+ 85-87 ATC 250ES © BIGREDHOW TO USE THIS MANUAL Sections 1 through 3 apply to the whole ATC, while sections 4 through 18 describe parts of the ATC, grouped according to location Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subse- quent pages give detailed procedures. If you don’t know what the source of the trouble is, refer to section 19, Troubleshoot- ing. ENGINE CHASSIS EXHAUST MUFFLER ELECTRICAL CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVES CYLINDER/PISTON CLUTCH/OIL PUMP/KICK STARTER ALTERNATOR/STARTER CLUTCH/ GEARSHIFT LINKAGE CRANKCASE/CRANKSHAFT) TRANSMISSION FRONT WHEEL/BRAKE/SUSPENSION/ STEERING REAR WHEEL/BRAKE/ ‘SUSPENSION/FINAL DRIVE CARRIERS/REAR FENDER/ Bese eee IGNITION SYSTEM. BATTERY/CHARGING SYSTEM STARTER SYSTEM ant LIGHTS/SWITCHES WIRING DIAGRAMS EE Be TROUBLESHOOTING INDEX 201. GENERAL INFORMATION ] GENERAL SAFETY SERVICE RULES MODEL IDENTIFICATION SPECIFICATIONS TORQUE VALUES TOOLS CABLE & HARNESS ROUTING NOISE EMISSION CONTROL SYSTEM 1 ce 12 13 15 19 11 117 GENERAL SAFETY Ifthe engine must be running to do some work, make sure the ‘area is well-ventilated, Never run the engine in a closed area, The exhaust contains poisonous carbon monoxide gat. The battery generates hydrogen gas which can be highly ex- plosive. Do not smoke or allow flames or sparks near the bat- tery, especially while charging i. SERVICE RULES Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in your work area, The battery electrolyte contains sulfurie acid. Protect your ‘eves, skin and clothing. In case of contact, flush thoroughly with water and eall a doctor if electrolyte gets in your eyes. 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don’t meet HONDA‘ design specifications may cause damage to the ATC. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3, Use only metric tools when servicing this ATC. Metric bolts, nuts, and screws are not interchangeable with English fasteners. 4, Install new gaskets, O-rings, cotter pins, lock plates, when reassembling. 5. When tightening bolts or nuts, begin wit ly in 18 steps, unless @ particular sequence is specified, Lubricate any sliding surfaces befor reassembly. larger-diameter or inner bolts first. Then tighten to the specified torque diagonet: Clean parts in non-flammable or high flash point solvent upon disassembly. . After reassembly, check all parts for proper installation and operation. 1-1GENERAL INFORMATION MODEL IDENTIFICATION The vehicl ation number (VIN) is on the steering head’s left side, ENGINE SERIAL NUMBER ‘The engine serial number is stamped on the crankcase lower right side. 1-2 "The frame serial number is stamped on the steering head right side. CARBURETOR IDENTIFICATION ‘The carburetor identification number is on the carburetor body left side.Oo ‘SPECIFICATIONS GENERAL INFORMATION DIMENSIONS — | Overall length 1,887 mm (74.3 in) | Sree waste ee aw acan | Sena 1.038 mm (0.8 Wve! bre ian aoa nt LT) Rear tread 840 mm (33.0 in} Seat hoght soe mn aes Foot pet eight der on Golem eee tenn ase ory | ger 180 ig t400 1b) ‘ar 05908 9 (210m Fb suspension, ave Fae ee 5 mm (45) romveureen eat | Sangean S15 mm te th ieee ont | Sim Rear | 9in ie ha, 24x 12.00-9, 0.18 kalem* (2.2 pa Fosrars sina osire 352 120008, O18 kulem (2 ba Peal consi {ates 0nd US ga 2 8 oe) Fuel reserve capacity 2.0 liters (0.53 US gal, 0.44 Imp gal) fat on om Fone eps 1Buab es 820.08 on oO yarcararénaensnt | Sac opinia eked ae | emer fabio em ot e228 m1 Brolecomont Zscotioocun | Compression ratio 9:1 ina lanai $583 9000 ro (1BPS/7C00 rom minut oe Vetgeve000 ran tia pea000 my oi eagacty 28 her 20 US 2.2 kp ahr seem Biter 22 US at 1.8 mp ater dining Lubrication system forced posse an wer sump Cis often ree atgiens 7088 pe comes | ate Save © extrcoain Sport| 35s Agog f at) mae Cone | “as abe Valve clearance fmore | 0.b8mun0.003 mp a Etresr | 6.08 en f0003 Eoin dy weight foane toes ev CARBURETOR Type Dual valve has By 08 in) me Aa orn ye a Senet 1 Bed groove © vee tesan cianGENERAL INFORMATION DRIVE TRAIN Cluteh Wet multi-plate, semiautomatic Transmission S-speed constant mesh with reverse Primary reduetion 2.407 (65/27) Gear ratio. st. 4,083 (49/12) 1 2.389 (43/18) " 1.609 (37/23) um 1.179 (33/28) v 0.906 (29/32) Reverse 7.383 (34/12) (44/17) Final reduction 5.684 (19/13) (35/9) arshift