Honda CBR 954 RR 2002 Service manual

HOW TO

USE

THIS

MANUAL

This service manual describes the service procedures for the

Follow the Maintenance Schedule (Section that

the

vehicle is in peak operatlng condition.

Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break

Sections dures for removaI/instailation of components that may be required to per form service described in the following sections. Section 4 through location.

Find the section you want on this page, then turn to the table of contents on the first page of the section.

Most sections start with an assembly or system illustration, service informa tion and troubleshooting for the section. The subsequent pages give detailed procedure.

If you don't know the source of

1

and 3 apply to the whole motorcycle. Section 2 illustrates proce

19

describe parts of the motorcycle, grouped according to

the

trouble,

Your

safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messages and other infor mation throughout this manual. Of course, to warn you about all the hazards associated with servicing this vehicle.

You

must

use

You

will find important safety information in a variety of forms including:

*

Safety Labels - on the vehicle

-

Safety Messages - preceded by a safety alert symbol d and one of three signal words, These signal words mean:

*

Instructions - how to service this vehicle correctly and safely.

your own good judgement.

DANGER, WARNING,

You

WILL

be

you don't follow instructions.

You CAN

you don't follow instructions.

You CAN

instructions.

KILLED

be

KILLED

be HURT

3)

recommendations to ensure

go

to section

it

is not practical or possible

or

CAUTION.

or

SERIOUSLY HURT

or

SERIOUSLY

if

you don't follow

CBR954RR.

-

in period.

21,

Troubleshooting.

HURT if

-

if

-

As

you

read this manual, you will find information that is preceded by a

1-

your

Date

0

symbol. The purpose of this message is to help prevent damage to

vehicle, other property,

of

Issue:

January,

Honda

Motor

Co.,

or

the environment.

2002

Ltd.

SYMBOLS

The symbols used throughout this manual show specific service procedures. If supplementary information is required per taining to these symbols,

it

would be explained specifically

Replace the

Use the recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine

Use multi-purpose grease (lithium based multi-purpose grease NLGl#2

Use molybdenum disulfide grease (containing more than

equivalent).

Example:

Use molybdenum disulfide paste (containing more than

equivalent).

Example:

part(s) with new one(s) before assembly.

Molykote" BR-2 plus manufactured by Dow Corning, U.S.A.

Multi-purpose M-2 manufactured

Molykote" G-n Paste manufactured by

Honda

Moly

60

(U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan

in

the text without the use of the symbols.

oil

and molybdenum grease in a ratio of

3%

molybdenum disulfide, NLGl #2 or

by

Mitsubishi Oil, Japan

40% molybdenum disulfide, NLGl #2 or

Dow

Corning, USA.

or

equivalent).

1:l).

-

I

\4

v

Use silicone grease.

Apply a locking agent. Use a medium strength locking agent unless otherwise specified.

Apply sealant.

Use

DOT

Use fork

4

brake fluid.

or

suspension fluid.

Use the recommended brake fluid unless otherwise specified.

I

l-

I

GENERAL INFORMATION

SERVICE RULES 1-1 LUBRICATION & SEAL POINTS 1-19

I

MODEL

DENT1 FlCATl ON 1-1 CABLE & HARNESS ROUTING 1-23

SPECIFICATIONS 1 TORQUE VALUES

TOOLS

-

3 EMISSION CONTROL SYSTEMS 1-37

1

-

12 EMISSION CONTROL INFORMATION

1

-

17

LABELS 1

-

40

SERVICE RULES

1.

Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that design specifications may cause damage to the motorcycle.

2.

Use the special tools designed for this product to avoid damage and incorrect assembly.

3.

Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners.

4.

Install new gaskets, O-rings, cotter

5.

When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque

diagonally in incremental steps unless a particular sequence is specified.

6.

Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.

7.

After reassembly, check all parts for proper installation and operation.

8.

Route all electrical wires as shown on pages

pins,

and lock plates when reassembling.

1-23

through

1-36,

Cable and Harness Routing.

do

not meet Honda's

MODEL IDENTIFICATION

1-1

GENERAL INFORMATION

(1)

The frame serial number is stamped on the right side of the steering head.

(2)

The engine serial number is stamped on the right side of the upper crankcase.

VEHICLE IDENTIFICATION NUMBER

(3)

The Vehicle Identification Number (VIN) is located on left side Labels.

of

the main frame

on

the Safety Certification

COLOR LABEL

(VIN)

THROTTLE

(4)

The throttle body identification number is stamped on the intake side of the throttle body as shown.

BODY

ID~NTIFICATION

NUMBER

(5)

The color label is attached as shown. When ordering

-

coded parts, always specify the designated

color color code.

1-2

SPECIFICATIONS

GENERAL INFORMATION

GENERAL

DIMENSIONS

FRAME

ENGINE

ITEM

Overall length Overail Overal Wheelbase Seat height Footpeg Ground clearance Dry weight

Curb weight

Maximum weight capacity

Frame type Front suspension Front wheel travel Rear suspension Rear wheel travel Rear damper Front tire size Rear tire Tire brand

Front brake Rear brake Caster angle Trail length Fuel tank capacity

Cylinder arrangement

Bore and stroke

Displacement Compression ratio Valve train

Intake valve opens

Exhaust valve opens

Lubrication system

Oil pump type Cooling system Air filtration

Engine dry weight

Firing order

width

I

height

49 states, Canada type: California type:

49 states, California type: Canada type:

size

Bridgestone Michelin

closes closes

at 1

mm

(0.04 in) lift

SPECIFICATIONS

2,025

mm

(79.7 in)

mm

(26.8

680

1,135 mm (44.7 in) 1,395

mm

820

mm

383

130

mm

kg (370 Ibs)

168 170 kg (375

195 kg (430 Ibs)

197 kg (434 Ibs)

160 kg (353 Ibs) 164 kg (362 Ibs)

