851 (4 ) Faulty alternator.
(5) Faulty COl unit.

5. Check ATAC system [~IN~C~O~R~R~E~C~TQ-!- - - - - - - - - -... (1) AlAe valve does not open
fully .
ICO RRECTI (2) Faulty ATAC valve.
(3) Clogged ATAe chamber.
(4) Damaged ATAe chamber.

16-3
TROUBLESHOOTING

POOR PERFORMANCE AT HIGH SPEED

CHECK POSSIBLE CAUSES

1. Check ignition timing [~IN~C~O~R~R~EC~T!l-I---------_. (1) Faulty alternator.

(2) Faulty COl unit.
IcorEcT I

2. Disconnect fuel1lnl.t carburetor [~F~U~E~L~F~L~O~W~R~E~S!T~R~IC~T~E~O~I-----. (1) Lack of fuel in tank.

and check for clogging (2) Clogged fuel line.
(3) Clogged fuel tank breather
UNRESTRICTED FUEL FLOW tube .
(4) Clogged fuel v81vI,

3. Remove air cleaner [I~O~I~R:!T~Y~I------------_. (1) Not cleaned frequently enough.

AIR CLEANER NOT DIRTY

4. Check carburetor jets for clogging [I~C~L~O~G~G~E~O~I-----------·~ (1) Contaminants in the fuel.

NOT CLOGGED

6. Install a larger carburetor main jet [~C~O~N~O~I~T~IO~N~W~O~R~S~E~lf--------~.~ (1) Jet size wrong, rejet in the
j ('S5)
opposite direction.

6. Cleek AT AC system [I~IN~C~O~R~R~E~C~TDI----------. (1) ATAe valve does not close

fully.
ICORRECT I

POOR HANDLING - - - - Check t;" .""''',

CHECK POSSIBLE CAUSES

1. If steering is heavy -----------------------~. (1) Steering head adjuster too

t ight.
(2) Damaged steering stem bearing.

2. If either wheel is wobbling - - - - - - - - - - - - - -- - - - -- _.. (l) Excessive wheel bearing play.

(2) Bent rim .
(3) Improperly installed wheel hub.
(4) Swingarm bearings excessively
worn.
(5) Bent frame .
(6) Loose sw ingarm pivot bolt.
(7) Loose engine hanger bolt.

3. If the motorcycle pulls to one side - - - - - - -- - - - - - - - - -_ .. (1) Misadjusted sh~k absorber.

(2) Front and rear wheels not
aligned.
(3) Bent fork .
(4) Bent swingarm or frame.

16-4
 TROUBLESHOOTING

NOTE
For the following recommendations to be useful , the motorcycle must be adjusted es follows : Fork - at standard fork o il
quantity and viscosity, and air pressure zero; Shock - nitrogen pressure 14 kg/cm 2 11 99 psi) compression and rebound
damping at full soft, and spring preload adjusted so the bikes sags 74 mrn 12.9 in) with rider seated - see Owner's Manual
for spring preload adjustment .
Make only one change at 8 time , then test ride and evaluate the difference before making further adjustments. The solu-
tions are given in the preferred sequence of adjustment .

4 . Front end oversteers ; it cuts too sharply (such as in sand): - - - - -- - -- - _ 11) Slide fork tubes down 5 mm in
•
fork clamps .
12) Raise fork oil lel/81.
13) Use stiffer fork spring.

5. Front end understeers ; it washes out or pushes (such as

on a tight track with hard ground): - - - - -- - - - - - -- -- - - - -_.. (1) Slide fork tubes up 3 mm ;n
fork clamps .
121 Lower fork oillel/el .
13) Use softer fork spring.

.. (1) Slide fork tubes down 5 mm In

6. Front end hunts at high speed; it wanders under power: - - - - - - - - -- - _
fork clamps .
12) Raise fork oillel/81.
13) Increase shock preload ,

7. Front end shakes under heavy braking : .. (1)

-----------------~. Decrease shock preload .
12) Ra ise fork oillel/81.

8. Front end hops over bumps in smooth turns: - - - - - - - - - - - - - - -- .. (1) Change to lighter fork oil .
12) Lower fork oiI 18\/8J.
13) Use softer fork spring.

9. Rear end hops over bum ps while aa:elerating : - -- - - - - -- - - - - - -_.. (1) Decrease shock preload .
121 Decrease shock compression
damping.

10. Rear end gets poor traction while accelerating away from a corner: - - - - - -- _.. (1) Decrease shock preload .
12) Decrease shock compression
damping.