pattorn Left foot operated return system, Forward: NSL-1234 Reverse :_N-R ELECTRICAL Ignition C.D. lanition timing Initial 13° BTDC at idle Full advance 31° BTDC at 3,500 rpm Alternator Capacity 200 W/S,000 cpm Battery 12V-10 AH Spark plug DRBES-L (NGK) X24ESRU (ND) Spark plug gap 0.6-0.7 mm (0.024~0.028 in) Headlight 12V 6ow/6ow Taillight 12V BW x2 Neutral indicator 12v aw Reverse indicator rv 3W 1-4GENERAL INFORMATION TORQUE VALUES "85 ENGINE om ow | treed Sie Tome ] ‘rom a is eb Cylinder heed socket bolt 8 x125 | 22-28 | 22-28 | 16-20 Cylinder heed cap nut ra [012s] 3505 | asnas | 25-33 Crankcase SH bolt 1a | 6xto 312 | 08-12 oe Gearshift return spring pin 1 Bx 1.25 18-25 | 18-25 13-18 Output gear case socket bol 3 ex125 | 20-25 | 20-25 | 18-18 | Output driven gear bearing holder socket bot 3 ex125 | 20-25 | 20-25 | 15-18 Output ger beeing outer bck nat | 1 | 6x5 e0-110 | 20-110 | 65-80 Output driven gear bearing outer lock 7 7 wt 1 | eons so-rro | 90-110 | 65-80 Output gourboarng iver lockmt | 1 | 28x 20 70-80 | 7.0=80 | s1=58 Kick stort stopper plate sockat bait | 2 x10 10-14 | 10-14 710 Flywheel bolt 1 | 124128 | 100-120 | 100-120 | 72-87 Raa seii a 2 5x08 12 | 08-12 eo 8 Fight eankcato cover SHBG 12 | 6xto e-12 | 08-12 an Lat laaineaTsctor SH alk 1 x10 e12 | oen12 on [Ot soparmor plate SH bore 2 ex10 12 | 08-12 69 Manuel etch ok rut 1 [texto | Yoo-120 | 10-12 72-87 teh ter cap bet ‘ ex10 10-14 | 1.0-14 710 [ Cenvitugateuteh tock nut 1 [20x10] 110-130 | 1110-130 | 60-94 [ Cynder bose SH bot 2 ex10 12 | 08-12 an om sprocket bot 2 71.0 7-23 | 17-23) 12-17 [Cylinder head cover SH bot 7 6x10 a | 08-12 o8 Vale ediustng lock nut 2 6x075 | 18-18 | 16-4 | 11-13 ‘Cam chain holder socket Bok 1 x10 12 | 08-12 | 6-9 3 71.0 e-12| 08-12 68 Spark plug 1 12 x 1.25 15-20 1.6-2.0 11-15 Intake manifold bend serew 1 5x08 a5 | 03-05 24 it fiter cover SH bolt 8 ex10 e-1| 08-12 can) NeutalReverse switch 2 | toxt26 | tit | 1.18 ai Starter ech sockat bot 8 axi28 | 18-28 | 18-26 | 13-18 Cam chain tonsionerHftar SH bol 2 ex1.0 s-1| 08-12 9 Alternator stotor SH bot 3 6x10 12 | oa-12 69 Breather plate socket bolt 1 ex1.0 10-14 | 10-14 710 Clute adjusting screw lock nut 1 ex126 | 19-25 | 19-25 | 14-18 Com chain tensioner Hier setng baw [1 ex10 s-12 | os | 6-8GENERAL INFORMATION FRAME seem any | Tmead Sie Torque (rom) Nem kgm | frlb Hendleber upper holder bolt 4 8x12 18-30 1.8-3.0 13-22 Handlebar upper holder nut 2 10 x 1.25 40-50 4.0-5.0 29-36 Fork bridge bok — 2 | 12x1.25 50-70 5.0-7.0 36-51 ‘Steering stem nut 1 24x10 70-90 70-390 | 51-65 Steering bearing adjustment nut Uniti) 1 24x10 25-35 25-35 18-25 (inal 7-8 07-08 56 [Wheel nut 12 10x 1.25 50-60 50-60 | 36-43 Front axle fa 14x18 7-110 | 7.0-11.0 | 51-80 ear axle nut 2 201.5 80-120 | 80-120 | 58~87 Rear brake panel nut 4 10x 1.25 50-60 5.0-6.0 36-43 |_Rear shock absorber mount bolt 2 10 x 1.25 so-60 | 50-60 | 36-43 Front fork mount bolt 4 10% 1.25 50-60 5.06.0 36-43 [Swingarm right pivot bolt 1 30x15 16-20 16-20 12-18 ‘Swingarm left pivot bolt 1 30x15 100-130 | _10.0-13.0 72-94 ‘Swingarm pivot lock nut 1 30x 1.5 100-130 | 10.0-130 72-94 Final gear case mount bolt 4 301.25 50-60 5.06.0 36-43 4 8x125 28-35 28-35 20-25 Fear left bearing housing bolt 4 8x 1.25 28-35 28-35 20-25 Engine hanger bot 9 10% 1.25 45—65 45-66 33-47 Gearshift pedal bolt 1 6x10 10-14 4.01.4 7-10 | Foot pes bracket bolt 4 101.25 40-50 4.0-6.0 29-36 Intake manifold bolt 2 6x10 8 06-09 s-7 Muffler clamp bolt 2 8x1.25 18-28 18-28 13-20 Front fork socket bolt 2 8x1.25 18-26 18-26 13-18 3f shock absorber rod lock nut 4 12x 1.25 38-60 38-60 27-43 ‘gear case cover bolt 2 10x 1.25 45—50 45-50 | 25-36 6 8x1.25_ 23-28 23-28 | 17-20 Pinion joint nut 1 Vexts 100-120 | 100-120 | 72-87 Pinion bearing outer race lock nut 1 60x 1.5 go-t10 | 90-110 | 65~80 Torque specifications listed above are for the most important tightening points. If torque specification isnot listed, follow the standards given below. STANDARD TORQUE VALUES ikem Torque Nem (kg-m, fib) tem Torque Nem tko-m, fb) Smmbolt, nut | 48-6 (0.45-0.6, 3-4) 5 mm screw 35-5 (0.35-0.5, 24) {8 mm bolt, nut 8-12 08-1.2, 6-9) Emm screw, SHbot | 7-11 10.7-1.1, 8-8) ‘8 mm bolt, nut 18-25 (7.8-2.5, 13-18) | 6 mmflange bolt, nut_| 10-14 (1.0-1.4, 7-10) 10 mm bolt, nut_| 30-40 (3.0—4.0, 22-29) | _&mmflenge bok, nut | _24—20 (2.6~3.0,17—22) 12mm bolt, nut_| 6060 (5.0-6.0, 36-43) 10 mm flange bolt, nut_| 35-45 (3.54.5, 25-33) 1-6 e e eGENERAL INFORMATION AFTER '85: ENGINE item oy | Teese Torque Nm kom feb Cylinder head socket bolt 3 x 125 2-26 22-28 16-20 Cylinder head eap nut 4 70x 1.25 35-45 35-45 25-33 Crankease SH bolt “ 6x10 a2 08-12 6-9 Gearshift return spring pin bolt 1 8x 1.25 18-25 18-25 1318 ‘Output gear case bolt 3 8x 1.25 30-34 30-34 22-25 i eh eee a | exis | m2 | 2025 | m1 Output gear bearing outer lock nut | 1 64x15 90-110 90-110 580 ae ten anne tes 1 60x15 90-110 80-110 85-80 Output gear bearing inner lock nut 1 28x10 70-80 79-80 51-88 Kick starter stopper plate socket bolt | 2 6x10 10-14 10-14 710 Flywhes bolt 1 12x 1.28 To0-120 | 100-120 72-87 Pulse generator serew 2 5x08 57 05-07 a5 Right crankcase cover SH bolt 2 6x10 a2 08-12 9 Left erankcate cover SH bolt i 6x10 a1 os12 | 69 Oil separator plate SH bolt 2 6x10 8-12 08-12 a9 Manual clutch lock nut 1 18x10 Yoo-120 | 100-120 72-87 ‘hutch lifter bolt 4 6x10 joa) Ota 7=10 Centrifugal cluteh lock nut 1 20x10 110-130 | 11.0-130 80-94 Cylinder base SH bolt 2 6x10 a2 69 Cam sprocket boft 2 71.0 1723 117 Cylinder head cover SH bolt 7 6x10 a12 69 Valve adjusting lock nut 2 6x 0.75 15-18 1-13 Cam chain holder socket bolt 1 6x10 10-14 710 il pipe bolt 3 7x10 10-14 710 Spark plug 1 12x 1.25 15-20 Ta Intake pipe band serew 7 5x08 35 24 Oil iter cover SH bolt 3 6x10 8-12 e-9 Neutral Reverse switch 2 TO 1.25 T=15, en Starter clutch torx bolt 6 8x 125 20-25 18 ‘Cam chain tensioner lifter SH bole 2 6x10 8-12 6-9 ‘Alternator stator SH bolt 3 6x10 312 o3 Breather plate socket bolt 1 6x10 10-14 710 Clutch adjusting serew lock nut 1 Bx 1.25 18-25 13-18 [Cam chain tensioner lifter sealing bolt | 1 6x10 8-12 9 Engine oil drain plug 1 12x15 20-30 1422 Intake pipe bolt 2 6x 1.0 10-14 710 Gear case drain bolt 1 8x 1.25 10-14 710 [Gear case filler cap 1 30x18 10-14 710GENERAL INFORMATION FRAME ‘tom ay | ease Torque Nem kom feb Handlebar upper holder bolt 4 Bx 25 18-30 18-30 13-22 Handlebar lower holder nut 2 10x 1.25 20-50 40-60 29-36 Fork bridge bolt 2 121.25 ‘50-70 36-51 Stering etem nut 1 2x 1.0 70-90 31-65 Stering bearing adjustment nut Univ) 1 24x10 25-26 18-25 (Final) 78 5-6 Wheel nut | 1x25 60-70 #051 Front axle 1 14x15 70-110 51-80 Rear axle nut 2 1x15 30-140 58-101 Rear brake panel aut 4 10x 1.25 50-60 36-83 Rear shock abrorber mount bolt 2 10x 1.25 50-60 36-43 Front fork pinch bolt 4 10x 1.28 50-60 36-83 [_ Swingarm right pivot bolt [oa] aox1s 16-20 12-14 Swingarm left pivot bolt 1 30x15 100-130 10.0-13.0 72-94 Swingarm pivot lock nut 1 30x15 100-130 | 10.0-130 72-94 Final gear ease mount bolt 4 10x 126 30-60 50-60 36-43 4 8x 125 30-36 30-36 22-26 Left rear bearing housing bolt 4 8x 1.25 30-36 30-36 22-26 Engine hanger bolt [10 mm 2 10% 1.25 45-65 45-65 33-47 8mm 2 Bx 1.25 24-30 24-30 17-2 Gearshift pedal bolt 1 6x10 14-18 10-13 Foot pe bracket bolt 4 10x 1.28 40-60 29-36 Intake manifold bolt 2 6x10 10-14 7-10 Muffler clamp bolt 2 x12 1828 13-20 Front fork rocket bolt 2 51.25 15-25 11-18 Rear shock absorber rod ock nut 1 12x 1.26 38-60 27=43 | Final gear case cover bolt [10 mm 2 10x 1.25 45-50 33-36 mm 6 8x 125 7328 17-20 Pinion joint aut 7 16x15 700-120 | _10.0-120 72-87 Pinion bearing outer race lock nut 1 0x15 90-110 90-110 65-80 [Front axie holder nut 4 6x10 | 10-14 10-14 7-10 Torque specifications lstad abowe are forthe most important tightening points. I @ torque specification isnot listed, follow the standards given below. STANDARD TORQUE VALUES —iem Torque Nim (kgm, feb) item Torque Nem (kom, feb) 5 mm bolt, nut 4.5-6 (0.45-0.6, 3-4) 5mm screw: 3.5-6 (0.35—0.6, 2-4) Gmmboit,nut__| 6-12 (08-1.2, 6-8) ‘mm screw, SHbole | 711 (0.71.1, 5-8) mm bolt, nut | 18-25 (18-25, 13-18) Emm flange bok, nut__| 10-14 (10-14, 7=10) TOmmbolt, nut | 30-40 (3.04.0, 22-29) ‘@mm flange bolt, nut | 24-80 (24-80, 17-22) 12mmbols, nut | 80-60 (6.0-60, 36-43) TOmm flange bolt, nut | 35-45 (3.54.5, 25-33) 1-8GENERAL INFORMATION © Tos ‘SPECIAL T REF | bescnieron TooLNumeen | aLremvariveToo. | TOOLNUMBER | 5cEhon © Frnten ioe Roar 07924100000 12 Pinion gear driver 07348-WA00000 Bearing driver 12 Universelbesring puller | 676310010000 | Commercially available 