Introduction ‘This service manual describes the service procedures for and technical festure of the VFR4OOR. ‘This Model Specific Manual includes every service pro- cedure that is of 2 specific nature to this particular __-model. Basic service procedures that are common x0 ‘ther Honda Motorcyclas/Motor ScootersiATVe are covered in the Common Service Manual. This Model | Specific Service Manual should be used together with the Common Service Manual in otder to provide com: | - plete service information on all aspects of this motor- oye'e. Performing the first scheduled maintenance is very Im- portant. It comperssates for tha initial wear that occurs duting the breakin period. ‘Section 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for rermoval/nstalation of com. ponents that may be required to parform service Beribed in the following sections. While Sectioh 4 through 19 describe parts of the motor- | > cycle, grouped according to locations, Find the seotion 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 how t0 use this manual Ht you are not familiar with this motorcycle, read Techn cal Feature in section 20. If you don’t know the source of the trouble, go to section 21 TROUBLESHOOTING, = | ALLINFORMATION, ILLUSTRATIONS, DIRECTIONS. | AND SPECIFICATIONS INCLUDED IN THIS PUBLI- | 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 PUBLICATION 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 SCOOTERS OR ATVS. HONDA MOTOR CO.,LTD. SERVICE PUBLICATION OFFICE Date of leave: February, 1980 © HONDA MOTOR CO., LTD. General Information EE Contents i = | Frame/Body Panels/Exhaust System ‘Maintenance Engine and Drive Train Brake System EK a Lubrication System [ remeiiody Penebexint Sem EZ —— Se ee | Se 7 | Fuel System Engine Removal/installation Cylinder Head/Valves Clutch Gearshift Linkage Crankshaft/Piston/Transmission Ek ke Front Wheel/Suspension/Steering 4 [ear wheat Suspension é fing Diag [79 | Wiring Diagram Charging System/Alternator a | ignition System [16 | . Lights/Meters/Switches Ha : z Technical Feature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 Fi ling Information You Need + This manual is divided into sections which cover each af 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 befare this page “The fist page of each section lists the table of contents within the section Feod the service information and troubleshooting related ‘0 the section before you begin working + Anindex 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 end installation of parts are for the most part Mustrsted by large and clear illustrations that should provide the reader with visual ald ia understending the maior point for servicing + The system ilustrations are augmented by calfoute whose numbers or letters indicate the order in which the parts should be removed oF installd. + The sgquence of steps represented numerically are differentiated from the ones represented alphabetically to natify the teader that they must perform these steps seperately. For exaimpla, ifthe stops prior and up to camshaft removal are performed with the engine inetalied, but the subsequent steps lke cylinder head removal require engine romoval, the callouts are grouped in numerical end alphabetical orders. + Taellustrations may contain symbol marks to indieate necessary service procedures and precautions that need tobe taken, Refer to the next page for the meaning of each symbel mark. + Also in the illustration fsa chart that lists information such as the order in which the partis removediinstalled, the name Of the part, and come extra notes that may be needed, *+ Step by step instructions are provided to supplement the illustrations when detailed explanation ofthe procedure Is naces- sary oF illustrations alone would not sutfice. + Service procedures required before or after the procedure described on that particular page o inspection/adjustment proce: ures required following the installation