2001-2005 Honda TRX250EX Sportrax Service Repair Manual Instant Download

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(No Transcript)
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HOW TO USETHIS MANUAL This service manual
describes the service procedures for the
TRX250 fX.
CONTENTS GENERAL INFORMATION
FRAMK/BODY PANELS/EXHAUST SYSTEM MAINTENANCE
Foliow the Maintenance Schedule (Section 3)
recommendations to ensure that the vehicle is in
peak operating condition and the em iesion levels
are within the standards set by the California
Air Resources Board fCARB.
Performing the first scheduled maintenance is
very important. It com- pensates for the initiel
wear that occure during the break-in period.
LUBRICATION SYSTEM
Sections \ and 3 apply to the whoJe vehicle.
Section 2 illustrates pro- cedures for
removal/installation of components that may be
required to perform service described in the
following sections. Sections 6 through 20
describe parts of the vehicle, grouped according
to location.
ENGINE REMOVAL/INSTALLATION
CYLINDER HEAD/VALVE
Find the section you want on th1s page, then turn
to the table of con- tents on the first page of
the section.
CYLINDER/PISTON/CAMSHAFT
Most sections stan w th an assembly or 8yetem
illustration, service information and
troubleshooting for the section. The subsequent
pages give detailed procedures.
CLUTCH
If you don't know the source of the trouble. go
to section 22, Troubleshooting.
GEARSHIFT LINKAGE
ALTERNATOR/STARTER CLUTCH

• Your aafaty, and the safety of others, i9 very
  important. To help you make informed decisions we
  have provided safety messagas and other
  Information throughout this manual. Of course. it
  is not practi- cal or possible to wern you about
  all the hazards associated with ser- vicing this
  vehicle. You must use your own good judgement.
• You will find important eafety information in a
  variety of forms including
• safety Labels on the vert Tele

CRANXSHAFT/TRANSMISSION
FRONT WHEEL/SUSPENSION/STEERING
REAR WHEEL/BRAXE/SUSPENSION

• safety Messages preceded b'y a safety alert
  symbol I , and one of three signal words,
  DANGER, WARNING, or CAUTION.
• These signal words mean
• You WILL be KILLEO or SERIOUSY
• HUF-IT if you don't follow instructions.
• You CAN be KILLED or SERIOUSLY
• HURT if yoU dont follow instructions.
• You CAN be HURT if you don't follow instructions.

HYDRAULIC DISC BRAKE
REAR DRIVING MECHANISM
BATTERY/CHARGING SYSTEM
IGNITION SYSTEM

• Instructions how to service this vehicle
  correctly ant safely.

ELECTRIC STARTER
As you read this manrtal, you will find
information that is preceded by a NOWTE symbol.
The purpose of this message is to help prevent
damage to your vehicle, other property, or the
environment.
LIGHTS/SWITCHES
ALL INFORMATION. ILLUSTRATIONS, DIRECnONS AND
CPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PROOUCT INFORMATION AVAIL-
ALL? ATTHETIME OF APPROVAL FOR PRINTING. HONDA
MOTOR CO.. LTD. RESERVES THE RIGHT TO MAKE
CHANGES ATANYTIMEWITHOUT NOTICE AND WFFIIOUT
INCURRING ANY OBLIGATION WHATEVER. NO PART OF
THIS PUBLICATION MAY BE REPRODUCED WFFHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRFFTEN FOR
PERSONS WHO HAVE ACQUIRED BAGIC KNOWLEDGE OF
MAINTENANCE ON HONDA MOTORCYCLES, MOTOR SCOOTERS,
OR ATVG. HONDA MOTOR CO., LTD SERVICE
PUBLICATIONS OFFiCE
WIRING DIAGRAM
TROUBLESHOOTING
3
SYMBOLS The symbols used throughout this manual
show specific service. procedures. If
supplementary Information is required per-
taining to thesa symbols, it would ba explained
specificaIIy'in the text without the use of the
symbols. Replace the part(sl with new ona(sI
before assembly. Use recommendsd angine oll,
unlesa otherwisa specified. Use. molybdenum oil
solution \mixtura of the engine .oll and
molybdenum grease in a ratio of 1 .1). Use
multi-purpose grease (lithium based multi-purpose
grease NLGI 2 or equivalent). Use molybdenum.
disulfide grease (containing more than 3
molybdenum disulfide, NLGI 2 or
equivalent). Example Molykote BR-2 plus
manufactured by Dow Corning, U.S.A. Multi-purpose
M-2 manufamured by Mitsubishi Dil, Japan Usa
molybdenum disulfide. paste (containing more than
409a molybdenum disulfide, NLGI 2 o
equivalent).. Example Molykote G-n pasts,
manufactured by Dow Corning, U.SP. Honda Moly 80
(U,S.A. only) Rocol ASP manufactured by Rocol
Limited, U.K. Rocol Pa9ta manMfactured by Sumico
Lubricant, Japan Use silidone greasa. Apply a
locking agent. UBe a middle strength locking
agent unless otherwise specified. Apply
sealant. Use DOT 3 or DOT 4 brake fluid. Use the
recommended brdkB fluid unles8 Otherwise
specified. Use fork or suspension fluid.
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1. GENERAL INFORMATION
SERVICE RULES MODEL IDENTIFICATION SPECIFICATIONS
TDROUE VALUES
LUBRICATION SEAL POiNTS -2 CABLE HARNESS
ROUTING 1-3 EMISSION CONTROL SYSTEMS 1-10 EMISSION
CONTROL INFORMATION 1-13 LABEL
1-15 1-17 1-21
i-x

• SERVICE RULES
• Uee genuine HONDA or HONDA-recommended parts and
  lubricants or their equivalents, Parts that don't
  meet HONDA's deaign specifications may cause
  damage to the motomycle.
• Use the special toola designed for thia product
  to avoid damage and incorrect assembly.
• Use only metric toola when servicing the
  motorcycle. Metric bolts, nuts and screws are.not
  interchangeable with English
• fasteners.
• install new gaskets, 0-rings, coaer pins, and
  lock plates when raassambling.
• When tightening bolta or nuts, begin with the
  larger diameter or inner bolt first.Than tighten
  to the specified torque diag- onally In
  incremental staps unlass a particular sequence is
  specified.
• Clean parts in cleaning solvent upon diaasaembly.
  Lubricate any sliding surfaces before reassembly.
• After reasaembly. chack all parts for proper
  installation and operation.
• Route all etectrical wires as shown on pages 1-17
  through 1-20, Cable Harness Routing.

