Honda Common Service Manual
Contents
1. er ee a 2 6 Date of Issue Sep 1988 HONDA MOTOR CO LTD MAINTENANCE Paper Elamant If the surface of the element is dirty remove the dust first by tapping the element gently Then blow away any remaining ust on the surface of the fitter with compressed aix from the inside lor carburetor sida toward the outside Viscous Paper Element This particular type of paper elemant cannot be cleaned as the element comains a dust adhesive These must be changed periodically AIR CLEANER CASE DRAIN TUBE off road motorcycles and ATVs Loosen the drain tube clip and remove the drain tube to empty any accumulation of fluids or dirt from the air cleaner case into a proper container Check the drain tube for damaga and replace Reinstall the drain tube and set the clip in plac CRANKCASE BREATHER es are equipped ent discharging crankcase emissions into the atmosphere Blow by gas is returned to the combus tion chamber through the air cleaner and carburetor A breather separator is necessary within the system to prevent moisture from contaminating the engine Vapor is allowed to pass through the air cleaner and into the engine to be burned Off Moisture is collected in a sealed drain tube Periodic maintenance is to remove the drain plug and drain deposits in to suitable container then reinstall the drain plug A portian of the drain tube is transparent so itis eesy to con firm the amount of accum2. Others use a spe tool to remove and install the master li ke The outer plate of this type of master link is secured by expan ding the ends of the pins with the special tool Position the masterlink clip so that its open end is opposite the normal rotation of the chain This prevents the clip being knocked off through contact with the chain guide or passing objects Check that the clip is fully seated CAUTION Improper positioning af the masterliak may cause the dive chain to come apart and possibly damage the crankcase rear wheel or exhaust 2 Date of Issue Sep 1988 22 HONDA MOTOR CO LTD MAINTENANCE Check that each chain link pivots freely on the pins Where binding is light apply a litle cleaning oil or paraffine making sure that it penetrates When the stiffness has been removed lubricate the chain On chains with O ring quickly wipe off the cleaning fluid ar paraffin oil and thoroughly dry the ch Replace tha chain if stiffness of the chain cannot be alleviated the movement of the links is not smooth or thera is damage tc the link plates or rollers Master links with O rings have 4 O rings fitted between rollers and master link plates Install tha O rings as shown in the illustration to the right and fit the chain lip to the pins Be sure there is no gap between the master link plate and the clip Cleaning and Lubrication Adherence of mud and dirt and tack of
3. or wire harm If these are not the cause check for wear or damage to the steering head beatings Check for misalignment of the tront wheel with respact to the handlebar tf the wheel is out of alignment loosen the wheel and fork assembly bolts nuts align and re tighten If the wheal cannot be aligned check for bent suspension components or a bent frame It the handlebar shows unusual shake during normal running Conditions check the handlebar mounting fasteners and whee ete Tum the handlebar fully from left to right and vice versa to check that there is no difference betwaan the two directions of movement Check also that there is no interference between the handlebar and frame Also inspect for snagging of wires and harnesses on the fork stops on the lower fork bridge Jt the handlebar moves unevanly binds or has vertical move mant adjust the steering head bearings by turning the stesring bearing adjustment nut Refer to the Model Specific manual for Proper procedure Date of Issue Sep 1988 2 38 HONDA MOTOR CO LTD MAINTENANCE WHEEL ALIGNMENT FOUR TRAX On FOUR TRAX models inspect and adjust the front wheel alignment toe in camber and casterl as necessary TOE IN Place the vehicle on level ground with the front wheels facing straight ahead Mark the centers of the tires with chalk to indicata the axle center height Align the toe in gauge with the marks
4. On motorcycles that have a decompression mechanism which lifts the valve when starting the engine the ad justment for decompression must be carried out first in Order to provida an accurate valve clearance inspection FEELER GAUGE VALVE STEM Valve clearance inspection on engines with common screw type adjusters is measured by inserting a fealor gauge directly between the end of valve stem and the adjusting screw In the case of one sided ball joint type engines the clearance is measured by inserting the feeler gauge between the rocker CAM LOBE FEELER arm and the cam In the case of valve litters in direct push type enginas the clearance between the cam lobe and lifter or chim is measured with a fooler gauge ADJUSTING SHIM M adjustment is needed loosen the lock nut end the adjusting scrow and insert tha proper dimension feeler gauge Proper in ve take and exhaust valve clearance dimensions aro given in the Model Specific manual Turn the adjusting scraw and adjust the clearance unti the in ADJUSTING SCREW am Sartad feeler gauge can only be pulled out with a litte tock NUT ADJUSTER difficulty A pes Leaving the feeler gauge inserted and being caratul not to turn the adjusting screw tighten tha lock nut to the designated torque CAUTION WRENCH Animprenany d htened tok rat may loan and cause a Be sure to use any special tools specified for valve adju
5. crack as a result l Specific gravity of fluid Checks are unnecessary in tha case of MF Maintenance Free batteries The specific gravity of the battery fluid should be checked on onen type batteries Measure the specific gravity of each cell with a hydrameter Specific gravity of fluid at 20 C 68 F Fuily charged condition 1 27 1 29 Low charge condition 1 23 and below BATTERY FLUID 30 jy BATTERY TEMPERATURE VS SPECIFIC GRAVITY ELECTROLYTE TEMPERATURE 2 26 Date of Issue Sep 1988 HONDA MOTOR CO LTD MAINTENANCE MAINTENANCE NOTE If the difference in specific gravity between cells ex ceeds 0 01 ra charge the battery If the difference in specific gravity is excessive raplace the battery There is a change in specific gravity of approximately 0 007 per 10 C change in temperature Be sure to con sider this when taking measurements Reading of the hydrometer s fluid level should be taken in the horizontal position Refer to section 22 for details of battery testing and charging Condition of terminal connections Make sure that terminal connections are not loose If corrosion is evident remove the battory wash rust with warm water and use a wire brush to remove completely Reconnect the battery and lightly cost the terminals with grease WIRE BRUSH BRAKE FLUID Firmly apply tha brake and chec