Diamond

Inverted telescopic fork

110

mm

Swingarm

135

mm

Nitrogen gas filled damper

120170 ZR17 M/C (58W) 190/50 ZR17 M/C (73W)

Front: BT012F RADIAL G /Rear: Front: Pilot SPORT E /Rear: Pilot SPORT E Hydraulic double disc brake with 4 pots caliper Hydraulic single disc brake with 1 pots caliper 23

"

45'

97

mm

18.0 liter (4.76

4 cylinders in

75.0

x

54.0

954 cm3 (58.2 cu-in)

11.5:

1

Chain driven, DOHC 25' BTDC

38

"

ABDC

41" BBDC

22O ATDC

Forced pressure and wet sump Trochoid

Liquid cooled Paper element

61.2

kg (134.9 Ibs)

1-2-4-3

in)

(54.9 in) (32.3 in) (15.1

in)

(5.1 in)

Ibs)

(4.3

in)

(5.3 in)

(3.8 in)

US

gal, 3.96 Imp gal)

-

line, inclined 30" from vertical

mm

(2.95 x 2.13

in)

BT012R

RADIAL G

1-3

GENERAL INFORMATION

,--

GENERAL

DRIVE

TRAIN

I

(Cont’d)

ITEM

Type

Throttle bore

Clutch system Clutch operation system

Transmission

Primary reduction Final reduction Gear ratio 1

Gearshift pattern

Ignition system Starting system Charging system

Regulator/rectifier

Lighting system

st

2nd 3rd 4th 5th 6th

SPECIFICATIONS

PGM-FI

42 Multi

Cable operating Constant mesh, 6

1.520

2.687 (43/16)

2.692 (35/13)

1.933 (29/15)

1.600 (32/20)

1.400 (28/20)

1.285 (27/21)

1.190

Left

Computer Electric starter motor Triple phase output alternator SCR Battery

(Programmed Fuel Injection)

mm

(1.7 in)

-

plate, wet

-

speeds

(73/48)

(25/21)

foot operated return system,

-

controlled digital transistorized with electric advance

shorted/triple phase,

full

1

-

N

- 2 -

3

-

wave rectification

4

- 5 -

6

GENERAL INFORMATION

Unit:

mm

(in)

Engine oil capacity

Oil pump rotor

Throttle body identification

number Starter valve vacuum difference

Base throttle valve for synchronization

Idle speed

Throttle

Intake air temperature sensor resistance (at Enqine coolant temperature sensor resistance (at 20°C/68"F)

Fuel injector resistance (at 2OoC/68"F) PAIR solenoid valve resistance (at

Cam pulse generator peak voltage (at 20"C/68"F) Ignition pulse generator peak voltage (at Manifold absolute pressure at idle

___

Fuel pressure at idle Fuel pump flow (at 12

nrip

free play

At draining At oil filter change At disassembly

Tip

clearance Body clearance Side clearance

ITEM

Except California type GQ44C California type GQ44B

20°C/68"F)

20"C/68"F)

V)

STANDARD

3.5 liter (3.7 US

3.7 liter (3.9

4.0 liter (4.2 Pro Honda GN4 or HP4 (without molybde

num additives) 4-stroke

motor oil API service classification: SG or higher JASO T 903 standard: MA Viscositv: SAE 1 OW

kPa

490

5,400

0.15

0.1

~~

0.02 - 0.07

(5.0

rr~m/(80"C/176"F)

(0.006)

5

-

0.22

I

188 cm3 (6.4

qt,

3.1 Imp qt)

US

qt,

3.3

Imp

qt)

US

qt,

3.5 Imp

-

kgf/cm2,

(0.006 - 0.009)

(0.001

-

0.003)

2

343 kPa (3.5 kqf/cm2, 50 psi)

US

qt)

oil

or equivalent

40

71

psi) at

SPECIFICATIONS

20 mmHg

No.1

1,200

f

100 rpm

-

6

mm

(1/16 - 1/4

1-4kR

2.3

-

2.6 kL2

10.5

-

14.5

20

-

24

0.7 V minimum

150 - 250 mmHg

oz,

6.6

Imp

R

52

oz) minimum/lO seconds

I

SERVICE LIMIT

I

-

I

0.20 (0.008)

1

0.35

1

0.10 (0.004)

in)

-

__

-

(0.014)

I

1-5

GENERAL INFORMATION

ITEM

Coolant capacity

Radiator cap relief pressure

Thermostat

Recommended antifreeze

Standard coolant concentration

1

Radiator and engine

1

Reserve tank

Begin to open Fully

1

Valve

CYLINDER HEADNALVES

ITEM STANDARD

Cylinder compression

Valve clearance

Cam shaft Cam lobe height

Runout

I

oil

clearance

Valve lifter Valve lifter

Valve lifter bore

Valve, valve guide

Valve spring free length

Cylinder head warpaqe

Valve stem

Valve guide Stem-to-guide clearance

Valve guide projection above cylinder head

Valve seat width

O.D.

I.D.

IN

open

lift

I.D.

SPECIFICATIONS

I

i

I

Pro Honda HP Coolant or an equivalent high quality ethylene

glycol

I

1,196

at

1

IN EX 0.27

IN

EX 36.45

I

IN/EX 1 25.978 - 25.993 (1.0228 - 1.0233)

i

IN/EX 1 26.010 - 26.026 (1.0240 - 1.0246)

I

IN

1

EX

1

IN/EX 4.500 - 4.512 (0.1722 - 0.1776) 4.540 (0.1787)

IN

EX IN 14.3 - 14.6 (0.56 - 0.57) EX 12.4 - 12.7 (0.49 - 0.50)

lN/EX

1

Inner

i

Outer

0.16 f 0.03 (0.006 f 0.001)

36.74 - 36.98 (1.446 - 1.456)

1

0.020 - 0.062 (0.0008 - 0.0024)

1

4.475 - 4.490 (0.1762 - 0.1768)

1

4.465 - 4.480 (0.1758 - 0.1764)

0.010 - 0.037 (0.0004 - 0.0015)

0.020 - 0.047 (0.0008 - 0.0019)