1-1
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GENERAL INFORMATION MODEL IDENTIFICATION
ENGINE SERIAL NUMBER
FRAME SERIAL NUMBER
The frame serial number is stamped on the front
cross- msmber of the frame.
The engine serial numbar is stamped on the lower
half of the rear crankcase.
CARBURETOR IDENTIFICATION NUMBER
COLOR LABEL
The carburetor identification number is stamped
on the right side of the carburetor body.
The color label is attached on the left frame
member under the seat. When ordering color-coded
parts, always specify the designated color code.
1-2
7
GENERAL INFORMATION
SPECIFICATIONS GENERAL
N
ITEM
SPECIFICATIONS
DIMENSIONS
Overall length Overall width Overall height
Whselbase Front trsad Rear tread Seat height
Footpeg height Ground clearance (Skid plate) Dry
weight Curb weight Maximum weight capacity
1,Y35 mm (68.3 in) 1,og2 ww (41.8 in) 1,073 mm
(42.2 inl 1,124 mm (44.3 in) 807 mm î31.8 in) 805
mm (31.7 in) 79.4 mm (31.3 in) 319 mm (12.6
in) 149 mm (5.9 in) 158, kg (349 IbsI 166 kg (367
Ibs) 110 kg (243 Ibs)
FRAME
Frame type Front suspension Front wheel traval
Front damper Rear suspension Rear wheel travel
Rear damper Front tire size Rear tire size Front
rim size Rear rim size Front tire brand Rear tire
brand Front brake Rear brake Toe Caster angle
Camber angle Trail length F\JeI tank
capacity Fuel tank capacity Cylinder arrangement
Böre and stroke Diaplacement Compression ratio
Valve train
Double cradle Double wish bone 150 mm (5.91 in)
Double .tube Swingarm 145 mm î5.71 inl Double
tube AT22 x 710 AT22 x 109 10 x 5.5 AT 9 x 8.0
AT DUNLOP KT171 DUNLOP KT175 Hydraulic disc
brake Mechanical drum brake Toe in 2.3 mm (3/32
in)
0.1 40 mm (1.56 in) 10.2 liters (2.5 US gsl,
2.24 !mp gala 2.7 liters (0.7 US gal, 0.59 Imp
gal) Single cylinder, Iongitudinally
installed 6B.5 x 62.2 mm (2.70 x 2.45 In) 229.2
cm (14.0 cu-in) 9.1 1 OHV, rocker arm and push
rod 8 BTDC at 1 mm lift) 38o ABDC (at 1 mm
lift) 34 BBDC (at 1 mm lift) 4 ATDC (et 1 mm
lift) Forced pressure and wet sump Trochoid Air
cooled Oiled double .urethane Unit type, two main
journals 34.s kg (76.0 lbs)
ENGINE
Intake valve
opens closas
Exhaust valve apens
Lubrication system Dil pump type Cooling
system Air filtration Crankshaft type Engine dry
weight
8
GENERAL INFORMATION GENERAL (Cont'd)
ITEM
SPECIFICATIONS
CARBURE OR
Carburetor type QP Throttle bore
ton valve 20 mm (0.79 inl
DRIVETRAIN
Clutch system Clutch operation system
Transmission Pr mary reductio Final
reduction io 1st
Centrifugal multi-plate, wet Automatic Constant
mesh, 5-speeds with reverse 3.087 (71/23) 3.692
\48/13) 2.846 (37/13) 933 29/15 444 26/18 1.130
T26/23) 0.913 t21/23) 769 3 f/T6 x 82/73) Left
foot operated return system, R N 2 3 4
5 AC-CDI Electric starter motor Single phasa
output alternator SCR shorted, single phase
full-wave reMification Battery
3rd 4th Sth
Gearshift pattern Ignition system Starting system
Charging system Regulator/rectifier Lighting
system
ELECTRICAL
1-4
9
GENERAL INFORMATION LUBRiCATION Unit mm Mln)
STANDARD 1.6 liters (1.7 US qt, 1.4 lmp qt) 1,9
liters (2.0 US qt, 1.7 lmp qt) Honda GN4 or HP4
4-stroke oil or equivatent motor oil API aervice
classification SF or SG Viacosity SAE 10W-40
ITEM At draining
szsvlCE LIMrF
Engine oil capacity
At disassembly Recommended engine oil
5 006) 0.11.21 f0.00 .008) "
0.20 (0.008) 0.25(0.010)
Oil pump
Tip claarance
Bodyelearsnca Side clearanca
0.OD.13 (0.0020.O05)
0.t5 t0.006)
FUEL SYSTEM
FFEM GPECIFICATION6 Carburetor identification number Main jet 95 FFEM GPECIFICATION6 Carburetor identification number Main jet 95 FFEM GPECIFICATION6 Carburetor identification number Main jet 95
Slow jet Pilot screw opening Float level Jat needle clip position Idle spaad 38
