Honda VF 750 C 1994 2003, VF 750 CD 1994 2003 Service manual

1994-2003

MAGNA® VF750C/CD

©HONDA MOTOR CO., LTD. 1994

,.--Important Safety Notice

INM@ii h Indicates a strong possibility of severe personal injury or death if instructions are not followed. CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not followed.

N OTE:

Gives helpful information .

Detailed descriptions of standard workshop procedures, safety principles and service operations are not included . It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe . Please understand that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda, might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such ways . Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected .

Introduction

This service manual desc ibes the service procedures for the MAGNA VF7 50C/C D .

This Model Specific Manual includes every service proce­ dure that is of a specific nature to this particular model . Basic service procedures that are common to other Honda Motorcycle/Motor Scooter/ATVs are covered in the Com­ mon Service Manual . This Model Specific Service Manual should be used together with the Common Service Manu­ al in order to provide complete service information on all aspects of this motorcycle.

Follow the Maintenance Schedule (Section 3) recommen­ dations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the U . S . Environmental Protection Agency and the California Air Resources Board . Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period .

Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections.

Sections 4 through 1 9 describe parts of the motorcycle, grouped according to 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 describe the service procedure through system illustration . Refer to the next page for details on how to use this manual.

If you are not familiar with this motorcycle, read Tech­ nical Feature in section 20.

If you don't know the source of the trouble, go to sec­ tion 2 1 Troubleshooting .

All information, illustrations, directions and specifi­ cations included in this publication are based on the latest product information available at the time of approval 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 publication may be reproduced without written for permission. This manual is written for persons who have acquired basic knowledge of maintenance on Honda motor­ cycles, motor scooters or ATVs.

HONDA MOTOR CO., LTD.

Service Publications Office

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Contents

General Information

Frame/Body Panels/Exhaust System

Maintenance

Lubrication System

Fuel System

Cooling System

Engine Removal/Installation

Cylinder Head/Valves

Clutch System

Gearshift Linkage

Crankshaft/Piston/Transmission

Front Wheel/Suspension/Steering

Rear Wheel/Suspension

Brake System

Charging System/Alternator

Ignition System

Electric Starter/Starter Clutch

Lights/Meters/Switches

Wiring Diagram

Technical Feature

Troubleshooting

Index

Date of Issue: June, 1 994

© HONDA M OTOR CO . , LTD .

How To Use This Manual

Finding The Information You Need

•This manual is devided into sections which cover each of the major comonents of the motorcycle.

To quickly find the section you are interested in, the first page of each sections is marked with a black tab that lines up with one of the thumb index tabs before this page .

The first page of each section lists the table of contents wi­ thin the section .

Read the service information and trobleshooting related to the section before you begin working .

•An index of the entire book is provided in the last chapter to 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 illustrated by large and clear illustrations that should provide the reader with visual aid in understanding the major point for servicing .

•The system illustrations are augmented by call outs whose numbers or letters indicate the order in which the parts should be removed or installed .

•The sequence of steps represented numerically are differentiated from the ones represented alphabetically to notify the reader that they must perform these steps separately.

•The illustrations may contain symbols to indicate necessary service procedures and precautions that need to be taken .

Refer to the next page for the meaning of each symbol.

•Also in the illustration is a chart that lists information such as the order in which the parts is removal/installed, the name of the part, and some extra notes that may needed .

•Step by step instructions are provided to supplement the illustrations when datailed explanation of the procedure is necessary or illustrations alone would not suffice.

•Service procedures required before or after the procedure described on that particular page, or inspection/adjustment

procedures required following the installation of parts, are described under the title Requisite Service.

•Standard workshop procedures and knowledge covered in the Common Service Manual are abbreviated in this manual .

		Detailed description
System illustration	Symbols	of the procedure
		-
		............................

..........

I!SI

---

_............

,

,....,..

Step sequence (numerals

or alphabets)

					lllil	-
					---
					Cllwfully
									..
		,	,		-
.......					....
		....		........
					, .............................
					---··--	..,_
..........	g ,	,		.,___,		-
............. . ............ _ . _	,
	13-111				t.eflllly,..
								111UNMGDIWD
					-				u-
					....			....	........
					, ..........................				1'--'
						-		l	h .....u-

12-14

12-16

Part name	Number of parts	Extra notes or precaution
		related to the service procedure

$ymbols

The symbols used throughout this manual show specific service procedures . If supplementary information is required pertain­ ing to these symbols, it would be explained specifically in the text without the use of the symbols.

-Replace the part(s) with new one(s) before assembly.

ls.TOOl! Use special tool.

lo.P OOLI	Use optional tool . These tools are obtained as you order parts.
1 0 c( 1 .0, 7)	Torque specification. 1 0 N·m ( 1 . 0 kg-m, 7 ft-lb)

,

,

Use recommended engine oil, unless otherwise specified .

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1 : 1 ) .

-	Use multi-purpose grease (Lithium based multi-purpose grease NLGI # 2 or equivalent) .

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, N LGI #2 or

equivalent) .

Example: Molykote® BR-2 plus manufactured by Dow Corning, U . S.A.

Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI # 2 or equivalent) .

......Example: Molykote® G-n Paste manufactured by Dow Corning, U . S . A. Honda Moly 60 (U . S . A . only)

Rocol ASP manufactured by Rocol Limited, U . K .

Rocol Paste manufactured by Sumico Lubricant, Japan

Use silicone grease .

0..Apply a locking agent. Use the agent of the middle strength, unless otherwise specified .

.t•.a!	Apply sealant.

IUse brake fluid DOT 4. Use the recommended brake fluid, unless otherwise specified .

... Use Fork or Suspension Fluid .

MEMO

1 . General Information

General Safety	1-1	Lubrication & Seal Points	1-17
Model Identification	1-3	Cable & Harness Routing	1-20
Specifications	1-4	Emission Control System (U.S.A. Only)	1-27
Torque Values	1-12	Emission Control Information Labels	1-30
Tools	1-15	(U.S.A Only)

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 an en­ closed area .

•The exhaust cotains poisonous carbon monoxide gas that may cause loss of consciouness and may lead to death.

Run the engine in an open area or with an exhaust evacua­ tion system in an enclosed area.

Gasoline

Work in a well ventilated area. Keep cigarettes, flames or sparks away from the work area or where gasoline is stored.