6. level is up to the lower edge of the bolt hole Refill o the lower edge of the cil level check boit hole with the e recommended oil if the level is low NOTE Gil level checks should be carriad out on level ground SEALING WASHER with the vehicle om the center stand or while in an L UPright position In scooters check for leakage and oil level of the final reduc tion gear case in the same way as for the engine Remove the level hole cap from the gear case and check whether the oil level comes up to lower edge of the hole tf the lovel is low refill to the lower edge of the hole with the recom mended oil NOTE Oll level chacks should be carried out on level ground with the vehicle on the center stand or while in an CHECK BOLT HOLE Two stroke engine transmission lubrication is achieved by the spray of transmission oil within the sealed crankcase Com OIL FILLER Consult the Model Spacific manual for the proper oll change d CAP interval CHECK connecr BOLT Olt LEVEL ine oil may cause ekin cancer i repeatedly lef in contact with the skin for protonged periods Although this is unlikely unless you handle used ol on a daily asia iis etl advisable to wash your hands with soap to soon a possible after handling used oj SEALING NOTE BOLT WASHERS on mavens IT sds ce Remove the oit filer cap Remove the drain bolt located at the bottom of t
7. low refill to the lowor edge of the hole with the recommended oil NOTE Oil level checks should be carried out on level ground with the vehicle on tho canter stand OIL CHANGE Refer to the Modal Specific service manual for information on the oil changa interval Remove the lavet hole cap from the final gear case Remove the oil drain bolt from the lower portion of the gear case slowly turn tha rear wheel and drain the oil When the oil is completely drained clean the drain bolt replace the sealing washer and tighten to the specitied torque NOTE Replace the sealing washer if it is damaged l Refill to tha prescribed level with tha recommended oil Cont the leval hole cap O ring with cil and replace the cap Tighten the cap to the specifiad torque MAINTENANCE AIR CLEANER INSPECTION CAP DRAIN BOLT SEALING WASHER ee Date of Issue Sep 1988 6 HONDA MOTOR CO LTD 2 25 MAINTENANCE BATTERY Fluid teve Battery fluid level checks sro unnecessary on MF Maintenance Free batteries Open type batteries should ba checkad for fluid level Do not allow battery fluid sulphuric acid ta come into contact with the skin eyes or clothes as it will cause burning If acid is spilled on you be sure to wash off auickly with large amounts of water If battery
8. lubrication severely shortens the life of the chain Cleaning and lubrication should therefore be carried out periadically Chains with O rings CAUTION Chains with O rings should not be treated to the follow Ing cleaning and oiling procedure This treatment will degradation of the O rings and loss of grease thus chain tite 1am or a high pressure water washing Use a chain spray containing a cleaning agent or use gasoline to clean the chain Clean dirt off the chain with suitable detergent dry completaly and thoroughly and apply 80 90 gear olf Wipe oft excass oil to prevent it from flinging off when in operation Chains without O rings Remove dirt fram the chain with cleaning oil or paraffin dry completely and thoroughly and apply 80 90 gear oil or a Suitable spray on chain lubricant Wine off the excess oil to prevent it from flinging off when in operation Check for wa and damage to the drive and driven sprockets CAUTION Bo sure to replace the chain and sprockets as a set The combination of an elongated chain and new sprocketls or the combination of a warn sprockatie and a new chain will result in rapid wear of the new components Check for looseness af the attachment bolts or nuts on the drive and driven sprackets and if loose re tighten KINKING or MASTER BINDING LINK CHAIN CLP O RINGS CLEAN WIPE ANO DRY GEAR Ol SAE
9. moving farther forward to support the motorcycle as the rubber touches the ground When the motorcycle is lifted upright the stand should ily move to tha first position and retract when kick If the side stand does not move freely disassemble it Remove tho return spring at the retracted position Remove the pivot bolt and remove the side stand assembly from the frome Check the following parts for wear or damage inside of the pivot and pivot collar pivot dust seals Lubricate the pivot area with clean grease and reassemble the side stand CAUTION Install tho dust seal with its mark side facing in Make sura thet tho dust saal spring is seated on the out side of the after installing the pivot collar Recheck the side stand movement SIDE STAND RUBBER FIRST POSITION RETURN SPRING WASHER DUST SEALS PIVOT COLLAR Date of Issue Sep 1888 HONDA MOTOR CO LTD 2 33 MAINTENANCE Inspection For Side Stand With Ignition Cut off Switch Check the spring for damage or loss of tension Check the sida stand assembly for freadom of movement Lubricate the pivot bolt and the side stand pivot area if necessary Tighten the pivot bolt and nut Refer to the Model Specific manual for specified torque Check the side stand ignition cut off switch Sit astride the motorcycle and raise the side stand Start the engina wi
10. stops and that tho axle is in proper alignment Always check to be sure both sides are adjusted to the same marks on the L__ diustment scales Re check the chain play Tighten the adjusters and lack nuts Adjust the rear brake pedal play This step con be omitted in the case of disc brakes Adjust the rear brake light switch actuation point fon cable operated rear drum brake models If after adjustment the adjuster s alignment mark is within the red zone ot the chain wear indicator label replace the drive chain and both sprockets Only for vehicles with an indicator label affixed NOTE T Away replace bath sprockets when replacing he dive chal for optimum wear characteristics Alter replacing and adjusting the drive chain attach s wear in dicator label sa that the alignment mark is at the start of the green zone On models without a drive chain wear indicstors measure the length between the chain s pins as shown in the figura and aplace the chain if the prescribed limits aro exceeded Drive chain length 41 pins 40 links CHAIN Size PITCH STANDARD SERVICE UNIT CODE mm m mmm mm fin 115 420 428 12 70 0 500 08 20 9 Sri 207 520 626 50 15 875 0 625 635 24 0 638 i25 LUI 630 19 06 0 750 762 30 0 766 30 2 lt CHAIN CLIP Soria endless chine require removal of ha eningem forte povaring chain replacement
