A Few Words About Safety: .. Warning

A Few Words About Safety
Service info rmation

The service and repair Information contained In th is manua l is Intended for use by Qualified .
pmfessiona l technicia ns. Attempting service Or repairs without the proper training. tools . and equ ipment
could cause injury to you Of others . It could also damage the vehicle Or create an unsafe condition .
This manua l describes the proper methods and procedures for performing service. ma intenance. and
repa irs. Some procedures requ ire the use 01 specially designed tools and dedicated equipment. Any
person who intends to use a replacement pan, service procedure or a tool that is not recommended by
Honda, must detemline the risks to their personal Silfety and the sale operation 01 the vehicle.
II you need to replace a part. use genuine Honda parts with the COrred pan number or an equivalent
part. We strongly recommended that you do not use replacement parts of infenor Quality .
For Your Cus tomer's Safety .. WARNING

Proper service and ma intenance are
Improper SI:>rvice or repairs can create an unsafe
essential to thl:> cus~r's safety and the
cond~ior1that can cause your customer or others to be
reliability of the vehicle. Any error or
oversijjht wh ile sl:>rvieing a vehicle can seriously hun or killed.
resu~ in lau~y operation. damage to the FoIkm the procedures and prOC<lutions in this manua l
vehicle. or injury to others. and ether service materials carefully.
For Your Safety

Because this manual Is Intended for the
professiona l service technician , W.. do not
provide warnings about many basic shop
safety practices II:>· g .. Hot parts . wear
gloves). If you have not received shop
safety training or do not feel confident
about yo<Jr knowledge of safe lWrvieing .. WARNING
practice, WI:> recommended that you do
Fa ilure 10 prope~y follow instructions and Pfecautions
not attempt to perform the procedurl:>S
can cause yo<J 10 tle seriously hun or killed.
described In this manua l.
F~1ow the procedures and precautions in this
Some of lhe most imporf<lnt genera l
manual carafu lly.
service safety pracautions are given
below. However. we cannot wam yo<J of
every conceivable hazaro that can arise In
perform ing service and repair procedures.
Only you can decide whether Of not you
should perform a given task.
Important Safety Precautions

Make sure you have a dear understanding of all b~sic shop safety practic<ls and that yo<J are wearing
appropr~te clothing and using safety equipment. When performing any se<Vice tas~, be especially
careful of the lailowlng:
• Read all of the instructions before you begin. and ma ke sure yo<J have the tools , the replaceml:>nt
or rapa ir pa~s, and the skills required to perform the tasks safely and completely .
• Protect you r eyes by using proper safety glasses . goggles or face shields any time yo<J hammer.
drill, grind. pry or work amund pressurized air or Hqulds. and springs or other stored-energy
compooanlS. If there is any doubt, put on eye protection.
• Use other protective wear when necessary. lor example gloves or ".,Iely shoes. Hand li ng hot or
sharp parts can cause severe burns or cuts. 3efore you grab something that looks like it can hurt
you. slojJ and put on gloves.
• Proted yourself and others whene'ler you ~ave the vehicle up in the air. Any time you lift the
vehicle . aither with a hoist or a jack. make sura that it Is always securely supported. Use jack
stands.
Make sure the engine Is off befom you begin any servicing procedures , unless the instruction tells you
to do otherwise . This will he lp eliminate severa l poiential ha~rds:
• Injury from moving parts. If the instruction tel ls you to run the engine, be sure your hands, fingers
and dothing are out of the way,
Gasoline vapors and hydrogen gases from batteries ere expklsive, To reduce the possibility of a fire or
explosion , be careful when woli<ing around ga~i ne of battenes.
• Use only a nonflammable solvent. not ga~ire, to dean pans_
• Never drain or store gasoline in an open containe r,
• Keep all cigarettes spar1<s and flames away from the battery and all fuel-retilled parts.
Your safely, and the safely of others, is very important To help you ma ke informed decisions we have
provided safety messages and oth er information throughout this manua\. Of coorse, it is not practical or
possible to warn you about all the hazards associ3ted with servicing this vehicle . You must use your
own good judgment.
You wil l find important safely information in a variet/ of forms including:
• Safely Labels - on the vehicle
• Safety Messagtls preceded by a safety alert symbol &

and one of three signal words,
DANGER, WARNING , or CAUTION . These signal words mean:
You WILL be KILLED or SERIQUSL Y HURT if you donl fol low

Instructions.
You CAN be KILLED Or SER IOUSLY HURT if you donl follow

instructions.
You CAN be HURT if you don~ fol low Instructions
• Inslructions - on how to service th is vehicle correctly and safety.
As you read this manual, you will find information lt1at is pre<:eded by a INOTICE symbol. The purpose
of this message Is to help prevent damage to you r I'eh icle, other property. or Ihe environment.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN

THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION
AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO ., LTD.
THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND
IN CURR IN G ANY OB LIGATION WHATEVER. NO PART OF THIS PUBLICATION
REPRODUCED WITHOUT WRITTEN PERMISSION . THIS MANUAL IS WRITTEN FOR
PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA
MOTORCYCLES, MOTOR SCOOTERS OR ATVS .
HONDA MOTOR COo . LTD .
SERVICE PUBLICATION OFFICE
IIlW TO Us[ TIllS MANUAL
FOllow ''''' Ma in tenance Schedule 1Se<:l i"" 31 LUBRICATION
rocommflndltlon. to enlU re INIIM ""hid. i.
in !>Nk 01'. ... ';"9 condition Ind the emillion MAINTENANCE
"vel, ,,' wllhin the nand.rd .... ' by the U.S.
Enviro nmtr1t11 Protection AgenCY , Perform- SYSTEM
ing the lirSlllChedu~ me;ntt".nce i. very im·
porllnt. 11 campen ..,., for 11>0 in;I;'1 wet'
tN\ occurs during tho break-in .,.riOO .
Stetion. 1 through 3 apply to the whole

motorcycle. while seello,," 4 through 21 CLUTCH SYSTEM
describe poru of lhe motorcycle, grouped
Iccording!" 10000tion . GEARSHIFT LINKAGE
•Z
Find the section you """" on ,hi. IIIII!. then
turn 10 the table of contents on Plge 1 0l tho1
-o
z
ALTERNATOR
section. • CYLINOER HEAON ALVE
MOst seClion. start with In ..... mbly or CRANKCASE

' ywIlrn illustration, service in lor ... tion I nd
,foubleol\oOling for 1M section. The sub· =-::
",Quen, PI9'" g..... detai Hld proced ... n.
TRANSMISSION
II you ... no, I.mih...... ith 'hi' "",'orcycle,
r.. d 1M TE CHNICAL FEATURES In seetlM DR IV E TRAIN
23
It you don·, know ,he k1urce o f 'M trO<.lble. "~ F~'~'~O~N~'~.:;;;":"~W~,"::":::'~N~'::'O~N~~~~
go 10 section 24 , TROUBLESHOOTING.
, REAR WHEE L/SUSPENSION
<.> HYDRAULIC BRAKES

AL L INfO RMATION. ILLUSTRATIONS. 01 ·
~ E C TI O NS AND SPl: CIFICATIONS INCLUD·
-' BATTERYI'CHARGING SYSTEM
5 F~'~'~N~"~'O~N~'~'~"~'~M~~~~~""~
ED IN TttlS PUB lICA.TION AR E BASED ON
TH E lA TEST P~ ODUC T INF O ~ """ TIOI<I
AVAILABlE .... T THE TIME O F APP~OV A L
FD A P11IN TlNG . HONDA MOTO A CO .•
LTD. REU RV U THE ~ IG HT TO IIlAKE ~ F=c,~,c,~,c,c'"':'~"
~A:'~':':'''''''''''''~
CHANOES AT ANV TIME WlntOUT NO· ~ ~~;;;;;;;;;;;;;;;;~~~~~~~'"
TICE AND WITHOUT INCU RRING ANY SWITCHES
OBLIGATION WItATEVER.
rtO PA RT OF TH IS PUB LICATIOo'I ...... Y BE WIRING DIAGRAM
REPRODOCEO WITHOUT WR ITTEN PfR ·
MISSION. TECHNICAL FEATURES
TROU BLESHOOTING
HONDA MOTOR CO .. LTD.
SERVICE PUBLICATIONS OFFICE
0". 01 1.... O<tob... 1 986

:CJHONO.l MOTOR CO .. lt~.
1.
GENERAL SAFETY ,-,
SERV ICE RULES ,-,
MODEL IDENTIF ICATION ,-,
,...
,...
SPECIFICATIONS
TORQUE VALUES
TOOLS ,-,
CABLE a HARNESS ROOTING '-I
EMISSION CONTROL SYSTEM 1- 1.
GENERAL SAFETY
e. *.",,,..~
;;t~:::,~ nod r, .... _ _ . __"
.. _, .. _ . _ _ ,Iw"'IiM"'·'*'-
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TIl. . .,,,., ,.,....Ift 1tr<I_ "., ...we", _ . . /qJtIJI

" ' ' ' _. D4 _ .... A' '" ...... fI-tn .. ~_lfw
to,"","'''10li.l' ..- _Pt4' II.
SERVICE RUlES
I. u .......;"" HONOA or HONO ... ~-",.,._ ,..n• .-.:I lobo-icon" ... ,,..il _;v_tr
POtt. '''"' do..,. "'., HOI'ID"",
d.oitn lQKiljeo'ioM may clem ... 11'1. mo.",.,C"' .
2. Uto "'" _ 101 .001"'......,
3. Uto .... 1y MW"O: ,.010 _
for III" .. : ~O<f.
.... iciftt Ihh ""","<,cIo. Mw.. tool ........ _ _ . . flO'
1..... <1.. F " willi E......
'oc,
I ........... n.. .... oj ;, " _10<"....
,<>OIl ........, ............. .t.........
u_.Il0<'l__
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2
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..... _ boll> tw.t. .....
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,,,'on to ........if....... 4 .. d'->olly,
''''.... .
7. An.. ..... , ..bl, . _ , " ...... ,00 IN: ;.":.::.:;0,, """ _ .,.... .
1-1
GENERAL INFORMATION
MOllEllllENTlflCITION
BEGINING From. No. SCl71 • EMOOOOO1-

E"IIiM No . SC17E·l0000Cl1- -,
Tho ... "" 1_ .. In"""od '0 'M I' ..... boh ilMl "'" lelt oidt
III
,.
Th • ..,.,;... ...1., numbor ;• •toml>Od "" '''' 01 ,hO

«t<>ko_.
,;g., Tho ""_'Of idtotif;u,ion "umbo.- .. on "'" I'on, 01
"'" ca<bu'ltor bo<!'y .
' -2
GENE RAL INFORMATION
SPECIfiCATIONS
,
--
0-01. noIght
Sool noIght
FOOl "'" .....'
G _ . ..........
1,IS5 """ IQ,1 iIIl
1,590 ...... 162 .e 1ft!
IllO """ 132.3 ... ,
355 """ (I~.O 1ft!
l.smrn I 5.1 io>J
2.05 t, ( ~IIII
--G~~~::::---t----;::
~;, • ...... ,
Ooublol"'ldl'
loloscopic IOfk . 145 mm 1&,1 1nl
Rn , .... ". ,"Ion. " ...1 SWillfl,m. 1M mm 10, 1 1nl
G,OI' ,,""",I... , llhl'OIi"ll osa " 9 (1010 Ibl
V_""";rvlood 186 o, 1~IOIllI
M 110J90.18 T,•.A:.".....
...
M lJ0191().17 T..... I...
Iood R,OI'
'w..,' .'..
.
, 1'8.0~ inl
"
Foo' <..... iW Imp 110'1
FuoI , _ _ _ It. • Ii.... 11.0 1
""" 110 1
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~~ _____+-_-"",.~.ro~ or: (15.e I>l). l ' ~~ or: I II.,;.~';;:-_ _
;Oi~~~:;:'- 1
...... ".....
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78.& • 55.3 """ 13.13 • 2.1S itol
1.008cm' ,81 ... ,111
10.&, I
V',... IIoin
M.. i"",m " " ' _ .,.,
I
, , ~". ",.",i· ,,,,., ,,~'~ dri.. and OOHe wl'~ ,ock.. OI'm.
118 PS./II.!iDD 'pm
M... imum ' ""'lUl V.eH9<I' 171.S It·!bl/J,soo 'II'"
Oil "",,;'y 3.5 ~ .. " 13.1 US ql. 3.1 I"", Q" 01", & 1'1 .otOy
CooWot _ _ ioy
'i,,,,
].0 11.2 US Q'. 2.e 'II'IC> Qtl 01", ...... ,...
]2 ~..... 13.. US Q' U 'II'IC> Qtl
l ............... ...- .
A k fill, ...,..
"'_ ;~;"'._."ion
F",aoI "' ....... ..., _
~ .....
13 ~ 2 '~cm· 1184 t 21 "" '
.......
.n......01...
E........ " .. I...
0_
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ro' (&TOCI )
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00' IBBDCI
"I """ 11ft
,~. 10· IATOCI

IH{U: 0 15 """ 1O,0DI1 ""
IM.7 ",1213.2 1111
1-3
GENERAL INFORMATION
I H,. i ____
;;;;;;_ _ -::::: SI'ECIFICATIONS
1.;,~;_~_~~:.~:'~:. .
Flo.. , _
Tr ....... ~. 1on 5~ with .,... d,i ••

Prl ......... re:luctlon
s.oondorv ..ducti .... ,...,
1.107
~ lr>OI , odunlon 3.182

Goo, rolla I ,~
G... , ..10 II 1.619

G....olio III ,~
Guo , • ., IV 1.074
Gur ,..io V
"..~
'M'
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Go.-oIIitt_ Loot. Ie,,,,, _ ..... ,

, .... d .... _ oil." ·,V ,
, ..
,.......
I •
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S"" i", .y,,,.,, S..r.... mo,.,.
"hom ..... 360W~.DOO .pm
8 .. ' . .... copacily I~V _ 18AH
OPR 9EA·9
0.1-0.11 """ 10.0;11-0.0:35 In!

1- 2-3 .....
~IGHTS Hoodl"-,, , ............. _ ~.w
To;,J..~"'" 8/27W 3Il2 q> SAE NO. "57

Front,,,,,, ....1 8/2JW 3I:rl q> SAE NO. 1~
R.... """ "",01 13W :n "" SAE NO. 1013
Inn,",,,",,, 'i;/>" ~
No.." .. indiat", ~
Torn ..... Ineotor ~
Hi;/> bo .... 'nda, ... ~
OH ___ lnt ItIdIcoIOl" ~
"'" ~ ............. ~
' -4
GENERAL ' NFORMAT~N
TORnta: VAUJES
• ENGINE
It.m a" Th,_ 0; . . .... "'1 T.......... tI'm Ik~. '1-Ibl ~om" k'
Cyll_hud~
• • 1_12 IO.S 1.2. 5.84.or $poer.l boi'
0.10 _ _
•
.
10_ 1. 11.0- 1.' ,7- 101
"•
",, . • )1 _ 25 12.1 - 2.5, I~ 1 11
~ 14.11_5.'2. 3!>-381
110_100 11.0-10.0. 5-8-121
""
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Clu,'" oonto< ""* ft",
0-........ ., .
~ ~~, 11..3-&.7.4_81
43-47 14..3-4.7.31_3.41
'"
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•
21 _ 25 12.0-2.5,14_18)
10 _14 11 .0-1.'.7- 10)
~ :""'~ LOeTlTE-
Rock.., arm rhon
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n
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'0-" 11 .8_ 2.0.13_ 141

271 'o,.... ~.
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Sl>1fI
, 11_20 11 .8_2.0, 11_141
Car>ohofI ............. A
, "" 21 - 15 12.1_2.5. 11>-111
Oil ' ;1, ..
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,~ IU_2.0.11_141
Ou .....
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21 _ 25 12.1_1.5 ,1 5_ 181
5001<01 boI ...
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0. ... bolt
Co<InaCIing 'od ......
•, "• 35-40 13.5-4.0, 21>-291
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11.8-2.0.13-14 1
12.0-2.5,14- 111
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,"-, ,
S<.rl>-fr ..... bol ..
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4O_50 14.0-5.0. N _ lII1
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•, "• ,,~ 13.0-4.0. U _ N I
...... II..... podol
, • 24_30 12.4-3.0, 17-221
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, • 10-11 11,O-U, 7_ 111
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' -5
GENERAL INFORMAT ION
,.. 0 '.
, Thr_O ... II.... ' T""IUO N.... ( ~ ...... fHI>'
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C,H .... oir _ bol, , '",· 21_36 12.6-3.6 . •11-2'5,
.-, 10.4-0.7. 2.9- &. 11
I ,' ~ '
m..... O"/liIIdo< holde, •, • .0_ 14 11.0-1 .4. 7- 101
Clul<tl m ... or O"/Ii_ holder
, • 10-14 11.0- •.4. 7- 101
,,"Io~""' ,
•• >O-~ 12.0-10. 1(- 2<' 1
f.-I"'" _ IN<
...... 'm ...... cvt _ _ ,• •
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,-,
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Io..-o.l. 0.7_ • •4 1
(O. 1-Q.l. 0.1_1 .4'
f ..... _ oil f~I"' _ ~ 10_ 1' n .o-U. 7- 101
frontal;.,...
fI ...... k.tor _ _ ,•, '"• ~4' 13.0-4.0.21- 291
,~a 11.1_ 2.5. 13_ .81
, '" ~4' (3.0-4.0. 22_29 1

5101. . .", I, ft t>i_ bOI1
, ~ 110_ 120 (9.0-.2.0. 65--871
'O-~ 0 .11-2.0 .12- 141
s..1....., 'ill" P;_ bolt
, ~
s..:.- ,,. ... P;.... Io<: ~ nut
Fiftol _ u . nut , ~ 100-130 110.0_ . 3.0. 72_ toI l
~ro 18.Q_l .o. '3-51 1
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$I......... "'"
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f '''''1 f ... ~ toll pO'IdI_
f ,,,,,, ror~ bon .... pincto bolt. ,, 9- ,3 10.9-1.3. 1-'1
"-M12IU.0--3.0.
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5, ... 1", ...... """'" _
, '"• ~~ ' ...... 221
f'''''' .... , ~5 -&6 (5.5-&.5. '0-47 1
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"..,. 12.1_3.5,20_151
-
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• STAN OARO TOROUE VALUES
..
, T....... V _
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5""" bolt wool .... t , .&-41 (0.''-0.5. 3-41 3.5-4 (0.35--(1.6. 2 .....1
• """ i00i. ond ..... 8- U 10.....1.2. 1-81 1 ..... 11 (0.1..... 1.1. 5-.'
• """ i00i' ......... ' ....25 11.1..... 2.5. 13- 1.1 • ..... nor. bolt wool "'" 10-" 11.0-1 ... 7_ 101
10""" bOlt wool nut 30-40 13.0-1.0. 22_ 2111 • "'''' ft .... bolt wool "'" 20-30 11.0-3,0. 1o_121
12 """ bOI, ..... "". 50-80 (6.0-1,0. 311 ..... 31 10 mm f t _ bolt wool "'" 30-401 3.0-1,0. n - 291
1-6
GENERAL INFORMATION
TOOLS
• SPEC ' AC
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1-7
GENERAL. INFORMATION
• COM MON
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IIH. 5.lC'T
,,•
•..... _.
• 1"_"."",,.,
,
......
' .XI . "' .....
011,0
,,"--
,'" _
• , _ _ 10,• •101,
Eo.. '_ ioU ........
..
•
._,
0111.
......
---
fo,
--
p ,-
V _ _ _ .... _
V_ _ . _
--
on,. "
.""" ,,-
~j)j£
on))
"_10
""...x"
O,,02-<X110H'"
onq...oo_
-
"lia .,
•.
.,.
~""-'. :11 • :!!I_
011_,,,,,,,,
~''''_'.l' ' <0 ..... ",,_,020II ".11
,.
~""_' . <2 . " """ ""<4_.0300
~''''_ . '' . 116_
..._ .n... _ """-00'0000
'.U
'I."." "
~,
...... Ii ....
0""_'0500
.
"" -"'"
,,,..,..,., ."
""...." ..... 011 ' ,
....:10_ "
. . ... - .
",,0, ~
" ,.
""'.:10_
- -,
.~
~" .._.2'_
- -
0" ..
~
-~
011 .....0111_
O"" ...OIlX)1""
01101"""'''"",
}.~
""....... ,,-
."1<•...:1110"'"
II.
1. U
,.tl."
~"
---......... "" - t __
.. _'.:IOmm
_ ... 'w", •
_"',a,,,"
_ ... 'w,'
V_ _ "
,
•
"""''
0""
WOW
0"01-00001 00
.................
01111_,_
'"'w,.......
lOll'
_ _ .. U.......
"11. '.
.""
1-8
GENERA l. INFORMATION
CABLE & HARNESS ROUTING

o x
-. " _ " ' ' '. " - Of ...... "'" lit
,,1m d ....' .. _
• Do "'" _ ....., . ago;n,' tI:o _III Of

It> <1 _ _ • _lei .... clomp;o u,"", .
oofo,.. ~ ...... .
00<1: wi . . . . lit .... I, II
..... 01
!5@
• s.c.", ..I,.. "'" ...,. h....... to tI:o 1._

... t/L tIL.,;. ~ ..... ,. _
.. tI:o . . . . ."'"
Ioc."""". ~_ tI:o _ ...... at _ tI:o
•
;mula..., ourl_ ___ tI:o ..;,. Of .....
110... h , , _ ... tI:oy ... not pull...

1:_ "<flOI.. " .... .
tIL., Of
o
If!), ,
x
o x x
• Do .." _ ..,.. Of /wi, _ _ "tI: • _ ...
;"w1otDf. lIopoi. I>v ..,.. I . Lj ....... "'If> .......
,,,,,,i.. ''''''' Of ~_ ........
--
• lIou ....,. "-'_'" to _ ...... ~ ..... Of
• K_ w;.o ~_ ......... _ tI:o ..h.." " ' "

_ 011: ... "'" pof'~
• So .. '" ""''''''''t> ......to<! if> ~, .. _

",_I~ .
• A' ... d ........ _00<1:"-tolit ........

If>.. It 10 ..... "' .. ,,'""" ...." IfLY mo ••• Of
.. Orij .......
• ... "., ,,,."i,,,. choc:_ 11:.. tI:o ..i,. h _......

""i"...
•
n~
Win h._. Of ~ "~od.
,0UUd ...... 'ho hand_ ..

~Id "'" lit .... 1ocI ... ~ _ .......1.........
lit .......... Of " ' _ . .If> ......, Of .... .
:OOi ....... lIOfI> .. 011._",,-,_.
1-9
GENERAL INFORMATION
CLUTCH HOSf
Sf'EEO
SENSOA COO£
1 - 10
GENERAL INFORMATION
~' ~ / ' " " " HOSE
F~ONT BRAKE ""~
FU EL ~O" ,/~;;
,
GENERATOR WI RE
1 -11
GENERAL INFORMATION
RfAR IIRA~E
RESERVOIR TANK
RAOIATOR
..... TTER ... NEGATIVE BATTER'!' POSITIVE
" . .,; ; \ MAGNETIC SWITCH

P'UMP RELA'"
ru ..
CABLE
1 - 12
GENERAL INFORMATION
1 - 13
GENERAL I NFORMATION
EMISSION CONTROL SYSTIM

Tho U.s. ( "", ,",,,",,,,1 "'0' ''''' ..... A90_ ...... Calil .. nI, A.. R"""!C,, II,,",~ lCARB) ,_ir.........100:''''.''
'0 <:elm.
"'., ",. ~ "",,_. <1 .. ooompI . . .tto tP!'IOC:lblo " IoMJII omi ....... " . _ ' " duri""l "'eo, ""'u'
m o, _ _ and .,td
",.;"uilOtd ooc",n""ol to 110. ;",,,,,,,'oon. ~o._. and ' hOI ",010«, .1.. ""H, , h .. J ......... I. '983 ..... 111. wi'h "'.. " .....
"'"'" ""iWOn "'''''>rd, lor """ Y'" 01 8,000 ~ '" (3.730 ",iI.. 1 .1, .. ,1>0 , .... 01 ",I. to "" " It.",,,, _ . _ . ".......
_""" _ """,,,itood oceord .... 10 "" """uetlot>< ",0._. ~i ..... wi"' .... to<m, 01 "" 0"";"",,,,',
WOffln' ....
I", Hoi' -. Mooor-cydo E........... eon",.. $y,...... .. • '-V ... "' .... to __ tho ""lu;on W"''''IV In .I!",,~
SOURC E OF EM ISSIONS
Tho oomtou""", ..""'" p o _ COItion .......... .... """ IoV<lr _ _ • ConDo! at hydoocatbono 10 .... _ .... , ___•
" . - ........ candi ............. , .... , to I",'" """'"..,..."", _ _ ... ~i"lOd 10 ... nhgh •. Cor_ """""olio don not
..... In ""' ...... "'r<.
bu';1 ~ .... 0<.
EXHAUST EMISSION CONTR OL SYSTE M

Tho • • h ... " .... illion """' ...., ...... '" ~ ""',,!>Ow<! 01 ... " ""b,,,,,,,, ""I""l" _ no odi"" ...... " ....... 1<1 1>0 modo ""'pf
;cj~ ....... ooIju.men, with ,ho oII,on" "010 _ .
CRANKCASE EMISSION CONTROL SYSTEM

Tho ....... io"", >.ocol"';th. _ ....... _ ' .... m 10 po ...... , eli"" ............. ___ ",,0'''' _ •. - '
by ..... ' ., .... _ '0 tho -.."",lIon _ 'i'rouIIh tho oj, d _ and ,ho _ .....
AI R CUAN(A
~'FRESH AIR
_ , IIl0W-B'f GAS
CAABURHOR
1 - 14
GENERAl. INFORMATION
EVAI"ORATIVE EM ISSION CONTR Ol. SYSTEM (Cf,liforn'- IVPt)
"i",,, ""If.
Futl •• "'" I,om , ho lu,l ,.,.. , .. o"~,, .. it ",... ,«1 i"'O , ...... ""' 1.. ;,
~ .boo<Ood ond ,W o< .~
i. """"",. _ , .... ongino ~ ",,,,,i,,, an<! ,ho ""''''' """"'" d"pl\tovm ",., ~ _ . Iutl "pot in ' M <1>0,-' coni"., 10
d,....,into 'f><
tngino 'Iv"""" .f>< ..",.. .... ,
CONTROt VALVE
ATMO$PMEA£
I N TA ~E PORT -~=
C~ AR COAl CANISTER
NOISE EMISSION CONTROL SYSTEM

T..... P£R IHG wrnr THE NOISE CONTROL SYSTEM IS PROH" ' TED F_,ot ,_ "'''''itti'' .... .aI-", oct. '" ,M
...."'" _ I , 11, T.. _ ...Of .. , _ ' ... , _ " , , , by .... ,...._ •• , . . ' ..... I .. ""'IIOM'I
01 ....... "ooonco. '"!*t."
..,. 0, doIi_.
.. plK ".,,'.01 ....................,,01 ....... ....",_.. 0<1 ...... "'" ""'" .... ' ... lot- ,., _ _ 01_ • ..,.,' ... , ........ it,
'0 , .. "" .... ' ........... ow .. _,Itt
i' I, in "10 '" 121 ....... 01 lito ... _ .".. 1UctI _ _ ...... ".", 01
........ hOI",""" , _ ... ,_,OG I_ot,........ "'" ,*'oon
"MONe THOSE ACTS PRESUM EO TO CO NSTI TUTE TA "'P(II ING ARE THE ACTS l iSTED aElOW
compo"""
I A......... I 01 •• ' P"no'" ' '''II 1~' ","!!I.,. b.tUIo,. ,..._, "',., or "IY 0' .... ' ....n,.., .,.....""" "~ ....,, p"'.
2 A..... .,I.I.•, pouno' """, 01 .n, po,'.I,no "" • • • IV"'"
l lo<l< 01 "'_, m"""nO ....
• 11 01>10<'", on. m_,...." 01 <lit .... "'Itt... ""', 01 "'" .. I",,,, 0, ..........." . m. .. "h pon. ",,,", "' .... Ii"''' '!'Kil ...,
..... " .. m ...... t.. ' ........
1-15
GENERAL INFORMATI ON
EMISSIO N CONTROL INFORMATION

LAB EL
M Emi"ion Co>nltol In iOf""'ion Lobol ~ located
on II>< !no"" .. . !>own . I, ~i ... bo<ic tI/Ot-YP
.Pt<;!><.o,lono.
VACUUM HOSE fl OUTING DIAGflAM

LABEL IC~l i fomi. type)
TIM Vtc ..... m _ Rou'ing O;.,g.-.m Lobel i• .,uch·
ed '0 , .... oir 01..... caH <Ovtr I)oh;nd tt>.I .... unk.
1-16
LUBR ICATION
- - ' ''PIPE SHIFT SH"'FT
2- 0
2. LUBRICATION
SERVICE INFORMATION ,-, OIL PRESSURE CHECK ,--'
,-, ,-,
TRO UBLE SHOO TING
ENG INE Oi l LEV EL
ENGINE OIL &. FILTER CHANGE
,-,
,-,
OIL PUMP
"INAl CRIVE OIL
CONTROL CABLE LUBRICATION
2_ 10
2- 10
•
OIL STRA INER CLEANIN G ,--' LUBRICATION POINTS 2-"
SERVICE INFORMATION
GENERAL
To 1ef'O .... ,"" ";1 pUmp. I, io _'co, ... ",. to •.-no.. th. '9'1'''' """' one! .... w _ ..ambly. $eo ...,.ion G lor _ tar pump
r.....,.~ , nd 1.... n.tIon.
SPECIFICA TIONS
Engine oil
Oi, _ _ oIion
U.. HONDA
API
'STRO K ~ OIL 0' ... ul. .... '.
SE RVleE CLASSI ~ 1c,A. TION: SE or SF ,
...
V ISCOSIT Y'
SA E 1(M'40
uMod ""'on tho ._0;0

0 _ .,ocosiH.....""'" ... \/,. ch'" m..,. bo
,...,por.""... V<><>'
fieH"" " .. it .. ;thin "'" llld"OIod 'onsII·
-- -~ . . . _.
~
5.4 ± 0.1 ~g/.m' In . ' 0 PIn ot 5,000 ,om 180"CII76" F I
~======
... i'ch)
Oi l pump ...... ic. <fa ..
2-'
LUBRICAT ION
FINOI d,'" geo'
ISO .. 15.1 Gr I.It..

.It.
1:1) .. 14.4 0••1
~io . . .
dr.....
" ....
TOROUE VALUES
E. . . . Oi' d'.in .... ~-40 H·", Il . 5~ .0 ~_. 25- ;01/ tl-lbl

( ..... 0;1 ' ilt.. 15_20 H·m t U _ '.D "'.... II _ I~ 1t·1>1 - AQp/y lOdl. '" ...... "'...." "'",. ..._ .
.... I>oh"'_
lD-l~ N.... (I.o-I.~ ~ ..... 1- 10 1t"'1 - I\w!v _ T....... ~.lIlOND.'"
'I> _"...." '" ....
t>o!l , .... odo.
_.
Oi' ........., . _
Oil pr ....,. . . . .n .........'"
OI,a... _ D1i12-f1110001
TROUtIUSIIIIOTING
011' .... _ _
1. ( . , .. n.'
<> , ,.. k.
,i""
Oil _ -
2. WOtn .. ~'''n
3. W_ ~.... .,ide <>< _
I . Oilor lau. _ do......, olton or c..,.

2. Hood",.... .. '-..I ..
l . Worn_,'"
low oil "'......

1. Oil '"""', low
2. ,.." ..... roIioI.ot .. ,Ndt; """"
3. ..... laiI"a......... _
' . 0 ;1 ......... _
i . ( . ....... , DiI .......
H""oiI_n
I . ', .. wn ..1;.1 ...... """" """"
2. "uwod oil ';11 ......,Iot •. '" me'". . ",II;".
l .I..-r.<t<>lboi .. u ....
No oil P'""'''
I. 0iI ....,_
2. OiI_dtM
3. Oil _ ,wIty
_n .."". .
t. 'n_oiI_...
2- 2
LUBRICATION
ENGINE OIL Ll:VEL

, ... ... """",eycIo "" ,,. cwo .....uncI "" _
.ound s,., ........... .., lot ;, _ .... 2_ 3
........ _. T"," Df! .... _ . 11............ d,... ""Io,
W<,," I, "'"" ..... o-n " ..I........ ' xnwo . . 11 ...
II ............ di"","" ."" _ .... Oil ......
If Ill. , ..., ia tic ..... Ill. Iowo, ..., n'lMII, ' tme> ..
" .. liII" • .., ..... 1" , '"
th. u~ ....,mo,\; .
0lo<I< "'" oi, "'..... '...,Ill ,h• .... nI.. ''''';<0''''

_ il "" " ' " Iht ....... """" Tho ...,lel1", """,lei
10 0 ft II ........ 0< " " " _.
" il _ ""~ ,top "' ........ """ _ .... 0<1
"""'" 1""",_ """"" "" <I .......
ENGINE OIL & FILTER CHANGE

Ow.,. ...... "" . ,,,, .,.. _ _ ........ """
.... ""' .... ~ OIl In <Cr. .... JloncI " ' _..
........ pIt" ttId.opIcI <1,.,_
S'OII"'._""
11._ "'. oil lillo, COlI. <1' i",,", ... oct ",I d..."
plug, mgi .. bOttom 011 d'M plug ..... d,"" 110. " " ,
w_........
II .... "" . .... o H "". , .. ,Ill . liller ... ,.,..., ."" 10, Iht
""''''''<'It
~
oil dr"" OUL 0 ....... 110 ••<1 Iii' ... .
... "' .. "'t! .,.. ...1..... d,".,
I'I1I9I ...... good <0<1(1"'"" and ......,1 "'. P.... ·
T O ll au~ ,
OR~ N '~UG : " .... 0 N·", 13._.0 k ......
t5---~ fI·1I>!
t Vl l NDlII HU.O OIl",N PLUG:
1""'" N'''' 1l.0000U k......
7_10 fI ·..1
... h ................1> d ' _ "" "" ,,,,,,, ..... oil
"11 ..... nil • ..w ..... 0lo<I< "'" "" oil f~ ... O ~ ....
.. in ....... _i,...... 00.0'
and
"'~I"" ;L Coot 11'10 Oil ' ,I,.. _
I....... 0<1 .. ton
... ,110 Oil
, ... ,.11 "" oil Iii ... ~tI'I .. oil 101"" wr""""-
TORQU E: "_20 N' '" (1.5-2.0 k......
', _ , 4 ft·lbl
~ 1I1 tho «."..........h
3.0 IIten 13 .2 U,S q,.
-._"" .........
2.& ' .... "" 01 m. ,""""'... _ Di' Ip", 2-11.
s,"" tho "'91'" and 10. I. Idl. lor 1-3 """"....
Moi<...... Ill.........1 ..., jo " tho _ I....

mn.
-. .." ...... __ ....u_ •.
2-3
L UBRICATION
OIL STRAINER CLEANING
I Tho 011 " ' - - t>o , ..... 00:1

....... _ ' .. 101 .... ,,_ .
H........ ,.., 011 ~ .... I>C,," ...... O~ _.
H..... o •• _ _ ..... ... , ott . .... .

0McI0; ..... _ ..Ion 01 ............... ..... , _ .
" ol .......... 04l1li It 101 pxod c<ond~ _ _ _
_ , .......iol ..... ,.." ,'" I t .
'~"oI' ,.... 01' "'.~ ...... o~_.
'",,01' cII, •• ~ ..."
pIpoo.
f ;n ...... onk....... ,,~ ,.., ,..."."..._ oil 1_
2·11.
OIL PRESSURE CHECK

~
,
~ .
-
W_ .. 'N ot>fIM "" ............ , 0..." '..... , _,
" ..... 1_0' '''''''''' eo"Cil 1S· fI.
5,,,,, "'" or>gI ......... di MOCt!h, oil pro ....... -, "'.
.. ·7' .":t "
,,""'" " ~' .
HotnO"<'< "" .... ........... owi.... • .... ..".....," on
01' ""....... .... '" .....
,_ ~·61 .
1".......
owitclo .....
•
\
""'
~",.
,~'e
~
••
CI>oeC< ..... .......... .
.
,
.
..
,.
.. ,
- V
/
,
•
• -.;; "
Iiiiiii....,
.~
~.'
~.',' ""- ~ 1.._,'
, " . ,'\ \.
0ll1'flESSUHE SWITCH
2-4
LUBRICATION
Star. tho ....". and _ th. oa "'.....,'. a. 5,000

'~.
OILPAESSURE :
5.4 • O.7 I<g/cm' 171 , 10 ",il .. 5.00a """ J ••
IBO*C/nS*f l
S,op 'M ..,yn •.
Apply 3·aO No. ...1,,,, 0' ,""~".I",,, to ,'"
"'.....' ....lton III".. , , .. 10,,011 .
TOAOUE : 10_1 4 N... 11.0-1.4 1<1.... 7_10 ft~~1
ConM<"! tho oil ",.. ,"ro ... i,<I1 wiro.
5,., tho ."ii"'.
0".,." .o. ...."''''llndi'''''''' ...... <11.
eNd. tN. tho oil """mo """nl"'l iodicalQl_
""Uft". ono or IW<> mo."".
It tI,,,
";1 .......... .. "n'fIG i,..j"""" noy • .,... """
,n, ....
1'" i",modi,,, ly And d .. " "' .... ,~. '''''10.
OIL PUMP
REMOVAL
Tn. 0< 1 Wmp <on be ,,,,,,,.-i witt. ,n, "", ..

........ n''''' in ,n, hom •.
O"in .h" eng'''' 0,1. Romo" ,'" oxhoult .v"'m.
R_ , ~. ,0;/>, .... ""'"" .
Romo .. 'M Oil p.mp d,;', n '11'_" """""'l
by
tho bo l' and wo"'".
Romo, •• ho ,'''''' pump .... mIltv 1 _ e. TOI.
OIL PUMP OR I V~N Sl' RtOCK ET
A"""", ,o. 001 ""..... ' 1_ 2·.) .nd ,ho oil

p.. , pi"" .
M.a. . "'.-. ,Il. 0 ·, 10;' ". in - " «>nO" ,,,,,.
2-5
LUBR ICATION
-..
~. _ " "'" oit _ by , ...................... , ...
SI>'",-, _ _ ""4" .... pin ) C'~ ....... .,;I

W""* ".y.
H_ ..... oit ...i........
OlSASSEM9LY
Homo .. tho 0') .,,,n,, bod. CO>'O! .,., , ........ t ho

_ 'g,"
~."'o ...... d".. p o. I""" .... "',.......,'
2- 6
LUBRICATIO N
M .. " ... 'M 'Ota< tiP clN,"",,".

STII,NDARD: 0.15 mm 10.00& in)
SERVICE LIMIT: 0.20 mm 10.00& inl
M..... '. !tI. """,p br>dv d . .... not.

STANDARD: 0.15-4.22 ....... 10.00&_0.009 Inl
SERVICE LIMI T: 0.35 ..... 10.01(10)
R.,.,.... 'M '0'''' "",., . nd _ ,. tho ""mp

ond <I..,,,,,,".
STAN DARD: 0.02-4.01 "'''' 10.001-0.003 Inl
SER VICE LIMIT: 0.10 .... 10.OM Inl
2-7
LUBRI CATION
ASSEMBLY oo~'" ROTOII
I_I .......,.. '01", ;"' 0 ,.... _ ..... _ , ....

"'_ ..... h .
In_ ,110 "'i.. ~in ""0 th. ,010. ""'h.
IOOTOR " ' "
.... ,;,.. , ......... , .., , .... """",-";111 0II0 .... 1yt ~~ .
Inn.lI ..... _04 oln one! oU 111''''0 body """.
2-8
LUBRICATION
INSTALLATION
I..".U 11M _ I ",n. one! O~ing iInCI 1",,011 11M

oil pomp.
In,.. 11 "'" ""inO< 'W! with ........ "'" oncI In.toll
",.ol l pipo.
I 101 ......... "'" O~ ....

",....,.... •..., and oil .....
Ott ......1i00i on 11M I
.
1.... 1011 .... oll ... _ ........ "'" boo. on 11M It."
..\d"I "" ""' ...... ol "'" ,tr_.
1",,"'1 <hooil.,..,.
"'..
PI ... "'" Oil pomp d,;'on 111'00II" Into ,lit d,; ..
~"
I. 1_.................
Tho -IN" MWio; on tho ckiw., _""01" M I.
1.... '00 ..... I0Il0 " " .:
_ ",... _ ....:16th .... ""'boll
_ ..... _ P'''' at><! ...... lIOSkn
_ lilt ,two' ,ido_.
_ IIM " _ pomp "'11_ $·111.
_ 11M • • h ... " pipe.
F,II "'" ..."'" with ,lit , . . , _ . ; oil h,.
2·11
2-9
LUBRICATION
FINAL DflIV[ OIL

CHE CK
!'loa "'" motorcyclo on I.. _'t< mnd on Iovtl
11'''''.-.3,
RoIn'I(NO tho oOllill., cop.
Cho<:k ......... nit ..... . - . . .... ' - " , ..... ~,

"'" oil !;II. . cop I>0I0.
-.
Chock ' 0' look .. il 1110 ~I ~ low. Poo, ,...., oi l
Ih<O<9> III. o~ lillo, holt ""'il ~ ........ tho_,
CHANGE
RoIn'I(N' "'" 01 1 ' il lo,...., lind ~,.i" boil to d,.1n 011
oil/,om tho h"oI .... , .,...
ImUl1 "" d,oi" t>oll oocu .......
f ill "'" ...... ""'" ..illl "'. ~ "', up to

"'" OI.·'ocl _ I _ I.
OllCAPA(:ITY " 3O .. 1'.""0)
RECOMMENDED OIl ,
HVI'OIDGEAR OIL SAE_80
CONTROL CABU LUBRICATION

Po,..,....oIly. di.w,,,,.,,, "'"
th."nlo cab ... . , "'oi,
"""'" """, T»oroogl'lly lul>l' ..... "'" cabl.. one!
1I>Oi' pi.." poinu .. i!l1 • e<>mme!cOal ly .. oil.bIco
oIbIo lubficoo' 0' "9>' ...""" oil,
2-10
LUBRICATION
LUBRICATION POINTS
_ c:iH
~ THR OTTLE GRI~ SWINGA.RM

0, ICABLE LUBRICANT I PIVOT
•
THROTTLE AND , DRIVEN FLANGE
~
CHOKE CABLES BRAKE SPINDLES AND
PEDAL PI VOT PINS
I (LITHIUM BASED
CLUTCH AND BRA.KE
, MULTIPURPOSE
LEVER I I GREASE I
I
STEUmlG I
HEAD I
BEARINGS
FINAL OAIVE
I GEAR AND SH ... FT
IHYPOIO GEAR OIL
SAE .801
SPEEDOMETER SHIH FOOT PEG STANO
DRIVE GEAR PEDAL PIVOT PIVOT PIVOT
'",," FOR K JOINT
' .... T.F.! (l iTHIUM BASEO
MULTIPURPOSE
GREASE I
2-11
MEMO
3. MA
SERV ICE INFORMAT ION ,.., CY LI NDER COMPFIESSION 3- 13
MAINTENANCE SCHE DULES 3-3 EVAPORATI VE EMISSION CONTROL
< ENGINE > SYSTEM 3-13
FUEL LINES 3~ < CHASSIS > I
FUEl. FILTER H BATTERY 3_1.
THROTTLE OPERATION 3- ' BRAKE FL UID 3- 14
CAA8URETOR CHOKE 3-8 BRAKE PAC WEAR 3- 16
AIR CLEANER 3-8 BRAKE SYSTEM 3- 16
SPARK PLUGS 3- ' BRAKE LIGHT SWITCH 3- 16
IGNITION SYSTEM 3- ' HEADLIGHT AIM 3- 16
VALVE CLEARANCE 3-8 CLUTCH 3- 18
CAABURETOR SYNCHRONIZATION 3- 10 SIDE STANO ,.."
CARBURETOR IDLE SPEED
RADIATOR COOLANT
3- 11
3- 12
SUSP ENSION
WHEELS
,.."
3- 19
RADIATOR CORE 3- 12 STEER IN G HEAD BEARINGS 3_"
COOLING SYSTEM HOSES NUTS, BOLTS, fASTENERS 3- 21
It CONNECTIONS 3- 12
SERVICE INFORMATION
GE NERAL
• E,,'M oil
• [""no l>illil ....
• F..... d" . . . . . ooi1
SPEC I FICATIONS
$pot!( plug I/OP: 0.1-(1.9 mm 10.031-(1.035 Inl
3-1
MAIN TENANCE
,,, ;,10<> 'iming

AI id..: 10" SlOC
_once ,..no: 10° aTOC ,t 1,501) ",m
Full ""'_. , 37° SlOC .t 3.800 ,pm
YaI.adM"nco
Cold (a._ )!i"C, V§"f f:
I d l t _: 1.000-', I 0(""",
c.,ll«, ...... ,v...,.._i ,..10<>: All «mo. ........ w i '~ i~ 60 mm (2.4 Inl Hg
Cyllnda, CClmptO .. Io<>: 11> a kg/ .... ' 1184. 28 ".;)
fI"ottlo griD I, .. Dlay: 2_~ mm 11/8-1/4 inJ
<CHASSIS>
TI .. :
T;.. ",.
321225.2.25) 36 (250. 2.501

ColO ,;'" pr ..... "', 011 (~ "'. kg/em' 1
Rt.,. ,,,,pen,ion ,;, p.",,"," 0--57 pol (1)-400 lI' •. Q-4.0 kg/em' I
TOOLS
Spodal
Yocuum IIOvQO'" 07406-0030000 01" M~37a--02 ! _XXXXX IU.S.A. .", 1.1
c..ll«",'", pilot ...... w'On"" 07908--422020,
Compr.,."ion IJOI.'QO O"~I 075!O--MBOO10l Corrvno:,cil il y ..~~.~e in U.S.A.
y, ... aOl""IfttI .. '''''''' 019Oll- MSOO1 00
FI\'WMoICOll" 0711118_ MIi\40000
C, m. h,I, h~"', 07979- MKJOOOO
3- 2
MAINTENANce
MAINTENANCE SCHEDULE
Po"orm ,1>0 ~RE _ RIDE INSPECTION ;n tho Ow_', Men...' " otd> _"led "",In. onlnoo _10<1,
. : INSPECT AND CLEAN . ADJUST. LUBRICATE . OR REPLACE IF NECESSARY.
C: CLEAN. A: REPLACE, A: ADJUST. l : LUBRICATE
FREOUENCY
,,
• 3-12
NOTE~ 3-13
••
SHOUlD BE SERVICED BY AN AUTHORIZED HONOAOEALER. UN LESS THE OWNER HAS PROPEA TOOLS AND
SERVICE DATA AND IS MECHANICAU Y QUALIFIED,
" "IN THE INTEREST OF SAfeTY. WE RECOMMENDED THAT THEse ITEMS BE SERVICED ONLY BY MIAUTHOR-
IZEO HOODA DEALER.
NOTES: 1. SERV ICE MORE FREOUHIT LY WHEN RIDING IN OUSTY AREAS,
2. CALIFORN IA TYPE ONLY.
: . FOR H IGHEA ODOMETER READING, AEPE.oT AT THE FREOUENCY INTERVAL ESTABllSl1ED HERE.
3-3
MAINTENANCE
FUEL LINES
Romo .. ,,,. lof ..nd .1oII,.;do '0"".
R........ the _ t by ,,,.... .;,,; tilt mountinv sod<"
~.
01 .... !he f utt ~""' ..-.I '_01 ..,~ pM" wi>ocn

. - _ i .... n-. _ I t 01 ~. k ....
1M'" "'"._ "'" "'" -.
FUEL FILTER
1Io~ ..... "' ......
T""' ..... I......... ·"Of f ~.
R• ....,.. _ l uoIlil,. ""'" ","~c1'" by "mo •••
~-.
Clip ,110 ,",Iii,,",.
0 ,........,..,' .... ' ''''' U..... ,....., tho li l. o<.
ROOIOOI tI>t ,",I lilt .. w ~, .... one _ "",ru.
"" b~ tho " " " " , - oct .~"' •. 1500 . . . ),31
Unelrp IIw Iuo! I.....
....,.11 .... "-' fil. "'" ' .... _ .... _ _ .,y.
c"JOI/Iu Is ,......... _
<w'''' __,t,... _ ,_.
II ~JI,.. .. _
f1-ws 01 ¥Om rio l» "'" " " . '" ~ ..
3- 4
MAINTENANCE
THROTTlE OPERATION
ChocK 10' omooll> ,oUIO .'P lull a_lng and
,,",om.Ue lu ll ,"0~"II Ito til " .. ,,"" po",,,,,,",
CMd< .~. mwU. carolo, and
... dot ...... _ . kinKo<I
,.p'_
orda.m ~.
"'om if ", ....
Lubra....... !llfo11" cab ... (P¥ 2-11). if ,~ ... "'.

o,,",.'ion I. not smoo'~_
,-
Mo,,,,,. ,hro"'. grip I""
FREE PLA y, ~-f
pi.... " "". '~,o"" g'~
..... {1/8- 1'4 inl
VALVE
Ad .... ,,,,",,,, coo ba "",,," at ,I,,, ... ,"d of ,~.
,~,o"l. cab!<. Mi!lor .d)." .... n.. or. "",do with
,ho upper KIiu<'" _ major od"",nwn" or. "",do
",ith ,h. 10_ ' adNn"'- ,
Ramo .. tho ... "
R.move ""'"tI torok { _ 6,181.
Ad"'" !>¥ I"","" i"ll tho Ioc:k ,,'" and wrn;"g ""
odi""",
_,",Ion.
TIItI'.., "'" 1<><1< nu' "'" , .. toock !!o",nlo
Rf." .. 11 "'" ,,,,,,,,0<1I>¥" In .... .. ,or .. .,<10< of
d ...... mbly .nd 0""",,, ,1\,0,,10 I,.. ", •• ""'" m_.
3-5
LUBR ICATION
CARBURUOR ClIOKE
..... _"" ............_

"".to_ ..,.._
Thor VI!i cN>k. """,,,, . - • !uti .... Cho .....
cor<UEE ..... ,...1ocI ..... Thor "" ........
coo"';, '" _ _
"'" cftok ............ "'" '-<II : boo io "" ...... _ _
~ .... """011> _ et>ok. ..... _ " ..... .
~ I<>< .,....." _ cN>k. .._ _,., ..... .
...,"'''''" .... """" . Ubi<, it .... _.,"'" .. no'
""""'h.
A, ....... 'ho 'ut' "nW 1 _ . -181.
Pull tho ct>o ~ .
It....... , ... "odltbo, " I the ....
-., '0 I,,". _ 101••••"'"
til. choI:. m .. io
__ bY 'fYing ,e ....... tho d"ooI:o It...- .... tho
COIbur ......
n..._ ...... h" ploy •
_<_
........ ' ~ :
<!AmI! on ..... _
!Iv ,
EE ....., .. .. tho cftoko <aIIIo
..... "'""' ""'''''' ............
so ..... dIoi<. ,._ i. lui" .-n.
lItio, ....... ... .....
"""' ..... _.,......
Mo. ...... ,.... _
,,. .... "" <los«!
••" .. io
•• 'uI'••.....__ ..
t~lIv
ing ' ''' Ito ,lIt to"" ""_ ,,. It... ....
I, . . p l••
,....."but.,"' ... to"', ... 'fti
R,I",,,II ,'" , _ .... _II in , .... "' _ .. Ofdo,.'
di ..... "..,. • •
A' ACLEAHEA
AIR CLEANER
R." ..............."" 1_ ' ·181.
R"""" ,~••~ ..."'.. .... «>_ !Iv """'....
Rtmo .. ,~ •• It ..... '" ,."i ... pl." B ,rod ' .... . '_nl.
3-6
MAINTENANCE
_ 'M _M ~ """............!110 or ...,. n....