10,12 | in U.S.A. Socket bit, 17 mm 077030020500 12 Pivot lock nut wrench | 078084680001 | Lock nut wrench KS-HBA—o8—469 | 12 YU usa Attachment 07868 -Sa00600 12 Steering stem socket | 078183710100 n Lock nut wrench, 67916 MES0000 10 Sanaa mim Clute holder 07923-HA80000 07923 -HB3000A— 8 U.S.A. only | Cluten puter 07933-HaBo000 07833 HB3000A— 8 U.S.A. ont | Hox wrench, 6 mm 07917-3230000 | Commercially avaiable in |inusa Cluten cont holier | 07823-KE10001_| Commercalyavaoble in invsA | Pinion holder 07924 mes0000 10,12 Crank nebo 27881 -KF00000 | 10 © | Massemin cots 07881 —KkF00100 10 —Threaded adapter 07931 —KF00200 [io ~ Shaft puller 07931 —Me40000 | 40,12 Bearing remover, 17mm | 07836—3710300 | | 8,10 emer aren 07936—3710100 | 10.12 Remover weight 077410010201 | Remover weight | 079363710200 | 9,10, 12 Bearing remover set, 10 mm | 07836—GE00000 | 8 Bearing remover sot, 20 mm | 078363710001 8 “oaring remover, 20 mm” | 078363710600 8 Reena bare 078363710100 | 8 Rartover weight 07741 0910201 | 8 Bearing vemover,18_mm | 07836-KC10000 07936-3710200 40 “Gearing remover, 15 mm | 07936—KC10500 [0 — Remover weight 07741 0010201 10 Attachment, 28 x 30 mm | 079461870100 B10 artachrene 078463290000 i Steering stem diver 87846 ~4300101 | Steering stem 07946-mBo0000 11 Giver and attachment | GN-HT-64 {USA only) | Balin ome 079532380000 n Valve guide ear 37384 0980000 8 CO | uniersstbeod breaker | GN-AN—958-B81 | (U.S.A, only [ia Lock nut wrench, 97916200000 10 30 x 64 min | Shock absorber compressor | 07959-MB10000 12 ose Besring remover 07936~4150000 | 07936-3710500 | 12 O eisai: 677470010100 079473330000 11 | Attachment 077490010501 | 079473330000 W L Water seal driver 07947—HA00000 12 1-9GENERAL INFORMATION GENERAL INFORMATION COMMON 7 REF, DESCRIPTION TOOLNUMBER | ALTERNATIVETOOL | TOOLNUMBER | gettroy Float level gauge (074010010000 4 Valve adjusting wrench, | 077080030200 | Commercially available | 3 10x12 mm inUS.A Valve adjusting wrench A | 077080030300 3 Valve adjusting wrench B | 077080030400 3 Lock nut wrench, 07716—0020300 | Commercially available 3 17% 27 mm in USA, Lock nut wrench, 077160020400 | n 30 x 32 mm | Extension 07716-0020500 | Commercially available a inUSa Flywheel holder 07725-0040000 | Strap wrench ho commercially available | inUSA Rotor puller 077330020001 _| Rotor puller 07933-3850000 | 9 Valve guide remover, 077420010100 _| Valve guide remover | 07942—3290100 | 6 5.5mm | Attachment, 24 x 26 mm 077460010700 | 9,12 Attachment, 37 x 40 mm 077460010200 | 10, 12 Pilot, 17 mm 077460040400 | 8, 10 Pilot, 15 mm 077460040300 10,11 Attachment, 42x47 mm | 077460010300 | | 8, 10, | 11,12 Pilot, 25 mm 07746--0040600 10 Pilot, 20. mm 077460040500 8,10 Pilot, 22 mm 077480041000 | 10 Attachment, 52 x 55 mm 077460010400 | 10, 12 Pilot, 28 mm 077460041100 10 Attachment, 62 x 68mm | 077460010500 12 Pilot, 35 mm 077460040800 10, 12 Attachment, 72x75 mm | 077460010600 H10) Driver 07749—0010000 | 8,9, 10, | 14,12 Driver 077460030100 | 10 Attachment, 30 mm 1,0. | 077460030300 10 Fork seal driver 077470010100 | Fork seal driver attachment | 077470010801 | Valve spring compressor | 07757—0010000 | Valve spring 07957—3290001 6 compressor Shock absorber compressor | 07859-3290001 2 Attachment, 20 mm'.D. | 077460020400 12 Driver 077460020100 12 Tire breaker set 07772~0050000 4 —Breaker arm compressor | 077720050100 4 — Breaker arm 077720050200 cf Pilot, 30 mm 077460040700 Digital mul-tester (KOWA) | KS—AHM—32-003 | Eleetic tester PIN 7308-0020000 | 14 Digital volt meter 074110020000 1-10GENERAL INFORMATION CABLE & HARNESS ROUTING Note the following when routing cables and wire harnesses: + A loose wire, harness or cable can be a safety hazard. After clamping, check each wire to be sure itis secure. * Do not squeeze wires against a weld or end of a clamp, * Secure wires and wire harnesses to the frame with their respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire hamesses. + Route harnesses so they are not pulled taut or have excessive slack. + Protect wires and harnesses with electrical tape fr tubing if they are in contact with a sharp edge or corner. Clean the attaching surface thoroughly before applying tape. * Do not use any wires or harnesses with a broken insulator. Repair by wrapping them with protective tape or