•Gasoline is extremely flammable and is explosive un­ der certain conditions. KEEP OUT OF REACH OF CHILDREN.

Hot Components

•Engine and exhaust system parts become very hot and remain hot for some time after the engine Is run. Wear insulated gloves or walt until the engine and exhaust system have cooled before handling these parts.

Used Engine/Transmission Oil

•Used engine oH (or transmission oil in two-stroke) may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Althrough this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN.

Brake Dust

Never use an air hose or dry brush to clean brake assem­ blies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the haz­ ard caused by airborne asbestos fibers.

•Inhaled asbestos fibers have been found to cause respiratory disease and cancer.

Brake Fluid

CAUTION

•Spilling fluid on painted, plastic or rubber parts wiU damage them. Place a clean shop towel over these parts whenever the system is serviced. KEEP OUT OF REACH OF CHILDREN.

1-1

General Information

Coolant

Under some conditions, the ethylene glycol in engine coolant is combustible and its flame is not visible . If the ethylene glycol does ignite, you will not see any flame, but you can be burned .

•Avoid spilling engine coolant on the exhaust system 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 some skin irrita­ tion and is poisonous if swallowed. KEEP OUT OF REACH OF CHILDREN.

•Do not remove 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.

If it contacts your skin, wash the affected areas immedi­ ately with soap and water. If it contacts your eyes, flush them thoroughly with fresh water and get immediate medi­ cal attention . If it is swallowed, the victim must be forced to vomit, then rinse mouth and throat with fresh water be­ fore obtaining medical attention. Because of these dangers, always store coolant in a safe place, away from the reach of children .

Nitrogen Pressure

For shock absorbers with a gas-filled reservoir:

•Use only nitrogen to pressurize the shock absorber. The use of an unstable gas can cause a fire or explo­ sion resulting in serious injury.

•The shock absorber contains nitrogen under high pres­ sure. Allowing fire or heat near the shock absorber could lead to an explosion that could result in serious injury.

•Failure to release the pressure from a shock absorber before disposing of it may lead to a possible explo­ sion and serious injury if it is heated or pierced.

To prevent the possibility of an explosion, release the nitro­ gen by pressing the valve core. Then remove the valve stem from the shock absorber reservoir. Dispose of the oil in a manner acceptable to the Environmental Protection Agen­ cy (EPA) .

Before disposal of the shock absorber, release the nitrogen by pressing the valve core. Then remove the valve stem from the shock absorber.

Battery Hydrogen Gas & Electrolyte

•The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate venti­ 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.

-If electrolyte gets on your skin, flush with water.

-If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician im­ mediately.

•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.

1-2

Model Identification

'94 MAGNA VF750C shown

(2) ENGINE SERIAL NUMBER

(2)The engine serial number is stamped on the right side of the upper crankcsase .

(4) CARBURETOR IDENTIFICATION NUMBER

(4)The carburetor indentification number is stamped on the carburetor body intake side .

General Information

(1) FRAME SERIAL NUMBER

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

(3) VEHICLE I DENTIFICATION NUMBER

(3)The vehicle Identification Number (VIN) is located on the Safety Certification Label on the left side of the steering head .

(5) COLOR LABEL

( 5)The color label is attached as shown . When ordering color-coded parts, always specify the designated color code.

1-3

General Information

Specifications

r- General		Specifications
Item	'94-'00
Dlmel..... Overall length		2,332 mm (91.8 in)
Overall width	After '00	2,338 mm (92.0 in)
	(VF750C)	1,136 mm (44.7 in)
OveraA height		854 mm (33.6 in)
	(VF750CD)	1,1go mm (46.9 in)
Wheelbase		1,652 mm in)
Seat height		710 mm (28(65 in)
Footpeg height		290 mm (11.4 in)
Group clearance		155 mm (6.1 in)
Dry weight

(VF750C: 49 states, Canadian type)	229 kg (5051bs)
(VF750C: California type)	231 kg (509 lbs)
(VF750CD: 49 states, Canadian type)	230 kg (507 lbs)
(VF750CD: California type)	232 kg (511 lbs)
Curb weight
(VF750C: 49 states, Canadian type)	247 kg (545 lbs)
(VF750CD: 49 states,type)Canadian type)	248 kg	(547 lbs)
(VF750C: California	249	(549 lbs)
(VF750CD: Californiatype)	250 kgkg (551 lbs)
Maximum weight capacity	180 kg (397 lbs)

Frame

Frame type

Double cradle

Front suspension

Telescopic fork

Front wheel travel

150 mm (5.91 in)

Rear suspension

Swingarm

Rear wheel travel

100 mm (3.94 in)

Rear damper

Double effect type

Front tire size

120/8017M/C 61V

Rear tire size

150/80 - 15M/C 70V

Tire brand (Front/Rear)

K555F/K555 (Dunlop)

Front brake

Hydraulic brake

shoe

Rear brake

Internal expanding

Caster angle

32'

Trail length

137

(5.39

13.91iter

3.

7 USin) gal, 3.11mp gal)

Fuel tank capacity

mm

(

Fuel tank reserve capacity

3.3 liter (0.87 US gal, 0.37 Imp gal)

Engine

Bore

and

stroke

70.0 x 48.6 mm (2.76 x 1.91 in)

748.1

cc (45.65 cu-in)

Displacement

Compression ratio

10.8:1

Valve train

Silent multi-link chain drive and DOHC

Intake valve opens (at 1 mm lift)

10· BTDC

Intake valve

(at 1 mm lift)

25"ABDC

Exhaust valvecloses

(at 1 mm lift)

35' BBDC

Exhaust valve opens

(at 1

mm

lift)

-5.ATDC

Lubrication system

Forced pressure and wet sump

closes

Oil pump type

Trochoid

Cooling system

Liquid

Air filtration

Paper filtercooled

Crankshaft type

Unit-type, 4 main journal

Engine dry weight

80.3 kg (1n lbs)