11. to allow adjustment Loosen the lack nut and turn the adjustar to correct the play CAUTION The adjuster may be damage out leaving eee imal thread engagement When more than 8 mm of thread is showing screw the ad juster in most but not all the way and make adjustments on the clutch arm end of the cable On models with the adjuster located within the length of the abla i e not at the end loosen the tack nut and turn the ad juster to alter the play in the same manner es described above On centrifugal clutch Loosen the lock nut tighten the adjuster bolt by about 1 turn then screw it back in until pressure is felt on the boit From this position loosen the bolt 1 8 to 1 4 of a turn and tighten the lock nut NOTE When tightening the lock nut be sure that the adjuster bolt does not turn with i Check the operation of the clutch after adjustment Clutch fluid love Adjustmant for play cannot be made on hydraulic clutches Howaver a check should be mado of the fiuid level It the level is naar the LOWER limit inscribed on the reservoi remove the reservoir cover and diaphragm and refill to the UP PER lavel with tha proper type of fluid Before removing the raservoir cover turn the handlebar until the reservoir is level Place a rag over painted plastic or rubber parts whenever the system is serviced CAUTION Splling fluid on p damage them red
12. 0 the comparatively large volume of oll 4 stroke Wet Sump Engine Start the engine and let it idle for few minutes Stop the engine remove the oi level gauge and wipe the oi from the gauge with a clean cloth Two of three minutas after stopping the engine with the motorcycle in an upright position insert the leve gauge into the angine without screwing it in The engine contains a sufficient amount of oil if the level is between the upper and lower lines on tha gauge If the oil level is near or below the lower lino add the recom mended engine cil up to the upper line Refer to the Model Specific manual for the recommended oil lt DIRECT PUSH TYPES OIL LEVEL CHECK DO NOT OIL CAP SCRE LEVEL s UPPER LINE LOWER LINE GAUGE Date of Issue Sen 1988 HONDA MOTOR CO LTD 2 11 MAINTENANCE es 5 4 stroke Dry Sump Engines Start the engine and allow the engine oil to warm up thoroughly NOTE Do not snap the throttle or the oil level reading will be inaccurate Allow the engins to idle for about 3 minutes and stop the LEVEL GAUGE OWL TANK engine Remove the oil level gauge immediately and wipe it clan With the motorcycle in an upright position on a level sur face check the ail level by inserting the gauge into the oll tank without screwing it in The engine contains a sufficient amount of oil if the oil lev
13. 80 OF 90 GEAR Oit SAE 80 OR 901 Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 23 MAINTENANCE DRIVE CHAIN SLIDER CHAIN GUIDE GUIDE SLIDER AND ROLLERS Together the drive chain stider chain guide guide stider and rollers all do their part to keep the chain cunning in its proper Path while prevanting it from cutting into the swingarm frame or other components Each of these components is made of a type of plastic that cf fers minimal friction and wear Still periodic inspection for wear or damage and replacemant is necessary as these parts deteriorate The chain slider attached to the front of the swingarm near is Pivot point must ba replaced when the depth of its waar grooves reaches a dapth specified for each particular model Failure to replace a worn slider will rasutt in chain damage to tha swingarm and damage to the chain Off road and dual purpose motorcycles are fitted with a chain Guide that ansures that the chain is guided directly to raar sprocket The guide itself should bo checked for proper align Ment aa it can be bent through contact with passing objects Tocks or crash damage Straighten or replace as necessary A plastic guide slider centers the quide on the sprocket with minimal friction and prevents the chain from wearing the guide A wear window is often provided to aid in determining a A lower chain roller or pair of upper and lower
14. Cartridge type oil filters are removed using e filter wrench Clean the filter araa of the engine with a clean cloth Spread engine oil thinly over the O ring of the new filter and at tach filter to the engine Tighten the oil filter with the proper filter wrench xj Oil Filter Wranch For small type cartridgel For large type cartridge 07HAA PJ70100 07912 6110001 Torque Smai type cortr dg Larga type cartridg 10 Nem 1 0 kg m 7 flbi 18 Nem 1 8 kg m 13 fib Confirm that there is no oll leakage by starting the engine after the engine oil has been set at its proper level Run the engine for about a minute then caratully for leaks stop it and inspect Element Type Paper Fitter Remove the oil filter covar and replace the filter element Reinstall the cover with a new O ring NOTE 7 Install the element with the rubber s making sure thet tha spring is in ment and crankco Replace the O ring on the fiter cover with anew one side facing out led between the elo Renleriish the engine oil with the proper type and viscosity and to the proper level Always tun the engine and check for o leaks after an oil or oil and filter change ENGINE OIL FILTER SCREEN Check to see if there is any dirt or debris on the oil filter screen which might hinder the flow of oil Remove and clean the Screen in solvent if any deposits are found on the screen R
15. Check for looseness of boltsinuts in connection with the following Axles Axle nuts Rimihub bolts On modals that have cottar pins check that the pins are at tached correctly Check for cracks deformation damage and carrasion etc of the following parts Rim Wheel Spokes Raise the wheel turn slowly and check far lateral and vertical oscillation Usable limit front and rear wheels Lateral direction Up to 2 0 mm 0 08 inj Varticl diraction Up to 2 0 mm 0 08 in Oscillation of Comstar or cast wheels cannot be corrected Therefore check for besring play or a bent axle shaft If necessary replace the wheel assembly If there ia deformation of the rim on spoked wheels replace the rim Jot the spokes for looseness by topping them with a serewdriv If a spoke does not sound claarly or if it sounds different from the other spokes tighten it Tap on the spokes and be sure that the clear metallic sound of the same tone can be heard on all spokes NOTE The spoke nipples are made of soft material Be sure to tighten tho spokes with the proper size spoke wrench After tightening check the rim for runout lH Check the pressure of each tire with a prossure gauge Check tire pressures when the tires are cold to assure ac curate comparative measurements Checking tires after they are warm will give inaccurate readings steering response and may result in a sudden
16. Check the oil fina for leaks detarioration or damage Replace parts if necessary strainer Loosen the tube clip located on the bottom of the oil tank Drain oil into a suitable container Remove the oil strainer joint fram the bottom of the tank Remove the strainer screen THROTTLE CABLE CARBURETOR ADJUSTER CES tocknut 5 4 177 CONTROL ARM OIL STRAINER rl OIL TUBE TUDE CLP en i s OIL STRAINER M JOINT on B 2 4 Date of Issue Sep 1988 HONDA MOTOR CO LTD MAINTENANCE Clean strainer screen by blowing it out with compressed ait To replace screen reverse the removal procedure After pouring 2 stroke engine oit back into the tank be sure to remove the air in both oil tube and oil pump See page 4 11 OIL STRAINER strainer cleaning and oil procedures tube and pump air bleed CARBURETOR CHOKE MANUAL CHOKE On the manual choke system check to see if the choke lever IOKE LEVER or knob can be opanad and closed completely 2 inspect the choke cable to see if itis bent crimped or damaged in any way lide operation and may i lead ta a loss of throttia control while riding Check to he suro that cable movement is correct on machines with manually operated choke Check by pushing with your finger to see if there is a maximum of 1 2 mm of free play in the inner choka cable when th