POO'" _ •• 5QwtH ...... IN .~ __
1oI,;,O<y.
So'" 'M _ " ' ~ (III_ Dri (S.O.E 4D 90) on6
. _ " ' .... , ,ho . _.
I............ , ...... "d ..... ";" ,ho .. _ord«o, .... ·
_t>l~.
~ mow "@, _ ~
.
... ~ "' ORY ,--
GEAR OIL
'
SQUEEZE
SPARK PlUGS saVEHE
TIGHTLY ISAE .080_ 4 1 TIGHTLY
CEHTE~';",,,
0 _ ",. "'''_ ~"i<_.
__
CI..., on. d," I,am or"""'" , ... ....,t <>Iu<l_.
~ ....... .
,
~''''' fO
"AII~
tOld d!Jc"d ..... ,p.,k ~ugI .
,11\0 _ ",.. k ", ... 1111>' u~r'9' w;•• ·", ,,,
.
'lUO 0 ..... ' 0.1-0 ....... (0,031-OJIl6 101
Adluot by _ . . ",. _ oIoc"_cototu"",.

Wi1!I , ... """ .. _ " ' _ . ,11<0011 . - - "
plug;" by " " '0 po .... " ...... ~
r ....,... "" __ .........,..... 1{2 ' ...n .,;", •
_ ..... w,""", '0 ..............................
Co " . ., "" .... .t. _ _ _
3-7
MAINTENANCE
IGNITION TIMING
Wi"" of! ..... oIllmm tho tl,.whHI .
1~.t.oIloI IV\Mo .04 .0_ (0799IH.IB4001Xl1.
COM.." ,h ••1"''''1 1;gII' '" 'h. h~ ..... i"" wi,.

01 tho No. I cy1l_.
StII" , ... ' ''liM'''''1ot it id1<o,
IDU SPEfD; 1 .000-1.100 """
r ... 'im"'sl I, cOn"", 11 tho "F" "' .. ~ "" , ... tiV'

.... 001 04it<'. wi,h tho c'on~~ ro .. """i"'l ... ,,...
0' ''''"~_ , .,..., olit<'I"'I ",.,1<.
VALVE CLEARANCE
1011>0<' an< ..1jI," .olvo ~ ... onco _ I,. tho
tnfi<to ~ cold, IB._ 35'C. W F)
A.mow "'...... 9Il"'0. ,adl..... <"" ..... d"", boI•.
O"ln """on' ""'" ... ", ........ ', ..... 1 _ 6-3),
NOTl,
0 .... on. 0001.,,' into 0 cloon con, ....... '0'

...... . Sd>odulod coolon. ~"''''''''""I ~ wory
2 yo ... Of 2HlOO ",ilo1 138.600 ~ ... ).
lIomo .. 11'1. ,1Ih' ..... 101\ ,,"". , ido coo,,, ancI

,.....,.. tho .... ,
II""".. the , .... , 'on'
1 _ 4_181.
II. "",.. tt.. ,odio'o< 1_ 6-&1,
A. "", .. ,o. ,,,..k plUOI " ",.
Aom.,.. 11>. ;~i.1on coih wi th .... i , I>roe\:.ot ond
,.mo.. tho 1ft""Oto, .".....
R"""...o. front ..... '"' cyli_, hN<l ".,..' boI ..
0"" bo,h <Vl; _ '-<I cown,
Romo .. tho 01 ... "", ... ond I.tt ....nkoo .. _"" .
I NS~ECTION
M....... on<! adjul1 'h. ",til" _ •• 11 .... " ' 01 ••

d . .....,.. _ ;10 "'" """'" i. cold.
110.... tho cr.n~""tt . ,_ .. "" '0 .....110 n .3
"'"'" wl.h .... cr.nk .... ""'i"l ..... f..,.~
M... "',. .... NO.1 ....on i. " TOC (To o 0..0
C""•• I on .... _ouion ,,, .... ,
•
3-8
MAINTENANce
1ft........ to"',"''' ",',,,

_ . hoO ".IOW· .....,., U,. end 01 .... _
$lip, u.. " "'V" """ .... _ 01 d>o "" ........" ......
,ftOII _ .
Firg" "II~"" d>o odjuoting knob. T ~ i. will ,.i..
'hoO • _ _ ........ ,,,11>0
0 _ _.
C.,..~.hoO
_
....... tlNrI"" •••Of d>o NO . '
,_ t..... _ . tor •• en _ '" _
~,
<>nO
".
to< .. th ."",. m.l 0/1.,... tommon 'ock., ......
VAlVO! CLEARANCE (I N. EX I' 0. ' 5 ....... ,O.OOS .. ,
~ ~ II Oil ~U . .... " - .... ""* ""', and

111'" ,.... ~ oc, .......1iI ...... I o/IghI <ng
on bo'~ _ go' ... 80111 , _ , ;...,;11 _
'-.on _
_
Hold
...
.... 'hoO oM "'00
.no od/<I.~ng
-.~
_.flI
....... ,.,...",.
Kt_ •• nd
001 _ ~
ogr.*' tho _
"""0Iry
......
T O ~O UE ' ~ ' - U N'm I~, ' _ ~ . 51o. g·"' , ,5_ ,."·1>1
CAUfOOII
I ;:;:::.. ~:;:=- "- if_lir~_ '"
IIoott.ck 'hoO .._ ...., _ .
Roto" ,ho .._Il10'' 210· ...,.., ..;.. '0 .1., ,ho

n .• motk ... , '~ ,ho cr."""" ",,,;,.. ..,,1-. ond
........ ho '.,' ....... -.Icr ,no No. 2 <v' ........
ROt'" H.. ,.. "",~ .., 90' <10<>."-;11 to ,100 "'11"

11.3 """ wi' ~ ,no ... ""~ m..",.. ..,,1.... ond
_ ,no No. 3 <vIi ......
,ho .. ,..... " ...... 1'"
Aoj j..... .... '''8 ,no ",_,.. 10. tno No. 1 Oyf_.
AOIOI. tI\o ..... Il1011 210' _ wi.. to " ... tho

"_<all
_ . . ,."'" _.non
n .' _ ......... moti,.. IUrl_ .....
10< t ... No . . . .' -.
Aojj.., ........ _ oroad"'.... 1....... _ ,
evI'_.
3-9
MAINT ENANCE
'"'~" HEAD CDVER

In".U III, r'~ - " . .. cop' III, rod lno. COlI.
in tfl, ' ...... or<lor oj di ..... milly.
B, IUfO "'" c." me'" ;".... th, .... "",'indor hood
",,_.or>d tho tab 01 th, <0 .... boso f..,. ,,,< ''0"'.
CYLINDER HEAD CDV~R

80 "'!I "'0 tallo of "'" I,,,,,. <:ylimo, "<od ro .. ,
, _ III. rOM.
a...:k ,,,< or>;ino oil HI ....

f ill tI>o ,000i.to, ,.ith eloon <oolon. '0 ",. ",.dfi o<l
~.
""""
At.., !O ~ I .,.. .... ,odl.'........ ""'""tiM one!
rn It ....... ttl ....,..... '0 ..""'.. on~ oi,
bo_ f',,", tho 00011.,.. ,.,.... _ Add tho mot~<t, "" ' ''"
_'It .tor>d.
.-
R _o th. ptylll f'''''' tho No, 1, 2, 3 one! 4 "", lin·
do< .... od "oft! on<! ;.,,,.11 tho .""""m _ odW-
3-' 0
MAINTENANCE
ADJUSTMENT
n.._' .......,..... _ b o ...,.......

I
:I••
. Iho _"'-'tDI'.
,,,,,.11 .". ......", _ """0'''' ..,.j OO<ln.:I .""

... ~u,""",
"'iu"'''''
SU"''''' ...i... ....., idl•• .,..0.
lOLl ,'UO: 1.000-1 .100 .....
_.'Of' •• ,..;,"'" r;c mm
...
C_ ..... ,.~ 1~.4 inl
$vnctI,_
_,._i. . . .
10"_"'" .-IIat.oon,oot.
to ''''' bv ................
...juo.... tho l!IKioi •
1I04...k ..... ;,;,Io!pOOd
lIomo ... t'" _ .....,..,,""" i~"oIl1l>o .....
r·',
CARBURETOR IDLE SPUD

""TI!
. ' nlll'Cl .'" "'lul! idlt .....s "'If "I 01"'"

... ino odjuI!""nll oro with;" IOO<ili •• t iottl .
• Tho ''''I'no "",., 1>0 w.rm ,'" oc<u"" ...
jull·
...... t. T.n .. lnut .. of
",fUc"n!.
"""_"90 ,0:1.." ~
t'w"..",_"".""
......<to........"'ift 10 NElJTA"L."'" lil_
"" _,.,. .tond.
~.
T",n ..... tIItonlo .. ""
tho .....' . , 0:110 I90I<l.
10"_ • ' OQ ..... '0 oil ....
'CIU "UD:l .000-l .100,..
3-11
MAINTENANce
RADIATOR COOLANT
... "'",, ..... !r..... ' . . . _ _ ,
o.oct . . " ............00"0110001 ..................

IU"""" ..........1 ..-01 .... _nwt.
Tho loft! "->1<1 bo bot",_ tho "'f ULL" ..-.d
··lOW· ....II .....
II n"""ry... mil ....... , .......... ..." """ fili i.
the "fUll" 10001 II.... .. Itt. • 5OJSO mi.",.. 01
di"I11.., ....tt'....,
.,,,I·h .., • .
R.i"...11 tho """ .oe! I""", . ... _or.
RADIATOR CORE
loc ron tt>o '''''''Of _ _ ottad"ont bait> ..-.d
,....... _.;.to'....... _ ..i"• .
o.oct ..... 01, 0'" : • "" <lowing '" """"".
SI1 • ..- .... bOtI, 11no _ <GII~ ."... "'bo<.
R....... "_,,. ""'" or """ obitrur:.ion .. itll <0lI'l'

....... d 01. or low .. "or .,.. ,u".
R. olK>o rh. ,0<11.'", III~" " II ... ~ ",''';0'''' .,"
mo<o "'on 201Ii . , ,ho ,tcIl.. inoj ",rlace.
Rot"".11 the vrtllo .r.d ,ho • ." co .....
COOLING SYSTEM HOSES &

CONNECTIONS
1 _ ..... _ tor "'.... Of d'''f~'';o". _
'",, ' il _"'~ ,
CtMdr ' ..... Iit!" ..... 01 011""'" ''''''''",
3 - 12
MAINTENANCE
CYLINDER COMPRESSION
W"","P , h •• ",,,,,
S'op ,M tnt"" ...... d"c,,,•.,.<t " '" ..,.,. 0 ....
c." .."" '"'"0" V>o ...". P'"II'.
I" .." , ... """,,,, . ..i... _
0 _ ,1>0 'hrottlt ,II V>o wly and u ri ,1>0 """"...
wi'h " ••• un" mol~.
C, ... k "'" ""... "n'O! , ... ~VO , ..ding

""01 rio;",. T... "''''''urn '.";n~ " "" JllI~
,. _ .. ,h ;" 4·1 ••ron,k
COMI'RESSIOIII PRUSURE ,
Il , 2 . ","",' 1184 . n ""I
" ",,",,, ..,;0,. it ,_, d>o< ~ f",!h. 'olio";",.

''''P'_ ,.IVI 01 ........,.
- L .~ k . VII . ..
- L.l k""'l C'f,,_ .. oct 00""
- Wo,n P'''onl''naiC'fI'''<Io<
11 ..,,,,,,, ... ;0,. ;. h;gh. ~ Indl,,"n "'It <¥bon
d."" .. " ..... 10«»"',,''''''C"""".
d>.mbo, and/or , ... . .. ",,,
"" 'hI _ " 'on
EVAPORATIVE EMISSION CONTROL

SYST£M (California model only)
OIock ,"" tie ... be' .... n 'h" br ........ _It.,..
I~ ,.ok.
oh..-<OOI con;"". "",go
«>ntrol ..... . nO
lir • • '" OO",,~ ..... I", do""," or '00$1 __
',"''I. C¢rr<o<1 • • n..,......,.
CAN ISTER
CARB U RETO R VAC UU M HOSE ROUTI NG
s.. <".f,,' fIOT '0 bond, tw~, Of ' ,nk , h.

",be< "'..., ", ,,. 11;<>;,
51><10 ,t" ..
,d 01 ..eh tu"" .""0 '" /;[11"11
'u ll¥ .00 >lCU," ... it" ho.o<'''''O'
Otoc~ "'It ,n. ""'"' • • "'" oonue:,,,"l
"""" .... or cor ....
3 - 13
MAINTENANce
(CHASSIS >
BATTERY
~o_ .. .
... " .... 'luol .....
_
It I....... lode _ ..... _
"'" livid . - . ,.,. to- ...... , _.. ,.,.

,1>0
110"......... _ diolillod wo ... 10 tho _ .....

, _ .. 1010... :
Romo .. tho bon .... ,,-,"<H, boll , o;"""".ct tho
<_, _ i".. c.......-.I _ ,.,....,."

nl9O, i... coble ., "'0
I~
bo""~ ' I>on di.
..
~_. rho l illo< ~ d;',,,'o<! .."" 10
Iho ~ _ _ I..... ~_ ... ,Iho bo'~
Add ...... d,,,,''''' ".,.. T... _,.. ..on

..... , ........... ,.. " ,. o! ,1>0 bo""y
1/1. b<oll"Y ..... ,ro/y" ,,,m"",.lpJtMrir

«"• . "'Q,..:I """ '~' • .. Ito. """ 'k>I~"'1
1/ .....m>I!" " " Ito !'"''
'!"I. {h<,Jo I~. FROO T
~! .,.;<11 ... ," _ 1'1 _ " .
_0''''''_
BRIKE flUID
_.
Cltock 'M "' ... fIo.< od , ... ,.,..,;, 10.. ,.
111M 11.ld
""~ wi'~
nNf' '~.,o_
DOT ... Bilk. FI.od '0 ,1>0 u_ . . .
..... """ k . lill ,~. ' .....
Q.od; .... .."i.... " .... '''' ..... ~ ,I tho .... , ~_
.~. b",k. ~ oI •• h ,~ •
...m"I.'" "'" if
3 - 14
MAINTENANCE
BRAKE PAD WEAR

Check tho IM_ podo for _Of by 1ook,"II th'ough
tho .... IndiaI' od by 'ho " ,""" ..., "" ,ho .. lOpe<
....mb,.,..
ROlli""" ,ho ... _ p_ ~ ,ho w .... ~"" "" ,ho_
,oech.. ,he odgo of tile ....... dil. (Pou- 17-51,
CAImON,
A ""'dY' ,,~ ,h. b",k. p4dJ I" ""/,, PO

..... " ....... dUe 1"""""
BRAKE SYSTEM
In~ ,ho "'oko ' - ond fmi"110 for ,*",0,10·
""on . e,octo .r-.a o;g .... 01 I•• kog • . T;gh'on any
_ fmi"llO.
IlopI.CO _ ond '''''''11'''
'ellu"od,
Atley'8 4
BRAKE LE VER FREE PLAY

M....,o ,ho di.toneo the fr"" ....... ~OI _ .
bef.". ,he fron' ....... ".n. ' 0 ~.,
Lw.oor fr .. 10 ..... ""uld be 21)..-.30 ""n ("1.- 1'.. "'I
" ,ho tip 01 ,ho _ . If odju ...... n< lo MOI ... ry,
'u,n ,ho odiu ......
CO......,N,
""i"" ,10- Indu _,k "" 'M '<Ii""" .·hh ,n.

_.1
.".dw,," ,n. 1<"",
-'wIl' ,h. br ... ti ...... nd cII.,;It 101 1,..

f,onl ....... IIO\.01~,
8RAKE PEDAL HEIGHT

Adju" ...... podol ho;gm 00 ,ho pe<Iol il 15 mm
IO.§9 "'I below ,ho 'OP of ,ho foot peji ,
I" CO',,,, hlOt , I"a.ln.;';h. "'" «"" b... t ,

.~
TO'""'Iu,,:
I.-Oo •• n 'ho SlOP ... ' bol' loci< nu' end 'u,n ,h.
"opper bolt.
-
Aotigh'"" ,ho Iod< nut.
An ... odjust'I>\I ,ho ....... podol hoogh'. cII.,;It

,he ' H' IM' ko ligll' .witch.nd 1M,.. podol
In.. 10 .... ond odiu" il "" ...... 'Y.
3-15
MAINTENANCE
BRAKE LIGHT SWITCH
_""". II<'~.I... , .";,<11 oIIju>.'mon' ....

oil ...." " tho .... k. _ .... y and~ .
..... ;........ lI<'k' I... , ...1. <11 00 .1>0 • •1>0 1>< .....
IjgM wil,,,,,,,,,, ...... _ ,1M "....... .. ii"".""
~n •.
.0.01 ... , by 1>01<11"11 . h, ...1.<11 bOd •• M !Utn;",
.... 0<I1.... '1nf ...... 00 not Mn "" >wi"'" bOd • .
rM It..... 11< .... ' ' ' ' ... ,,<11 - . "'" ,-~.
I
. 011;.......... '.
IfAOlIGHT AIM
.0.0.... , hotl . .... "tfy by _"'II boIn _ . .'
c_ """"""'II ......
..... ;.." , ... all. by Ioo.. "~ bo'" 1>0"".... '
""oc;k" """""li"9 boIII.
•
...,TO. "'1
..... ju" tI>o !M0II1"", .. am .. woe,lied by
..... I.... ...., ' ...... ,ono.
,"n..,
A~ ' - - " " _;.~ .'-IIP' .., . -
,MH'a. '" H.., f.6 .. ..... ' 1M
,.. f*. Mfo 1 ; - ..
ClUTCH
0.00:>. ,Ioe "",,<II fluid , ......... ~oI.
_.
II tho II .. ;".....,., .... ,...... , I.... "'''k.
toll ,lIt ,_ .
..... ";U"I DOT .. S" k. Fluid 1(1 m. " _ 10, 01
Chod; ,h. on.". IV""" '''' 10...... if '''' ...., ;" looo .
1M ",,<11 ..-- toil. 1M

will ~....., 0111 if 1M
Iypf> 0{ fI./d • ..
3-16
MAI NTEt<lANCE
Al te r ' 84
CLUTCH LEVER FRE E PLAY
M ..... ,. Iho dill.no. Ih. OlutOh I..... ' mo. ..
boloro tho dlllcll ...... to di.on~. , L _ freo
pi..... "",,1<1 bo lO-:JO mm ('IIi_ 1'.4 in) ., tho 'iI'
of 'ho , _ If odiu"mtnl is ............. , t",n II,. \
""i""'"
AIiz" ,I.. _~ Ot'
.. O~ ,Iu- .a;",," ,,;,~ rio.
"""ow o. /10. ",..,.,
S tart . he e"Vin .. pull in tho dy. "" I... . . n d Ihift

.ho "on. m i.. ,,,,, into lir" go .. , Choe, thot .ho
ongi"" <Ion oa' "011 .nd ,hot tho moto,<'(de <10M
oat c...op Q,oduollv "IHlo'ho clulch ~, 000
open ,tJe Ih'oUie. Tn. mol"",y elo .lIould slarl
smoo.hlv."" ."""lorOle ~""uollv ,
SIDE STAND
000' NOQOO O
c_ .ho ,ubber pod 'or <iotoriorotion '" .. eor
R..,I",- ~ 0"'1 ....' .... MI ,,, 'ho .....' I,no I t
.t>own , Choelt tho .,rIo .,000 ""''''11
lot d.m.
a nd ,,,.. of ' . nl ion, . ncI ,ho l ido ..."" .... mbl'!
'''' ,,"110m of m""omonL Mo' . I Uro ,no l ido
'1000 '. not "'"".,
-"'01'1,
W hen !Oploa"ll • pad. " . . <>no w iln.ho

m o", ""0.., 2 60 IbI ONl Y"_
SIH'ing to nl ion il co"oct if 0 foreo of
2 --3 kg (4 4 _ 6 6 Ito) io ''''l"''"''
to pull
x
",. S.,. .1000 into ~I low","" p<>I~ion .
SUSPENSION
(.WAR~I~G
Il<r _ '""It
" . • "<Iti<lt ,
r.ir~,N,,""'!!""
L....... ...'" '" a""_I,1 ...,,,...<1,,,, _ ,
&oop4rIr wit"" <Job;'i ., .... """rot
FRONT
Ch'" tho tc1i<>r> of tho f,on' f""" by """,,,, . . .irrg
,hem _ ...1 " " '. ..
Choelt ,no '""'''0 1"", _ trt-; lot "''''0' ~mtgo,
R..,la.oo domove<l com"""."'" w h;ct, conn'" boo
r~. l rod ,
Ti;h' t " til nUtll nd bolt.,
3 - 17
MAINTENANCE
Ch_ ,"e I,,,,,, '0" ." ",esou'. """~ ,"e 10'''''

.'. cold.
~I",,"
11-.
,h.,"e '.t\ '''''' a.ff ..........
_",I. "" ," C"",..... nol.
0<1 """u,. ,"e
.i, ","Ou" .
AlA P1'I£SSURE :
0 _ & ...110_ 40 kl'o. 0-0.4 kg /em'l
Tho righ' lork . i, ......'p ollOuld ~." 100

,ernaved u"'..' ,ho rig'" , ... <i. _'~.ulod.
ANTI -DIVE SYSTEM INSPECTION
C~_ tho op."."oo 01 tho .",i·d;. . .y... m try

,iding ,ho motorcy." .M firmly .... ly l~ g t~ .
lor .......
Posi'ion
UGHT "Nn-DIVE
MEllfUM
""' HARD
MAAIMUM "NTI-DIVE
"
I~"","" 00<1 i! ~..,.. ...... ,_~ tl>o ....-"om 'r.""
to ..... "'" 1~ I_
DAMPING AOJUSTEII
Ah .. odjuot ing ",eIoad .it ",..."' •. HI 11>0 I,,,,,,

for k ,obounct domprng ""ius, ..
REBOUND
DAMPING RIDING CONDITIONS
"DJOJSTER
, G."",.' .""",d _
, H ig~
Of ,;cI;ng
'" ... ""-ling rood ,;cI;ng
,
3 - 18
MAIKTENANCE
.....
1'1_ ,,," motOfCYC" "" ii, con'" "~and
M_ the , _ _ _ ........ " 'Ofce '" _
~ ......... W .... _ . . . . . _"-
11.",0001 ,,," *'oneo ~ ,1>0<. to ony 1::,. ••••
(pOgo 16-15)
CI>or:t; , .... . - _bor.!or - . or oII"'~
TOo/III" oil '.0' ' __ IOn nUll end_.
11._ , .... ''III''.nd'''' _ """'"

II.""" .. , .... _ .
... "'_.....
II." c .. , .... . - ..... nd ..,.. ...... Iho , _ . . -
,,'
._bot,
CMdI 1110.~ ",_u,o _
to caI<I
,,," '.0'''-
IIEAII SHOCK A.SDRIEII AIR PRESSUlli :

0-117 pol CO 4 00 kP .. 0.". 0 ", /cm'1
AIR VALVe AIR VALVE CAP
REBooNO DAMPING ADJUSTEII - ._ _
-"11-'
AdjuOl ,.,. ,-."" 011"",,,,'11 o<eou""11 to 'M
• • l..... n~l~ lIN, Su.~.n"'nlodi"" ___
REBOUND R'DiNG
_
R•• , Ai, R,1Itf1
CO,
P'u....,.
,~ ,
~
O~
DAM I'1NG
ADJUSTER
, ..
._-
DInONS
. ~.
O ,g, ..... '1
I , -
57 p,,;
j
.-."0 ,
H.,-yO!
wilndi"ll ,Old
(400 kP •.
.. 0 kefc m'
-
cop",;'" R""II" ,"'"
'''''''11
3-19
MAINT ENANCE
WHEELS
~ O T ",
Tir, pr •• ",'. """"10 bo "'oc, ed wilen t~. .
C~_
• " COLD
tho 'no for <uto,

oh.,o objocts
i_ n'~I, or ot~.,
RECOMM ENDED TIRES AND P1lESSU R ES :
,-, ""'
Tiro .... MllQ/ 9O_18 M \30/9O-\7
~""...
COlO
","'u'.
Ii,.
-
(200 11><1
..
"
(225, 2 251 "
1250. 2.50)
poi ('~"
' g/em'l
-.~
1200 '1><1
.. ~I . " ~
-
Ill5. 2 25) 1275,2. 75 1
,,"
-""'
DU NL()P
.~ '" U2 7
Ch_ , h. I,,,,,t ."" 'U' w"". 11 lor ""en...

15oc""" 15 ."" 181.
M ........ II,. ".'" _ h or , ho cent.. 01 lhe ,;, ...
Reploco 'ho "'.. ;t tho ,,_ dep'h fOo<hOI ,he
follow;ng l im i...
MIo>I"',",,.,, ttHd depth:

Front: 1 .5 ...... 11 / 18 ..1
A_ : ~ . Q ...... 13 / 32 " I
STEERING HEAD BEARING
Ch_ ,1'>0, ,he """,,01 colli .. <10 r>Ot ,n,or '

f .... ... "h """"lobO, ">lot",,,.
R,ilo "'" fr"", _ I oIf ,1'>0 g'ou"" ond oheCk

Ih .. lhe h.""~b." 'otOl.. holy.
If Iho h."",obo, """"'" un ....... Iy, 0,,,,,,,. or h..
......... , """,o,,,,.m, 'diu", ' ho "oOting he",
boOl'''9
nut
by
I"og. 15·331.
tur"'''11 Ih. " .... ing hOed "'iu , ,,"11 j
J
3-20
MA,N11:NANCE
NUTS. BOLTS. FASTENERS

C"-<k 'IMI' .1 1ch ..." "uto ..... tIOhl Ito 'i9h'''''''
'0 ,""if ••_
i~",,"j
tOn e'" '",OUO ' ",uN 15..,,1011 , )., 'ho
;n ,"" M.inlO" • ...,. Sohadul.
1 _ 3-3).
C..... all ""',.. piN. ..I..... <I,.... -.. ctompo
.nd.-.......
3-21
FUEL SYSTEM
••
. , po onlV
Cililorn i....
CL: ,", 'I
, . ,~).
, ' ?ID/ Sa
.. "-- . ~~/ ~
"'",.~ \
~D
4-0
4. FUEL SYSTEM
SERV ICE INFORMATION H CARBUR ETOR INSTALLATION 4 - 16
TROUBLESHOOTING ,-, PILOT SCREW ADJUSTMEN T 4-17
CARBURETOR REMOV A L , -' FUE L TANK 4-18
VACUUM CHAMBER ,-. AIR CLEANER 4 _ 19
FLOAT CHAMBER ,-, FUEL PUMP 4- 19 I:
PILOT SCREW ,-, HIGH ALTITUDE ADJUSTMENT . - 20
CARBURETOR SEPARATION 4-1 0 (USA only)
CARBURETOR ASSEMBLY 4 _ 13 PUR GE CONTDl/A IR VENT 4_ 21

CONTROL VALVES INSPECTION
(CALIFORNIA TYPE )
SERVICE INFORMATION
GENER AL
Ct=l iM I> u,,~, ",,.,,,d,. #~ d .. upil>li"" .fIIk, « n.iw rondfflDlu_ WMk lit • ...-I/ ...'iia"d ...... [)(I,.,,, ....ott
or olf... "._. '" $I>UI<. I. ,'" ....... l ' "".
• Tho t",.IlI ""Ii_" ... down dron oo.rbu,.' OR.
"'It can .. _'*" to d -.in

• Wh.., d ... _ l i " l l l uol •• ",,,, """ . ""to IN loa,;.,,,. of tI.. O-.i. .. R, pl.", ,"'m wl<" ...... 0""" on , .. _~ .
• Tho II.,.. _I, no •• d,,," ocr ..... ,.. ~ .. III"" ;"".
• flit ' pump l!'tIptCt"" ~." ~oon 21.
• Tht No.1 >nd No.3 wbo"."''' ..... ",ff ..... t - 0 1, jo, "",do" _ •• ,,,,., ,ocyum p;.",....po ;, . ,non ''''' M,,2 , 00 NQ, ~
co.!:oJ .. ,Ol" . Do'lO'
in, .."' ...... _ p."',
TOOLS
$90<:;01
P, ...... ,* P""'I' ST - .... H_ ~ 55-MC 1 IU.S ...... ""IV)
V"","m pump ST - AH_ :1I5O-MC1 IU.S.A. M ly}
01401-00\0000
SP ECIF ICAT IONS
4-'
FUEL SYSTEM
TROUBUSIIOOTING
( .................. .....
I . Nofu.l ln .....
-~ 1..- ......
I. 0 A j fuoI IoU
2. No fu.I til "'''''''''0< ~. V_ pil_.1Id< ,'wd
3. (,..no fIDoc:Iod ... ~~ ...... 3. F.., ... _ .....
4. No __ .. 1IiuII1 .... ~""' ...."'" r..,nyl , . FIotI_ .....
5. Ai, <Ie • .. <Ioggo<i I . F..... "",, ..", blockod
8. '"10"••i, I.... ~. F......".,...... ""...,.~
1. 1"",,0,,", _ . _"Ion 1. ~Ktrklod , ..... Ii",
B. 1"'1"0,,", '~ro\,1t _"ion 8 . AI, ,,'''' ,ubo "oe9O'I
t. I",,,, ol< I....
_I. 1"'1"0,,",
......,.._
0< ""'lilt
-
R.",ictod Of ' '''IV fuo4 .......
Itt .. , ..,.;,. 10.
. _._
2. 1.,11"" .... ,fun<tlon
"'........
3. Corbu ...", I_v
, . FuoI ..........",00<1
6. ln' ....... _
1. 1<11........ _ _
F_V_'_
1. 0 . I ali ,...
z..
l . F _ _ toohith
4. 0.0.:.. _ 00- <~ ¥i
5. 0;", ... d""If
..... "111 ..
I . I................. '..,R.
l.
_
'_'OCI.
2. 10" '_'OCI.
_mOO- .yndMoniu"""
• • Corbo,o'KO< I..,,,,
~. f UII.om .... "''"'"
I,HIt "I", ""rI.. ~tI.tion

I. '''''nio'' ........ '... ".
_11M.
I. 1Qn~"" . ... " .... ' ... ,IV
2. Corbu ...", 'wRy
_ ... "",,_ (cIr_itv, ..... _ """ '" '."'.

I . f ....."".... I " r
2. I...."'" ."".... I..RV
4-2
FUEL SYSTEM
CARBURETOR REMOVAL
R."", .. t ~ . . .".
Romo .. or.. luoO t..,~ 1P<90 4 ·18].
R.move tho ,...., "', ......... ,.mo" .1It .~ <I..".,.
~.
R,.,..,.. tn, bolt '''_;'''l !h, ""'""",to, haul;""

'0 !h • • ;, ""omt>o, ,,", tt>, "ou,", 00111 • •
BO LT
-.
R,.,..,.. "" ~ ..." .... , ..... ,., .;, " " _, top
4-3
FUE L SYSTEM
0'.-"'*', ..........o.a.. _ _ ,otIO ..... ,,,.,....

,otIO tw Ioo .. olti; ",110 d;P.
lIomo •• ,ho .. rtIu,tWf <:hDIo.. , 1_ ond d ~, •• ".,

.... chol<. ond tt.«>n\o COltl'*'.
-.
_ . . . .... _""", ... ""';td< ..... "'" _t
""" ..... /f0fll Iht "'""- .......... . ir _ _ hoot
l_
boirttor
m.
._~
<_'0""
I,,,",,,
bonrlo ond ''''''''''* .... .,..
t~.lol'.kIo.
4-4
FUEl. SYSTEM
VACUUM CHIMIil:R
REMOVAL
R........... ,,", """"" I,,,," ..... if " " ' _.
~.",a" .... """ .......... <fI...bor _ _ .............

h_.
--
Of> _ . " ....... , . _ ' " _ ... ......
.",..,.. p/o_ .... f<r Jt«dkt N.·..... ...
II .. ".... , .. _ ••:on ....... diolW .... """

......... .,;.0...
, _ ..................... to. _ . oid..... I0".. _
...M_-~.
....... , .. ,.,,'" _ "" """ - . , I....!. ,.
~-.
No .. mo, .... No. 1""" No. 3 <.arboJ .."". "'"
dllt.. "" """'to it. ""lden one ."",'or _ .. ,....
t ho No.2 end Ho,l .. , boJ ... ,,""
\
COMPRESSION SPRING
4-5
FUEL SYSTEM
~~ ,r. "..,II. 1>01<10, I ......
- . . • ..,..~ ..... _
~ 60 'u'.
.. 111'1 ... 8 ..." ""'01. Tlwo , _......
If.......... pmOll.
_It
<10\1'' '
1 - , 11M _Itt... "0010 '" __ " ..... tip .....

t..._ina. ... _ - . . -.
RING
o-a ..... Ii"""'.... t... dtloriar..................
N~EDLE
1
NEEDLE HOLDEII
INSTALLAT ION
I ....."'..... io _ i tl.., .... , _ ... _ I I.
1.....I1 ..... ct•• t, _ ....... ib_ioy .....
,. ~~ 'N _ ito .... dioQlv .... .
a. ..... tho _ .. , ""into ... 1..'01~ ito ,r. No. I
1M NO.3 _tou,.-..
4- 6
fUEL SVSTEM
FLOAT CHAMBER , ,', , ' , CHAMBER
REMOVAL
~....... ,1M ''''''' , _ ct. • ....,." , ..........., tIM ,loot
~-.
FLOAT LEVEL
Muto,. rno IIOtt _I,.;th tho COfbol,.'or ;n,;!int(j
!5" --45" 1<_ ••"bl on<! ,1>0 II.,., UtI\I ju>t
<:<>n"''''f>g tho 1",-, . 01.. .
I;(Hl,
1 M. ...... <1>. ft"., _ I """.., tI>o fl""'.01 ....
SPECI FICA TION; 1.5 ",m (n.29 inl
,-
Adj..", tho II"", ,,", by <...!utl. _inQ .... 1101'
FLOAT ANOJETS
4-7
FUEL SYSTEM
1~1QKt tI>o 11_ ", • • ro, 1'00'" Inc! "idol.

I....PtCI ,IN 0_""," 01 ,lit "OIl' ,,1,,_
~ ....... tho .... ,,' itol. "' .. ~ ~ .....Iow 10 ••

~_ It!t !loot . _ ..., ...., , ;" ...
fl~TER Y... ~VESE ... T

, _ ,.,. _ . _ ... , ...., fiI , .. ro. . " ....
nld<.or~
ASSE M BLY
_''' ,.... ,. ,1>0 _ dIo_ """,_" In tilt
' ..... ",<lor 01 d;oo". .. b ... .
4-8
FUEL SYSTEM
PILOT SCREW
REMOVAL
".
00 ....... _ . . , .. , .. ,od.
eo... 011 open .... wi", _ 10 ~_ ........
p..,leIoo .." ....... tho ......... ';dllool.
c..... lI\> .... "'" ",lot OCO'_ ...... '0 _ ... tho
"'iII,..I"'.
0<111 _ _ ............ ith •• """ 11132 Inl d ,~1
Ito,. - . _oNl not ,0 .~ I ......... p;1ot _ .
&< ...,.., "'" drlII _

10 ,,... pOkJt MMi'.
All pMo' ....... I,.", M "pIHod.-I/CIIJ,
0". 'fqllm it [or (JfOfItI pJJot J(TtI&OIIIIJuIf·
""nll"... ~·/7).
F........ II·...,pitIg 4 mm ocr_ Irt/C 0611399.

pm i3903_35"' O) lnl<, .... "'II .... I>Iui .....
_,10... """"" .... KI_'~
'0 .. '. . ... ;,11 ....... _ .
""'"
tho oIu;
....,..,..,',moul_""
..... .... tho ... _ hod
U .. "",lOP'
w,,,, ..... '0 '.0_
• oir to do .. tho P;IOt ... _ .... """
tho
4-9
FUEL SYSTEM
Tum __ fIi/o. ~ ;" """ 00<.'"'''' ......., tho

"""""" 0' M .... bol"" ~ _. , ~" ....
M..... """ 01 'hi> ,,, ........ "'.. onoo when
"''''''''Ing 'no ""01 ""'..,,_
c a UTOON
I D' '4< ,., "" pilo' "' ...... _ I ...at....,.., If

. ,1><,.;Jot ...... b 'fPs,mtd ..... ,,.. _ .
1'1 ... ,., ..... p,lot _,...,. ""-' _ . R"""",

" - II !My ... wwn '" do- ,2 cl.
P2l0T SCREW
INSTALlATION
...... " ,too ",lot ",..... ...., ,.t,,," ""'" ,,, .....,
"'...... _, ............... (C'' ... _ .. .
.... ,"'''' plot ICrcw odjustmmt ;....... Plot ... _
... ;,.,,,.qed , _ , 11).
""'i' "" ......
-
Do root ",,,.,2 __ PiLot
ECr10W ~oLot ... ;: ,It.. .. Ju ....... ,:..,_
I f ....... '1!Ii><>< tho ",lot a<noo ito "'" 00<'

..." ........... ""'" 'opiocoo [no iii'" ... _.
I.. oho ",,,.. - . ..... lot ,.._, ..."
_odi .... _ .
CARBURETOR SEPARATION "" ',"'''''''"

'''''''''''12 tho OJ, _
R...."., ' 2:0 ......... '0 tho
eo<bur .. ou ...., _"to .ho "",..Isot< ...., urtIu-
'.......
4 - 10
FUEL SYSTEM
-.
"O,~...,..O LEVERS
R.."O........... , .. ...., ............. _ . - . . . . . ,
............ ....
R _ ..... "'"•• p;". ..... ..-n. rod
, ,.,=<
ear."" .. _.tt_.tt
M""-.I,. Theft
,he No. J _ _ ""'" ,ho
,ho No. ...rtru<9lCll".
CAUTION
~ .. IIH ~,..,.,... _"",lilly '0 pn.

....' d_, 10 t~t /Ow., plpn.
~ tho 1hto"" I.nl< I""" tho No. 1 rod No.

2 ..."",.ton ~~ nmo ..... tho D.... <0,'"
4 - 11
FUEL SYSTEM
No. CARBURETOR fUt l JOINT PIPE
>
~. ,
~omo •• tho c!>oI<. """ coIlo' ..... ' ....0 ...... c!>oI<.
orm ond ""inl.
~ ....... tho ......... _ ""'- .... inti '"" .....
CHOK[VAlVE
0I0di. tho _ .......nd .................... _ .
or othor d .......
•
,
SPRING
4-12
FUEL SYSTEM
CARBURETOR ASS£MBl Y VALVE
ti-._
,,..,01, 11>0
,~.
","*, ...........
nul.
"","11 .... nul oncI
Inl1.11 th. eIIok. "m ..... ~ ""'i" h _,ng ,~.
If'" ' " th. gmo.o In 11><0 elloIo., "I... ,,,,,,II tho
chol!. arm collor.
eo...... now (l.,iop w~~ oH ro::! ,,,,,,II 'hom on

,ho Iuol loin' pipe tor No . I .nd No . 1 cart.l,no".
,,,,,oil tho , .... joint pipe to th. No. 1 ro::! No. ~
c.bu,ot"".
RICOtItII<\ tho ,1><0"" II . . . . bot\Wl!l tho No. I

, oil No_ 2 -"'11", •• "';"11 now <0"" pi...
4-13
FUE L SYSTEM
Coot MW 0..-1"" wI,h 01' .nd 1nn.1I ,hom"" ,ho

"* ,nd .11 )0<0, .......
"", .... No.3 ..... No . •
,ho jolft' ,,1*_ _otOn '..u- w~h
fUH JOlf'IT P'PE A lA J()'~ T P,PU
Locll~ !hi .. ""',...,....", 1<11"";"11 ""OWl "",I,

'or _rr_
, ..... Ir ""
,"" ....... OV'd ...... ,.1on ""....
'",,01' _ _ --. 1M,,,., u.. ,"''''''.. . -
N~
_ ........... IuoI joIfII ..... oir join! .. _ ...

_ .. y ...... ,.,".
4-14
FU EL SYSTEM
CHO KE ""~"O LEVERS

10". 11 th, _ . <0<1,...:1 ."". ",i"lltno ""....>¥Of th, ",,_,oton . Ijgni"ll

II" <Iowel "'''' wi,h ,no ""~ ,,,,,, -.."'.
Anach tho . ;, _""", to ..... cotbu"'ot. w ith tho
.." ""......
4-15
FUEL SYSTEM
Turn tho .hroW....,.., OCt ... to "ign .... No, ,

.hlot.' ••• 1... wilh 'Il1O .... of .... b~_ hoi •.
AI ... _ throt'll ..... witt. Itrolry-pou_ ....

..... Moll .. ,Iro .., __orrl.......... j ......... _ .
' _ _ Io_..Ioft .. _ _ _ ,
Open _ ""OItio ...... Iy try "' ............... 01110

Il ...... n- ... _ ,,,. 111/01110.
_ ...... !hot ~ ..... r,.-"I~ .
"W<I ""'. ,hot \lit,. II rIO drill _ _ I...

• "" _ .. , ... 'twoUI• •
_ _ ...... tJrat _ ...... _ ...... . - " .....
_I,. _ _ • In.....
""'" "" _ •• _ ..... 1UtN,. <110_. ,;,,_
HtI_ .ho ....... _ ... "'" ................. ~
r... "',. ..._drly.
CARBURETOR INSTAUATION
InotoIIotion io _ioIly "" r_ of r.' .......
".,,"'
11;""" ,... ",",,,,. "'" _. eobl.. '"
I
. 1 _ , - ito, - 13L "
_""" tho !col_I,. ' - ' _ "'" od/<m .........
Thnmlo_ •• oonl_ U I.
~_. ( _311.
Cor1M ..... idlo "*" 1_
Cut _ .... $V,""o "";''''''' 1_
:)., 1)_
:).'0).
4-16
FUEL SYSTEM
PILOT SCREW ADJUSTMENT

IOLE OROP PRoceOURE lU.SA ONL YI
Th' pi~' ""OW> ,,' I'Cl0<1 p, ...... _ no

..:II""",,'" ~ .....,....... "nI...
,ho .. lot
scr<w, Ot. "PIKed (P<9I.-9I.
u.o • \.Od'>o""IO' ",i'" "oII"otio", of 50
",til
Of ....... 11 ..- ,not "'ill """"'tolv Il>II icoto
• 50 ",m ""_.
!. Tum ooch pilot ocr .... ck>d< wiot "",;J ~ .....
I ~' I . "'" """" i, 0'" 10 ,ho _ I' "",ion
~ v tn. Th~ ~.n ini,;,1 IttII.-.;t>rio. 10 tho ' .... 1
pil o, ..... _ oIIl... """n,.
INITIAL Of'ENIN G: ]]{8 "', .. 00'
2 "',"' ... , ICaliiornio """')
Da_ to ,~. pile, 1<,", ""'" will <J«'"

if ,~, p~o, ""'"' " 'iI%I<"ro "lOin" t~.
-,
2. W.. m up , ho .."ino '0 o .... "i,.. ""'PO" M'.
5,,,,, .1>11 go ", Ivl,.. 10, 1() "'i .... ' .. ~ .... ff"'"'nl .
J. An ...... ' " _,, ~i,.. ' 0 I" ",.",,1..,.
'u ...,', 1."'''''';01».
•. /1.(11"" ,lit idl' IPOod .. i,,, 'h, ,IwOl,io "op
-~.
IDU $'EEO: 1.000-1 .100 """
5. T.... n ....... pilot 00_ \1:1 Mn ou' ,,_ ''''
in i,iol .. " i...
6. II ,ho "'!liM ....... Ino, ..... I>v 50 'pm Of
010", WI" .""" pilo' "'''W oot by ~i ..
In WlM ",,,i! .."... . -
I....
a,_
I>v 50 ,pm '"
1. Adju" th' 0:1 1. $pH(I wi,h ,h. , ~"o,,10 "o p
8. Tu rn .", No.1 corb\l,oto, .'0'

""OW In u".11
,1>0 .,..'''' "'"" d,_
50 'pm.
9 . l,,' " ,1>0 No. I c><bu,elO, ";10' "".w
I , ... "
ou' !rom tilt po~"on obtoinood in 8. "'p
I(). Ad;"" ,1>0 OIl. $pH(I ",i,,, ,h. '~"ottl. ItOo
-~
II . Pm",m nap< 8, i.1>II 10 r", ,ho No. 2. J _
...rtI",,,,,, p Do, wow~
Il. 0';........ oilO' ",10" "',. ;",. '''' pilo, OOIOW
",".. .. i, ... 7 tntn ",., guido a,;,Of I'IN 019012
_ 8230000). WI>o" ,,,11, ....00 ,ho P,,", ",1I0c0>
w;II boo """,ltd I mm ;"'0 tfI, ";10' .,"_ bo, •.
4-17
FUEL SYSTEM
Fill TANK
r rov,.-.,;·~ . .~
,p ''',...~_,Jp
O' .... ; . ...
~. ..
UMQYAl
~...., ..
t!oe ... ,.
Tum !fit 'uO! .. I.. "OFF" .nd disco.",«! PM , ....
1_ '.....1«1 ~ ...... pN 1..llIna .
o..c:r.
IN ......, ""'" of Il'1O , ;1* _ "" _ ....
Otdt Ihlt l1li1 iI tI(IIOIlo; OUI 0' IN " .. VlIvt
""'V. II fuoI , _ ~ ""1rlclad. d ..n pN "'O!
"'.1......
INSTALLATION
1..... 11 tilt I ....... ~ In ,,,. ,e ....... "' ..... 01 """' ... .
M.... "'''' '''"' , .... or. "" 1..1_ •.
FUH ... "'lVE
FUEl Sl'NSOR
4-18
FUE L SYST EM
AIR CLEANER
CASE/CHAMeE~
CRAN KCASE V~NTILATION SYSTEM
Check th .. th. b~.., * 'ube ~ ,,," , .. " ictod.
fUEL PUMP
~ .... "". tho , ;<10."",... &'1<1 "" .
moronMCt tho "''''' un;' &'1<1 fu. 1 ",mp wi"
-.~
Rom ..... tho "' • • u";' l,om th. he>do< .
4-19
FUEL SVSTEM
0\ ._, """ "'"' utlit wi .. _pIoo-. Romooo ...