1

0.90

I

34.80 (1.370)

1

37.97 (1.495)

1

39.60 (1.559)

I

108 - 137

antifreeze containing corrosion protection inhibitors

1:l

kPa

(12.2

350

rpm

-c

0.03 (0.01 1

-

36.69 (1.435 - 1.444)

-

1.10 (0.035 - 0.043) 1.5 (0.06)

liter

(3.3

US

qt,

2.7

at,

0.4

kgf/cm2,

minimum

Imp Imp

3.1

0.4

liter

(0.4

US

kPa

(1.1 - 1.4

80.5 - 83.5"C (177 - 182°F) 95°C (203°F)

8

rnm

(0.3

in)

mixture of antifreeze and

kgf/cm2,

-r-

0.001)

-

174

psi)

qt)

16 - 20

soft

psi)

water

I

SERVICE LIMIT

36.72 (1.446)

36.43 (1.434)

0.04 (0.002)

1

0.10 (0.004)

i

25.97 (1.022)

I

26.04 (1.025)

I

4.465 (0.1758)

1

4.455 (0.1754)

I

33.1 (1.30)

I

36.1 (1.42)

I

37.6 (1.48)

1

0.10 (0.004)

Unit:

-

mm

i

(in)

1-6

CLUTCH/GEARSHIFT LINKAGE

I

-

Clutch lever free play Clutch spring free length

Clutch disc thickness 2.92 Clutch plate warpage

Clutch outer guide

Mainshaft Shift fork,

forkshaft ~

O.D.

at clutch outer guide

I

Fork

Fork shaft

ITEM

O.D.

'

I.D.

~

O.D.

~

Ew

thickness

1

I

1

,

Unit: mm (in)

STANDARD

I0

-

20 (3/8 - 13/16)

48.8 (1.92) 47.4 (1.87)

-

3.08 (0.115-0.121) 2.6 (0.10)

-

25.000 - 25.021 (0.9843 - 0.9851) 25.03 (0.985)

34.975 - 34.991 (1.3770 - 1.3776)

24.980

-

24.993 (0.9835 - 0.9840)

12.000 - 12.018 (0.4724 - 0.4731) 12.03 (0.474)

5.93 - 6.00 (0.233 - 0.236)

11.957 - 11.968 (0.4707 - 0.4712)

1

SERVICE LIMIT

1

-

0.30 (0.012)

34.97 (1.377)

24.96 (0.983)

5.9 (0.23)

11.95 (0.470)

I

1

ITEM STANDARD

Starter driven sear boss

CRANKCASE/PISTON/CYLINDER

I

Taper

1

WarDase

Piston, piston rings

Piston mark direction

1

Piston pin

i

Piston-to-oiston Din clearance

j

Piston rin$-to-rin'g groove clearance

i

Piston ring end gap

i

Cylinder-to-piston clearance Connecting rod small end Connecting rod-to-piston pin clearance Crank Din oil clearance

O.D.

ITEM

O

I.D.

.D.

I

1

TOP Second

Top

Second

51.699 - 51.718 (2.0354 - 2.0361)

I

STANDARD

-

1

"0"

mark facing toward the intake side

16.994 - 17.000 (0.6691 - 0.6693)

0.002 - 0.014

i

0.030 - 0.065 (0.001 2 - 0.0026)

I

0.015 - 0.045 (0.0006 - 0.0018)

1

0.28 - 0.38 (0.01 1 - 0.01 5)

I

0.40 - 0.55 (0.016 - 0.022)

1

0.020 - 0.055 (0.0008 - 0.0022)

I

17.016 - 17.034 (0.6699 - 0.6706)

1

0.016 - 0.040 (0.0006 - 0.0016)

1

0.030 - 0.052 (0.0012 - 0.0020)

(0.0001

-

0.0006)

I

i

SERVICE LIMIT

i

51.684 (2.0348)

Unit: mm (in)

I

SERVICE LIMIT

0.10 (0.004)

,

0.10 (0.004)

~ 0.05

(0.002)

-

16.98 (0.669)

I

i

1

-

0.08 (0.003)

0.06 (0.002)

0.5 (0.02)

0.7

(0.03)

-

17.04 (0.671)

I

'

-

0.062 (0.0024)

I

GENERAL INFORMATION

CRANKSHAFT/TRANSMISSlON

r

Side clearance

Runout

Main journal oil clearance Gear I.D. M5, M6 31.000

Bushing O.D. M5, M6 30.950

Bushing

Gea r clearance c3, c4 0.025

Mainshaft0.D.

Countershaft O.D. Bushing

clearance

-to-

ITEM

I.D.

bus

-to-

h i ng

s haft

STANDARD

-

0.20 (0.002 - 0.008)

0.05

-

0.017

c1

c2, c3, c4

c3, c4

M5 27.985 - 28.006 (1.1018 - 1.1026)

c2

M5, M6

1

M5

1

Clutch outer guide I 24.980 - 24.993 (0.9835 - 0.9840) C2 29.967 - 29.980 (1.1798 - 1.1803) 29.96 (1.180) M5 0.005 c2 0.005 - 0.039 (0.0002 - 0.0015)

26.000

33.000

32.950

29.985

0.025

I

27.967 - 27.980 (1.1011 - 1.1016)

0.035 (0.0007 - 0.0014)

-

31.025 (1.2205 - 1.2215)

-

26.021 (1.0236 - 1.0244)

-

33.025 (1.2992 - 1.3002)

-

30.975 (1.2185 - 1.2195)

-

32.975 (1.2972 - 1.2982)

-

30.006 (1.1805- 1.1813)

-

0.075 (0.0010 - 0.0030)

-

0.075 (0.0010 - 0.0030)

-

0.039 (0.0002 - 0.0015)

SERVICE LIMIT

0.30 (0.012)

0.03 (0.001)

0.045 (0.0018)

31.04 (1.222)

26.04 (1.025)

33.04 (1.301

30.93 (1.218)

32.93 (1.296)

28.02 (1.103)