16·5
 17. INDEX
Air Cleaner ......................... ' .................... ' ..... . 3-5 Ignit ion System ...... .... .. .. ......................... . 15-2
Air Cleaner Case: '85 ... ... .... ............... ......... .... . 4-23 Coil ....................... ........................ .... . . 15·5
After '85 ....... ..... .......... .. . .. ..••......... .... 4 -24 Ignition Coil Timing ... .. .. . ....... ......... ............. . 15-7
Alternator ........... .. . .. ................. .. , .. ............... . 15·3 Kickstarter ...................................... .. ............. . 8- 13
ATAe (Automatic Controlled Torque Lubrication ............ ................................ . 2-1
Amplification Chamberl System (' 85) ............. .. .. . 7- 1 Points .............. .. .................... . .... .. ............ . 2-4
Atae Valve Adjustment ................................. ... . 7-6 Maintenance ......... ... ............................ .......... . 3- 1
Brake Fluid Replacement/ Air Bleeding ......... .. ...... . 13-3 Major Carburetor Adjustment : ' 85 .... .. .. .. ............ . 4 -7
Pad/Disc ................. . 13-4 After ' 85 ............................... .... .. .. .. .... ...... . 4 -9
System .......... .. . ............ ... .. .. .. ............. ... .. .. . 3- 10 Minor Carburetor Adjustment ........................... . 4-7
Cable and Harness Aouting ................ " ............. . 1-10 Modelldenlification . .... .................................... . 1-2
Carburetor Assembly ..................................... . 4 -16 Nuts, BoilS, Fasteners ...................................... . 3- 17
Installation ............... ... ............................... . 4-17 Optional Palts ................................................. . ' · 15
Removal .•................... .. .. ............................ 4 -12 Optional Parts : ' 85 .......................................... . 4-3
Theory ............... .. ..................................... . 4- 5 After '85 .............. .. ................ ... .. . ............. . 4-4
COl Unit ................. ....... ..................... . . 15-7 Piston Installation .. ... .......................... .. ...... .. .. . 6-9
Choke Valve ..... ......... ...... .. . 4 · 16 Removal .............................................. . 6-7
Clutch/Kickstarter/Shift linkage ..... .. ... .. ........... . 8-1 Pulse Generator ............................................. . 15-5
Clutch ......... ............. .. ..... ............................... 8-5 Radiator ........................................ ........ ...... .. 10-6
System ....... ........ ... ........ .... ........ ....... .... . ..... 3· 13 Cap Inspection .................................. .......... . 10-4
Competition Maintenance Schedule ......... .... .. ..... 3-2 Coolant ....... .............................................. . 3-7
Control Cables . ....... ..... . ...... ........... ........ ... .. ..... 3· 14 Hose Inspection ........................... .. .. .. ......... . 10-4
Coolant Replacement .... .. . .. . .. ........................ .... 10-5 Rear Wheel /Brake/ Suspension ............. ........ ..... .. 12-3
Cooling System ........................................... 3 -7,'0-2 Rear Brake ....... . .................................. . 12 -14
Inspection .......... ..... .... ................... .. 10· 5 Fender .......... ............ .... .. .. .. .. ..... .. .. ............ . 14-4
CrankcaselTransmission/Crankshaft .......... ...... .. . 9· 1 Wheel .............. .... .. .. . .. ........ .... .. .. ............ . 12· 5
Crankcase Assembly .. .... .. . .........•...... ............... 9 · 1 1 Brake Caliper ................................. ............. . 13-15
Separation ..... ........ ...... ........... ..... ............... 9-3 Brake Master Cylinder .................................. . 13- 12
Installation ..... ........ ... ... ............ .... ....... . ....... 9·9 Reed Valve ............. ........................................ . 4- 19
Remo val ... ................. .. ................ ............ .. . 9· 7 Right Crankcase Cover ..................................... . 8 -3
Cylinder Head/Cylinder/Piston . .. .. ..... ... .. ............. 6-2 Service Information
Cylinder Head .... ... .... ... . ...... .......... .... ...... 6·4 ATAC ~Au t omalic Controlled Torque
Installation .................... .. . .. .. .•..... .......... .... 6-10 Amplification Chamber) System ('B5) ..... ... .... . 7-1
Removal ..... ..... .................. ........... .... .......... 6 -6 Clutch/Kickstarter/ Shift linkage .................... . 8 -1
Drive Chain .......... ... ............ .... ...... ........ . .... ..... 3· 7 Cooling System .......................................... . 10-2
Slinder ................... .... .......................... .. .... 3·9 CrankcasefTransmission/ Crankshaft .............. . 9- 1
Drive and Driven Sprockets .... .... ... ............ ......... 3- 7 Cylinder Head/ Cylinder/Piston ....................... . 6-2
Engine Installation .......................... ".... ........ .... 5-4 Engine Removal/Installation ............ ... ........... . 5-2
Engine Removal/Installation .... ........... .... . ........ .. 5· 2 Front Wheel / Brak.e/ SuspensionISteering ......... . 11 -2
Engine Removal ....... .. .. ..... .................. ..... ... ... . 5·3 Fuel System .. . ......... . .. . .. . .. .. ... .......... ...... .... . 4- 1
Stop Button .......... .. .. .. ......................
Expansion Chamber ....... .................................. . 3 - 14
Exhaust Pipe ............................ ............ ... ....... . 14-5
1 5·8 Hydraulic Brake (After '85) ........... .. .. .. ......... .. 13-1
Ignition System ......................... .................. . 15-2
Lubrica tion ........... . ..................................... . 2- 1
ID
Float Level Adjustment ............................. ... ..... . 4 · 17 Maintenance ... ... . ... ................. ... ............... . 3- 1
Float , Float Valve and Jets ................................ . 4- 14 Reaf Wheel/Brake/ Suspension ...... .. .. .. .......... . 12-3
Fork ............................. ... . ... .. ..... .. ................. . 11 - 16 Sub Frame/Expansion Chamber .... ...... .......... . 14-2
Front WheeIIBrake/ Suspension/ Steering ............. . 11 -2 Service Rules ........... ...................... .. .............. . 1- 1
Front Brake : ' 85 ......... .... ................... ... .. ... ... ... . 11 · 14 Shift linkage .. . ............................................... . 8 -10
Brake Caliper ............ ......................... ...... ... . 13·9 Shock Abs orber .............................................. . 12· 19
Hydraulic Brake : After ' 85 ........................... . . 11 -16 linkage ........... ......................... . 12-37
Master Cylinder .......................................... . 13-8 Spark plug ..................................... .. .............. . 3-6
Wheel ........................ ..... ..................... ..... . 11 -9 Specifi ca tions ................................................. . 1-4
Fuel System ................ .. .. .. ............................. . 4-1 Steering Head Bearings .. .. .. .............. ....... ..... ... .. 3 - 17
Fuel line and Fuel Filter .................................... . 4 -20 Stem ........................................................ .. 11 -23
Tank. .... .. .... ......... ... ..... .. .... .. .. ..... .. .. ........ .. . 4 -21 Sub Frame/Expansion Chamber ......................... . 14-2
General Information ......................................... . 1- 1 Sub Frame .......... .. .. .... .. .. ............... ...... ... .... .. 14-3
Safety ....................................................... . 1- 1 Suspension ........... ...... .. ............. ...... ......... ...... 3-15
Governor/Rack/Cam ...... .. ............................ .. .. . 7-4 Swingarm ....................................................... , 2-3 5
Handlebar .................... ................................. .. 11 -5 Throttle Operation . .... ............. .......... ........ ........ 3·4
Head Pipe ............................................ . . 7-2 Throttle Valve Assembly.. ................. ....... ..... .. .. 4- 17
Hydraulic Brake lAtter '85) ....................... ... . 13- 1 Disassembly ................................. ............... 4 · 1 1
Tools ........... .... . ... ....... ... ................ .......... ..... 1·8