replace them. * Route wire harnesses to avoid sharp edges or * Also avoid the projected ends of bolts and * Keep wire hamesses away from the exhaust pipes and other hot parts. + Be sure grommets are seated in their grooves properly * After clamping, check each harness to be cer tain that it does not interfere with any moving or sliding parts. * Wire hamesses routed along the handlebars should not be pulled taut, have excessive slack, be pinched, of interfere with adjacent or surroun. ding parts in all steering positions ‘After routing, check that the wire hamesses are not twisted or kinked * Do not bend or twist control cables. Damaged: control cables will not operate smoothly and may stick or bind. 0...Correct X. Incorrect, 1-11GENERAL INFORMATION THROTTLE CABLE PARKING BRAKE CABLE AR — S VA cotnecror 80x | [connector 30x SY "85: THROTTLE —fEte aS CABLE NiGENERAL INFORMATION THROTTLE REVERSE LOCK CABLE CABLE ‘CHOKE CABLE PARKING BRAKE CABLE REAR BRAKE DRUM BREATHER \ TUBE REAR BRAKE DRUM AFTER ’85: BREATHER TUBE REAR BRAKE DRUM BREATHER TUBE fh / PARKING REVERSE Lock CABLE REAR BRAKE — REVERSE CABLE LOCK CABLEGENERAL INFORMATION FINAL GEAR CASE BREATHER TUBE TAILLIGHT WIRE HARNESS AFTER '85: FINAL GEAR CASE BREATHER TUBE“15GENERAL INFORMATION AFTER '85: 1-16GENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM The U.S. Environmental Protection Agency requires manufacturers to certify that vehicles built after January 1, 1983 will comply with applicable noise emission standards for one year or 1,865 miles (3,000 km) after the time of sale to the ultimate Purchaser, when operated and maintained according to the instructions provided. Compliance with the terms of the Distributor's Warranty for the Honda Vehicle Noise Emission Control System is necessary in order to keep the noise emission control system in effect. TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by eny person, ather than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while itis in use; or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person, AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: Removal of, or puncturing the muffler, baffier, header pipes or any other component which conduets exhaust gases. Removal of, or puncturing of any parts of the intake system, Lack of proper maintenance. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specifiad by the manufacturer. 1-17LUBRICATION (CRANKSHAFT ‘OIL FILTER ‘olL PUMP. MAINSHAFT COUNTERSHAFT 2-02. LUBRICATION YU | ‘SERVICE INFORMATION 24 | TROUBLESHOOTING 24 ENGINE OIL LEVEL 22 ENGINE OIL & FILTER CHANGE 22 2, FINAL DRIVE OIL 23 LUBRICATION POINTS 24 SERVICE INFORMATION GENERAL ‘+ Section 8 shows how to service the oil pump. SPECIFICATIONS Engine oll capacity 25 liters (2.6 US at, 2.2 Imp at! after disassembly 2.1 liter (2.2 US qt, 1.8 Imp qt) after draining Ol viscosiries Engine oll recommendation Use Honda 4-stroke oil or equivalent. API Service Classification: SE or SF Viscosity: SAE TOW—40 Other viscosities shown in the-chart may be Used when the average temperature in your riding area is within the indicated range. Final drive oil capacity 100 cc (3.4 oz) Final drive oil recommendation Hypoid gear oil SAE #80 TORQUE VALUES Engine drain plug 20-30 Nem (2.0-3.0 kg-m, 18-22 fib} Gear case drain bolt 10-14 Nem (1.0~1.4 kg-m, 7~10 ft-lb) — Gear case filler bolt 10-14 Nem (1.0-1.4 kg-m, 7—10 ft-lb} il level too low — high oil consumption ll contamination 1. Normat dil consumption 1. Oil or filter not changed often enough 2. External oil leaks 2. Head gasket faulty 3. Worn piston rings 3. Worn piston rings, 4. Oil not changed often enough 5. Faulty head gasketLUBRICATION ENGINE OIL LEVEL Place the ATC on level ground, Check the oil level with the oil filler capidipstick Do not screw it in when making this check. Ifthe oil level is below or near the lower level mark on the dipstick, add the recommended ail (page 2-1) up to the upper level line. ENGINE OIL & FILTER CHANGE NOTE [ Change engine oil with the engine warm and | the ATC on level ground to assure complete draining. Remove the ol filer cap and drain plug. Remove the three bolts attaching the oil fiter cover, oil filter and spring Discard the oil filter. ‘Check that the sealing washer on the drain plug is in ‘9004 condition