of parts, are described under the ttle Requisite Service. + Standard workshop procedures and knowledge Covered in the Corman Service Manus! are abbreviated in this manual, Detailed description of the procedure ‘Symbol mark System illustration Step sequence (numerals en ‘or alphabets) ~ Part number ber of Extra notes or precauilon related to the service procedure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 WW ‘Modet Identification 13 Specifications 14 Torque Values 4 Tools Lubrication & Seal Points Cable & Harness Routing 7 General Safety Carbon Monoxide If the engine must be running to do some work, make.su‘e ‘the area ia well vntilated. Never run the engine in an en- closed ares = Wm + The exhaust contains poisonous carbon monoxide gas, ‘that ean cause loss of consciousness and may lead to death. Fun the engine in an open area of with an exhaust evacui tion system in an enclosed area, Gasoline Work in 2 well ventilated area. Keep cigarettes, flames or sparks away from the work area or where gasoline is stored * Gasoline is extromely flammable and is explosive ‘under cortain conditions. KEEP OUT OF REACH OF (CHILDREN, remain hot for some time after the engine is run, Wear insulated gloves or wait until the engine and ‘exhaust system have cooled before handling theee parts Used Engine/Tronsmission Oi! ‘Used engine of for transmission oll in wo-strokes) may cause skin cancer if repeatedly eft in contact with the -tkin for prolonged periods. Although this is unfkely tuniess you handle used oll on a dally basis, itis stil ‘advisable to thoroughly wash your hands with soap _and water as soon as possible after handling used oll. | [KEEP OUT OF REACH OF CHILDREN. ~ Brake Dust hnover use an air hose or cry brush to clean brake ‘assemblies, Inhaled asbestos fibers have beon found to cause respiratory disease and cancer Brake Fluid — cauTION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Units rar find = evtinderPston hem Standard Service Limi Cylinder 18 35,000 65.015 1.16582 166 55.07 (2168) E¥linder out of round = 0.10 (0.008) | Cylinder taper — 0.10 (0.004), Cylinder warpage = 010 (0.0041 Piaton mark erection | "IN mark facing toward the intake side — Piston OD. (0) 54.970~54.090 (1642.2 1650) 54.02 2.160) | Piston OD. measurement point (Hl ow = Paton pin hole LD. fd) 14.002~14.008 (0.6513-0.5515) 14.02 (0.552) |__a : | TET ee | D fas _ | | Cylinder t-istn clearance 0.010—0.085 (0,0004—0.0018) 0.100.004) | Piston pin 00 13.994~14.000 (0.5608 0.8612) 15.92 (0880) | Piston-to-piston pin clesrance 0.002--0.014 {0,0001—9,0006) 0.04 (0.002) | Connesting rod-o-picton pn clearance 0.016~0.040 (0.0008 0.0018) 0.08 .0021 | Top ritgowing groove clearance 0.018 0.050 (0.0006~0.0020), 0.10 (0.008) | |, Second ring owing grove clearance 0.015-0.048 (0.0008 0.0018) 0:10 .004) | Top ring end gap | 0.18—0.33 (0.007—0.013) 0.65 (0.026) Second rng end gop 0°18-0.28 (0.007 0.013) 0.88 1.028) Duta liaes one | 20-080 foosv-o0s) 095 (0037! {peg mark. "i" mar tale up — Second fing mark “'e! mark facing up = [Cranks =— Connecting rod small end 1D 14.016-14.094 0.8518 0.5525) 1405 10.86 Connecting rod ig ed sie clearance 0°10~0.30 (0,008 0.012) 0.4 0.02) ‘adil locrance = pais | Crankshaft runout = 0.03 (0.001) a) i i | Cranksin ot clearance 0.028-0.082 (0.0011—0.0020) 0.07 0.008) Grankpin bearing eolecion See page 110 — Man Journ! olltearance 0.025 0.049 (0.0010 0.0019) 0.07 (@.008) Main urna bearing selection See nage 1140 a [= Kiokstarer Kickstarter pinion goer 1. = = Klekstortergpinle OD. = = Kicketarter it gear = _ Countershalt OD. at kckstrter ite gear = = Kicketerter le goar bushing OD. = = b _ =— Tansmission Unit: en nb tem Standard Service Limit “Tanemission gear LD. MS, M6 2, ¢3, ca “Tanemission geer bushing O.D. MS, M6 c2, €3, c& “Tansmission gear bushing LD. MS 2 Gear-to-bushing clearance at MS, M6 gear at C2, C3, C4 gear Mainshaft 0.0. at MS gear bushing Countershaft O.. at C2 gear