30.02 (1.182)

0.11 (0.004)

1

27.957 (1.1007)

1

24.96 (0.983)

0.08

(0.003)

0.08

(0.003)

)

I

1-8

Minimum tire tread depth Cold tire pressure

Axle runout Wheel rim runout Radial

Wheel balance weigh Fork

Up to 90 Up to maximum weight capacity

Axial

Spring free length Spring direction Fork pipe runout Recommended fork oil Fluid level

Fluid

-

load adjuster initial setting

Pre Rebound adjuster initial setting Compression adjuster initial setting

kg

(200

capacity

Ib)

load

-

kPa (2.50 kgf/cm2, 36 psi)

250

kPa (2.50 kgf/cm2, 36 psi)

250

-

255.8

(10.07)

With the tapered end facing up

-

Pro Honda Suspension Fluid

73

(2.9)

513

k

2.5 cm3

18.1 2 0.09

7

turns from

2

turns from

2

turns from full hard

(17.3 * 0.08

Imp

02)

full

soft

full

hard

SS-8

US

02,

1.5 (0.06)

_____

-

0.20

(0.008)

2.0

(0.08)

2.0 (0.08)

250.8 (9.87)

-

0.20

(0.008)

-

Cold tire pressure

Axle runout

rim

Wheel

Wheel balance weight

Drive chain

Shock absorber

runout Radial

ITEM

Up to 90 Up

Axial

Size/l i n k DID

Slack Spring adjuster standard position Rebound adjuster initial setting

Compression adjuster initial setting

kg (200

to

maximum weight capacity 290 kPa (2.90 kgf/cm2, 42 psi)

Ib)

load

RK

kPa (2.90 kgf/cmz, 42 psi)

290

50VA8

50

(1.6 - 2.0)

C1/108

full

DID

RK

GB50HFOZ5/108

40

-

4th groove 2

turns from

2

turns from

STANDARD

-

hard hard

SERVICE LIMIT

2.0 (0.08)

-

0.20

(0.008)

2.0

(0.08)

2.0

(0.08)

60 g (2.1

50

-

(2.0)

-

02)

max.

-

1-9

GENERAL INFORMATION

r

Front

Rear

ITEM STANDARD

1

Specified brake fluid Brake disc thickness

Brake disc runout

1

Master cylinder I.D.

1

Master piston Caliper cylinder I.D. ~ Upper

Caliper piston

Specified brake fluid

Brake disc thickness Brake disc runout

Master cylinder I.D.

1

Master t7iston O.D. Caliper cylinder I.D. Caliper cylinder O.D.

O.D.

Lower

Upper

I

Lower

SERVICE LIMIT

1

Honda

I

4.5 (0.18)

I

17.460 - 17.503 (0.6874 - 0.6891)

I

1

17.321 - 17.367 (0.6819 - 0.6837)

1

32.025 - 32.035 (1.2608 - 1.2612)

30.250 - 30.280 (1.1909 - 1.1921)

~

31,965 - 31.998 (1.2585 - 1.2598)

I

j

30.082 - 30.115 (1.1843 - 1.1856)

1

Honda

I

i

5.0 (0.20) 4.0 (0.16)

I

,

15.870 - 15.913 (0.6248 - 0.6265)

1

15.827 - 15.854 (0.6231 - 0.6242)

38.180 - 38.230 (1.5031 - 1.5051)

38.098

DOT 4

Brake Fluid

-

DOT

4

Brake Fluid

-

38.148 (1.4999 - 1.5019)

1

3.5 (0.14)

~

0.30 (0.012)

1

17.515 (0.6896)

I

17.309 (0.6815)

,

32.05 (1.262)

1

30.29 (1.193)

I

31.953 (1.2580)

i

30.074 (1.1840)

0.30 (0.012)

15.925 (0.6270)

1

15.815 (0.6226)

38.24 (1.506)

38.090 (1.4996)

-

I

1

I

Battery

Alternator

-

IGNITION SYSTEM

Spark plug Standard

Spark plug gap Ignition coil peak voltage Ignition pulse generator peak voltage Ignition timing (

Capacity Current leakage

Voltage

Charging current Normal

Capacity Charging coil resistance

~

Optional

"F"

(2O"C/68'F)

ITEM

mark)

12V - 8.6

0.2

0.421

-

0.90

S

13.0 - 13.2

0.9

4.0

PECl

(NGK),

mm

100 V

0.7 V 13

"

Fully charged Needs charging Below

1

Quick

(2O"C/68"F) 0.1 - 1.0

IMR9C-9H (NGK),

I

1

IMR8C-9H

0.80

Ah

mA max.

V

12.3 V

A/5

-

10

h

A10.5

h

kW/5,000

Fl

minimum

BTDC at idle

rpm

R

CAT1 ONS

VUH27D (DENSO) VUH24D (DENSO)

(0.031 - 0.035

in)

7-70

GENERAL INFORMATION

Starter motor brush length

Bulbs

1

Brakehail light

Front turn signal light Rear turn

i

License light Instrument light Turn signal indicator High beam indicator Neutral indicator Oil pressure indicator PGM

-

FI warning indicator

Fuel reserve indicator

Fuse Main fuse

-

FI fuse

PGM

Sub fuse Tachometer peak voltage Thermo sensor resistance

ITEM

signal

light

Hi

!

Lo

80

"C

1

120

(176°F)

'C

(248°F)

1

10.0 - 10.5

(0.39

-

0.41) 3.5

SPECIFICATIONS

12v - 55w

12V - 55W

LED

12V - 32/3~p (23/8W)

12V - 32cp (23W) X 2

12V - 5W

LED

X

LED

LED LED

LED

30 A

20

A

X

2, 10A X 3

20A

10.5V minimum

2.1 - 2.6

0.65 - 0.73 kQ

2

kQ

x

(0.14)

2

X

2

1-11

GENERAL INFORMATION

TORQUE

5

mm hex bolt and nut

10

mm hex bolt and nut

12

mm hex bolt and nut

-

Torque specifications listed below are for important fasteners. Others should be tightened

NOTES:

3.