..Uk,,,,, II.~' _ ""'" .... ~_ .
FUEL UNIT "1" COU'UR
T_ """ """ _ orr...., _ """ /uti ...... '"
...... , .... fuoIl< ..... _ ... out.
,_ .... "'"'pump.
0;- .......... fuoI _ "om .... """'" . . . .
HIGilIlIITIIIIE IWUSTMENT IUSIIDJI

_ "'" _ido ;, '" _"'tel ""'..··......tv
- _"''''I ..._ .......
110
_ lJXlO '" (1.Il00 _ , """ catbur;toI ....... bo
.....
l"OIdiwl;d • • "
-.,.~ .... hi . . ~ d ..... - . . . .......
......
w.... up 'II; ......... ' 0 S"""
....... to .,,"''''' lot 10
R _ ...... ~_
"''''''1ft 10 ....If.....'.
........ 1_ 4·0!.
Tum_ ,.101 _ _ .... ' """.
Alii ..' "'" 1el1e ..... 10 , pro. 100 'pm ... '" tNo
lIo",nl. ""'" _ .
Dn •• .ow plio' "',ow ,"u,," ;"10 "', plio, "''ow
bo,.. 1".4.'7) .
OOOTI .
I !'!.:'t::: 7"'~:::'II:":.
Anado • Votoldo [ ",,'d • ConttoI ... _ ....
-.
IJQdow _ _ "'" 1<.............
5 , _ Iu"'" .llSL'32 lot It> ....... _...,_~
........
~~
R,"" '"
!.A IEL
00 _ OCt.." .... 1_ ...... y -' "'II con

110 . ...., I.h, •• d "'"'" tho ""ido.
0_'_ ., .. • ",.i<
ID ..... , liwo I.JO(J ...
(5.«» ""'/ -..(,~ IA ............ "" odjN,/td 1M
~ ... lilfll/lln "' .... _ .. w ...
t/1ot '" k!w
I"IHIfIIJy .. 11_.
--It»
I!'.... tw ""'/tit .. '" H IIfI#'"OtH .. ~fI.
Iofto-w J.JH .. (5._ /NI). """
.... ,." ................"".. """'1 '-'0 In
"illhol ,.;!t~. ofW< _ • ...., .... ,..,
"...... ,... _ ....... dIt "'" ~ ..
£ 101 .,.... /)rf... _ , ., ".,.... ~ ,...
1._
1Io,.,. ......,,_..
• , . . ' . . - ...... (_4./1}. ........
Of ..... oItltotk.
4 - 20
FUE L SYSTEM
PURGE CONTRO l/AIR lENT CONTROL YALYE

iIlYES INSPECTION
(CALIFORNIA MO~El)
0** II, IuoI ... , ""'II
Co<1tral
AI, V..,. can.roI Yllft IAVeV) ond d I _
"'1Ift
IPCVI .
.. "~, .......... '" Do ... ,. ItI............ ~i"~od """
.... ..eu.... v c:onnoctod. 11... _ on'\' h OM !to ll
"'..... '9'1' Of dom. or 0.,.. ;0.-.. ;0...
PURQE CONTROL VALVE (PC")
-,
_...
0 1 ......, .... Pf:II _ ............. coo , ... •
rioroo .-.I ,..,,,, •• III. PCV ""'" ~ _~ 11,10< '"
............. ~ on tt. , _ boh ......... '"' .'"
"',..,.......
Con.__ ,. _ _ "","p 10 ..... 8 "'"' I.D."_ thOl
".. '" '1>0 No. 2 "''''''''''''t
body. AOI>Iy .... ,
'-;Ii... _um '" th, pcv.
SfI€C" ,lD VACUUM : 250", .. It.B itll",
Tho IPOdliocl ....... m _ bom ..... _ . R._ ,. , YALYE
111_ , .... ~y II ......... i. "'" ""Ontoinoll.
11_0.0 ............." """"'.., tooua h 10'"

I'"·''''''''' ~"
VACUOM "'-'MP
_ _ _ '" 11'1. No. 3 _ _ bo<ty. "POlY Sl .AH.2eO-MC1 '"" A ~.,
"'" _ il\oll ........ to .... PCV.
II'£CI ,,10 V"CUI,IM: Z50 .... 11.1 1ft) lit
Tho ....0_ •........., ","",101 bo ....... _ . II ..

........... I'CV " _ io ..... _ .. _ .
c._c,. _"..,......
"'O! _ I..... """'"eft
11> .... B ..... 1,0._
...... Whil<"""", ....
_ II,od • ......., ... "'. PCV _ "' .. _ I .....
-,
"G, 3 , .."" ...... boctv. _ oil ~ ....
..n;' ... "OM. Air o/>"",'d flo .. th,.,..q, "'0 PCV .....
....II....,"'._ '"0'_ I" III. No. 2 _"'0<
"'" tho PCV If ,I< _ ..... ".n.
!law
bo<ty .
T<> P'""'" ,g".- ,., / •• ".,~_roI_.

do _ ~ ... ~ . . pnlfIOnt aJUTC4 U• •
looN opaWll<tl .. _ q,oo/y.
" _ .... - . innoll ..... PCV "" hi _fIt .

•.., •• ..., " ...., .... - . ..... d;ng to ...
.......... 1_.
4-21
FUEL SYSTEM
AIR VENT CONT ROL VALVE CAVCVI

01 ".t .... AYCV _ ""'" _ , _ _ _
..d , .. " ........ AYCV_ ... _ It.Io<"' ....
• ""' . . lobo! "" .... .... . . . ., uw ""_ ,.,.._
" • • t;"" • .
...,
PRESSUIIE P\IMI'
ST·....U56·MC1
C· ..... ' I P'flIU" p,ornp '" "'. B.rnm 1.0. ""'" "'..
.".. I. III. 3...... Ioint ..d pump oW "'~ ....
8 _ 1.0 . h_. Air ,"",,1<1 flow Ih~ me AVCY
TO No. 1.3 ,
on<! "", th' _ "'II lIDO< to "'. No. 1. 3 cor· CAR8UIIETOR
bur .... " . . .n, ,~bo . R.pj_ .... AVCV il .I, _ Alit VENT TUBE
nOl t_ ""~
I VENT
CONTIIOL YAlY£
C " . , ........ pump '" III. 8rnm 1.0 . _

..... , _ to ..... "" .... _ , tubo. """'" .... opocitied
10 au ...... "'. A YCV
'I't:ClfIE 0 '!lEISURE : 15 "'"' 10.5... I Att
Tho "", <l tlocl _ .. Ii' , old be mo ..... inod. R,·

p," ,M AYCV. II 100_" is no' ....inl.;.... d.
PRESSURE PUMP
ST· AH · ~5-MC1
(U.s.A. ontvl
Coo • • ' •• -.... _ '" .... _ "'.. _ '"

.... No. 1 ltNI "",,'IoId. AIItltv .... IPO<ilied
................ AVCV .
SPECifiED VACUUM : 260 ..... 11.1 ",I HI
T""
pi_
_it""
'no
._urn ......, be .... lntoi_. A. ·
AY CV II, ...... ", ,, no' .... ,0"' .... 0.
4-22
FUEL SYSTEM
eo-.., • ......... ....,.., '0 ",. -.-.um _

_ _ 10 ",. No.1 ....... ""' " _ ..., ........ ,
• 1 1 ' _ "''''11 10 "'" _ ...... _ 10"" 3 _
_It """"'. .
ID....
,110 _food YtcUUm to ,110
AVCV 10 ,,,. .......... ' - .... to .... No.1 10 ...
....... 10 .... """'" ..... """il;'" 11'....... 'lwougll ....
J_~ !oO"_.
5PECI~ I EOVACUUM , 5fi nom 12.1 inl Kt
SPECl flEO PRESSURE : 15""" (O-IItI, AI
To ph"" .1&''4' ,,, lIN! .;, ..", roN>oI

Nh. 41> _ .... AWr'I .. _ " ..........
/lot.".. 4 ,,'N fit _ MJIy,
....,
R.mo" "'" 0' ,"" ...... 11 .... AVCV on its mount •
..;".. ..., , .. ~ '" .... _ ....... dio .. to ",.
"""... 1boI.
4-23
ENGINE REMOVAL/INSTALLATION
~ _ OI!i N....
(3"" .1 "' .....
2&-321t · ~ 1
18-28M...
(, .. - Z.. t .......
1)-;10 11-1111
(3.5_'.&.,.",_
25-l2tl-lbl
5- 0
ENGINE REMOVAL/
5. INSTALLATION
SERVICE INFORMATION
ENGINE REMOVAL
ENGINE INSTALLATION
SERVICE INFORMATION
GENERAL
• A Itoot IOoCk or 0 _ 0<1"'....,,, "'QOO" ~ ..""I.od to ."~ ond _ _ ,flo ongino .
•
• The 10llowing p.ott. or 00,---" CO" bo ..... ~ .. ; t~ 'hO""tiM ......11ed In .ho Irom .:
Clutch A~omot<N
Coo""I" II...
C\l lindor had.
$tori .. motO.
CMbu'H<Io"
SPECIFICATIONS
E""ino d ..... -"'" 96.1 ~~
1213.21111
0 11 capoc:~~ 3.~1i!." 13.1 U,S. qtl
TORQUE VALUES
Engi .. no""" bolt
8 """ bol. 20-30 N·m 12.0-3.0 k, ..... 14_ 22 !HII)
10 "'"' bo~ 36-45 ri"" (3.~4.6 kt-m, 25-32 ft-Ibl
SU/)·If_ bel.,
"-
,- 60-70 I!'·m ( 6 .~7.0 k_. 43_51 It~b)
36-4511'.., (3.5-4.5 kv-m. 25--32 ft· lb)
5- 1
ENGINE REMOVAL{1 NSTALLAT10N
ENGINE REMOVAL
1'1... tf>o ..."""",do "" in ",\1Of u...:l.
' ......... lfw ...,...:1 , .... _ .
R.... _ lfw 10" ond ,..,., II ................. .
0, . .. .........,. .... 1_ 2·21 ond "'.......... ,
1_8·31.
R.mo.. ltM , ... _ '1_ 18031,
R....... tho ,odi.to< 1_ 808).
~_ . lt!o <.11<1 .. ,,,, 1_ . ·3).
0 ' ,,, ...... ' ,hOwlro -.>Ier. t ... II........ Iso _"lOtl
011 .. ill"", _ _ ion ....,'" ond II' ..... ' ....
"
SWITCH COUPLE R
MUF fLER
toe ,n ..... ><I\ouI, p.,. _ _ •.

_lOr """""
-
FIo_ ,,,...t ..... ,
R.mo .. "'" • • _ , p ... loi

bOIl> ond ....
5- 2
ENGINE REMOVAL/INSTA LLATION
II."",........ _ , _ ...,...., bOI, """ .....

.......... I>W... 'b '.
A....., .. , .... ".our _Irom , .... , ......,..

R _ . "' •• '"td1 .,... cylind.,.
00 """ _tIO ................... ",,,,, _ ...

..... cluldl "'_ <vI_ To do 10 *il __
difliculty ill 'tin".I1"" "'" .... cy'_.
~
-.
II...,.,'..... ~ .."';"."" I'""' ..... ""in ",indl • .
..... w.............. hooo bond """ .......,.......
...............
...A......,_......."" d"""""'" . . . 1I'O""d .......
bolo .nodI ......... . - _ '" ""
II ...,................. Itom , ....... eI.......

II."............. "'..... _ '.
1'1_ .. 1100do. ... ",no. *"1.... 01>1. _ , " _

, ... ..-.gino.
n.. jad. "'it/I,

-.0' be """'1nuouoIv *"1"" ,
od 10 ................ bolt ..... be ,.,,_"0<1.
""" .. II, ... it ,oI-.od _ _ boIU "",I
!hoy •• , .. ,.... od.
II."", .. , ........ ,.... "","", 1"0 bO'lI.

11."""".111. loft "'M'..... !>eMIt""" ..... __1,_.
A _ , ........ ,.... 1< ..... , ..... " bdo.
5-3
EN GI NE REMOVA U tNSTALLATI ON
ENGINE INSTAUITION
Inotollll>o .ngi ... mount , _••
Engine i"".II" .... ~ ....... ially 11>0 ....... ' .. 01
,otnO>' •.
u... floor I-d< '" ot~ . . . . justablt 10_' .0
coW\ol.,. ..-.,,, tI,•• ngine Into pi .....
c..ot\J l.,. 01.., ""","' ing~ " w ~h 11>0 Iod<

.0 pt""on' d _ to """"ntlng !>oK . _
and wi • • Mo'.-s or>d cabl ...
r~ .. n .11 f....".., to .flo ' '''''''" ",''' l i_ on

_5-2.
R"" .. tho wi ... and cab ... PfOI>O!1v IP.

1-IH.
F il l "'. cr.nkCHII to .~. pt_ ..... wit~
.ho , ..,,,,,,,,r>d.. 011 IP. 2·1).
Fill tt.. cooling 'Vot.m I' . e·31. TOROlJE , 18·2810· ...
Pt."""' ,"" lollowing inspoct ..... nd .... 11.8 -2.8 ,13-20 1t1bl
jUII",""'"
T.,,,,,, .. 000,.,10" (P. ] ·5).
Clut ch IP'III ] ·16).
'...toll tho •• ""'ot ",,"m,

1....1 .-- .. houst pioo loin\ II"I<"~
A _It ,ho 1.II.nd right ..""'ot ~ I "..
Tigl".n tho ..""'n pi.,. bond looooIy ond imtol.
tho .. b" .. pipos.
Hand 'ioMon 011 110"" .nd "'Ii. _
tor ..... _
In tIIo ordoor ~ ..n balow :
I . Till"'''' 11M .. ""'n pi.,. !oint ..... ,

TO ROVE :
TOROUE: 8-1' H.... 8 ·14
10.8- 1.01 ....... 8-10 _ 1 10.11-1 ,4 ~ II"" 6-10 fHbl
2. T>w>ton III• •• ~ ... " ch..,bo, """'ft1ing boll.

• TORQUE: 8-12 N·.,
OD.l-I.lIot-<n. 1-fI ft ~ b l
l. TOj~ .. n ,~. r.., _flIa< ........ , ""iIIg boI...

TORQUE : la-21N ...
(1.1-2.8 q..., 13-20 ft-lb l
4. Tighton tho ,"""It

pi.,. loin' _ bolt •.
TORQUE: 18_21 N·...
11.1_2.8 "' .... 13-2\1 "-1111
- --TOROUE: 18·28N-m
11.8.2.8 kt-m. 13·2'(1 fHb)
5-4
"'E"'O
COOLI NG SYSTEM
6-0
s.coo
SERVice INFORMATION
TROUBLESHOOTING
THERMOSTAT
RAOIATORfCOOLINO FAN
........
SVSTEM TESTING WATER PUMP 6-10
OOOLANT REPLACEMENT
SERVICE INFORMATION
GENERAL
Do ............It< .....'"
TN~ • .....,
ft, ......
It< «MIl ""ftHt I/oI.'",IW.,-",,,_
"'F 7It6.. ' , ....... _" ........
iJ """ t VwJ cowltl ........
• u. OOly ...".r ond ..~v ..... • yeol In ..... oooli.". ......... " SO-60 mi. ",,,, i. reo:ommond .. 1or mo.imum
.~'ilOod <On'<>
""" p<OW<:tiofl. 00..,' .....
leoftoI obeoOCI..,'il< .....
• """ _toRt " ..... ,_.... tonk. Do "'" , _ ttl. , ... IoW _ t • .,.. t<I .. lill '" 0 ............. - .
• AU ........................ _ bomodt .. itto ..... _ ... In ..... If""'.
• ....oid "",m". _ , on ...... ""'-..
o An.. ... .a..
the l'fIIom. _ 'Of _ ... "". cool............ , ..... .
• R_ toSoct_ l 1 lor I ... _ _ ..... _ ..i<_ift:tI ond . _...... _ _ ......
SPEC IFICATIONS
,
2 .. ' i.... C2..SUS Qtl

0.8 1m.. to.' US ....
3.4 U... 13.5 US ,,0)
n,..........'
80i" ... 1\0;'" h. l", 50- &0 ml, .....I,
TOOLS
S. h'
TROIJIIL£SHOOTING
-'*" ...... _'- .. _ _....
I. F.... I.... tom_.M._"' .........""'"
I ...... _,... ..... _
2. Tho".,.",,,.tuCk el_
hfllo 1......
I. ,om",,,tur._
F..,lt.
2. TIl.......,,, It"""'_
l . F..,ltv ,000 '<tor.,..,
•. I..... U"';..,'oool.'" C·'·' M ......
5. Pm ; • _ " " In ,..,;ou", _ ... .....' 10<*" 1. F....... _ - . . . ..
e. F... _ _ , 2. o..otlot.IOdO~;"p
7. , ..1.., .... _
6-1
COO LING SYSTEM
TESTER
SYSTEM TESTING
COOLANT
T .., tho coc''''' ",;, ,,,,. wi,~ .... n'i', .... ''''''.
For mui"",,,, <0,,"';0. pmtocl"'n. 0 SO-6Oll.
<oM;"" 01 "~vl_ Illy. . . .nd "'''illod ...... ;.
,ocommo_.
RADIATOR CAP INSPECTION

p""",. '"II tho fldi ..o, coo R'9loc. ,,,. ,od,.,,,, COOLING
_ j!;,...,., 1>0' nok! """"''' •. ''''' '.,.. , ......... "
~ ' 00 ".,. 0' '00 lOw . It ""," I>ok! ..-.1;,0
pr .. ", " , .,. .. 10 • .,
00«><rd. ,i,
Non,
B.'",. 1n".I1,"8 tho _ "" ,,,. '''''' •• ""Iv
"' .... 10 ..... ;"' .. ,1"" ...
RADIATOR CAP RHIEf PRESSURE:

0.' t O. l~ kt/em' (12.1 ~ ~.l .... )
P" ..w i, e Ih' ,odjoto,. MOl ... ,,'" ....... , on<!_ok

, , ,
COOLI NG SYSTEM TESTER
;0, _ •.
CAUTt"'"
Execsl.. P"'=" ",n dantOll' t., ,.diato,

D<! ItO/ ur:t<d 1.0j 1:8/"'" 110 l'>I/
R_i, Of ''9'''''' 0",,"_" i! ,n. """" " iff no.

IIOk!1(IOCiliO<l 0'''''''' 10' " ...., ~. _ .
--
6-2
COOLIN G SYSTEM
COOLANT R!PlACEMENT
I 7JHI ~ "'.... k <001 kfow ...."'" lIM

00011>11 .,.It"'_ at OCI'_ a:./dtr,. OW)' rauIr.
A""", .. "'" ,ocI."", .." tcrlW . rod ..... " ,d ""'" ..".
Of.... IN ........ , , ............ , ocjl""" l>y _ _ .... "'"

a'
d,"" lIIt>t ....... od tho _ 1tflIUI>f'.....
0,,," ,1M ......... , , .................. by ' .......... ""

Onl" bot. . .t ,1M ... ,., pump "".., _ ",,(;r,(Io<
1>0 .... .
~ _ ..... 0,,,,, P..... """ bolo ,
Fill ,1>0 OV"'" .. I.. 0 &0-100 ml",uflI 01 d,,,IHocI
...,O!.rod nhV_ '''01.
BlOOd . 1, Itom .... ,odiotot,
• S.... , ,......,... """ fUn "",11 "'Of..... no
_1>1+0 In .... _Ion,. orod .... IovtI " .•,'m....to'
• S'op ............ rod ..... 0001 .., up to ,1>0 " ' _
..... II _.-.v.
• ~ .. notoll "'" , od....,.. """_
• CI\odo; .......... 01 COOlon, In tho . - . . ..... _
liII '0 .... """oct ..... ;r tho _ io low.
6- 3
COOLING SYSTEM
THERMOSTAT
REMOVAL
110"............ ',", ....1" .,... on<! <\I .... \lit 'o':!: M
01.......-, III • .n.. lrom \lit _,I».. _ .....

R........ 11>0 bol' III" . , , _ ",. III.'........ '
0
houOi ..... \lit ,I, _ . """ ,"""'.. tho ,'0'"''''
•••
l .. t"Iho _ _ .
II............ ttw.-,..............
II""•• , \I'Ot _,,""'.. , houoitI!I_.
rnERMrn;TAT
HOUSING
6-4
COOLING SYSTEM
INSPECTION
1 _ tho 11>0"'10........... Iy lor 110m....
500_ 11>0 ""'""oct" _,001 ,."..
in to . . - IU
-"
00 _......I" tOo """"'01'" or "'., ........... 'ouch
11>0 _ or ,.,. , .... i. . . . ill ,.,..It.
A,pt "'" _ _ , II 'Oo ~ .. ,toyO _ ,•
_.--. .......
' __ ''''''.
_ _ ~ II
'" iod. <M it.,
.. . !OFF' ........
$ ... , ... _ IfIJ' to . .·c m" _ 11:tF I

8 ..... "' ... _ 10.3 1 ..1
....." .... _ to es"c 1203"FI
I .. I i.. ",I... , •.
INSTALLATION
-.
, ............ _ " ............ 11>0,
1......, • _
l ".toIl "'" It."",....

11>0 bat ...
0 ..... "" .... _ , _ ...
r.o.o ..... _
.....
toG
~ ....
,iI/I_
c.,...... "'" _ 10 "'" hOi"'....

_ _ . I....... "'" _
.. "'""' ' .... , .... "'"
'0 11>0 • .... i ..
_ ..... wo """ ''''Oti tho ocrtwo ..........
s.c." ,h ..... """"', .. h""tI .. 10 lit. I~ eIi_,
u.. bat,. ,,,oeItinR "'" 11'' ' ' ' .......,..,,...
_.ItJ. _ .
... 11It
"lit........ , ......
eo ....... "" I..... " " ' _.
6-5
COOLING SYST EM
RADIATOR/ COOLING FAN

REMOVAL
R. _ \hO _
_
8-31.
~
on<! \hO '",I tank.
dr""
.. "'" dr .... .,.. on<! lilt
,,,. ,adl.",,, • .,. .""" .n""';"" b<>IU ond

_til
\l1OlIO
,oono" ,,,. eo"",.

.ide
UF'PER RAO'ATO R
0' ._, \hOI.., ............. I" .
lDOMt>,,,. _ 'odio _ _ _ .
A. ...... ,,,. tadiotor t~, ""'"'I! b<>I ••
-.
0';,--_., ",. ''''''fI, ,, ",bt .. "'" .011; ..... 11110t
0;'-- "",,<, "'" "'.,,,,,,....., <w11d> "; ,.. ,",m "'"

""';Id'l
Lo<. • "'" _ 'OIl ...... ' - _ .

A,...,.. ,,,. ta<Ii.o,.,.. t.I, ....,..", b<>I ••
R.mo .. ",. .ocjioto< ..... ,10 ",,111"11 !1'40 _ , ond
I.. _ _ off.
6-6
COOLING SYSTEM
DISASS EMBLY
A...., .. ,ho !W~ nu' ....., ""II ,ho I,n off
"'. too MOtO< .
• •
"-,
•
-
~'.
Aim"',," "'. "'....... "oc:hin; ..... ton mo, ... to "'"

Itn .~r<><.<f.
6-7
COOLING SYSTEM
RADIATOR INSPECTION
-.
In.-ct tt>o , ...
... J .... " _

...... ....... 011 _
iI.... ....,.",,, !coin"
_
..........,
. ..... ,,;.., ...., ""'" bo''''' ' __ r... .."" .....
I Of
....... ... " . -. "'" ' adiltcor •

... , . ... _ .
ASSEMB LY
,n"oI' ,too I ......... tot .......... Ion sIofOUd ....
,~_ ,too ..... ..,......
,..,,.,, IN Ion _ ............ "'oiL
A,ppty • """". _ , ...... I . . motOr "'oft
" ' _. ;"'UII "'" IO<QIIO ... pi .... .._ . ,.,....
.. _ _ .... L
... _.......
, .... toII "'" ton ..""'" ...... "'" ,"'iI"" .... tlgh_
6-8
COO LING SYSTEM
FAN MOTOR UPPER RADIATOR

INSTALLATION
,.,,01' th. " _ , ond Iowt, ""'"' ""'0 tho ,od;'"".
Inl1o1l tho ,od,I1Of ""'" 1110 If..... .,.., ~"'" tho
mou ... ,jnw /10111.
--
CoMoc1 ,.... u...,.,. ond lowe, h_, end ,Ogh.on tho
Connoc1 tho wi ... to tho .1>0"""",,1< ,wi.en.

eo-..-..et tho o"",,low 'ube.o.1>o l il,.....<k.
CoMo", ,1>0 Ion mot", COUpiOf.
Inu.11 .h. ,ad"lO, grm •• 000 . ido c<>"<'W •.

Fill tho cool;"" mtom ( _ 6-31.
In."" .h • ......, tonk.O<I ...1.
6-9
COOLI NG SYSTEM
WATER PUMP
MECHANICAL SEA L INSPECTION
~ ........ ,1'10 ","c........ ..,.....
I~,,*, ,1'10 .-I1t.1. holt lOt 'ifn' 01 _..,ie.1
...1.......'" Itok.,..
~opIKO .......ott< .......... .., . - t y II fI'Io
'" "'_ ., 01 .... ~ _;.,.
REMOVA L
R."............., .... "- ,,.. _ Itll I .....
""' .... ift ...............
R................ bot ... ..... ...... _0IId • ...,
..... ;1,", It"", ..... cyl-..
_ .. ,h•• tot ... mole< ..bIt ond .".".... , coblt

''0", ,1'10 cI.mp<.
,
(WATER PUMPI
-
t);... _c' ..... ,.. ... , h"'" It"", ........., ... mp
R _ ..... .....' _ _ Of bot" "'" _ .
"VA.
6-10
COOLING SYSTEM
Loosen .n. ..... .. , 1>0<0 band.,

R' mo .. ..... dowol plm,
R........ ........ , .. , P""'P l,em ..... cr.n ~ ""' .
'IIDA.
INSPECTION . ,
a...a.. tho ......... II'I"'P for "''''''' .. 001 ...lluk 'g'
ond bo"i"ll de, ... "".tjon .
RopI",, 'n. .... tor ""mo .. on ....mb ... if roooo"''V,
INSTA LLATION
.0.0011 • <-00'
of <Iun ongi .... 011 to ...... O ~i "ll
.nd "'toli i... tho ,. .... ""mp ",OCY."
"I;go th . ......., ""mil .....It . ' _ witll
II"mp ''''It rod In.. " tho w..... ""mp in.o , ....
oil .n.
cr'''CAM.
6-11
COO LING SYSTEM
Co ... ,
'....... --_.
tho ...... _ 10 "'" w.... """'" .....
I .......... _ , ..... into "'" ...... _ . and

.,..A,HII ',"''''''''"
-
itIolOll ...... O-rint in "'" 111'_ 01 "'" .. _ """'"
In,ul l ' ...... , .. _ "" ......... I.. ooblt clomp'

..... 'igt."" "'" 1>01".
IA
..... ,.,_ ....

C ••
_-
• ......_ _
II"" .. ..... domp "'"

tof . . bIt.
to .... _, .. _ _
,1M'" """'" ,,"bit and .,' .....
I....,.nlh ......k........ ..,....

r." ", "'" dtolfo """ ., tho Iotlt ... boltomo.
f ,~ ......V' ..... ""'" • ~-§I) " ' ' ' ' _ of d;,~11ed
....., "'" ."'~ ,,"f<'OI {poqo 6 31.
6 - '2
COOLING SYSTEM
WATER PIPE REMOVA L
Or .. ~ ,I>< oool,n, IP' 90 6")

1'1.,.., .. 'M " "',.. mo'", cato.,,,,,,, ,.....mp
lOOM" ,,,. ""'" bor.d ,ed """,\00 1ho '", .. "",.
I'om ,ho W,,,' pump C"""'.
loo>on ,,,. ""'" _ ,r.d ,.,n,,,. "'" _,ot """"
hom .hl "'" ... """"' .
R.",o\OO,M "'''or
pi.,. mo",,' bol.
0<"'0"'''':1 ,h. "'.." pl.,._ w,II> lhe O~i ng. I,om

,h . . ."",l1or.
WATE I'! PIPE INSTALLATIO N
'"ml l • <leW O-<ir>e "" "'. w.... P''''' , r.d COMIC'

I. '0 ,,,....,... ,.,
, .. ",II .h. ,..""" bo l'
,,,,,,II ,h. "(>$OI . r.d '~' ''' ,h."o>o bon<J>.
Socu,. ,,," ''', ' .. mo"" c,bIe In ,~. ",,,,,,.
F~' I~. coolic,; ,v,,,m 11>090 6·31.
6 -13
CLU TCH
.. "'''or
1_ 1
'u
~' m
. 0.7-1.5 It· "') (O. , -0. 2 ' g_", n 7- ' ~ ft -"')
11>- " N '"

"I>-U 'II' '''. 7- '0 IH b)
-,
•
0- 7 N' m
ro" 1" Kg·",. 3_~ hJ b )
I
'"
12.S_3.5 . ~...,
'6 - 25/1,,/:1) •
7-0
7. CLUTCH
SERVICE INFORMATION ,-, CLUTCH COVER REMOVAL 7- 11
TROUBLESffOOTING ,-' STARTER CLUTCH DISASSEMBL V 7- 11
CLUTCH FLUID REPLACEMENT/ CLUTCH OIS.·SSEMBL Y 1_13
AIR BLEEDING ,-' CLUTCH ASSEMBLY 7-1 8
CLUTCH MASTER CY LINDER ,-' STARTER CLUTCH ASSEMBLY 1- 21
CLUTCH SLAVE CYLINDER ,-' CLUTCH COVER INSTALLATION ,-"
8O-100 N- m I
18.o-,o.Okg·m, ~
58-12 fI-lbl C"::\ (!;> \
\ ~~~_o
\\;'" ~
\
26--30 N·m
1 Z.6~3 .0 kg.m.
18-22 I>-Ib)
7-1
CLUTCH
SERVIC£ INFORMATION
GENERA L
o TlIIi W<I;o., _ , ' _01ond "'lallo<" 01 .... _ ~¥OIt"'ic ..,...... , ....... ond . . - . ........
o DOT .. boob _ rwo-ouO., ... ... 11>0 _Ion. 00 "'" Il1O 0",", '''Il00
_bo_ .
io uood lot .... oct! .,., II .. I• .,.d to . . . ..." _
01 _ _ 1IIOY'" "'" =,
~Oliblo .
o a..td\",,,",,- iIPI1t>o .,...", "'" I, .....
SPECIFICATIONS
TOROUE VALUES
a..tcn " - oil boI" 2t--3IJN ... i2~' k...... le~ft""
ClIo..." flu01 '0."'._ 2-3.5 "",,, (Q.2 ~.36 kt-m. U-2.§ 1,·110)
$ ....... _i00i,
0....,, __ ... _ "'"
80-100 N'" 18.0- 10.0 k...... !IoI-lll
n-e7 It.... (8.3-11.1 ......... *-48 " ·Ibl
S,. 1Or duOch_ H - lIO It.... (2.8-3.0 k...... le-:n " .. )
M...... ",1; _ _ , 1>011 HI-I( N.... 11 .0- 1•• k..... . 7_ 10 11-Ib)
'i W
"'"- Unn. ....0 1 _

~ft
0172'5-(1(130000
07141-0010000
. _••,·•• _,~ . ~ •• 7 """ 077 ~ ' 001C300
f'jlol. JIS ...... 0"" IXI4uano
7-2
CLUTCH
TROIJIII'SIMIIlTING
ClIo"'" ' - ooft or 4 ... , MOl ,oIo_ .. IItI ....... 41.. '£ 2
1. .... 1, Itl.t~bl .. i. h\'dt". .,1c ..."_
1. .... " b<lbl>looln ~"" .. "'Ic ... " ....
2. L.,.. !Md 1...1 2. ~ Ih.tld 1.. 01
3. 1-1 .... '0111;,; .v... m"01<1", 3. H..... ouIlc .v".... "'.i",
4. Hv ... oulic .......... ,,;ocint
0",,,,&00... __ I . " ........ pod
I. Stlclol,. .,;n""hl
2. Oon Ih .....,ic ........ l_"' __";oc ...
, . .......Iie ... _ ..
a. ........ 2. LlIt....'''''.. ,i.".'', ·s .
1. H.... 'oullc ........... ~ ...
2. 0 1... ___ CIvtdo_ ....... _ ......
3. 5I><i.... _ , . (lu, .. d""'" _ ........
2. Slide ... "'""b)
CI~"'" wlM .... 41..-""
'n
1..... " 1><>1>101" h.... ' .. ,1c ..........
2. L.,.. II" .. ,...
3. H ........ ,1c .y ....... _ ...
1."_ ...'ic.,..
4. H.......
.......... lIide ...
7-3
CLUTCH
REPLACEMENT /
O>od< "'" _ _ w>tl'l ..... ""ill .... " 0 , __

Ie""' ..........
,"".11 .". dl.",·, ,_ on ,,,. ... " ... - . .
_.~ ... ,... ct. .... _ . f" lu, •• o 110 10
.. I . ..' - ct..", thtill '0 leu,n "'" .......
..... . 010 __ ........... 00".' .... .
......_.'011 -.......... . .""'- . . . . . ,

A_ I9iIlWoi ""ill "" ..... wet
, ~ "...,~
""'0<01.
CLUTCH FLUID DR A. INING

Con_ •• _ _ '0 riot b _ ..I••.
L<,,," ............
1...... _ .......... "" ... p ....
ct. ........,.
5."" _ ....... __ ....... "" __ "", ...
thob_ .....
CLUTCH FLUID FILLING
NOTI,
.I ....., no. be _.ibIo.

00 ""' MI. d;Itt .... ' fYIPft 0' ''' id >iIoco .....
Clc. tho _ ...... l ill .... , ___ . ..... _
ttood ....... _ .
To "' ... ,., ~ .. "" _ .........."-"'"
_ . k H O • :xl trufI (ll' ",I 1110.,.' bO,""",, ,,,.
,,,,id_·
...... 1_ .Ip , .... _ _ b_i", "'" ...... <10
",......~""'" "" .... .... ""...........".ho _
,~"
_ ;1 ...... ore 110 ... "" ' I.. .. .... ,""" ftc ;"
"", 01 .... " ... " ... 011 _ ond _ , .. ~ ..
fe11. no.. _ ......".....
7- 4
CLUTCH
AIR B LEE DING
C h oci< III, Ilu" I<Y" olton whil . blnd'ng

t ... dut"" to ",<Yont ,W 1._
pu"""" into tho o¥"om.
""'' II
U .. ""IV DDT 3 '" 4 ,.. k. I luid I<<>m I
Ie.'ed con,,""".
Do not mi. br . ... I..... tv.,.. on-d ......
...... .... fiu" whi<:h ~., bOOn "..,mpod "'''
du,ing blooding. 01 til< 011 .... _ of , ...
eiutch 'V" ...... ill bo """,ind.
R,,,,,,,,, tho """.. tVl ,""" c>p , ... lill ,no .. _.

'0" to ...... lu li .
C",""", tn. Mitv... B"k. BI...., '" _",14m '0
tn. b'. _ v, I••.
Pump ,I,. M,' V'''' B,_ , 1M _ " t>.., ely","
bI.O<lot .. I., .
Add lluld .. ... " In. lluod 1...1 In !h, mo"" <,/11 _
,...,.0. i, I"....
R . ...., obov' ",,,,,"w, . . un, il

. _.. in ,,,,, ~I."i< h_,
"'IT~,
If .i, ;, ........... 11>0 bI ...." 1<"", """M ,h.
OIoood ....1.. ,nroodo, ...1 tho "',_ with
,otlon t_.
II • Mi "",.. Bnk. BI4_, '" ~fI.IIft' not ... ~.

obl'.bind , ......,,,,, to foI1"...I:
II Con ..... , • bind" ",bo to III, bI_ v.....
21 Squ . .10 tl>< clutch I..... OPO" 1h. blooOt, "I ••
In 'u .n.n<! tn.n clo.. "'" " " '.
(i
b l ' -,,,Iv, h .. _,I_.
Do no' " I... . .1>0 , ,",on """ "n,,1 !h.
31 A. I.... !h' .... "'" I",,, , 'owlv ond ... i, .......

oecond • •1,,, it ,NCh .. th, ,.0 of i" 0,,01.
A....., ""'" I and 2 un,iI ...""". ".... ! o """or

.. ,"" fluid" ,h •• M of Ut, no...
7-5
CLUTCH
Oil 80l T
CLUTCH MISTER CYLINDER
DISASSEMBLY
D•• in dutch fluid f,om ",. hyd'lOllc ' V" .... ,
R.mon tho Hlft .... ,iew mi"".. on<! .lutch HI, .. ,
Di,.",.., .... , tho c1u,,'" ...i,,,,, ..
i .., .nd ,.m,,..
,tit "u, ".,..,
A...oi rpiUIItJ du,dt flWd o~ 1'1111,«1 ",,~ ....

MIl« • Fq 0 . . . I~~ fl<tI IQoA: ..iIt~ .... II",
dul<~ .1)""'" ;'-..1.
'W" ,
Whon ''''''''''ng ,tit o ~ bo~. <CW1 ,ho ond cl
,t.. h .... '0 _on, «><I'omi",~on and """"
'h.h .....
R. mo .. lh. ""'" ,cd bool •• hon '.""' .. tho "'<1'0

tr"", tho .,.".. cyli....... bedy.
01914-3130001
Ro",_ tho "',,"" on<! " •• 0:1, ... CIOO.

Rom_ ",. ............. p and "" ing.
Rom ... ttlt <M"" "'~"" . ~ ....... ""'.
PRIMARY CUP
:r r'
ClUTCH
/""""'"
SECONDARY CUP
SWITCH
7-6
CLUTCH
MASTER CYLINDER 1.0 . IN SPECTION

M_,. ,''' "'......,_ 1.0.
O>oct.. IN ",.,.. . . . - lot ocotOi. 0<1"_
... !We....
SEAV,CE U M1T : U .tl .... (O.Ullt!l
MASTER PIS TON 0.0. INSPECTION

101 . ................ 0;"..., 0,0.
SEAV, CE ~ ' M1 T , 15.10 .... (0,ll221n1
C.... k ,,'" ",itntty ...... _ ' " cup< I.,. d...,.,.

bol........ mill'< .
ASSEMBLY ...-
. I COVER
I CI<P''''
No""" 1M -.,,,. "woo.
_fT""Pa. WI.
~.
Coo, . 11 POt" wi'" ....., DDT·, bflko hUleI bolotl LEVER

.u'nbly.
In...n 'M ""...... itn ........ O..... ~m..,. PISTON AND
SECONDAAY
""
"'"
-,---,
I
,..........
..... _ _,....
,... ...
, ............ aid", "'......... 11 ;, -.tid ' ....... It!
,...,01' ,,.. .... _

,d> .11 rt ...... ",",ocI.
C'ACll' /
""" "' .I'USII ADD
[N O ~ t [C[
7-7
CLUTCH
HOSE
P'''' ,ho """or ".r,i_, on ,ho ~.""'_,botto,
,,,,, .' , ,,,. "",dOl .M 'ho twO
.""
",",,",in~
A'ign 'ho ..... of , h. J>oIIIOr with ,ho pundl INI,k
on tho ,,"ndio ... , .
,h.
TiV"'.n ,ho '<II> boh ,,, ... '''''n ""nom bolt,
TORQU E:
'0_ '4 ",.", (I .0- 1 .4 kg·",. 7_'0 It-II»
,,, ... 11 , ... e'u''''' """ wi'h ,,,., bol, 'M ill twO
HII~ WIOMrO,
'n ... 11 I'" PlJOh "." _~...,. 'n'o Ihl <'u,<" ,.... or
nolo .... ;""oIllho .... ,"" IfMtr
ConoOct , ho "",<" ow itc"¥<l,,, 'Q'ho ow"ch
,",,,,In''I.
fill '''" ' ..... rv<>i. OM b1oo<l .n. <Iuleh .vot.",
I""~ 7·41
Ah .. •. . ;
Adju., e"""" 10... ,,. . plOy IIII~ 3· HI,
CLUTCH SLAVE CYLINDER

DISASSEMBLY
PilOt • oontoi_ undor II••• 1..... q linder. rom"".

'''0001 bGI, ond "'""""nod ,ho dut"" noH.
~.
A\/<IKl ..,illing elu''''' NuKl "" lII.med .u,-

' .... 0 .
7- 8
CLUTCH
R,,,,,,,,,, til. pilton f,om ,,,- ",,1;.,00, .
-,
If "'" ~""" .. mo. .1 ;. h ... d. "'_ ...."" ",","I
".... ..... p~t"" ,,, ...,,"ion ,,,- pi""" _ il it
. ~ po ll od. ond P'»i,ion "'" <ylindo, .. ith "'" pi' '''''
Apply tomp<eSSOd Il ' to th. fluid iftlt, to '"""""

"'" P<""".u.. "'" Ii, in """, """".
R.mo ... 11M <P" .... f,om 11M .1 ... <ylindo<.
R"""vo th. oil ond o~."" ..",.
co........ pi" .... groo.....it~ <"'tet> ~uid .
PISTON O.D . INSPECTI ON

CI>ocI:. Ih, p<n.., f'" """i"ll '" "",,,,,,... •
M. _•• ,,,- outlid. d......... of tho ~ .. "" w;th.
",icr.,........,.
SE RVICE LIMIT: :w.D.2 ...... (1 .• 91 .. )
7-9
CLUTC H
CY L IND ER 1.0. INSPECTION

a-I< \ho ..... cylm.!or r", ...... ~ Of . . . _ .
loI.. ou ....... ....,. d ....... , 0' \!Io ....' _ ""'0.
IfRVICf LIMIT, ll1.11 """ 11.&03 ..1
ASSEM8LY
_" ,bit ...... _ cy_ In .... , _ _ 01
d;:·" ... W. Tho 0;1 ............ bo "ph . $ with
..... _ .r.....' _ _ _ ,_. , •. .....,
L""'leo" \!Io pIoton ..... pj_ ..., with ...........
D''''' 01 I1 I.TtmPf!"'!\Ii"I ~I""" IA" or till'"
I 'u~
-
bol.... 01lOmb1,.
.0....
80 conoi ....... p j _ ... " . .1Od Iro ...... itt""
l'1ooo .... ..-.- 1ft .... cyl j_ ,.",. .... 0;1 _ ,

SIL ICON
GREASE
"'" '............ INSI.ILATOA
'n,,,11 the I",ul..., oM . 1... c~l j _' .

Con;,..;' ,ho cllitch _ ... '" 'ho 011 Il0l, oM .....
IWO ......... ..- .
."'........ Iolt cr.. kcaM ... _ .
Fill .......... fluid ...... 01' -M'" DOT-t ...... ou.
II ........ "" bralt. podol.
II ....... "" ""'.." .......
Il00 • • E ......... " " ' _ pino
STAIlTElI lOlE GEAII

STARTER ctUTCH DISASSEMBlY
II ....... II>f ...... 011 ....... ohatt_ .....
7 - 11
CL UTCH
_ . . "" 01_ .... _ 4_ 11-2).

Hold .... '1 ..... 111_."'""""-1_.
R.", ... " " " ............ _
R_1ho .\at,. .......
r
.
.. 0lil, ond_.
sr.", .... ..wi'" . .... _

IIrirnoty _
. . . . 10 1M, po . 1 I ott tho
.. '_IN 10"--" _ _.
.....
11'--.. d .... _
lIofroo.,.". ......... ~ _ and _""_in!

R_.
, .................. <to.d>. STAAHR ORIVEN G EAR
Ift _ N ,0I1o<. 1ot ....,..'" _ .. lot>. NEtOLf8EAR ING \
tho . _ dwl<lo _ ..... '_ing
.... "" .. toolt~
R.,,_ ttl, du.d> ,01"",........""" and
CI>ooII "'" ••H,.. ,'" . . ... ~ •• _ .
"" ......
STARTER
Sl"AING _ _ __
-, """
7-12
CLUTCH
STA RTER DRIVEN GEAR INSPECTION
_.,.
Iftll'O<" <h. d,l .. n _ 10' domogo Of . . ....1...
M.."". ,h. d,I,.n golt 0 .0.

' ~ IIV'CE L IMIT: $ot.1..... 12.132 1"1
CLUTCH DISASSEMBlY
Do not 0\*0" ,n,

Clutdl "'.. , .It.,
,.....,.1"11
' M <Mm . T o do '" ";11 ...... ,J;llto.I!1 In
, ......bli"ll tho cHItch .
R.m"". tho <n.p ~, Iii,,,, "' .... lift.. guldo.

,.10_ b..,I"'I and Iii.., rod .
1",..11 ,h. . ... bt ..... podol ,
stlifl "" "..,ornicoi"" In.o high VO" and ~y!IM

.... brok. ,
W!Ion!IM ...... ~ not in !1M I ' ...........11t tho

" """,10> .... In.o 11'0' ..... "" .", Moin·
,h.
..... " Hold ... PIN 01923 6890101. '0 hold
linol ..... fI.
II.....,... !1M <lut<:l1 ",,1"'1 .., "' . ... 0.... "'" .... i"'l
and ........ "
7-'3
CLUTCH
on ",b /v.
7 - 14
CLUTCH
ClUTCM OUTER
Rom.,.. "'" d", <1'1 "",., ..... "",.. ""iOo,
_ .. me <1",<1'1 Ii i,,, ,.."
I:
INSPE CT ION
CLUTCH OUTER
a-.. tIw "" .. '" ..... ""',." ...... lot tudo. .. ..... '"
_lOtiom ",.. lOy "" ";0,,,,,, dj"",
Chock I.... ct""'" ""to, ....... __ bot .. "", {", dom ...
'" .' 00,,;•• 9''''
II "" ,,,,ell. _~ ;0 d,f ...... U to '""""'. fn>m ""
t_ ... "
ctot><fl 1'oau1i............ tool"
Oti_: 071'Il-00 . 0001)

A , _ " 42 •• , ...... : 0710111- 001B300
~, .... , 3~ "''''' 071"4-004,,*,"
CLUTCH OUTER GUIDE

Mo ...... tIw 1.0 ot "" oIIotd'l ........ ..,;do,
llRV I(;E LIMIT: "',01""" 11,1" Inl
7-15
CLUTC H
CLUTCtl SPRING
Moo_tO d>o '*"" 01 tho .... tdI ""~ _ ft,..,~_
URVICI! LIMIT : :u """ ID.141001

11 .... _ tho ....1nI ;1 , ......... ' io .... "'"" tho
...100 I.... , ~
CLUTCH DISC
11 .... _ .......... ten ~*' ,I ........ " - '"" <>lOCO!.
I.. '" ~ ;_ot5on. Moo ...... tho " , _ 01 • .."
.,~
SER VICE LIMIT : 11",," (0.1 2 ..1
1I.",tet "W d lICI tIotl.tO tIo lnnt. 111." ItoI ...... kIt
11 ..11.
CLUTCH PLATE
.'". ,......
O>odt .... "' ... w ...... ",., • ",floc. ............
IEIIVIC I! LIMIT: O.lO .... (O.Dll;,o)
7-16
CLUTCH
ONE WAY CLUTCH INSPECTION
Chock ,1>0 roll"" 10, • • .,..,1.. "' . ...
"'..,u,. the to. 01 clut<h a-nto, 8.

SERVICE LIIIIIT: 7'.60 mm 12.93310)
III • ..." . ,1>0 D.O. 01 ,ho """ woy clute/> I".,....

SERVICE LIIIIIT, ~7.1 rom 12.27 .. 1
7-17
CLUTCH
ClUTCH ASSEMBlY
I.....n tho duld> DIller . . . . Imo 11>0 o;j _
m-I.. ""OC~.. _ 11>0 _"""""-
....UIllhe" "._lngln",dIodutdl_.
In..., ,he t1utd'llifw< ,ocI,
#.lip:> .... _ .. the """'" ""lOr .nth .... plnt

"" .... oi l pu"", lifi.. """""". ood ...... 'Il10 ,.,"'"
"" •• , .... r , 1'10 .,000.
'no'oIl th. OlIO ..... duld> .. .., du!dl <ento, 8 ""ith

I,. 1I..,c1 ..... ' ........
7-18
CLUTCH
"',''" INNEA
1",,.11 .... tlut<h inno, ;,.,., .... ."....,..... <Mch by
"'rnir>g i1 oI«l:. .. i ...
In,,.n '"" .,.... ... v dutd>/oluI"" cenl,,, 8 .... mtJ!y

CLUTC~ CENTER \~: " ' ~;;;.~.=;,;:;;:
.",.. ,h ..... ;"'O.!l
M. k. to,. .... " ' V <lu"'" _bly i<

<>nO
inlla llod """.''''v by Mnl"'l oM"" _ .. ,
S ""'il. Midi .... ,1>0 .... insI1,lt. The oIu","
""".., hwld 'urn ..,"",0«'''''........
h~V .nd
"'''<lId not .... n olockwi ...
Co,", tho di"" ond pi"" with clo., Mg;" oi l.

1",.. 11 ,I>< <lu tch dl"" ,lid p l...... "'own.
<:AlIT'''''
Dc ,,,,, ""U <,",c/o <~It, B WI 0/'" Ito"ol/blr
rho d~ ofN plJltJ "'. p.,,~ .... 111 /.11 I>tr·
....." <h<I<~ ..... ,.,.. 11 _ B.
nm ";/I~, tho <",rdo from Qj~_
7-19
CLUTCH
.- ..
In.......... clutcll
100110
ocW>I ... pIN. _1PO'Io:-.. ...,
I lnnOIl ..... ciutcll _ . . . . th 11>0 dioMd , _

......'" Iho _ .
1"'1011 "'. loci< ....I'" .. i.., I.. OUTSIOE m.,k

, ........1.
I
WASHER
~,.
_ ..... ~ Iho ............ "'" ..... "'"

01 Iho " ' _. .... " ......_ _ ...... _
ond _ "'" ""'WI ~"', ..'" . . HI'
07123 .2 )101.
TORQUf : n.tJ ...... (I .U .' k _ "'"" h~bI
7-20
CLUTCH
In"oll tho oMeil lift .. ~ott. !;f,., guldo ond bI",·

,~
In,,01 1tho ""OIl ''''~.
STARTER CLUTCH ISSlMBlY
. . ._.1_.
1""011 ,,,. I'I'imaty d , i.. 110" ""'" tho ••."IuII,1t
mo
.... il • ....".i"'l "'Om ..... d.i .... ",,,,,.. w ith 0
7-21
CLUTCH
,......,_ ,lINd, wi ...... tho .....".." .
In,UII tho " ...... iOlot ......... ",.It.
._-
'nn'" , ............ U , ..... ...Ion ;"'0 tIoo
Innoll _ _ .....
,,,,.... , ."" ......... dU,cto _ .......... "'" _
roWo '>010 .. i1Io .... _ ""'""" ,~, ........ bot".
TO~OUI : 2t_ lO H·m 12 .8-:1.0 k_. "_22 ft-ltol
OOOt l 1
.t.,ppI •• _ ... _ '0"'" bo~ o;IYNdI.
,,,,,"1' ,.... n..... o,i_ 000' &y '"'"'''' k""",,'ot·

.o",;:",.. ;::~:::"" COVER
. _..iN.
7-22
CLlITCH
"'''' ""'
...... "'""...:1
",,,"Ch """'. '1M1O<
ntlll \110
Oft \110 """0< ......... and
oI\<,d\.
_ ,~ . ftV_ wi,~ !h. Unl...... H04 ....

