Introduction ‘This service manual describes the service procedures for and technical festure of the VFR400R. ‘This Model Specific Manual includes every service pro- cedure that is of @ specific nature to this particular model. Basie service procedures that re common 20 ‘other Honda Motorcyclas/Motor ScootersiATVs ore covered in the Common Service Manual. This Model Specific Service Manual should be used together with the Common Service Manual in order to provide com= plete service information on all aspects of this motor. yole. Performing the first scheduled maintenance is very im- portant. It compensates for the intial wear that occurs ‘uring the breakin period. Section 1 and 3 apply to the whole motorcycle. Section, illustrates procedures for removal/instalation of com: __Ranents that may_be required to, perform service de ‘scribed in the following sections. While Sectioh 4 through 19 describe parts of the motor. cycle, grouped according to locations. J+ Find the section you want on this page, then turn to the table of contents on the frst page of the section. “Most sections describe the service procedure through system illustration. Refer to the next page for details on hhow to use this manual. Hf you are not familiar with this motorcycle, read Techni cs Feature in section 20. | it you don’t know the eouree of the trouble, go to section 21 TROUBLESHOOTING, [ AtLinronmarion, 1LusrRanions. omECTIONS | AND SPECIFICATIONS INCLUDED IN THIS PUBL | CATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF AP- PROVAL FOR PRINTING. HONDA MOTOR CO.,LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUSLICATION MAY BE REPRO: DUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAIN: ‘TENANCE ON HONDA MOTORCYCLES, MOTOR - HONDA MOTOR CO.,LTD. SCOOTERS OR ATVS. ‘SERVICE PUBLICATION OFFICE Date of leave: Feorvary, 1990 © HONDA MOTOR CO., LTD. € & 6 z Crankshaft/Piston/Transmission E ka Electrical |__| wiring Diagram [19 | Contents i Cooling System Fuel System [_cooten seem SES | Engine Removal/installation Ea a ae Le ¢ | Cylinder Head/Valves Cluteh Gearshift Linkage [10 | Front Wheel/Suspension/Steering E EA Rear Wheel/Suspension E 13 | Brake System }14 | 7 Charging System/Alternator Ha Ignition System Ha Electric Starter/Starter Clutch a Lights/Meters/Switches Ea Technical Feature EQ Troubleshooting Ei a Index E41Important Safety Notice ———————_——___ Indicates 2 strong possibilty of severe personal injury or death if instructions are not followed. Indicates a possibilty of equipment damage if instructions are not followed, Gives heloful information Detailed descriptions of standare workshop procedures, safety sincipies and service operations are not included. I is | importa te note that tis manval contains some warnings an cautions against some specific service methods which Could enuse PERSONAL INJURY to sorvice personnel or could damage & voice or render tunaete Please understand | {hat those warnings could not caver all conceivable woys in which service, whether or not recommended by Honda. might be done or ef the pocily hazardous consequences of each conceivable way, nor could Honda vestigate al uch woys, Anyone using service procedures oF to's, whether or not recommended by Honda, must sasty himself thoroughly that neler personal safety nor vehice safety wil be eopercized by the sevice methods or tools selected ‘Type Codes S ' “+ Throughout this manusl, the following abbreviations are used to identify incividual model Code roars E U.K. ale aa Rasite | Fi Model ot France =a] 1M Model oni “Tammany — = |How to Use This Manual Finding Information You Need + This manual is divided into sections which cover each of ‘the major components of the motorcycle. To quickly find the section you are