Slow jet Pilot screw opening Float level Jat needle clip position Idle spaad See page 5-11 14 mm (0.6 in) See page 5-11 14 mm (0.6 in)
Slow jet Pilot screw opening Float level Jat needle clip position Idle spaad 3rd groove from top \,400 e 100 rpm 3rd groove from top \,400 e 100 rpm
Throttle. lever free play mm (1/ /16) Throttle. lever free play mm (1/ /16) Throttle. lever free play mm (1/ /16)
Unit mm (in)
CYLfNDER HEAD/VALVE
fTEM
STANDARD
5ERVlCE MMIT
Cylindar cpmpression at 800 rpm
I 1,275 kPe (13.0 kgf/cm, 185 psi)
I
Valve clearance
IN/EX
0.13 (0.005i
I
IN EX
5.47 5.490 (0.2156-0.2161) 5.45 .470
TO.21 .2.154)
5.45 (0.215) 5.43 (0.214)
Valve, valve guide
Vafva stem O.D.
s.son.s2 (0.2tg .2170) t 0.01 ,037 f0.000 .0015)
lN/rx
Valve guide I.D.
5.525 T0.21Y5)
IN
( 0.12 (0.005)
Stem-to uida clearanca
EX
0.03 .057 0.00120.0022)
0.14 \0.006)
Valve aeat width lN/EX 1.2 (0.05) 1.5 (0.06)
Valva spring Inner valve spring IN/EX 42.4 (1.67) 41.2 (1.82)
free length
Outar valve spring
!N/EX
44.2 (1.74)
Rocker arm I.D. I IN/EX 12.00 12.018
(0.472a.473a) Rocker arm shaft O.D. I IN/EX
11.9 11.984 (0.47110.4718) Rocker arm-to-shaft
clearance "0.01.052 10.0006-0.0020)
Rocker arm
11.92 10.469) 0.08 10.003)
0.10 (0.004)
Cylinder head warpage
10
GENERAL INFORMATION
CYLINDER/PISTON/CAMSHAFT ITEM CYLINDER/PISTON/CAMSHAFT ITEM CYLINDER/PISTON/CAMSHAFT ITEM Unix nnm (in Unix nnm (in Unix nnm (in
CYLINDER/PISTON/CAMSHAFT ITEM CYLINDER/PISTON/CAMSHAFT ITEM CYLINDER/PISTON/CAMSHAFT ITEM STANDARD SERVICE LIMIT
Cylinder I.D. I.D. I.D. 68.50 8.510 T2.696 2.6972) 68.6 (2.70)
Cylinder Out of round Out of round Out of round 0.10 (0.004
Cylinder Taper Taper Taper 0.10 (0.004)
Cylinder Warpage Warpage Warpage D.1D (0.004)
Piston, p'' p"I piston ring Piston mark direction Piston mark direction Piston mark direction IN mark toward the intake side
Piston, p'' p"I piston ring Piston O.D. measurement point Piston O.D. measurement point Piston O.D. measurement point 14 (0.2O.6)
Piston, p'' p"I piston ring Piston O.D. Piston O.D. Piston O.D. 68.46268.482 (2.69532.6961) 68.4 (2.69)
Piston, p'' p"I piston ring Piston pin bore I.D. Piston pin bore I.D. Piston pin bore I.D. 15.00215.008 (0.590A0.5909) 15.04 (0.592f
Piston, p'' p"I piston ring Piston pin O.O. Piston pin O.O. Piston pin O.O. 4.994 s.000 (0.5903o.5s06 lt.ss o.ssg/
Piston, p'' p"I piston ring Piston-to-piston pin clearance Piston-to-piston pin clearance Piston-to-piston pin clearance 0.D020.014 (0.0001 .00061 0.020 (0.0008f
Piston, p'' p"I piston ring Piston ring-to-ring groove clearance Top Top 0.01.045 TO.000 .0018) 0.09 (0.004)
Piston, p'' p"I piston ring Piston ring-to-ring groove clearance Second Second 0.0150.045 10.000 .00181 o.og (a.004
Piston, p'' p"I piston ring Piston ring end gap Top Top 0.200.35 (0.00 0.014) 0.5 (0.02)
Piston, p'' p"I piston ring Piston ring end gap Second Second 0.400.55 (0.01.022) 0.7 (0.03)
Piston, p'' p"I piston ring Piston ring end gap Oil (side rail) Oil (side rail) 0.200.70 (0.0080.028)
Cylinder-to-piston clearance Cylinder-to-piston clearance Cylinder-to-piston clearance Cylinder-to-piston clearance 0.01 0.048 (0.00070.0019) 0.10 TO.004)
Connecting rod small end I.D. Connecting rod small end I.D. Connecting rod small end I.D. Connecting rod small end I.D. 15.01 15.028 IO.590A0.5917) 15.06 10.5931
Connecting rod-to-piston pin clearance Connecting rod-to-piston pin clearance Connecting rod-to-piston pin clearance Connecting rod-to-piston pin clearance 0.OU.D34 (0.00D40.0013) 0.10 0.004)
Camshaft, cam follower Cam lobe height 35.76A35.924 (1.4081.414) 35.6 (1.40)
Camshaft, cam follower Cam lobe height 35.29235.452 (.3891.3961 35.1 11.38)