(On25....QO"«)()Q1 ...:I 'itt>_ "'. lIor'" d u'm
bOIl '0 ,"" ,,*,Iied """ ....
TOROUf : 10-100 N' " , .. 0-10.0 ........
~ - n"4 1>1
ClUTCH COVER INSTlUATION

1...... ,o;he _~...:1._ .......
(!)
'""~ " ~. dulC~ CCft,.

,,,,,,,1 "'....... poo;!oI.
F," ..... e< ........... wi'" ";11_ 2·3).
7-23
GEARSHIFT LINKAGE
8-0
8. GEARSHIFT LINKAGE
SERVICE INFOR MATION 8-'
T ROUBLESHOOTING 8-,
GEARSHIFT LINK AGE REMOVAL .-,
GEARSHIFT LINKAGE INSTALLATION 8-.
SERVICE INFORMATION
GENERAL
.,.i,"
• n .. _,M' 'Oirodl • • nd " , 0 _ " , , , , , con boo ..... ,"*<1 ,he tng ino., the f,ome.
o II til. "'ilt I""' •. d,"m .rod ,,.,.mi .. ion ,_itt .. "'i<i~ ........... tho ongi . . . <"<11<1*"_ .ho or .........
TROIBIISHOOTING
Hord to .... ,It
1, A i, oobrllo, .. 'ho clutch hVd, ... ';'; IV"""_
l. Sh ift lo" .o.n'
3, SII;1t <I ... ben,
4. S" i" drum cam 11'00'" d.~
T""'''''''''''lum", o,,,ol~'
I. Go"d"" .. or"
2. Shill ""'11 b.."
3. Sf,ift drum , , _ btok."
•. Sh;1t f""',
bon'
8-1
GEARSHIFT LINKAGE
GEARSHIFT LINKAGE REMOVAL

Dtol" "'" .........
II.....,.. . ... Ion <I'_ c.o , ..........
_ ...... vo .. ",;,. .'" h _ .... . . . ",;It

.P;~ •.
110 _ , .......1Ch ..,.., one! ca."", '_bIv
I.."'.... n
11_ 'Oo 0>11 """'" d,l ..n 'I>'«U' I>O~.

IIIMO" , ... o~ """",lit," <hoi ... d,"o ond "' .....
qw-. ...
8-2
GEARSHIFT LINKAGE
A.....,,,, "" ... _

dk'..... c"I1 ...
dr;", ""ocb\ w_ . . .
-.
""'II HI. ~,"" i lt '!Iindlo ... _ . ".., ot .two "onk·
8-3
GEARSHIFT LINKAGE
SHlfTOR liM
~ ..... .,., "', no",,01 , , _ or" bol! , orm In!!

SI" ing.
A _ tho shilt d",,,, ..... JO'" bok .,., com

0>/01'.
GURSHIFT LINKAGE INSTAlLATION

1",'oIltno d""'. pi. It. 11>o~ , of lho shilt d",,,,
I ... " '1>0 I ... pin, I. tho 1>010< 01 , ho oem P ~ I'.
Allfn ,ho COM pIo ........ ... ;,~ , "" dow .. pin "" to,
sh llt drum.'" 1...... 11 ,I>t com paolO,
Tlghlon tho boll ......... ~.
--.
' ...... 11 to. "''''''' . ...",.01
Tight '" ,I>t otm t>ok IOCUroly.
" " _ .. m. 1pi"0Ig Of>d
8-4
GEARSH I FT LINKAGE
............. til, ",,_If! ",,0<11, ond rotu'" . ",1"11.

'ond "",.11 .. I/o",.".
GEARSHIFT SPI NDLE
'''',''' th' """,,ifl OQirKjj, _ ..... "'e ~ ..., .

...., with .... lNoj..,;on on ......._ ....
............. d........ _ ...... .... Iot. "".... "'_
.... "'" .... u" ..... _ .
,.".... , .... .... , "",01 • .
RO' ... tho ___ III ..,Indio ...., eNd: ..... 1"*....
101' _ h _.,;on.
8-5
GEARSHI fT LINKAGE
'm.... ,ho 0 ..... . . - 0 _ ........... shoto.

,,,Ita" .... all pump .... """ _ lCO'oct; ...
-MtIo !ht d'M ....in """ ';ru" "'" dn....~ ..
.I ,."'
bolt-.. ·t1v .
Tho ...... lCO'oct;lt ""' . . "'N" "'"'" -

....... I_ .... ~ .....
Align .... _ morlo.l Oft tho """,,,itt Ofm

and _ .. II •• ~ndlo ond I"".~ ,ho 1IOO,lhil\ Of"'.
II tho lINflhltt podol tio~"" w.d ...... m .. ocI . od·

"", ............. t·" I I ..... dillOnal by _inti
.... kid< nub """ ............. 110-«><1.
STANIl""1l tIISTANCl , 21 .1 """ II .IM I/oj
IAAXIMI,IM I)\ST AN e l : ~ O. O """ (1 .1' 1n)
1",, 011 " .. lott ...... ~ ' ... _ ...... I~I ....
• , ....... ",Ith 0;1 (_2-3).
8-6
MEMO
ALTERNATOR
@;, . ]
8O-100N"m
18.0 - 10.0 ~9-M. ss_ n !Hb)
9-0
9.AL
SERV ICE INFORMATION 0-,
FLYWHEEL REMOVAL
0-'
STATOR REMOVAL 0-3
0-3
STATOR INSTAL LATION
FLYWHEEL INSTALLATION ....
SERVICE INFORMATION
GENER AL
•
•
,.nd
Th~ ,"",ion ..,. ... " . ......... """"'0<.
1"".'I,tlon 01 ,ho
Aofor to SKlion 18 /00 in","" l i~ ond ".,..bloclloo';"I.
TORQUE VALUE
Ajtomnor rotor/Fly,"""., boll SO- IOI) N' m 18.0 - 10.0 "''''' 58-72 h -Ib)
TOOLS
~- 01725--00 ............
Un;.....' _..
ROt.,. ""II., 077 33--00:10001 '" 07933-32\1000 1 (USA anM
9-1
ALTERNATOR
flYWHEEL REMOVAL
p~ • ..,..,,;_ uf'do< 'ho '""'noto< .",.. '" "".0/1
...... Oll,
F\emo.. 1he1oft ....." " " _.

........... 1he_tOt"""".
Hole! .ho fI ,w ....1 .. ~~. ""M,.. I _ _ ond " .

_ tho II, ,,' 001 bolt.
11_ !he " . ... III ","!II "'" to'''' pJnor.

II.",,,,. ",. _ ",II by It_ 11>0 ........ fI.
9-2
ALTE RNATOR
STATOR REMOVAL
Remon \flo ....."" Ir. .....,. .ido .,.,.... ,
DilCO!>01oct tn •• It . matO< coupIor.
R"""". tn. , It.,,,atO< Iud. !rom tn. cI .... ",.
--
RO/I'IO'I' tho . ta.."
STATOR INSTAUATION
by romo\l;n; t~ . bel ..... wi "
1"",11,''' ........"" wiro cl,mp.
Rouu \flo oI "'no"" "o,h """'0 1"9 to .... di . . . .

in 5o<tl_ I ......""MOt' .....1<.",,,.,. w; .. 0",, 1>"'
to , .. wi" II.".....
So",ro tho .It.,"..", I. ..... m. tho ol.-npo.
I"uol l ,ho .. ot ond f,om o IoU .<10 ",,",or.
9-3
A LTERNATOR
flYWHEEl INSTILLATION
~ -.
.................
Hold "'" "" .... 77 1 with • """,*,101
" " _ ..... ",wt 771_.
""'tI.
.... 01. !he .. oodrull ~ .... 11010 U... '" ....
, .... 011 11>0 ", ." ,I b~""""" Ito k~ w M> .....
"""57 .....
TOllOO( ; 8O--IOON ' "
'1.0-10.0 k...,., N_72 1Hbl
."', .. , ..... 0 1 _ coo.f.

I"'........ l riI.«..... COIf ...... .
O..ol ...... "" _ ..... .:lei oil If .'_ _"Y (_
N I.
9-4
.~,
CVL INDE R HEAD/VALV E
I Q-I~N,,"
II.Q-I.H• • ,~ n ·lb)
' '0·
, •,
11-20 N ....
11 .'~2.0 ~t'". I3_I~ ft~bl
..-62N ....
14.1_ 5.1 ~ ...... 3&-31 ft-lbl
10-0
10. HEAD/VALVE
SERVice INFORMATION 10- 1 VALVE GUIDE REPLACEMENT 10-13
TROUBLESHOOT ING ,"-, VALVE SEAT INSPECTION!
REFACING 10- '.
CAMSHAFT REMOVAL ,"-, CYLINDER HEAD ASSEMBLY 10- '5
CYLINOER HEAD REMOVAL 10_7 CYLINDER HEAD INSTALLATION 10-1e
CYLINDER HEAD DISASSEMBLY ,,-' CAMSHAfT INSTALLATION 10-111
SERVICE INFORMITION
GENERAL
• T"" evl_ ... od ..... bt.".,.,d-.; ............... In .... " ......
• If "" . ........ och .. 0 1 .. _ f""" 0< , . . cy1 . . . . . . . , . ,....... ......... , . , .... 01 ....... eylindon ...... 110 _OIl llurinl
feino\.OllotiOfl.
• eo ..."",,, _Ut.nt 0;1 iI 'ocI ..... - ... an ojl I.... So ......... _ in .... oil !;no io "'" .'<U " ,
• 0...... _ ...., _ _ I J,._d_......... .-...... _ ...... __ to ....... ;"itlollubr;eo,;"".
• Tho <'W1_ ... " t , '..., ....... _ ,
FRONT
.
(0 0)
speCIFICATI ONS
(0 LE fT
8
10-1
CVLINOER H EAOIVA LVE
111.53_13.30
TORQU E VALUES
0.1 ...... _ ..... ' 1 _ 1' H..... IO ..... ' .2 ......... e I~lbl
~"', -.&""" 10- 14 N.,., (1.0-1.4 ~ ....... 1_ 10 '1-Ibl
Com ct>tin .... "" A. l l-1!i N·m (l .I_' .1 _....... 1&_ 18 h ·lb)
0.11""" ~.ad. 1(1".." 48_ 62 N·m 14.1-6.' kll""'. 3&-311 h ~ b l
C.' ~, ~...o. B""" 2 1_ 1!i N.,., 12.1_2.& k."". 11_11I,·lb)
RO<II .... '" "'01. .~ SO N.,., (• .5-6.0 k...... 32_ 3II 1I·1 b)
C......... ,., 11_20 N... (1.5_2.0 k,,,,,. 13_ 1. fI-lb)
I, 101
v ..... ..,Ktt _ . 5.5 """ 01' '_ 2000000
V.... ..,IdU''"", ~ 2 -3NO I OO .. 01142_ 0010100
Votl'lllllkM d, '.., 01U3-«120000
TROUBUSHOOTING
~ ... ,.. ,~_ II"""'"'' "",oily , flOCI ....... ....-tor.... """. T_ .... bo
...... ..Ith • ...,<>dinll ,.,., .. . tot!' ." I
~ i llll ocwcl by , CGmDI_ ......, <i,,,
by tr..
.... _"'....... Com",....... ~1tI'I

I.
_l_fOCI._
v_
- ............ _,......
ad;"''''''''''
1. ~. __
""', b on;'" _
Ito illl..,pon~
bo:
..
_l_fOCI._ '. . . .
- 1 ........ _1Gring
.~~
I. I..-roeo . .... ...,......... ,
1. St;ck" ....... - . . . . _ .......
1. 0. _ _ 3. 0 .- 2 I ......" comonoft
- to........ cIom-' _ ....... 4. L_ or _" com .".....
_ W ...........ocI<'" <\,1_ "'''' 6. Wo<" ., ............ com ..... " _ _
I. Wo<" com ",,0<11.. 'oo'"
3 . Cyllnde< ,rrd p~ ,,,,, IAof...o So<tlon 121 1. Wo<" _ ... ' '''' .. rodJ.. ", ..It
10-2
CY LINDER HEADNA LVE
CAM SHIFT R£MOVAl

Drain tho _ .... 1 _ 6'31 .............. N '"""
"'. """' ... _ _ t>I' i.'....... "'" both_
............
A.mo .. tOo ""'k 0>"Ii 0"",.

R.me" "'" .,,1I1on ",,01. w;,h ttoo ~ ".e"'" _
."""' ... 'hOlnouIoto< <0_.
A_ttoo.,. _ _ _ _ _ _
Ifom 1I>t .... evlinder Mod.
~omow tile evlinder I\wd «JI<tt !tom 111. Iront
oyOin<Io' hull.
Roo '..... "'" 011 pipe _ ..... _ ... ;0. .-Jnlint

boI" ...... ,"""' .. !!>to.... <h ........... .
R."•.,.. ,no ."....,'" ...... ' ...... ",,,,,. ,hO or .....·
... of' . _..... "",II thO cam o;hoo" 110. f reo 0>1 •• ,
Aomo •• tho ......... _ ......... ""on .... "'lddlo

0 . .... eII ....
A.....,. ....... h..., ...... IMelion I I.
R"""",. tho <01"11<>, ...... I..." "", 41.
R.....,.. tho "'vi.. """""';'" boll on"" cy l.....
~.
10-3
CYLIND E R HEADIVAlVe
r .... -
,
!lit ......... of< _ ..i. ~"' i l N11.3 "' .....
oI ......ilt! ....... «...u.. ",o\itlt ",,1_.
"_ •• or 'Mp _ 1"WOf tIIo "or CV11n6t. hood

to III""" ....... from "'i"'l d."!>POd .. to .... ,,.111<.
OM.
,
Ao"""'o ,he . _
.... oc~ .. _ .
~,Ii< Ie< ...... _
T",n ,he cronUlloft .Ioc k"'" ono IU<n (380"1 and

.. _ . urn
,
r o _ , ... o' ho •• om '1"<><"" ........
• fl.)
Tum .... c._<Iock_ _ N 12' marl<
CIoon .... _1PfGd_ . . . .

..... _1'111'10 . _ ......"... " ...... _.';";..,
COlI .... tIo •••
_ ..... frOt.. "Ii< ... _ _ clots ......
INDEX M""ItS
-.-.
..........1 .... 'flindo'
hoed. Uoo I _
Sotno co"""olt ""o<k... mo~ h........"' • .

pioof
.,.tot in<I« . clots .. IIIown and \Oil "'" ''''''''0

..... kin ;
"'"'10" tho ,,,,.,, .......... _ ........ _ , ......
....ocU,_
T",n ......- - . ,oun ... _ _ _ "'"' FRONT CYLINDER
(311O"( _ ' ............ 01 .... urn .... oc . .. _ . C"MSHArT SPROCUlS
SI;,:to "'. ,..., """"Iur"with tho ...., .... ain 0 11 ,ho

""" ....1' 11"""'01 11"'901.
II...... " .... """ ........ fr om N
-
-..................... ,.;",,- .
""'G" "" ........" ,""",,,,- ...........
........ ......
_
~t
-
k... """
10- 4
CYLINDE R HEADIVALVE
A""", • • tho com"'..-'

""10 ... _ , pi .... onO 'he
in.. ~ . ond ..h~" oom$holtl.
CAMS HAFT/CAM HOLOER

INSPECTION
I~_<t th. eom",.1t onO """, •• Iou"'" .,111..,..,

fOf o<oring oenI"""'.
Of .. i<IO<>to of ...... f1i....."
o.."'icali,,".
CAMSHAFT RUNOUT
.uo,",,' ,.i,n • d",1 lndicalOt.

C/>od; .....,011.11
Sup""" Do'" ond, of .h. c"","'att "'itl1 V.,lod< •.
S~RVIC E LIM IT, 0. 10 mm (0.00. In)
10-5
CYLINOER HIEAON ALVE
CAM INSPE CTION
"""". _ ......... " " ... _ ..... lobo.

URVlCI LIMI": IN. l)t , 36A ..... 11.3. jill
WI". ... cHllr ..... "'"Iou .......

l..oy • pI.,,_
",ip 01
..... ""'11 J_.
""'do . ........"" 01_
Ift"011 _ _ . h - . . oncI '...... ... •

a;"a_ ....... n.
NOH:
I
,
00 "". '0""
pi .., ......,
TOROUI :
A: '",,,,IOLT: 10_ 1. N...
11,1I-l .......... 1 _ 1D" ... 1
. : • """ IIO Ll : U - 25N ...
12.'-l.5 ........ 15_ 1' " ... )
C: l0 ...... lOll; "'~JN ....
1~._.2 k_ J5..-'.....1
10- 6
CYLINDER HEADNALV E
RomO"
.. 01'" o. __...... _
",. ........ " 'O'h, "'" _ _ 1M
Tho .. _ _ .....
_"'I.... "'. oil do.onco.
Il~ V 'Cl ll""T:
CENl'U : 0.085 """ (0.003'1' .. ,
IIOT*4 tNOI , 0.0IIIiI """ (0.003'1' .. ,
Who" tho ..,..i<o 1...1" • • •• <0«10<1 •• 001_

.... . -..... ft .... ._ ,hooil tlt._.
RI9I_ tho OI'llncIo' h .... and oom ..... " hold ...
II tile ...., ..... ,,;11 • • CMCI, . . .i<o IImi .. .
CYLINIlR HEAD REMOVAL ''''\"'''

t _ "" ...... _ dom~.
R.... oo ......" . P.... "'" .....

~ .... oo tho ""... I>f... o~ ....
R"""" 1M ""'" "'" , .... com _ .. 1M 1 ..

_ """"" ... Il0l,,,
1 0-7
CYllNOER HEAO{VAlVE
"""'r,, ....,..__ ..... .." .•.00 ..

II.
....... ..... ~-.
, WASHER
"_ ...... ey''''''' _ ......... K".d._

...... I"V ""'!O.
- ......
II.......... It ..... , ..........
......
<yeo-- ...,., ......"
10- 6
CYL INDER HEADIVALV E
A......... Ito. ",or Oy' ;",,", um "'0" i"~ 1101"

and i"KIo.
~,.
I
.
w,..n - .... "'" Iron ...... _
..", •. tho cr .. • , ....... be _
com <h...
• ...,.
HNSIONER SLIPPER
CAM CHAIN GUIDE AND CAM
CHAIN TE NSIONER INSPECT ION
Inti*< tho
"-'-.,. ................
COOl' . . . . . . . . . ;;0. and ,,~.,'''''' ""
In","", .110....., ""In ,,,,Non.<- .,;_ 10< d.,.,,,,
--..
O! . . .... ;. . _ .. .
InlPK1 tho ....... fO< ........ n ...... : ..pj_ It
SPRING
CYLIHIlR HEAD DISISSEMBtY
~"".,.... , .... ,"""" >< .........1"" and O~"'II " .....

I~' .... ,' 1>01'
SPR NG
10- 9
CYLINDER HEAD/VALVE
R............ ,.1•• """'Of'. ,.......,•.• prlnll>

.Ad .01_. "" ir>g
Nor",
M.. k .11 di ........ blod pallI to .., ...... .., .... <1
,.-...bIv.
R."", .. ,~ . . .... n ....... 1•.
-
VALVE
,
R.,.,.,.., OOfbon •• potlu '"'''' "', _"Ion
" " ' _ .... <!un oil ,n, ..... 00"''' ""I.....
,.,,,.,
Awo," .,m""I"II til, 00"''' "'''acto.
Gnlrt" w ill ""'" of! ...,,' il IOIkod in
"'lnnt.
CYLINDER HEAD INSPECTION
Oo",k tho "' .... "",9 11<>10 and ,.,1 .. '"'' 100'
OI'od< •.
o,od< ...... <\,Ii_, ... 1<1 I", ...
",.;gr.t _ .... 1<001" ... .,go.
or_ with .
$ERVIC£ LIMIT : O.os mm 10.002 .. 1
10- 10
CY LINDER HEAD/VAlVE
ROCKER ARM INSPECT ION
..
In .......... ,ocI< .... ,m, lot _ .... ~ '0
,~ ........... " <OntKt .... , ....... , ...... "'wId oil
~
.... _ , •• 1It 1.0. 0' ..... f<Id< .. "''" '

IUlVlCf LIMIT: 12.05 .... 10.'1' Iftl
ROCKER ARM SHAFT AHO SPR ING

INSPECTION
Il10...... _ . -............. 0 .0 .
UIIV'Cf LIMIT: I I .U ..... 10.470 1111
In,,,",,, 1M lnal, IOf we ... Of ~.m",," tnd ~~C\OI'I'

.1It ....1'.0 ,ocI< .. I<m .10 ....... .
UIIVICE LIMIT : 0.12 ..... ",,00II .. 1
...... ,
IAIQIeI .... . -.. '"" " " " ""~ 10<' _ Of
......... " ,lit fl .. Io""h of ........., .",,,,.. , .. . _
~""
UIIV'CE LIMIT:
I"''''E II
titHER
(I"'.
EXI: 38. " ..... (1.60 _I
(I"'.
(>(1: 4101 _ 11.10 Inl
10- 11
CYLINDER HEAON ALVE
VA LVE ST EM ·TO·GUIDE
CLEA RANCE
CI>od< .01.. mo....,.,,' in ,flo ,.,~ .n<! ...._'"

..... .-<11 ..... . 01 ...ttm 0.0.
SER YICE LIMITS, 11<1 : 5041 own 10.2 15 ""
EX, 5.46 .. m (0.2 141<0)
"on:
Rwn .... ,.,_ to ",m_ .n, carbon bIoild·
"" btl ..... (f••d d ", d •• """",.
M............ rKOfO ..... . . M "idol 1.0. uling •

boll_ '" ;".~ "' .., .............
$ERYIC E LIMIT: 5.55 """ 10.219 1nl
Sub""" ..... ,01 ... ".m 0 .0. " .... ,flo co ....·
pondlng "Id. 1.0. '0 "",.in 1110 , ,,,,,"'~Tdo
d ••",>Ce.
SERYICE LIMIT : IN, 0.08 "u"
(O.OIIJ Inl
EX : 0.10 ",,,, (O.IXM 1,, 1
II ,~. "om · ,,,,,,,~ Md.

the
""Q lim;". de, ........ ;1 • _,.,,,, w;,h
" ..... ...., di""MK<K """'kI bting tilt .~ ...
...... O/;th;n ,~"' ....... II 10. ,..,1.,.
.ny
"ido, .. """'Wy .... "om '0 ,;,.
II tho """·'0",","" .~., ......., ,,",,, the .. ,.. ...
II",;,. with ..... "Idol.. ,01>1_ tho ••I¥o< 01",.
R.I..,. tIIo ,01..... t! ..... _ .... "IYO
"i<Io, or. ",plocod ( _ 11). 1~ 1 .
10-12
CVLINDER HEADN A LVE
VALVE GUIDE REPLACEMENT

"""' 11>0 evI _ _ '" l00"C 121t' FI *"" •
..... pIM.OI-.
Do I0OI u.. _ I<I«'Ir ((} loa, 1M qlRd<r,

II ....y_ .. ~.
To _OO/J boIm .. ....... ~ .. .,. Ib... ""''''
Modll"f 11K Ioaud qll";tf ~<Od.
. 1_,_. ..,.,.h"....
$10_, ,110 <I'll""... "" ........ d,i.. .,.., tt>o oid
... .,.. t.......... cfI ... bor sOH ot , ...
......., .... _ _..... """" b\I • poi< oj ....IH
~-
Ol,nt, 11.11 "'''' 10.4& I...
VAlVE GUIDE DRIVEIt
0, ... _ . . . - .. t. ........ ...do. ........ """ 01

......1_ _ •
c.,.- _ _ _ id "III tit .. l00"C

121~FIIor .. " ......... 01 '110 ......... id...
Lt, 1110 "'1__ cool '0

and 'N'" ,110 ................ ides.
,oom to"'l*"""
NOn .
_.......
I)..... " .... 011 "" tM IN ...... d"," 'h~
11o........ _ _ .. "'" .....

_ _ _ _ ....,. ••• _ ;'. 1<.
""octIon
It.loco "'" . _ .... 1 _ 10-1 ' 1 ond _ ....

<1'_' _ _ ~. '" .,... _ ...., "".oJ
~,-
10-13
CYLINDeR HEAOIVAL VE
VALVE SEAT INSPECTION /

REFACING
CIMn .11 10.... ond ."""",, . _ "-"1Ihl¥ ...
........• •-~-".
,AI'lI'I _ , .... 01 ..... - . . . COil .,und
I~ ,
........ "..... r_. L"" ...... _ _ _ ......
• , _ _ or 0.'" "'nd~~ .. tool.
T.o 01" .... " 0 .11"", tn. compoo,ond '" .., ..

1>0""... !IIo . _ .tom end ",,;do. AIt ... lop-
pine. "WI ..., tho compo<ind COi I.. t...1y
ond oppIy • 00" 01 ........ 0;1 to tho . _
, _ ond ....
R.... c ....... _ _ ""-' ..... , _
SEATW IOTH,
In_ ,~ ••• ',. ,..,
0." _ 1.27 ,,""
10.1)3;..(1.060 Inl
II ........ io '00""". ,"""",_. 0' .... _ _ ".
tho .... Wlu" ............ .
SEAVICf LIMIT:
A"or ...,'.... ".. . . t . _ 't< ... _ (100 . ...

I 1 .~ "'''' 10.011 ;,,)
... 1M .._ t_. _ t." "'" . _ ...... I ~,

IN ........
A~ " . " .....""' ..... ,.....,.. """"_
cy'_ hood..., . _.
ell ....
I~: Cvnf" (30_1 I~ . U cun UlIJO ...... ) IN : Cl/TTEA 1211 m ....1

EX , Cl11"n~ I~ ........J U :CU"EA I~U m....1
-- ',-,,<0."-'.27 mm
10.1)3;-0.050 in)
10-14
CYLINDER HEADN ALVE
CYLINDER HEAD ASSEMBlY " " " .' SPR'''IGS
In"oIl ....w ..I•• ".m ...,'.,""" .nombling.

U.. vol .. .,id. d,I.., 07Hl- 0010100.
lib..... .om ••1.. "om wl'h

di",'fid. ~'" ... . nd "'00ft
""",bel..."",
me '01 .... ;010 , ... vo,.,.
0.0"0. To • • oid dam. to
• " .. ,Iowlv _ ;",""ing.
,h.
"om "", ''''n , ...
IM..,I ' ... " '" _i<vo one! ro ..;.... ". Th. 'l"i"ll"
j;g"'" wound <0< 1, "'QUid 1_ ,,,,,,on:!
th. h.o<I.
,
SHMSE/I,L
!
U/I,LVE C1J TTEAS
10".11_ .01.. """"".
O~U"ON
Too ~t 10.., Qf ",,,tHo. tkJ ••ot rom_

P'~' lilt ",r...",1tw mbrc lI»n nt<:tna?
""Iv< kttptn.
'0 ",<lOll ,It<
Ft>dr>:>n Ihr kuJ. 'fllJ.M a~ II,UOmpm.
." ottt>ehm.",. >0 'h< lY)IllpniI<N will,."
'o...~ ,~< cylllldtl' 1rttJd.
Top
t~m"'
tho .. I.. " ..... _Uv ."th 0
.... ,hO <Ott ... .
So"""", ,,,,
toft hommer 10
cylltodo. ... 0<1 otoo .. th • .,0""

-.
booch ",rlooo ,0 ".. ... n'
"""ibl< , 01 ..
d,,,,,,,".
10-15
CYLINDER HEAO(VALVE
In...n !II. O~;ng ..... 1lM';r>; 011'0 ,1>0 ,ock., or'"

""'" bOl'.
~~ LOCTIU e .o IN «",k.. or", .....It 1>01,
'''''11~
, , _ ...... 0;, 10 .... rock.. ""' .... h """ _
..... ock ....... .
In.... """ ......, .... "'" _0' ."" .... of<_.
TORQU E: ,~ 50 N· ..
1'.6-6.0 k...... 32-3(1 "~b l
sPRING R'NG
CYLINDER HEAD INSTALLATION

C_ "'" .-,1_ _ .,rt... 01 .. ~ .......
", .... ;01.
IM\OII I h o _ .......... _ _ gMk ....
10- 16
CY L INDE R HEAD/VALVE
~.>'."" BOLTS
Inn.U "' ..... H..... , ...O"" th..... ,i.....' 1>00<1 bolt< at "'~
With ,h.lodo; 0>1 ... puot,od OO'M1,"'" tho oom choin

tomklnot """ roiMd in tho di,""""" 01 "" ",",W,
i""," • pin or pi""" 01 wi,. It".,.,., "'. hoi< in
",. t .......... b_ ond t.n.k>no, .. m.
"."',,,. "~,
10-17
CYLI NDER HEADNA LV E
TEN$IONER
~... _.,..., .,,,10 !IItough ..... .,..., <Nolo ,ot?" ..
.. mondlno,..".. _ _ .. ~ .. - . .
....."
OIock ,~ ., tilt tow .. om of tilt ,,1_ , !it<
;" th ...1_' ..... <","".1•.
1.",11 ,he . . . .. Ior 0< 1 p i ~ .. I .~

~I_ .... ",,1_, Mod.
w."'"" ""to tho
OIL ~IPt
In ... 11 tho ...... .,; .... one! _ _ '~"" ,"'_

bond • ....,"I.,
1 0 - 18
CYUNDEA HEAO/VA LV E
CAMSHAfT INSTALLATION c.o.MSH.o.n , .""

Fol_ "'i. prOC4du,. I,,,.., boojlnni"ll ' •
• ..d, .,on If VOJ ... oo l~ ..... I<in<j _
cyUnd., Mod .
o..d< .... <a"O",.h .,.."I!;et,_ "'....
'" "'., "OJ ",,,all .oct. <a"O"'of, .. i ..
_,oct Iocotion.
no. _ .......... ~." ....on
EX RR IER), R....... _ ........
IN AR (l A); R.... cy1_ ;",oI!.
Ell FR (EF) , F""" ...1 _ •• t>ato,
IN FR IIF!: F,OfI'cyl_ .. , ....
11>00
~.
.,.....,of, '1"_'" .... in'on:n....
lubfOC:lle "'" F,om _ _ ..iii' ~" _ cam

~II ... _ _ ......-.... t _II'
REAR CYLI NDER CAMSHAFTS

Tu,n ,.,. . .."klII.h <Io<k .. i.. un,iI 1M TI .3 mOfk -
0fI1t>o " . . - ' ,0!Of ooIigno ..i,., 1M ..... ,"""'_
m"ltoe .."r-.. ,
_ ....... 'M - . - p, _~ .. ~ 'M
.... choN _',;.... 0' 1M .... tIvir , ....
-. ot., ,~. <NJtkJJto/I. \
10-19
CYLINDER HEAD/V ALV E
, ...... 11 the ;",01<0 ..-.I • • ~ .... " <."...,, *""

_a·
<1<." "'fOUiI1 1M "' ... oylin<l<, Urn <l>.;" .. "'''''''' .
Tum the eom",.h. 10 t!M <"", . . at, m.. ~. faco up.
1\ the hon' <vI""'" <""''''at" _NO ",It ,..

"""'<d. c!oook "''' ,0' I,,,,,, <om...tt m.,k.
, ... up, II "O~ ...,. the <ronk",.1t <i_wi"
360 <io?"_ 1_ M"I _
II ...... oI .... 0nc0 .... " .. k _ the "",,"'of!

l tom ....;,-.g l ully .. the <v1~' ".... bOck Ih,
odju"" ""' ,II the _y,
C"Uf(O~ ,
If you fi"':~ • ".""., opt. whll<! flul.m", I~~

COmtM/1 holJ<n, you ...y dOm4J< I~'
Itol:ImI '" t~. <OmJMft b".
">t a.ifllUJ.
91",. the ooomoflol, _oldf" .. Ih...... ,,,,,,,;0",
"",ed dufi"'l ........ 11, 1 ". ;ro"", ...... ""ttom
,,' Ih. hold.. "'"<! .,ign";th thf ooom .... ft 10<.. ,"11
'i09t.
-..
,,,.,.11 ,,,- """",.It 1I,,1do, boit<. bu, do not ,!go,....
NO....
Tho emm pin 00I'I> _ "" 1n . ..tIod "

•• 011 eo,no .. 00 ",,' ' _00 ,hom "'". on.
",ho-! bol".
d>,;n
pj.,.
_.i
_ , w."
II III • ..,Iindon
I",
no' ""u,.o<I. ;OOk the eom
"'inimum .. ",ion : ""'"
down ,.hilt ""lIi"ll Of """i"ll ,,,. ""'d on "m
1h.,ocI<
up : I>okI ,,,. "m up
th'<><4> tho k>ek ho....
",.,it
V"" In.. " , P'" '" ,.i,.
lOCK PLATE
WIRE - - -
'"
10-2 0
CYLINDER HEAD!VALVE
CAMSHAFT MARKS
CIl_ '~>1 '~ e <1m"',!! mOf" ... ,"', !King up.
'nen oHgn th.",,<>eke' indo, Ii.... ,.ilh th.
10<> ot
th, ' .., <1 lindtf h'od. PI... "'" clm ",,';n on .....
"",oe ' ttl. {yiowod I""" 'ho iofl _ oI .... gONlI
" ' " :'OC'" BOLTS

Slido ",. "",oek. " ""'" !lot <""",.h " ....... , ond
in", 1I 1ht <p,oek" ""'tS
in Iht .. ".,..d hOln.
Ch«:« th., "'"lP'ock .. indo. li_ .I .~ " Tl-3.
Unlod ,h. um <h,ln ""'I......
FRONT CYLINDER CAMSHAFTS

NOn,
\Vt1. n .... mbling """" "o-nl ~, h • • d.
,omov.lho " I f .... ~def he"" """., to mok.
WfO tho com","tt m., " foc • .,p. II 'u,n no,.
,~. cfOnhh.ft clock", ... S60 do<g ,_ (....
"-"nl ·
II,h. I,on, cy(ond., co""holt woe' oa wo" nOt
.,do • • d <IOOng "mov~ .nd .ft no' m"bd ..
DRAW INOEX MARKS
mown follow II,. P'ocedIJ,. beklw'

Cloo" .... ' p'ock4to ,.uh oo-nlOCtolo ..... ,.oo wipo
'"
On ....... of "'"PO'. d!lw two _ po,.,.ndO:",.,
'" uch otho, 100"), U... P'01'OCto< .nd d ,.w two
diog",," ,",0. It I 4~· I ngio. Con", 'ho """'"""
on tM i"".
wilh tno "''11 ...... 1 ",",Oh mo,".~gnoct
on 'ho hO'«o"toIlino,
M••• flO w iro.. m.,k. on ,no woc'" ...-ho,. "'"
45· d>.g"".I"""" oro.. ,n, _0"""
~".
It 10 no, _ ..... ,.,.to mo •• !HI'" indo. m. ,k, ORIGINAl l"'OEJ(
10' tho ,oa, c\'lina...· • ..",01>0110 _.,. •• , .. MAIlKS
10-21
CYLIND ER HEAD/VALVE
110"" .... cr ... ~"'." oo..ntorcloclcw,. eo d.....,

(' 1<1 ......1. u"'.I .... n"'l .... ~
.......,... _ ' ......toa.
~ .................
, ,
I ,
\
- liE ""
.-
In"tli ..... In ..... "'" uh ... " <om"''''' "'"
"".... ... ,,.,.,, .... I,,,,,,
<y!;ndo, <om "'.., ..
<P''''
IIc ..,. .~ ...... , comst.oIt <OUtt",,,,...kwi.. oS

. ...... 11/8 fU"') '0 .." ' ho com lully ......
eyHnOo' ~ ... .
II . ....... ott;... _ _ ............ h f"",,_otint

"'. . in .... cvI_ hoott. _
",. ...... "'" ... otIjuoto, ..
In".11 . 00 "00'1' ey" __ .-....,' ...- . ond

boI" ... doi(:,;bod ' ''' ........ cyllndo< Mott.
Do not .;gnton " "". ~ .... .
~ "'" urn <1> ... 1M ., 1"' ..... _ .d,n.
-'"lin ..... poot ......... _ . "".. '" ...... _ . ma<k

on"'" !'OO'II <)'IinOo' com _""k." w;,~ .... 1011
01 .... c.,..."..... 00",1._ I,."." ,00 I. " _ <>f
,no OftIIInof
Slidio .... oprocI<o .. 00'110 .... _ I I 11- . and
...... 11 ",. .... ock .. Il0l .. .. tho • • poood _
(,Ott" tho " ........,,' . _. . . . nlt II .......
... ~f.
10-22
CVLlNDER HEADN AlVE
O>o<:k .... """,.,...... <vl_ C_oI, ';m;"g

..... IIow<,
_ .... 11-l ..... . 01"", .. ltII .......

«."keno m........" .... til, 1_. ' - '
011 01' com ",rockou -..leI
..... 01 tho <vlindot _ .
"'., witll tho
-
All _oft ..... ~...I. 01_ 1_ "" ...
T.... ~ "" coonltsllat, .........w ' 0 ......1(

rom ........ ~, boI..., ." ....., _ o f ...
....
T,-" .. '" t..., .... ft ""oo••• ~" "'';'0 """ IOod

''''_.
TOROU! : llJ-:lO H·", 11.8_1.0 ", .... 13_1( IWbl
r .... _ "" Otnci""", _ ""' ......... "'.
T"'n th. «."k",of, ""' i l W,. I, m.. im"m 0."

<!loin " .. ploy. ,;, ....... "tli til, 0<1 pl",,"-. tht
tom_I".
...
,,,,,.11 ....
r ... _
com <!I';" . .;.so 011 tho .,;I pipo _
.... <vIO- Ioood 10 mm Il0l.. IrI . ....

<1000 ... _nio 2~3 ,,_
TOROU l : ~2 H·'" (' .• -6.2 kpIft. !II • ft4bl
~_ til. <vii"" ... "ood 8 mm ""'" In • «lo.., -

p."""
io 2 ~3 .1ejlO.
TOROUE : 2 1_2& N·.., 12.1- 1.11 ....... 15-1' "~b l
TI" ... "'" com " ' " " " _ 8 """ ""',~
TORooE : 10---1. N·", 11.0-1)1 q...,. 7-1 0 " "1
10-23
I4>1>v sulont of tho hoad '-"'- ~ ~ 't
\nuol\. now "",Ii......,. h..<I eovo, ;ask0l,
I",toll tt.e froo' "",lindo, hud """"'.
NOT"'
s. "'''' tho 'obi. ol tho fron' "",Ilndo, hoad
..... loco th. fUr 1_3·10!,
INSULATOR
10,,011 tho , ... <Vii ...... MOtid tho tab of tho '-"'- baM
loco tht I,,,,,t.
I",tol l thO In.ulotor .,.,..., .<><1 'M ivn i,ion coil

1><........ . ngll'O" .... 1><0<1<" _ , 1»1" ";Ih
'M ,.ou"" OIbi<o,
1",,,11 ,ho '>dittor 1 _ 6-91 .

In".11 'h' 1....1 unk. 'Ht , oO .1Ot «"... ,
HEAO
10-24
MfMO
CRANKCASE
'mm
21 25N·m 16_1 81H t )
1 2 .1 -2 .~ .. g~
\ \\
a
\
',mm
,
"
Omm
10_ "N,m 7_101t_lb)
11,0-1.4 kg"",.
IOmm
43 .... 7 N·m
{4.3 ..... 7 "lI,m,
J l-~ INti)
11-0
11. SE
SERV IC E INFORMAT ION 11 _ 1
CRAN KCASE DISASSEMBLY 11- 2

CRANKCASE ASSEMB L Y 11_ 3
SERVICE INFORMATION
GENERAL
• To ....." "', Qi.ton. ",_,"of!. conM<ti"'l ,od ."., """""~.""'. tho cr."""",,, 1>11... m.JO' be IOpo<.ted.
• II. __ "' ..... "".. i. iM!O'iod...... Io<m ''''<In,ont.,11 ","" .......", Pr-"'" I' ..... 13- t&l.
• Tho tollOW1"'l pan. "",n be fI''''''od btlo<, d i..... mt>li"'l tho or_caM.
Oiloon A, I., 10 """ion 2
Oil ""mp A,'Of 10..., .... 2
W.... ... mo A, Io, 10 >OCt'' ' 6
Clutchl",,,., du"'" A, I.. ,0 .. ",;On 7
G .. , ""fl lin kogo R,,*, o 00<.000 8
AI",",..,. R... , 10 ...,.ion 9
C~lin<Io, Mad. A, I.. 'o ...,'ion 10
Surl" """or R. t.. to 00<.00" 20
(leo< <nonvo .w.,,,,, R, I, . 10 >OC1;"n 21
TO RQUE V A LUES
10""" boll' 43-47 N·", 1~.3-4.7 k ~-m, 31-Jo1 1t-1bl

8 """ 1)0'"
6 ,,"''1 tool"
21 _ 25 N·m (2. 1_ 2.5 k. -m, 15- 18 IHbl
10--14 N .., (1.0--1.4 k • ..". 1-10 1t·1II1
TOOLS
01949 - 3110001 0. 019019-3710000

01948_3110200
11-1
CRANKCASE
CRANKCASE DISASSEMBLY
!Ie"",,,,, ,he ...... ' <,."ke." ""....
Rom to 0......1 lofor ......... 1_ n ·ll forthe
Ii.. 01 pm' to . . . .mow«! bofo .. . he era"""""
..... bod_mbltd.
R.... o•• t ho ",.;0,,"," tIOO''''II ""Id.,. "v ,,,,,,,,,,;ng

m. ,"" " ."" Do'''_
11 -2
CRANKCASE
T"," .... onoi.. .,.., _ ......... tho ''''''' ..."" .

•
... lx>I t ~
, • ,
• •
• •
•
Rom .... ,1>0 !>Clb ... """ ............ "091 ond
'0 • •
In • ",;,.eros, ... nom to ... ...." domogo • •
11>0 e,,,,kc_.
s.w... Iht"'.........
R.....,.... ,,," lollow;ng ...... "
,- • \•
••
•
• P;non.nII conMel..., """, Is..:."", 121.
• er",k"'." !SocIi... 12) .
• St. ... fork rnd lIIin ""'''' ,s..:.ion Il l.
" •
• T....... ;..<on Is..:."", 11).
•
· ~
• •
CRANKCASE ASSEMBlY
11-3
Ciil\ HONDA
CRANKCASE ~ V6S SABRI
I~".II ,1M 101_.... .,.,,0:

• SIIIIt for _ ..... lIIilt dflom ISoctto. 131.
• Tran""i ....... ISoct .... UI ,
• C.an ~ III . 1t [Soct .... 121 .
• '"'onond~,,, .-CSoct .... 12L
ADPI'/ ....... -..... diou,' 1cIo ...... '0 ,1M "'ii,

foR ,..00." of tho I0Il2. (;Ii ..... 08 00....
11-4
CRANKCASE
0 . ... U.....oke. .. m"'inQ wrl .....

A\I~y
u_ «.""._.
liou;a ...1.", '0 ..... ","'1"'1 ",rloce 01
Iow ... r><!
,h.
Do ,.." .pply _bltl 10 I~' .... """ do •

.... irtb~.
A ... .,tII. tho ... ok .... hoI_ . •HI">no ,,.. ""I,

fOl k d ..... wllh 'M;00'''.
T~IOft \II. bol" '" "'" _ II ;od 1Ot_ ,,'u..
1ft
tho toou.na .-n.
TORQU~ VAlV U,
10 mm bolt: u..-.1 N·m
14.:1_ '1.1 ........ :11--34 ft.Il>l
"t"" boo": 2' _ 25 N·m
(2.1-2.5 k".... 15_11 fI~b)
, ..... bolt: 10_14 N·",
11.0-1.4 k.. m, 1_ 10 1t·"1
r9>t'" ..... bolt. In • • ,is",",. "",or" ond In ~

Of J ..."".
11-5
CRANKCASE
T!trot... 1M U""" cr.""....

bol" to m. ",.."...,
1O«I",In. cr;ucr"" pont'" '"" In 2-3 "<90.
TOfIOUf : ..... : 21 _ ZI H ....
C:t.1 _ 2.l ........ 15-11 ft. )
1 _: lo-l4H ...
CI.o-U ........ 1_10 ft....
•
,,,,,01111>0 ",_.ft _ ... h _ _ till""' ....
....... _IboI ...
,..... 11 .... _ _ ............... _ _ _

'or_ 10 .... lI>O<ifioclIOf_.
TO~OUf :
'21_21
..... _boIIo'
N· ... IZ.l -U ........ 101- 11 ft~b .
,..;; " " ' " ~OlTS
11-6
0.(0.0
CRANK$HAFTIPISTON
I FRONT
12-0
i(1) HONDA
~ . Y65 SABRE 12. CRANKSHAFT
SERVICE INFORMATION 12_ 1 BEAR ING INSPECTION ,,-'
TROUBLESHOOTING 12-2 BEARING SELECT IO N 12- 10
CONNECTING ROD REMOVA L 12-3 CRANKSHAfT INSTALLATION 12- '2
PISTON REMOVAL ,,-' PISTON AND ROD INSTALLATION 12-1 2
CRANKSHAFT REMOVAL 12_1
SERVICE INFORMATION
GENER AL
•
in",,, ,,,,, ""'"
!)o" ;n;<. , _ them with ,"",;g....go to . ... i'"
Al l bOo.;"" ...."'." ..10<, l i, .oO I re denM;.d by colo' cOOo . Select ,.plocorn ... , ""~ ""'" tho cod ...bta. Aft ...
010'''<><0.
• AWlv ",~lybMnum di"oIfidt 11' .... '0 ,~ . ma;" 1"" ,.,.1 •• -.1 ero""o;", du.il'lll .... _ • .
• BoI",. ,""''''';og til, P;. too .n<>nKI i"" .00 .... mbl.... cl• .., ' ''' tOP 01 ... , .... Iind ... ot ' ny 0"""'" d._itl.
• F", .... "' i"li tIM Oi""", connod;ng ,od . od « ... k""I,. '... ,,""".... ....
mbI~ ""'" bI' " 1>" HOd Is.ction II).
SPECIF ICAT IO NS
TORQUE :
C.ooI<"';" , 3O - 3~ N.." 13 ,0- 3.• kg_m, 22_ 25 ft·lbl
s".c:iol
Pinon ~ ""mmo"" Com~. II • .,,'; 1_ <:O<?Ip"""" IAu'omo'l........ 101
s..n"li "",Ie Com<Mt< •• lIy .. 011 .... in U.S,A,
12-1
CRANKSHAFT~ ISTON
TROIIIlESIIOOTlHG
Eo"" ." .......
1. Ct ......... h
• W"", .... . ~ bo ....,
• WOfn rod bo .. ,",
2. PI" "" _ CO"'..... ,.,. 11<><1

• W .,.~ ~, ... Or .."ind.,
• W .,. ~ Ill"... pl • .,. oi. hOlo
• W",n ,od "".11 ...
L_ """' . .. _
I . W........ ' _ ...
... " _ _
~, ... ,ing
pr_
E-.,,",,_.
1.W"'~ "" ,_. ~~ton ... oi""" ' ....
2. '''''''_10 .... _ .''''''' ,i,..
3. 0 . ....., ";,, ... '" OVI_
-- C¥_
1. Eo ...." ..
2. 8 _
Du,IO ..... "",,;,ton
.........,,~"" , _ 01 '"
3. S,CIo "'ll_......,,,
,lor"
_
K_ _lott ... ...""..... _

1. W", • .,; ...... ... .., lit>do"
2. har"i •• , .. bon build .... on .,;.10. nU<l.
12-2
CR~KSHAfTIPI STON
CONNECTING ROO REMOVAL
CI>odc ,.... """' .........."" .os. du."""".

S! " VIC ~ LIMIT , 0.-.0 _ 10.0" Io j
~omo,. "'" ........col,. t<>d _ing capo 0tICI ""'.

""'. _ion>.
""" "'" ""'"""'int ,..... ...., I>iotono out ""......

"'" '011 0 1 "'" . .' _ bof ...
12-3
CRANKSHAFT/P1STON
101"", ' ''. "";" 0>< .. 0', . "'I<u.g. •.., _, " VOU
,omo.. ,n.m ,,, !t>d ;<.., ,he ""'_ ""I .....' """
_;,ioo 0tI I'" ClOt\!t;P;",.
PISTON REMOVIL
"1"" ,.," CLIP
A"""", tN ....,"" p;n eli".. PuJ/l tN pnlOn .....

" ," ,.., ' ......... tho P~'''''.
M,tIt "'" ""',,n pin, ,,, indicOt<t ...i, ""'_

0>< .."" P<'Ii,io<I.
PISTON/PISTON RING INSPECTION
101 . ....... ,he p il1"n 'in'l·to1l'oo" ~ooran<o_

$fRVICE LIMIT: 0.10 """ (0'- in)
(TOP/UCOIIIDl
R,,,,,,,,. ,he p ~ '"" 'iOIll ...... m"k '''om to-ind;':, ..