interested in, the first page of each section is marked with a black tab that lines ‘Up with one of the thumb index tabs before this pag. “The fist page of each section lists the table of contents within the section. Feed the service information and troubleshooting related ‘to the section before you begin working + Amindex ofthe entire book is provided inthe last chapter 10 directly locate the information you need. Note on the Explanation Method of This Manual + The removal and installation of parts are for the most part Ilustrsted by lenge and clear ilustrations that should provide the reader with visual ald ia understanding the major point for servicing, + The system ilustrations are augmented by eallouts whose numbers or letters indicate the order in which the parts should bbe removed or instalied. = + The egquence of steps represented numerically are differentiated from the ones represented alphabetically to notify the raader that they rust perform these steps seperately. For exainple, ifthe steps prior and up to camshaft removal are performed with the engine installed, but the subsequent Tike cylinder head removal require engine removal, the callouts are grouped in numerical and alphabetical orders, + Thelllustrations may contain symbol marks te indicate necessary service procedures and precautions that need tobe taken. [REfor to the next page for the mesning of each symbol mark. + Also in the illustration isa chart that lists information such as the order in which the part is removediinstlled, the name ff the part, and some extre notes thet may be needed. *+ Step by step instructions are provided to supplement the illustrations when detailed explanation of the procedure is neces sary oF ilustrations alone would not sutfice. + Service procedures required before or after the procedure described on that particular page orinepectionfadjustment proce: ures required following the installation of parts, are described under the ttle Requisite Service. + Standard warkshop procedures and knowledge covered in the Common Service Manual are abbrevisted in this manual Symbol mark ‘system thstaton Detsed desrnon step (numerals ‘or alphabets) Part number Number of Extra notes o7 precaution parts felated to the service procedure ren: |Symbols ‘The symbols used throughout this manual show specific service procedures. f supplementary information is required pertsin ing to these symbols, I would be explained specifically in the text without the use of the symbols BP | rentace tne paris) with new ones) before assembly Use special toot Use optional tool. These tools are obtained as you order parts. Torque specification, 10 Nem (1.0 kgm, 7.2 feb) 20) Use recommended engine cil, unless otherwise specifies. Use molybdenum oll solution (mixture of the engine cil and molybdenum grease with the ratio 1 : 1 Use muit-purpese grease (Lithium based mut purpose grease NLGI #2 or equivalent) Use molybdenum disulfide grease (containing more then 3% molybdenum disulfide, NLGI #2 or equivalent) Example: Molykote® BR-2 plus manufactured by Dow Corning, US.A, Multipurpose M2 manufactured by Mitsubishi Oil Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NUGI #2 or equivalent) Example: Molykote® G-n Paste manufactured by Dow Corning, US.A, Honda Moly 45 (USA. oniy) Rocol ASP manufactured by Raco! Limited, U.K Rocol Paste manufactured by Sumica Lubricant, Japan Use alicone grease | Apply a locking agent. Use the agent of the middle strength, unless otherwise specified Apply sealant Use brake fluid, DOT 3 or DOT 4. Use the recommended brake. fluid, unless otherwise specifi bleml'si Pik | RI Also Use Fork oF Suspension Fld1. General Information General Safety mW Model Identification 13 Specifications 14 Torque Values 