Camshaft, cam follower Cam follower O.D. IN/EX Cam follower O.D. IN/EX Cam follower O.D. IN/EX 22.46722.482 (0.884 .8851) 22.46 (0.884)
Camshaft, cam follower Cam followsr bore I.D. IN/EX Cam followsr bore I.D. IN/EX Cam followsr bore I.D. IN/EX 22.51 22.526 TO.88620.8868) 22.54 (O.887)
Camshaft, cam follower Cam follower-to-bore clearance Cam follower-to-bore clearance Cam follower-to-bore clearance 0.02 .059 10.00110.0023) 0.07 (0.003)
Unit mm (in
ITEM ITEM STANDARD SERVICE LIMIT
Change clutch Spring free length 35.2 (1.391 34.5 (1.36)
Change clutch Disc thickness 2.93.0 (0.11A.12) 2.6 (0.10)
Change clutch Plate warpage 0.20 (0.008)
Change clutch Clutch outer guide O.D. 27.95927.980 (1.10071.1016) 27.92 (1.099)
Change clutch Clutch outer guide boss I.D. 28.00 28.021 t1.102 1.10321 28.05 (1.1041
Centrifugal clutch Drum I.D. 116.00116.20 (4.567-4.575) 116.5 14.59)
Centrifugal clutch Weight lining thickness 2.0 (0.08) 1.2 (0.05)
Centrifugal clutch Clutch spring height 3.0 (0.12) 2.85(0Il2I
Centrifugal clutch Clutch weight spring free length 30.75 (1.211) 31.6 (1.24)
Centrifugal clutch Drum bushing (.D. 24.00A24.021 (0.944 .8457) 24.05 (0.947)
Centrifugal clutch Front crankshaft O.D. at primary drive gear 23.95923.880 (0.94330.9441) 23.93 (0.942)
1-6
11
GENERAL INFORMATION
CRANKSHAFT/TRANSMISSION ITEM CRANKSHAFT/TRANSMISSION ITEM CRANKSHAFT/TRANSMISSION ITEM Unit mm (in Unit mm (in Unit mm (in
CRANKSHAFT/TRANSMISSION ITEM CRANKSHAFT/TRANSMISSION ITEM CRANKSHAFT/TRANSMISSION ITEM STANDARD SERVICE LIMIT
Crankshaft, connecting rod Side clearance Side clearance Side clearance O. 50.5O IO.020. 020 0.80 f0.031s
Crankshaft, connecting rod Radial clearance Radial clearance Radial clearance 0.000.012 (O.00020.0005) 0.05 (0.002)
Crankshaft, connecting rod Runout Front Front 0.06 (0.002)
Crankshaft, connecting rod Runout Rear Rear 0.03 (0.001)
Transmission Gear I.D. M4 M4 23.00 22.021 (0.905 0.9063) 23.04 (0.907)
Transmission Gear I.D. M5 M5 18.00008.021 (0.70870.7095) 18.04 10.710)
Transmission Gear I.D. Cl,C2,C3,R Cl,C2,C3,R 25.000-25.021 (0.98 0.9851) 25.04 (0.986)
Transmission Gear I.D. Peveseide Peveseide 13.00013.018 (0.51180.5125) 13.04 (D.513)
Transmission Mainshaft O.D. t M4 t M4 19.95919.980 T0.78580.7866) 19.93 t0.785)
Transmission Mainshaft O.D. at MS at MS 14.96A14.984 T0.58920.5899) 14.94 (0.588)
Transmission Reverse idle gear shaft O.D. shaft O.D. 12.96 12.984 (0.510 0.5112) 12.94 (0.509)
Transmission Gear bushing O.D. M4 M4 22.85922.979 (0.903 .9047) 22.94 (0.903)
Transmission Gear bushing O.D. M5 M5 17.95917.980 (0.707 0.7079) 17.94 (0.706)
Transmission Gear bushing O.D. C3 C3 24.95924.980 (0.vsega.ga3s) 24.94 (0.9821
Transmission Gear bushing O.D. C1, C2, C3, R C1, C2, C3, R 24.95934.980 (0.982A0.9B35) 24.94 (0.982)
Transmission Gear bushing f.D. M4 M4 20.00020.021 10.78740.78821 20.04 (0.789)
Transmission Gear bushing f.D. M5 M5 s.00 5.0 a (0.5g0 .s9 3 15.04 0.592I
Transmission Gear bushing f.D. CZ CZ 22.00022.021 (0.B6610.8670) 22.04 (0.868)
Transmission Gear-to- bushing clearance M4 M4 0.0210.062 (0.00080.0024) 010(0.0041
Transmission Gear-to- bushing clearance Mg Mg 0.02 .062 (0.00080.0024) O.10(0.004)
Transmission Gear-to- bushing clearance c1, C2, C3, R c1, C2, C3, R 0.0200.062 (0.000 .00241 0.10 (0.D04)
Transmission Bushing-to- shaft clearance M4 M4 0.02 0.062 (0.00080.0024) 0.10 (0.004)
Transmission Bushing-to- shaft clearance M5 M5 0.01 .052 (0.000 .0020) 0.10 (0.004)
Transmission Bushing-to- shaft clearance Cl Cl 0.O2 0.062 (0.00080.0024) 0.10 (0.0041
Transmission Reverse idle pear-to -shaft clearance -shaft clearance 0.01 .052 (0.000 0.00201 D.10 (0.0041