4.

5.

6.

7.

8.

9.

10.

11.

VALUES

I

FASTENER TYPE

to

standard torque values listed above.

1.

Apply sealant to the threads.

2.

Apply a locking agent to the threads. Apply grease to the threads. Stake. Apply oil to the threads and flange surface. Apply clean engine oil to the O-ring.

U-nut ALOC bolt: replace with a new one. CT bolt Apply molybdenum disulfide oil to the threads and seating surface (after removing anti-rust oil additive). One-way bolt

TORQUE

N-m (kgf-m, Ibf-ft)

5 (0.5, 3.6)

34 (3.5, 25) 54 (5.5,

40)

I

5

mm

screw

small flange)

6

mm

flange bolt

large flange)

FASTENER TYPE

(8

mm head,

TORQUE

~

N-m (kgf-m, Ibfbft)

4 (0.4, 2.9)

I

12 (1.2, 9)

r

ENGINE

ITEM

MAINTENANCE:

Spark plug Timing Oil drain bolt Oil filter cartridge

LUBRICATION SYSTEM:

Oil cooler mounting bolt Oil pump assembly flange bolt Oil pump driven sprocket bolt Oil pressure switch Oil pressure switch wire terminal screw

Lower crankcase

FUEL SYSTEM (Programmed Fuel Injection):

ECT (Engine Coolant Throttle body insulator band screw Throttle cable bracket mounting bolt Fuel pipe mounting bolt Pressure regulator mounting bolt Starter valve synchronization plate screw Fast idle wax unit link plate screw Fast idle wax unit mounting screw Starter valve lock nut

COOLING SYSTEM:

Water pump cover flange bolt Thermostat cover flange bolt

ENGINE MOUNTING:

Drive sprocket special bolt

hole cap

20

rnm

sealing bolt

Temperature)/thermo sensor

,

O'TY

1

;;RE:)

10

45 12 20

20

6 6

PT

118

4

20

12

5 5 6 6 3 3 6

10

2

1

6 6

10

I

TORQUE

~

N-m (kgf-m, IbfW

12 (1.2, 9)

18 (1.8, 13)

29 (3.0, 22)

26 (2.7, 20)

74 (7.5,

8

15 (1.5, 11)

2 (0.2, 1.4)

29 (3.0, 22)

23 (2.3,

See page

3 (0.35, 2.5)

1 (0.09, 1 (0.09, 0.7)

5 (0.5, 3.6)

2 (0.18, 1.3)

54 (5.5, 40)

54)

(0.8, 5.8)

12 (1.2,

10 10

12 (1.2, 12 (1.2, 9)

9)

17)

1-14

(1.0,

7)

(1.0, 7)

0.7)

9)

I

1

REMARKS

NOTE NOTE

NOTE NOTE NOTE

NOTE

NOTE NOTE

I

3

6

9 2

1

2

9 9

1-12

r

ENGINE

CYLINDER

Cylinder head cover bolt

PAIR

Breather plate flange bolt Camshaft holder flange bolt Cylinder head sealing bolt Cylinder head mounting bolt Cylinder head mounting Cam sprocket bolt Cam pulse generator rotor bolt Cam chain tensioner pivot socket bolt Cam chain guide mounting socket bolt

Cylinder head stud bolt (exhaust pipe stud bolt)

CLUTCH/GEARSHIFT LINKAGE:

Clutch center lock nut Clutch spring Shift drum center socket bolt Shift drum stopper arm pivot bolt Gearshift return spring pin

S

h ift d ru m bea ri n g/s h ift fork retaining bolt/was h er

ALTERNATORETARTER CLUTCH:

Alternator wire clamp bolt Flywheel flange bolt Stator mounting socket bolt Starter one

CRANKCASE/PISTON/CY LINDER:

Mainshaft bearing set plate bolt Crankcase bolt,

Connecting rod nut Upper crankcase Lower crankcase Lower crankcase

(Cont’d)

ITEM

HEADNALVES:

reed valve cover flange bolt

bolt/washer

boltiwasher

-

way clutch torx bolt

10

mm

9

mm

(main journal bolt)

8

mm

skaling bolt

20

mm sealing bolt

10

mm socket bolt

GENERAL

I

20

10

‘

12

4 4 3

1

2

10

4 2 1 1

8

3

1

I

6 6 6

6

18

8

9 7 6 6 6 8

22

6

8

6

8

6 6

10

6 6

6

10

9

I

10

1

N.m

10 (1.0,7)

12 (1.2, 9) 12 (1.2, 9)

12 (1.2, 9) 27 (2.8, 20) 25 (2.5, 18)

51 (5.2, 38)

20 (2.0, 14)

12

10 (1.0, 7)

12 (1.2! 9)

See page

127

12 (1.2,

23 (2.3, 17)

12

23 (2.3, 17)

12 (1.2,

14 (1.4, 10)

103 (10.5, 76)

12 (1.2,

16

12 (1.2, 9)

39 (4.0, 29)

(2.0,

20

25 (2.5, 18) 35 22 (2.2, 16) 29 (3.0, 22)

12 (1.2, 6.5)

TORQUE

(kgf-m,

(1.2,9)

(1 3.0, 94)

(1.2,9)

(1.6,

14) + 150”

(3.6,

INFORMATION

I

IbfW

1-14

9)

12)

26)

REMARKS

NOTE 2 NOTE NOTE NOTE 2

NOTE 5

NOTE NOTE 2 NOTE 2 NOTE 2 NOTE 2

NOTE 4,5 NOTE 2

NOTE 2 NOTE 9

NOTE 5 NOTE 2 NOTE 2

See

NOTE 5 NOTE 5

NOTE 2 NOTE 2 NOTE 2

2

5

10

page

1

11-12

1-13

GENERAL INFORMATION

r

ENGINE

IG

N

IT10 N SYSTEM

Ignition pulse generator rotor mounting bolt

ELECTRIC STARTER:

Starter motor terminal nut

LIGHTS/METERS/SWITCHES:

Neutral switch

(Cont'd)

ITEM

:

Q'TY

I

Nm

DIA.