bushing cz eter _ Gear-to-shatt 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 8 728,000~28.021 (1.1024~1.1032) 28,000—28.021 (1.1024~ 1.1032) 27,959-27.980 (1.1007 1.1016) 27:959- 27.980 (1.1007= 1.1018) 24,985~25.006 (0.9837—0.9845) 24,985 25.006 (0.9837-0.9845) 0.020-0.062 (0.0008-0:0026) 0,020-0.062 (0.0008—0.0024) 24.987—-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—0.0018) 8.93--6.00 (0.283~0.236) 8,936.00 (0.283-0.236) 8,936.00 (0.233-0.236) 12.000—12.021 (0.4724--0.4733) 12,000 12.021 (0.4724—~0.4783) 32.000—12.021 (0.4724—0.4733) 11,969— 11.980 (0.4712-0.4717) 141969— 11/980 (0.4712-0.4717) 11,969— 11.980 (0.4712-0.4717) 28.04 (1.104) 28.04 (1.104) 27.84 (1.100) 27.84 (1.100) 25.03 (0.985) 25.03 (0.985) 10.10 (0.008), 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) 11.95 (0.470) 11.98 (0.470) 1-9General information eee OI EEeEee—EEEE— Unite ma Gin) [— Clutch system tem Standard Clutch lover free play 10-20 (0.4-0.8) | Recommended clutch fluid — Clutch master cylinder LD. = Giuteh master piston OD, I — Gluten outer 1.0. 28.000—29.021 (11417— 11426) 28.08 (1184) | Clutch outer guide 0.0. 28.967—28.980 (11404— 11408) 28.98 (1339) to. 21.995—22.016 (0.8659—0.8667) 22.05 (0.868) | Mainshatt O.D. st clutch outer guide — — | Oil pump drive sprocket LD. 29.025-29.075 (1.1427~1.1447) 29.11 (1.146) Clutch center B LD (63.964~63.990 (2.5183—2.5183) 64.00 (2.520) One way clutch inner O.. 47.968~47.378 (1.8642—1.8653) 47.36 (7.8846) Clutch spring free height (As a set of Spee) | 8.5 (0.21) 4.8 (0.19) | Clutch spring fee length j— — Clutch dise thickness | 2,92-3.08 0.115-0.121) 2.8 (0.110) Clutch dise thickness A (= — 8 = = Clutch plate warpage a 0.80 (0.012) | Centrifugal clutch drum 10. = _— bushing 0. — — Contrifigal clutch center guide ID. — — | on. — — Centrifugal clutch center guide collar height — — Centsifugal clutch spring free length a = | Clutch tining thickness — — Cranksheft O.D. at clutch center — —_ [7 Contin Svatom Coolant capacity (Radiator and engine} 2.1 ters (2.22 US ft. 1.85 Imp at — M Model | 2.0 tars (2.11 US ft, 1.76 Imp at) — (Reserve tank) 0.2 iter (0.21 US qt, 0.18 Ima at) = Radiator cap refef pressure 108-137 kPe (1.10~1.40 kgfemé, 18-20 psi) — ‘Thermostat begins to open 80—84°C (176—189°F) = Thermostat fully open 85°C (209°F} — ‘Thormostat valve litt 8.0 (0.23) min = = [— Drive Train Recommended final drive ol! Final drive gear oil capacity at disessembly at draining Final drive gear backlash Final drive gear backlash ference between | Ring gear-to-stop pin clearance (A) Stop pin shim 1 Ring gear spacer Pinion spacer i Final drive goar assembly preload Output gear backlash Output gesr 1.0. ‘Output gear bushing OD. 10, Output drive shaft 0.0, Output gear damper spring free length Output shaft adjustment shim Countershatt drive shaft adjustment shim [TTL HH i HILT LI LD 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General information —_—_—————— ee” ‘Units men iad = Ianition System | om Standard Service timit | [ odemeee cect | Spark plug gap os = eres eno ERSEH, Y27FER ERGEH Y2areER ERIOEH YotFER 0.6~0.7 (0.024~0.028) 18° BTDC at 1,200 min’ (rpm) 4,800 200 mint (rom) 42,000: 200 min" (rpm) 372° BIDC at 12,000 mi 25-350 44-2540 31-14 Ko 460-550 0 1 (com) PEPPER {ight nters/Switees —$£$@$@ $$ Main fuse | Fuse Headlight (high/iow beam! ‘Tallforake ight | License ight Position fight | Front tuen signalrunning light | Front turn signal ight Rear turn signal light i instrument light "Oil pressure warming indicator Tailorake light warning indicator ‘Side stand waming indicator Low fuel indicator Coolant temperature indicator Oil temperature Indicator High beam indicator ‘Turn signal indicator Neutral indicator Reverse indicator Overdrive indicator Oil temperature sensor resistance Fuel unit resistance (At ful level) At empty) Fuel pump flow capacity (min.fminute) ‘Thermo sensor resistance (60°C/122°F) (soecii76°F) (tz0°c/248°F) Fan