Shik fork, fork shaft Fork ''D' ''D' 13.00013.018 (0.51180.5125) 13.04 (0.513)
Shik fork, fork shaft Fork Claw thickness Claw thickness 4.935.00 (0.19 .197) 4.60 (0.181)
Shik fork, fork shaft Fork shaft O.O. Fork shaft O.O. Fork shaft O.O. 12.96 12.984 (0.510 .5112) 12.96 (0.510)
1-7
12
GENERAL INFORMATION
Unit mm pin)
FRONTWHEEL/SUSPENSION/STEERING
STANDARD
FFEM
SERVICE LIMFF
Minimum tire thread depth
J 10.16)
Standard Minimum
30 lcPa (0.30 kgf/cm2, t.4 pail 2g kun to.ze
kgf/cm2, 3.8 psi)
Cold tire preaaure
Maximum
34 kPa 0.34 kgf/cm2, 5.0 pgi.)
With cargo 30 kPa f0.30 kgf/cm2, 4.4 psi)
Tie-rod diatanca between the ball joints zzg.z 1
12.88 o.t Toe I Toe-in 2.3 mm (3/32 in)
REARWHEEL/BRAKE/SU6PENGION
ITEM Minimum tire thread depth 4 (0.16) Cold tire pressure Standard 20 kPa (0.20 kgf/cm2, 2.9 psi) Minimum 17 kPa (0.17 kgf/cmm, 2.5 pgi) Maximum 23 kPa 10.23 kgf/ciyi, 3.3 psi) ITEM Minimum tire thread depth 4 (0.16) Cold tire pressure Standard 20 kPa (0.20 kgf/cm2, 2.9 psi) Minimum 17 kPa (0.17 kgf/cmm, 2.5 pgi) Maximum 23 kPa 10.23 kgf/ciyi, 3.3 psi) ITEM Minimum tire thread depth 4 (0.16) Cold tire pressure Standard 20 kPa (0.20 kgf/cm2, 2.9 psi) Minimum 17 kPa (0.17 kgf/cmm, 2.5 pgi) Maximum 23 kPa 10.23 kgf/ciyi, 3.3 psi)
With cargo 20 kPa (0.20 kgf/cm2, 2.9 psi) Rear brake Drum I.D.. 140.0 (551) Lining thicknâss 4,5 (0.18)
With cargo 20 kPa (0.20 kgf/cm2, 2.9 psi) Rear brake Drum I.D.. 140.0 (551) Lining thicknâss 4,5 (0.18) 11.0 (5.55) To tha indicator
Unit mm (fm
HYDRAMLiC DI6C BRAKE
SERVICE M/IFF 2.5 (0.101
STANDARD
Recommended breke fiUId ke di
DOT 4 braka fluid 2. .2 (0.110.131 12.70 12.743
IO.5000-0.5017) 12.6!T712.684
(0.498 .4994) 33.9644.01 (1.3371.339)
Th Ru ut
0.30 (0.012)
Master cyltndar I.D.
12.Y55 (0.5022)
12.646 (0.49781
Maatar piston O.D.
Caliper cylinder f.D.
34.01 t1.340)
Caliper piston O.D.
3387 33.028 (1.33 1.3357)
33.87 (1.333)
REAR DRIVING MECHANISM !TEM Raar axla
runout Final drive Recommended oil
Unit mm (in)
GERVICE MMIT 3.0 (0.12)
Hypoid gear oil SAE 80 75 cm AZ.5 US oz, 2.6
Imp oz) 100cm f3.4 US oz, 3.5 Imp oz) 0.OF.2b
f0.0020.010) 0. .8 (0.010.02)
At draining At disaesembly
OII capaci1
Gear backlash Baddash dlffarsnce Rfna
gear-to-stop pin Clearance
0.40 10.002) 0.2 (0.01)
1-8
13
GENERAL INFORMATION
BATTERY/CHARGiNG SYSTEM
ITEM
SPECIFICATIONS
Battery
Capacily
12 V8 Ah
Current leakage t Voltage (20C/68F) Cha
gin rren Capacity
1 mA maximum 13. 13.2 V Below 12.3 V
F Ily ha ed Needs charging
0.9 A x 510 h
C " Ouick
4.0 A x 1.0 h
Alternator
123 W/5,000 rpm
Charging coil resistance (20C/68F)
0.1-1.0 cJ
IGNITION SYSTEM
SPECIFICATIONS DPR8EA9 tNGK) X24EPR-U9 tDENSO)
ITEM
Spark plug
Stsndard
DPR7EA-8 (NGK) X22EPR U9 TDENSO)
For cold climate (below 5C/41F)
0.80.9 mm t0.0 0.04 in) 100 V minimum
Spark plug gap
Ignition-coil peak voltage
Ignition pulse generator peak voltage
t
0.7 V minimum
Alternator exciter soil peak voltage
100 V minimum
Jgnition timing I"F" mark)
J4 BTDC at 1,700 rpm
ELECTRIC STARTER
SERVCELIMIT 9.0 mm (035 in)
ITEM
STANDARD
Starter motor brush length
12.5 mm (0.49 in)
LIGHTS/SWITCHES
ITEM
SPECIFICATIONS
Main fuse
15 A
Headlight Taillight
Bulbs
2 V35/35 W x 1
12 V5 W x 1
Indicator (Reverse/neutral)
12 V1.7 W x 2
1-9
14
GENERAL INFORMATION TORãUE VALUES STANDARD
FASTENERTYPE 5-mm bolt and nut 6-mm bolt and
nut 6-mm flange bolt (SH type) 8-mm bolt and
nut 10-mm bölt and nut 12-mm bõlt and nut
FASTENERTYPE 5-mm acrew mm screw 6-mm flange bolt
îB-mm heady and nut 6-mm flange bolt l10 mm head)
and nut 8-mm flange bolt and nut JO-mm flange
bolt and nut
TOROUE Nm (kgfmlbRl 0(0.5,36) 10(1.0, 7Î 10
(1.0, 71
TORQUE Ibn 4(0.4, 2.9) 9 (0.9, 6.5) 12 (1.2,
9) 12 (1.2, 9) 26 (2.7, 20) 39 (4.0, 29)
22 16
1
34 (3.5, 25) 54 (5.5, 40)