(rnrn)

(kgfm,

IbfW

I

REMARKS

4

NOTE

5

Insulator clamp (Throttle body side):

7

-4

Exhaust

't

1

mm

(0.3

i

0.04

in)

insulator clamp (Cylinder head

-4

side):

12

it

2

1

mm (0.5

i:

0.04 in)

1-14

-

FRAME

ITEM

~

FRAME BODY PANELWEXHAUST SYSTEM:

Upper cowl stay mounting bolt Upper cowl stay mounting Upper cowl pan screw Lower cowl pan screw Rear cowl truss screw Pillion seat mounting nut Pillion seat hinge special screw Duct cover pan screw Windscreen mounting screw Seat rail mounting bolt, Seat rail mounting nut, Pillion step mounting socket bolt Exhaust

FUEL SYSTEM (Programmed Fuel Injection):

Fuel filler cap bolt Fuel hose banjo bolt (fuel tank side) Fuel hose sealing nut (throttle body side) Fuel pump mounting nut

pipe

joint nut

(see tightening sequence below)

8

10

SH

mm

bolt

8

4

5

2

41

7

2

1

41

8'

7' 4

1

6i

5

8

10

8

7

12 12

6

GENERAL INFORMATION

I

TORQUE

I

N-m (kgf-m,

-

26 (2.7, 20)

7 (0.7, 5.1)

1.5 (0.15,

1.5 (0.15, 1.1)

1.5 (0.15,

11

(1.1,

12 (1,2,9)

1.5 (0.15,

0.3 (0.03, 0.22) 39 (4.0, 29)

39

(4.0, 29)

39 (4.0, 29)

12 (1.2,

2 (0.2, 1.4) 22 (2.2,

22 (2.2,

12 (1.2,

Ibf-ft)

1.1)

8)

1.1)

9)

16)

9)

1

REMARKS

1

'

1

NOTE7

See page

I

2-8

FRONT

f

Bank angle sensor mounting screw Exhaust valve mounting bolt (front)

(rear) Exhaust valve cover mounting bolt Exhaust valve pulley nut Exhaust valve pulley cover mounting bolt

02

sensor (California type only)

COOLING SYSTEM:

Cooling fan nut Fan motor nut Fan motor shroud mounting bolt

ENGINE MOUNTING:

Main footpeg bracket mounting socket bolt

Main footpeg mounting bolt

Lower bracket mounting nut

Lower bracket mounting pinch bolt Engine hanger bolt (front)

Engine hanger bolt (middle)

Engine hanger nut (rear)

Rear engine hanger pinch bolt

Side stand bracket bolt Side stand pivot bolt Side stand pivot lock nut

21

4'

4~

3

11

1

i

3

I/

31

2

1

2

1

6

12

5 5

6

8

10

14

14 (1.4,

25 (2.6, 19)

3 (0.3, 2.2) 5 (0.5, 3.6)

8

39 (4.0, 29)

44

42 (4.3, 31)

26 (2.7, 20) 39 (4.0,

54 (5.5, 26 (2.7, 20)

44 (4.5,

29 (3.0, 22)

11

(1.1,

8)

(1.4,

10)

12 (1.2, 9) 12 (1.2, 12 (1.2,

10

9)

(0.8,

5.8)

(4.5, 33)

29)

40)

33)

(1.0,

7)

4

NOTE

8

See

page

7-12

NOTE

7

i

NOTE

7

1-15

GENERAL

INFORMATION

FRAME

CLUTCH/GEARSHIFT LINKAGE:

Gearshift pedal link pinch bolt

FRONT

Handlebar pinch bolt Handlebar weight mountign screw Steering stem nut Steering stem adjusting nut Steering stem lock nut Fork top bridge pinch bolt Fork bottom bridge pinch bolt Front axle bolt Front axle holder pinch bolt Front brake disc mounting bolt Fork bolt Fork center bolt

REAR WHEEL/SUSPENSION:

Rear axle nut Rear brake disc mounting bolt Driven sprocket nut Rear shock absorber upper mounting nut Rear shock absorber upper bracket mounting nut

Shock arm plate nut

Shock link nut (frame side) Swingarm pivot nut Swingarm pivot pinch bolt Drive chain slider bolt

HYDRAULIC BRAKE:

Front brake master cylinder cup mounting nut Brake lever pivot bolt Brake lever pivot nut Front brake light switch screw

Front brake caliper mounting bolt Caliper body assembly torx bolt Front caliper pad pin Rear caliper pad pin Rear caliper pad pin plug

Brake caliper bleeder Rear brake hose clamp screw Brake pedal joint nut Rear master cylinder push rod lock nut Rear master cylinder hose joint screw Rear brake caliper pin bolt Rear brake caliper Brake hose oil bolt

LIGHTS/METERS/SWITCHES:

Ignition switch mounting one-way bolt Side stand switch mountinq bolt

(Cont'd)

ITEM

WHEEL/SUSPENSION/STEERING:

bolt

Q'TY

1

2 2 1 1 1 2 4 1 4

12

2 2

1 4 6 1 1

3

1 1 2 3

1 1 1 1 4

8

4 1 1 3 1 1 1 1 1 1

5

2

1

THREAD

DIA.