14 General Safety Carbon Monoxide If the engine must be running to do some work, make sure ‘the area is well ventilated. Never run the engine in —— * The exhaust contains poisonous carbon monoxide gas ‘that ean cause loss of consciousness and may lend 10 death. Fun the engine in an open tion system in an enclosed (ea oF with an exhaust evacu: Gasoline Work in @ well ventilated area. Keep cigarettes, flames or sparks away from the work area or where gasoline Is stored * Gasoline fo extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. temain hot for some time after the engine is run, Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts, Tools 17 Lubrication & Seal Points 119 Cable & Harness Routing rar | Used Enginertransriission Oi! *+ Used engine ol (or transmission olin two-stiokos) may ‘cause skin cancer if repeatedly Taft in contact withthe -tkin for prolonged poriods. Although this fe unlikely unlass you handle used oll on a dally basic, i is etl advisable to thoroughly wash your hands with soap ‘and water as soan as possible after handling used ol KEEP OUT OF REACH OF CHILDREN. ~ Brake Dust ever use an air hose ot cry brush to clean brake assemblies. —| + inhaled asbestos fibers have been found to cause respiratory disease and cancer Brake Fluid CAUTION + Spiling fluid on painted, plastic or rubber parts will | | {damage them. Place a clean shop towel over these parts whenever the system s serviced. KEEP OUT OF REACH OF CHILDREN.General Information ee Coolant Under some contitions, the ethylene glycol in engine coolant Is combustible and Its flame is not visible, If the ethylene ‘lycol does ignite, you wil not see any ‘lame, but you can, be burned. ‘Avoid sping engine coolant on the exhaust syatem ‘or engine parts. They may be hot enough to cause the ‘coolant to ignite and burn without a visible flame. + Coolant (ethylene glycol) can cause seme skin ita ton and is poisonous if swallowed. KEEP OUT OF REACH OF CHILOREN. + Donotremove the radiator cap when the engine is hot. ‘The coolant is under pressure and could scald you. * Keep hands and clothing away from the cooling fan, as it starts automatically. It contacts your skin, wash the affected areas immedi- ately with soap and water. If ft contacts your eyes, flush them thoroughly with fresh water and get immediate mect- cal attention. IFit is ewallowed, the vietim must be forced ‘to vomit then rinse mouth and throat with fresh water before cbtaining medical attention. Because of these ‘dangers, always store coolant in a eafe place, away from ‘the reach of children Nitrogen Pressure For shock absorbers with a gas-filed reservoir: * Use only nitrogen to pressurize the shock absorber. “The use ofan unetable gas can cause a fie or explo. sion resulting in serous injury + The shock absorber contains nitrogen under high | pressure. Allowing fie or heat near the shock aby orber could lead to an explosion that could result Serious injury + Failure o release the pressure from a shock absorber | before disposing of ie may feed and serious injury iff is heated or pieroed To prevent the possibilty of an explosion, release the nitrogen by pressing the valve core. Then remave the valve stom from the shock absorber reservoir. Before disposal ofthe shock absorber, release the nitrogen by pressing the valve core. Then remove the valve stem ‘rom the shock absorber Battery Hydrogen Gas & Electrolyte ‘The battery gives off explosive gases: keep sparks, flames and cigarettes away. Provide adequate vert. lation when charging. | + The battery contains sulfuric acid (electrolyte). Con- tact with skin or eyes may cause severe burns. Wear protective clothing and a face shield electrolyte gets on your ekin, flush with water, = electrolyte gets in