.... <0,,,'" ""I;oe!or ,oe! "",,,,, po,~ion .
CIN" U... P;,too """"". _~ ,U eo,bon .,..

po~ ".
In.".., til, P;I1"O I., ".od\, ", "'''"' 0""", ......
tho '0..;, . ' _ 100- , • .,..~ ....." ond ""bon
1>u;Id-up.
12-4
CRAN KSHAFTlPlnON
u...... D' OIOO, ""on '0

,lit " "II ... 1110 ",lind ..
rqumlv ond _,,'1It onc:I~.
IIRYICf lIMITl :
T~ : 0 ...... 10.02 110'
IlCONO: OJ """ 10.02 .1
OIL ISido ,.,,: o.t """ 10.035 ..1
M..... ' ...... 0;.,,,,,0,0 ,
To.... _ _ _tr 10 1NII 10.4 in! I,,,,,, ....

1>00, ...... ond flO" '0 .... "'...", g iro 11010.
IfRYICE LIMIT : n.» .... (I. l~ 101
'"'''"''' .... " " ' _ ""'.. !of ..... or <Ioomaeo.

_ . rho <YI_ ,.D • • , III... _ ... 10; ..., V
.....
IfRVlCf liM IT: 1I.to""" (1.1301101
Col..,... ,lit D~''''·to-ey''_ deoraMt.

SERVICE LIMIT: 0.10 ...... (0.0001 111 1
o..n;,. ,......... or. . .ol_ .. "'" 101_....11..:

0..211. 0.6CI. 0.7$0.... 1.00 .......
12-5
CRANKSHAFTfPlSTON
"'............ ,.' ... p;.._I .D.

IIIIV'CI ~ I N I T : lO.OI""" 10.110 ..1
N o - ......." ... I>in 0.0.

UIIYICI LINIT: 11.• """ 10.111 inl
Calwl.,. ,,,. ........ rOn....""'_ ...........

UIIYIClll""T : O.IM "'''' 10 .00210)
"' ..... " ........ _' . . ,od ...... , """ I.D. " ....
"od.,. ••.-. ....... .;." t;,M..." ' _ .... ""'.
SERVICE ~I"'m 2O.0I", .. IO.7tl in l
12 - 6
CRAN KSHAFT~ ISTON
CRANKSHIFT REMOVAL
R... , .. "'" ...........,. ond ,,,.oow ""'.,.... __
CRANKSHAFT INSPECTI ON
s.. ,too .,...-""'It ................. "" _ •.

s.. • d", ""'..,,'" on "'" _,Of ",Hot bor.,.
,lou,
........ Ro.... "'" cr"''''''' ..............,.,...
"'" ru_,. ond
SUW' CE LIMIT: 0.03 mm 10.0111 In)
C.... M CH AI N LENGTH MEASUR EME NT
Ploco ",...... ""ti. POO;'_ .. ' '.It ,po-<>ck."

"';tro ..... po.otoCIo ..... , ~ .
0'" ,too .......
lndi<ot.... .
s-.o-o """ """....It """"".............. ! ] ~I
129!too1 "".... ,"'0 ,too _
T_ .......... ,too d . ~ b o _ "'" ... _
_ k ... _ " ,
...
ICc "" •• dol..,
_ )
SE~\l1C 1 LIMIT: :IM.I mm 1' .... 31 In l
I !:::""- ......... ' . . too ..."101 ... 000:10
~---'''lINCH '....,R U
ROIII_ ........ _ . " ~ io .......... "'"" .......... 001
I.m~ . ,
12-7
CRANKSHAFT/PISTON
BEARING INSPECTION
CONNECTING RODS
Inll><Cl II" 100.,;"8 ;" •.,,, I.,. <10m.,. 0' ><1>O<.,o,n ,

c o.", . n ,,;1 hom , ... """"8 i""", ,M ..."",,; .....
p", , p*,," 01 pl"'~ 0<\ uch ",.nKp;n "o;d l"8
UIoQ il M h,
1'1« bm"6 I.bt 1/omo1d Ion l O>l'llT<l 1M

",,/to.,.,
cyliftd~
pon~ 11._., .lto {ron • .,..; ,.",
.xhtwu pc", 14<'< oppour. dirt<:-
I"",~
In".11 rio. 1oo01 ;"lI C"", _ ",", "" ,h. "'"..-.

«.""pin" , ne! .;gt! ..n ' hom ..,nl • .
TORatJE: 30-30 N·m Il .l)..l .• k,.m, 12-25 fI-lbl
00 no, ""'" , ........... "'01' du' .... ; n _

tio<>,
lIomo .. , "" <OIl' _ ""' .... ,. ''''' compr .... '"

pl..,oglOgO 0<\ ~ «.""",n.
OIL CLEARANCE SERViCe LIMIT:
0.01 mm (0.003;"1
12-8
CRANKSHAFTIPI STOH
MAIN BEAR INGS
In-,,' ,ho boO'"" i..... " Io<~_o, .. _.,;On,

C"'" . 11 ",I ,,_ ,ho boO'ItItI ..... ". _ iou'''''''
, . " . D_ 01 "''''4N9t
0 t I _ jouRlI . ...idint
tho ... , ........
'n".11 "'" "'''''' bo ...... 0tI " "

0tI .... _ ....... "... _
..,..'teI
, ...... _ _ •
Io<><RlI.
... 2 ... 3 . _ ;" "'" "Q ,_-.

TORQU E V ALUU :
• """ bolt: 10-1. N·",
11.0- ' ........... 1_ 10".... 1
• "'"' _ : 21 _211 N·",
12.1 _ 2.1 ........ 1~ _ ' I IHb)
10 .... _ : u-<l1 N·",
14..14.1 ......... 3'~ft-4b )
ro'''' ..........".." ..........-

I 00"",
. ,;0".
R_ _ .... __ ....... "... ..... _ _ "'" _ .

" ' _ ..... _ "" _ lou'ntI.
OI L CLEA RANCE SER VICE L IMIT :
0.07 .... (0.0(13 ""
12-9
CRANKSHAFT/PISTON
BEARING SELECTION
It ,od bo"inI oIH,IfICO;' boyo,," '0'"'........,oct
'1'1>1"""""'" b.., inp •• '0110"",
CONNECTING ROD BEARING
INSERTS
O."rmi"" """ _ d ,ho "", ..... po""i<>j ,od ' .0,

<odo .... _ .
T ... n ~_ 1 c< 2 01\ otch oOh'"OOCtin; ,od I,

ttooood. for otch """"octinl rod 1.0,
,
0 ... ,"' .... """ _ 0 .... ..,.,,,,,,,",,,,,, cr"'~ , "
0.0. cod ..... ...,., I", """" ... , ... <'O"~~in 0.0.).
T... Io-!tor, A or 11 01\ oOo;h "'"K~' I, "',

oode fo' oed> ","'Kp;n 0 .0.
00.. "f.....,. ,ho <'''''k9in 0"" ,0<1 """ .. to 00,.,·

m ;"" ...... pIoco",,"' bo"ing 0010< .
CA ANKP'N 0.0. CODf NO•
.~-
•
40,000_ --- •
311.110' ...
t8 ~ ,
~~<i ..
''"1 ,
0-
---
~ .ooo _
--
~.o"...,
t,v_
.'~I
• 'G,_)
A ,",_I
BEARINa INSERT THICKN[5S,

... (8<_,,), l.(900_lAN """ (0.0588-0.0690 In)
B la ... n ): "'90_1 ... 900 ",m 10.0681-0.0618 1101
C IV ....... I: 1.(116-1 .(90 .". 10,0585-0.0617 ;,,(
12- 10
CRANKSHAFT (PISTON
MAIN BEARING
Tho 10' .... II or 21 Oft ,I'll _ _ .......

<_ - . , ... tho 00000100 !I'll .,..,.Iout~
1.0. f,om Iotr ... ,~t.
001 ........ .,., - . I tho ~ .... ...-

Iovt .... 0 .0 . _ _ • 10< 'IL W .... .... ......,
1ovt~IJ . D.I .
... ....- lor ' Oft .ocII CI'" _"''' io

..... 0000 , .. ",. ""~, "'... jou, .... , O.D.
c.- ,. '-'_ .,.. .... .,., jour.... - . . '0 do, ..·

"'... 1M ,opI.",troOft,_ ......
--
, "-- • ''''-1
..... IN "fAIliNG INSUlT TtlICKN[SS:

"' lar_ l: 1._ - 1.501_ 10.01>110 0.0&11 101
• IG..... I: ' .''''-U'' _ 10._ _ 0 . _ loll
C IV _I: UIO_ 1.."' .... IlI..lIY7~._ loll
1 2-11
CRANKSHAfT/PISTON
CRANKSHAFT INSTALLATION
I~"'II
AWl. _,,_om
..... main !>N,i"", "'0 II,. oppo. ."nke... ,
,..,j - . m ... lMori",.,

e ilOl'id. 11' . ... '0 ,,.. ""po,
In" ....... «.nk""" ", i,~,.,. com ""'in.
PISTON INO ROO INSTAlLATION

CI .. " ,~ . a ~ t .", o$omo •• , i"9 lond •• I t><! ok l'"
Canofolly In, ull 'M PH"'" . "", .",to the pin"".
$1_ tilt .;,-.g .t><! _ .. >hown.
~ Clf'tlul "'" 10 do_ the ";"0" on<!

p;,ton , Ing> 110.1"11 . _ 1 , .
.. II 'i"II< """,01 .. ItI"OI,«I w.,., "..
m"", i.., tociJ>; 00.
M,,, .. ".11, ... 1M ling. 'M" 1Io",,1d 100,,,
It..ly. ",in,,,,,, ";O; i"9.
RAi l
12 - 12
CRANK$HAFT/PISTON
FRONt CYI.INOEl'I
.......
Coo, .... 'ocI .......I...,.,;'" " ....,1 · .....
......mblo ,ho ~ I" o"' ....<><>"-1 ....

d ~ I ido
"X" ,.1," ,~,

~I"O", .... Oirton .. iOl " lo llow •.
No.. "'...... I ...... <vI ...... _ " ' I I .........

",_ MI4~ .
' n".U .... tH_ on .... """" _ ' .......... 10

......... In..... " IN- ...... .. f...... O~""";I
_ ...... 'od.
"IN" M... RK
R ~""R CYLI NDER
No," "'01 ........ cvli_ <0 . . . . , .............

.... ~ 1Id Ma-.R.
1''''''1 ,ho ~;.""" on 'ho "'......... 10 'n" .... .......

"I N " _ k ;,; I ""'I>g ......... tI~OCI!on ....... 011
...... In .... ,od.
Do not In'"-",, .... ~;........ ....,on

"flO" .......C,Iftt .......
M ......... """
",_Iv _'lid. ....... tOft Dioo d"" ...
.... ,... III. 1101 • ., 'n, oonnoet"".od tIt••i......... ,

... ill'l ,n. .."'" 10 .... conr>OCtirlg 'od ..... .,"01' ....
In.....
1 2-13
CRANKSHAFTIP ISTO N
In.tal l 'M conno<lT"'l ,od ."" be.,i"'l inM«.

A"",. mol~ d.",IM. ~, .... to '''" '''''noet·
i"'l'od bo .. i"'l'.
Coo, the ",limon,

wTth ,,~.
pi""" 'T~. ond pdto ....
In"011 ",. rod ,tid pi".,., ......" .... i",,, 'M

<.,Tndo" from "'" ''''' 01 ....... " k .... , e .......
• Id'> .... me,.,.
;, (Om,nod ,. ~. ",;.gin" po,T,ion ..
"",0<1du';"'l " ..... 01.
TM !>i.1On int"'. "IN" mor'" """-'1<1 be

'oeing old'> 0 .....' . . >!>own,
PISTON RING COMPRESSOR
C<>mpt" ' 'M pi.",,,

, i"'l' .. i!~ • "JIg oompt .. .,.,
, "
0"" i" .. " 1M o'"on.tId ,od in'o 'M ",lind ...
NOT'
e_ .... ,ul "'" ,0 dom. . ,M ~;"on, 0'

mil,.,..
N_
,~du'ing ....
n.'.,pte"'"
To domlQO '" "'" ........ pO<>
"ip "'0" ..<II"", 01 ~_
ioo"
0_
",. ,od bolt> bof .... ""'011""""
12-14
CRAN KSHAFT/P ISTON
'0". " _torque "" «>nne<I,ng rod .. po.
TORoue : 31)..-3-' N_m 13,1)..-3.4 k...... 22_ 25 "~ . I
B. ou" tI,. bo"inII COl" "[01'''''

or •• in
'M ;' <0<'0<1 ",,;ot;on •• mor""" du"'"
, _01,
T;"" ....... ""t! in two 0' mo<. "' po.
Aft" [r(II>tt<1u" 111, bo~' . mod< 'hot .h,
,0<1. mo" 1r..,V w;tnou. bind ;"\I.
A... ."blo , .. ".nk.... Is.. . . . 11-3).
12-15
TRANSMISSION
]1)'-'0 N"m
(3.0-4.0 k' .....
22-29 h "'J
110_ 110 N"'"
1Il.Q_l l'O k..... VO
!I5-8Of ' ~ b l
llIO_ 12ON''''
110.0_ 12 .0 ki'<'!.
72-87 h"'l
80-110 N· m
IUI-lI.G ....... 58 85 fUbl
3O_ 1O N ....
13.0_3.4 k ..... 22 _25 h"'l
13-0
13. T ION
SERVice INFORMATION
T ROUBLESHOOTING
'3-'
13- 2
COUNTERSHAfT INSPECTION
SHIFT FORI( AND SHIFT DRUM
13-1$
13- 11
TRANSMISSION DISAssEMBLY ,3-, TRANSMISSION ASSEMBL V 13_ 20
OUTPUT DRIVEN GEAR COUNTERSHAFT 13- 22
REMOVAL 13- 9
GEAR TOOTH CONTACT
PATTERN CHECK 13_ 14
SERVICE INfORMATION
GENER AL
• Tho ........ " ... ~ ... _ ...... - ... 111 11M ...... in tho 10._ rs.c.;""81 .
• ~'" ..... " ... ,,,,,,......."'" ... E .. ,M ...... _ """" 110 .. "" ..... l$ocr"", lU.
• R.o' .... count ...... " rod out"".d ....... _ .......
• _ u ........ __ nut .. E....... "o. • dolloct;", - . tyCII ""QUO ......... ,.-20 __.TIM I0<Io ...... ""...... in·
Ct . . . tho 101'_ .. ,,,,,,,,', _..,.. "' .... t " , _ w t _ ",:I'"IMR bo _ _ tho , _ OCIuoII. _ ... to .... _
...... Tho 10K;... ......, ......... ' M ........ , _ _ 00<1 to .... __ ......................... "'" , _ ......." ....... .....,
..,,~ tho""""" ........... Tho ''''''''" w,_ ..... ..ad;.. ~......, w;t/o "'" oct............. ..,..;' ",,- ,
(0.001 ill)
10.(0210)
13-1
TRANSMISSION
TORQUE VALUES,
Output _ <Me _iooa " ' I JO-JoI H _", 13.G-3.4 ~ ..... 22_2S ""'1
Output _ ..... mm - . . . bolt :10--"0 H-", 13.0-4.1) k...... 22_ 29 " ~ b l
0..,,,,,, 11<"' _ " " lock n~ , 10..,..,1 110_ 110 " .... 19.1)- 1 1.0 kg_m. M-1lO 11·11>1
11 ...... '1 70-80 H. ." 17.0_8.0 " ""' . 51 _~ It·lbl
Cou~' .,._ "..mg lock nu'
10.,..,1 100-120 N'm (10-0- 12.0 kg""" 12--117 "~I>l
U~_I 10_ 110 N'm 18_0-8.1) k' ..... 58 ~ h~b l
TOOLS:
So 11 ' 01
Lock ..... _ . 1Il11!ol """ 01816-M800000
loci< "'" . ........ . . 21M """
.......... """''''. 11 """ 01U&--3710l008

~ • ....,... h...,lo 07838 __ 31101 Of 8 ...... romo,,, .. , 07l13li_ 311 0000
~ .m"" .. wtl~' 01838 __ 3110~00
~-
0,,_ 01"0...(1010000 0.- 1)0-;"- 0_9--3110000
',101 . 3D """ onoM....(I(N01OO
l'ilot. 35 mm on.....(iI)4(l(IOO
"'".... " ...... &2 . 118 """ 017~1~
An ........'''. 52 ~ 6Ii mm 011 48...0010400
Attochmoft,. 42 • U """ on. e...(1011l3OO
Pi ... , 11 ",."
0,- ,
on • • IIO'GO-OO
' __"''''''1. 30 ......
TROUBLESliOOTING
Hood .....ill
1 ell",:" _ .... t _ noel<,..
T' _ ;_jIoontoo ....
Go .. """'...,."
et_
, _ $Po'" 1orIo_, I.
1. $h,It ... oft boo'"
3. $h;It .... h_' 3. $h,!, ....... , , _ "'ok.n
4 . $hilt <,_
bO<'1 4 . $h,!, !O,k, bOn'
5. SM, ~n,," ..... _ . d.......
13-2
TRANSMISSION
~ ..
IF", ••1 . 4 .... ......,. 11,,_...... s"n- , . I
TRANSMISSION DISASSEMBlY
So.,.",< t ho « ... _<_ ISoc:,_ II'.
11",,_ thO II.... ' ~ I""" tho <ron""",,
'ft_ ,~< _ ,00II 01 NCh ,.".
SEII\lIC~ L'M" :
~, O.N "'"' 10.001 ...
ZoG. 3 'd • • tII. StII. 1tII: 0." "'"' 10.007 ... .
11.'00 .. '''' .... _ .

A.","" .... _ _ with tI>t CI. cs. a_
C3 ftM'. _ ..... ..,. ... " _ " pi .... _ ......
_ .... I, ........ or .......... I'uII , .... """"...",a/t
e"" 01 , .... or ....... wltII tho ,_oi<I!I ,......
-
A_ _ .... <....n..' _ If............""" _
.
•_ . tiW coun_.1t ........ _ , to .... ""'PU'

III" u., ror .... 01 "_""'Y.
13 - 3
TRANSMISSION
TRANSM ISSION INSPECTION

1.0.
CI>o<k ,,0< ",*, ~ _ ... ,",h!o< • • <ft<, . .
or _mol "'.', or ..... _ of ;"..",;c;o",
lubriu' .... .
M•• ..". tilt 1.0 . 01 .oefI _ .

II-IlIIYIC;1! LlMln :
. .. .... 1;2. Q . a _ : 31." """ 11.ne 10)
lilt...,. _1 .0 . ond 0 .0. 0 ..... _ .... " ......

IEIIYIC;t: LIMIT'S: 1.0 .
M5. MI. Q. <:3.<:4_ .......... 0 .0. '
_ _ 1121,101
M5. C4 _ ..·...... 1.0 .:
a .OI!' _(1 ,1001 10)
0 .0 •
"'.,,.
......... th. 0,0. 01 , .... m.'."'' ' . . . . . . m..'-
IUIYIC;1 LIMITS,
A"' ...... " ...1: V"~_ I1 .DIf 101
• "'.C; .... *.): V.ll ...d l .0II101
CH:uI ....... .,.........,. be ......... .... ...... _
....11 II< _q.
IIIIYICI LIMln :
MIl. ".. C2. Q. C4 _ _ "q'
0.10 ..... 10.004 ;,,)
MS. C4 _ _ ....._oft:
0.011""" 10.00210)
13-4
TRANSMISSION
DR IVE GE AR REMOVAL
DR IVE " , . SHAFT ' " ) ' " GEAR CAS.

PI ... "'" ""'PO' III" c_ In. vi .. wi'~ IOh jaw, .
boi", ca, .... no. '0 di"Of' "'" c....
PI... "'. shof. " _ , tool on "'. ""'1""

d,;.., III"
,"of~ wodgi", I. opaiM' "'" vioe to loc~ "'" 11001 •.
U"mk. til. JOIM' _i", •..,. lOcI< Out ,.,tIl • d<lll

or 111'1_" 8< , ... ful th., """,
p .. , io;l.. 110 "'"
..... ' ",. !>H.;"" and thot "'" ",ruck "" til. "'ott
... not •• rnOllld.
R.....,.,. .n. ;"....

DI", ..d th. nutt.
!>H,i", , ... I""k nul.
SHAFT HOlDER lOCI( NUT WRENCH. 42/56 mM
13- 5
TRANSM ISSION
1'1 "'00'" _ _on ....... " _;ng - . ...........

hoIdooIY ......... UM.
1'1.....,.. ,lie .... ,p."d,;.. Il00' ..... ",im.
PI_ tI,., -....,..""'~ In , po- ,,~

P, ....... _",..""" "'" of ",. "".. "" _ ,.
BEAR ING
NUTWAENCH . ~2M ......

MOTto
I Tho -.... ...... .,....... ""

.. pr...... _ir9.
.,0.0"," boI.... )
I'Ioeo "" _ .... _ In ..... ,..;ttI toft 1_

... ""'" ,_01.
100'"
i Do no, <It<N9t .... _ 1"1 - . .., ..,!IV
8EARINGHOlOER
A....o ...... _;ng ...... ,_ ..... nu' willi •

,"'-;01 .oot Oi_d .... ""* ....t
13-6
T RANSMISS ION
~ ... "'. "''''''11 no..,., in • 0'......... ",.",... ,,'" DRIVER

"''''''1.
PILOT. 35mm
DEARING 017415 _ 0040800
PIO<>I tM "''''''11 ",1<10, .... , ...... i! ~ ",ft 1_,

,0<1 in,..11 ..., .;gII,," • n... """t <1<0 1<><1< """ LOCI!: NUT WRENCH.
'0 1M '"'""if .... ''''QUO.. lu I . 42/58 ......
TOROU£ : lOO-12!1N''''
01916-MII4OOOO
IID.D-nO ~..... 12--417 "~bl
TO,"" . .... _ ,",0 ,UjfHlI:
92-110 N· m 111.2- 11 .0 kt-rn. H-7i tNbl
S,tk, ,I" Mw Iocl< ,...,.
aEARINGHOLOeRr,~::::::::,~,
COUNTERSHAFT INSTALLATION
Tho coon,,,""!! ond d>i.," ~., mo.'" bo

""K:Od .. if l~'"
0 . .,.~. VO"- co .....
'"
.. , booMi"ll ,,,,,,,i ...... oco-mon'.
PlOOf 1M """""",,",, ond _"",Sh.h _;"11

I>0I<l ... ;"'0 • "'.... F'>.., '0, c",,,,,..,,,.h ;"'0 ,~.
"''''''11.
PI..,. "'. "',,0<Ied end 01 tho pi lOt In,o "',

co.mtor"'o/t,
If t~. """"""".it/d'....., 11"", 110,,;"11 '"

11"" c ... or< "placed ......... odju" .... n' "' ...
""''' bo ..11I<,ed IP"VO 1J·1 5. 800:1.,., ' " " " " , , HOLDER
I n..,.."l"", I,
13-7
TRANSMISSION
1'1_ the <0<>0_01.-1<>\1 "<>Ido, ...., ,,",oe'

""luatlnt oh ... ;"10 Iho ,,,..,,,,, ........
I.... Iho boIn _ -.... _ _ ....111 .... __
.~~
t~ ......... boI" in • ailoaoa po"orn urnll Iho
drl.. _ _ 1"1 ~_ ..." .nn t!lo <OM.
Then ,j~ •• n.o tho .poeWad 'OIQUt.
TORQUE : ]0-301 /II.", 13.0_].• "...". n _25 to.fbl
1'1..,. ,,,. co.. 1.00 . " .... j", "'" I..... LOCK ~ UT WRU.CM .
1."01' '...." • MW _.,.,,"01, nu' '" ....

00-1 ...._, _
TOllooE : I0-IO H· .. II.O)-t.O
101_ ... _ _ .."'I...:
k_
iii 8Sft4b1
13-82 ~. to 11.3..... 2 t ...... 53~' ft...)
St... IN ""'k .... t
13 - 8
TRANSMI SS ION
OUTPUT DRIVEN GEAR REMOVAL SEAL
A,mo ... tJ,. "".....' ",j.." I/O" oi l ...1 f""" ....

"" """ 900< co .. .
PI"", ",. ""tpu, ....... 0'" in,o , yi .. , d"",ping it "
",. ",,10 ""It ",iodle _._
l
lOCK ~UT WRENCH, JOJ&I mm
01915_ M8OOIX)O
u .... ,oI:. . ..... I"".." "'" 0.""." d,i_ 1100< boorH>!i
,.,..i" 1_ nu' wi",""
.....
inno, ,..,. 1_ nu' U';"I ,
"' . It~_, .
A""" ... tho d, j.. " .... " bo" j"U """"" """,n, ,"U
boIu , roO ' "'''''' '~';O' ,od ~ol<l<, from , h. u>O .
13-9
TRANSM ISSION
-.
~ • ...,.. III. "'im ond O·"roo I,,,,,, 'M bo";roo
GEAR BE A RING
,.... 1M OU,,"",' d,,_ ... _ ......... I~to •

•• w.III ",II ...... U........................ ou"""
cIt_ go .. _ .......... ' ... I0<Io ..., I,,,,,, IIw
~~ .
" ' - "'. bo .................... on<! _ ....

_~"'L
80 car. f ~1 ..." to domogo 1M _ ... 100 .... ,

..... c.o ..m.'.....
",01000.
~ILor.30.""
07U&o-ClO'0700
13-10
TRANSMISSION
Pro" in • . - b..ri"G _ m"' ...... it "".t.. DRI VE R

1<.. ,• • 07749-0010000
An .o.tHMENT 52 • 55 mm
071415-1XllCl4OO
PI_ " .. bo ... ,ng Mldo! ,",o •• f>< with ",It j. ..... LOCK NUT WRENCH
,,,,,,II ond ,ogto,." . ...... bt.,,"11 ouW ',_ 10<1<
"..-
OI<l"~ <10 • .-ilio<l tor~u . . ."' • .
019115-M!!OOIXlO
TORllUl : 9O-110N·m
1~.0 _ 11.0 ~ ...... 6$- 8(1 1I·lb)
Torq ...... nc/1 ""I. "adi ... :
82-100 N'm 182_10.0 kg-rn. ~t-71 tHb)
BEARI NG HOLDER
OUTPUT DRIVEN GEAR

INSTALLATION
"O'l:
Who" ,~. lIN' " ' . dd.on 110'" _iO\l ond'
o. _ co .. " .. 1>00<0 ,"0_."'""'im
0.30 mm 10.012 1ft) ,hlel< lot inl,I., ...
fer."",.
Ploeo ,1"00 ou""" drl•• n 110" bo'''''G - . r in.o .

ot ....
Th.n ....... In tIM """",. 6ri.." 110".
In",n ..... o-rlft~ ond COt"'" $hIm. s.. Q..,. 13·14
lor $him 1010<';0" "'-.......
13- 11
T RANSMISSION
An"'*' "'- _ .... hel' to'l>o _ CMO ";!h

"'" lou< ..... boIn.. r ......... Iht 1>01..................
pon Otft iI'I twO .......... ' " " "
TO~OUI : "':M N.... I'.O_ U k ...... 22_ 25 IN~ I
IMtoil. ft _ _ ... WIno< , _ _ II,.. """ "gI"....

h to .... _Iood , _, INNEIIIIACE
TOIlOU( : 111-10 N·", 17,0--&,0 k..... ~, _ !Ia l.rIII l ,
T",_ w,_ ..... oocI;"':
W _ 7l N·.., 1_.' _7.l k.... . "-63 11 ....1
St ... . _ '- Iodo ..... or.! .... 011 • rww oil _ .
13- 12
TRANSMISSION
Oli TP UT DRIVEN GEAR CASE

BEAR ING RE PLACEMENT
Ho .......... , .... ' _ . - .. ""nd ..... _ ... '0
IO"C i l1e"f l
A~. _ JI<>... -../I .... IttIndlltw. ~",td

' ' ' ' ' C'O • •
BEAR ING IIEMOVtI'I. 17 """
~ • .....,. .... 1>0........'" .... _ ....." .....
01748-00 10000
0. .... _ _ _ ........ to ..... """"" _ ......
13-13
TRANSM ISSION
GEAR TOOTH CONTACT PAnERN

CHECK
II ........ 1ho o,j ...... o,i . ... "Of, (~""'" 13-~,
lUI.
A""I. ' ",OIl.., I ..... , .. "'" d,l_ "Of ,......
-
,","" 1ho "''''' .... "' _ _ • wi'" .... "..-..
110 ........ elf"" "Of _01 ' .....

difoet .... 01 , .. tot .... .
ill "'" _ .....
II.,....," !hi elf ... _ .... _ "'" _ ,_

...... O<! po_no
CotI ..., ;, _ it ......... lluo ;, .. _ _

....... - . . . ......... _01 ..... ' _ ...........
'0 .... _ .
SHIMS
OUNHRSHAJ' T
fACE t _ ,o.~
"~~ -_ _"'"
- RIY E CO
f LANK f SlOE SlOE
"Of ..liu......n'COO"'
If , •• """"" ~ "".
d,i. o.
""'. 'orne...001 'OI>loe:< ,n.
""m.
II.......... ",1m .,,"' .... _ "'" II ","_10<1.

"""om ~_ ""'.
TOO HIOH :
DRIYE SIDE
13- 14
T RANSM ISSIO N
fI,,,",,,, "', ~, i ,," ..... ",HI,,,,,,",,, ",im ..itll , DRIVEN

I~i< ~ ,. con,,,,,, i. ' 00 low.
GEAA~HAFT't::;::::::;-;;::
0"" it "'"
TM pan",n .,.i ll ",i!t _ , \ .~ - l . O mm 10,06-

0,06 ,nl w~ ' n 1M "';ek,n" 01 tho '~;m 1, <~onQO """ 10.Ol2 101
0.60 mrn 10.02<1 101
BAC K LASH INSPECTION
Pi..,. ,1>0 'M'M~" .... in ••i.. .. i!~ I.,,, I........

• ,n"" 'owo\,
Hold 'no
_n,
So, • "",",."., .. ",
,h.lI.,
dr;,on ~ ..
~ i.\ rodO(",." on
.,,;v. 'M ""ft

I~'
~.,kIo, ood
countOf'
,a'," "'0 """'", .... ,,.1\ bv hond unt"~ ... tock ~

,"'on up,
Tu,n ,M <." m",,,,. h b.<:k """ t",," ,a ,,0<1

~kl."'.
STAN DAR D, 0 .08-0.23"""
10.003 _ 0.00II inl
SE RVIC E LI MI T: 0,40 mm (0,(116 i,, 1
R,mo" ,M dOli ;,""",,,.,.., Ty," "'" <"""'0'''''''

I l'O' ... me"" " b><kl.", . A.",,, "'i, orocodu"
."..,. "'0".
CompMo "'" difl",,,,,,, of ,.... h ... me .... '.men".
Dlff tE RENCE OF M€ ASUREM ENT
SERV ICE liMIT : 0. 10 m m (0.004 ;"1
13-15
TAAN$MISSION
II to.
limit. I, "",1<.1' " ""'. tho _""I ;,
Goff ... """ .. m...... ' ....... "
......./y. , _ , tho .,." ... ond ,.""..n 1' _

. ,,_ .
no, .. " .. lOG
.
,o.
~.
II _ , ...... , _. ' ........... <OUft,......1t

_II ...."'iu""'"'"
1>00:. 1"",
....""_ wi'""oil.
~
" •"" .....................
,~
. n...•
"'." lItim "",n .....Iok.. onto
8 .... ,"'" II
(0.00241.003 "" _
ch....., by _"
"'a.....
0 .06-0,07 """
ot "'" ...... ;0
.........,~O.10 ...... (O OOO "').
COIJNTEfilSHAFT/OUTI'UT DflIYE GEAR

AOJUSlMUH SHIMS;
0.'" OM! (0.012 Mol
0.311 """ (0.011 1111
0.40""" (0.016 Inl
0,46",," 10.0181nl
0.100",,,, 10 .020 Inl
0.$1 ..... 10.0221101
o.eo __ (O_0211to1
COUNTERSHAn INSPECTION
toun _ _ _ _ _ I,Ud 1>0 .....

roo".. . Mt>o . .. _ to ...... ...., '" IN
'011 ....... _to
C,..kc_ (Soc! ..... 111
eo."'.......I' _Itot 15fct ..... 111
CW n .. , .... I'
'......., .......""" _ .....,.,obl> ""' ..............

... '0 .... _ ....
,0,._10 ......_ . _ .,,'" t'" or ....... _ .
M....... "'" tit .. ,,,,,, bon ... " "" b..,i"i ond
........ ;,/\. 1.,,, ;....go
CLEARA NCE : 0.1 41.'",'" (0_01141.035 jill
1/ .......... """ .. ~ ,ho I""". ..-. _ to

_ ....... " 'K'dufoo>co
Sf' ACERfTH ICI(N(S·S:
0"" "'"' (O.o)3 .. t
0.10 "' ... 10.o:lfi 1101
0.115 ",m IG.on 1"'
1.00 ",m (0.038 1"1
1.0Il "'"' 10.011 "'I
13- 16
TRANSMISSION
SHIFT FORK AND SHIFT DRUM

REMOVAL
...... "'" _ " ' _ ,ab _ ond .""0.' "'"
_ ,.' 'OfII .-.n..... bait.
R........ "'" ",H, lotio ",.tt ond "' itt 10<1< ..
-.
R _ ,ho _~ .. _ pIotoo ond "'" .... itt
GEAR SHIFT DRUM A ND SHIFT

FORK INSPECTION
In",",,' .... ""I, d",,,, ...... lor """'int ...... , ...... ,

or .. ;"............ It"';.", Iubt""ion.
Cl>od< ,.., "'lit ",um 111_" 'Of "om",,",
13 - 17
TRANSM ISSION
In_ ,~ • ..,.11 d",,,, _01 •• "" ""'" 10<1< ... tI,_

I ...... ~ ". .... "'"".
_ ..... ,'" ,,"II I~ .....It O.D . • t ,.,t"'" loft

",if t _ ... >1-..
~ for ... , , - . ............. _ 01 .....1.
fit ..................- .
SERVICE l IMn , 1J.lIO - . 10.5011101)
M_. tho ' . ' "",10" ....11 I.... I.D.

M......... "'." IorII d _ "'d.-.
URVICl LIMITS:
1.0. I.... ' _loft for _I: 14.M """ 10.563;" )
CLAW THIC~NESS : '.1 mm 10.24 ifI)
13-1 B
TRANSMISSION
INST ALLATION
1......1.... "'I""""" .
APO/v • _ ... - " ' '" .... O<HW _ R
....utI .... _ ... "'I , ".._
I :r:~'7..'!~~ -:: 10 tltlII,A. ~tpd

lnolall " .. lO0Io; .. _ . ond
~,
'ifII'........ _10' I"'"
rOllOUI : 'l_lOH·.. 11.... 2.11 q..... U - I.".u.1
_ .... 1ocI< .._ ,""" "~.
,d" WASllt ll
13-19
TRANSMISSION
TRANSMISSION ASSEMBlY
MAINSHAH
.. "'_.
In,,"1 11>0 " ' _ ." .,. .. Ing wi "' .... ~ .. tool'
CN<t; _ --" to< I. I h 01 " ' 0 ' _ " ........

1iOt> .... m. 1I\oIt.
CN<t; _ ..... _ ' ...... _od ;" tho 11'_
13-20
T RANSMISSION
COUNTERSHIFT
8<10'" pltci"'l tI>t OO<In'....,.ft In !he cronl<<:aoo ,
In.",11 , .... 01 .... C6 ~,., wWlff. one! 0011 ...
Inmll . .... Cl lit .. • nd wlinod coli...

In,,,11 .... , , _ ...."", ""' Ito 01 9>1"'1 \1'1 ' " ob or
m. , , _ WI"'.. with 11''''''" in ..... '!>liM<!
.04 1...
A... "",to ..... C2, C5 on<! CIllO""

.,.,.1",.
w
_ .,.;
13-21
TRANSMISSION
I o..c.. "'" oil ""'oco ,,,. <109\1'''.

• 1......1... "'" """,.. ...........
-. I
•
13 - 22
MEMO
DRI V E TRAIN
".
l00-11ON ' m
no.o _ 120~
. . "- " ' " 100-1 10 N ' m
, (10.0 _ 12.Q k
72_117 "·Ib l g.<n,
6O _ lON ' m
15.0_ 1.0 ~ 1i""
n _ 51 "" b ~ ,
14- 0
14. VE
SERVICE INFORMATION 14_1
TROUBL ESHOOT IN G 14- 2

FINAL DRIVE REMOVAL 14_ 3
DRIVE SHAFT ,'-'

fiNAL DRIVE OEAR ,'-"
FINAL DRIVE INSTALLATION 14_ 1'
SERVICE INFORMATION
GENERAL
m"" ,.,,",od
• Tho , ...... *I¥o .... ....,..t
• 1l000_.U ......1. _ 0 ...... _
be
-ir4._
to 'WI:, E , . . d .... 1IIoIt.
.. or ..... ftlcIr ... ,.• • _" .. '" II diwo..,.
• Choo:t< , _ _ <act """"'" _ _ _ 1ft> _ ...
w.
WI ....sIor _ _ _ _ . . . . . .
SPEC IF ICATI ONS
TORQUE VALU ES
~", ..., bo.. ,,. r.ta;"., 100-120 N .... 111)..- 11 kl ..... 12"'1 !I ·III)
' ini"" ""t 100_120 No.. (10- 12 kl"" . 12"'7 It~bl
Go .. co .. co .... bolt 10 "un . 5_ 50 N'm 1• .6 -$.0 k ~ ..... 32-30 IHbl
'mm 23_28 N.", 12.3-a k...... 11 _20 ft.tll)
f .......... "....n.<."......., 1!O_ 70 "I • .., 10.0- 7.0 k' .... U-fi, ft~b l
14-1
DRIVE TRAIN
TOOLS
$o>oc:1..
A,,_nle 07Q6.1- M800300
R... lno, w,oncI> 07910-4630100
Pi r>ion ho Iojo< 07916 - M~9«OJ
5/laill>" llor 07Q31_ME.OOOO or Pinion ""II., ... 07935_MBOOOOO
0' Pinion I>"lio, 07931-4630200 olIO
Pi"",n p.,ollo, ..,oct. ....... , k j,
07931_M800000
Ori_ 07949~710!Jll 0' 07949~71000
,~m 07947--634021l1
A"ocI'wn8n' 07945~3301oo
en,i"ll ,_ I"",,, . , , _ "' 0793 1-4630300 or Forir oW 0,1 .. , 07947~710101 ond
AtlooIImtnl3hWmm 07746-0010200
... nO<hmon. 07945- 3330300
... "odtmen .... 07964-MBOO 100
~-
0,;' .. 07149--0010000
"""'dlmon'. 42.47 mm CI746-OOIC3OO
"""'dlmon'. 52 . 55 mm 07746--0010400
"''''dlmon!. 32. J5 mm C17411-OO101OO
Pi"" . 30 """ 07746-(1040700
Of .... C 07H6-OO.JOHXl ]
AUI<'J\nwn,. 25 mm 1.0 . 07746--OO.'lO:lOO 0' 0, ... , 07945 _ 3110200
Shod< tboo!btr comp,""", 07959-3290001
TROU8USHOOTING
hoo"; •• ooi ..
I. Worn ", "",rO<l , i"ll_ 1II, Ir ...:I d'i'''' ~."""
2. _ .,1.", II""," ,,'" .." .., hub
3. Worn "" "",,0<1 dd .. pin'on ..... ..,In·...
4 . W"", "inj""...:1 ,;'" ON"
5. h oo";" I>o<I:IMII bo' ..... n p lniGo ,nd ring 1101<
6. Olll.,ej '00 low
O~ I••
1. Clowo<! br._
2. Oil 1....1 '00 n;w.
3. S.. I, •• mogod
14-2
DR I VE TRAIN
FINAL DRIVE REMDVAL

PI.,. III, _ .......... ,II ....,., "...,. D.... tho
''''' . . . 01' , _ 2·10) ..... .."..,ft ..... ' " ' _
( _ ,8-31 .
PI_.~ "" G,"," ..... U-.. tho go" <OM ..... "''''11
Ofm ""'''''' ....1-. to <.tct. .. y domper com 011
til" m.y look """I.... Inoj ..."""1I cl'IIo golf u..
R ...... ' . !tit !inol golf """ ",ocr.1noj """ .....
,0M0¥f "'" goOi .... I,om "" .wi"-",.
DRIVE SHAfT
REMOVAL Pull "",II
" , .... dd••n .... I' ..... " ... c l ,110 lWI~m ot,ocr.·
.. 10 "'" IIn.' ..........,til I, ,. .. ,omo.-d. 110 "'"
'··~I,
10llowll"Oll
'n.." "'" " " """"\It' "'" .... COlO ..... . -,. "
COlO I~ .......1'" 00" "' ... '" Ihop 'OQO b. <Jam,..
Inoj "'" .. II. "'... tho . -_ """'"' " . _ tho
""" I", """', ,,.
" ' _ 1ft 00' "' . .. ..... u.-tho dam_ .,.. to
.."" .... dam", ",11IlO' ...1' wi" ..... .
s.-........ dan\pot ..... , Ifom ..... _ .,.. "..
.....Iy _
.... ilo ...
... "" _
a ·......... 1ty
<_'If """"'"
in •
AI ... ,., ..... . "" doom ......... lrom "" go_.,...

,,,, .......... G..... d .... DU'" """ ' ......... !;os in
*_ . . . .
..................... opt....., one! cl .... d _ "Olio
' ......' - . . . 0IIl in .... ~ . . . . , _
.... , bo I... ' ....., old, ... ~ wm"b:ocl.
DISASSEMBLY
0, ... th ....", col from "',domper 0 ....
~ .... _ th. ,,, ... ""Inoj d ip Ifom "" dom_ <am
'e ...old dom_ I•.
Com ..... "'" d'......... " w,,., tho .... 11>_ lb·
...... , ..".,"'..... ..., .n- "IrIOn, tooI<.
ABSORBER
COMl'RESSOR
07V5i-uiOOO1
14-3
ctl\ HONDA.
DR IVE TRAIN ~ V6S SABRE
--_...
A.... o .. ,,.. ........toe> ro,....... d".. ",oft , , _
....
R....... ,M "";". " ..... ........ _ ..... ...., " -

Ii_ It"", 1M tlti.. _
0...0: tho d,,"o, ..I!" ............ I", _ .. '"
dom. ,
DI>t. J lA, 'lOp rI"f.101 I,,,,.". now <>N

"""" ........"'b(lo
,}
I II,
SP RING STOP
I
STOI' AING
OIL S!'AL GUID~

A.... o.. 1M "" .... """ 001 ..or ,... ... ,,,'''' ....
...... _< ...
:::::::" .... on .. or willi • ..., "'" ,I i", I
14- 4
DR IVE TRAI N
D AMPER ~'M ,..,,"

M ... ulo , ,,, <Iom_ com ""Ing I _ l...;<h.
URVICE LIMIT , &3 ..... 12.5 In)
FREE
A.mo .... t ho dam_ eo ... "" 0 ... ;"" "om ,,,, d,i,..
",.IL
In,,*,' ttl. O ... i"\l ...:I .. plooo l' If ""'''>tV.
. ,
ASSEMBLY
ORIVER
In,utl 11M <Iom"" r <am '''' ;''' ;"'0 ..... d.",,,,,r ..... 01749 _ 0010000
0.". ,h. oil ...1,.,;cIt ...:I oil ...1In ...,h ,h. dri. ..
At1~' and dfi..,.
A,..."bhl 11M ,.",oIn,"'l P"" It! .... ,...," ordo<

old; ..... m......
A""ICO tho 0 ... 1ng. oil ... , . ,.., "op ';ng wi'"
""'" """ _ ' ..... mtlHn ~ Ih. d, .......It .
ATTACHME NT. 52. 55 mm CIS/ASSEMBLY TOO L

07H~-1)OI0400 0 196-1-MB401oo
14-5
ORlve TRAIN
FINAL DRIVE GEAR

RING GEAR REMOVAL
A,,,,,,,,. Ih. di"..,.. coil .. ,
A.""",. "'" !lull .... d "'... bDIIL A _ . "'" 0.."

..."" ...... by ........... II .Iook.... ,
A.~.", "'" . . .1 co. _ _ _ • _ _. It .....

.... _ ............ _ .... ""', . oi,., ""'"
1'11<0 !he _ 10 • _ ... '" ........ ... _ .
M ............ _ _ ill _
,..., 11>0 'int _
n NIH' '10<1.
""" 01 "" _
017'in()(Jl0000 on<! ,nod"...
... '" ",no..
ft' 07''e--0O10100. •
~."'o ....... 0 . ... . ,. . by , I : : .... II hOI" ""

r ,'.. tldo.
, 4- 6
DR IVE TRA IN
,
RING GEAR REARING REMOVAL
-
lIom_ ,ho 'ing _ _ ,,. .... tN' teI)u,,"'I
RIN G G eAR
CASE COVER OIL SEAL REPLACEMENT

11'''00'' Tho oil _ from tho .... _ ..., ......
.. . _ " ;1_ .
PINION GEA R REMOVAL
In".11 to. ,,",ion " " _ Of"" .ho I'Inlon Join •

..., .om... <hi " ", ,,,,, ...It ......
II ...."'" th. ,001 ..., ,, ___ ;0,"'.
14-7
DRIVE TRAIN
R...-. tho plnIon ... _ ... 11> "" ...... .... ,

w,onctl.
14- 6
~ HONDA
~. V65 SABRE DRIVE TRAIN
PINION SEARING REMOVAL
DRIV E R
PINION RETA INER QILS EA L

REPLACEMENT
..
R........ "'"
......; ,.
O~~ , 00:1 ~;I ...1 f""" tho P,",on
079015_3330300
Ori .. . >lOW 011 ...1 in,o ,no , ,, . ..... ,.
....,.
Coo, • . -
,.,
O ~; "Il w;th 0;1 and ;n". !1 ;, ""'to tho
,
14-9
DRIVE TRA IN
CASE SE AR ING AND OIL SEAL

REPLACEMENT
..... , tnt _ u . '0 8O' C 111e' f L Till'
CIOO ... Itt • ph "i~ h .......... ond , _ . tile
tIIe_<inti
. . . ond 10''''_.....
AI __)':I _ p6m ......... -Ihof 1M ""'
<-'.~ It .... ...... MtN.
I Utt "..~ ' ........ .. , 3tI """. 01838- 3110400
DRIVER
Df;" • now "I .. .. .. to tIIo COM. ~ ..... """I"

...... "'own.
Dfift . . .
<_.
p_ . . . ,;tIQ ... _ ,,.. ;.... 'M
01$.15---l330300
,
14-10
OR IV E TRA IN
8REAT HER HOLE CLEANING
A"",_ "'" brut"', Il0l. UP.M _ '''' ...... "'.

br.""... _ w;t!> como<...... ~ .
,EAIIING
PINION GEAR ASSEM8L Y
.-
W"""" ,,,. _ "'. .,;"..., be ........... , ... ... '
(,\, "
GftC hOI bern tlplOCId. UM I 2.0 mm thick
. . \ .. I:H
~ I ;;..
\.,.. lI!".
"'.., ..... "... ,,,, ""'0 tho P

""" (10"' "'." w,"" .....
""';oIlOOl,_n.
, .... '011. nowO-<q_ ..... 1W'1on ",.,,
:/fi ..... I.D.
14-11
CRIV E TRAIN
...... _ .... 100> "bly"'" ..... _ .............

0. ... ",. .... 100> ...... .. '" _ ........... Iit
_ " ' I,n ..." " " . ' con •• I ...Ilh'ho ...
AP/>t>t .... oil 10 _ 0 ........... tilt .... "" ....
pItoio~ .... tlftof. , ....,.u .... O..ing ",ide moo.
_ ............... moO ..... '0 __ ..... pWoro
two ....... I~ pi .... ...... tiIoto_ I, ....... --"*I
T(Ntau£:
100-120 N.... (10-12 q... n-v "'"",I
~INGGEAR~~"
RING GEAR ASSEMBLY
IN\.OiI tht .. ~ . . - onto"" .w., _ .
II ............ ........ bow . .. ' .... _ _ .

... .-.oIlor _ co. II ,.p ..... , !no.oIl. 2.0
"'''' ink!< ...... , .
...... • ....... .... ..... two ................ _ IIoott.

" ....... old twowifte 01'1 lOP 01 i,. Thoo, d,'" "'"
.... 1:0. .,;l'1li 01'110 ..... IIo,It .. ilh ..... old two ... jny .....
otto<l_.'. Thon 'omo" "'" old twow~
14-12
DRIV E TRA IN
O~IVE~,,,~,
In"'" ...... o~ ... "" .... o~ ...........
... ~ " ••• to .... O~i ... ....:l a,"" .... 0 .....
... Idt onto tho ,in; .... 1IIttt.
",,,.,," '... _ ""0 me _

... _ . me ............ _
<aM..,...
.... ' ... _ ...,
"'" ' ... _ Iot _ .
,,,,,,,,.. .. i .......
Clf .... U HCE' 0._ .10",," lO.II lZ-CI.ON "1
It "'" ............ _ .........i<o Ilm i,. ,.....,. •

.... ' ... 1/1". Ho.t .... "'"' .... _Of
mOl.,IV IId'c IHe"fl"" , _ .... " ... "'" &y
to _ 0.· RING
111" ........ _ . O.lO-CI./IO """

,
.-.
In".11 • " ...
' HIM THI CKNUS,

Q ," "'im to ""'.'" "It ""rron " .., .
... 0.10 """ 10.00( Inl
B 0.15 mm 10.001 10 1
-.
I~"'" ........ ..., tI<;.. , ....._ ~n In,o ........
14-13
ORIVE TRAIN
a-. _... _......