17. KE SYSTEM INSPECTION FOR AIR IN SYSTEM On hydraulic brakes firmly apply the brake lever or pedal and check that no air has entered the system If tha lever or pedal feels soft or sponay when operated bleed the air from the system FREE PLAY ADJUSTMENT On mechanical brakes measure the free play at the tip of the brake lever or pedal as indicated here and below Brake pedals on scooters should be measured for free play as Indicatad hi Make adjustments for free play on cable oparated brakes at the end of the cable Mejor adjustments cablo Loosen the lock nut and turn the adjuster nut to correct play at the le made on the brake penel end of the NOTE If the upper adjuster on the lever is screwed in most but not all the way before adjustment is carried out subsequent adjustment by use of tho uppor adjuster can be conducted more easily When the brake cable is fastened to the fork by a clamp i doosen the clamp batora making brake adjustments Secure the adjuster nut and tighten the lock nut on completion of adjustment Be certain to tighten the fork cable clamp as well In cases where there is only an adjuster nut as on many rear brakes turn the nut to adjust the brake pedal free play NOTI The adjuster nut s indentation and brake arm pin should seat against one another as shawn here in the upper right portion of the illustration to the right If they do not seat there may
18. WS Be sure that the muffler fd bolts and gasket are in qood condi tion Replace the bolts and gaskat if necessary Install the muffler id and gasket and tighten the bolts securely NOTE Do not remove the two screws that hold the exhaust baffle in the ond of the spark arrester muffler The two mounting screws must be installed in the spark arrestor body at all times for the spark arrester to be effective ae GaskeT Se MUFFLER LID ARRESTER BOLTS NUTS BOLTS FASTENERS Check that all chassis nuts bolts and screws are tightened to their correct torque values at the intervals shown in the Maintenance Schedule Check all cotter pins slip pins hose clamps and cable stays WHEELS TIRES Making sure the fork is not allowed to move raise the front wheel and check for play Turn the whee and check that it rotates smoothly with no unusual noises It faults are found inspect the wheel bearings Raise the rear wheel and check for play in either the wheel or the swingarm pivot Turn the whee and check that it rotates smoothly with no unusual noises If abnormat conditions are suspected check the rear wheel bearings NOTE As the swingatm pivot is included in this check be sure to confirm the location of the play i e from the wheet beatings or the swingarm pivat 2 36 Date of Issue Sap 1988 3 HONDA MOTOR CO LTD MAINTENANCE
19. a e 2 MAINTENANCE FUEL LINE FUEL STRAINER SCREEN THROTTLE OPERATION OIL PUMP AND OIL LINE 2 stroke separate oil supply motorcycles CARBURETOR CHOKE AIR CLEANER AIR CLEANER CASE DRAIN TUBE off road motorcycles and ATVs CRANKCASE BREATHER SPARK PLUG VALVE CLEARANCE ENGINE OtL ENGINE OIL FILTER ENGINE OIL FILTER SCREEN DECARBONIZING 2 stroke engine CARBURETOR SYNCHRONIZATION CARBURETOR IDLE SPEED RADIATOR COOLANT COOLING SYSTEM SECONDARY AIR SUPPLY SYSTEM EVAPORATIVE EMISSION CONTROL SYSTEM TRANSMISSION OIL 2 stroke engine 22 22 24 25 2 6 27 27 28 29 211 2 13 2 14 2 15 2 16 217 2 37 218 219 2 19 2 20 DRIVE CHAIN 221 DRIVE CHAIN SLIDER CHAIN GUIDE GUIDE SLIDER AND ROLLERS 2 24 DRIVE BELT 2 24 BELT CASE AIR CLEANER 2 25 FINAL DRIVE OIL LEVEL 2 25 BATTERY 2 26 BRAKE FLUID 2 27 BRAKE SHOE WEAR 2 28 BRAKE PAD WEAR 2 28 BRAKE SYSTEM 2 28 BRAKE LIGHT SWITCHES 2 30 HEADLIGHT AIM 2 31 CLUTCH SYSTEM 231 SIDESTAND 2 33 SUSPENSION 2 34 SPARK ARRESTER USA only 2 35 NUTS BOLTS FASTENERS 2 36 WHEELS TIRES 2 36 STEERING HEAD BEARINGS 2 38 WHEEL ALIGNMENT FOUR TRAX 2 39 NOTE This section covers the normal inspections and adjustments that are necessary to maintain the vehicle in qood condi tion Perform this maintenance at each scheduled maintenance period Refer to the Model Specific manual for the pro per maintenance schedule and applicab
20. be a chenge in brake play whan the ad juster finally seats in its proper position Chack for play after adjustment BRAKE LEVER BRAKE PEDAL ADJUSTER BRAKE PANEL ADJUSTER NUT Bn C P Date of Issue Sap 1988 HONDA MOTOR CO LTD 2 29 MAINTENANCE Minor adjustment is made at the lever end of the cable It is necessary to tum back the lever dust boot to g to the adjuster NOTE There may be damage to the adjuster if it is positioned 100 far out leaving minimal thread engagement Whan there is more than 8 mm of threads showing screw in The adjuster most but not all the way and make ad justments an the brake panel end of the cable Check for looseness of the following SRAKEROD Brake lever and pedal fasteners and adjuster lock nuts 1 Brake torque rod fasteners Broke rod cable imecharically operated drum brake Broke arm mechanical linkage drum brake Caliper attachment bolt thydrautic disc brake Check that the cotter pins on the brake rod torque rod etc are securely in place Opurate brakes independently while riding in order to deter mine the effectiveness of each brake COTTER PINS etsy PEDAL HEIGHT ADJUSTER BOLT LOCK NUT BRAKE LIGHT SWITCHES Check the brake light switch operation and adjustment by ap plying the brakas Visually inspect tor any damage and make S
21. dition disassemble and replace parts as necessary NOTE Replace any fork tube that is heavily scored 2 34 Date of Issue Sep 1988 HONDA MOTOR CO LTD MAINTENANCE On moiels with bottom link type front suspension check for cracks and damage to the fork rocker arms bottom Finks Check for play in the fork rocker arm bearing section and in spect all fasteners for looseness Check for oil leakage around the shock absorber Inspect the rod for scoring wear and peeling of the chrome plating on the working surface Check for looseness cracks and damage to the attachment points of tha shock absorber assembly Re tighten nuts bolts if necessary SPARK ARRESTER USA only Walt until the pipe has cooled before removing or install lid Touching the hot exhaust may result Partorm this operation in well veniated area tee from combustible materials Carbon particles may blow out of the clean out hola whan performing this service Wear safety glossas to prevent possible eve injuries j Remove the mulier tid Block the end of the muffler with a shop towel Start engine and rev it up to blow accumulated carbon deposits out of the muffler Date of Issue San 1988 HONDA MOTOR CO LTD PIVOTS amp FORK ROCKER ARM NS SHOCK ABSORBER MUFFLER LID MAINTENANCE SS es er SCRE