your eyes, flush with water fo ‘at least 15 minutes and eall a physician. + Electrolyte is poisonous. = If swallowed, drink large quantities of water or milk ‘and follow with milk of magnesia or vegetable oil ‘and call a physician. KEEP OUT OF REACH OF CHILDREN.General Information Model Identification (1) FRAME SERIAL NUMBER ‘The frame serial number is stamped on the right side of the steering head, (2) ENGINE SERIAL NUMBER (3) CARBURETOR IDENTIFICATION NUMBER “The engine serial number is stamped on the top of thecrank- The carburetor Wentification number is stamped on the ‘case right sie. _ carburetor body intake side (4) COLOR CODE LABEL ‘specify its designated cor.General Informations Specifications Uni: man tn [— Generat 1 from Specifications | Dimensions | Overall ngth | 1.288 (76.1) ‘Overall length {M Mode! only) 2,036 180-1, G: 2,070 (81.5) Overall width _| 705 27.8) Overt height 1,076 (42.3) Wheelbase | 17305 (63.0) Ground clearence 1251.9) Dry weight 175 kg (385.8 ib) Dry weight [M Model only 176 ig (288.1 15) Cure weight Maximum weight capacity Maximum weight capacity (M Mode! only) 192 kg (423.3 1D) 347 kb (765.0 1b) 842 kg (754.0 15) Frame Frame type Front suspension Front wheel travel Rear suspension Rear whee! travel Rear damper Front tre eize Rear tie size Tire brand (Bridgestone) FRIRR Tice brand (Dunlop) FRIAR Tire brand (Yokohama) FRIAR “Tre brand (IRC) FRR Front brake: Rear brake Caster angle ‘Trail longth Fuel tank capacity Fuel tank reserve capacity Backbone Telescopic fork 120 (4.7) Swingarm 120 (4.7) Gasrfiled damper with reservoir 120/60 VRI7 180/60 VR18 KS10A RADIAL/KE10 RADIAL Hyaraulle double dise Hydraulic single dice 25°20" 96 (3.8) 15 liters (4.0 US gal. 3.5 Imp gal) 2.0 liters (0.5 US gal, 0.4 Irnp gall Engine I Displacement Compression ratio Valve tein Intake valve opens at 1 mm tft Intake valve closes at Umm It Exhaust valve opens at 1 mm lift Exhaust valve closes at 1 mm it Lubrication system Oil pump type Cooling system Ae filtration Crankshaft type Fring order Cylinder arrangement Cylinder number UTS see | | Snel _ 55.0 x 42.0 (2.16 x1.65) £298 om? (24.3 eu ia) Wait — Gear driven BOHG, 4 valves per eylings 15° BTOC. 35° ABDC ‘38° BEDE 5° ATOC Forced pressure and wet sump “Trockoia Liquid cootes Peper filter Unittype, 4 main journals 1 90° — 4— 270° ~ 3 — 90° — 2 4 cylinders 90°V> General (Cont'd) General Information eee es Units mm Gi) tem Specifications ‘carburetor Carburetor type ‘Constant velocity, 4 carburetors | Throttle bore 2203) Drive Tain Ciutch system ‘Mutt-plate, wet Clutch operation system Cable operated Transmission 6 speeds Primary reduction 2117 (34/72) Secondary reduction = ‘Third reduction _— Final reduction 2.666 (15/40) Gear ratio tot 2.928 (14ran) Gear ratio 2nd 2.166 (18/39) Gear ratio 3ro 11300 (20/38) Gear ratio ath 1.891 (22/35) Gear ratio Sth 1.435 (23/83) Gear ratio 6th 13te (22/29) Gear ratio reverse a Gearshift pattern left foot operated return system 1-N—2-3~4—5—6 Electrica? Ignition eystom Digitalized ful wansistor ignition Starting system | Electric starter motor Charging system TTiple phase output alternator Regulatorirecifier type ‘SCR Shorteditrple phase ful Lighting system Battery AC rogulator type = 1-5General information Unit: man find 1-6 — twbvicaton kom | Standard |) Service Limit | Engine of copacky a draining 2 Wher 254 US at D4 imp wT = 5 cisassemby 510 tere (217 US qt 266 Imp ath = tol fiter change 2.5 ites (2.68 US ty, 3.20 imp) = | Recommended engine cil Use Honde 4-stoke ol or equivaane Olt viscosmes Viscosity: SAE fOW=a0 | Other viscosity shown in the chart moy be Used when the average temperature in Your fing area fs within she incated range Oil pressure at oi! pressure switch ‘490—588 kPa (5.0—6.0 