• Torque specifications listed batow are for
  important fasteners.
• Others.should be tightened to standard torque
  values listød above.
• NOTES 1. Apply locking agent to the threads.
• Apply oil to the threads and seating surface.
• Apply grease to tha threads and seating surface.
• Do not reuse Replace with a new one.
• Castle nutTightan to the specified torque then
  tighten to position suitable for cotter pin hole
  direction.
• Stake.
• Left-hand thread

ENGINE
THREAD DBA. ?mm)
ITEM
Nm
U, bfft)
REMARKS
MAINTENANCE
Oil drain-bolt 1 12 25 (2.5, 18)
Spark plug 1 12 1B \.1.B 13)
Timing hola cap 1 14 10 (1.0,.7)
Valve adjusting hole cap 2 30 20 (2.0, 14)
Valve adjusting screw lock-nut 2 6 17 (1.7, 12î NOTE 2
FUEL SYSTEM Carburetor insulator stud bolt CYMNDER HEAD/VALVE Cylinder head cover bolt Cylinder head flange nut Carburetor insulator bolt Cylinder head 8-mm stud bolt CLlNDER/RSTON/CANISHAFT 2 4 2 6 10 (1.0, 7) 6 12 TI.2, 9) 8 30 î9.1, 22) 6 10 (1.0, 7) 8 6 (0.6, 4.3) 6 10 (1.0, 7) 6 12 TI.2, 9) 8 30 î9.1, 22) 6 10 (1.0, 7) 8 6 (0.6, 4.3) NOTE 2
Cam chain tensi.oner arm pivot boh 1 ó 12 T1.2, 9) NOTE 1
Push rod end piece 6 13 (1.3, 9)
Front crankcase stud bolt 2 8 12 1.2, 9)
' Rear crankcase stud .bolt 2 12 (1.2, 9)
CLUTCH
Centrifugal clutch-drum lock nut 1 18 88 (9.0, 65) NOTE 2, 6, 7
Change clutch center lock nut 1 16 79 f8.1, 59) NOTE 2. 6
Change clutch lifter plate bolt 4 6 12 \1.z, g
GEARSHIFT LINKAGE
' Gearshih return spring pin bolt 1 22 (2.2, 16) NOTE 1
Gearshift.cam plete bolt 1 J6 (1.6, 12) NOTE 1
Gearshift A arm bolt 25 (2.5, 18)
Gearshift drum stoppar arm bolt 6 12 (.1.2, 9) NOTE 1
ALTERNATOR/STARTER CLUTCH ALTERNATOR/STARTER CLUTCH ALTERNATOR/STARTER CLUTCH ALTERNATOR/STARTER CLUTCH ALTERNATOR/STARTER CLUTCH ALTERNATOR/STARTER CLUTCH
Flywheel bolt 1 10 74 (7.5, 54) NOTE 2
Starter one-way clutch outerTorx bolt 6 6 16 (1.6, 12) NOTE 'I
Ignition pulse genarator bolt 2 6 6 î0.6, 4.3Î NOTE 1
CRANKSHAFT/TRANSMISSION
Neutral switch rotot socket-bolt 1 10 (1.0, 7 NÒTE 1
MGHTS/SMTCHES Neutral switch and reverse switch
2
10
t3 f1.3, 9)
1-10
15
GENERAL INFORMATION
FR4ME
THREAD DIA.
TOftQUE N-m lkgfm, Ibfft)
ITEM
REMARKS
FRAME/BODY PANELS/EXHAUST SYSTEM Footpeg
mounting nut Skid plate bolt Mufiler band
bolt Exhaust pipe protector bolt
MAIMTEMAMCE Spark arrester bolt Reverse control
cable adjusting nut lock nut ENGINE
REMDVAL/INGTALLATION Engine mounting nut (Lower
teft/lower right) Cylinder head mounting rubber
bolt ALTERNATOR/STARTER CLUTCH Gearshift pedal
pinch bolt FROMTWHEEL/SU 'PENSION/STEERING Handl
ebar lower holder nut Steering shaft end
nut Tie-rod ball joint nut Tie-rod lock
nut Steering shaft holder bolt Upper arm pivot
nut Lower arm pivot nut Knuckle baI joint
nut Shock absorber upper mounting nut Shoclt
absorber lower mounting nut Brake hose clamp 6-mm
bolt FroM wheel hub nut Front wheel nut Throttle
case cover screw REARWHEEL/BRAKE/GU6PENSION Shock
absorber upper mounting nut shock absorber lower
mounting bolt Raar axle nut Rear axle nut lock
nut Rear wheel hub nut Rear wheel nut Swingarm
right pivot bolt Swingarm left pivot adjusting
bolt Swingarm left pivot lock.nut Rear brake arm
nut Rear brake pane! drain bolt HYDRAUMC DISC
BRAKE Brake disc cover bolt Brake disc
bolt Master cylinder reservoir cep screw Brake
hose oil bolt Brake pips bolt Brake
caliper/bracket mounting bolt Brake caliper bleed
valve Brake caliper pad pin plug Brake caliper
pad pin Brake lever pivot bolt Brake lever pivot
lock nut Brake caliper 9lide pin bolt Brake
caliper bracket pin bolt
4 3 1 3
8 8
32 (3,3, 241 32 3.3, 24) 23 (2.3, 17) 22 (2.2,
16)
3
8 6
12 f1.2, 9) 7 (0.7, 51)
10
54 (5.5, 40) 32 (3.3, 24)
1
6
2 1
NOTE 4
39 14.0,. 29) 108 (11.0, 801 54 (55, 40) 54
(5.5, 401 32 13.3, 24) 30 f3.1, 22) 30 (3.1,
221 32 13.3, 24) 30 (3.1, 22) 30 (3.1, 22) 12
(1.2, 9) eg î7.0, 51 84 16.5, 47) 4 f0.4, 2.9)
14 12 12 8 10 10 12 10 10
NOTE 4
2 4 4 4 2 2 4 2 8
NOTE 4 NOTE 4 NOTE 5 NOTE 4 NOTE 4 NOTE 1 NoTE s
14 10 4
NOTE 4
10 10 32 32 18 10 30 30 30 6 8.
44 (4.5, 33) 44 (4.5, 33) 39 \4.0, 29i 127 l13.0,
94) 14y (16.0, 10i) 64 (6.5, 47) 112 (11.4,
82) 4 (0.4, 2.9) 112 (11.4, 82) 12 (1.2, 9) 12
(.1.2, 9)
1 1 1 1 2 8 1 1 1 1
NOTE 1 NOTE 3, 5
6
2 6 2 3
12 (1.2, 9) 42 (4.3, 31) 1.5 10.15, J.II 34 (3.5,
25) 17 11.7, 'I2) 30 (3.1., 22) 6 (0.g, 4.3) 3
(0.3, 2.2) 18 (1.8, 13) 6 (0.6, 4.3) g to.e.
4.31 22 (2.2, 16) 18 (J.8, 13)
NOTE 4
10
NOTE 4
10 10 6 6 8 8
4
1 1 2 2
16
GENERAL INFORMATION FRAME (Cont'd)
ITEM
m g m, bf-ft)
EMARKS
REAR DRIVING MECHANISM Final gear case mounting
bolt (FronVleft) final gear case cover 8-mm
6oIt 10-mm bolt Pinion bearing lock nut Final
gear case drain-boit Final gear case oil check
bolt Final gear ease oil cap LIGHTS/SWITCHES Head
light aim adjusting screw
10
!ñ4 l b.b, 4U) 35 \2.6, 19) g (s.0, 36) gg
(i0.0, 72) t2 12 (1.2, 9) 12 (1.2, 91
NOTE 1 NOTE 6
10 64
30
4 (0.4, 2.9)
1-12
17
GENERAL INFORMATION