Firing order

1 -go· -4 - 270. -3- go• -2 - 270. -1

Cylinder arrangement

4 cylinder oo· v

LEFT

-

Cylinder number

G

8

FRONT

8

-

8

1-4

General Information

	r- General (Cont'dl		Item		Specifications
			Carburetor type	CV (Constant Velocity) type,with flat valve
	Carburetor
			Venturi diameter	33 mm (1.30 in)
	Drive Train		Clutch system	Multi-plate,wet
			Clutch operation system	Cable operating
			Transmission	5 speeds
			Primary reduction	1.939	(64/33)
			Secondary reduction	--
			Third reduction	--
			Final reduction	2.500	(40/16)
			Gear ratio 1st	2.846	(37/13)
			Gear ratio 2nd	1.882	(32/17)
			Gear ratio 3rd	1 .450	(29/20)
			Gear ratio 4th	1.227	(27/22)
			Gear ratio 5th	1.035	(29/28)
			Gear ratio 6th	--
			Gear ratio reverse	--
			Gearshift pattern	Left foot operated return system 1-N-2-3-4-5
	Electrical		Ignition system	Full transistor ignition
			Starting system	Starter motor
			Charging system	Triple phase output alternator
			Regulator/rectifier type	SCR shorted/triple phase,full-wave rectification
			Lighting system	Battery
			AC regulator type	--

1-5

1 0W - 40

General Information

r-

Lubrication

		Unit: mm (in)
--
Item	Standard	Service Limit

Engine oil capacity at draining

at disassembly

at oil filter change Recommended engine oil

OIL VISCOSITIES

I I

I I

o zo 40 eo eo tOO •F

-20 -oo o 10 20 :so 40 'C

3.0 lit (3. 2	US qt,2. 6	Imp qt)
3.8 lit (4.0	US qt,3,3	Imp qt)
3. 1 lit (3. 3	US qt,2. 7	Imp qt)

Use Honda GN4 4-stroke Oil or equivalent API Service Classification: SF or SG Viscosity: SAE

Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range.

--

--

--

Oil pressure at oil pressure switch	490 - 588 kPa ( 5 - 6 kg/cm2,7 1 . 1 - 85 . 3
Oil pump rotor tip clearance G)	psi) at 6,000 rpm (80°C/1 76°F)
	0. 1 0	(0. 004)		0. 1 5	(0.006)
body clearance ®	0. 1 5 - 0. 22		(0. 006- 0.009)	0. 35	(0. 0 1 4)
end clearance @	0.02 - 0. 09		(0.001 - 0.004)	0. 1 0	(0. 005)

--,

FueiSystem

--

	Carburetor identification number (49 states type)		VP31A
		(California type)	VP30A
		(Canadian type)	VP32D
	Main jet		# 1 02
	Slow jet		# 40
	Pilot screw initial opening		see page 5- 1 6
	Pilot screw high altitude adjustment		see page 5- 1 7
	Float level		1 3. 7 (0. 54)
	Carburetor vacuum difference		Within 20 mmHg (0. 8 inHg)
	Base carburetor (For carburetor synchronization)		No. 1		carburetor
	Idle speed	(49 states type)	1 ,000		± 1 00 rpm
		(California type)	1 , 1 00		± 1 00 rpm
	Throttle grip free play	(Canadian type)	1 ,000 ± 1 00 rpm
			2 - 6 ( 1 /8 - 1 /4)
	Pulse secondary air (PAIR) injection system		PAIR check valves are buit in to the PAIR
		(California type)	control valve
	Pulse secondary air inje'ction control valve vacuum
	pressure
	--, Cooling System --
	Cooling capacity (Radiator and engine)		2.4 i	(0. 6 US gal,0. 5 Imp gal)
	(Reserve tank)		0.4 i	(0. 1 US gal,0.09 Imp gal)
	Radiator cap relief pressure		1 07.9 kPa ( 1 . 1 kg/cm2, 1 5. 64 psi)
	Thermostat begins to open		80 - 84°C ( 1 76 - 1 83°F)
	Thermostat fully open		95°C ( 203°Fl
	Thermostat valve lift		8.0 (0. 3 1 5) min.

1-6

General Information

Unit: mm (in)

Cylinder Head -- Item Standard Service Limit

Cylinder compression	1,275 kPa (184.9 psi,13.0 kg/cm2)/
	500 rpm
Cylinder compression synchronization difference
Valve clearance IN	0.16 ± 0.02 (0.006 ± 0.001)
EX	0.25 ± 0.02 (0.010 ± 0.001)	0.10 (0.004)
Cylinder head warpage	35.980-36.140 (1.4165 1.4228)
Cam lobe height CD IN		35.95 (1.4153)
IN	(California type)
EX	35.670-35.830 (1.4043-1.4106)	35.64 (1.4031)
Camshaft runout ® EX	(California type)	0.05 (0.002)
Camshaft oil clearance	0.030-0.072 (0.0012-0.0028)	0.10 (0.004)

HOLO

Camshaft journal O . D .		24.949-24.970 (0.9822-0.9831)	24.94 (0.982)
Camshaft holder I.D.		25.000-25.021 (0.9843-0.9851)	25.05 (0.986)
Valve stem O . D .	IN	4.475-4.490 (0.1762-0.1767)	4.46 (0.1 75)
	EX	4.465-4.480 (0.4758-0.1764)	4.45 (0.175)
Valve guide I.D.	IN	4.500-4.512 (0.1772-0.1776)	4.56 (0.179)
	EX	4.500-4.512 (0.1772-0.1776)	4.56 (0.179)
Stem-to-guide clearance IN		0.010-0.037 (0.0004-0.0015)
	EX	0.020-0.047 (0.0008-0.0019)
Valve guide projection above cylinder head IN		15.30-15.50 (0.602-0.610)
	EX	15.30-15.50 (0.602-0.610)
	Before guide installation:
	1. Chill the valve guides in the
	freezer section of the refrigerator
	for about an hour.
	2. Heat the cylinder head to
	212-300°F (100-150°C)
Valve seat width		1.0 (0.04)	1.5 (0.06)
Valve spring free length		37.86 (1.49)	36.1 (1.42)
Valve lifter O . D .		25.978-25.993 (1.0225-1.0233)	25.96 (1.022)
Valve lifter bore I.D.		26.010-26.026 (1.0240-1.0246)	26.04 (1.025)

1 -7

Crankshaft runout G)