kg/cm’, 71-85 psi) | 4 5,000 remi@o°cni76¢F) — Oil pump rotor tip clearance @ 0-15 (0.006) _ body clearance @ 0.15-0.22 (0.006—0.009) = tnd clearence @ 0.040.09 (0.0016-0.0035) = [— Fust System pe = Carburetor identification number OE 3A (6), VDE 3C (aR) = ation number (M Model oniy) | VDE SF te 1 = VE 36 (AR) bE ati (6) | atin jot a = (igh sisaced = = a) = = was a = (Front) #22 = ‘Rear #120 = Stow jot #35 = Jet needle clip postion it = Pilot screw inal apering 2 ms out = Pitt screw high altitude acfustment = = Pilot screw final opening 118 turns out = Pilot sorew final opening (M Model ony Turns oot fF) = “2 ene oat AR, G) ‘it screw inital opening “ — ‘ir serew high slttude ediustmont a = Frost level 6.8102 = | Carburetor Vacuum cttoronce Within 40 mmf (1.6 int) = S2se carburetor (For eatburetorsynohronization) | No. 2 carburetor = tele speed 1,200 2 100 min (mi = Throttle grip fre play 256 10.08~0.24) , Accelerator pump clearance = =General information oo Unit: mm fe — oytnder Hood 1 : tem ‘Standard Service Limit ‘Cylinder compression 1,274 © 196 kPa (13.0 £ 2.0 kgiem’®, tae 28 pal200 mir bd = | cylinder compression iterence _ | 0 mami (8 ni = Goi elesrance Iv O13 048 (0,008-0.0071 a \ Ba 0.21027 (0.008-0.0111 = | cyinder need warpage = 20.10 0,008 Stave neh I Ja717-92.987 01.2002—1.2975 sar th2e8) & Seazo—az.e0e (1.2707—1 2860) a2.80 (1278) Comshat unaut = 008 1.00%) Camhalt of larance A 0.040--0.082 (0.0016-0.0032) 0.082 10.0030) 3 eas oa Camshaft jours OD. A 27.889~27.960 (1100013008) 27.88 1.0101 C = jas Combat older 0. & 75.000-28.021 (1.1024~1.1082) 28.03 1.108) : os aay Valve etm 0. 1$a78~4.490 (0.1762-0.1720) 447,0.170) & ees 4.490 (0.1758-0.1760) Gite (01780) valve gue 1. IN @S00=2 812 10.1772-0.1770) 10.100) x Sis00—4612 (01772-01770) 4.5e f.t60) | ‘Stem-to-guide clearance IN _ | 0.010~—0.037 (0.0004-0.0015) 0.08 (0.008) x 0.020-0,047 (0.0008-0.0019) o.12 1.008) | vv aude projection above evindar head Nth) | $00.4 = xin | 1204) = Bator guide neta Fin, eshte ate gen oe wr, eer tection of 9 refigerator FE ter sso anton act a ‘2. Heat the cylinder head to : | Yoo 18080 12-200") | Velve seat width IN 1.70—2.30 (0,067—0.091) _ x 170230 9.067=0.099) _ Valve sping fe length = -_ & = -_ tre Ba .20 202 19) tho Bx gua aa 30.31.18) ure IN aba Gael ss2tian Outer EX bea 381 ga tian | Rocker arn 0. 8.600 2.516 0.2940-0.99821 e.83 0.220 & £800 a.516 foe46—0.99621 f183 (0.936) Rocker arm shaft O18 8.t00 0.408 (0.0909 0.2240) Bae (0.290) & 8 466—8.488 (0.9889~0,39401 a6 (0398) hocks smtovockr orm chat clomance as i Vote titer Ob a _ Xie ter bore Lo. = — Haru appa acjster assist spring tee natn | — = Ferautclapet acter compression vata wit) | — = ierovene aUnies mae find — Crinderiston tem standard Serve Unt Cynder 1 35.000 65.018 165s 2 18Be) 8607 16a Minder ovt of ound bay 0.10 (0004) | Cylinder taper — 0.10 (0.004) Chine woroge = 10 (0.004) Piston rank section IN mak facing toward the nae side a ton O30! | stvomsaee0 16022 40s s92a.100) | Peston Q. measurement pin | tows) 28 Pieter pi ote a) 14.002 14:008 (0.6513-0.5518) 14.02 10882) oS - ry : * | co | | Cylinder-to-piston clearance: 0,010—0,045 (0.0004—0.0018) 0.10 (0.004) | Piston pin O.D. 13.994 ~14,000 (0,6503—0.5512) 13.98 (0.550) | Pistan-to-piston pin clearance 0.002—0.014 (0,0001—0.0006) 0.04 10.002) | Connostng rod sopiston si clesrance B.o16 0.040 0.00060. 