22. e choke lavor is in its completely off position i the amount of free play is not sufficient loosen the cabl clamp by moving The position of the outer cable Tighten the cable clamp curely when the adjustment is complete BYSTARTER CHOKE The choke action on motorcycles equipped with auto by starter type choke system can be checked by the way engine starts ond runs NOTE Difficulty in starting bofore itis warmed up ea5y once it is warmed up starter valve is not completely opened tof j Idle speed is erratic evan after warm up limperfect com bustionk starter valve is not completely closed oni When the above mentioned symptoms occur inspect and overhaul the choke system according to the procedures specified in tha Model Specific manual If you find nothing wrong with it proceed with the overhaul of the other items on the breakdown diagnosis list ee Date of Issue Sap 1988 HONDA MOTOR CO LTD 2 5 MAINTENANCE AIR CLEANER When the element becomes dirty the air fuel mixture will become too eich Periodic cleaning or replacament is necessary Vehicles used in dusty areas require more frequent inspections When replacing the air cleaner element be careful of the following points NOTE W the semen joint Pas s rubber seal a it wi become mora aight fa smell amount of gree nap Plod tote seal Check to see that both th ar cleaner and th older are rope s
23. ed opening closing type throttle the adjustment of free play can be made by loosening the lock nut on the pull side of the cable and turning tha adjuster i Tighten tha lock nut after the adjustment has besn made Date of Issue Sep 1888 HONDA MOTCR CO LTD 2 3 MAINTENANCE If the throttle cable has an adjuster anywhere within its length besides the ends major adjustmant is made there Adjust the frae play by loosaning the lack aut and turning the adjuster Tighten the lock nut after the adjustment has been made If the adjuster has a boot reposition it properly after adjust ment is made OIL PUMP AND OIL LINE 2 stroke separate oil supply motorcycles The oil supply on some 2 strokes is controlled by e throttle cable that is coupled with an eil pump Gil flow is regulated in a direct relation to thrattle movement and position by combined oi control throttie cable that simultaneously moves the throttle slide in the carburetor and a control arm on the oit pump When the innar cable of the olf control cable stratches the amount of the cil flow changes and is not suitable for the size of throttle opening Theratore it is necessary to inspect end rwadjust it periodically Thore is matching mark on the oil pump thet must be aligned with the matching mark on the control arm pump body etc Hofer to the Model Specitic manual before making any adjustments Oil lina
24. eep your hands and clothing awe from the cooling fan It may start automatically without waming YORICLE EMISSION CONTROL INFORMATION UPOATE MONZA MOTOR CQ LI ms varus m amp m LS IMPROVE EMISSION CONTROL PERFORMANCE WU WIN OPERATED WI Moi ALTITUDE ALTITUDE PERFORMANCE ADUISTMEXT STRICTIS ME AVAILABLE AT TOUR AUTWIMIED VOMOA DEALER NOTE Fuel vapor from the fuel tank is directed into the charcoal canister whila tha engine is stopped When the engine is running the purge control valve opens end fuel vapor in the charcoal canister is drawn into the engine through the carburetor The tubes deteriorate naturally due to wear and time Check the condition of these tubes at the intervals spacitied in the Model Specific manual Check the hoses between the fusi tank canister purge control valve PCV air vent control valve and carburetors for deterioration damaga or loose connections Chack the charcoal canister for cracks or other damage Refer to the vacuum routing disgram iabel for hose connections Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 19 MAINTENANCE TRANSMISSION OIL 2 stroke engine Check for cil leakage over all sections of the transmission Check the oil level LEVEL Excessive oil leakage necessitates disassembly CORRECT CHECK BOLT With the engine stopped remove the oil check bolt and make id Sure that the oil
25. efer to the Model Specific manual foc cil fitter screen removal cleaning and installation procedures for specific models 2 14 RUBBER OIL FILTER COVER SPRING ILTER ELEMENT O RING Date of Issue Sep 1988 HONDA MOTOR CO LTO MAINTENANCE DECARBONIZING 2 stroke engine Carbon accumulation accurs mare rapidly in 2 stroke engines than 4 stroke engines because 2 stroke engines burn engine oil If the build up of carbon is not removed periodically the carbon accumulation increases to an excessive amount caus ing hot spots on the cylinder head and pisten crown This may cause knocking due to praignition and may cause poor engine performance Accumulated carbon in the exhaust port hinders the flow of the exhaust causing a drop in power output Therafore removal of accumulated carbon should be perform ad according to the maintenance schedule in the Model Specific manual CAUTION When removing carbon be caraful not to damage the combustion chamber piston and cylinder Take off the cylinder head and remove the carbon from the piston crown whan the piston is in the ton dead center position Remove carbon from the combustion chamber area of the cylinder head Take off tha cylinder and remove accurnulated carbon trom the walls of the exhaust port Fomove uny remaining carbon within the cylinder In liquid coaled engines be sure to remova carbon part
26. el is between the upper and lower lines on the gauge I the oil level is near or below the lower lino add the recom mended engine oil up to the upper line See the Model Specific manual for the recommended oil Louk inspection Inspect to see that there is no oil engine oil oll hoses etc It any oil leaks are detected perform the proper maintenance to correct the problem king from any part of the Oll Change In 4 stroke enginas sludge can build up due in part to the gas which blows past the piston rings and the gasoline composi tion contaminates the oil causing a weakening of oll s perfor mance To alleviate this contamination problem change the cil periodically Because many newly machined surfaces are moving against One another for the first time in now motorcycle engines s noticeable amount of powdered metal circulates with the oil during this early stage af use Therefore it is extremely important to change the engine oi and to replace the oil filter or clean the oil strainer screen at the first maintenance interval aftar 1 000 km 600 miles in arder to prolong engine fife See the Model Specific manual for oil change intervals NOTE Draining the engine oil while itis still warm is the most rapid and efficient method OO Date of lesue Sap 1988 2 12 HONDA MOTOR CO LTD MAINTENANCE Remove either the oil level gauge or fi