General Information

	..-	Clutch System					Unit: mm (in)
				Standard		Service Limit
		Item
	Clutch lever free play			10-20 (0.4-0.8)		--
	Clutch outer guide I . D .			24.995-25.012 (0.9841-0.9847)		25.08 (0.987)
	Clutch spring free length			44.4 (1.75)		41.2	(1.62)
	Clutch disc thickness A			2.92-3.08 (0.115-0.121)		2.5 (0.10)
		B (Judder spring side)		2.92-3.08 (0.115-0.121)		2.5 (0.10)
	Clutch palte warpage			--		--
..-		Cylinder/Piston
	Cylinder I . D .		70.000-70.015 (2.755-2.756)		70.10 (2.759)
	Cylinder out of round		--		0.10		(0.004)
	Cylinder taper		--		0.10		(0.004)
	Cylinder warpage		--		0.10		(0.004)
	Piston mark direction			With "IN" mark facing to the intake side	--
	Piston O . D . (D)		69.970-69.990 (2.755-2.756)		69.85 (2.750)
	Piston O.D. measurement point (H)		10 (0.4)		--
	Piston pin hole O . D . (d)		17.002-17.008 (0.6694-0.6695)		17.02 (0.670)
		d

!""-"'

	[OJ(1'--'l (0]<				H
W'		D			0.010-0.035 (0.0004-0.0014)
Cylinder-to-piston clearance
Piston pin O . D .					16.994-17.000 (0.6691-0.6693)
Piston-to-piston p i n clearance					0.002-0.014 (0.0001-0.0005)
Connecting rod-to-piston clearance					0.016-0.040 (0.0006-0.0016)
Top ring-to-ring groove clearance					0.015-0.050 (0.0006-0.0019)
Second ring-to-ring groove clearance					0.015-0.045 (0.0006-0.0018)
Top ring end gap					0.20-0.35 (0.008-0.014)
Second ring end gap					0.35-0.50 (0.014-0.020)
Oil ring (side rail) end gap					0.20-0.80 (0.008-0.031)
Top ring mark					Install with the marked side up
Second ring mark					Install with the marked side up

--

16.98 (0.669)
--
--
0.10	(0.04)
0.10	(0.004)
0.5 (0.02)
0.7 (0.03)
1.00	(0.039)
--
--

Crankshaft

--

Connecting	rod	small end I . D.	17.016-17.043 (0.6699-0.6706)	17.04 (0.671)
Connecting	rod	big end side clerance	0.10-0.30 (0.004-0.012)	0.40 (0.016)

radial clearance

0.05 (0.002)

Crankpin oil clearance	0.030-0.052 (0.0012-0.0020)		0.08 (0.003)
Connecting rod bearing selection	See page	11-9
Main journal oil clearance	0.019-0.037 (0.0007-0.0015)		0.05 (0.019)
Main journal bearing selection	See page	11-8

1-8

General Information

Transmission

Unit: mm (in) --

Item	Standard		Service Limit
Transmission gear I . D . M 5	28.000 - 28 . 021 (1.1024 -1.1032)		28 . 04 (1.104)
C 2	31.000 - 31.016 (1. 2205 -1.2211)		31. 04 (1. 222)
C 3	31.000 - 31. 016 (1. 2205 -1.2211)		31. 04 (1. 222)
C4	31.000 - 31.016 (1. 2205 - 1 . 2211)		31. 04 (1. 222)
Transmission gear bushing O . D . M 5	27 . 959 - 27 . 980	(1. 1007 -1.1016)	2 7 . 94 (1. 010)
C 2	30. 970 - 30.995	(1. 2193 - 1 . 2203)	30. 95	(1. 219)
C3	30. 950 - 30 . 975	(1. 2185 -1. 2195)	30. 93	(1. 218)
C4	30. 950 - 30 . 975	(1. 2185 - 1 . 2195)	30.93	(1. 218)
Transmission gear bushing I . D . M 5	24. 985 - 25 . 006 (0.9834 - 0 . 9845)		2 7 . 94 (1. 010)
C 2	28.000 - 28. 021 (1.1024 -1.1032)		28 . 04 (1.104)
C 3	27 . 995 - 28.016 (1.1022 -1.1029)		28 . 04 (1.104)
Gear-to-bushing clearance a t M 5 gear	0.020 - 0 . 062 (0.0008 - 0 . 0024)
at C2 gear	0 . 005 - 0 . 046 (0.0002 - 0 . 018)
at C3 gear	0.02 5 - 0. 066 (0.0001 - 0 . 0026)
at C4 gear	0.025 - 0 . 066 (0.0001 - 0 . 0026)
Mainshaft O . D . at M5 gear bushing	24. 95924. 980 (0.9826 - 0 . 9835)		24. 95	(0.982)

Countershaft O . D . at C2 gear bushing

27 . 967 - 2 7 . 980 (1.1011-1.1016)

2 7 . 96 (1.10 1 )

Gear-to-shaft clearance

Gear bushing-to-shaft clearance at M5 gear at C2 gear at C3 gear at C4 gear

Shift fork claw thickness L c R

Shift fork I . D . L c R

Shift fork shaft O . D .

0 . 005 - 0 . 047	(0. 0002 - 0 . 0019)
0.020 - 0 .054	(0.0008 - 0 . 0021)
0.015 -0.049	(0. 0006 -0.00 1 9)
0.015 - 0. 049	(0. 0006 - 0 . 0019)

6.43 - 6 . 50	(0.253 - 0 . 256)
6.43-6 . 50	(0. 253-0. 256)
6.43- 6.50	(0. 253 - 0 . 2 56)

14.016 - 14. 034	(0. 5518 - 0 . 5525)
14.016 - 14. 034	(0. 5518 - 0 . 5525)
14.016 - 14. 034	(0. 5518 - 0 . 5525)
13. 973 - 13. 984	(0. 550 1 -0. 5506)

6.40 (0. 252)

6.40 (0. 252)

6 . 40 (0. 252)

14. 043 (0. 5529)

14. 043 (0. 5 529)

14. 043 (0. 5529)

13. 965 (0. 5498)