00re) 8.08 (0.002) | torn 8.018 0.080 (0.0006 0.0020) 2:10 (0.008) | | Second 8.018-0.048 (0.0006~0.00"8) 0 f.0os) Tong end gor | St2"0129 oer oor 0.08 (o.02s) Second ng nd gop 048-0128 (0.007=0.019) 2.88 (ooze) Oivng (ed ral rd gap | 2070.00 foooe—o.034) 038 (oar! ‘oo ty ae “mane tacng — Second tng ark : mark tang up = Cranshat = i Connecting rod small end 1.0, 14.016—14.034 {0.5518—0,5525) 14.05 (0.553) | Conestng rod ig end ede searance dri0~0.20 19.008 0.012) xt 1.02) Tada! clooronce = = Crankshaft unout = 0.08 (0.001) ° rh | Craton ot cosrance 0.028-0.082 10.0011 -0.0020) 0.07 (0.003) rankpinbearng sleton See poe 110 a Nain ural of denranee 8.026"0.049(0.0010-0.0010) 0.07 0.003) Bain fourelbaag sletion See page 1140 = [Wotan | Kickstaner pron gear 1. = = Kickstart’ opine OD ae = Kcktarte le gear 1D a a Coumsrehat Oat Nera le gear = = Rcdeater ie gear bushing om = ‘D = =General information ———_—$S$ —— ml ale: ran ab = Tansmission. | tem Standard Service Limit “Tanemission gear LD. MS, M6 2, ¢3, ca “Tanemiseion gear bushing 0.0. MS, MB c2, €3, c# ‘Tansmisston gear bushing LD. M5 cz | Gear-to-bushing clearance at MS, M6 gear | at C2, C3, C4 gear Mainshaft 0.0. at MS gesr bushing Ms == Countershatt O.. at C2 go: bushing Gearto-shaft clearance Gear bushing to-shaft clearance at MS gear at C2 gear Shift fork clew thickness © R Shift fork LO. L € R Shift fork shaft 0.0. L c R 28,000—28.021 (1.1024~1.1032) | 28,000— 28.021 (1.1024~1.1032) 27,959-27.980 (1.1007— 1.1016) 27959-27980 (1.1007= 1.1018) 24.985--25.006 (0.9837—0.9845) 24.985 25.006 (0.9837--0.9845) 0.020--0.082 (0.0008—-0:0024) 0.020-0.062 (0.0008—0.0024) 24,967~24.978 (0.9830—-0.9824) 24.967—24.978 (0.9830—0.9834) 0.007 -0.039 (0.0003—0.0015) 0.007—0.039 (0.0003—-0.0015) 5.93~-6,00 (0.233-0.236) 5,936.00 (0.283-0.236) 8,936.00 (0.283-0.236) 12.000- 12.021 (0.4724~0.4733) 12,000 12.021 (0.4724~0.4733) 12.000~12.021 (0.4724~-0.4733) §1,989— 11-980 (0.4712-0.4717) 111969— 11.980 (0.4712-0.4717) 141989— 11.880 (0.4712=0.4717) 28.04 (1.104) 28.04 (1.104) 27.84 (1.100) 27.94 (1.100) 25.03 (0.985) 25.03 (0.985) (0.10 (0.004), 0.10 (0.008) 24.96 (0.983) 24.96 (0.983) 0.08 (0.002) 0.08 (0.002) 5.8 (0.23), 5.8 (0.23), 5.8 (0.23) 12.04 (0.474) 12.04 (0.474) 12.04 (0.474) 11.98 (0.470) 11.98 (0.470) 11.98 (0.470) 1-9General information ————— Units mae Gin) [Clutch System tem Standard “| Clutch lover fee play | Recommended clutch fluid Clutch master cylinder LD, Ciuteh master piston OD. Gluten euter 1.0. Clutch outer guide 0.0. to. Mainshatt O.. at clutch outer guide Oil pump drive sprocket 1.0. Clutch conter 8 LD One way clutch inner 0.0. ‘Clutch spring free height (As a set of Spee.) | Clutch spring fae lenath Clutch die thickness Clutch dise thickness A 8 Clutch plate warnage Centrifugal eutch drum 0. bushing O.. Contrifigal clutch center guide 1D. oo. Centrifugal clutch center guide collar height Centrifugal clutch spring {ree engthn (Clutch fining thickness Crankshaft O.D. at cluteh center 10-20 (0.4-0.8) 29.000—28.021 (11417— 11426) 28.967—28.980 (11404-11409) 21,985~22.015 (0,8659—0.8667) 29.028-28.075 (1.1427-1.1447) 63.964~63.980 (2.5183 2.5193) 47.365 —47.378 (1.8648 1.8663) 5.310.211 2,92~3.08 (0.118~0.1211 ATTELT TLL Hilt 28.06 (1184) | 28.99 (1139) 22.05 (0.268) 29.11 (1,146) 64.00 (2.520) 47.36 (7.8846) 4.8 (0.19), 2.8 (0.110) 0.30 (0.012) | EE Coolant capacity (Rediatar and engine) (Reserve tank) Radiator cap relief pressure Thermostat begins to open Thermostat fully open ‘Thermostat valve lift [Sesto M Model 2.1 ters (2,22 US ft. 1.86 Imp qt 2.0 titers (2.11 US ft. 1.76 Imp at) 0.2 iter (0.21 US gt, 0.18 Imp a) 108-137 kPa (1.10—1.40 kglem?, 16—20 psi) 80—84°C (176-183°F) 95°C (203°F) 8.0 (0.23) min it WH [— Drive Tain Recommended final drive oi! Final drive gear oll capacity st disassembly at draining Final drive gear backlash Final drive gear backlesh difference between Ring gear-to-stop pin clearance (A) ‘Stop pin shim Ring gear spacer Pinion spacer Final drive gear assembly preload Output gear backlash Output gear 1.0. ‘Output gear bushing OD. 10, Output drive shaft 0.0, urput gear damper