27. fluid enters the eyes wash with water and coneult a physician Check for cracks in the battery cai f the battery s electrodes show accumulation of s white substance sulphation or heavy deposits are observed at the base of the battery the battery should be replaced Check the level of each cell by the UPPER and LOWER level lines inscribed on the side of tha battery IM levels are approaching the LOWER level line remove the bat tary take off the filler caps and refill to the UPPER level with distilled water Check the battery capacity with a battery tester page 22 9 If the battery tester is not available check the gravity of the battery fluid see below CAUTION UPPER LEVEL LINE LOWER LEVEL LINE DISTILLED WATER contains minerals that wil shorten the life of tho battery Filling the battery above the UPPER leve mark may cause spillage while riding and subsequent corrosion of LL _vehicte pares KI After refiling replace aach of the filler caps firmly and re install the battery Always refill battariee with distilled water Top water Follow the instructions on the battary s CAUTION label Make aure that the breather tube Is correctly positioned and not inked trapped or bent in such a way as to obstruct the passage of air CAUTION I the tuba is blocked the battery e internal pressure wil not be relleved the breather may come off or the bat tery could
28. having an adjusting screw on the side of headlight Tim turn this screw to make the horizontal adjustment On some models the headlight is completely encased The ad justment can be made elther with the light beam adjustment knob on the back af the light case or with a remote type cable and knob Refer to the Model Specific manual for the proper adjustment method CLUTCH SYSTEM Check the play at the ond of the lever on cable operated clutches A lot of play results in clutch drag and stiffness in operation of the shift pedal Too little play however rasults in clutch slippage When the clutch play is not adjusted within the prescribed amount correct this using the adjuster locatad at the end of the cable Major adjustment is carried out at the clutch arm Loosen the lack nut and turn the adjuster nut to adjust play NOTE Before adjusting cable play et the clutch arm screw the adjuster at the lever end of the cable in most but not all the way This makes subsequent adjustment at the lever end easier After adjustment is complete hold the adjuster nut securely while tightening lock mut ADJUSTING BRAKE I PEDAL ee L PUNCH MARKS CLUTCH LEVER ADJUSTER Lock NUT Date of Issue Sep 1988 HONDA MOTOR CO LTD MAINTENANCE Minor adjustments are mada at the lever On models equigped with a dust caver turn back the cover
29. he base cerburetor s in take port and the vacuum in the other carburetor s intake ort js below the specification Refer to the Model Specific manual for base carburetor location of each synchroniza tion adjusting screw and difference in vacuum between the carburetors 3 Be sure that the synchronization is stable by snapping the throttle grip sevaral times 4 Repeat steps 1 through 3 for each carburetor 5 Snap the throttle grip several times and recheck the idle speed and differences in vacuum between each carburetor cue VACUUM GAUGE SYNCHRONIZATION ADJUSTING SCREWS uf 2 16 Date of ssua Sep 1988 HONDA MOTOR CO LO CARBURETOR IDLE SPEED Check for any unusual noise while the angine is idling If noise is detected investigate with a stethoscope to locate the source Carry out the appropriate maintenance inspection depending on results of noise investigation Check to see that the engine speed increases smoothly from idle Check the idle speed and adjust if necassary by turning The throttle stop screw NOTE MAINTENANCE THROTTLE STOP m Check and adjust after first warming up the engine There are differences in idle speed between hot and cold engines Place the vehicle on the centar stand or support upright on level ground when checking end adjusting the idle speed If the vehicla is tiked there wil be fluctua
30. he crankcase and drain the oil When ali the oil is drained ciean the drain bolt with its sealing washer and tighten to the designated torque NOTE e mara eoaca a eeatng washer Wik donee Remave the oil check boit and refill to the prescribed level with the recommanded oil Replace the check bolt or cap 2 20 Date of Issue Sep 1998 z HONDA MOTOR CO LTD MAINTENANCE DRIVE CHAIN ADJUSTMENT the engine is running Imepecthg the dive chai wii cam resin serious hand o finger ju When there is too little slack a change in the distance bet een sprocket centers due ta suspension movement results in excessive tension on the chain In this condition the chain and transmission or crankcase may be darnaged and the large amount of friction adversely effects the running performance of the vehicle Too excessive slack in the chain leads to large oscillations whan the vehicle is running n this condition the chain may come off the sprockets or damage parts it contacts With the vehicle in neutral support on the center ot side stand Some models need to be checked with the rear wheel raised Reefer to the Model Specific sorvice manual for details Check the slack in the chain at the mid point between the two sprockets On models with a chain tensioner loosen the tensioner before checking Carty out the following procedure for adjustment Loosen the i axle nut un
31. icles that may have fallen into the coolant jackets around the cylinder by blowing them out with compressed air Refer to tha Model Specific manua for the proper procedures for cylinder and cylinder head removal and installation PISTON HEAD CHAMBER EXHAUST PORT Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 15 MAINTENANCE CARBURETOR SYNCHRONIZATION NOTE Carburetor synchronization adjustment is required to ad just the throttle valvo opening and to synchroniza the vacuum in each carbureter s intake port whenever 2 or more carburetors are reassembled Synchronize the cacburetors with the engine at normal operating temperature the transmission in neutral and the motorcycle on its center stand Carburetor numbers match the cylinder number j Remove the plugs from each cylinder head port and install the Vacuum gauge adapters If the motorcycle is equipped with the fug auto valve discon noct the vacuum tube from the intake manifold of the car buretor draw vacuum and pinch the tube with a clip as shown Connect the vacuum gauge Vacuum Gauge 07404 0030000 for both two and four carburetor engines 07404 0020000 for dual carburetor engines 1 Adjust the idle tpm to the specified idle speed Rater to the Model Specific manual for the specitication 2 Tum the synchronization adjusting screw so that the dif ference between the vacuum in t
32. k for fluid leakage from the br tern If thera is any leakage of fluid from any part of m quickly raplace the damaged parts Check for degradation and damage of the hoses pipes and joints Check for looseness of joints and clamps Also make sure that hoses and pipes do not come into contact with mechanical parts when the fork is turned or due to vibration when tho vehicle is running Before removing the reservoir cove the reservoir is lovet Place a rag over painted plastic or rubber parts whenever the aystem is serviced turn the hondleber until CAUTION Brake T wa argo ed plastic or rubber parts Refill with the recommended fluid Ig incompatibie fluids can impair braking efficiency Foreign materials can clog the system causing s reduc tion or complete loss of braking ability Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 27 MAINTENANCE COC When the fluid level is low i e near the LOWER level inscribed on the reservoir remove the reservoir cover and diaphragm and refill to the UPPER level Check the brake pads for wear when refilling with brake fluid A low fluid level may be due to wear of the brake pads If the Pads aro worn the caliper piston is pushed out and this ac counts for a low reservoir lavet I the brake pads are not worn and the fluid level is law check for leakage A leak in the br id to reduced braking efficiency and possib