1-9

General Information

		r-	Wheel/Tires					Unit: mm (in)
				Item		Standard		Service Limit
		Minimum tire tread depth (FR)				--		1.5 (0.06)
		Cold tire pressure		(RR)		--		2.0 (0.08)
				Up to 90 kg (200 lb) load (FR)		250 kPa (2.50 kg/cm2, 36 psi)		--
				Up to 90 kg (200 lb) load (RR)		250 kPa (2.50 kg/cm2, 36 psi)		--
				Up to maximum weight capacity (FR)		250 kPa (2.50 kg/cm2, 36 psi)
								--
				Up to maximum weight capacity (RR)		290 kPa (2.90 kg/cm2, 42 psi)		--
		Front and rear axle runout				--		0.2 (0.01)
		Front and rear wheel rim runout (Radial)				--		2.0 (0.08)
				(Axial)		--		2.0 (0.08)
		Wheel balance weight (Front)				--		60 g (2.1 oz)
		Drive chain slack		(Rear)		--		60 g (2.1 oz)
						20-30 (3/4-1·3/16)		--
		Drive chain size/link (DID)				DID 50V4/118		--
				IRK)		RK 50 MFOZ1/118
								--
	r-		Front Suspension	--
		Fork spring free length			410.7 (16.17)		402.5 (15.85)
		Fork spring direction				Tapered coil facing down	0.2 (0.01)
		Fork tube runout
		Recommended fork oil				Fork fluid
		Fork oil level			122 (4.80)
		Fork oil capacity				521cc (17.62 US oz, 18.29 Imp oz)
		Steering bearing preload				0.1-0.15 kg-m

r-

Rear Suspension

--

Shock absorber spring free length	241.8 (9.52)	237.0 (9.33)
Shock absorber spring adjuster standard position	2nd groove
Shock absorber spring direction	Small coil end facing down

- Brakes

Front

Rear

--
brake fluid		DOT 4
brake pad wear indicator G)			To the groove
brake disc	thickness	6.0 (0.24)	5.0 (0.20)
	~
brake disc runout			0.25 (0.01)
master cylinder J . D .		11.0-11.043 (0.4331-0.4348)	11.055	(0.4352)
master piston O . D .		10.957-10.984 (0.4314-0.4324)	10.945	(0.4309)
caliper cylinder J . D .		25.400-25.450 (1.000-1.0020)	25.461	(1.002)
caliper piston O . D .		25.335-25.368 (0.9974-0.9987)	25.33 (0.997)
brake pedal free play		20-30 (0.8-1.2)
brake drum J.D.		180-180.3 (7.086-7.098)	181 (7.12)
brake lining thickness		5.0 (0.2)	2.0 (0.08)

1- 10

		General Information
r- Battery/charging System		Unit: mm (in)
Item	Standard	Service Limit

Alternator/charging coil resistance (at 20°C/68°F)	0.1-1.0 0
Regulator/rectifier regulated voltage/amperage	14-15.5 V/below 0.5 A/3,000 rpm
Battery capacity	12 V-10 Ah
Battery charging rate (Normal)	1.2 A (5-10h)
(Quick)	5 A (1h)
Battery voltage (fully charged 20°C/68°F)	Over 13.1 V
(needs charging 20°C/68°F)	Below 12.5 V

--

--

--

--

--

--

--

r-

Ignition System

--

	Spark plug
	(Standard NGK)			CR8EH9
	(Standard NIPPONDENSO)			U24FER9
	(For cold climate/below 5°C/41°F NGK)
	(For cold climate/below 5°C/41°F NIPPONDENSO)
	(For extended high speed riding NGK)			CR9EH9
	(For extended high speed riding NIPPONDENSO)			U27FER9
	Spark plug gap			0.8-0.9 (0.03-0.04)
	Ignition timing "F" mark			12° BTDC at idle
	Advance start			2,000 rpm
	stop
	Full advance
	Ignition coil resistance (Primary: at 20°C/68°F)			2-4 0
		(Secondary with plug cap)		23-27 kO
		(Secondary without plug wire)		13-17 k0
	Pulse generator resistance (At 20°C/68°F)			450-550 0
	Starter System	--
	Starter motor brush length			12.0-13.0 (0.47-0.51)	6.5 (0.26)
	Starter clutch driven gear O.D.			47.175-47.200 (1.8573-1.8583)	47.16 (1.857)
- Lights/Meters/Switches --
	Main fuse			30 A
	Fuse			10 A x 3,15 A X 1
	Headlight (high/low beam)			12 v 60/55 w
	Tail/brake light			12 V 32/3 cp
	Position light bulb			12 V 3 cp x 2
	Front turn signal lights			12 V 32/3 cp x 2
	Rear turn signal lights			12 V 32 cp x 2
	Instrument lights			12 V 1.7 W X 1,12 V 1.4 W X 2
	Oil pressure warning indicator			12 v 3 w
	Side stand indicator			12 v 3 w
	Coolant temperature indicator			12 v 3 w
	High beam indicator			12 v 3 w
	Turn signal indicator			12 v 3 w
	Neutral indicator			12 v 3 w
	Coolant temperature sensor resistance		85°C (185°F)	39-49 0
			120°C (248°F)	14-18 0
	Fan motor switch	Starts to close (ON)		97-103°C (207-217°F)
		Stops to open (OFF)		92-98°C (198-208°F)

1- 1 1

General Information

Torque Values

	r-	Standard		Torque
		Fasteners Type
			N·m (kg-m, ft-lb)
	5	mm hex bolt and nut	5	(0.5,3.5)
	6	mm hex bolt and nut	10	(1.0,7)
	8 mm hex bolt and nut		22	(2.2,16)
	10 mm hex bolt and nut		35	(3.5,25)
	12 mm hex bolt and nut		55	(5.5,40)

	Fasteners Type	Torque
		N·m (kg-m, ft-lb)

5	mm screw	4	(0.4,3)
6	mm screw	9	(0.9,7)
6	mm flange bolt (8 mm head)	9	(0.9,7)
6 mm flange bolt (10 mm head) and nut		12	(1.2,9)
8	mm flange bolt and nut	27	(2.7,20)
10 mm flange bolt and nut		40	(4.0,29)

Torque specifications listed below are for important fasteners. Others should be tightened to standard torque values listed above.

Notes:	1. Apply		sealant to the threads.
	2.	Apply a locking agent to the threads.
	3. Apply molybdenum disulfide oil to the threads and flange surface.
	4. Left hand threads .
	5.	Stake .
	6.	Apply oil to the threads and flange surface.
	7.	Apply clean engine oil to the 0-ring .
	8 . Torque wrench scale reading using a special tool.
	9. Apply grease to the threads and flange surface.
	10.	UBS bolt.

11.U-nut.