motor switch Starts to close (ON) ‘Stops to open (OFF) | 308 20AX1, 10Ax3 42 V 60/50 Wx 2 (Ha) 32V 5121 Wx2 12V5W 12V 5 WIE, AR), 12V4aWEF,G) aeva7W Rv Vvizw viz 130-1800 45-600 10-209 98—102°C (208~216°F) 93-97°C (199-2079) rtSrs—SsS — Starting System —— Starter driven gear 0.D. | Starter reduction gear shaft OD, Starter reduction geet 1.0. ‘Starter motor brush length 41,978~42.000 (1.6526—1.6535) 8.884~ 10.000 (0.3935~0.9937) 10.070 10.110 10.3965~-0.3880) 12-13 (0.47—051) 41.96 (1.652) 9.80 10.380) | 10.18 (0.400) 6.5 (0.26) 1-13General information ——— Torque Values aan Fasteners ype t | Sr hor bot andaat | 808,38) | Smmarew 408.3) Smmbex bot andnut | 1011672 | Simm screw 8109.7 | Smmnex ot andmt 22.82, 16) | Bim fonge bot (© mm nea) | Sean 1Ommnox bot and nat | 354.5, 28) | ammtango bol 10 mm heed aneeut | 32,1. 0) 2mm ex bot ardnst 8846.5, 40) | Simm forge bak and mr | arezz0) | a | 400, a8 + Torauespecitistion ltd blow ae for imporanefesenes + Others shouldbe tighenes fo standard toga aus Reta sbove Notes: 1. Apply lacking agent tothe trends 2 Appy of tothe eae and Nang surface. 4: Apply molyodonum suite ol he treads and lange ste 4 App saat tote tee & sae 6: Appt clean engne oto the Oxing, 4. Ube bot 8 Saftcting nat 'B, Never apply molybdenum disulfide cit, [-Ensine = . Thee = hice Oty | gia. tram) | Nm tkorm, tetby | Remarks Lubrication: ] Oi pump even sprocket bolt Sf . wsasi | Now Ot pump mounting bat oe ata, Oi pump cover bat jo |e 1202.8) | 1 fier i | a toner Note 6 Oil drain bolt, ‘er a 12 | 38138, 27) | Oi preuare sich : 1) ene 12th, 8) Nowe a | Ful ayta | | ‘Carburetor insulator band screw ai 4 10.10.77 | | Cooling system: | Water pump mounting bott 2) 6 10 (1.0, 7) j ‘Thermo sensor ‘ Prve ~ | = 1011.0,7) | Note 4 Cinder nesloindeaton: + am ger case reutig al 2} 6 | asa | now2 am gear cose st batt ae 128, 9) Note 2 Gyiner head cover bot Bele 1910.71 | Camahat holder bat a 1112.8) : Rocker oom chat pg | pn e088 Nowe 4 inde nead pec ot, 8 mm bef TB" | apa | tees | SVindr ead Boe 8 mm 13 c ting a) Spare pg ‘ ° oan | ChthigearsiHnkage: | fagm crankcase cover le) a 1011.0,7) | it ook nt mle 0 sesen | noes | Gear rota eping tu pn ra ¢ Pe | Shit drum centr bolt 1 6 z23 i | nowt | Sit drum set plate ol — 1200 9) Nowe 1 Sit foe shat sot bel i 6 iia. 8) Note 1 Timing hoe ap ifs won | Nowa 1-14General Information er faleteiateahte) ‘Thread “Torque ol ay | aia. (mm | nem tage, tea) | Remarks CGrankcate/crankshattitransmission: Drive sprocket bott 1 10 55 (5.5, 40) Neutral switch 1 10 1211.2, 9) Connecting rod bearing cap nut 8 7 24 2.4, 17) Note 2, 9 Grankcase bolt 6 mm 2 6 12(1.2, 9) a mm 1 8 232.3, 17) 10 mm 1 10 40 (4.0, 28) Lower case oil bolt 1 10 2312.3, 17) Alternator: | Flywheel bolt 1 10 85 18.5, 60) Note 7 Starter clutch: Primary drive gear bolt (starter clutch bolt) 1 10 85 (8.5, 61) Note 7 ‘Starter clutch cover bolt L3 8 28 (2.8, 20) Note 1 [Frame Frame/body panols: Main step holder bolt 4 a 27 (2.7, 20) Note 1 Main step bolt 2 10 45 (4.5, 33) Pilon stop bracket bolt 4 a 27 (2.7, 20) Sub-frame mounting bolt 4 10 27 (2.7, 20) Side stand pivot bolt fa 10 38 (3.8, 27) Side stand bracket bolt 2 8 35 (3.8, 28) Note 1 Exhaust system: Exhaust pipe joint nut 8 6 8 (0.8, 8) Cooling system: Fen motor switch 1 16 2312.3, 17) Note 4 Fuel system: Fuel tank breather check valve 1 18 114-4, 1.8) Foel valve i 18 23123,17) | Engine mount: i Engine mounting bolt 7 10 40 (4.0, 29) Engine mounting adjust bolt 2 2 1100.1, 8) Engine mounting lock rut 2 22 55 15.5,40) | | Engine mounting nut 1 10 40 (4.0, 29) Gearshift pedal bolt 1 6 1211.2, 9) Front suspension: Handlebar holder pinch bolt 4 6 1211.2, 91 Ignition switch mounting bolt 2 8 25 (2.5, 18) Note 1 Fork socket bolt 2 8 20120, 14) | Note | Fork bere 2 7 2312.3, 17) | ‘Upper fork pinch bolt 2 7 itn 8) Lower fork pinch bolt 2 10 40 (8.0, 29) ‘Steering bearing adjustment nut at 35 50 (5.0, 36), Note 2 Stearing stom nut ha 33 140 (14.0, 