.....
HIITI:
oil ........... 'lfiol olt ............. Nrl_ 01
K_ dUOl _d ~ ' "'" 01 .... _ ""It.
--
- lie coroll>! "'" to _ " , .... ", ..lilt
,. ...........
A _ 10Quid ....... , ,.
,
u.. "''';''11 .... ,0<. 01 , ...
GEAR T OOT H CONTACT PATTERN

CHECK
ApoIy ...... ..,., 01 , ........ 8 .... '" 1100 oOnlon

_ _ loro _ _ OOtItIa_d
"oar _ ......__ '... _ ..'0 .... _
r
.".
Awl'< _
.... _
~I '0 U.. Ii. 01
.N! .....11 thO ... '
,h.eo• ..,....
011 ...1 on "'. Il00'
T.,_ ,... ..,... boH. In 1 ... l.,..,. U"'~ ,1M

...... .-y ,............ _ ..... "'"" ,"",on ,...
8 ..... boI ......... opodllod _ _ In ...·m caa
_ " _ .. .-ellopo.
TORQUE : U - zt N... (2.l _ 2.1 ~ ..... 11_ 2<1 11 ....1
T., .... 'IM'O mm bO ....

TORClUE : .e UN_", ,'.5-1.0 ~ .... ,:O...". fl" )
14-14
~ HOlVDA
:.;. V65 SABRE DRIVE TRAIN
AI"""" ."" oil hll .. cop f,om tho 1,.01 \/H' c ....
NOR MAL
Ratite ,,,- ,ing ill"' .... '.1 timo. in III< "",mol
dIrect"'" 01 ,o,",ion. CIIock 'hI 11'1"' tooth con1>ct I
"""tm through .flo oil Iil l.. ho". Tho PI'te,n "
indie,,'" by 'hI P,uui.., a ..... _ 'ed '" ,hoo
pin;o.. !>O'' ' "_'y.
Con, .. , i. "",mol if me ""''''on ~I ... i. " ..,1.«<1
to tho ,ppm>i.,." can'" 01 ood> toott. ond .ligMIV
10 Ih' fl.,k ,;do.
- _ TO.
II ,lit P"'"'., ... "", <'0<'' '..."",., ond ,.pl_

,0. pin ion "' ....... R,pl... ,,.. pOfHO(I,~ .. i , ~.
,nk"', on< il .... con100::" or, 'oo n;gr,. '0""" tIM
,~
"IC~ ' ACe

~ ~!
OA'''l "Of COAST Sl oE
R."looo 1M pinion • .,.c., ..

i1h. Ih;Me<"" II m.
= 10<" II. I"" low, to 'M " ,nk ,idol, T... ".",m, PIN ION SPACER
TOO LOW
w; 1I .... ,It 1bo<J, 1.5-2.0 """ 10.06-(1.08 ,n) .mon
ttl. thOck ••" 01 .no wooe' I, <n..,god by 0 .10 "''''
10.004 in).
I
PINION SPACER,
A 1.82 mm (o.on ' 01
B 1.88 mm [0.07.10 1
C mm I O . O~ 1. 1
I.~
o 2.00 """ 10 .0711 101 Stand ....
~ 2.01 "'M 10.081 Inl
f 2.12 m .. (0.0801 in l
o 2. 11 ... ", 10.08t io)
14-15
OR IV E TRA IN
BACKLASH INSPECTION
$0, ,hO finol ill.....",.,.. into' III 0< .. ,,.., .0

"old I. ........ , $0 •• r>o<;,,,,,,aI tVl>I dlol l.... i<_
Oft thO ,1"Ii .... til, ..... . 1ot ..1 lin., _ .
Hold .hO pl.v... ill......... by h..... Ro .... thO ""'
. . . by hand .......... ~od<" ............ T~m thO
,Ina _ - . and ' - ' 0 ,ood bor: ~ l lIfI .
ST ANOARO: 0.01-0.1. """ (0.003-0.007 I~I
SERYICl LIMIT: 0.30 "'''' 10.02 hoi
,
_.
R.",o •• ,lot di_ inrICator. TIIrr'I thO
.... ","IOUIO 1Ncf<1nI>. R_ ' Itn...._
-Ina ..... •'lIf
.. one.
eon-. ,"" dino"""" of ,"" til.... "",,,,,_,,.

DIFFlRIENCf OF MEASUREMENT
SERVICE LIMIT, 0.10 "'''' (0.004 Inl
/ -,
I ,' I
\' ,,/
\
~
'--
It ,"" di l l."nco ;n ........ '.""n" • • """ •• 1ot Ii..;••

i, Indi< It.. til" ,"" bot ... in; i, "'" k\o.allod ""' ... tl 1 '
In"""" .........."" .... ,.,n,,..11 1 ' ... " .....
If _ 1..... 10 ..... _ . ~ .... tho ,I"" .... Il""'"
";tIl. tII""'_.
_ . . " 10 """""'"' by _ , 0.0.-0,01 """
10.002-11.003 ;,,) - . , " ' _ ot "'" _ 10
_ _ 1>1 0.10 """ 10,01)6 irli.
AING OlEAR "'ACER '
A 1.1.2 .... 10.012 inl
II 1.18 mm 10.01' h.1
C 1.1104 mm 10.0161nl
D Z.OO mm IO.o711 1nl , ........ '"
f 2.041 ..... 10.0811nl
f 2.1 I ..... (o.au Inl
o 1.1' """ (O.OIMI .01
H 1.2' """ CO.OIMI iIIl
I 1.30 """ 10.091 ;"1
14-16
~) HONDA
~. V6S SABRE DR IVE TRAIN
PINION JOINT INSTALLATION
tt.4 •• two tvpoo 0110<1< tabs .. _ .
PIN IO N fiOlDER
A""I~ ","' Qil I" tho oi l ...1 I.p """''''' ""/000

"I .1" ~;" ion 10,",
In(! ;~",' I 'h' Di""" joi",-
1"'1011 ' 1>0 !>ni"" hOItIo, ,,,,,land 'iiI1'''' rho pi""",

"".
TOROU£ : lOO_121l ~,,,, 110_12 k......
72 ....71t-1bl
Remove Iho pinion ""kill ,<>01.
M......... ,. ",., ,,," got ...... mII ly .otot.. "''''O'"'V

wi!l101J' b,"","" by ,", nin~ 'hI p""'" )0;"" . •
14-17
DRIVE TRAIN
Imtoll ....... " ....... pIono one! ' " " - .... bolt.
Imtoll .... dil _ _ •
FINAL DRIVE INSTALLATION ,

' ~I
ond _
..... dom".. CMO W,,,, .... ,," ,.,..,' , IV'"
ollull<icom.
IIlCQMMENOIO Ol l : HVPOIO GU,~ Oil
Oil C,,"' ,,"CITV , 50 .. (1.7 0.1

~. '"
" "P''''l "'" d ........ c_ """' ... pO",," .... d .... ....
spr;n; onto .... d _ "*" _1."011 .... I;""
d , l.. 110M , ....... ' .... dtml>ff ....,.
..... '" d _ .... am ..... _

80 ~I
oil .... dU' ... 777._.
00 "'" \0 ..... _ c_ It"""" ,""" ....
d"",,,.. coot Of .... oil .. in ""II ......
14-18
DRIVE TRAIN
M....... " ..... "" ....... ,,",' ;,. in line ..,'" .....
"'.......". n- ...... .... d ........... " imo tho
..,;......... oI9'inII II> opi;noo wi'" tho .,.... Ill'"
opt ..... K_p .... 110... _ ond dompo< . . . _ .... ,
or ""'- oil will "' ... 0'''.
s..u" ,ho 110_ ... '0 ,,," owI_m wI'h tho ,h, ..
'"""''''Il ""II. To .o. .. I. "'''oIl..i"". do "" •
•ith'." .100 ,... . . . . "" .. un.;1 ,h......... It ~
"", 100d .
In"orl ..... " " ,",,"11_ 16.a].
T¥o'" "" ••It ""' .

TORQUE:
" _ 101 N_ 11.5-10.6 t ...... 11_78 .......
Tigh ....... _ r", .. _ c.. """"'" null.

TOROU E: 10-7(1 N'''' 1t.0-7'O ...... 4l-6IIf.!bI
r .............. Io.-.boIt.
TORQU l : 2O-JII N.... 1 ~ , O _ l.O _ ...... ,._u
It·• •
M .... "" •• "'.. tho 0;1,. .. bolt I> ... _ .

<I"
II ........ "" "II,I~
~". 01 ,ecomm..- Qi l.
ond ""." "' .......... ihoo
RECOMMENOED OIL: Hypoid Goo, OM

SAl #80
OI L CAP"'CITY:
1M ... tt.l ..1 0..,
uo ..........1 RtfiII_d'........
14-19
fRO NT WHEEI../SUSPENSION
30-'10 N' "

(3 0-'1.0 k~ "". 22 _:ii h~bl
2!i-30 N' '"

(H-3.o kll ..... 18- 12 h~b l
_ . _ - - - 1lO_11O N' '''

... (11.0-12.0 "t..... M ....1 "~bl
~~-5~ N'm
14.5_§li kll .... ,
:n-'lO h-Ib
M-&.:i N'm
(S.5-U • ....,.
40 .... 1 '1-1'"
20_25 N'"
12.0_2.5 kf ....
1'-18 "~'"
15 - 0
15.
SERVICE INFORMATION FRONT WHEEL 16- 8
TROUBLESHOOT ING FRONT FORKS 15- 16
HAND LEBAR S STEERING STEM 16- 30
SERVICE INFORMATION
GENERAL
SPECIFICATIONS
STANOARD SERVICE LI MIT

A,I. ",.1, '"""0" 0.2 """ 10_01 Inl
F,,,,,, ........1';", "''''''''' Rodl.1 0.3mm 10,01 .. I ""'>, 2.0 to'" (0.08 Inl
1\.101 0.3""" 10,01 Iftl "" ' , 2.11 """ 10_DIllnl
1'0'0'" _"'" pI .¥ ~ O.oJ Mm IO.QOl ;n]
FOIk~;"g r, .. lon;t~ U4 """ (21.02 ;"1 ~l m., 120.6 1<11
Fork ,...,. "'''''''' ~ 0,2 .".. 10,01 ;111
f..,,,,
fork ""><l_~v R>grI' 470 CO 11 S.a 0". LoI, 4~ Ct; (16.7 ",)
F root I...... " .......... ,. 0-40 V. IG--{).4 kal""" > O~ poi) ~
lID
TORQUE VALUES
H ..... r.oo, U",,"' .....'" 30-40 No", IJ.o--4 D kg·", . 22 _ 29 !,·Ib l
H.odl."", 9'_ ""I, 25 - 30 N·m 12.5-3.0 k9<'l. 18-22 f1·lb)
Cal l_ m.,..~';"11 ""II 3Q--40 N· ... (3.0-4.0 kg.,.", 22_ 2'\1 h-lbl
F,,,,,, .. ,. 5ei-65 N·m ~5.S-6 , 5 " _ •• 0_17 tt-I~)
A. I< pi_ ""I, :/0-30 N'", I~D _ 3 . 0 kg"". 14_21 ,,·IM
F,,,,,, 10'" _" ""I, 15-25 N·m 11,[,-2.5 ke-m. 11-1 B 1!·lb)
For. ,"IM_ 15-30 N,m (1.5 - 3.0 k~m. 11 _ 72 II·lb)
S,_'''II " '''''9 od;u."".nl nu, 20-22 N'" 12.0_2.2 ~g ...... 1.-16 h~b! (So. POII" \ 5- 34 )
S,"';..; """ .... , 110-1:10 '-\ .... (9.0--12.0 ~ ........ 85-87 IHb)
B,ok. diK 75-30 '-\ .... (2.5-3.0 kJ<n. lB_ Z2 /'·111)
F,,,,,, 1<>'" lop 0,""" bO'l 9- 13 N·", :0.9- 1.3 kg.... 7-9 h "bl
F'00' 'orl< ""'ton!O'"C" ",,\,
f ,oo' lork >lobil; .. , 11011>
.5 _~S '-\." ('.S-5.5 kJ<n. 32-40 ft·l>1
18- 28 ,-\ .., (1.8-2.8 k ....... 13- 20 1t·11I1
F'OOI 1><... m."., ....
1; .... ' ~"'<Io< boU
Clu,a, ....... , cylindo, 1>01<10, bO',
10- \4 '-\,'" (1 .0--1 .' k ~"", 1-10 /'"111
10--1. '-\·m (1.0--1 .' k ~ . m. 7-10h~b)
An,i_ P'''''''
pin tool, 20_ 25 N' n (2.0_ 2.5 kg ..... 14_18 It"b)
15- 1
FRON T WHEEL/SUSI'EN$ION
' 00<.5
",..;.I
Ho . ..,._. e ",m Cll~11 _]l","""" '1.00' ;oonmo<ciol'y ..oilablt in u.s .....
$0110 "'" pit" 079 12_ 3230001 ~
' '''' ' ,..I d,;, ... OJII&1 - KM0100
fM ...Id,' .., ."oehmont 0111&7-KfOO100
5,_1", "om IOoko, 07iI6_J710 100
8.ol1 , ... ""...", 0111L6---3710500
II...... " ••• , at,,,,•. ,,., Om:l-MJ 101X1'" IU.$A co"M
5_".-..",_
~~
Co ."_
~~ 01749-OO10c00
"" - . . 2 1 . L7 mm 017 ~ -(II:nOJOO
"' ~ 11 ...... 07 1~-(I040J00

Lock .... t .. _ . 30 x n on,., 01716_002!lLOO }
e.,.",lon ~ ..
8_1", ,am"".. ",.1, ~;;~::: ~, ...........,.;oI ly ...i l _ In U.S.....
_ ... rom"" .. Ioo.d. 15 """ 0174fi_005(I<.00
..."...-.. ]/ • ao """ On26--00102!l0
... "."'.,... ,. $1 • 55""" 01746--0010<00 Of 0J9.te-J710 100
TROIJBlESliOOTiNG
Hood ".ri.,.
1. S,_I", bo"'~ "'",11"'"'" ..... '00 ,..,.,
2. Foul,y "_."1 ".." bo.. .....
1. D.... _ ".,Inoj "om bo"'",
• . 1"",II.e; ... , , ;" ...."'''
I i - . t. _ ..... '" _ .... , ,,&<I< ""..,.,
1 u."."",,v .djunod '>11>' .... Iel! ......... b .... bo..
1 Be", loon' ""-.
3. a.., ftont . 1t
•. _!no ......................
' ..... _ _ i..
1. a.", .Im
1, w"'~ loon' _ _ i<9
J . Foul", '''.
a. .... 1. """"",ontd Imp",,,,,l y
Soft ........ oIoor
1, w..... 10<\ ,......,.
2 . •_lIie ....' !lu"''''!Tom /otOo;,
J . Front tool<." ......... inc<><'&<1
Hood "'F' ,rio.,

t . i_..ct ' 10,0", --aIo," Iron, ....k,
1. ,""', totk ." ............. ""0<'1
]. 8.", to'k ,ube<
• . C'owed II.", p . . . .
e. clowed .",1-<1 ... 0"''''
f""" "' ...... _ ""' ..
1. Woo" 01 ""' Of ",060 _int<
2 '_me ....' f ..... in '''''',
3. lOOM Iron,!"'" ,." .....
a. lock.f ....... '" k VOO'" ... to,
15-2
FRONT WHEELISUSPEN$ION
CLUTei' MASTER CYLINDER

HINDUB!RS
REMOVAL
D;"""","", .,.. ch. "'" ,.,..;w. wi ,n.
Aomov. "' ...... td'I "".to, cyilndo,.
CLUTCH SWiTCH WI RE
CAgLE
15-3
FRONT WHE EL/SUSI'ENSION
" " . MoUlt" CYlINOEII

0' ...." IN It"", .... k..... td> """10.
0 ... . "'"'" IN ",",It" a _ from "" lfIto"'"

"l~.
15-4
FRON T WHEEL/SU SPENSION
HAND LEBAR COliER

Romo .. ,1>0 bolt capo ond ,1>0 ~ondlot>. co ....
..
Romo,. "'" hond_ u _ 00100, 1)0110.
Romow .... no .... _ uPIIO< holder ond "'" hondo
~
PUNCH
INSTALLATION
Ploeo "'" handl_ 0"'0 \l>O I.,.,.., 1>oIdof. olignl<>Q
ilO pu...... _~ wi'" ,1>0 uppof .url_ gf '1>0
_ , t.oIdor .
... _ tho 'ith' uppof 00"" onto ,1>0 _ , 00....
wI,h lit "",""", m.k I"';ng ''''''';JI"d.
,,,,,,11 _ bolb. bu, II<> "'" , " '..... thorn .......
,,,,,,11 "'" hondl_ """"' on tho hond_.

OIigning ib lug> wi,"
,no ...... '" , ho Iowo, Ooidon.
15-5
FRONT W HEEL/ SUS PENSION
,,,,,.11 ,... left u_""!do< ""'0 ,... ",-, holde,

-.
"",~ 1!1 """"" f ..1IIt kKword. Ulcl,. co<o
_~
"0' to dl,.,...,. 1Iarod_..,.... .... _ ,... _
,,,,,oil tIIo _It _ ! . $ _.
T¥>.... tho I...-d bolt. r.... IlWI 'iIt!.... Iho

... bo~L
l O AOU E, :JO--.tO ", .",

(3.Il-0l .0 k ..... 22- 28 ft.II>1
1\Pr>ty ...... 11>"" "'ttlnlo ... ,~ 11"1,. ",rf_ ...

.... ..., "'" ",,"<>..10 grip _ "'" h._.
C,~, ,... ""0,,10 _
,........,. t"ho ,1ghO _ _ ..........
II> ",. _Io.~
1",.. " .... ,.." _ " ' " oM,,*, 1>1' ....,. . , ....
10<>1,,. "'" wi", "'" _ '" ,lit h_,o.
,~'''>n" GfUP
n,n_ , ...
II..............
'_d ...ow 'on,. ,...., 'iIt!_
15-6
FRONT WHEEL/ S USPENSION
In".1 1 , ~. If0<\' 10,01<. mH'" o~ l i_, with "UP"

m " ~ 1"';"9 up.
,01, 19> ......... 01 tho ~oklo , with tho ~ondl . bor
...............
n.. _ !h, u""" baI, r,,,,. thon tho I<>wo, bol~
TOR OU E: lG-l . 1II .... l l .0-U ...... 7_10 It ~bl
Conrooo. tho I>rokt I ~ t ... ild! wi, ...
,~O. ' LEVER

Con_. ,~ . chok. ubi< '0 ,ho """', IO .. , '''0"",
tho I.ft hond_ ,wit"" .
In,,,11 til< left noodlebor , .. i,,,, .....
'ign,"I! ,1>0
locating pin .. itl1 ",. hole In '"" """""bir,.
.... ....--.
r~,on tilt I.",.or. wOW II ...... 'h«> ti",,_ ,110
Inl1l11 .1>0 olut<:h .... "., O'/Ii_, with .ho "UP"

.... ,~I.cSn ~ up.
AI"" Il>, ond 01 .n, noklo' with !ho ......... m......
on tho hondl .... '.
T9'<"" tn, u""" bal. Ii,,,. """ '9'< " n th, I<>wo,
bol,.
TOR QUE : 10_1. N·m 11.0_ 1.. ...... 7_10 It~bl
Conr>oc, tho okl'<:II IOrOW wi ... .
15-7
~ HONDA
FRONT WHEELISU$I>ENSION ~ V6S SABRE
FRONT WHEEl
REMOVA L
FIotno.. tbo."...._ .... =-ord_.
R."", .. <lit ' . .' brlk. ",Ii.,.. brICU, "",un,lng

flOIto ,'''' romo .. ' .... col.,.,.
0.. "'" _ ....... "ont br .... _ of ...

.....-......... OOIipoft. To do to .oN '*'"
diHicult . .. fin ... <lit br ..... ~ioc: 110_
tho l><.... pod..
. l
Loosen ,loa • • 10 _ _ •
L.-.n Ind """'.. tho I...... ' ..10.
Ro"", .. t .... " " " ' _ .
15-8
fR ONT W HEE L/ SUSPENSION
WHEEL BEARING INSPECTION

O>ock ... 1>«1 "'"lroj
""'~ by Qlocin, .... wI1 .. 1 in
I tr~ l n~ It........ III;"nll1ll tIoo ... 1>«1 b. ~Iod .
PLAY
R.."""" <h. ".,,1, . .. ith ..... MO, If ' '''' .... noisy
'" h . . . . ."" .. ". ~ ... [r
CC"'l
WHEEL INSPECTION
Choci< th. rim ",no." by ~"" I "" th. _ I In •
'ru"~ nand . Tu," th. _ , ,'(N01y and .. Id ....
" , , * , , .... "" • di.1,od icalor .
SERVICE LIMITS,
~"'I" Runoul: Z.O mm 10.08 inl
. ..1.. R~_t: 2.0""" 10.08 Inl
NQTL
TM .. hool ~, .. ," o. i,"; _ "'~" ".

"oIoc.d ....,~ I now <>no if ......,. id liml"
. . . ~od,
AXLE I NSPECT ION

Sot th . ..I. In V blo "",,.n<! m........ '''' ",no., .
SERVICE LIMIT: O. Z mm (0.01 Inl
15-9
HONDA
fRONT wtlEELlSUSPENSION Y6S SABRI
WHEEL 8A LANCE
..."...1 _ ...... dintll! .n.m M. "_1)1.

tt..di«z .Itd ",,<Nil -1'1)1 0{ 1M _ou:rdt.
•.
A MY. dtft,I &rl "" ...." IIot _ "., ""'"
" ~'M"""
~
For OI" ...... m bol.oct. ,... ,ir.bobn<>o_k

I. ". ... , dOt on ,~. oklo w. 1I 1 m .... be """,''''
ntA\ '" tho ............ ~ ••''''.. n'
tho ,~. H
nib. " .
~."'o .. tho duot . _ """ or" d _ .... ......

~- .
M"..,., tho _ .
1n1l1O<l .... " ......
'ir.""" b<... dioc ............ In on
Sro;" .... _ . _law h '" .top. _ .... ~ .....

_ 1_ _ ) ..... ' 01 ,,,. _ 001'" _ • .
Do thh _ .......... _ ... _;!y ..............
"N. If .... _ h bol, ' . 11 w~1 not """ ___
""on,I, ....... _ .... , .~
to boIonoo tho _ ........, _ w.."" ........
mork~ ""'" 10m on, .......,., ...... _

........... , .. "" .. tho _ ..... , _ _ If._.
h ........ .;do 01 tho ....: tho ~ .. , ,:.. " " cftoIk
w ~1
Do not oodd ....,. . "' ... il{llI'amt to , ... !<on,_1

I..., w ~, 1011'...,.1,
15- 10
FRONT WHEEL/SUSPENSION
OISASSEMB lY
R,,,,,,... ,he If" lit" ,
'""""Ot
Ro""". !he bnko d;,e _ 0 . ; boIli. ond d;,e,.
11 """,,_ "'" >de <;oil .. ond ,~, .. 01.

R_ _ ..... I• • u,. ond .~" 0'...... , "'.. r.' __.
GEAR RETAINER
,
_EEL 8EiIoRING REMOV ER HEAO.lr.tMI
R _ ..... _ I _into ond .". " " _ .... ,..
Ir........ _ .
II .... bo ........ _ . <hoy ....... Id bo

,,,,'_.-Ith _ .......
on~6...ooso100 • •• _ ;., U_S_ .....

"
15-11
FRONT WHEE L/SUSPENSION
ASSEMBLY
T.... 0.' _ _ •00 rim "-'<I.

Tho 1<0"" _ I "'"' • ",tool .. , "r'. F",
,ubOtoH ' ir. r_". "fo, '0 , .... foIOOl DA
TUeElE$$ TI RE MAOlUAl .
Poe\< .11 _ '''" c,.i" " wa" 0"'"

Dd .. In " .. ,ogII, bo.. i ... I;",.nd .'".. , .... dill,,,,,,
<011" 1"'0 ~ I(O.
e ..... ,.;" " .. d in""" colli' " '" poI;'i""

",,10 •• ,,,,,011'''11 '"" II" ,,,, ..In;.
0';'" In tho "'It bo.,in; ",,,,,,oI~. moki"ll "".

,h .. ;, I!. 1"1", ... tod .r-.! tIIlt ,1M .. ,Iod "'" ~
f..,;ng""L
15-12
fRONT WHEEL/SUSPENSION
'm"'" to. opoodomo'" ""or ,."'..., in

~ub. 0I;g,.ir>g , .... '""" wi'" tho do",
llo._,
,,,,10" Ill' ,i';" .. 01. AWIV

lip ..... in"" tht "'" <01 11(,
~.... 10 l o. i",.., .. 01
15- 13
FRONT WHEEL/SUSPENS ION
'n"oI' .... ~,.... d;': ""III .... ~R" ....... 01\ ....
,"'" ond '''" d;': wi'" .... "l " ....... .., ,,," loll.
TOROUE: 2!i_:KI N·.. 12.5_ 3.0 .. ...... " - 22 11.111 1
I..., . u... I, " N" _ In .... _ _ •

• . ,. . lho ..... will> "'" ~"".
0 - ..... \M .... diia ""III. ~",_ i ' V O,g.,.,O'It

-,.
IN STALLATION
p..,;IIon .... _ , b t _ , ... t",O; log wtoi lo
IIttl,. ......" coli"", _ ,no d"". '01<1,. ~.
_ t o d _ .... IM ..... pood, •
.... I0Il .... ' . .' coIi_ 1M...... _ ... tIOI".
,t.,I;fn....
,." I or ~ ....., _ 'N"". _
'c ...'" ........ "" ....
Tith'''' ,M ,. 10 '0 ,M >j>IQ1"'_.
TOROU l : ~~ N.... 15.$ .....1 k..... . 'O ...1 II·lbl
15- 14
f RONT WHEEl/SUSPENSION
M,,,,,," bot .... n 11>0 ...... Ido ""I..,. 01 11>0 'IojM

1If,i<, di", on<! tho inoldt 01 tho rqn c,'i _ _ r
wi.., , 0.1 """ 10,078lnl I.."" _ ,
II "'" _ <MInO'' ' In ..<1........IlYIl
..... "",d "'" _ _ ". _ .
tho " .. , loot<
PINCH BOLT
r",,_ ""' .... ~
1>01, II> 11>0 """il' " .... 0....
TOAOOf, 20-30 N' '" 12.(1.4.0 k..... 14_ 22 "~III
Thoto .......,'"
_
.ti_ ". .. 10..._ 0-1 .....
...... bo_II>o . .;po.
""" 10.078 lnJ
dite.
-
AlI<r imtoJl~ Ihf ...It«t "I'PIY '~t Ml.ttr
' .......1 11m.. wid mAW< thf .,..."",.,. ""
-.
110m lida. FoUun II> ptOrtl. ~1tCt wIJJ
d.""",. IIw _ dbto wid .u.."
bo ' 'IV
,
4
Inll.1I tIoe _ _ ... ,n ""' ... _ .
15-15
FRONT WHEEUSUSPENSION
f1IONT roRKS
REMOV AL
_ ...... _'_I_l~8l-
R_ .. 11>0 .. " bo-ok. <0l-'I>o< bo-_ _ "'It

_ •. _ . O~! .... p'""''' coil. _ Iof! broh
, oupo<.
R_ ...... ho."_.
A.... _ 011_.....
l _ .... 10<11 u_ _ _ , pW\<II ........
15-16
FRONT WHEELlSUSPENSION
P.... , 0"" ,.,..<...... down , 0<1 "'" g/ "'" 10<1:. IW

b<0dv0 ..... 0;' )0.". Ro'''' Iho 10<. lube "";10
.... II ;"~ .
R.......... "'" I.,... "OIl tints.
Pull 'O<~ loti< ,U"" 0'" 01 "'" """om bt;.!go.
If . ;, joint ~. ",m.. ,"""'.. tho h_,oIt ...

I.,. 15·31,
RtmO>'. Ih' two .." .... ottoc:h;"g "'" loti< ai, 10","
to "'" lOOt. to!> "'0190,
15- 17
OlSASSEM8Ly
Hold .... I",~ ,,,,," I ~. vi ... ..ith ... 11 ..... '" • . -
_ 1_ , _ .... 10<1<. _ _ .
• [)(; ,,,,, ..""'.. III< "'"'w Oft ,II< 'w" lot/< /IIbt
UP. QlI~' J.".""" m"","~bm /»'1' ""'''' bt
",.lItmJ ....... 1M oop Is """,,"d.
H........ "" """ 0IIrint. _ . . d .._ .

f ........11 ...... ' 0<1< , ...... by IIUO"Qir<t ..............
"""'_"_.. ' 1......
,
R_ -.
Hold "'. I.... ~icIot In • ,100 "' .... "'" ;-. '" •
"''''' ...... _ kit boI. "'I..... I,.. ""oncI\.
T.m _ _ lly In""1 Iho ""inti ""'" fOl k lUbo

.... II d l ll~I ' y ~ _nlO«<I In ........In<j
Iho boI •.
""'" ... ,.,.. -.

Tho pi..... "'" '-''''' "" ..... "'" """' bo ...._ ....
15-18
FRONT WHEELlSUSPENSION
'M
' .
R.m ...... ,No du" ...1. ' oom ...,. "" p"";c .... n_
or. Dioeo,d ,n. 'o.m ••• ,."" p'OI' ie ... . ~e'. 'n.v
,oin".""'.
... " O\ot l>oI
Aft .. ·84
Ao,...,." ,No dust ...,.
,
S'-IAP A' '-IG PL'ERS 01810_3230001
Pu" '"'" ''''k 'ube ou' un,i, , •• i... nc. ',om ,h •

• ,,,,., ""shing il 'oil. Tn.n """'" i, in .ncr out.
,00\10"'"
..,,,,"11 'hoI,ombUln'''II '09h". "",i' "'" 'ork , _
,n. . , _ Tn. .. _ bulhi"ll will
boo '",ceO .... , -.,. In. IO<k lUboo "".Mng.
Rorno'\'o 'h' ,,;, loci< 9~ Irom in",," '"'" or ....
ro~ K TUBe roRK S~'DEA
15-19
FRONT WHEE l/SUSPENSION
Sl1DER .~.
1 1 _ ,IM ..I _I. _ .. g ' ... . nd 01 _ _ ......
I,,,,,, ,"' .... _,......
,
F,,,,,, .... Ittt _ . ..... "'" .... <irchp. oil __
.04.. . "";,,.g . ...., ""Inll .. " h om til_ pinon.
~ ""o ...... g,,,,,,, ..-.I ,_nd ""'"'1 fr"", " ..
~-
VA LVE
INSPECTI ON
FORK SPR I NG FREE LENGTH
Mo. ..... _ ,,,. 10'_....."'1 I," ....... ~.
SERVICf l'MlT : 523 .,," 120.' 1. 1
15-20
FRONT WHE EL/SUSPENSION
FORK TUBE/FO RK SLIDER/PISTON

P ISTON
C~ocI< tho to<l< ,u bo. Io, ~ ~.;t .. OM oilton to<
..,.". ",.<1< •••,,,,,en...
or .. oo<~ .. '" ,b"",mal
FORK TUSE, f-l
"'''' . Rtf'lo.:o .n. """,,,,,,... n,, whid1 ... wo,n or
d",,~.
ChICk ,,,., 'or~ "i""" ,ing to< wN. 0< dam .....
Chock , .....00.. ..... pr;ng lor ,,,...... or dom • .
FOR K TUBE
So, tno 'or" tubo in V btodu ..... , .... tho 'u_t.
S ERVIC ~ LIMIT : 0.1(1 ",,,, (O.OO8lnl
BUSHING/ BAC K·UP RI NG

Vi.,. 11y inl()OCl "' , .,.;tor .M to,. ",bo """';"g •.
BUSHING BACK.lJP RING
A,,,lo.:o ' M I>u.ning< if 11>0" il o> .."i•• ocoring 0'
.'''.. chi ...... 0' if , h. ,. tlon i. w",n 10 th.t 11M
<_, ...,t..,. •...,.." on ""''' "'''' 3 /4 01 11M
onti" ",rio<o .
CM<:Ic .... boc • ...., r;"g; ,.pll<. " it tho,. i• • n.

di"""ion" 'M ""in" ",_n.
, CH EC K POINTS
_~'. COPPER
SURFACES
15-21
FR ONT WHEELlSUSPENS10N
ANTI ·DIVE CASE I I CASE
A.... "... !he _ _ .. _ _ ""'." ...... " .

d ,.. case,
~ ....."., .... poo, ... ,rod

At""'''' ,I>; 000',
""i,._,u_ •....,.,.,.
O~''''l, o d
... .
•
.: ' 0
"- 1"
O-AING .ISTON CASE BOOT
15-22
R. mo ....... _ ,.1.... tt"", 1<"''''. •"., _"'~

on<! ..... k bIl l.
SPRING
A."",blo '''' .",i« i,. co.. ,n tit. ,,,,,.. «do< 01

di,.,>embI1 .
R. ploco t!>o O·, inll' ";th flO,.. ones,

Appl1 1ock'''9 . ' , to t!>o ,h, ..,,, 01 t!>o
.,:!..........lOCk .. ""It> ... ,Of• ....",01 • •
O-RING PISTON CASE

~,
15-23
ASSEMBlY
ht"" '0MmbIy. W''''''~'''no wiI~. ~Iv~ u.o/1
"""" .. "",,·II.mm_ ......." ..... W"," ,~ 0"
«Hft~"''',
, ,
!
• PlSl'()IO
REBOUND SPRflG
/
,-
, ~-. 'M '-...ncll!I'irov . .... ~I! ........ 1M
On u.. '-" 10<1<, Iftstofl ........ "'If _
oif _ ...... . .... ""dip ... II. . ., ....
''''k
. .............
~'" '' SEAl
....... !he OIl 10<* poeoo on !he ..... 01 .... "'"ton..
O'L VAlVI
15- 24
FR ONT WHE El./SUSI'ENStON
,,,.,.11 , ... OI'IocI< pMC1t on , ... ' . .' tOl~.""""",

, ... t ... """ 01 , ... 01' lad ~iooot 0<Id '''' ~'''''
~.
'""" , ... tOl~ , ..... """ , ... ~_
....... '''' ... 'ou' of , ... oM _ ~_ ..u .. , ...

dill<> 1>0'" .... , ... ~_
CUTOUT
" ... ,"" fo,k ,'.... ," ........" ...." 1_ ' .' •
"''''' ,'''''.'
"<>1''1' • ""'~' ''I OOtn, ,. ,h. _II~' 0<Id '"10'''
il ,n,o ,......"_ T .......... "". e """ .... .....""'"
r.... I10< .. "v ......., "'. ton; "'''''1 ..., Io<~

1..00 u" 10 ' ........... -'to, ~t
f OAQUf : " _ 25 ", ... 11.5-l.' k'·... 1 , _" 1, 4bl
15-25
FRONT WH EEL{SUSPENSION
FORO; se . . l DRIVER
P'IIco ,1>0 .. _ ..... oI>i"ll _ ,N Iot_ ,obo."" f'"

~ ... ,N ., ..... ~"' '1>0 t..cI<_up ""II ....... ole!
......... "11 ... ~ ......_ _ on '<>II
DrM ,N - - . intoplooo";'" ,1>0 _ ...........
,." .. . . , .... ok! ..... -.g Of . . _, , ' , " , 001
""" ....... oil .... WJm ....TF _ Ift" . 11 ~ ""th
'ho .." m. r-.. ....,. loel"; "". Or .... '1>0 ... ' 1ft wi,h
_ _ I ......
-
Itoo.... ,,.. _ r.... _ ito r"~_ ..s.,. I ......
07i4 7 _ I( F()()1 ()()
.. SEAl. Ah .. '110
,...... '..... ___

OiK'.G ,.,. I<>,rn ... ' ,nd pl,.,,< w •• h., Do "'"
,.'ft ... III"'' ' pon •.
.... ". ' ..

1IlI"IIthe d..... _1
AI"'G
,~
""'" ,,., '.' :,f," _ 01 rO.Tf IftlO"" ...... """',
C.... ~ .... CITV :

RIgto,,,,,,, , nO ocl ' f .IOI I
LofI _ 091 "' 111.701 1
SP'ECl fl(O l£\IEl:
R5eI<I fOlk: 23& mm II .U "'I
LofI _ : 221 m m (I .to Iftl
15- 26
FRONT WH EEl/SUSPENSION
--
Im,'"
100.. '
_
,he """ _Int."""'" _, """ .......
.... _' ... d; ..... ion ...... :f:_1y h""rod

ill .....
............ to _ "'" bottom. BOTTO'"'

".
0.. .... rif:tI .... t . ..... ..... Cftity Oft ....

~ .~ "'t!o ..... II.. _
........
d... "" ....... _ .......
TOROVl : lB-30 N'''' I ' .B-3.0 "'..... l' _ 22 h ·lbl
GROOVES
0. ..... ,''''' .... ~ ..... ......... t "'" ..... ,"' .....
"......, ..... ~ Oft ..... d...."". &<ijuI'' .
Thon ;!WI&'
..... 4'nplnoj &<1/0.10'" _. ";"';<>; ..... &<Ij ...... , ....
"'Ih ,n. _ ,"",," .. ,tit "'No. ' "' .. '_d 1"-
lUi "" ,ho loo-t _ .
15-2 7
FRONT WHEE LiSUSP ENSION
INSTALLATION
It , . . . . join. is dis,,,, ,\to...,. 1"..011 __ 0 .......
ill ....... Join. II"'''''.
1"..,, 1 "Ch. j,on' 1m...... ,"""""or;,", .90........

'-t, ' Otk pinc!o i00i ...
'",101' _ ... loon...... __ In 1M p"o ... .......

to<lt ......
• ." , .... _ to<lt """ boll> .........., ....

to<lt •..toe _ .. _ ....... ;o;no ringl _ "'"
_ _ 01 ..... _ "'" ... .,...
T;v. ......... )oirot _""Ii ""_.
15-28
TigIl."" "'. u_, _lowe, Ion p"'do Doll>,

TO~QlJE:
U_ : i - 13 N'm (D.i-1.3 k...... 1_ 1 IHbl
t ower : 4&-66 N'm ( 4.&- 5~ kf"" 32_.0"-111
In ...11 ..... ....,..-.1 J)fo''' in 1M ....... ""'or 01

.. """,aI.
_ nandk bar (pogo , ~ · 3 1,
_ 1'00 , 1_ ,.
,,,... n .he Ie" r' o",a' ipoor brOCk .. w; .......... ,"...

O~'ngo _ ";.,on co'lo,
T~" . " tho on,i <l i .. p; .... boI.,
TO ~ OU E : 2O-2!iN'''' (~O -2 .s k.. m, 14_18 ft·lbl
n il">"~ ,he colipor moun. boI,.
TORQUE : 3G.... O N' " (3.0.....0 kll""'. 22 - 2 11t~b)
,,,,,, 11 ,he 1' 00' _ ( _ 15 .... 0).
W,,,, th. I,...., b,"""

."",iod. pump ..... Ir ...., Iort.
up and dow" ... . .. , , i",".
Tilll> ......... I"" " lI>I'k .ubi l;.., ",,,,, ..ti"'l bol ...
r
PISTON COltEII
TOROUE , 18- 28 N·., !\.8-:U .... m. 14_21 1t4bl
In .... 1tho bolt 0.",.
F;II "'" tort. '"bot with tir to 0-40 1<1'. (0-0.4

kill""" 0--6 poil. and cII«I< 10' .....
UN anly _ ""nil
or-_tm _11 ""'"" to fill
tlo,IOft tul>n. Do ""t u'" <emP'tutti .Ir,
kh (J lqJatI',
.1o(. u;"'u," P'<tIW< jJ JO()
43 I'fJl Do ,'''' ucud thlJ ()I'lo,k tub.
rompon<n/ dor",.,. ">OJI <>«w.
Wi.... no I'ont b' .... .",,'iod, oumo ,n. '1<.."

'o.k. up and down ......1 t ..... , PI..,. ,he motOf'
<~d. Of> ito con'" ... tId. Che<k ,he . ;, p.o ..... ' ••
ond .,Ijo.", if nece...,.,.,
15-29
fRONT WHEEl/SUSPENS ION
STEERING STEM MEAOLIGIH

\
REMOVA L
R.:oo •• tho I • 0014 DO' pc .• ,,"
_ _ ........ 'U 1_2.·21.
_1'10 -.."ond _ I _ 2 13)_ bo .....
_I••",......"", !I>a\IIl.·. )
_ ..,IHo" , ... ,<10 (pogo 2 ' ,10\
- ~0I'IdI0bt< . Ipogo 15 ·31
_ Ire.", _ , ( _ 15-11
R...., ... !ho .. ok. Ihroo-wty :OOlln bv " me" ....
,... ".....
R.mo .. lhe.ngIo .........

A.",." .................' ,_
_,
___ _
..... ft . . . . . ancoI , .... .
0':,,."_.,,.,, ,'"
R.,ooc," tho .. , I", ........... t"", btid9t ...."'"

.........ell""' .. ioInlO1_ '!-'e,'7)
15-30
FR ONT WHEELISUSPENSION
Slf~'" "'" lock ... _ ..... and _ . "'"

_ ...1 _ _ " _ .
, '"
STEM SOCKET
_.. ""'_ .....

l _ "'" _ ... odjuo ....... "" ..
-...
R.mo_IM _ing i ....... ,..,. ..... _ boo!!ng.
FIomo .. 1M .. _ing """'. gr .... row_ ............
0>00; tho t· ' •. and "" ... one! _ , _ ....

.... ord.ri orod""",",,,il-urv.
1 5-31
FRONT WHEE L!SUSPENSIQN
BEARING REPLACEMENT u....lJt RACE RU'OVAl lOWER AACt Rtot()VAl
!<On' ~nACHME "" 07K3·

AIw, y" ,.""co .~. boo, ing'. ;noo, . ond ""'.' .... ,00(lA 'U.S-"- ONlYI
' OC" 'og.,ho, o. 0 H1
Romo •• 1M up<HI ' beor;ng roco; "',.,. lho d"." . AnOCHMtNT.

w ; ,~ ". ,,;to,', I" go 0 .0 .•"" loo",g up. , he "" 0 37 • 00 """
Q1101 -oo.02OO
..... "ng no<" ' ,om , flo bott"'"
P!e<. ' " ' ''oe~m.n' ....I~ , ho "A" ""0 on "'"

III>
d,,,or , b1 tIlting "'~ 'OUgh , ho ..... po, ' OC • . ~'"
.~ ,
HoId'flo d,,,or'. p;j<>1 ogoin .. ,flo low" " , . 0""

d, j"" 1M up<HI ' "00 ""' of rho ._ring _ _ ,
"E " OVE" AnACH MENT
O,i., ,~......., b<N ,;nQ ;n"or """ fro-m 'M._. 0 __ ·3710600
';"g lIoad M<o.. w ittl 'ho toolS .h<lwn ,
AttOCkmon, 07J4a ·OO 10ZOO;. "'00"" in 1M

.. _in; ood to g'" , be... , dd";,,g "" ' oeo
ogoo"" .flo ,om.,.,.,
o"o,tImo" t . "" '0 ....
""". d0""ll' to tho dd •• "
R. mo .. <to" _ booriny in ..., nco ond dus, _I

',om lho " ... .., " .....
....
@"'"
lOCK ~ UT
LOCK WASHER
STEERI ~ G ADJUSTMENT NUT
~ DUST SEAL
~ I ~ ~ [R ~E
~, SEAJlI NG
8 OUTER RACE
~
"" GREASE HOLO£R
OUTER RACE
E6> MARING
§ I~ ~ ER RACE
~ DUST SU<L
15-32
In.'' 4 _ dull .... _ ..... _ ..........

tn. .... _ _ _ _ .. _ ..u.,... ....
" _ ... ,,.... u .............
,I""__
.... .. _ _
. ,...., _ _"'CUlo< ,_;_
INSTALLATION " , .,_ BEAR ING .. 6"

Po<Ic 'h bo ........;' It, ,.;,jo, " .... _
'""01' tho " ...... " .... on<! 1_.. bo......
, •• ,, 11 "'" " .... .. ,.., ... UPPI ' be .. ;..,. ""'''1
'" ... , ,oa one! dUll ...1.
)
,
15 - 33
FRONT WHEEl/SUSPENSI ON
'" ..... Il1o _ .........., '-I' _ . ~_ n

' 0 tt>e . - Il iod """,,",
TOROUl : ZO_ 21 No..

12.0_ 2.2 k..... I. _Ie h ·'M
l "," Il1o ,,_Int ....... In Il1o WIV II,,,, _loft Ilwo

,..... '0 ... tfIo_ ......
"'"""', ....... odjuo ..... ' .... , .., .... _ " " _.
l "'" .... ,,_ ......... .., .., .... "".......
'''·...11. _ " " " .... ",., bV

11'_ 01 .ho .dju •......" ,..n.
. lIon~ 110 ..... w ,,~ ....
flnll'"' ,~(" (ho lock .... ' III .... "ov .
Hold .ho bo."", o<Ijo ............ _ .~_ tfIo
_ ....\ 1oOi_ 110 <109 .... '" o!""
k .... _ ..1111
....... oltht _ w _.
,ontI l1li <he _ .. _ ..1> .. ", ....... _ "' ....
-~,
'"'
u.
15-34
F RONT WH E ELISUSf'ENSION
eAR 011'6-00205000A
. voiloble in U.S.A
TomP",.;ly ;",toll 1M /ron' too: .. '.
In .. oIl tho for. b,idvo ood ,';It"" ,,,. ....'If'I!I
"om n ut .
TORQUE:
110-120 N.m III.D_12,D kp-m, 6S-87 ft~ bl
TieI'lOn tn, ,_1f'I!I

" om pin<~ bolt .
TORQUE: 18--30 N,., !U .... l.O kp-m. 13_22 ft~bl
Commo'ota"" . voila"" in
STEERING HEAD BEARING PRELOAD
In".11 ,1Io/r"", tor k, IP"" 1 ~·2SI
'n".11 , .. fron,"'- IPogoo 1 ~-I.I·
~.., •• " .... d undot ,,,. eowi ... o<>d ,oi .. , .. frO" '
""..I of! tho lII"",nd.
l'<>~tI"" tn, "",i"ll ".m .. ,.. ",.iv/lt _
"""i'i"".
liook • 1!'''f'I!I scol. 10 In. to,~ tube.nO ..... "'''
til< " .., ioa"''''' .... if'l!l p,.lood.
Mako tlJ" t~" mo, . .. no cobl. or wi",

n" ...... .,WI ... '1Ct.
Tn, ", . Iold ",,,,,1(1 be w ithin 1.0-1.6 ~ ~ (1.21 _
3.531bl fo r ,ige,.r>d loft ,",n •.
It ",. r........ rio "'" 1.11 wi"'in tho '''';1.
Iawo r 11M
If"'" w .... 1 on "'0 1I'000nd . r>d odjuU 11M booting
ad"'''''',n, "ut.
Alt. , . n 01>1i "'; oa tho boti "i <"""et ~r.Io"". in'" II
tn. '.mo .... plr" In.n. ro..". Orrllf ot "mo,.l.
15-35
~
'"o, ,.,..
:;;: ~ ...
, ,
;;; ?ii
'",- ..'"z -1..
?;;o
•
~
.. ~lS
~oz
-,
~':"i -, ,
"-0-
- -,.
,.z
-
.!!:
0-
3
,••
z
., I c
...
,
:::!wl$
-0-
,oz
) e 'I
••
~
•o
'" ----1 z
'1 '
t--·~
.-.
, .,
:;!'i:&
1II1.!!l
:t:>z
."'-... -'" •,.•
i:r
••• - -~
-.,, '.-0-,
;:
'0- :::I..I!I
:bz
w'; .
, ;;,
~.!..:t •
' 0-
~l3 -, -0-
-, ,
;:;'z
"
16. REAR
SERVICE INFORMATION ,'-'
TROUB L ESHOOTI NG 16- 2
REAR WHEEL ,,-3

SHOCK ABSORBER 16- 9
SWING ARM 16- 16
SERVICE INFORMATION
GENE RAL
• Th •• _ _ I u... . ,obol... t~ •. For 'ubol ... ,;,. "PO;", ,. 1., to t~ . ruBE lESS TlR E MA NUAL,
• F<>r w.-
NIondnll, ,.1., to ~.... IS· '0.
SPECI FICATIONS
STANDARD SERYICf LIMIT
A ~ 1o ,"no<>' 0.2 mm 10.0.1 .. ,
1'1... _ , rim "',.,"" Rodl" ~_O mm 10.08 "I
2.0 mm 10.08 in l
TORQUE VALUES
ShooI< ,,"'·to·"_
Shock Iinl<·\o_.,m bol'
1>04" 40-50 N·m (4.0- 5.0. kg...... 29- JIl IHb)
40- 50 N·,., (o.O-.i,Q 1'. ,."" 29- 361"'11)
1'1 . .. !hock ,boorbor mourn boI" 4()-50 N·.., (•. 0- 5.0 kg."., 29- ;16 'Hili
Swing I,m loll pi"", boI, 90--120 N,m 19.1)-1 2.0. xi-"', 65~7 11-1111
S>o;"g atm .Oyh'
p;"o, 1)01. 16-<0 N.m 11.6- 1.0. k ~ , 12_ 1. " ·Ibl
Swi"ll''''' p;'Ol _ nut 100-130 N·m 110.,0.-13.0 \:g.m. 72-94 /'~bl
Au. br. ~ . ,or_ ,00 'mm IE_ 25 N.m 11.8-2.5 kg_"', lJ - 18 .Hb!
Fi~.IIIO", COlO '"00"''' nu'

"mm 30-'0. N.m 13 .0 ..... 0. kg-m. 22 _29 h~bl
45-10. N,m 10.5_ 7.0. kg .... , n _ 511! ·lbl
A.... b,. ' .di'" 3~-4(I N·m lJ,5~ , O k~ "", 25 - 29 !I,lbl
R..... . I. "'" 8~ - 1O!'i N·m ~,~_ 1 0_ 5 Kg"", 6 1-76 l1-1bl
,-
TOOLS
Anldltnen,
oa ...1d,I,..
Swi"ll tIm P;_ lod "0' .... oetI
07S66-MA 10loo
07966_MlIOOloo
07908_4690001 or KS_ 1-!8 .... _ OB~69 IU.S.A. ONL VI
Soc • • ' bol, 17 mm 07;03---0020600 Com .... ,ci.ltv .... ,.1><0 in U.S.A.
Ilea, ... 'om<>_. 30 mm 07936 _8800300
R.-no .., """dl. 01936- 3710100
SuI "''''''... pump 07911 - M01000A
Rt""'''' "";91" Q1~3(J _37102oo
Com....... 0,; . .. ont9-OO 101Xl11

Alto<""'"O', 4~. 47 mm 07'148_ 0010300
Pilol, 2 0 mm 01.46_ 0040500
A" .. h"","" 37 . 40 mm on46_ oo102OO
A''"''''",""" 52. ~ mM On4e-ool04oo
8''' ;<>9 "mow, th." Om8-00;0",!~ }- Commc"",IIV
0"46- 00""""",
" .<1_ ", U.sA
S"';<>9""""'" hNd
16-1
AEAA WH EEUSOSPENS ION
TROUBLESHOOTING
o...u."....
I. Worn ti ...
2. T i •• p ...... '"
3. F", lty .1",
_.oc'
~. hn' "'"
5. ~ .. Io
t1. SorMt ......
~
_u-.. """"
_ _ ;"g,
SoftWIP' • ,
I. _ "";,,g
2. Inwlfld,." 11ui<!;" _ _ btr
,,,..,.,0<1
_",_i0<1oo
3. ~ oIw
I. 1......
-bi, oil "' ........
filii. A''JI'' ;,. IIto<Ir _boor

2. e.nr. _ _ bi.
3. _ _ iii ...-.... _.0<1
" I wI _ _
1._0.._""
2. l _ t.. _ .
16-2
REAR WH EEL/SUSPENS ION
REAR WHEEl
REMOVA L
f'j oce tho "'ot""'.... 0<'1 ,,. " .."., , tarod ond .. """'"
III, ..I ' .... L
loo<on III. ", I. pinch belt ond ,...,.". III . ..ar

..I•.
R, ...,'" t ~ • .... 10<, •• 0011"" belt ond tho <.>Iioo'
{.,.go 11_ 101 .
M .... tho _ I to tho '9>' '0 ..p ..." . i, l oom .....