(mm)

6

8

6 24 26 26

8

8 18

8

6 42

10

22

8

10 10

16

10 10

24

8

6

4

8

10 10 10

8

5

8

4 12

8

10

8

6

TORQUE

N-m (kgf-m, Ibf*ft)

10 (1.0, 7)

26 (2.7, 20)

10

(1.0, 7)

I;:

;;005\;q

-

23 (2.3, 17) 26 (2.7, 20) 78 (8.0,

58)

22 (2.2, 16) 20 (2.0, 14) 23 (2.3, 17) 34 (3.5, 25)

113 (11.5,

83) 42 (4.3, 31) 64 (6.5, 47)

(9.5,

33)

69)

33)

44 (4.5, 93 44 (4.5, 44 (4.5,

118 (12.0, 87)

26 (2.7, 20) 9 (0.9, 6.5)

6 (0.6, 4.3)

1 (0.1, 0.7)

6 (0.6, 4.3)

1 (0.1, 0.7) 30 (3.1, 22) 23 (2.3, 17) 18 (1.8, 13) 18 (1.8, 13)

3

(0.3, 2.2)

4.3)

6 (0.6, 4 (0.4, 2.9) 18 (1.8, 13)

18 (1.8, 13)

1 (0.15, 1.1)

27 (2.8,

20) 23 (2.3, 17) 34 (3.5, 25)

26 (2.7,

20)

10 (1.0, 7)

REMARKS

NOTE

8

NOTE

8

See page

NOTE

8

NOTE

7

NOTE

8

NOTE

7

NOTE

7

NOTE

7

NOTE

7

NOTE

7

NOTE

7

NOTE

8

NOTE

7

NOTE

8

NOTE

2

NOTE

8

NOTE

2

NOTE

2

NOTE

2

NOTE

11

13-30

1-16

TOOLS

GENERAL INFORMATION

NOTES:

Valve spring compressor Valve seat cutter

Assembly Steering stem driver

Fork seal driver Driver Valve spring compressor attachment Driver shaft Oil filter wrench Peak voltage adaptor

Tappet hole protector Valve guide driver, Valve guide reamer,

Drive chain tool set Needle bearing remover

Vacuum gauge set Pilot,

1.

Equivalent commercially available

2.

Alternative

3.

Newly designed tool.

4.

Not available in

ECM

test harness,

Fuel pressure gauge

Oil pressure gauge set Oil pressure gauge attachment Clutch center holder

FI

yw heel holder

Rotor puller

17

42 x 47 52 x 55 22 x 24 40 x 42 40 25

mm

28 30

24 x 27

base

Attachment, Attachment, Attachment, Attachment, inner driver, Attachment,

Pilot,

25

Pilot,

35

Bearing remover shaft Bearing remover head, Driver

Seat cutter,

Seat cutter, Flat cutter, Flat cutter, interior cutter, Interior cutter,

Cutter holder, Snap ring pliers Steering stem socket

Rod holder, Driver attachment, Driver shaft assembly Bearing remover,

Driver shaft

tool.

U.S.A.

DESCRIPTION

26P

mm

I.D.

mm

I.D.

25

mm

24.5

mm

26 30

4.5

A

(45

(32

mm

(45

"

(60"

(60

IN)

EX)

IN)

29

"

EX)

"

IN)

body

4.5

mm

4.5

mm

32 x 50

mm

in

U.S.A.

TOOL NUMBER

070MZ-0010100

07406-0040003

-

07506

0751 0

07724 07725 07733

07746 07746 07746 07746 07746 07746 07746 07746 07746 07746 07746 07749 07757

07780-0010100 07780-0010300 07780-0012100 07780-0012200 07780-001 4500 07780-0014000 07781-0010600

0791 4-SA50001

07916

07930-KA50100 07946-KM90 100

07946-KM90300 07946

07946-KM90600 07946-MB00000 07946-MJ00100

07947-KA50100

07949-3710001 07959 07964

07HAA-PJ70101

07HGJ-0020100

07HMG-MR70002

07H M 07HMH

07 HMH

07LMC-KV30100 07iMJ-001 OOOA

07MAD-PR90200

3000001

-

MA70000

-

0050002

-

0040000

-

0020001

-

0010300

-

001 0400

-

0010800

-

0010900

-

0030100

-

0030200

-

0040400

-

0040600

-

0040800

-

0050100

-

0050800

-

0010000

-

001

-

3710101

-

KM90401

-

KM30101

-

MB00200

D-M

LOO 1 0 1

-

M LOO1 01

-

MR 101 03

0000

NOTE NOTE

NOTE

-

1

-

NOTE

NOTE NOTE NOTE NOTE

NOTE NOTE NOTE

REMARKS

2: 07406-OO4000A

(U.S.A.

1

1 1

2: 07933-3950000

(U.S.A.

1

2: 07916-3710100

(U.S.A.

4 4 4 4

2: 07HAA-PJ70100

4 1:

IgnitionMate peak

voltage tester

(U.S.A.

4

1:

07HMH-MLOOIOA

(U.S.A.

1: 07HMH-MR1010C

(U.S.A.

only)

REF. SEC.

5 5

4 4 9

10 10

9, 13, 14 14

14

12 12 14 13, 14

9

13, 14

13,14

9, 13, 14 8 8

15

13

7, 14

13 13 13

13

14

13

14

8

12 3, 4

5,

17, 19

8 8 8

3

14

5

14

1-17

GENERAL INFORMATION

DESCRIPTION

Race remover Driver attachment Compression gauge attachment Fork damper holder handle Installer attachment, A Installer attachment, Remover attachment, A Remover attachment, Fork damper holder Oil seal driver

Driver attachment, 25 Installer shaft guide

Installer shaft installer shaft, 14 Remover, 14

Cam chain tensioner holder

Batterv tester

x

B

x

30 mm

16 mm

B

x

38.5 mm

TOOL NUMBER

07NMF-MT70110 07NMF-MT70120

07RMJ-MY50100

07TMB-00101 OA 07VMF-MAT0100

07VMF-MAT0200

-

BM

MAT0300

-

MAT0400

-

210-AH

00

00 00

07VMF 07VMF

07YMB-MCF0101

07YMD-MCFOI

07Y M D-MCJOI

07YMF-MCJOI 07YMF-MCJ0200

07Y M F-M CJ 0300

07YMF-MCJ0400

07ZM G-MCAA400

REMARKS

NOTE 4 NOTE 4

U.S.A. only

U.S.A. only U.S.A. only U.S.A. only

1: 07NMD-KZ301OA

NOTE

NOTE NOTE 2: 07YMF-MCJA200 NOTE 2: 07YMF-MCJA300 NOTE 2: 07YMF-MCJA400 U.S.A. only

NOTE 2: BM

(U.S.A. only)

2: 07YMF-MCJA100

(U.S.A. only) (U.S.A. only) (U.S.A. only) (U.S.A. only)

-

210 (U.S.A. only)

13

,I

8

13 13 13 13 13 13 13

14

5

3,

16

REF.