101) Front axle pinch bolt 4 8 2212.2, 16) Front axle bolt 1 14 6046.0, 43) 1-15General Information [Frame (one lea Thread Torque = ts jew) atin | nmastee | here [er evepenston | | Rear weet nut ia 18 120 120, 87) | f neapesetense oa i 38 weues.1a | sews |, Swingarm pivot nut 4 18 | 86 (a.8,69) ‘Swingarm pivot adjust bott Loy 30 | 16 (1.5, 11) | Stinger pet occ nor 4 30 20 (8.0, 58) | Drive chain slider sew fa 3 | 404,29) Driven sprocket nu 16 8 3513.5, 25) | Torgue ink borne \-2 10 35 (3.5, 25) | Rear shock sbsorver mounting bolt 2 10 45 15, 33) Note 8 | Rear shock absorber spring ache lok nut Va = | 90180, 68) | Rear shock absorber reservoir holder band ae - 4 (0.4, 2.9) Shock linkage boltinut Js | 1 | 44630 Note 8 | Rear bearing heder pinch bot \4 “4 56 (6.5, 40) ' Drive pin bole al 12 180.5, 1) Note 1 | Brakeclutch system: | | Master cylinder mounting boit | 4 8 12 (1.2, 9) | Master cylinder oil bolt = 10 38 (3.5, 25) Front eaiper bot a a | 3303.25 Note 1 Front eatper ol bot 2 10 35 (3.5, 25) Front brake disc bot 2 8 | 2012.0, 14 Cater mounting bot je 8 | aan20 Caliper ped 3 10 1707 1 Caliper pod 0 3 10 | 281025, 1.8) | Cater bleed va i 3 3 | 6006.43) | fear bake reservol mounting bot aa 8 | 908.7 | Fear brake reservoir hoc joint sorew 1 5 16015, 11) | Now1 | Rear caliper pivot pin bolt (5 mm HEX side) eae 8 13 (1.3, 9) Note 1 Fear caliper pivt pn bot 1a 8 232.3, Note 1 | Rear brake hose joint nut those sided ja 10 14 (14, 10) |_ Rear bake hose join (caliper sie) ja 10 35 (35, 25) | Roar brake ioe mit [a 3 35 (3.8, 28) Note 8 1-16General Information —_——— zc Tools «The newly designed tools are indicated with * mark inthe fs. Description | Too! Number ‘Application Section |" Compression gouge attachment, 8 mm | O7KME—MR8O100 | Cylinder comoression measurement 2 | Git pressure gauge attachment (075104220100 | Engine oil pressure measurement 10 filter wrench ‘O7HAA~PJ70100 | Oi fiter replacement Spark plug wrench, 8 mm so7KMA-MAEO200 | _ Spark plug removalinstalation Lock nut wrench O7HMA=MR70200 | Engine removalinstalation 7 Vaive spring compressor tachment | O7989-KMOTO1 | Cylinder hesd disassembly/essembly | 8 Vaive guide dtiver O74MD—ML00100 | —Veive guide replacement | Valve guide reamer, 4.8 mm O7HNH—ML00101 | Valve guide reaming | Valve seat cutter, 24 mmm (45 IN) (077800010800 -}-7- Valve seat refacing j Valve seat cutter, 22 mm (48° EX) 07780-0010701 Valve fat cutter, 24 mm (32° IN) 07780-01250 Valve fat cutter 21.5 mm (82° Ex) | 07780-0012800 + Valve interior cuter, 22 mm (60° INIEX) | 07780- 0014202 Cutter holger, 4.5 mm 077810010800 { Lock nut wrench, 26% 30 mm 077160020208 1 Cuichdnarsombiylessembly 8 | Seension ber 07716-0020500 + | Geor holder 07724=0010100 | Primary tive gear removalinstal Fork seal diver 07947 KASO100 [Fork ol seal neater 12 Fork seal diver atachmont 07947--Kr00100 -} Lock nut wrench, 3941 mm O76MA—KS40100 | Steering stem nut removalinstaliation | Steering ster socket O7HMA-MR70100 | Steering bearing adjustment net tightening | seeing som ever attachment Co7+MID~MA70100-+- Steering bearing lower Inner race Inner ver C (07746-0030700 -|) instalation Diver attachment B (2 pes. requires) | 07946—KM80200 Steering bearing outer race removal Driver assembly shaft 07946—KM80300-1 installation | Bearing remover B 07346 -KM0500 | Assembly base 07946—Kw80600 Driver (07749-0010000 | Baering instalation 13 J Attachment, 4247 mm 07748-0010300 -}-- Bearing holder nee bearing | ‘attachment, 6268 mm (07746-0010500 + repiacement | Pilot, 40 rar 07746--0040300 -[) ' Shock absorber compressor attachment | 07959-MB10000-1---Shock absorber disassembiyiassembly | | Shock absorber compressor o7eme-0010000 1 ' Bushing dever 8 O7sAF =H1N190200 | Shock absorber upper mounting ! | bushing renlacement | Pivot adjust wrench 07908-see0001 | _ Swingarm pivot bot removafnaalation | river shaft (07946~MJO0100 -}--Fight swingarm pivot bearing | | Attachment, 37% 40 mm 0746-01020 