and install the drain plug TORQUE: 20-30 N-m (2.0~3.0 kgm, 14-22 ft4b) Make sure that the oil filter cover O-ring Is in ‘good condition, and coat it with oil before install- ing it Install the ol filter spring, fiter and cover using the three bolts, Fill the crankcase with 2.1 liters (2.2 US gt, 1.8 Imp {tl of the recommended cil (page 2-1), Install the ol filler cap/aipstick. Start the engine and let it idle for 2-3 minutes. Stop the engine and check that the oil level is at the Upper level line on the dipstick. Make sure there are no oil leaks, OIL FILLER CAP/DIPSTICK UPPER LOweR LEVEL LeveL DRAIN PLUG. NEW OIL FILTER aS ‘SPRING OL FILTER COVER O-RING OIL FILTER COVERLUBRICATION FINAL DRIVE OIL CHECK Remove the oil filer cap. Place a support block under the engine. (The front and rear axles should be in the same plane.) ‘Check that the oil level reaches the lower edge of the oll filler cap hole. Check for leaks. If the level is low, pour fresh oil through the oil filer hole until it reaches the lower edge. CHANGE Remove the ol filer cap. Remove the drain bolt to drain all oll rom the final ‘gear case, Install the drain bolt securely. Fill the gear case with the recommended oil up to the correct level OIL CAPACITY: 100 ce (3.4 US oz) RECOMMENDED OIL; Hypoid gear oll SAE #80 TORQUE: DRAIN BOLT: 10—14 Nem (1.0—1.4 kg-m, 7=10 ft-lb) FILLER CAP: 10—14.Nem (1.0—1.4 kg-m, 7—10 ft-lb) FILLER CAP DRAIN PLUG. Om LEVEL. 23LUBRICATION LUBRICATION POINTS Use general purpose grease when no other is given. Apply oil or grease to any 2 1ces and cables net shown here. nn DRIVE SHAFT/ a rsa} AL JOINT. UNIVERSAL JOINT BRAKE LEVER [eALE LUBRIGANT) SPLINES FINAL DRIVE Gear SPU Byars: BRAKE CABLE/ THROTTLE CABLE! (See page 2-3) CHOKE CABLE BRAKE CAM/ANCHOR PIN, STEERING HEAD ‘SWING ARM PIVOT BEARINGS evewe eR PoES BRAKE PEDAL [ON 9 4) BRAKE CAM/ANCHOR PIN PivoTiFooT. PEG PIVOTSERVICE INFORMATION MAINTENANCE SCHEDULE AIR CLEANER SPARK PLUG BREATHER TUBE | VALVE CLEARANCE CARBURETOR IDLE SPEED FUEL LINE FUEL STRAINER THROTTLE OPERATION CYLINDER COMPRESSION SERVICE INFORMATION SPECIFICATION Spark plug gap Recommended spark plugs Valve clearance: Intake: Exhaust Idle speed Throttle lever free play Cylinder compression: Front brake lever free play: Rear (parking) brake lever free play: Rear brake pedal free play: Reverse selector lever free play: Front tire size Rear tre size Recommended tire pressure: Front Rear Standard tire circumference: Front: Rear TORQUE VALUES Clutch adjusting screw lock nut Valve adjusting lock nut TOOLS Common Valve adjusting wrench, 10 x 12 mm '85: valve adjusting wrench A After ‘85: valve adjusting wrench 8 3. MAINTENANCE 31 BRAKE SHOES 39 32 BRAKE CONTROL LINKAGE 39 3-4 CLUTCH 341 3-5 SUSPENSION 3-12 3-5 SPARK ARRESTER 3-12 EE 3-5 REVERSE LOCK SYSTEM 3-13 3-6 LIGHTING EQUIPMENT 313 3-7 TIRES 314 3-7 STEERING HEAD BEARINGS 314 3-8 NUTS, BOLTS, FASTENERS 314 3-8 ENGINEUNDERGUARD AND SKID = 3-14 PLATE 0.6-0.7 mm (0,024-0.028 in) DR8ES-L (NGK) X24ESR-U (ND) 0.08 mm (0.003 in) 0.08 mm (0,003 in} 1,400 + 100 cpm 3-8 mm (1/8—1/4 in) 12-13 kg/cm? (170-185 psi) 15-20 mm (5/8~3/4 in) 15-20 mm (5/8-3/4 in) 15-20 mm (5/8-3/4 in) 2-4 mm (1/16=1/8 in} 25x 12.00-9 25x 12.00-9 0.18 ka/om? (2.2 psi) 0.18 ka/em? (2.2 psi) 1,915 mm (75.4 in} 1,918 mm (78.4 in) 18-25 Nem (1.8—2.5 kg-m, 13—18 ft-lb} 1518 Nem (1.5—1.8 kgm, 11—13 ft-lb} 07708-0030200 Commercially available in U.S.A. 07708-0030300 0708-03040MAINTENANCE MAINTENANCE MAINTENANCE SCHEDULE "85: + The maintenance intervals shown in the following schedule are based upon average riding conditions. ATCs subjected to severe use, oF ridden in wet ar unusually dusty areas, require more frequent servicing. 'tems marked * should be serviced by fan authorized Honda dealer, unloss the owner has the proper tools and is mechanically proficient. Other maintenance items fare simple to perform and may be serviced by the owner. Perform the Pre-ride Inpsection in the Owner's Manual at every maintenance period. I: Inspect and clean, adjust, lubricate or replace C: Clean’ it necessary. i 5 a ‘TEM - ‘operation operating days) |_| BREATHR TUBE 1 35 FUEL LINE - |: (EVERY YEAR) 37 * | BRAKE SHOES i: (EVERY YEAR) T 3-9 * | SPARK ARRESTER c 3a | REVERSE LOCK MECHANISM t ~t 312 | TIRES ' 1 P3413 NOTES: 1. Replace every 30 operating days or every 3 months, whichever comes first. 