spring free length Output shaft adjustment shim Countershatt drive shaft adjustment shim Wn TUTTE TERE Gl etal 1-10General information eee ost: me ti) — Wheels/Tires ' tem Standard Service Limit j Minimum te tread depth (FR) ARR} Cold the pressure Driver only (FAL Daver only (RA Driver and passenger (FR) ' Driver and passenger (RR) | Front and roar axle runout | Font and rear whee! rim runout (Rady axis) Front west hubsowim distance Front wheal hub standerd surface Fear wheel hub-torim distance | Rear whes! tb standard surface |, Wheel balance weight (Front) (Pear Drive chain slack Deve ehain size line (01D) 228 kPa (2.25 kglem’, 33 psi) 225 kPa (2.25 kglem’, 33 psi) 15-25 (6/8—1) 1.5 10.06) 2.0 (0.08), 0.2 (0.01) 2.0 (0.08) 2.0 (0.08) 160 9 (21 02) max [60 9 (2:1 02) max les x) | RK aBszssmeri04 = Front Suspension Fork spring free length 277.3 (10.91 271.8 (10.70) Fork spring free length A — — 8 = - oe Fork spring direction ‘Tightly wound coil end facing down = Fork tube runout a 0.20 (9.008 | Recommended fork ot Fork hid — Fork a level 122 mm (4.8 in) — [Fork vet i _ = | wu _— — Fork oi eapacity 380 ce (13.2 US 02, 13.7 Imp oz! — | Fork oll capacity (M Model only) 404 ce (13.7 US 02, 14.2 Imp 02) — Fork ofl eapacity (A) — — wu = = Fork air pressure a — Steering bearing preload 1.0=1.8 kg (2.2~3.3 1 — Rear Suspansion Shock absorber spring free length 168.7 (6.2 in} 185.5 (6.12) | | Sheek absorber soring free length (R] : 0 ' Damper gas pressure Damper compressed gas Damper rod compressed force at 10 mm compressed |, Damper driling point | shock absorber spring installed length i (Standard ' ‘Adjustable range) ‘Shock absorber spring adjuster standard position ‘Shock absorber spring direction Recommended shock absorber oll | shock absorber aif capacity sie pressure 98 kPa (10 kglem?, 142 psi Nitrogen, 15—20 kg (3344 Ib) See page 13-13 147.7 16.81) HA LETT 1-11Unit: men tin) With digital type) [— Brakes 1 : tem Standard | Service Limit | Front brake tid Dora = Brake lever fee play _ — Brake ped wea indicator = To the groove 1 | | | | | | broke dise thickness 410.16) 3.5 (0.14) se runout ae 0.30 10012) master cylinder 14,000~14.085 (0.9512 0.5829) 14.06 (0.852) | master piston 0.0. 18.957—13.084 (0.5495—0.5506) 12.98 (0.549) | Caliper ovinder 1D. = — | Caliper evlinder LD. Upper) 30.280-30.280 (1.1902~ 1.1921) 30.29 (1.192) | ftowen 2.40025, 450 (1.0000 —1.0020} 25.46 (1.0024) caliper piston O0. = es Satiper piston 0. (Upper) 30.148-30.198 (1.1869—1.1689) 30.14 (1.1886) : (tower) 25.318 25.366 (0.9986-0.9887) 25.31 (0.9965) | Broke drum Lo. = oe broke fining thickness — a | Rear broke fia | bora = brake pedal height = a brake pedal fre play = — broke bad wear inleator = To the groove 2 ' @ brake dise thickness 6.0 (0.28) 5.0 (0.20) bate ise runout — 0.30 10.012) master oylinder 1. 14.000~14.088 (0.5512 0.6828) 14.06 (0.588) master piston OD. 13.857—13.986 (0.5495 0.8506) 13.98 (0-549) Caliper evlinder 1. 25.400—28.480 (1.0000 — 1.00201 26.46 (1.0028) alper piston OD. | 25.916-28.368 (0.9060-0.9987) 26.31 0.998) brake drum 10. = — brake fining thickness = a | BattoryiCharging System —aae Alternator charging col resistance (At 20°C/68°F) | 03-100 _ Roguiatorhectiter regulated votiagelamperage | 12.5-~15,6 VIO-8 A at 6,000 min (pm) = Bottery capacity av ~ Gan = {Maintenance Free betery: YTXTA~BS) = Specified current teskage pins 1 mA max Battery specific gravity (Fully chargec) = | (Seeds chargingh a = | Battery charging rate (Normal 0.7 A/S—10 he — | (Ouiek) 20 Art he = | Bortery voltage (Fully charged at 20°C/68°R) | 18.0~18.2 V _ (Needs charging at 20°c/eaem | 12.3 = Alternator lighting col resistance (at 20°C/68°") | —— — ‘AC regulator regulated voltage With anelogue typel| — = ee 1-12