1} instalation | Riot, 20 mm 07748-04050 Bearing remover set |, 97936~3710001 Fight ewingarm pivat bearing removal | Remover handle o7936- 3710100 +] Bearing remover 07938 —3710600 | Sizing weiant 077410010201 || Needle Bearing remover O7HIMC—MA70100-F-Lete swingarm pivot bessng || Baver shaft (07346 -ms00100-11 replacement | Plot, 28 mm 07748-0041100 1-17General Information ee... Desrnon Teatnuntar | Appleton | sect Fe diver ssmmby O76M0-=1780%00 | Shock wm rood beving moval | V8 Beng rrr 7a38- 3710300 1 Shack in saccs serng removal |S | Remover hae Graae=ari0%00 4] | Sing wei errat-corozor Dre 877490910000 + Shock am and Ink nese besng \ eachrane, 26226 men Grrae=ooro7s0 -] wsanaen fie Tr S778 2040400 | rr |” o7oiesti0001 | ate asrevnaer @uesonyy | evonsiy Peak voltage adaptor O7HGJ~0020100 ++ Peak voltage measurement | 16 Data ete Gras 9920000 21 | Universat hetder 077250030000 + Fiywheet removailinstalation 17 rover per | srs-omnsoer 4 1-18y Lubrication & Seal Points General Information — — — — eeovl'] [Engine Location Material Remarks Valve stem (valve guide sliding surface) Connecting rod small end baring Trentmission gearshift fork groove ‘Timing hole cap theads Connecting rod beating Grankahatt main bearing Molybdenum disulfide oi! Cronkcase mating surface: Liquid seatant| Do not apply sealant near the main bearings Piston Cylinder head bolt threads Connecting red bearing eap nut Rocker atm sliding surface ‘Camshaft journal, cam fobe thor sliding surface ‘CAUTION Nevee apply molybdenum diulfde ot Rocker arm shaft plug Sealant Oil pressure switch threads Do not apply sealant to the ‘witch tread head as chown, | i - 24mm “Thermd sensor threads fon29%6 io) Voit titer O-ring Engine oll ‘Clutch lifter rod lifter cam contacting area} ‘Multipurpose grease Cylinder head cesling belt threads ‘Shift drum center bolt threads Gearehite return spring stud pin ‘Shift drum set plate bolt threads ‘Shite fork shaft set bolt threads ‘Oil pump driven sprocket bott threads me Locking agent| 1-19General information —oo—$ [Frame Location Material Remarks Drive chain Gear ol! #80—30 1 || Axle holder bearing Multipurpose grease Side stand pivot ‘Shock linkage bearing collar | Shock linkage bearing ‘Seat lock hook Gearshift pedal pivot ‘Shock absorber upper mounting collar ‘Swingarm pivot bearing Steering head bearing - Step pivot Speedometer gearbox | ‘Throttle pipe tlange Rear brake pedal pivot Dust cea! lip Pad pin threads Pad pin plug threads Caliper piston DOT 4 brake thud Caliner piston seal Caliper dust seo! Master cylinder piston ‘Master cylinder piston eup ‘Steering bearing adjustment nut threads Engine oi Fan motor switch threads Seslant Handlebar grip rubber Honda Bond A or equivalent Caliper pivat pin T"sttcone grease Caliper pivot pin boot { Side wand bracket bl reds Toakng oon | Drv chan ance actow onoeos Drie pr toe oes Font etic bat trends Teton smc runes ble eae ces for cape por bok tree | Borba avec hee sew tds 1-20General Information Cable & Harness Routing (2) CLUTCH CABLE (6) CLUTCH CABLE (6) LEFT FRONT BRAKE HOSE (6) FUEL TANK BREATHER TUBE (7) LEFT FRONT TURN SIGNAL WIRE CONNECTORS (10 Ol PIPE 1-21General Information (2) HEADLIGHTS, (9) LEFT FRONT TURN SIGNAL WIRE CONNECTORS \ (6) RIGHT FRONT TURN SIGNAL aI WIRE CONNECTORS: (4) POSMON LIGHTS (7) SEAT LOCK CABLE (8) SPARK UNIT (6) FUSE BOX (10) BRAKE/TAILLIGHT WIRE CONNECTORGeneral Information (1) THROTTLE CABLES. a sue AIR CLEANER TUBES: (4) CRANKCASE BREATHER HOSE (6) REAR IGNITION com 7 ® eatery (9) AUTO FUEL Valve Vacuum Tug — (10) THROTTLE STOP CONTROL CABLE (@) REAR SHOCK ABSORBER DRAIN TUBE’ I) SPEEDOMETER CABLE (12) CLUTCH CABLE = (13) FRONT IGNITION Com. (18) THROTTLE STOP CONTROL KNOB (17) FAN MOTOR swiTcH 116) FUEL TANK DRAIN TUBE 1-23General Information (2) STARTER RELAY SWITCH 15) FUEL TANK (Main FUSE) (4) AUTO FUEL VALVE BREATHER TUBE VACUUM TUBE (1) RESERVE TANK OVERFLOW TUBE (3) FUEL LINE (6 RADIATOR OVERFLOW