17-1
INDEX

Torque Values 1-6

Transmission Assembly ... .... . .... ... .. .. ........... .. .... 9- 10
Disassembly .. .... . ... . ..... ... . .... . ...... .... ....... .. ... . 9 -4
Transmission Oil ... .. .. .. ............... ... .. ........... .. .. 2 -2 , 3 ·6
Troubleshooting
ATAe (Automatic Controlled Torque
Amplification Chamber) System ('85) .......... .... .. 7- 1
ClutchlKlckstarter/Shift linkage ................. .. ... . 8-2
Cooling System " . .. , .................. ................. .... 10-3
Crsnkc8sefTransmission/ Crenkshaft ............. .... 9 -2
Cylinder Head/Cylinder/ Piston ..... ... ... . ..... .. .. ... .. 6 -3
Front Wheel/ Brake/ Suspension/ Steering ... ... .. .... 1 1-4
Fuel System .... ... .. ............. .. ... .. ... ................. 4 -2
Hydraulic Brake (After ' 85) .... ... ... .... ................ 13-2
Ignition System . ............. ..... ..... .. ................... 15-2
lubrication ........ ... ............. ... .. ........ .. ............. 2- 1
Rear Wheel / Brake/ Suspension ........ .. ... . ...... ..... . 12-4
Tuning for Special Conditions ..... ... .. . .... ...... ........ .. 4 - 10
Water Pump ......................... .... .. ........ ............... 10-6
WheelsfT ires . ..... .. ... .............................. ... ......... 3- 16
Wiring Diagram ... .. .... ... .................................. .. .. 1 5-9

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