• TOOLS
• NOTES 1. Alternative tool.
• Equivalent commercially available in U.S.A.
• Not available in U.S.A.

DESCFIIPTION TOOL NUMBER REMARKS REF. SECTION
Carburetor float level gauge 074010010000 5
Flywheel hotder 07725-0 040000 NOTE 2 10
Rotor puller 077330010000 NOTE 1 07933-2000000 10
Remover weight D7Y41-0010201 NOTE 1 07936-371020A TU.S.A. only) or 9, 12,14,16
07936-3710200 (U.S.A. only)
Valve guide driver, 5.5 mm (IN) 07742-0010100 7
Attachment, 32 x 35 mm 07Y46-00J0100 9, 10, 12, 13
Attachment, 37 x 40 mm 07746-0010200 13
Attachment, 42 x 47 mm 07Y46-00t0300 12, 13
Attachment, 52 x 55 mm O7Y46-0010400 12, 16
Attachment, 62 x 68 mm 07746-0010500 14, 16
Attachment, 72 x 75 mm 07746-0010600 12
Attachment, 22 x 24 mm 07746-0010800 16
Driver, 22 mm I.D. o7Y46-0020100 13
Driver, 40 mm I.D. 07Y46-0030100 13, 16
Attachment, 30 mm I.D. 07746-0030000 16
Pilot, 15 mm 07746-0040B00 9, 12, 13
Pilot, 17 mm 07746-0040400 13, 14
Pilot, 20 mm 07746-0O0500 12, 13
Pilot, 25 mm O/746-0040600 12
Pilot, 35 mm 07746-0040800 12,16
Pilot, 40 mM 07746-0040900 16
Pilot, 14 mm 07746-0041200 16
Bearing remover shaft 07746-0050100 13
Bearing remover head, 15 mm 07746-0050400 13
Driver Valve spring compressor Valve seat cutter 077490010000 9, TO, t2, t3, t4, 16 7 7
Driver Valve spring compressor Valve seat cutter 077490010000 9, TO, t2, t3, t4, 16 7 7
seat cutter, 29 mm (45 INT 07780-0010300 NOTE 2
seat cutter, 33 mm (45 EXT O7780-D010800
flat cutter, 30 mm (32 IN) 07780-0012200
flat cuttar, 33 mm (32 EX) 07780-0012900
interior cutter, 30 mm lb0 IN) 077B0-0014000
cutter ho(der, 5.5 mm (IN) 07781-0010101
Pilot screw wrench 07908-4220201
Swingarm lock nut wrench 07908-4690003 14
Valve adjusting wrench, 3 mm 07908-KE90200 NOTE 1 07708-0030400
Snap ring pliers D7914-SA50001 15
Lock nut spanner, 4t mm 079\6-9580200
Lock nut wrench, 41 mm Lock nut wrench, 30 x 64 mm 07916-9580300 0791g-MB00002 14 16
Puller shaft 07931-ME4010B 16
Special nut 07931-HB3020A 16
Remover handle 07936-3710100 14
Bearing remover, 17 ww Bearing remover, 15 mm Attachment, 28 x 30 mm Oil seal driver attachm n, ss.s mv o7g3s-a71oaoo 07936-KC10500 07946-1870100 o7gz7-SD90t01 14 9, 12 13 14
Driver handle 07949-3710001 13
Thread adapter 07965-KA30000 NOTE 1 07VMF-HM801OA (U.S.A. only) 12
1-13
18
GENERAL INFORMATION
DESCRIPTION TOOL NUMBER REMARKS REF. SECTION
Oil seal driver 07965-KE802O0 16
Assembly collar Assembly Shaft 07965-VM00100 07965-VM00200 NOTE 1 07831-ME4010B IU.S.A. only) and 12, 13 12
07931-HB3020A (U.S.A. only)
valve guide reamer, SI.5 mm 07984 200000a I\IOTE 1 07984-200000D (U.S.A. only/ 7
Clutch center holder 07GMB-KT70101 NOTE 107HGB-D010t0B (U.S.A. only) 9
07HGB-001010A (U.S.A. only)
and
07HGB-001020B IU.S.A. only)
07HGB-001020A (U.S.A. onlyI
Clutch puller 07GMC-HB30100 NOTE 1 o7g33-HB3000A (U.S.A. only) 9
Peak voltage adapter 07HGJ-0020100 NOTE 1 Peak voltage tester TU.S.A. only) 18
Clutch holder 07HMB-HB70100 NOTE 107923-HB3000B (U.S.A. only) 9
Pinion puller set 07HMC-MM80101 NOTE 3 16
shaft puller 07931-ME40000 NOTE 1 07931-ME40J0B U.S.A. only) and 16
07931-HB3020A IU.S.A. only)
pinion puller base Pinion puller base 07HMCMM801t0 07HMC-MM8011A NOTE 1 07HMCMM8011A IU.S.A. only) 16 16
Oil seal driver 07JAD-PH80101 14
Driver attachment O7LAD-PVV50500 16
Remover base 07JAF-SH20200 13
Ball joint remover/installer 07JMF-HC50110 13
Clutch spring compressor 07LAE-PX40100 9
Ball joint remover O7MAC-SL00200 13
Pilot, 32 mm 07MAD-PR90200 14
Bearing remover head, 14 mm 07WMC-KFG0100 or 07936-KC10200 and 16
07YMC-001O10A IU.S.A. only)
Remover shaft, 15 mm 07936KC10100 16
Differential bearing clip compressor 07YME-HN4010A 16
Universal bead brsakar GN-AH-958-BB1 13
1-14
19
GENERAL INFORMATION
LUBRICATION SEAL POINTS ENGINE
LOCATtON
MATERIAL
REMARKS
"Cylinder bore
"
Engine oil"
Connacting rod big end Connecting rod small and
Inner surface Piston ring whole surface Piston
pin outer surface PiBton pin hole and piston
outer surface Cylinder haad flanga nut
threads Cam Chain tensioner inner surface of
pivot Cam chain and oil pump chain whole surfacss
CentrifugaJ clutch drum lonk nut threads
Centrifugal clutch shoe sliding surface
Csntrifugal clutch drum bushing inner surface
Change clutch ball retainar ball Change clutch
disc linings Change clutch center lock nut
threads Primary driven gear teeth One-way clutch
linings of cam Flywheel bolt threads Starter gear
teeth Starter driven gear teeth and needla
bearing inner surface Reverse stapper shaft
bearing inner surface Transmissiori bearings and
gear teeth Transmission bushing and collar
sliding surfacas Mainshaft gear teeth and bearing
inner surfeces Countershaft gear teeth and
bearing inner surfaces Shift fork and shift fork
shaft sliding surfacas Shift fork paw! pin
sliding surfaces Gearshift drum inner grooves and
bearing inner surfaces Gearshift master erm
bearing inner surfece Gearshifi A arm bolt
threads Gaarshifi spindle outer surface and
bearing inner surfaces Sub clutch lever whole
surface and bearing inner surface Bsarings and
needle bearings
Valve stam sliding surfaces Camshaft journala and
cam lobes Rocker arm slippgr surfaces Rockar arm
shaft outer surfaces Changa clutch outer guide
sliding surface Startar idla gear shaft otJter
5urfaCes Starter reduction gear shaft outer
surfacea
Molybdenum oil solution la mixture of 1/2 engine
oil and /2 molybdenum disulfide grease)
Alternator boss oil seal lip Oil saal lips
Multi-purpose grease
Camshaft retainer bolt threads Mainshaft fearing
retainer bolt threads Cam chain tensioner arm
pivot bolt threads Cam chain tensioner adjuster
bolt threads Centrifugal ol filter cover boh
threads Gearshift drum stopper arm pivot bolt
threada Gearshift return spring pin bolt threads
Neutral switch rotor socket-bolt threads
Gearshift cBm plate bolt threads Starter one-way
clutch outerTorx bolt threads Ignition pulse
generator 5-mm socket bolt threads
Locking aaent
Stator eard grommet
Saalant
20
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21
GENERAL INFORMATION