TUBE (8) HL BEAM RELAY (7) stARTER MoTOR CABLE SS 03) (0) RIGHT CONNECTOR BRACKET A: IGNITION SWITCH WIRE CONNECTOR (SP-BLACK) B: PULSE GENERATOR WIRE CONNECTOR [4P-BLACK) : OIL PRESSURE SWITCH/NEUTRAL SWITCH WIRE CONNECTOR (2P-BLACK) ©: RIGHT HANDLEBAR SWITCH WIRE ‘CONNECTOR (6°-RED) E: ATERNATOR WIRE CONNECTOR (aPvHITe) 04) VEw® 1-242. Frame/Body Panels/Exhaust System Service Information 24 Fuel Tank Removal/Installation = | Seat Cowling Removal/installation 2-2 Windshield Removal/Installation 26 Upper Fairing Removal/installation 2-2 ‘Muffler Removal/Installation 28 Side Fairing Removal/installation 23 Exhaust Pipe Removal/installation 2-10, | Lower Fairing Removal/installation 2-4 _ Sub-Frame Removal/Installation 242 Service Information Gasoline is extremely flammable and explosive under certain conditions. Serio Jums may rasult if the exhaust systom is not allowed to cool before components are removed or serviced. ‘Work in @ well ventilated area. Smoking or allowing flames or sparks in the working ares or where gasoline is stored can ‘cause a fire or explosion. ‘This section cover removal and i : lation of the frome body panels, fuel tank and exhaust system. + Frame body pane! installation sin the rverse order of removal, unless noted otherwise. + When remaving the cover, be careful not to damage ary t2b oF groove of the covet. — + Be carsful not to bind the wire harnesses when installing the sub-frame.Frame/Body panels/Exhaust System Seat Cowling Removal/Installation Unlock the rear seat by turning the ignition key clockwise. Remove the rear seat. Remove the six attaching screws. Rage the rear of the seat cowling and release the two bose {8 from the grommets Disconnect the brake/taitight wite connector and remove the seat cowling resrward. NOTE + Be careful not to damage the front of the cowling. Intall the seat cowling, while inserting the hook of the ‘cowling under the frame. Insert the bosses into the grommet by pushing the rear of the cowiing, Inctall the rear seat, aligning the hook withthe coving, and push the seat down to lock the seat. Nove — oe + Grease the seat striker and latch, | + The rear seat is not installed securely if any obetue- tions are under the seat. + Be careful not to bind the wire harness etc. Upper Fairing Removal/Installation Disconnect the left and right turn signal wire connectors. Remove the following: both side feirings (page 2-3) = front panel (page 2-4) = both rearview mirror mounting nu. = both rearview mirror. ~ both rearview mirror mounting rubbers. = both turn signal lights. = upper fairing. Install the upper fairing in the reverse order of removal. > CAUTION | (3) REAR SEAT (4) Bosses BRAKE TAILLIGHT CONNECTOR «1 Screw je (6) GRoMMers (1) REARVIEW MIRROR (2) MOUNTING RUBBER (3) MOUNTING NUT (6) SCREW (4) TURN SIGNAL. LIGHT (5) UPPER FAIRING ——_——Frame/Body panels/Exhaust System Side Fairing Removal/Installation ®, ‘Align the tabs with the slots propety. CAUTION + Be careful not to damage the tabs. + Make sure that the clip nut for the tapping sorew is installed properly I itis missing, install it securely with the threaded side L_ facing down. Procedure ary Remarks Removal Order Installation ion the reverse order of removal an | Quick serew (2) | Screw (2) | Tapping screw (4) | Lett sce faving 15) | Right ade faringFrame/Body panels/Exhaust System Lower Fairing Removal/Installation . a ‘CAUTION + Moke sure thatthe ofp nut for the tapping sorew fs installed property. If tis missing, install securely with he threaded ede facing down. Procedure ay Remarks Removal Order Installation isn the reverse order of removal, 1 | im clip sorewiout 4 (2) | Front pane! screw 3 (3) | Front panel 1 | wore ‘Atinatalstion, inser the tep ends under the tab of the upper faring property a shown, (2) | Mounting serew 2 (6) | Mounting bottwasher 2 (6) | Mounting colar 2 (7) | Lower faring assembly 1 2-4 aFrame/Body panels/Exhaust System Fuel Tank Removal/installation