I I"" d. l " go.. <....
A. mao . ..... ,_ wto..L
16-3
REAR WHEEUSUSPENSION
INSPECT ION
AXLE
Sot ,110 . . .. in V blod" _ •• od ,110 .. " ' " ""'"
",ilh. d,., ...... iu101'.
SEAVI(:E l iMIT: 0.2 "'''' 10.01;")
WHEEL BEARINGS
,.,.,. lIoo _ ;" • "". . """,, _ _ "'"
_ , !>o................ '010' . . "'" _ ..... "-'d.
R.",... "" _ .... 'Oi'" _ <>not i' ","y at. ~oi'Y
"'".. ••• ""' .... ploy ,
WHEEL RIM RUNOUT

Q,odo; tI. . .im '01' '"""", ............... tho _ III
• Wing .,...,. T"," ..... _ , -v, .... ,. od .....
","",,' "oi",. 11"" lOll ..."".
$EAVI(:E LIMITI:
Rodlol Au_ : 2.0 ",m 10.08 i.1
A.1o " ' _, 2.0 "'''' 10.08 in)
Tho _ I ........ bo '''''''' ..., ""'" bo ~

~ tIo, _ , ... 1" ON . K . I.
16- 4
RE,IIR WHEEL SUSPENSION
~'mo .. th •• i<Io coli ...

~ _. tho " .. 11,1< t>ol" onO tho 01<.••
~ ........... CI-<....
lI.mo..... , _ <1,,_ f\orovI ..-.'" boI" one! hll
.... <I, ..", fI ........' 01 .... ~"'"
,
R,.,.o" "'" 001 ...1hom .... ""b.
R....... "" _ boor)"" onO ",. d~...,,,, coli ..
"om .... ~"b.
16-5
flEAfI WHEELISUSPENSION
ASSEMBLY
Tho _ , u .. , • 1Ubo.... ,I... F", ... be ....

,". '-"~ ,of.. IQ 1M rubor. .. n. M, ,....I.
VII 1;,11 ..... _ """'''''''- .._ ..;,II

MoS2_n.. .. foltowo:
_""010 HR1.plln _ _ ,,,,,,,,td by
oowCom ..... u.5.A. .
.... , ' ~ U-2 ....... t...... td by 101m...
"""iOil .........
Stt-Iube ~lGI Jl"2.
0..,.,. Iubt""",u ol ""'......" ~.litV .
. Cn
i'. ".
Poe< .11 Ioo ... i,. ...it '" ... it "
....... ,,'" ~i"..,.,. <01 ... ,nto ~ ""'" 'M I."
,1_....
..... 0,"," 1M ' .... Il0l1 _ ... 1ft ""' . ,hot> tho
101\ ...
16-6
REAR WHEEL./SUSPENSION
.............. .,;t ... in.., ......... ~ ,
......1 "'" , .... (iol_ 11_ 0l>IO tho ' ... _

"'" .if:'..... ..... boII._
TOIHIUE :
110 10 N·", 1!i.o-eJl k...... :JII .) 1t..,1
.,.,..
1""..1...... CH;,-. in ......""'" 0' .... ' .... drl..,
1.. '01 1 tho ... d;'" .-.d 'iIII'_ ............

TO'U)Ut :
• 40 N'" 13.5..... .0 k..... 26_ 29 1t ,"1
I" .... tho oldo 00II .. _
16-7
REAR WHEELISUSPENSION
_i... .
INSTALLATION
.o,.ppI .......iIM_ NLGI No. 2 Greaoo ('*>52.
1 ' 0 ... 1;,,01 ... _ fIontt IPI __ 01 ,,,.
_Iond.~_ .
E......... tNt _ -..;'" .... , .,,, d.iwo ....

malIlnoo ... cot_1Iy "igned.
lit""".....10 1fIf....."
' " _ ..... _
toIipof ~_ ... __ 1.,,, __..
... I'IrinI: ........ _
T ~ .... tho ..I0""l

TOROUE :
._1015 N·... (1.1- 10.1 ~,. ... 11 - 7$ "~\>I
T~ ... tho • • 10 """" boll

TOROUE :
20-30 N·", (1.O_:J.0 "'""'" 1'- 22 fW.1
, .. tal, "'_ f'" t...k...,I... 1_ lH31.
16- 6
REAR WHEE LISUSPENSIO N
REGULATOR/RECTIFIER
SHOCK ABSORBER
REMOVAL
,._ "'" moto<cy<lo on i .. <on'., ,,0<>11.

Rom"", ttIo "". ,~, _ !ott , , _ ,ide COWf' .
•O·""'"Ii,,_,
tan " .
,110 ..... """pion _ ''''''' .. tho
IoI........,por...
_ bo,,~
_ '""" "'"
_ t .......
_ .oop ..,.; ta~I ... , _ .
.It."..""
_1_
Oi __. - . tho '..., .. ' '''lrlClil .... "'"
-~.
R..",.. """ .......... /~if;".
R _ tho ''''' 4_ril.
R., Col tho "",,, "'_'or: ........
R _ ,'" t>otltry I ,,,,. boo I,om ,lit I,..". by

~""boIt.
L _ "" lock .... , _ """'.. "" _ ..... ;0.,
...... _ ...;... ... ""'" .... brockol.
o..con-.:I "" domplng adj ...., ... _ by _ ...

m, ~ip and _ ... 1110 IocIc ""' .
R""", .. ,11011>0<1< .boo<blt 10_ -...nl'" boh.
R.",,,,, ,''' _ _ _
tilt "" " - " ._bot ,.,,_d ."" ,_ """",t ' " bolt.
~
""'" tho " ..... by """... it .....
BOLT
16- 9
REAR W HEELI SUSPENSION
01 L SEAL REPLACEMENT
Alte ... Ii, !.om "'" ... _ .blmbo, t>v <Io_i",
tho '01 .. ""'0,
Homo", tIIo boa' f'''''' tho ... _ by ""'0""'11 tho

boot .~~
BOOT CLIP
P, ... the bocI< ... p .i"ll in 1.0-2 .0 mm 10 .0 4-0 .08
inl with 'ho oil ...1d,l_ 07965-MBOOIOO ond n ·
~m.nt 07965---MA. 10100.
/J(Jno. P"D I~~ b.>ck ... p rIn8 In IOO [o. '" .he
~Id" 1N<Ir/>tr wIJJ """ Url() Ihe >Ioo<k ~.
",01.1"1 ~1d.INUri", ","0"'" dill""'/',
Rlltno" '~I 010P ';11\1.

C,"" , ~. shocI< "",., co .. ,
"'..,. • ttI,"k ~ ti< bog " ound ,lit ba,rom of "'"
.n_ on<! d"", ' - it ..",,,<ly to "'o lhock', ""w QUIQ£ BUSHfNG
co .. . Tho bog will
,,,,_ oUl ,
<0'' ' ' "'" ATF ........ ,IIt ...1 ..
n... SLoi win

lit """,,<>1 ,,,'Ilk kyd1tlJ<& P""
" ' ; RINQ
"''' ., U. rOTe< """ lit JjJ,.;jloQnl. _ pro-
' <elfIN! clolki", IUId foe< ",an:! to prol«,
qllbtD poIflbl< A TFrpi/uv.
The ""ook m"" bo kopt "I'fight p .... n' AIf

In,m Io,ki", 00' ,of tho dampo, and in'o tho
..,""'" cUI ... .,....
Fi ll rn. .... ",.",,_ pump ,.;,h ATf I nd conn_

'hI "'_"..." h"", '0 rn. """,,', oi, .. I.. ".m.
",,",p A TF into tho rf>ock Ibto.-bor '0 hydt-oulicolly

l Ola th . o~ ... 1 ond gui';' b"",l", 00' ,
Hon , ,,," BUSI1U. Q
It tok .. on ...... of 2 to 3 minu'" of P<>'J'Ip'

I!>II '0 fOf"" ~ o~ ...1""' ,
16-10
REAR WHEEL/SUSPE NSION
l _ .......... _be< ...... .;.I0<..., " ' _

r-">Int ATF <It .... from .... _~.
tolot.".,.
K ...,... ~ ""'1fI't~ "",_ .... _ from .......
S,\II 10M...... ",. _

tNt. "';1 .. ~ ...... ,..." _
u"''''''.
...
,.""'...... piIo'ic
In""' ........ .., moli"". 'u,n tho .... ock u_ _ .
Then ,"clomp ",.. hod< in I..... i...
"'" II....... ""'. bocIo: inl<l tIlo .. , YO ....

Fill .... ohocIc bod~ .. .., tho """,l ied ......... , 01
A Tf .
UlCIFIEOAMOUHT :
l20cc . ( ,(11 US .... 3.38 II"" ",I
DAMPER OIL
ASSEMBLY
A,IR VA,l VE STEM
6 1
Uf>pEA MOUNT BUSHING
_ _ OUST SE.Al
Oil SEA,l
16-11
REAR WHEEL SUSPENSION
'n"oI' .". ~lcIo _int in'o .... _ ....
To ",,,.n, .,........ to ' - ........... _

01...,. ,___ ....._ ...... _ot .... ...-...
Dip .... cOl .... in A TF _ , ..... it onlO ....
-~ .
'A~'IOtI .
~., = .. tho _ I'.... tho _ _

-
Pr ... ,o. 011 .... In.o oloo II,,).~ _too, "itfl . ~ • .

~' ... II< po .. ' ""'il .....nodl"""" """' •• ""' .....
01 "'" ""...... _R..."" tho ..... i... ook ,
ATTiOoCHldEtl T
1m'" tho _ .....i,. in .... _ _ boo .....

.. ,"'* "'" 'I ... _ _
_ ... .... _...., rint 3 _o.,........ or

4 ~
__ ...... 0\ ,t. """ 'int_bo._I~I ... _

In ........, .. __ .
lilt r_ ," I~' o~ lUI ",_y Itt pmit'd ... I_

GUIDE ;c-
I", ..",k-/4 ,.", #m ,~t ",/tit " ...hlnt. e/,"'" BUstli NG
,~. rI-......, 1/'" J "'...
OlllVlft 0'"5· ....... '0100
16-12
REAR WHEEl SUSPENS ION
/'''~ lUNG
.",p """ bf;.., ..... ., ;, IuIty .._
Iloo ,""._In ................
10.<011 "" 10
fJ. •• ' f • .".., I. ,,.,,.11 ••,.,.

I~ ri.... :I~.
_k ro . . . . . . ,...1 "-/Ih_I '~I. ,/"".
INSTALLATION
_. p.'" .-_ I................. thoo 4S'" 01
"",...,b</ ........I '" .'" ' - ond 10_ >N>Ur>t"
bush ...... .
u .. p,," ..... loon .. I,,;"" mo" .I>on 4S...

01 m olybdonuml .. Iol/ows:
'MO LY~OIE Gn p... sn ... ""1",.",,,,
..... Dow Cor ...... U.SA
'Loco! P.". """"IKlu,'" s.....-
_io_.
I>y
l ..... _ ._
'00,* ..t _ _ , ouoOitv
IMI.II .'" "-~ .bob" In .... ,,_ ond .......

•'" """. ond _ _ . . 1>01"
T OROVE : 000-lO N·.. I4.G-6.0 " ""'.
tt-3f1" ..,
16- 13
REA R WHEEL SUSPENSION
Connt<t ttl. ';""9"'" .oj",,", .,.bIo to til. "1<""

.boo,bo< ,
T\gh!On \hI 1"". ""' ,nd "" till 'hI lOOk 9'" '_"'~ .
In' tllI to. "'''',,",'1 odjult .. on ,.. bot<k. ' .... d
tiii>_ . fIo Iod< n.......... , . ~.
,,,,,011II" bin... / .001 box in'o tho I" ..... ,

1"",11 t ho 'OVU '''o<l .. ",'I;',.
" " ' ; " . Re CTIFIE R
In'toll to. It.""m ..... ti< <Wltdt .

Inlt, '1 I .. 1",1pump 1 _ 4 19) . II EGU LA TOR/II EeTI FIEII
Conroo< t tho regulotor/' t<tWoer ond ~ .. ,".tot
"""pIo".
In",11 til. lo llow'ng ,,,,,,,'i'Od PIt,",
_ "nrk ""'tI,
_ n op ond tai 'l;;/lt .."..,. .
- bit ..... {pogo 18·31,
Coono< t \hi ""'0 "",,"PI.. , ""',,,,'v.
NOn ,
Roull .... "";",. n""" ."., tube< ProI>Oflyl
1_ 1-9 !h,,, 13]. .
,,,,,,'1 ,flo lull tonk. " " •• Ogn, ..... " " fr,mo.""
<0"".
Mjull ,flo , . po'Ol$"," 1 _ 3 ·19).
COUPLER ......G .. ETIC SWITCH
16-14
REAR WHEE L/SUSPENSION
SHOCK ABSORBER LIN KAGE

RE MOVAL
R, mo .. ,ho Iolt ..... ''wI1' mulfi, .. 1 _ 5-2).
Romo.. tho >h<><'< ..-", bY " "'lOving !II. _

.""'.-be< lowe, moutI'ing bolt . <hook . m,.,"....,..
boI'.
ond tho.m """'"' ing boi,.
A, mo" .... sh_ coMOC1ing ",d f.om .... fr.,.,..
LINKAGE BUS HING INSTALLARION

CIIocI< ,", """'i"", r", __ or <10"'"90.
I ;" ~ .
'"lI>O<t '"' dust ..." fO' <10m ••

R. p''''' p.." . , _ ..... y.
SHOCK LI NKAGE INSTAL LATION
A,:oply 0"" 11' .... ("""toining ""''' "'"" 4OlI.

molybdenum) to tM """';"9' ..... d .......1•. s..
"""M POO9O '8 -13
,,,,,, 11 ,110 >hock CO<lnecting.OO .n<! ' hock • •m If><!

,;gil!'" l och bolt in ' I>oorde. I ~ t od .
TORQUE:
SHOCK CONNECTING ROO·lO· FRAME
4IJ-.~ N·m 1• .0-li.0 ~ .-m. 29-36 IHbl
SHOCI( ARlo! Io!OVT1NG BOLT
40 _ ~ N·m ('.0-5.0 ~~ ..... 29_ 36It.II ,.
SHOCK A RM ·lO-CONNECTING ROO
40_ 60 N· ... (, .o-li.o k~"". 29_ 361,.11)
SHOCK ASSORSER LOW~R MOUNT BOt T
<40-50 N· m ('.O-li.O ~ ....... 29-36h·IM.
SHOCK
16-15
IlEAII WHEEL/ SUSPENSION
SWING IRM SHOCK A~'" OO~.
REMO VAL
110............ _ '-15-31.
~'_"""ifttI d<; .. _ . . . !pago 14-3 1.
R._ ..... "'"" :1 ,boo _ """""ti", bolt
ono:1.""<!c ...... """"". ;", bol,.
TORQUE ROO RE"'RBR"'K~
II...",..... "'" ..uti .....

1I.",e.1 ... _ tIf.... r.o. ,,_ .... dompo ...
'M 1n~' ' ' ' ' - ,od.
II_" ' M _ plio I,om 1M ,Nt tlfak. ' .......... 'od
bo~ and ,omo .. II.... or ...... ,od boll .
R_ o ... IWWI\I .,m pjoooct ""'" ono:1 _ ...

,~, p loo' bolt leek .... t.
~._ ...... ,~, pi.., bolt • .,.;ng. 17""" lecb.
~.
16- 16
lIomo ........ "';"II..-m 10'0'_.

Rom"", .". !Oft p,.o, 1>01, ..-.cI ,om".... III. ,wlnll'
om.
1'1""".... ,~. 1>000 hom III, ,.,,;,-,gorm.
PIVOT BEARING REPLACEMENT

REMOVER
R,,,,,,.. ,ho d"" ...Ii ond bo,d"", hom 1>0111
. ..... 01 ,ho _i'l\l '"'" .. 'oll.,..., HANDLE!"",•
R,,,,,,,,, tM $Wm..r or", be .. i"ll """ "';"'1 ,n,
_inll ,emo_ .... ~gI1'. Inml l ' M "move<
ond ...... ~ .. ""',., .. """ ibM behind ,ho
bolring rkf:. Su ik. 1110 ,..;11" lighl11 .... ' . 1
lim .. to mon 1M ,,.. 0'" .n<<JVI1 ,., lIIot ,h.
"" ow .. c .... "" ••".,.. """,plot'lv. hpond Il>o
,.mow, oomp .. "IV. Slido Iho ... 0;1>, 19Iin wi'"
""""III> 10''''' '0 '''''''''' ". ' ....
INS TALLATION
NOTE:
1'1"""," Iho innor ond ""to,
boor;,-,g ,..,., ..
• soL Roploco.n.~ ... "toi"" ".... when·
.... it ;. , .......... ocI.
1,,",,"1 ' - " ......,. inor pl ..... 0,;' • . - """,

bo.. iOll , _ inlO "" IWfnII .. m.
GREASE OUTER eEAR ING

RETAINER RACE
16 - 17
REAR WHEE USUSPENSION
A4>I>I ~ ..... to t ... pnoo, _I"" dvn ... 1> .....
_i,. ..... d... _I>.

.... '" boU ~"",
,,,, .. 11 II'HI
'C" " MARK
IM'.' ",. -w. omt ..... p;_ boll>.

r ............ .." pi.... boI' " tho .poeil_ ,",1 't ,
TOfiOOl: 1II-12ON·",
IUI-12.o k......-47 It... )
16-18
REAR WHEEL SUS PEN SION
p,,''''
--
T",,, .. , •• ,..,., boll 10 oQ '-I .... " .0 k' .....
211 " ....1. _ " on<! , ..... , .. '0 "'. "*.,....
TOROUl: le_ 20 '-I ... {l.IJ-~.O kt ... 1~ _ " tHbl
""
. _.
M_ "'111~"'''''''
,
on<! _ _ 01 ~ ......
R..... ' ... tho ,.", .....,. 1>01, '0 "'" ,,*;1;,,0
T"", .. ,tit _ ,." ..... _ ........ ' ... ' .......

~,.
TORQUE : 100- no H·",

110.0--13.0 k..... 72_" " ~bl
1,,·.,tlll00 ,-..I", "m P;"" ,,-,
16-19
,,,,,oil "'_ ~ _,n .... twinoj .... _ .
C.... _, ...... OO' to .... '0ftII'0 root '0 !hi ......

• mond~_"""""
TOROUE, 11_ 2& N·", !I .ll-loS k....... 1l_ " ft~1>J
So"" .. 11>. nu' ,.i", ....... "", ... pin.

A."'" ''''' to .... _ ~.
Cor.nocI .... _ ... '" "" ........!'IG orm .,..j

_ _ be<.
1....-, ond 'ith"" .... _ .'" .... _
boo mount .... boI".
TOROUU,
"<1-$0 Jrj • ., ( • •_.0 k...... :tf- 3CI " ·lbl.
1... ,011 .... 'jo\oI dol..

1....- 1......... _
"Of case
(_
1 _ , • . ,t!.
's-.).
16-20
MEMO
HYDRA.UlIC BRAKES
1-2N''''
10.1-4.2 kg..,... 10-14 N' '''
01_ 1.' !,"bl - - - - . , (1'O _ I ... lg .....
1 _ IQ!HbJ
.~
•
, ,'"
.'"
3O..-.oN·m
13.0... .0 k......
22 _ 2tfl ~bl
25_ 3ON'm
12.5-3.0 kg·m.
18-22",b]
~ .• .~/?
25--40 "I ' ''''
12.5"'.0 kg .....
'8 - 29 " ,,*,1
20-75 N'm
1211- H kt"".
16 - 18!HbJ
75- 30 N'm
12.5-3.0 kg ....
",0-.'"<"
"'" . :10_ 25 N'm
12.0_1.5 kg"".
" _ 18fl,bl
17-0
17. HYDRAULIC KE
SERVICE IN FORMATION 11_ 1 FRONT MASTER CYLIN DER 17_8
T ROUSLESHOOT I NG 17- 2 BRAKE CALIPE RS 17 _ 10
BR AK E FLUID REPLACEMENT I REAR MAST ER CYLINDER 17- 13
AIR BLE EDI NG 17- 3 BRAKE PEDA L SHAFT 17-18
BRA KE PAD/D ISC 17- &
SERVICE INFORMATION
GEN ERAL
• Tho h.,." and ro .. bo . . .. .,.... be ,.,...,..0 w it!lout • ...........,, 10\1 "'" "Vd, ... !>" .~" .... .
• 0"", "'. hyd, .. I., ... "om. h . .. bHn _ _ . '" II t!>. "'01<.. 1001 <pO<lg'/ . tho .y" .... m",' bo blod.
• Do..." .11.,.. \0< .... mo, .. i.1 to on'" tI,. .yu"", when li lll.,.. 1M ,...,ooi...
• A.oK! "';II~ b' .... !Iold on ".intod ",,1_ Of , ... ,,""'"'" _ . . . _oro dOfN91 ceo 0_1<.
• ........ y< <hod< b, • • o""'otion bofcno 'Kling tl>o "",.orCl'd ",
SPECI F ICATIONS
i ru.-,'
TO ROU E VALU ES
Fron , 1:» •• • ""I i".,. botch, _un, bolt tAoghti 3O ~ 5 N- m 13.0 ..... 5 kg..." 22_32 " ·It,1
hon' b<.~ . ""I i... , !KK k" moon, bolt floh -"",,",i 31:_40 N '" 13.0_4.0 k~m, 21- ;>9 It-Ibl
Pi"o",.,., bot. Iltl'l 11>-14 N. ," 0.0 _ 1.4 kll"", 1- 10 f1~bl
B,oko eali.... """'''' tool, 20--25 N·m 12.0- 2.5 kg''', 14_ 18 It-Ibl
8, • • , O.li.... ,,",01 bo l' 15-.30 N·., (2.5- J_0 -t-m, 18_22 1Hbl
Hr"" _ 001 1»1, 25-40 N·., 12. 5-4.0 k9-m, 18- 1'9 It-Ibl
TOOL
Snap , ioll pi .. "
17-1
HVDRA ULIC BRAKES
TROUBLESliOOTING
. . . _1_ ""'or ,~ "
1 ,t.l. _ ' " 1ft hyd,..1k OV,,"'"

•• 8 ..........
1. P.... oon1_ .....O(!
2. Oite '" _ _ .....,
2. ~11"i:j_
1. Hydta<LIi< tyllMft _ina
5< ... ct:on. . . ......
...... _lpodoI , .... hotd 1. Pod. _ , .... I.,.,O(!
I. St~"'II""'''''h) 2. E ........ dioc •...-:,
2. c,~ """,""lie
.~"om l. COl i..... ,"".Uod it>o:r::L"r""'v
4. Oite or _ m;,.l ....
3 . POLio g l.zed '" "''''" . . . . .;.ti,
•• _ d" ,
I. _.ulic:.,..........id:w.
2, $t;d..i ......""(01
3. ,.......,."" _ b:oIe, _ odjuo........
17- 2
HYDRAULlC8R AKES
BRAKE FLUID REPLACEMENT I

AIR BLllDING
Chocl< t~. ~"idl .. o\ w~h tIM fluid , ... "'o~ ,..,,,It,

to t IM ~"..,,"' ,
I~"d ,ht dwpImIp a ~ tht l"<Jn'ooil wh ...

ap<nlin, tot b,.k, ~I'" p<daIJ. F.flI<,.
to do .., wllI.Uo,.. b,.t t jlNid to kjui<' a."
of tM tntIW' du"", b",kt o_,kJro.
A""'" 'Pll1int flJsid an palnt«i 0' pWllk
rutflKtO. flo« • "" a .... ,ht /otl t.1Ik
wlltn"" Ih••y,"m it <erriMl.
FROtn REAR
BRAKE FLUID DRAINING
eo,."..,., bl..... ~"" to th • • _ , •• Ivo.
l".,..." m. e. H,*, b _, ,at .. and oump <1>,
." ..... ,.... (0' pod'il .
StOP op . .. ting Ill. In.. (or pod. 11 ... ~.n .., IluOj
1I0w> out 01 "'" 11_, ,at.. ,
A "",.m/Mlld h,,,", dis< '" pod • .d.m

"0''''''' ,,0_. D/s(~ dpoih
"" "."""" ..
.1Id ,Ito • • rot>,. ",/"",td dlK ";Ih • hilA
~_'Y &.oM d..",..;.., 01'"'.
BRAKE FLUID FILLING
"0'"
Dc 1'0< "" , dill ..... ' ...... of bI-.o ."';:!
';r><e ""V "0"'" """,,..,;blo.
Po not o llow I",o'wn "", .. ;01 ' 0
,om wI>oo ' ;111".. thO , ..., ..... .
.nt.,
tho ... ·
Ckno ' ... b< ..... '''''. fill tho ,..."'''',

1<'01<0 11.;,;....... "aI,.... d .."I"~ .
w,'" Do'·'
'V"''''
Pum p ,,~ "',
t~ .. , ... nO oi,,,,,_ or'"'''' ";Ih tho ~, un.il
in Ill. 11u;:! HowI".. .. 1 01
th. , .......,1 ...... 11 holo and I.... ''';''.n<e i, to4 •.
Blood ttl . .. "om .t d••« lbo<! on "'" no" PIV'.
17-3
H YDRAULIC 8RAKE
AI R BLEEDING FIIONG
"OTI,
"'" b ...... , . . . . . . " oj, ffOm bei", _ _

od into 11M 1'/ .......
'MIen ....... "'" MI,y... B, " B', ... .
IJJ< <mIJo DOT 4 ...... ""14

C()t!,oUu<.
r",,,, 0 _1lI<d
Da """ .... ""'U P.1d 'Yp« . ftd " .... ,..
~ ... ""',_w ""Id ouI,irk . . 11«<1
tlo<
~ "." ....~.--;",.-
"'If ... ...,.... IN t/lkl<rrrr "r'" Iod:t
",-
Pu"", "'. b. ... _ , 0.- _ •• bri"ll "'" .oI ,1Itf
pocb i" .0.-"00' .... ,... th. <Ii ...
~ _ "'" mO"" •• ,""'" cop onO fill"'" It·
..,.."', , ..... M I.
CotI-. ..... Mi'..... B' .... B _ '" _I..."", to
""'tll ......_ .
"""'" "'" b.-.b bl . , on<! , _ "'" t ' , , . _
_ _ _ tho flu", ....... tho ......., cyIindo<
~".
If o!t I, ........... "'" bl"~,, """' .......... "'"
I ••_ " ' _• • 01 "'" t h _ ....
10ft"" . . ..
,I • Mi..... to B,"'" B_ 0.- _;.-oIotI ...... .,011 ·

_ . tlHd .... . , . , ' - . foil""",
I, Con_,. _ 'ubo 'O,no 1>1...,., .01 ...
21 s..-zo ,,'" ...... It... 0.- 0.,.-." ,"0 "....
...,.., "'*' "'"
-""' ...... 11_ ...... 112 ... '" >rod Il>1o
""'_ .........
00 ...,. ,..._ "'" 1><... _
_-, 0.- podol ...... ,
3) 11.,.... " .. 1><... In.. 0.- pod.1 ~owl. >rod ..... ,

....... .-..;, .f,.. " " h., tho om of I"
"......
, , _ , 'Up< , .... 2 "",d _,", _ , . _..
.. "'" 1Iu;d at ""'""" .f "'"
~ ; M .... "";d .." ' _ \0 . . . u_ . . . . . . .
h_.
A b,..t. /hIid NM_IM'~ v.u

d~ "',..
.-.d~ Jlo""lq " , _. IJ/sI:offiI ",,",_,
oW ,... Md . - 0 _ _ I!."~ dl¥ ,.;,h
• hIP fWIU7 '-1,.,
17- 4
HVDRAUlIC BRAKES
BRAKE PID/ DiSC

FRONT PAD REPLACEMENT
1 :::..:"!: r-"':;, !~k.

A.. " ........... p;n .... _ bolt.
R._......
R._ ...... col .... bolt ond jIioot _
coI ......
.
,
RETAINER BOl T aOlT
A.......................... ..., ....., . . . . . .....

0lIl01 ..... <00 . . . ..
R...... ,1"00 bnk._.
""'n; 'n
J>ooitloto .1"00 peoI to. call_ ..
""'" , .... coo!~ p;,tON.,.1I ,1"00 .... .
_n.
17-5
HVDRAULIC BRAKES
1"". 11 to. __ poe, I" to. ""';"...

,,,,,01, thor .,.0 P"'; 0<>0 .,.0 p1n Ii"" II... " 1".,.11
, ... 0",", pi<! bV Mohing \lI • .,.o. "" in" tho al i"..
'0 o!tp. ... ,t.> .,.0 W,;"!!.
Pl ... , ... .,.0 pi<! m"i".,. 0.... ,"" .,.0 pi",. ""'"
,t.> ,,,,.1.- <lew" '0 ..."..
t .... pi ... ,
~_k to . . .,,,. to", .... ,." ..... , dip ~ in pi ...

on tt.> <0';"" brock."
17-6
HYDRAULIC 8RAKES
_'y_
, ....011 'hi _ _ boll
I...
•.
,..., 01,--.0 ~ to "'* ..hper ""'" bolo.
in_ "'" _, bolo 1>000. ""ipor bolo 1>000, and
~
,.n
.hI " " _ I...... 1><....., 10 .... d ilC ;. __
, _ b t _ t!>o _ . I>W>i coroful _ to
d.nogo .... - .
1" ..01' 'IId ,I.,.... I,," <.,1_ b<>I, .IId Q""" lIoh .
TOROU£ ,
'-ho'8oII, zt-lO N·.,
12.1-3.0 \Ii"". 11_22 IHIII
CoIl_ 8011 ' 2O-ZIi N·...
12.1>-2.5 ....... 14-11 fl·... )
T"-,_ , .......... _ boI~
TOROU~ , I_UN· ..
fO.1- 1.3 _....... 1-.....1
REAR BRAKE PAD REPLACEMENT

L,,,," ..... col, .... boI, ..... ,.. ,"'" i, ,,_ ....
coI .... l><ock •••
'i.... "'. tI,i .... uQ GUI 01 ........ .
A.... _ "" , ......010;. ""'" UI'" " " . . - .... lIIod
.. u* IOf 1,,,,,, ....k. pod ,,.pI .......,,t.
DISC TH ICKNESS
I,j ..... , . ' hi oft< ' " _ WO'" • mN:'''''''....
SERVIC~ ~IMIT :
F, .... " • •0 ...... (0.11 ... )
R.." •. 0 ...... 10.2'", )
8F1AKE OISCWAFlPAGE
I,j ........ 'hi 1><01<0 oft< .... _ "" 0 .... 1000 ~".
wi"" o too.. _ .
SERV.CE ~ IMIT : 0., ...... (0.012 inl
17-7
HYDRAULIC BRAKES
FRONT MASTER CYLINDER

DISASSEMBLY
0.... br.... 'Mel ,...... tho hy<Ir .... ic
11...- .... b...,," _
""om.
..... 'oo, . _ mirror ' ,om
,,,. ........ ~_ . 01 • • • , "'" brlb hoM.
A ",U ."m;.., brvl:. f/uid "" P<dtrl<d ()/"

",..'k ..if_. Pkct • l"O&" 0_ r~. /i<tI toJrk
.......... _ '.. bnUtyrltm .. .....-.
_ .-1,.. 'N oil ""'" bolt....... "'"

.....
s-.r.0'"'"
"'"_""'"to '0"'.......
"'..-_ ............ ,.....
-
II • ..-. ............ eyt; .....
hom_Ire
FIoo L I I " ' " plot .... !lOOt ..... "'" e;.d;p ""'" tho
........ cyli.-lIoOcIy.
• SHAf" RING l't.'ER$
-1,_...",.
01Sl1. -32lOOOl
"0<,"'" "'" "" ."'"' ...... ...., .......... n.... .,,,,,,.,

,,,. """'"'"' . . . .......
II........ ,,,. broil. ,~, ... itct. ,,"'" tho m .....
<vii-. _ • •
00.., tho lotlOo 01 , .... !11K'" <"1 1;_, Ind IOIOI>'Ok

w~h bt ..... Iluid.
17- 8
HYDRAUL IC 8R A KES
INSPECTION
_
.....
.. Il10 ........ evil.- I.D.
O>odo .... _'Of ...._fClf K<nI. ocr_ Dr
JEIIV ICI ~I M I T : 1!.ll .... (0 '&77 .. I
_ .. I110_ ......... O.D.

SE IIVICE LIMIT : 15.12 ..... (o.ln Ift l
ChodI tho "'I.... '" .,... N._01..., 0<111 ('" d_

bo/""'''IE "blv.
ASS EMBLY
,
•"
_ ....
I R.."w.."..." ,. lIN ",..,.. q - pG'ow. qliltdfr
,obit .... ill..... eyli- . . eo.. .n

pM" "';,h
PISTON~--'
010 ... br'~'

ond p<lmo rv o<p
"_iii,_htf.
"'Ion _-v. 1.."11 .... ""In;
Dip " " pill"" ... p i" "' .... fl." "'''''... ,,0lil0.
c.u'_.
""... '", ...... /IHCtq1I.do_dIow'IH . .
.. """ _~ ""( & <VUiIo 1M <irdIp iii
- -/fmtI1'" ""'''''''''-
' .....lI .... _ _ "'" dilL
Jr.'"" 11... - .
17- 9
HYDRAU LI C 8 RAKES
o , u,o~ BOLT
P'au ,ho ",,"or ""indo, 0" ,ho o.ocI'obat ,OCI
,...." " 1M no_ ,,.j ,ho '''''' ""","HI'I\I bol,,_
... ,~ 1M .0<1 0' tho hOI<lo, ""'h .... ",,_ mOl' ~
0" tho ~ond'.,*. and tillh,," tl>o u _ bolt f""
II,." ';gn,*" ,ho ...... , bo"_
TOROUE , 1<1--1 ' N· .. 11.<1-- U kll ..... 1_ 10 " -fbi
,","' 1 1M oil no .. ,.;ttI m. bolt and ,to two ..01;1'1\1
..moe,.
,,,,,,1, 1M b<.kolo"",.
Fill ,h. , ... ",oi, to tho "PI>" ,...1 ..-.I blot<! , ho

",.aI< ••,,,' _ ...-dl"ll to pogo 11 -<1 .
BRAKE CALIPERS
REMOVAL
Pl ,o< • 0'''" """to i_ undo, tn. 0.01;"" ond <I.,.
COMO<' 'ho b,oI<. l>ot.o /, .... tho cal;"".
CAUT'ON,
I A><>1d spilJi", blOb fluid OIl pain'<rf "'ifo«<.
Aom.,.. tho coli"" bolt and P""t bol, .

A.... "". "'. co';po'.
''''''" BOlT
17- 10
HYDRAUL IC BRAKES
DISASSEMBLY
R.",••• 1ht ,.,._",:
_ .... I>Od .... m_.
_ .... P .... _P<d .......·
_ 1ht uI..... .,;.... cdl.- ..,j boots.
~.mO'l. ,"- ... IOtI. "om 1M c_
II"' L.rl.•".,.¥ " ,... _ ... '0 .... car_

t"'"' ...... '0 ... ,........"" out. PI_. ""'" '11
~_ ....... _ .0 ............... ""''''' ""'" It ;.
. . .... 10<1. u.. ,....1. 101 """" """".
r D/l "", M", ,lot "PH.... 'OO tk>.. '0 tM ;,.,.
h.mI". , ... ,"" ... , .cd <.Ii-.. f<>< .,,,,, 1"11 •

.............. <>11>0<.,...". ocd ' ... _ ;1 ...,. ........
-.
""'" .... '"',........ "'. iii, .... "' .... , .011 di..,.~
CIon , ... oil .... p _ w;th tin.... lIuOd.
8",,{-.
. ~"'I I,m to d . _ th~ pi""" IM/n.t
1 7 - 11
HYDRA ULIC BRA KES
PISTON INSPECTION
CI>od< tho ~iotQ'" I<>< ...... Ine, "". _ '" ot~.,
"",...
loullO. M ........ t~ . plf<on d;'mot., ... "" , micro·
Sf llVICE l IMI T:
ll.&4 mm (1.2&11 j~1
:10.10 mm (1.187 I~I
CYLINOER INSPECTION
CI>od< I~ O ooli_ ovlind .. I<>< lCOO"ine, OCrt":",, or
_ I,u ~~ Mo ....... 1M oolipo.- ovlllldtt boro.
SERVI CE l IMIT:
FIIONT : 3%.09 mm (1.283;")
IIEAII : :10.29 mm 11.1 93 ;,,)
OIL SE.lLS
ASSEMBLY
If ,~. p,""on _ " or, ~or""l>Id '" """,.",,.,,.

",pi..,. th .... w'ln Mw - . Tho pinon ...1. "",n
bo '"11_ .. i '~ now """ ""............ y oro
~I"""" 11'0_ or br.i..
""",,,",,, Coot tn. 1001 . .. itn
~uid bolcr, .... mbly,
~ ..
1...,,11 ,~. pinon> with .... dishod .1Id. 'oward ,ho
1",,,11 thl 00I1t, tx>ou ,lid 001 1., """in; .... " 'hot
tho """to ... ".,ed
In ,ho COIl" "'" ool ip« !ll00II..
p<oporly_
1...."11 , ........ ""i"i ,lid pod"
P.lDSPR ING
17 -12
HYDRAULIC BRAKES
INSTALLATION FRONT
lit ....,. thot tIM "I'~' .UP It in "",i'ion on <!I.

eaI_broc .....
--.
1 _ tho C<IOlCI~"" 01 Iho cel i ~ pivot boll - . •
......,.., ~_ , , _ ... br..... fluOd to "'" collQO<
I..... , .... caliper 0 " "obi. _ tho br..... clio< ...

...... , ......... ;, pooitionod MM .. ntho pod>.
CAYTlON,
,. ~fwl "'" to 11_ ,k. p.J~
I", ..U tho ealiptl" J>loto< boll ...... coIipor bon.

e ,_, tho 10...... _....,....,_ Iho b...... _
~c
fO~OUE : 2S-35 N_ IU-3..I , , -, 11- 21 "~b l
f l. ",. 110-..... fluid II."oil ...... _ "" tw ....

•Y...... lpago 17·. I.
REAR MASTER CYLINDER

REMOVA L
Dr,;n U,. .... nuOd f,_ .... ~Y"'flJl;. OVal ...
1_ 17 -3 1.
A_III. ''9:>1 1<>01 I>O'j brockot.
17- 13
HYDRAULI C BRAKES
M,o.STER CVLlNDER HOSE

CONNECTOR
, ' - ...... 1It _ _ _ , IIw M . . ., <V'_
..., dh w"''''' bot.... _ I,,,,,, ............
~-
""'
I ._. .pIlIboIl-<o.t. /l<1rI "" pHlltd ",""'1/(
A ",1rI
",if«n II, F' '." '-'" ""....,..
R..".,... .ho m"'" <y'ioo.r ''''''*''''11 tool .. ...,
,."""'. "'. m,,,tI <ylonclo<.
FI_. . .... m .... <vI;_ """""0;>1 boIu ond

,11
......... til ...... <yMdor I,,,,,, "" ,,_.
l _ .... _ "'" ond 11m',....... tor.to .... '01

<Vll_ ,, _ .... torok. ,ocI
join, "'" 'Ulning "'"
'.... """"ocI.
FlOO JOINT
1 7- 1 4
HYDRAUL IC BRAkES
DISASSEMBLY
~ .... "". "" ..,.. ,Ing wi.h "'II> ' ... ~it" IOlil~-
m.""
323000 1) onrI ,.....,.. "'. ".11" , .... I,.." .....
.... 1...... ,.
.,"""",':""'.BOOY
It "'''I' 1M "''' " .... '0 - ' " • _ - . 0 1 oi,
_ ..... to tI>rr fII>" ou .... to '."' .... tI>rr ........
.... ,on onrI ",im.,- ... p.
MI"'.t,RY CUP
.t,NDSJlRING
"EAR MASTER CYliNDER 1.0.

INSPECTION
-.
Me ...... tI>rr _ d_, of tI>rr ........ ",'inder
UiIIVICE LIMIT : 1'.l1li """ 1O./iU 100)
17-15
HYDRAULIC BRAKES
REAR M ASTER PIST ON 0.0.

IN SPECT ION
M...... !h. ",..to.!>iotor1 0.0.
SE RV ICE LIM IT : 13.85 10m IO~ 1111
D>tcIt "'" prim.,.. ""P 0.-.1 IOcord..-y OUP I...

1Itm09O be""" ...."""V .
ASSEM B LY PISTON
"''''' "'''! '''''" BODY
R.pJoc.,M I,.,,,,., cylbtd... pU'''''. cylbtdg
I
. . >rd l1Hf"l" • ..,.
A...,..blo m. "',,,., <vll_•.

Coot 01 1P.I$ ...illl Cit'" 1111,," Jluicl .
Dip tho pio'on wp in DOT 4 !)<. k. Iluid bolo ...

.. _III • •
"""" wt.11inI: IhI c..p•. do "", oJJo", lip. ,A.

'0 /Um lPU/de ""I. fH «"oil, ,~. ""'P ritw IJ
_'N Jlrmly .. I~"IOO".
In,,011 "'" Pritn¥y wp one! pilton. PRI MA RY CUP
In",U "'" "" ... ,od "'" ""P ' ;I>i-
INSTALLATION
,,,,''" tt., m..to. cyi indt. "" till br, k"oo join' by
lUI"i", in 'h< Push '00 • ...! 'iV>'on tho 'oc' ""'.
CYL INDER
1 7 - 16
HYDRAULIC BRAKES
SKu .. . "- ",,,"r <'1'11_ to "'" homo ond .~ ....

C.....
"'" moun.Onoj boll>,
tho ""Of <'01_ "-
<'1'1_ .,.;'" • . - O~"'II'
to tAt ... tor
c.... _. the 1...1<0 _ to ""' ........ <VI;_ ......

• hO oil bal. _ . - ........ _ - .,
r""""' .... tiro/<. ' - bOI. ,
TOROUE :
~ N'm (UI-<I.o k ...... lB_N j'~b) ,
Insull Il1o r.... /00. ""' tlrockot.
f,U the broh IIu;'( _ ....... .., _ ... rUr

br .....yo ...... ( _ Il..t) ,
17-17
H YDRAULI C B RA KES
BRAKE PEDAL SHAFT ,

BRA KET LI GHT
REMOVAL
U" MO~ II>< .. ok, I ~' ,..I,d> 10""11 ond .omo"

.... to .. b,,~. pod.t.
A. _ .... .. ok. mo"" cylindo, f,om "'" b,ok.

,od join' (. . . 11·14) .
Unh""" tho ..... ,,'um 'P'ing 1<1<1 """"' . ....

" ,., b"k . pod~ " ,fl. REAR BRA KE
COTTER PIN
e RAK~
LIGHT SWITCH
A._,. "" 00""
d,ooonn<ct ....
p'" 1<1<1 jou" p"'. tho
... .. 'Od 10." from
,,'" podol
"',n ."
JOI NT
shoft.
DRAKE
PEDAL
•
BAA KE PEDA L SHAFT
INST A L LATION
,
BRA KE ROD
Co<111Oct tho b<.~ ' ,0<1 ioint \0 tho lI<ok. podoI .....tt
wi ... tho joint Pin ond. new oot"" pin,
'""I'M' 1"0_ 10 tho b,ok. podol ohlll 1<1<1 in'toll il

In""f,...,..
!n.toI l .... 11<, •• mo"., cylindor (PIVI 11·16).
In,toI l Iho br .... podol .I!going .... .... _ m .... ""

... , "'oft ,nc! podol.
ro;l\_ tIl. broke pod~ boll ,

TORDU E, l<I- lO N·,. eU-10 k.. ",. 17_ 22 h ·I ~ 1
Hook tho Dfoko li;l" • .-itch 'P, jo>g.
1 7-1 8
MEMO
BATTERV/CHARG ING SVSTEM
~~ IGNITION SWITCH
"
REDIWHIU
I
"" L- •
-=- "
-=-
FUSE 30.0. - 1=
- •<
-
i "'" I-
SWITCH
-
GREEN
B.... TTERY/CHARGING SYSTEM
18- 0
18. BATTERY SYSTEM
SERVICE INFORMATION 18- 1
TROUBlEStlOOTING 18- 2
BATTERY ,'-'
CHARGING SYSTEM ,'-'
SERVICE INFORMATION
GENEAAL
• 1IIot•.,., lluol loft! "'-'''' be mIChel -',,'v, ~ ;. wiUo di._ "'........... ,::z !' "r .
• o..ido cMrvoO btltorv only in ............... Slo .. <t>or.........,."... ,
• Rt_ .. ,ho 1)0 ........ It"", \lIO ""'''''..... lot _fH'it. II tho bo' ..... ..... , be cfto<tIod "" ,'" """....... , clT,« -.-1 tho
... , .... cobl .. ,
• .... _ . . . .1",.... =, 2 .... _be _ .... 11>0 ",,",ooqoclo.

• ",....".,,,,....-01 io in $ocllon t.
SPECI F ICATIONS
18-1
BATTERY /CHARGING SYSTEM
TROUflUSlIOOTI NG
N01M>_' _ ko. ,.,MII on:
I. Mlin fu .. bumfd OIl'
Int.,mit,,",
1.
_r: _
loo<o ban ...... ,Ion
2. D..d~, ... 2. ~ r;IIa~ng • • ntnl cor.... "ion
Lowl..,id 10..1 3. lao .. . tanl .....vo,.m co,,,"""'"
_ Low.- Ilicgt .... l .... 4. l ""'" CClMlCtion '" mo" dmr i. in itni'.,,,,
- Ch"ll;n... >V ...... 10110 .. .yn. m
3. 01~ ba' to .... <01> .. 5. L""", CClMoct;on '" ' '''r1 c;'cu l, In Ilgh'l nQ
4. Foul .... igtIltion rw1 1C!1 ..... M
Low _ , _ k.,. , ........... : 0."";",, ......... 1, ;10,.:

1. W_ ba' to,. i,.
1. loooo. b,<*.n '" ohor1od ... 0' o:><>ne<:1io"
Low f1<Iid 10'101 2. F..,lty W>ltogoo ,_ I" ",/foctil'"
_ low . ~ I i< pr •• iry 3. F.... 'y.I'tf""'Of"
_ o.., ging •• n . m I.il."
2. L.,.". ~ ltto ry -"""Ion
Low _ , _ .""no ,." ...... :

1. B.... I< • • _<t>or\IICI
_ low II"'" lonl
_ On< 0' ...." ........ .,.41.
2. Cta<t1r>g'V" .M I,ilull
18-2
8ATTERYICHARGING SYSTEM
BATTERY
REMOVAL
Oi'M .... ' ,ho 1Ir"..",d _ ottho N"''Y ,.,mi"",

,li0ii d;,con ... , ,ho poo;,I .. 001)10,
Ol.....,nec! ,n, N!!"", Ioto._ tube,
TESTING SPECIFIC GRAVITY

T... _ _ w~~."""_'"
SI'(Clf.C GRAYITY : 1.1l'D-1.2!KI I2O"C. " · f l
"'''
NOTES
T... be" .. ~ ..... , be ,od10rv0d if !ho _ .
• il" "" "~ " _ 1.230,
Tht '~Iflc 1I".ity...... witn ,no '''''II'''
,.M' .. _ " 1ft ,ho """,m!"",yl"li tobl •.
Rolll_ ,no N!!"Y if >Ul'''","
io ..'<Itn'
'" If ,no ....... _ ,no coli ....... It 'ino"
..ltn I0Il1""""
11k' "'''''1 ..... _ ,.If- <rill. A_

t r" , ""'. ioU•. ~•• '" .......w.q.
"8'_. .....""'A _,,,
_wi.",ltDII MIl 1" .. " ' "
R_. ""'OIl"
CHARGING
f ~' !ho
,no""...., ""'' PO.
0011 ... ~h "",il'-d .. " .. '" ,no
" _ ...... 11"'. 11 _ ' Y .
ConttOCt ,no """II" poo;'; •• (.) 011>1. ' 0 ,no bitt ...
_iii •• 1_I..,Mlnot.
CotIttOCt ' .... _ _ ~,j... I_I ~ . to ,no
bonOll" ~t;'" 1-1 ... mi",,'.
CIIOttitIII ... '''"'' 1.. .. _
0.00 .. W ..... "v
... _ ..
..... 11 rpoe;!lc " ..;ty It 1.210-
o
1280 .. lO'C . ' F).
18- 3
BATTERY/C HAR GING SYSTEM
.. ,
" ..",
........-.
... 11.. iftoI:.lI~ tho \>On ....... coot tho _ ... " with
CHARGING SYSTEM
CU RR ENT TEST
..,Ot.""t'""100-.........
It It.. b .. ' ........ 1ft ,.,.,.. cot>diliotl
.. , ... .
,~
Worm up ,,.,. ongl ....