2. Service more frequently when riding in dusty areas. 3-2MAINTENANCE AFTER '8! ‘The maintenance intervals shown in the following schedule are based upon average riding conditions. ATCs subjected to severe use, oF ridden in wert or unusually dusty areas, require more frequent servicing. Items marked should be serviced by ‘an authorized Honda dealer, unless the owner has the proper tools and is mechanically proficient. Other maintenance items. are simple to perform and may be serviced by the owner. Perform the Pre-ride Inspection in the Owner's Manual at ‘maintenance period. **In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer. Inspect and clean, adjust, lubricate or replace, if necessary G: Gon Fe Replce Att wwitia [REGULAR service | Service PentoD PERIOD garg ee mee EVERY operation) operating days) (peas: + | FUELLING YEAR: 1 37 * | FUEL STRAINER SCREEN “| YEAR: C 37 = THROTTLE OPERATION i 38 = [eARBURETOR CHOKE 1 “ A CLEANER nore ai ¢ 34 | [AIR CLEANER CASE DRAWN TUBE (NOTE 3) | 1 36 SPARK PLUG i 36 = VALVE CLEARANCE a i 38 [| ENGINE OW R R p22 ENGINE OWL FLTER A AR 22 * CARBURETOR IDLE SPEED | 1 1 3-6 FINAL ORIVE ol | YEAR 23 Rake SHOE WeAR EARL | = BRAKE SYSTEM I i i 3.10 * | REVERSE LOCK SYSTEM 1 1 343 = euwren svete i at * | SUSPENSION to | ang * | SPARK ARRESTER “(NOTE 1) c 3-12 "NUT, BOLT, FASTENER i a 314 [+=] WHEELS: 7 1 1 314 =| STEERING HEAD BEARING YEAR: | 314 ENGINE UNDER GUAD AND SKID PLATE | NOTE 4) i 34 NOTES: 1. USA only. 2. Service more frequently when riding in dusty areas, sand or snow. 3. Service more frequently after riding in very wet or muddy conditions, 4. After '86 models only.MAINTENANCE MAINTENANCE AIR CLEANER RETAINING CLIPS S Romove the seat by pulling the seat latch lever. Release the retaining clips holding the air cleaner Remove the air cleaner case cover AIR CLEANER CASE COVER ELEMENT ELEMENT HOLDER SCREW Loosen the sir cleaner element band screw. \ Remove the element holder attaching screw and remove the air cleaner element assembly from the Remove the element holder by turning it counterclockwise. Remove the element band and remove the element from the element core. | ELEMENT BAND SCREW Wash the element in non-flammable or high flash point solvent, squeeze out the solvent thoroughly, ‘and allow to dry. Soak the element in gear oll (SAE 80-90) and squeeze out excess. Place the element onto the element core and replace the element band and holder Install the element in the air cleaner case. Install the air cleaner case cover and clips. Install the seat WASHIN SQUEEZEQUT GEAR OIL SQUEEZE OUT| SOLVENT SOLVENT (SAE 80-90) EXCESS OIL THOROUGHLY 3-4MAINTENANCE SPARK PLUG [cane evsormose tf Paconnect the stk pup cap and remove the 06-07 mm fe soon po {0.02420028 i CHECK: GAP wear Visually inspect the spark plug electrodes for wear. The center electrode should have square edges and IDE ELECTRODE the side electrode should have a constant thickness. Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped. CHECK: SEALING Measure the gap with a wire-type feeler gauge and DAMAGE adjust by carefully bending the side electrode, SPARK PLUG GAP: CHECK: CRACKS 0.6-0.7 mm (0.024~ 0.028 in} RECOMMENDED REPLACEMENT PLUG: DRBES—L (NGK) X24ESR—U (ND) Check the sealing washer and replace with a new one if damaged. With the sealing washer attached, thread the spark plug in by hand to prevent crossthreading. Tighten the spark plug another 1/2 turn with a spark plug wrench to compress the sealing washer. BREATHER TUBE Remove the tube from the drain tube to empty any deposits. Install the drain tube. NoTE Service more frequently when riding in rain oF at full throttle, or if the deposit level can be seen in the transparent section of the drain DRAIN TUBE | tube VALVE CLEARANCE TIMING HOLE CAP ROTOR CAP NOTE Inspect and adjust valve clearance while the engine Is cold (below 35°C/95°F Remove the frame side covers, seat and fuel tank Remove the timing hole cap and rotor cap. Remove the valve adjusting covers. Rotate the crankshaft clockwise and align the ““T" mark in the rotor with the index mark. The piston must be at TOC on the compression stroke. INDEX -T" MARK MARKMAINTENANCE "85: AFTER ‘85: Inspect the intake and exhaust valve