roy 7 Gasoline s extremely flammable and is explosive under cer tain candions. Workin a well ventilated area, Smoking ora towing flames or spas inthe work area or where gasoline onic ceca acer (1) BREATHER TUBE (2 MOUNTING BOLT Remove the seat cowling (page 2-2) “urn the fuel valve OFF. Disconnect the fuel tank breather tube from the tank: _ Remove the fuel tank mounting bolt. {Raise the rear ofthe tank and disconnect the fue line and vacuum {ube from the fuel valve. Install the fue tank inthe reverse order of removal Note = Moke sure that the fuel tank maunting eubber i installed tonto the frame properly before instaling the tank. “After connecting the fuet fine, connect a vacuum pump tothe auto fuel valve vacuum joint and apply vacuum. “Turn the fe! valve ON and check the fual ine for leakape. (GIFUEL TANK 2-5Frame/Body panels/Exhaust System Windshield Removal/Installation 3. Install wth using new pins, LeFrame/Body panels/Exhaust System +_ Be catoful not to damage the windshiol oo Procedure oy Remarks ‘Removal Order . 1) | Rearview miror mounting nut 4 | Nove Loosen until the clearance is made. (2) | Set pining 6 | note (Cut the pin to remove, (3)_| Windshield 1 Installation Order (3) | Windshield 1 (2) | Sat pining 6 | Nove. ‘Temporarily instal the sot rings, position the windshiets propery and fit the pins Rearview mitror mounting ut 4 27Frame/Body panels/Exhaust System Muffler Removal/InstallationFrame/Body panels/Exhaust System Do not service the exhaust system while Rishon. CAUTION [Be not bond or twist the brake hose. Support the removed fight step assembly oo that R does not hang from the brake hose Requisite Service + Seat cowting removalinstallation page 2-2) 2 Lower faiing removalinstaliation (page 2-4) Proceoire Tew] Femerks Removal Order Tratalotion she reverse order oF eo «| Heat guard mounting bots 1 (2) | lone step bot 2 {81 | eon step + | note Remove togter with he het guard Never hang fom the brats hove | (a) | Exhaust pipe band bot 2 | Nore lesen the bot. (5) | Exhaust pipe mat | 3 (8) | Motegmoming boivnut | v2 | nove [Ainstalaion, loosely instal he board nuttin the | ‘vhost pipe nuts and band bats frat then ight tem. «71 | Lat ion stp 1 (8) | Hutter assembiy 1 1 | Gasket 2 2-9Frame/Body panels/Exhaust System Exhaust Pipe Removal/Installation - WAN 4 | OMAY 7) = 2-10iS Frame/Body panels/Exhaust System ee casTon [Fe core tor isto revo them om danagin when sing te ont emul bs. Requisite Service «Muffler removalnstaaton(pege 2:8) Procedire ow Tenens Removal Order Train sin te rovers order of omar «| oor exhaust pipe joint nut 4 | Roar exaust pipe i 63) | Lower radiator mounting bok 2 | nore Fomove the bolts nove te radiator forward and old it ‘wat srg. | Front exhaust pipe ent nut 4 {8 | Front exhaust pipe 3 [16 | caster 4 2-11Frame/Body panels/Exhaust System ‘Sub-Frame Removal/installation ( 2-12Frame/Body panels/Exhaust System ee CAUTION 7 Tum the ignition switch OFF and disconnect the batery negative cable from the battery terminal 1 Be careful nat to bind the wire hamoss when instaling the eub-frame. |_| 5 Route the wire hamess, cable etc. (page 1-21). Requisite Service + Seat cowiing remavainstalition page 2-2) 1 Fuel tank removalinstallation (page 2-5) 1 Battery removalfinstalstion (page 15-4) Procedure oy Remarks Removal Ordor Installation fen the reverse order of romoval (01 | Spark plug eaplrimary wire connector 22 (2) | Regulatortectier connector 1 (G) | Tur signal relay connecter 1 (a) | Spark uni wire connector 2 (6) | Rear turn signal wire connector 4 (6) | License ight wie connector 2 (2) | Fuse box i (8) | Fight grab rat 1 {0) | Shack absorber reservokvbracket 1 0) | Rear brake reservoir 1 | caution Koop the reservoir level to prevent air rom entoring the system, (11) | Radiator reserve tank (92) | stutter mounting boteinat v2 (93) | Sub-frame mounting bort 4 | nore Remove the msin wire hamess from the clamp. (04) | Rear fender bott 1 2-13