33. l and hand tighten then tightan about 1 4 of a turn after the sealing washer contacts the seat of the plug hole Reused plugs should be tightaned to the specified torque Do not overtighten the spark plug CAUTION Overtightening the spark plug may damage the cylinder head Ba cure to use the proper spark plug torque CENTER ELECTRODE SIDE ELECTRODE INSULATOR SIDE ELECTRODE PLUG GAP SEALING WASHER eS 2 8 Date of Issue Sep 1988 HONDA MOTOR CO LTD MAINTENANCE VALVE CLEARANCE ADJUSTING Adjustment is unnecessary on motorcycles equipped with hydraulic lash adjusters hydrau amp c tappeti However ap propriate clearance is needed between both the intake and ex haust valves and the vaive opening closing mechanisms in all other 4 cycle engines This clearance allows a change in tha siza of the valve by thermal expansion as the heat of the com bustion chamber is transmitted to the valve H there is too much clearance it may result in engine teppet noise If there is too little clearance the valve is push 9d during the heated period causing a drop in compression resulting in bad idling and eventually burned valves NOTE Inspect and adjust the valve clearance when the engine INDEX CRANKSHAFT CRANKSHAFT is cool under 36 C 95 F MARK Inspection and adjustment of valva clearance should be per formed with the piston at to
34. le items Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 1 MAINTENANCE FUEL LINE Check the fuel line far Gasoline leakage Loose or improperly positioned line clip Dateriorated or damaged iine FUEL LINE Replace any defectiva parts N FUEL STRAINER SCREE sg Turn the fuel valve to OFF position O RING Remove the strainer cap below the fuel valve and drain the gasoline into a suitable container STRAINER SCREEN Gasolina is extremely flammable and s explosive under certain conditions STRAINER cup Work in a wail ventilated area Keep cigarettes flames or FUEL VALVE sparks away from the work area or any area where gasoline is store Remove the O ring and strainer screen Cian the cup and strainer scroen with non flammable or hi flash point solvent Raplace the O ring with 2 new one Reinstall the strainer screen O ring and cup than tighten the up to tha specified torque CAUTION Overtightening the cup may break or deform the O ring causing a fuel leak Turn the fuel valva to ON and check that there are no leaks 2 2 Date of Issue Sep 1988 HONDA MOTOR CO LTD MAINTENANCE THROTTLE OPERATION T Check for any deterioration or damage to the throttle cebl Check that the throttle autamatically closes completely in ail steering positions If the throttle grip does not return propert
35. le loss of braking ability Tha recommended brake fiuid differs according to models Cartan madais take DOT 4 and others take sither DOT 3 or DOT 4 Do not use DOT 3 standard brake fluld in a modal designated for DOT 4 brake failure may result i BRAKE SHOE WEAR I the wear indicator arrow aligns with the A mark on the brake panel when the brake is applied remove the wheel and brake panel and check for shoe we NOTE L WER M no adjustment remains before the wear indicator limi is reached this indicates excessive wear and the brake shoes need to bs replaced Specific brake shoe checks are listed in the Brakes section of the manual Inspect the brake drum for wear or damage any time you remove the whoel and brake panel If the broke drum shows any signs of cracking or excessive corrosion that cannot be removed with emery cloth be eure to replace it BRAKE PAD WEAR Replace pads as a sot if worn to the brake pad wear limit line for wear limit groove A quick visual inspection can be made at the leading edge of the pads where the disc enters the caliper However if this proves difficult a check can be made at the indicator on the cafiper marked by the arrow A INDICATOR isc WEAR LIMIT WEAR LIMIT LINES ROTATING DIRECTION LEADING SIDE 2 28 Date of issue Sep 1986 HONDA MOTOR CO LTD MAINTENANCE BRA
36. level is somewhere between the upper end lower lines or below the lower line add a 50 50 mixture of antifreeze and distilled water to the upper line See Caolent Mixture Prepara tion page 6 6 LOWER LINE RESERVE TANK Check to sea if there are any coolant leaks when the liquid level decreases very rapidly If the reserve tank becomes completely empty there is amp possibility of the air getting into the cooling system So be Sure to remove all air from tha cooling system as described on page 5 7 NOTE The eitoctiveness of coolant decreases with the ac cumulation of rust or if there is a change in the mixing proportion during usage Theretore for best perlor _mance change the coolant ragelary Sev page 51 COOLING SYSTEM BADIATOR FIN To pravent injury keep y is and clothing away from the cooling fan It may start eutomatically without _waming Check the radiator sir passages for clogging or damage straighten bent fins with a small flat blade screwdriver and omove insects mud or other obstructions with compressed air or low water pressure Replace the radiator if the air flow is restricted over more than 1 3 of the fin surface Remove the body panels and fuel tank and check for any i Coolant leakage from water pump wator hoses and hose joints Check for any deterioration or damage to the water hoses A rubber hose detariorates naturally aver ti
37. ller cap to allow rapid draining Remove the oil drain boit at the bottom of the crankcase and drain the oil Imm in contact with tha skin for prolonged perlods Although this is unlikaly unless you handle used oil on s daily basis it ia stil advisable to thoroughly wash your hands with soap as soon as possible after handing used oll After the cil is completely drained clean and install the drain bolt and sealing washer and tighten to the dasignated torque NOTE Replaco the sealing washer i t is damaged Pour the recommended engine oil into the engine through the il level gauge filer hole The oll filler hole and cap ore d from the oil level gauge on some engines Pour in the oil periodically checking with the leva gauge until the upper line on the gauge is reached Install and tighten the level gauge and or filler cap after replenishing ENGINE OIL FILTER Small dust particles and metal dust which do not filter through the nat type oil strainer screen are trapped by the paper oil filter When the filter is clogged the oll flow is reduced and contaminants may reach vatious parts of engine by way of the relist passage causing premature wear and possible damage SEALING WASHER Ww DRAIN BOLT OIL LEVEL OIL FILTER WRENCH Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 13 MAINTENANCE Cartridge Type Paper Fiter