12.ALOC bolt; Replace with a new one.

	r- Engine		Thread
	Item	O'ty
			dia. (mml
	Maintenance:
	Timing hole cap	1	45
	Lubrication:
	Oil pressure switch	1	PT 1/8
	Oil filter	1	20
	Oil filter stud bolt	1	20
	Oil drain bolt	1	12
	Oil pump bolt	3	6
	Oil pump driven sprocket bolt	1	6
	Oil pipe nut (After '94)	1	6
	Fuel Systems:
	Connecting tube band screw	4	5
	Cooling Systems:
	Water pump cover	2	6
	Water pump mounting bolt	2	6
	Cylinder Head:
	Spark plug	4	10
	Head cover protector	8	6
	Cylinder head cover bolt	8	6
	Breather case bolt	6	6
	Cylinder head protector bolt	12	6
	Cylinder head sealing bolt	4	18
	Cylinder head bolt (9 mm)	16	9
	Cylinder head bolt (6 mm)	4	6
	Camshaft holder bolt	32	6
	Cam chain tensioner mounting bolt	4	6
	Boost joint bolt	-	5

		Torque		Remarks
	N•m (kg-m, ft-lbl
	18	(1.8,13)		Note 9
	12	(1.2,9)		Note 1
	10	(1.0,7)		Note 6
	18	(1.8,13)		Note 2
	34	(3.4,25)
	13	(1.3,9)
	18	(1.8,13)		Note 2
	12	(1.2,9)		Note 11
	1	(0.1,0.7)
	13	(1.3,9)
	13	(1.3,9)
	12	(1.2,9)
	10	(1.0,7)
	10	(1.0,	7)
	10	(1.0,7)
	12	(1.2,9)
	44	(4.4,32)		Note 2
	44	(4.4,32)		Note 6
	12	(1.2,9)
	12	(1.2,9)		Note 6
	12	(1.2,9)
	4	(0.4,2.9)

1 - 12

General Information

r- Engine
	Item	Q'ty	Thread	Torque	Remarks
			dia. (mml	N·m (kg-m, ft-lb)
	Clutch/Gearshift Linkage
	Right crankcase cover bolt	13	6	12 (1.2,9)
	Clutch cable holder bolt	1	10	23 (2.3,171
	Clutch spring bolt	5	6	12 (1.2,9)
	Clutch center lock nut ('94)	1	22	90 (9.0,65)	Note	5, 6
	(After '94)	1	22	110 (11.0,80)	Note	5, 6
	Gearshift link joint bolt	1	6	9 (0.9,6.5)
	Change pedal pivot bolt	1	8	27 (2.7,20)
	Drive sprocket cover bolt	3	6	10 (1.0,7)
	Drive sprocket cover rubber bolt	2	6	12 (1.2,9)
	Drive sprocket bolt	1	10	51 (5.1,37)
	Shift drum center bolt	1	8	23 (2.3,17)	Note 2
	Shift return spring pin	1	8	23 (2.3,17)
	Crankcase/Crankshaft:
	Upper crankcase bolt (10 mm)	2	10	39 (3.9,28)
	Upper crankcase bolt (6 mm)	7	6	12 (1.2,9)
	lower crankcase bolt (9 mm)	8	9	31 (3.1,22)	Note 6
	lower crankcase bolt (8 m)	1	8	23 (2.3,17)
	lower crankcase bolt (6 mm)	8	6	12 (1.2,9)
	Cam chain tensioner slipper bolt	2	6	12 (1.2,9)	Note 2
	Cam chain slipper bolt	2	6	12 (1.2,9)	Note 2
	Connecting rod bearing cap nut	8	8	33 (3.3,24)	Note 6
	Sealing bolt	1	8	18 (1.8,13)	Note 2
	Alternator:
	left crankcase cover bolt	6	6	12 (1.2,9)
	Flywheel bolt	1	10	83 (8.3,61)	Note 6
	Stator mounting bolt	3	6	12 (1.2,9)
	Ignition System:
	Pulse generator mounting bolt	3	6	10 (1.0,7)
	Starter Clutch:	1
	Starter motor flange nut		6	10 (1.0,7)
	Starter motor case bolt	2	5	5 (0.5,3.6)
	Starter clutch bolt	1	12	90 (9.0,65)	Note 6
	Starter clutch outer cover bolt	3	8	40 (4.0,29)	Note 2
	Lights/Meters/Switches:
	Neutral switch	1	10	12 (1.2,9)
.---Frame		Q'ty	Thread	Torque	Remarks
	Item
			dia. (mml	N•m (kg-m. ft-lbl
	Engine mounting:
	Front cylinder head mounting bolt	2	10	54 (5.4,39)
	Front engine mounting bracket bolt	4	8	39 (3.9,28)
	Front engine mounting bolt	2	10	44 (4.4,32)
	Rear engine mounting bracket bolt	2	8	39 (3.9,28)
	Rear engine mounting bolt	1	12	64 (6.4,46)	Note 9
	Rear cylinder head mount bolt	2	10	44 (4.4,32)
	Rear cylinder head mount bracket bolt	4	8	39 (3.8,28)