FRAME
LOCATION
REMARXS
Steering buahlng sliding surface Steering shaR
oil seal lips Steerlng shaft dust seal lips Front
wheel hub dust seal lips Rear brake cable end and
parking brake cable end Rear brake cam dust seal
lips Rear brake panel dust seal lips Rear brake
panel duat seal side lip Regr brake cam
.shaft.sliding surface ftaar brake shoe-to-brake
cam contacting surface Rear brake shoe-to-anchor
pin contacting surface Brake pedal 9haft eliding
surface Brake pedal duat seal lipa Brake lever
pivot sliding surface Brake levar parking arm pin
sliding aurfaca Raar brake penel O-ring Final
gear caee pinion joint oil seal lipa Final gear
Oase ring gaar oil seal lips Final gaar case oil
cap Oring Swingarm bearing and greaae
holder Swingarm bearing duat eeal lips Throttle
G8bIa end and throttle lever side threaded
portion Oil seal IIpa and dust saal lipa
Multi-purpose grO8BB
Spreeding 2. .0 g (0.09 - 0.11 ozl
Sproading 0.11.0 g (0.02 0.04 oz)
Sprasding 0.U.0 g (0.02 0.04 öz) Spreading
0.11.0 g 0.02 0.04 oz)
Fll\ up 3 g IO.1 oz) minimum
Raar brake am falt seal
Engine oil
DOT 4 brake fluid
Brake.master cylinder piston seals BrakB ma8tar
Oylinder piston Brake calipar piaton Brake CBIÏ
OF _at_iBtOn BeB(9
Front brake lever pivot Front brake !evarto
master piaton contacting area Brake caliper slfde
pin bolt sliding areB Brake caliper pin sliding
area
Sllicona greaee
Front Bhock absorber lower sida oil seal lips
Front 8hock absorber lower aide metal bushings
Rear axI6 Bhaft Bpllnes Universal joint
aplines Finsl gear easa pinion joint
splines Finpl gaar cgae pinion joint needle
bearing Rear ahock absorber oil.seal lips Rear
shock absorber matal bushings
Molybdenum disulfide grease
page 1t-12 and page 16-3
Locking agaht
Rsar akte nut lonk nut thfBada
Final 9ear eaae
Hypoid gear oii SAE 80
Fioal gaar case-to-gaar case cover matlng surfaces
Liquid. sealant
Air cleaner afement
Pro Honda Foam Air Filter Oil or equivalent
lmpregnation 20 a.3. g (0.7 z 0.1 oz)
Each cable lnsids
Cable lubncanz
Handle grip rubber In8ide
Honda bond A or Honda grip cment (U.G.A. only)
1-16
22
GENERAL INFORMATION
CABLE HARNESS ROUTING
NE UTRAL IND ICATO R
REVE RSE INDICATOR CHOKE KNOB
IGNITION SWITC
THROTTLE CABLE
TWOWIREBANDS . HANDLEBAR SWITCHWIRE
BRAKE H OF E
REAR (PARKING) BRAKE CABLE

• WIRE CLAM P
• HANDLE BAR SWITCH WIRE
• INO ICATOR WIRE
• IG NITION SWITCH WIRE

REVERSE CONTRO L CABLE
BRAKE PIPE
CHOKE CABLE
BRA KE HOSE S
FINAL GEAR CASE BREATHER HOSES
INTAKE DUCT

• IRE CLAM P
• MAI N WIRE HAR NE SS
• REVERS E CONTROL CABLE
• HANDLEBAR SWITC H WIRE

• CABLE CLAMPS
• THROTTLE CABLE
• REAR (PAR KING BRAKE CABLE
• C HOKE CABLE

1-17
23
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