clearances by ADJUSTING SCREW LOCK NUT ADJUSTING SCREW LOCK NUT inserting the feeler gauge between the adjusting screw and valve stem, VALVE CLEARANCES Intake: 0.08 mm (0.003 in) Exhaust: 0.08 mm (0.003 in} FEELER GAUGE FEELER GAUGE "85: AFTER ‘85: VALVE ADJUSTING WRENCH, VALVE ADJUSTING WRENCH 10 x 12. mm 07708~-0030200 10 x 12mm, 07708~-0030200 ‘Adjust by loosening the lock nut and turning the ad COMMERCIALLY AVAILABLE COMMERCIALLY AVAILABLE justing screw until there is a slight drag on the feoler NUS. INUSA. ‘gauge. Hold the adjusting screw and tighten the lock nut. Rocheck the valve clearance and install the valve ad juster covers. Install the rotor cap and timing hole cap. Install the fuel tank, seat and frame side covers. VALVE ADJUSTING WRENCH A eeu VALVE ADJUSTING WRENCH B 07708-0030400 CARBURETOR IDLE SPEED NOTE ‘other maintenance items have been per: formed and are within specitications, The engine must be warm for accurate idle ey speed inspection and adjustment. Warm up the engine for about ten minutes. Turn the throttle stop screw as required to obtain the specified idle speed. IDLE SPEED: 1,400 = 100 rpm THROTTLE STOP SCREW 3-6& iS MAINTENANCE FUEL LINE Remove the left frame side cover and check the fuel ” lin. Replace any parts which show signs of deteriora: tion, damage or leaks. FUEL STRAINER Turn the fuel valve OFF Remove the fuel cup, O-ring and filter screen, and drain the gasoline into a suitable container Gasoline is flammable and is explosive under] certain conditions. Do not smoke or allow flames or spakrs near the equipment while | draining fuel a FUEL CUP, Wash the cup and filter screen in clean non flammable or high flash point solvent. Reinstall the screen, aligning the index marks on the fuel valve body and fiter screen. Install 8 new O-ring into the fuel valve body. Reinstall the fuel cup, making sure the new O-ring is in place, Tighten the fuel cup CAUTION [ono overtigin the Ful up After installing, turn the fuel valve ON and check that there are no fuel leaks. FILTER SCREEN 3-7MAINTENANCE THROTTLE OPERATION Check for smooth throttle lever full opening and automatic full closing in all steering positions. Make sure there is no deterioration, damage or kinking in the throttle cable. Replace any damaged parts Disconnect the throttle cable at the upper end. Thoroughly lubrioate the cable and pivot point with a ‘commercially avsilable cable lubricant to prevent premature wear. Install the throttle cable in the reverse oder of removal Make sure the throttle lever free play is 3-8 mm. (1/8-1/4 in) at the tip of the throttle lever Adjust as follows: Slide the rubber boot off the cable adjuster. Loosen the lock nut and adjust the throttle cable free play by turning the cable adjuster. Tighten the lock nut and install the rubber boot securely CYLINDER COMPRESSION Wiarm up the engine to normal operating temperature, Stop the engine and remove the spark plug Insert the compression gauge. Open the throttle all the way and crank the engine with the starter motor. Crank the engine until the gauge reading stops rising, The maximum reading is usually reached within 4-7, seconds COMPRESSION PRESSURE. 12-13 kg/em? (170-185 psi) HH compression is low, check for the following, — Improper valve adjustment — Valve leakage Cylinder head gasket leaking — Worn piston ring or cylinder It compression is high, it indicates that carbon deposits have accumulated on the combustion chamber and/or the piston crown, 3-8 RUBBER BOOT ADJUSTER AVAILABLE IN U.S.A. 3-8mm y (1/8—-1/4 ind Lock NUTMAINTENANCE INDICATOR “85: INDEX BRAKE SHOES PLATE MARK Replace the brake shoes if the indicator plate aligns with the brake index mark when the front brake lever, roar brake lever or pedal is applied i INDEX MARK. INDICATOR PLATE AFTER '85: INDEX MARK Sey INDICATOR PLATE BRAKE CONTROL LINKAGE FRONT BRAKE 15-20 mm Check the cable and brake lever for loose connec: Oe tions, excessive play, or other damage. Replace or repair if necessary. or Disconnect the brake cable at the upper end. Thoroughly lubricate the cable and pivot point with 8 commercially available cable lubricant to prevent Install the brake cable. Measure the front brake lover free play at the end of the brake lever. FRONT BRAKE LEVER FREE PLAY: 15-20 mm (5/8~3/4 in} 3-9