1-13

General Information

r- Frame		O'ty		Thread		Torque
Item
				dia. (mm)	N•m (kg-m. ft-lb)
Front Suspension:
Handlebar upper holder bolt		4		6	23 (2.3,17)		=:]
lock nut		1		26	12 (1.2,9)
Front fender bolt		4		6
Steering stem nut		1		24	105	(10.5,76)
Steering head bearing adjusting nut		1		26	30	(3.0,22)
Fork pinch bolt (upper)		2		8	27	(2.7,20)
(lower)		2		10	39	(3.9,28)
Fork cap		2		37	23	(2.3,17)
Fork socket bolt		2		8	20	(2.0,14)
Fork drain bolt		2		6	8	(0.8,5.8)	.=j
Rear Suspension:
Frame pivot adjusting bolt		1		20	15	(1.5,11)
Frame lock nut		1		20	64	(6.4,46)
Frame lock bolt		1		10	39	(3.9,28)
Swingarm pivot nut		1		14	89	(8.9,65)
Chain slider screw		2		5	6	(0.6,4.3)
Chain tensioner		2		8	22	(2.2,16)
Shock absorber mounting bolt (upper)		2		8	27	(2.7,20)
(lower)		2		10	37	(3.7,27)
Wheels:
Speedometer cable screw		1		5	4	(0.4,2.9)
Rear axle nut		1		18	93	(9.3,63)
Front axle bolt		1		14	59	(5.9,43)
Axle pinch bolt		4		8	22	(2.2,16)
Brake disc bolt		6		8	42	(4.2,30)
Driven sprocket nut		5		12	108	(10.8,79)
Brake System:
Brake hose bolt		2		10	35	(3.5,25)
Caliper bracket bolt		2		8	31	(3.1,22)
Front brake hose clamp nut		2		6	12	(1.2,9)
Front master cylinder holder bolt		2		6	12	(1.2,9)
Front master cylinder reservoir cover screw		2		4	1.5	(0.15, 1.1)
Front brake light switch screw		1		4	1.2	(0.12,,0.9)
Front brake lever pivot bolt		1		6	1	(0.1,0.7)
nut		1		6	6	(0.6,4.3)
Pad pin plug		1		10	2.5	(0.25,1.8)
Pad pin		1		10	18	(1.8,13)
Brake caliper bleeder bolt		1		8	5.5	(0.55,4)
Brake caliper bracket pin bolt		1		8	13	(1.3,9)
Brake caliper pin bolt		1		8	23	(2.3,17)
Rear brake pedal pivot bolt		1		10	39	(3.9,28)
Rear brake pedal linkage joint pinch bolt		1		8	27	(2.7,20)
Rear brake arm pinch bolt		1		8	29	(2.9,21)
Rear brake stopper arm nut		2		8	22	(2.2. 16)
Frame/Exhaust Systems:
Exhaust pipe joint nut		8		8	12	(1.2,9)
Exhaust pipe band bolt		4		8	21	(2.1,15)
Exhaust pipe protector bolt		6		6	12	(1.2,9)
Muffler mounting bolt		2		8	27	(2.7,20)
Lights/Meters/Switches:
Side stand pivot bolt		1		10	10	(1.0,7)
nut		1		10	30	(3.0,22)
Side stand switch		1		6	10	(1.0,7)
Others:
Footpeg bracket bolt		4		8	27 (2.7 20)
Fuel valve		1		22	23	(2.3,17)

Remarks

page 12-12

Note 2

page 13-10

Note 11

Note 11

Note 12

Note 11

Note 12

Note 11

Note 2

Note 2

Note 12

1- 14

			General Information
Tools
Description		Tool Nunber	Applicability
Maintenance:
Oil filter wrench		07HAA - PJ701 00
Drive chain cutter		07H MH - M R 1 0 1 02
		or 07H MH - M R 1 0 1 0B	U . S.A. only
Link plate holder		07N MH - MW00 1 1 0
Lubrication:		or 07PMH - MZ20 1 1 0
Oil pressure gauge		07 506 - 3000000
Oil pressure gauge attachment		07 5 1 0 - 4220 1 00
Fuel System:
Float level gauge		0740 1 - 00 1 0000
Pilot screw wrench	(Canadian type)	07908 - 422020 1
	(49 states, California type)	07MMA - MV90 1 0A
Cylinder Head/Cylinder/Piston:
Valve spring compressor		07757 - 00 1 0000
Valve spring compressor attachment		07959 - KM30 1 0 1
Tappet hole protector		07HMG - MR70002	Not available in U . S.A.
Valve guide drivier		07HM D - M L00 1 0 1
Valve guide reamer, 4. 5 mm		07HMH - ML00 1 0 1
Valve seat cutter
seat cutter, 24. 5 mm (45° EX)		07780 - 00 1 0 1 00
29 mm (45 ° IN)		07780 - 00 1 0300
flat cutter, 25 mm (32° EX)		07780 - 00 1 2000
30 mm (32° IN)		07780 - 00 1 2200
interior cutter, 26 mm (60° EX)		07780 - 00 1 4500
30 mm (60° IN)		07780 - 00 1 4000
cutter holder, 4. 5 mm		0778 1 - 00 1 0600
Compression gauge attachment		07JMJ - KY20 1 00
Tensioner stopper		07NMG - MY90 1 00	Not available in U . S.A.
Clutch/Gearshift Linkage:
Lock nut wrench, 26 x 30 mm		077 1 6 - 0020203	'94 only
Extension bar		077 1 6 - 0020500	'94 only
Clutch center holder		07724 - 005000 1	Equivalent commercially
Crankshaft/Transmission:			available in U . S . A .
Universal bearing puller		0763 1 - 00 1 0000
Inner driver C		07746 - 0030 1 00
Attachment, I . D . 25 mm		07746 - 0030200
Front Wheel/Suspension/Steering:
Bearing remover shaft		07746 - 0050 1 00
Bearing remover head ,	20 mm	07746 - 0050600
Attachment, 42 x 47 mm		07746 - 00 1 0300
Pilot, 20 mm		07746 - 0040500
Fork seal driver		07947 - KA501 00
Fork seal driver attachment		07947 - KF00 1 00
Steering stem socket wrench		079 1 6 - 37 1 0 1 0 1
Ball race remover		07953 - MJ 1 0000
- attachment		07953 - MJ 1 0 1 00
		or 07953 - MJ 1 000A	U . S.A. only
- driver handle		07953 - MJ 1 0200
		or M9360 - 27 7 - 9 1 774	U . S.A. only
Ball race remover		07946 - 3 7 1 0500
Attachment, 52 x 55 mm		07746 - 00 1 0400
Steering stem driver		07946 - M BOOOOO
Driver		07749 - 00 1 0000

1- 15

General Information

Description	Tool Number	Applicability
Rear Wheel/Suspension:
Bearing remover shaft	07746-0050100
Bearing remover head, 20 mm	07746-0050600
Attachment, 42 x 47 mm	07746-0010300
Pilot, 20 mm	07746-0040500
Attachment, 52 x 55 mm	07746-0010400
Attachment, 62 x 68 mm	07746-0010500
Pilot, 25 mm	07746-0040600
Shock absorber compressor	07959-3290001
Driver shaft	07946-MJ00100
	or 07949-3710001	U.S.A. only
Attachment, 28 x 30 mm	07946-1870100
Pilot, 22 mm	07746-0041000
Attachment, 32 x 35 mm	07746-0010100
Pilot, 15 mm	07746-0040300
Needle bearing remover attachment	07GMD-KT70200
Bearing remover	or M967X-038-XXXXX	U.S.A. only
Attachment, 30 mm	07746-0030300	U.S.A. only
Driver	07749-0010000
Brake:
Snap ring pliers	07914-3230001
Charging System/Alternator:
Flywheel holder	07725-0040000
Rotor puller	07733-0020001
Electric Starter/Starter Clutch:
Gear holder	07724-0010100
Electrical Equipment:
Digital multimeter (KOWAl	07411-0020000	Equivalent commercially
		available in U.S.A.
Analog tester	07308-0020001 (SANWAl	Not available in U.S.A.
	or TH-5H (KOWAl

1- 16

General Information

Lubrication & Seal Points

Engine

--
Location	Material	Remarks

Crankcase mating surface	Liquid sealant	•	Wipe off the excess sealant
		•	Do not apply the sealant to
			near the bearing

0

L....