/1,"", _ _ I.."" lido ""'"." _ Iho .....
0",,',-, tho !>lido. wi, •• , tho ' ..... ''''''octll;O'
-".
,,.
~ ,,.,. bot, .... _ .... _10 " ,,.,. bot, ....
,.. _, ..... _ , ....... ,oc'" beI_ tho
bonwy _ _ ............
.... Iow ..... i ... '0 1dIo.

......... _ _ "-'Y.
0 . .... • _ . "-0111 .......i".... mo! '0.2 ..
1.000 ,~ ......1" "" 1>0 .............. 0' 15
.. '.000 ''''''
._to
Chodo ,110 ...,'" (_ '''I"'" """ ,1M '.... ,.. /
,000i ..... ( _ 18.f1. ~ .... """g'", """i~"" i"'"
. iI <>01 mOt .
STATOR CONTINUITY TEST

I.'k',',_ ,"" .',.'...,,,, ..... ~I .."'/..
"""011; .
"','io<
C!>od< ... _~ ....,,, ,,,, .Ioc _. _ .....
,_ .Ioc -. ond ..au.....
11 .... _
-. ...... _ " ...... it "" COftt .... ,'" ... _

,,.,. _ . '" ~ ...... ;, _ ',.., ~Vbo" ' =' ,,.,._
.......
18- 4
BATTERV!CHAR01NG SYSTEM
VOLTAGE REGULATOR/ RECTIFIER

TEST
R.m.,.. tho 'igIIl o;do <""",
Oi""' ..... '" l ho ,_III",lfoctiffot """""".
CMd tor <OM ;.... ;I_ bo'wNn IM I..d'wi'~ ....

o~m"""".
,,,>TO:
Tho , ... ' ....1" mown 0" to, 0 _ Itl..

gtO"M O~mtn"" . fI!I 'M oPl><>l I" ' ....1"
wi ll be oIl" •..o w!>on . _,I". $<ound ""m·
mot. is "ood.
NORMAL DIRECTION: CONTINU ITY REOiltHITE
!
•
2 "0
••
"•0 0
.- C._
@
REVERSE DIRECTION : NO CONT INUITY
GllEEN YELLOW
•0
~
••• ••>
•
-1'- •••
•>
••
" YELLOW REOIWHIH i
f
VOLTAGE REGULATOR
PERFORMANCE TEST
BLAC ~
Cotw>Kt. 'ollmotOf..,OM ..... bon .. y.
Cl>od< 'tgUloto' _ t",mo",," w i l ~ ,~ . "'II"'"
----
'"Ming. TM 'tgUl.. ", ""'" d i..... ,,"mn! '0
$<0 _ _ bon. ", 1<>1_ "'_ 13.0-
---
lS.oV.
--- ,J
IC
1\
18-5
IGNITION SYSTEM
",;;:>-- ENGlfiE STOI' SWITCH
I I 'I
1t21" ~ 1
Efi Gl fiE STOI' IGfilTIOtI

IGfil TtOfi COilS SWI TCH SWITCH
,-.
"IJLSE GE N E ~ 1oTO R S
r;,,. RK Ufi lTS
19-0
19. I ION
SERV ICE INFORMATION 19 _ 1
TROUBLESHOOTING 19- 2
IGN ITION COIL 19_3
TRANSISTORI ZED IGNIT ION SYSTEM 19· ...
SERVICE INFORMATION
GENERAL
SPECIFICAT IO NS
19-1
IGNI TION SYST EM
TROUBlESHOOTING
Tho ... it ............ h. two oub ............ ; .... 10<
\1>1 No. I ..... NO. 3 .ylindo" .......... 10' t h. No . 2
..... No . . . . Ii....." . Dt, .. m;"" wh "" "'b·.. " .... ~
IO"ny. , _ ~< :,, ~ ,0 \1>1 "" ..11od ,aU .... _ .
[ ......................111_ .....
I . [ ......... "" ... """OFf
2. No..",.' .......
3.'_ """'to<;'" - " u";t
' . foultvoul._
.... ....,to .. .....

1. ~ ..... "" .."" .... ;do OF F
2. P_'y _ 'od.blok... 0' ...... 'od 10"',
- Borwwn ignit"m .,.i,,,,, _ ""Ill .. ,,"" owlt""
- eO'W9On tOil'" u";, .,., ontint 'too ... i,..
_ ao_ - " unit .........., .......'
- a.""....... ;0" coil ..., .....
- ' _ n - " unit ..., jIUI. . . _et ..
3.F..,1ty ..... ion<Oil
, . , .."" . .. ......... <1'1
5·' ....'v-"_
I . F...1tyouI.. _ _
l ....... otttt . .... t Nno ~ " "

1 • tll"h ItIM II< i..,. .. <i .." it
- h "lty ignj".,. <Oil
- ~ootO 0' bo' . ... ino
- Ift'o""~ ...... .no,, <~aJ i t
2. S '" . 'ttY ,""""
_ f ...1ty ~
_ F",,',y h~ ' .... ion..i ..
1. F... ,ty oul.. _.IOt

noo. ........""" ~ . joe,
2. F... ,ty -" .... '
19-2
IGNITION SYSTEM
IGNITION COIL i/2 , •• IG N ITION :::~
REMOVA L
~tmO .. ,"' .... , and tuo4 tonk 1 _ • • (8).
Di,.".,,*,, ,no . .,>on coil wito loado .
Oioconoec' "'0 "";'10<> w i.. Itado.

~.""' ... tho coil Or""h,. by , . "",ving ,~. Ittac!oinQ
bolu ,
~."""" 1110 coillfom ,'" Orod<.u ,
CONTINUITY TEST
M.,,,,ro rn. ,..im,,.,. coil ",.111..-.
~ ESIITANCl : 2.801"m
M..... ,. ,'" _and". coil ,..;",,,,,,, wi,h ,'"

"'" P'~' c",. in p!oco.
RESISTANCE: 2'~28 k ""'"'
19-3
A_. tho
,...".... I,.,..,
_,~ ~'"
tho ..... '
.." ... ~_ .. "i"." lind
................... d..... coli , .. ,,_ ,

AUISTAHCE : 111-1'" k _
TRANSISTORIZED IGNITION SYSTEM PULS E
PULSE GENERATOR TEST

~_"""_',""""'_
0 " " ....." tho ""'. _ _ _ .... IInd_
'-"1" .
.... 11>0 aMI ..... ' .. 00.
AESIITAHU : A _ .........., <&10 ""'"'
--
Bt ......... ~;"/ytl low ...... ytllow It"'" 11, 3 ey"".
a._ """ ................ ,*" 1ta6s f2• • cylindo",
PULSE GENERATOR REPLACEMENT
"'-_.....
" _.. "'" .... ,... _ 1_ 7·11 ).
A", ....... 1'00100 _ ' ..... _u-.; 1>01... ....
,,,,,,11 - "
p.tI. _ ..... ~
,
GEN ERATOR
19-4
IGNITION SYSTEM
CMck tIwo 0;' _ wilft • '""" ~""IJO.

STANDARD AIR GAP:
D.40-O.60 "".. (Q.Q1t1-l).02. io)
I."all tho <illt<~ «>'0< I~ogo 1-231 .

R _ k 1M i" i, ion 'Imin~ Ipll/O 3-8).
SPARK UNIT
If .... ""I. . .Mf.tor •• ~n',,,, ceil, """ w>r i"ll
... 000<', 10<1 1M itoi •.,., . i",,"11 ~ no' ,.il~l"
_iliu. iOn; ..1>10« 'M _,k
uni" .. i l~ new """
10<1,"""lid<
1M i~ni'"", 'imio;.
19- 5
ElECTRIC START ER
~;:- " . . ,," lunON
"
ST ... ~n~
Af L...... SWITCH
ST ... ~nR MOTOR
S T "'RT~R
eunON
20 - 0
20. ELECTRIC STARTER
SERVICE INFOR MATIO N
TROUBLESHOOTING
STAR TER MOTOR
STAR TER RELAY SWITCH
CLUTCH DIODE
SERVIC[ INFORMATION
GENERAL
• Th. "."If motor <I~ bo r"",O'I"" wit~ tho '"'Ii... in "'" t .. mo.
SPECIFICAT IONS
S,m.r meto,
TROUBLESHOOTING
S"',.r mo",," ,.m "'" ""." $ ... ,", mOt<l. '.ml, .... , ...... d_ ... , ", .."
1. B.tt~. 4.""'.'VOd 1. F"" W ".,to, <lui""
2, f...,,,. igni""" ... ",*, 2. F• .>IW 'U'''' MOtO<~"
3. foulty "'" .. ... ;,d! 3. flJlty , .."., ...0"', "f
;clio' "".,.
4. f .... ".!IOM ,"- ",,;,d!
5. F .... lty " .. , .. rol •• ",,;,01> SUr", moW ......... ie.. "'ml, bu ' ....... d ... ,
6. L _ '" d ,,,,",,,>O<1«l ",;ro or eabl. M'~
7. Clu,"" d ;od. 0_ 1. raJll. ;v.~iotl.V""'"
2. E<"9no ,",obi.""
S...... "'Olor .. , .. Mgin, ~_y
1. lew -,,;,., g''';'y
1. h "' ...... ,"'''.r><:<
on .ireu"
3. B;,.,inol in ,,.,,., molo'
20-1
ELECTR I C $TARTER
STARTER MOTOR
REMOVAL
0, "_, ",. .... , .. _ ...-" ",. """"'.

~""_ ,M ... " .. ""''',. _mint i00i11. an:!
",•• _ "'0'"".
."'~: HOLOER
~'U' ",",,,,1. ANO &PiUSHES
' " ' ' ' \ COVER
20 - 2
ELECTRIC STARTER
6R US H INSPECTION
R""", .. U.., " ... t ... ""'to< .,... .." .....
In.-. . ho _ _ and m"", .. tho b""" l ongt~ .
Id o","" b,u'" IP";" "M"", w i t~ , ",,;,. teal •.
S~RVICE liMITS:
8 ....... 1""1111>: Ui mrn IO.2e ",I
Bruoh ""i"'l ""~o," !i4~1 ( 11 .2 ... )
COMMUTATOR INSPECTION
Rom .... t ~ . ,,,'''f ""'toI" caw,

NOTE :
toe,,;"" .Il<! """,bo, ot t~"'''
In ...... " ... ..,."","',,0< be" 10< d<soolo,,,;"".

B, .. diocolO,.d in poi" i""ieo1O "",.. _ Orm""'"
t<>II ••
NOTE :
!lG r>Ot uoo om.", '" .. "" _ on t~ . com ·
""'''to<.
COMMUTATOR BAR PA IRS

CONTINUITV: NORMAL
Chad< lor """tl'. my botween O'~' o' ..,."mu101OI
1>0<1. A.... , m,'" ....
i"..... <ho<:k bo ........ ",.
diYid"" """"'""to< bot • ....0 .... ,,"'Olure "'oft.
Tho .. "' ..... Id be no co,"i",,~ y.
COMMUTATOR BAAS ~~?.'

NO CONTiNUITV: NORMAL
20-3
ELECTAI C STARTER
CA8LE lEAIo1INAL·"'OTOA CASE
_"'-
FIELD COIL INSPECTI ON NO CONTINU ITY , NORIo1"L
cr.odI lot _ .....Itv ""'" 'M ...".. •• I0Il .... '0
................. .,.., "- ....
"' ..... witt.
'" "'"
~.ploa
_.1,..,,,,,............. mo.or It "'" ! ltIeI colt II "'"
or II I. I. oI>Onod .0 " ,. mo.o, co ...
ASSEM BLY/INSTALLATION
INO~ "''''~K
1ft ..... _ , ... _ .. ~ .. i .. ...., .,'" .............
_ p i n.
",. k. _. 'M ' ..' <_, ;".,•• '""~ io '109_

with 'M cO ....... , mo,t.
20-4
ELECT RIC STA RTER
Inn,lI .h....to, mo.or.

Coo~ "'....... ' ...... .... ,,",' Of)' ,...""nd col>lo.
SlIRlER RELAY SWITCH

I NSPECTIO N
0 _ , "'" " .. to,"';w. boJnon ",111> 11>. . .,;0"
0 "1 . Tn, ooi' ~ normal il tIw "orto, ....... ""'; 1</1
.Iich.
eoo-.!Io • ." oIl ...... to, to \fit , ..' to' ""V"';":11

. "" .......
Connoc' • 12\1 bon• ..,. to tIw ..,..;.a, coblo tormi·
nol •. Th, ,witci> " nor""" if ..... " I. ",n, muit\'.
20-5
ElECTR IC STARTER
CLUTCH DIODE
REMOVAL
R....., .. ,~ ...., ..... 1\101 .. n~_
RtMO .. ,~. , 1"teII diode ',om ,,,. wire hOI ..... ,
INSPECTION
NORM .. L DIR~CTION: CONTINUIT'f

REVERSE DIRECTION : NO CONTINLlIT'f
e
/'
IN O N ~ DIR ECTION' CONTINUITY

IN TflE REVERSE DIRECTION: NOCONTINun V
20-6
21.
SERVICE INfORMATION 21 _ 1 BRAKE LIGHT SWITC H 21 _ 12
fUSE/ COUPLER HOLDER 21 - 2 CLUTCH SWITCH 21 _ 13
HEADLIGHT 21 -3 FUEL LEVU SENSOR 21 - 13
INSTRUMENT ,,-' f UE L PUMP 21 - 1'
SPEEDOMETER 21_7 FUE L PUM P R ELA Y 21 - 14
SPEED SENSOR 21 _ 7 THERMOSTATI C SW ITCH 21_15
TACHOMETER 21 - 7 TEMPERATURE SENSOR 21- 15
HANDLEBAR SWITCHES 21 _ ' TEMPERATU RE GAUGE 2 1_ 11
IGNITION SWITCH 21 - 9 BRAKE AND TAIL LIGHT SENSOR 21- 16
GEAR POSITION SWITCH 21 - 11 TURN SIGNAL CANCE L SYSTEM 21 - 11
OI L PRESSURE SWITCH 21 _ 12
SERVICE INFORMATION
GENER AL
• _ .. ~ .. _ d,If..... _ ... _ _ _ _ _ , "'" _ ... elCi. lMM ... " ........ to om- "'.... -...".
=rm .... w ~h .... _ _ .
• ..... , ~1Mt i< ......... _loci"", 'oIM ............. boo ,,'nud
_ . d "' .......... -.1 ...... "0 ....... "",""" ....... ... '
• Tho 101_.", _ - . . ~ ... lrIdalod "" ........ u, thio -..", ."" on ,,,. ,,1,,"'1 d;l9'om.
a.. • III.. LG o l ilh. Q,"" R _ Rod
a - 0......
81 .......
at • Blo ... , -,...... W
V
• Whitt
- '(01_
• 10 ioo\o..... oIo<ttlcal t.~u ... _ .... """"""ltV'" tho oIoctrUl .... h .... , ..... me - ,. A _ .... ;,-, _ _ _ 11
1>0 _ .. ,I'-' , _''''' Iho 1>0"1 ,, _ tho """,,<cvcio. $i'"lOl. d'.,, __ , tho .........c .... _, ...........;,.; ,...., or
.oI, ·oh.......,., ."."" ... ""........ "..,.--0-"""
• Po """,;""" . ' .. ' . r i. ","lui "'''''" _'''11'0 "..c "'" ","'''''r or "'" ....... 10 on 040ctriell ........eti<>n 1>0,,,,",, tho two
"","to. All ohmmot ... ~ .-... 10 .......". ,"" r.. '''''''''' 01. ";ra,oij, """, .. ""'"" , ...... ~ ...... iI;c 0011 r.. i"onoo ,,,,,,,y.
.... "" ........ _ . . , .. ~ . . , ..1... _ co....c by _r_ ................
21-1
LIIl HTS / SWITCH£S
FUSE/ COUPLIR HOLOER

FlEMOVA LII NST A LLA liON
R,m,., _ ..... ~ - . . . . . boll and ..... , "'" '"" ~\""

_ ... from ....... "" _ . 0; ,e'" .... horn
_ _ ..........iNI ..
_ ... Iht t ... - . ....-:I>. . 'CRWI.

O... ~CCI .100 .. " ..... ,... from "'" ..... _ .
21 - 2
LIGHTS SWITCHES
Pit,,-.'" til __ =
<0 ' . ' . ', , Ho ..
' 0 $, ,,",,,,
tho ~ _
ccnnoc\oI'< "
tho
...... I«_of,.,
1" ... 11 •• _.
R.I"o .. tho ""'" .,todI...... """ 00'<1 .........

~01"" b<ockn '0 ..... _1"11 " .....
~_ .. £lot b<OC~" til' ....... "'''11 "'" nut> ."..."
I,. .1It br.k, w " ",y join"
In ... 11 ,,'I, 1U1tloa<>plof ....100. bnclo.lI In tho '0,
..... OrOor 01 .omo .."
HEADLIGHT
RE MOVAL
R........ tho " ...II~' "' ..... 'inv ........,
--
01""""*' .M wi,.
11tI1',
_pIo • ..:£ '''''''"'' tho h.lII, ,
CASE REMOVA UINSTA LLATION

R........ tho lIt"'I~' CtoO _ , ing~ .. lind ",.
"''''''gl'l1 <....
1",..11 ....... lIIlog/'1l COot ....... thO ... .,.., 0 1
, ........1,
21-3
LIG HTS SWITC HES
HU,OLlGHT 8RACltET
BRACKET REMOVAUINSTALLATION foIOUNT' NG BOLTS
0;",. . . . . <,
lIN I....... ",m oitnoI wi ..... ~ ......
Rlwe," ......"" .... lItadlo' ..-.nbng be .......
lit....."""" ..... • " .... In.
''''''01' oht .."" ... ' lItadlot in ..... " ' " . """"'
,,1_01 .
•
I
~
•
...
INSTRUMENTS
REMOVAU INDICATOR BULB
RE PLACEMENT
RI""''' , .... 0<11 .... Inc! taN ( _ I~I .
R........ , .. 'n",,,,,,",,' ."''''-'fI.

Oi........ "'" \1>0 """"'"" If"", \1>0
I'Iauoi", '""oM;"' ..........
tho hCIu"",,.
21-4
LIGHTS SWITCHES
LOWER COVER
CAUTION,
Do owt I.... I~ ImtTUmmtl uPf/<k _ OF

dampillf fhJ.id wll/ kat o"to tht Imid. oj th.
~
NUTS. SPRING WASHERS .... ND

PLA IN WASHERS
Rom<> ... !he ""It"mon, o.ock" """"" I"" ""t> •
• ",I"'l ... uh... . na pl.1n w.'h ....
R. p.......... ",_ "i' .bo lt>..

Afto ' I"" ofl i"'l ...... bo lb. <Ilo<k to< cont;"u i, •.
II ........ o.lb dot< not lili/l,. In.""" "'. w i,1ng ,'"
.noptn '" "'01'1 cireu it, or 1_ _ ~ono.
21-5
LIGHTS/ SWITC HES
OISASSEMBL Y
1100'''''' ........"......... _ ao_ .., .........

N _.
ASSEM BLY/ INSTALLAT ION
.. otoOo ..... ;.",011 ",. .... "" ........ ;" ..... _ _

_ 01 di'-"Ollly ..... ,...-01.
~. •
•
21 - 6
LI OHTS/ SWITCHES
SPEED . T...cHO
SPElDOM£TlR
II HIe 'U'~: , ...., io io :oor,bYe. ~ .. _ _ ...
10 c_~ bo.~ .... _ ............. t..........
I • u
• II only ,he , .. _ .. , io 0","!U>g,. e__ 'he

0I>Hd _ _ " .....,, _ _
• II ,he _ . . . __ • ..;.,,""" 'hll .... _ _
• Nn ..... io "0''''''.
,..~_,., .i,....."'... roploe, Iho _0"""
11.1 IIII.b.,... _lIIek.I'" to ',",n "II , he ~oto ·
...... the ....... it>on io in , he W' fO h"n'"
Ito ,he
in"" •
-
"'"..... Diocord ,he ... ,,,,. . . <><1 now
- ._.....
• H ...... ,,,. ............. ' II _'-"Iii. chock ....
0I>Hd_'" '01 _
H'................... _
or ''''''' eon!lOClor • .
..... _ , ..
" " " ' . . .No .o,,~ ... _ _ '..... _ ~

the eonell. . . .bI _ .....
• H both ........ "" rool _ ....
.... ""'1 ,~. _ 'o<l'omot.. eooo:Uil
1"_""....
SPEED SENSOR
f '""" "'0 .......... .,.;,.,. ON.
Mo...... "'. ""..... 00_ ,,,. 8,_ISltek low
(j)OOJ,i»t) I<Id Iht G'MniBIKil looG ("'9"ij.".) 01
Ihoo "''''~''''''' ..... "'.,.
VOLTAOE : IV"' ....
Me_ !hi """. Oo_c. tho

8~.' 1_
Iood (po,HI .. ) tr>d ..... G....t8lock _ I~ '"
01 !hi ...""""'" _"11 ""'ill tumi"ll i!oo Ii.....
_ .14 ""
VOLTAGE : flII - 4V .... V ...... ...,...."".
I I - ' I o .... ~. _!hi " , ; , . _
TACHOMETER
" .... ,w;i'Oi'.. ttr d_ .... , It>::Iic... - " . _
...0 ,...." i!oo N o, I OVI_, .,ilion .V"..... TACHOMETER
" on' ... _ '~II

- " " , eI>ocI< _ ' ....1'" SPARK UNIT
I''''''H" "'t "IIOw wi.. ..rminol 01 'ht ",i..
hOi ...... , _.. , .... .,." ond Iho wi",.1Iow
"""" 01 01 1110 No. \ ..,i",,", itrti'ion .., ~ ...0
.. poi< " " .Ira,t~ i. -.ory,
II ""'" 10 """';""1..,. """"_tho tad ... ,.... ""'"

• now ......
- PULSE GlNERATOII
\
21-7
LIG HTS/ SWITCHES
HANDLEBAR SWITCHES
Tho ""r><JI_ """.' """_ iIOgh", tu,n .9101>.
horn ..... I m,,,, bt ,.~ocod •• .......tlli...
Con'",ui,v ..,,' lor ,"" components 01 ,"" ""r><Jl.-
...., eI.".....i,<ft. foHow :
Corni,.. i,y """'Id ..
wi'" '" __ chArI_
i" bot ..... ,"" """" <»do<!
HEADLIGHT HI_ LOW SWITCH -

'0 "U
"'
HI :
MIODL~ (N):
8uJW IkJ
8uJW to W to IkJ "
"'
~~
LO: Bu/W '0 W
'"'
"
~--
C
,.'" ~ ~
TURN SIGNAL SWITCH Tu," Signal S.. it<!>
RIG HT : G, '0 lB. B,I8" , 0 LB/W • , , PI PR Pl £ ~ ,

LEFT:
G ' oP
G,'oO.B,/Bu,oOfW
RIGHT C
--;,; ::2. 0 Ls El '"
G,oP LHT C :0-
,~ ~
PUSH: G , . lGfW
-- "
PUSH
'-r-
O!W ~
" 0 B'/8u
HORN BUTTON
LG to G .. ~ h buno" ""',. -
No ..""..,lty .. ~ h bvtt". "" .. ood
-
" , ."~
"- BAl3
, I I ,
f f
~.-
" .'"
21-8
GHTS SWI TCHES
STARTER BUTTON
BlIW '0 V"., .. ~h ""ItIHO .. _ I ...
BlIR te. 8WW with ""L
n , ... n HL .... ~
",R
ENGINE STOP SWITCH
RUN , BlrtI ' 0 BlILO
OfF , N o _.......
U'. "
''" :$:j
"""
''"
~-- .". 11/1.0
IGNITION SWITCH
_ " " .". 1_
.". Ig,"''''''
c_
Ow.'ch c _
hOI. ""'" dooc",,_,
0>0<1< C<II'I<""'~ V ,I ,.. mI".~ on "'" ignit....... I.a.

_ " " In _ ... nd'I ",*, 10 ...
SWITCH POSITION
lOC~, No..,,,,I...,,,,,
OfF , No ........ iIy
~, R ... BI. BI 10 hJO. 8uJO ... 1.1I'f. "1I'f ' 0 .. _ Comi""; ..
..---
' '''RK: R ... B, _
B...n
'"
c.o.-..,
,.,
'" '" .
•
~ 5':::<.: ~ ~~
'"coc'
- " • """ .~
• •
I
21-9
LI GHTS SWIT CHE S
REMDV A L/INST AL LA TIDN

R.",,,,. tho hNd ligh' ,roll ~ ... Iigt>' c ....
A."", .. ,no ;".""mon,, lpogo 21 · 4 1
Di...,.",.., ' ,h. ifni';oo ""11m ..... ooupIo, at !I>o

co""'., ~""'
Rom.,.. tho igni,;"" ""Itch mountin; boill. on<l

itni';OO .... 1I0I"l.
In,,,01 .... .... " "" Mach in tho " .... , .. oulot 'ol
,.....,.01.
DISASSEMBL Y / ASSEMBL Y
O!>on tho ..1<0 eI,,,,,,.
In .. " U.O ign";oo ~ •• ord tum it '0 be ...... " 11<.

O~ end OFF do,,,,,, pooi,;O",.
WIRE CLAMP IGN I T IO~ KEY
""'" "'0 ~ 10'0 .... . 10" end pull !ho eo<"lto<,
"'.....","'..
A...mblll ,h. ign'';'''' "";tm in .... " .., . ",do, of
21-10
LIGHTS SW ITC HES
GEAR POSmON SWITCH f>QS ITIO N SWITCH COUPlER
R. "",.. ,n. ,," .nd tuol ..nk.
0Ie0:k to< ..,nti .... ~ y bot", .. n ooel> , .......1 ond

or""'" in . - \1000< """,ion.
AEMOVAL
Ro""," ,"" ""0< "",i"on ,"';,<11 eo .... _
R''''''''' me "".'
, 1M! , "" ,"';,<11.
"",i,,,,,, . "';,eI> .n""''''sI 1«......
21-11
LIG H TS/ SWITCHES
Oil PRfSSURf SWITCH

Dr.i. tn. "'II;'" o il.
01"""""",, 'M ";1 PO""''' .... ~cn 1_ ... """.,...
,1M .... adl,
Chtd<. Ie< ocntl .... I'V whil •• p"'v"-! ","'u'" '0 t+. •
.... i":h.
1I, "'oce.1M ... rtch il _""'y.
Ap"'v • 1;""01 ... I.n, '0 'M ...1,... ,Iv_
bol",.
1"1OlIi"ll'M ...I,ch,
'"" .... I...,,,, ,h.

",..m. d 10<~"'.
Ttlon ' ' .otI
Screw th. switch In'o tho cronkc_ on<! 10 ... ,.,..,
bOt,,,,,,, i. 10 ",.
TORoof : 10-1' N· .. !I.O- '''' k...... 1_ 10 It·lb)
Non,
I 00 nO' .... 'ighl", Ill. ,.,.;tch.

, eN mov bo ~omogod,
Of tho cronk·
BRAKE LIGHT SWITCH

Chode . .. " " t.rol<. light twi.ch for con,jnui'v
.. ~h lhe ' .. , bU'k' • ...,.i«I.
FRONT SRAl(f LIGHT SWITCH

Chock ..... "CIO' tI, ..... iigh' ... ;'</1 lor "'"" ....ily
w i. h.ho front h' ..... .ppH. . .
R."'oco '''' ,wit'''''' if n",..-y.
I
-
21-12
LIGHTS SWITCHES
CLUTCH SWITCH
CLUTCH SWITCH
CI>odI -,,_no ot ,,,. clutch _C ..1eto1 ... ;, ...
•.
wn~ , ........, ... ,oIf""..-.I _itO.
~ ~~-,
FUEL LEVEL SENSOR

REMOVAL
R.m".. ,,,. , ...1 ,ord< _ d, ... '»O1l>Ol

R.n..... ,~. 1",1 1oY.1 _ _ .,,""''"'' .. " .....
'u.' 10..1IOn"" .
..la.....
~
1.. "'" ' 0 _ ,»01'''''' Mm.
INSPECTION
Muw,. ,»0 ,001 10-<01 _ _ , .... , ...... wit!< lull
."" om",. ,""', -";0,.,
FULL
RUIITRNCE : 'ULL 3.5--'.50"""
(MPTY 110- 100 0"""
II
o
(
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21 - 1 3
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':'0,,£ __~ "'" ~!~"'~tij:i::>1I""I-_
.. 00 <:1",_", ...... '" __ ",,,_u
~
OJ
LIG HTS SWITCHES
THERMOSTATiC ·SWITCH
Tl>t toOI"'II ton molo< I....",,1«1 t>y .1>0 ""' ......
""i< ...,.;.ttlIO<.I .... In , _ ...... odilt"'.
I! \lit ... mot<>< """' "", ...... d,,,,,,,,-, .... _
..., '""'" _ _ "'" u... " ......,• ..;td!...t
_, ........ .... u... ........ juorcIft w ....
T"," \lit q,;'''''
lWI.dI "".
Tht """"'''' ... """... ........., .. on """""8-
I! I, _ . M. 'U ••• _ ~ t", t..!'o<v 001."11' I<om
,Ot bI ..1t I..d IlIO<i "") '~block/blu. (__ " .. ) of
..",... - ..."'- .. .. """"

........ mot", """ .... .
I! , .....
,ouIt.
II \t ........
•,,110..,;
;0 "" ..,.. . . , _
;",po<:t ....
to! • bI.".., ......ltv
... """' ""'. '"

ton ".,0"",., .. "';\dO ..
s..~ ,h. , ..it", I. , Qm of ..,.",01 (50_ 50

,"",po."...., .. ""icI> lho
.-........
"" . ' ....1 _ dot'd< " "
,";,dI <>J)O<>'' ' ....... , t.l>k' "". "'......... ~ ....
"" ...... " "_""". "....,;....
,w('dI continvity II '-" k"opoo ....... ....,
........., ...... ..,....".lfy~) ,,1I8_102"C (201-

~l!"F).
M.lnul. ,Ot hiiii' "m.,... 'u" lot 3

"""'''''';\y. A ......
ml..."., bofO<. IeItI",
cion dI..... '" _ .........,. ";11
am>< in ............, ...... _;"11 100_
cou. ""
"'" II... _.w'" ..... "'" ...;,ttI .
00 ...,. II, ..... "............... ... IWII<tI
" ...,ttI "" _ .. \t "';11 ..... I ....."""e.
t\I._.
_ 1M 'w>,dI I. """"..., up '" IU
fEMl"ERArulitE SENSOR
TEMPfRATURE SENSOR
,,,...........
o; ...... nKt "" .-.'bIue d , ,,_ 1M .. _ .
Or ... ,ho «><>Ion, ..... "",,,.. "" ,,,,,po••,,,. ,

....... I.om "" th ........ ,., .....
21 - 15
LIGHTS/ SWITCHES
SOJopor.d 'ho uni, in ~II ~, .. , bu,,,.., nd mo>," "

' ho , ..I... """ ""oogI> 'h, ""It,, tho ~II M'U ..". """""'"",SENSOA
8S'C I Hi'C 120'C
18S' F ~30' F ~48' F
4l-9!l 1O.m 16. m
H ~TI ;
0 11 ",.m ... ,,"'" " 'ho .... ,«1

<hod: ,,-"ion .-. 1OO· C 1212· FL
'0 '''"i<!
VOOI'II go, 1.1.. ,, 000iog' II . i,"'" '"-
,"'"'mo....,..
Of ,,,,,,,",I1ut. """ ,OU<!> ..
'~ ... n,
TEMPERATURE GAUSE
Di",.....,.." Ill • ..-i " hom Ill' ,"" ...... tutO ""SO'
..... ,hon i' to U'''''''''.
T"," !h. ;gni'"", ""itch ON. TM ""'P''''"''
_ IeII"'Ontt "'wid mow III Ill ...IV 10 1111
''9h''
f)" "",1m.. rh. '''''1'''''''''' .......,. wi..

VW'ld<d {Of "'lIP'
,1wI • f~ H«m/i. Of I~e
"""' .... /U" zaul' wI/I be m.~.
SRAKE AND TAil

LIGHT SENSOR
BRAKE AND TlllUSHT SENSDR
T"m "'" i9n i,i"" ,wi"", (H'I,
CItf<: ~ tnt _"'" .oItogo " , .. ~_awrt I..d.
i! tho" 10 "" .... ,q. <hock ........ ~, "'. ""If'"
circui'.
If ""',.. ;, ""'ogo, mo_.-.
tho wi'"" " II><
""" ,./voHow l_itillO' and ..... """.lIow (MglUIIO'
w i....
VOLTAG E; 6 V
11 ' hO" i, no .oI,~ ...ol_ 'M ton"" ,,"it.
21 - 16
LIGHTS/ SWITCHES
TURN SIGNAl CIRCUIT
,
R. RIGIfl TURN
.,
SIGNAL
SPEED
•
TACHO .L_
CIRCUIT
COMPo
R. LEFT TURN S IGNAL
POSITION
llGHl
RELAY
TURN SIGNAL INSPECTION
cr..::t< 10< o:>ntu,"iW b e _ ,"" ,wllcI> ttfminal,

in""" I""I,;on .
A: 8'/ h '0 O/ W and 0, '0 lb

N: B'/ h '0 O/ W to lb/W
l : B./ B" to lbl W ond G, to 0
HOld the~!lOII,o 10" 0; .~t: P.e G
Puc~ tn. kncO : L;IW to G
T."";,, ..
,"
,
PUSHH
COlOI! G, lb 0 Bf~" lI>IW O{W
21-17
LIGHTS/ SWITCHES
CONT ROL UNIT INSPECTION
T.... I M h _ rip>t .... Ittt.

Qood. ........... _ . :: , ..... <OIl,"" ...-.iI
" " _. ........ .,.. .. .: J •••
•10......... _I~q_ 2 1-3).

T........... \tM .........."'ON.
Qood. ..... \dOl .... bi." "" .... ~ ....

.. _ "'" ...mIn... 01 .... _'"" ......... ,~
""..;Ia •
YOlT"GI : tv mlft.
TIK. ",. tu,n ~gn " ..-I.d> '0 ..... 10" or ,~,
..AOO
BoIBI
_Ill"" . Tho .o!tmo' if ............ Id d,op I ,,,,,,
8V'olY •
...." til ............ . - " ".
Tho ...., _ , .... II' ' ... ,100 I,,,,,, IV t(I av .
21 -18
LIGHTS/ SWITCHES
TURN SIGNAL RELAY INSPECTION
Romo.. ,ho h,odli", 1 _ 21-3)
CoMect • jumpoo< wi " bo'_ft ttIt bl ...lI>acI<

wi .. 01 11'>, tum ~ vn al " ,,,,, aM fl' o.,nd. Tum ,~
i",i'i.,., ...... eI'> 001.
T~ M" .i",. 1 'iV" ,"0"1d 0""" on .
WI RE
II m, ligh' - . "'" """'" on, dlacI< m. """..

""I, . at tho III' V wi" .. ,min" whi .. llloundi<lg
th, .,. ... /black wi" 01 tho ""n.ign"
" I"" ,",uoIo,.
POSITION LIGH T RELAY IN SPECTION
R _ tho ~l g'" <_ ;11-31 .

Rom_tho poo;.lon li'-" "',,,,.
Chodr lor _ti""iW botwftn A .,d e ,«",;"aI •.
ConM<' ,,,. ""'v ""..
..,,,,, ."mi....... III""", .
good IN ba" ... V '0 tho
TI>o po<ition 1i;/1' rol"" ~ nomtal if tho", i. ""

""" lft" I'v _ th, bot,.", ~ oo,,,.. oted.
POsITIOOl LIGHT
RELAY 12V B.. n ERY
21-19
M EMO
•
22. WI DIAGRAM
,
...,... . . .
....,'' ..,.",., _._.,
~-'
..... ~ '''' '
............
. . ..- .....",.
' .... "' ...".'... ,eo',
~ . ""-" . ,
-'
• " . . . . . OLl:"" .... , .
".-IIEU' ...."";
"'I""''''
..."....,.•..•. ' ::
...... ",.,
, ".,." '''''''",on,,:""
.- • .-
r·,... "". " ...,0 . ". ,w,.to ,' _ It.. , • • "" ,
•, ,, -
-.
[vol" " ' · "' ,.' ...
r ;-r.. ,
_.
.._... -- ,- 0
•
,
--- ". ...... -
0_
0
"
•
~-
'"~
'•••
-
,-
• •
-•~
- I
~
•
0030 Z-MB3 -6700-
22·1
23. TECHNICAL FEATURES
NEW TRAC (Torque Reactive Anti·dive Controll FRONT SUSPENSION
GENERA L
Thi. mot<>r<,!cIo ~ •• .., ..",-d ... I,on\,"'pen""" "",., ..itn 10........ ><IJu... bMV to pro.i... , ... <Ioo1.-d ,;,10 ""do, .or"""
.... k;..... oon.!;Iiom. Tho .. ,tom "on,,," of • pi"on, rot,,," '''''<>g. oi l ton".,. 0<;1100 >tid bod.,
RETURN "'''~,
23-1
TECHNICAL FEATURES
OPERA.TION
_ tho """01",'" ;, _ 01 nOd I I..... f' .... ' S.~.,..","", ......1"''''''''' Chon
....... "''''' ;, _ l t d by .... "'ok, _. 00Uli", DAMPING EHECT
..... "'ok, ... ,.....to po..,'
on I.. "'.ok"_~ , ~~
,
~,.
"'1, mo ....... n' ...... , tho 00' 0' Dol, 10 puth th,
, "'''
.. ,,"" in. """""',' ........ 0» ....... ~ .,...11 ... ST"ND"AD
~_ th' 01;;'" 11M ;".... .. I PM U • of d ;f/ ..... ,
",..,.ton. "" _rod _"'.,.. lit ..lie.... by , P IR'"
""""'"
_ it. """'v.
1IOSitIc><o. ""!un tho ' ...' """ loft '0 ""
• EXT RA f illM
NOIlMAl CONDITION 811AK INCi
23-2
24.
ENGINE DOES NOT STAR T OR IS HARD TO START
I'OSS,.u CAu,"
1.0-1< ..... '0- ............... NOT ~"'C~ IN G CAR.URrmA _ _ _ __ ~._ I\I ......... ........
121 ~ ........... fool ",O'
III $1 . . . . . _ _
I.,"1 _ ....
..... _ _
_._t_
, ............ '_'_.,... W' A K OfINO""~ K ....,._ ......
'"'" ...... _.on"
f OUl . . _ , "'.01
- _
'" ....... '" ... ,.., ..... "......
GOOOPA~ K
'" ......, -' """ ~
'"'" .........
" ' _ '" _
..........,. ..........
~
....
............ <OIl
'"'"
, n .. ""' _ __ .... LOW CQM"AE"OOIl
'"'" "-"0"'-"
' _ _ ....... d ..,..... h~
CO ..... USuj.. NOR .... l
-"
''"" V .... . - . _
W . . " " " ' _ .... ~ ....... ' ....
'"'" I,,,",,,, ..... ,......

0 . . . . " ... ' _ _ .....
_._
$0,.... _
'" .....
• . ..... "T ' -............. r',,,
E"o'''' OOU NOT . ,AE
ENGINE STARn .uTITo.' •
'"'"
,-,,--
,_.__ _
I , ''' ' ' '
r;.n,., .. "" _ _ .. " ' _
''"" '-"""""""". ...""......,,,,,"" ..,.,

..... ......
'"
• R..".,.. .... _ _. _
.. EHWO
-.-
• c.... '-','.: ,
'"''"" ...r ............
'" _""'"
_
24- 1
TROU8LESHooTlNG
ENGINE LACKS POWER

OOS8 llli CAUSE
,. ""t"_'011 _ _ ~"' ''''' .. HULl DO NO' ",N . IIU LV - - - - -_ 11I _ ....IiI· 4
111 - . . .. . .' 4 ' _ _ ...
_I.....-_. eo,.....
..... H ........ ~ULy III _ ' •• _ . '
1' , .;",. _ _ .. ' I
~
....IIIUfI.LOW---_ _ __ _ _ __ I'1 _ ...
_,.-
UI .......... _
.... 1"""£ _ "A L
) .........;I .. ,-" ... I HCINE UUO INC"USIlIU ... OTO"' - -' 11I Q , .... ~ .., ....
CYC"O ooil NOT ACCLE"AT! .. ELL 111 ""'"' _ •• ,. d""",, _
• HCIN . ... UO I"':~U.IU .~(). _ INCLUTC+<" ~H I"' " O III ......... _ • ...,.....
"OfI T'OHALLY TO ACCHI~ATtoH
..----I ......
_.N CLUTCH .. ~IU .... o
--_. '" c.-.... -._

'"m
'"'"
OHroIO" ECT - - - - -_ _ _ _ _ _ _• In . ..... _ , _
t2I , _ _ ;,;,;,,_
COI'I~ .cr
.. c:o-.t.... __ INCOOI"oo;1 ------------· ,.1 '. __

m ..... _ _
'. ,..... ---

COI!~ECT
t .~ ~------ _ __ _ _ __ _ 111 v..,. ,_ ,_
,l! ......... _ _ _ _
III LooO"' __"
..
I ~ _ _ _ , ......
•. ....'""...
~-
NOr CLOGGEO
_ •• - - - - -- - -- - - -_ I" ~
!,.. ' .., .
_ .
'"
0'
--
t '()IJLIO 011 OOSC<A"".O _ _ _ _ _ _ _•• 11> _ _ _ _ I, ,,,, ,Iy
I. ~""_ -' _
fOOT '()IJLI D O ~ DlfCOLO~EO (II _'_"".'_,0<,_
I 1) 1 "" _ _
'NCOIIIIlCl - - - - - - - - - - - -· UIOoI _ _ .....
III 001 _ _ _
I" Co. ,.", .. "" ..
V ... Vf T ~A'NNO ' I...,."IC.t. . . ._ _ __ _ '" Q. ',",on 4
"""O"LY m _'"'_" .. ..";,,,
Ov ..... U """ _ _ _ _ _ _ _ _ _ _ __ III I ",,'0' _ .. M""

.. to. "'."... ' 0 "
HO'T O\f. IIHU '''''G m ....... _ _ "'"
eJi _~_
I ___________ '" ........._ .......,_

-"_.... .
' l , _ _ .. ""' ...... _ .""'N.~NOaS
"""'N( DOUNO' ~NOCK Il'III w.._.M_

.... ,..... .....
........ ..
, .....
..I ""', .... , _ _ ,, '
1...... - - -
24-2
TROUBLESHOOTIN G
POOR PERFORMANCE AT LOW AND IDLE SPEEDS

__ _ __ _ _ _ _ _ _ __ . QSlHn. CAU"
' .. "",,". CT III ' '' ''" , ..... " .. _
111 ,,, .. :,, ....... ,;",' ..
CQR"tCT I ..... '''' __ ".tI
2.
t
CI>oo< _ _ _ ..... ,,_ "'"'_.."
l .AK ' .. G'_ _ _ _ _ _ _ _ _ _ _ __

•
~
"..,,, ,...,,., , ..., _ 0 . ...

'"'"
NOUAK
' ..........
I _.... ... ,, ~ O~ 'NTI"M'TTE"" P .. IIK _ _ _ __
•
~--
~
''"" ,...... ...
.."" ..-''ou""' ,
..........
'" '_''"~'"''''
POOR PERFORMANCE AT HIGH SPEED
' NCO~RECT _ _ _ _ _ _ _ _ _ _ _ _•
•
'"'" ,"-_ ..... ,...,.-
....,,, - ,"""
2.
"""R . CT
o~ ,.., ..... ,,_,_ '" 0' """ '" ,_
,n
''''' ' ' ""I.. _.~
loo'
c_ ,.... ,...
''"'"" C_ ".., _ . ....,.... ,"""
FU.LfCOWHRU lY
I
C_,"" .....
3, .. _ _ _ .... _ _ "" CCcGGEC _ _ _ _ _ _ _ _ _ _ _ _ _•

• ~
'" ... '.... """'"
",
" L ' joo.
N" " I.OGGEOJETS
4 , """' . ..... , ..... INC""R.CT _ _ _ _ _ _ _ _ _ _ _ ___ ;~;;;;:""O< ... "'" ,"".11""

.., I.
.."""""t ...... -..........

COfIRECT
.~, _ _ _ _ _ _ _ _ _ _ _ _ _ _••• F ... ," ......
POOR HANDLING - - - - - - -•• Check lire pr..",. "
, ~ <I- ... ~....,-------------------------~ '" _ _ " ' _ ....... , ..... '

12) "," , • I n _ " _ _ ' .
2. H ....... ,,_~_ ..... - - - - - -- _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ 111 • . -... _ _ ' .......
I~\ .... ,;",
13) , _ - ' " ""'oH""
_001 ...,
'- I ... _ _ _ _ _ '"
.""-""" ""'"
IGI e"" ,,_
Idi ... "-",, _ "'p'''''''' ,.,.
';gil'
3. " .... "" ... "' .................. - -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. " , f .... " ...... ' boo
12 ' F..... _ _ _ ..,..~_
13' .... ''''''' "".

I·' __ "F'"
24-3
•

A Few Words About Safety: .. Warning

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A Few Words About Safety: .. Warning

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A Few Words About Safety

Service info rmation

For Your Cus tomer's Safety .. WARNING

For Your Safety

Important Safety Precautions

• Safety Messagtls preceded by a safety alert symbol &

You WILL be KILLED or SERIQUSL Y HURT if you donl fol low

You CAN be KILLED Or SER IOUSLY HURT if you donl follow

You CAN be HURT if you don~ fol low Instructions

• Inslructions - on how to service th is vehicle correctly and safety.

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN

Stetion. 1 through 3 apply to the whole

section. • CYLINOER HEAON ALVE

MOst seClion. start with In ..... mbly or CRANKCASE

<.> HYDRAULIC BRAKES

0". 01 1.... O<tob... 1 986

TIl. . .,,,., ,.,....Ift 1tr<I_ "., ...we", _ . . /qJtIJI

BEGINING From. No. SCl71 • EMOOOOO1-

Th • ..,.,;... ...1., numbor ;• •toml>Od "" '''' 01 ,hO

,~. 10· IATOCI

Tr ....... ~. 1on 5~ with .,... d,i ••

~ lr>OI , odunlon 3.182

G... , ..10 II 1.619

Go.-oIIitt_ Loot. Ie,,,,, _ ..... ,

0.1-0.11 """ 10.0;11-0.0:35 In!

~IGHTS Hoodl"-,, , ............. _ ~.w

To;,J..~"'" 8/27W 3Il2 q> SAE NO. "57

'0-" 11 .8_ 2.0.13_ 141

, '" ~4' (3.0-4.0. 22_29 1

• STAN OARO TOROUE VALUES

""""... -~. - a""

--- 11,"" ,_ _ ' G- u .S.... _

CABLE & HARNESS ROUTING

• Do "'" _ ....., . ago;n,' tI:o _III Of

• s.c.", ..I,.. "'" ...,. h....... to tI:o 1._

110... h , , _ ... tI:oy ... not pull...

• K_ w;.o ~_ ......... _ tI:o ..h.." " ' "

• So .. '" ""''''''''t> ......to<! if> ~, .. _

• A' ... d ........ _00<1:"-tolit ........

• ... "., ,,,."i,,,. choc:_ 11:.. tI:o ..i,. h _......

Win h._. Of ~ "~od.

,0UUd ...... 'ho hand_ ..

~' ~ / ' " " " HOSE

F~ONT BRAKE ""~

..... TTER ... NEGATIVE BATTER'!' POSITIVE

" . .,; ; \ MAGNETIC SWITCH

EMISSION CONTROL SYSTIM

EXHAUST EMISSION CONTR OL SYSTE M

CRANKCASE EMISSION CONTROL SYSTEM

EVAI"ORATIVE EM ISSION CONTR Ol. SYSTEM (Cf,liforn'- IVPt)

NOISE EMISSION CONTROL SYSTEM

EMISSIO N CONTROL INFORMATION

VACUUM HOSE fl OUTING DIAGflAM

- - ' ''PIPE SHIFT SH"'FT

uMod ""'on tho ._0;0

5.4 ± 0.1 ~g/.m' In . ' 0 PIn ot 5,000 ,om 180"CII76" F I

Oi l pump ...... ic. <fa ..

FINOI d,'" geo'

ISO .. 15.1 Gr I.It..