3

8

SEC.

1-18

LUBRICATION & SEAL POINTS

GENERAL INFORMATION

LOCATION

Crankcase mating surface

)iI pan mating surface

MATERIAL

Liquid sealant

1

(Three Bond

I

1207B

or

~

1

REMARKS

3ight crankcase cover mating surface

Oil

pressure switch threads

Do

not apply sealant

d

3

-

4

mm

to

(0.1 - 0.2

the thread

in)

I

1

I

1-19

GENERAL INFORMATION

ENGINE

Cylinder head semi-circular cut-out

Main journal bearing surface

Piston pin sliding surface Connecting rod bearing surface Connecting rod small end inner surface Crankshaft thrust surface Camshaft Valve stem (valve guide sliding surface) Valve lifter outer sliding surface

Clutch Clutch outer guide sliding surface

M314,

Starter reduction gear shaft outer surface Cylinder head special bolt (after removing anti

oil

additive)

Primary

(Cont'd)

LOCATION

lobes/journals and thrust surface

outeriprimary driven gear sliding surface

C5, C6 shifter gear (shift fork grooves)

sub-gear friction spring sliding surface

-

rust

MATERIAL

Sealant

Molybdenum disulfide oil (a mixture of engine oil and mo I ybdenum d isulfide grease

1/2

REMARKS

I

APPLICATION

Piston ring sliding area Oil strainer packing Clutch disc surface Starter one

Connecting rod nut threads

Flywheel bolt threads and seating surface

Main journal surface (after removing anti Clutch center lock nut threads

Oil

filter cartridge threads

Camshaft holder bolt threads and seating surface

Oil

cooler center Each gear teeth and rotating surface Each bearing rotating area Each O

-

ring

Other rotating area and sliding surface

AREA

-

way clutch sliding surface

9

mm bolt threads and seating

-

and

bolt

threads

rust

O-ring

oil

/c7f-===$

additive)

1-20

Engine oil

GENERAL INFORMATION

LOCATION

Timing hole cap threads Each oil seal lip

Upper crankcase sealing bolt threads Lower crankcase sealing bolt threads Cam chain guide Cam pulse generator rotor bolt threads Cylinder head sealing bolt threads Cylinder head cover breather joint threads Starter one

Oil

pump driven sprocket bolt threads

Shift drum bearing set plate bolt threads

Mainshaft bearing set plate bolt threads Cam sprocket bolt threads Cylinder head cover breather plate bolt threads

Shift drum center bolt threads Cam chain tensioner pivot bolt threads

Cam chain guide pivot bolt threads

Gearshift return spring pin

A

mounting bolt threads

-

way clutch outer bolt threads

j

1

MATERIAL

Multi-purpose grease

I

~

Locking agent

Coating width:

REMARKS

6.5

2

1

mm

4

-

21

GENERAL INFORMATION

FRAME

LOCATION

Front wheel dust seal lips

Rear wheel dust seal lips

-

Rear wheel hub O

Footpeg sliding area

footpeg sliding area

Pillion Rear brake pedal pivot sliding area Gearshift pedal pivot sliding area Gearshift pedal tie Clutch lever pivot bolt sliding area Throttle pipe sliding area Pillion seat pivot sliding area Pillion seat catch hook Pillion seat spring sliding area

Side stand pivot surface

Throttle pipe cable sliding surface Steering head bearing sliding surface

Steering head dust seal lips Swingarm pivot bearings

Swingarm pivot bearings Swingarm pivot dust seal lips Shock arm and link dust seal lips Shock arm and link needle bearings Shock absorber needle bearing Shock absorber dust seal lips

Side stand pivot surface

Throttle pipe cable sliding surface

Shock absorber spring adjuster cam surface Steering stem top thread

Brake pipe joint threads

Throttle cable

Clutch cable casing inner Variable air intake valve cable inner Exhaust gas control valve cable

Brake master cylinder cups Brake caliper piston seals

Brake caliper dust seals Front brake lever pivot and piston tips Rear master cylinder boot inside and push rod tips Rear brake caliper slide pin surface

Rear brake caliper slide pin threads Rear master cylinder hose joint screw threads Driven sprocket stud bolt threads

____

Handlebar grip rubber inside Fork cap O

Fork oil seal lips

~~~

-

ring

-

rod ball joint

A,

B casing inner

A,

B casing inner

MATERIAL

Multi-purpose grease

Urea based pose grease for extreme pressure (example: EP2 manufactured by KYODO YUSHI, Japan, Shell Stamina equivalent

Multi (Shell Alvania EP2 or

equivalent)

Molybdenum disulfide grease

Molybdenum paste Engine oil

Cable lubricant

DOT

Silicone grease

Locking agent

Honda Bond

Fork fluid

multi-pur-

EXCELITE

EP2) or

-

purpose grease

4

brake fluid

A

REMARKS

1-22

CABLE & HARNESS ROUTING

GENERAL INFORMATION

BANK ANGLE SENSOR

/

RIGHT

TURN

CON N ECTORS

~IGNAL

HEAD LIGHT CONNECTOR

(Hi)

HEAD LIGHT CONNECTOR (Hi)

\

1-23

GENERAL INFORMATION

CLUTCH CABLE

I

MAIN

\

HORN WIRE

1-24

GENERAL INFORMATION

FRONT

BdAKE

HOSE

1-25

GENERAL INFORMATION

'I

-

26

GENERAL INFORMATION

EXCEPT CALIFORNIA

TYPE:

STARTER

MOTOR'GROUND

CABLE

1-27