- ..J

Right crankcase cover mating surface
20-30 mm	'l
(0.8-1.2 i1) (""
	.)T
----·--..
T
Left crankcase cover mating surface
20-30 mm	0
(0.8-1.2 in)	0
	,\
0	--===::w
Cylinder head semi-circular cut-out
Crankshaft main bearing thrust surface		Molybdenum disulfide oil
Connecting rod big end bearing		(A mixture of 1/2 engine oil
small end		and 1/2 molybdenum disulfide
Valve stem (valve guide sliding surface)		grease)
VaJve lifter outer sliding surface
Camshaft lobes/journals
M3/4,C5 and shifter gear (shift fork grooves)
Shift fork shaft sliding area

	Shift drum
	Primary drive gear sliding area
	Each gear
	Cylinder head cover gasket mating surface	Honda Bond A
	(cover side)

1-17

General Information

- Engme.
Location	Material	Remarks

Right crankcase cover rubber plate bolt threads	Locking agent
Drive chain guard bolt threads
Crankcase sealing bolt threads
Oil pump driven sprocket bolt threads
Cam chain tensioner slipper bolt threads
Cam chain slipper bolt threads
Mainshaft bearing set plate bolt threads
Shift drum bearing set plate bolt threads
Shift drum center bolt
Starter clutch outer cover bolt
Oil filter stud bolt threads
Cylinder head sealing bolt threads

-

-

-

-

-

-

-

-

-

Clean and apply to the threads Apply area: 5.5-7.5 mm

Oil pressure switch threads	Liquid sealant
Thermo sensor threads
Lower crankcase bolt (9 mm) threads	Engine oil
Cylinder head bolt (9 mm) threads and flange
surface
Camshaft holder bolt (6 mm) threads and flange
surface
Piston sliding surface
pin hole
ring
Connecting rod bolt and nut threads
Starter clutch bolt threads and seating surface
Flywheel bolt threads and seating surface
Oil filter threads
Clutch disc lining surface
Clutch center lock nut
Each bearing
Clutch lifter guide	Multi-purpose grease
Timing hole cap threads
Each oil seal lips
Each 0-ring

1-18

			General Information
	Location	Material	Remarks
Side stand pivot bolt sliding surface		Multi-purpose grease
Rear brake pedal linkage sliding surface
Rear brake pedal pivot surface
Rear brake spindle sliding surface
Right/left footpeg sliding surface
Gearshift pedal pivot surface			Apply thin coat of grease
Throttle pipe sliding surface
Clutch lever pivot bolt sliding surface
Steering head bearings		'94-'02:
Steering head bearing dust seal lips		Multi-purpose grease
		After'02:
		Urea based multi-purpose
		grease for Extreme pressure
		(example: EXCELITE EP2
		manufactured by KYODO
		YUSHI, Japan, 'Shell Stamina
		EP2)
		Or equivalent
Swingarm pivot nut flange surface		Multi-purpose grease
Swingarm bearings

Swingarm dust seal lips Front wheel dust seal lips Rear wheel dust seal lips

Rear wheel sliding surface (driven flange) Rear engine mounting nut threads and seating surface

Each bearing Each dust seal lips

Throttle cables Choke cable Clutch cable Speedometer cable

Steering stem lock nut threads Flywheel bolt threads and flange surface

Handle grip inner surface

Engine oil

Honda Bond A	Honda Hand Grip Cement
	(U.S.A. only}

Front brake lever pivot and piston tips Brake caliper pin bolt sliding surface

Brake caliper bracket pin bolt sliding surface Brake cam sliding surface

Brake anchor pin sliding surface

Brake caliper pin bolt threads

Brake caliper bracket pin bolt threads Fork socket bolt threads

Front fork oil seal/dust seal lips Front fork

Brake master cylinder

Silicone grease

Locking agent

Clean and apply to the threads

Fork fluid

DOT 4 brake fluid

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General Information

Cable & Harness Routing

(8) RIGHT HANDLEBAR	(1) LEFT HANDLEBAR
	SWITCH WIRE HARNESS
SWITCH WIRE HARNESS

(6) COMBINATION METER WIRE HARNESS

(2) CLUTCH CABLE

(5) HIGH BEAM/TURN "SIGNAL/

NEUTRAL INDICATOR WIRE HARNESS

3) SPEEDOMETER CABLE

(10)9P-RED CONNECTOR (TURN SIGNAL SWITCH HORN SWITCH, DIMMER SWITCH)

(9)9P-BLACK ECTOR (STARTER SWITCH,ENGINE

STOP SWITCH)

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(5)IGNITION SWITCH WIRE HARNESS

General Information

(2) EVAPORATIVE

EMISSION

PURGE

CONTROL

VALVE

(3) CLUTCH CABLE

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General Information

(10) HIGHT BEAM/TURN SIGNAL/ NEUTRAL INDICATOR WIRE

	( 5) PULSE SECON DARY AIR INJECTION
(6) STARTER MOTOR CABLE	PIPES (CALIFORNIA TYPE ONLY)

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General Information

(8)FRONT

PULSE SECONDARY AIR INJECTION CONTROL

VALVE (CALIFORNIA TYPE ONLY)

EVAPORATIVE EMISSION CARBURETOR

AIR VENT CONTROL VALVE (CALIFORNIA TYPE ONLYl

FUEL TAN K BREATHER

TUBE

(6)EVAPORA VE EMISSION PURGE CONTROL VALVE (CALIFORNIA TYPE ONLYl

( 5) FUEL

(4) REAR PULSE SECONDARY AIR INJECTION CONTROL VALVE (CALIFORNIA TYPE ONLYl

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