38. me dus to heat and wear If the hose deteriorates too much it will rupture due to the pressure in the cooling system Squeeza the hose and look for cracks WATER HOSE 2 18 Date of Issue Sep 1988 m HONDA MOTOR CO LTD MAINTENANCE MAINTENANCE SECONDARY AIR SUPPLY SYSTEM xm _ To prevent injury keep your hands and clothing away from the cooling fan It may start automatically without warring NOTE The secondary air supply system introducas filtered air into the exhaust gases in the exhaust port The sacon dary aii is drawn into the exhaust port whenever there is amp negative pressure pulsa in the exhaust system This charged secondary air promotes burning af the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water Check the air supply tubes between the valve and exhaust ports for deterioration damage or loose connections Make Sure the tubes are not kinked pinched or cracked NOTE If the tubos show any signe of heat damage inspect the reed valve in the system for damage Check the vacuum hose between the intake pipe end valve for ration damage or a loose connection Mako sure the not kinked pinched or cracked Refer to the vacuum hose routing diagram label for hose connections EVAPORATIVE EMISSION CONTROL SYSTEM To prevent injury k
39. ocurd and donot contaln any dust or or Oiled Urethane Foor Element Remove the air cleaner from the holder and wash away any ac cumulated dust or dirt by gently squeezing it in non flammable or high flash point solvent Using gasoline or low flash paint solvents for cleaning purs may rest im a fre or explosion CAUTION T Cloning tha oloment with gasoline or any acid alkaline or organic volatile type oil may cause improper ignition daterlorat on of the element or a loosening of the ole ment adhesive AIR COVER AIR CASE em M CLEANER CLEANER ELEMENT CONNECTING TUBE WASH IN SOLVENT soueeze soak squeeze 980 90 for four strokes Honda 2 stroke oll for two strokes Be sure to allow the element to dry thoroughly before applying ail Otherwise the oil wilt be diluted by the solvent and the filtering ability of the filter wil ba much less affective Spread clean 80 90 gear oil 4 strokes Honda 2 stroke oil for 2 strokes on the element rubbing in thoroughly over the surface with both hands and then squeeze cut any excess cil CAUTION T Using air fitter ait when riding in extremely dusty condi tions prevents premature engine wear due to dust dirt drawn into the engine Apply air filtar oll tc the entire sur face of the element and rub it with both hands to saturate the element with oil Squeeze out excess oil
40. on the tires as shown Check the readings on the gauges scales Slowly move the vehicle back until the wheels have turned 180 so the marks on the tires are aligned with the gauga height on the rear side Measure the to point in on the rear part of the tires at tha same When the toe in is out of specification adjust it by changing the longth of the tie rods equally while measuring the toe in CAMBER CASTER Remove tho wheel cap cotter pin and front axle nut Install an attachment onto the front axle Put the camber and caster gauge onto the attachment Measuta the camber Set the turn gauge under the front wheels Measure the caster Camber and caster ate not adjustable If they are out of specification check the suspension and frama for damage and replace any parts necessary then recheck alignment TOE IN GAUGE ATTACHMENT Date of Issue Sep 1988 HONDA MOTOR CO LTD
41. p dead center of the compression Stroke This position can be abtained by confirming that there is slack in the rocker arm when the stampad T mark on the flywheel rotor and the index mark on the crankcase cover ere aligned If there is no slack in the rockar arm even when tha T mark and index mark are aligned it is because the piston is moving through the exhaust stroke to top dead center Turn the crankshaft one full rotation and match up the T mark again The piston will then be at the top of the compression stroke top dead center On in line 4 cylinder engines wit tiring order 1 2 4 3 the inspection of valve clearance can ba conducted by rotating the crankshaft twice Aftar the above procedure has been properly carried out the inspection and adjustment of all cylinders is complete n line 4 cylinder engines are numbered 1 2 3 4 starting from the left cylinder Cylinder at top of compression stroke Cylinder number n p x wem on fo Ms e E EX IN EX On V twin and V 4 engines inspection and adjustment are performed by glacing sach cylinder in the compression top dead center position Date of issue Sep 1988 HONDA MOTOR CO LTD 2 9 MAINTENANCE The valve clearance adjustment is correct when tha specified ADJUSTING SCREW fealer gauge fits snugly but the next size larger faeler gauge eee will not fit in NOTE
42. plastic or rubber parts Refill with the recommended of fluid CAUTION Mixing incompatible fluids can impair clutch operating efficiency Foreign materials can clog the sy tion or complete loss of clatch ability LOCK NUT ADJUSTER apuyster LOCK NUT CLUTCH ARM Lock NUT tower LEVEL LINE 2 32 Date of Issue Sep 1988 HONDA MOTOR CO LTD MAINTENANCE SIDE STAND Conventional Type Check the wear of the side stand rubber Replace it if it has become worn Support the motorcycle in an upright and fevel position using a support luse the center stand if available Hook a spring scala to the end of the side stand rubber and check the load before the stand starts moving Acceptable load measurements for side stands 2 3 kg 4 4 6 6 Ibs Road type 3 5 kg 6 6 11 0 Ibs On Off Road type If the stand moves too easily tighten the pivot bolt and recheck If it still does not have the required tension measure ment replace the return spring See if the side stand moves smoothly and retracts fully It not grease the pivot Check the side play on the side stand It it is too great tighten the pivot bolt Recheck and if it i still too great replace the parts es necessary Dual Motion Type The side stand should lower easily to its first stop then lock after
43. roltors are us d to toko up excess slack in the drive chain es the rear Suspension comprasses and extends to its furthest points These rollers also help prevent the chain from cutting into other components on the motorcycle like the sitbox or ex haust on some motorcycles when the suspension is near or fully compressed These must aiso be periodically inspected for wear damage and security of mounting DRIVE BELT A drive belt is used on the Honda V matic beh automatic transmission The beit must be checked periodically according to the maintenance schedule shown in the Moda Specific manual A worn or damaged drive bett may cause a loss in scooter performance Removo the drive beit cover see the Model Specific manual and check the driva belt for wear cracks or pesting of the cogs or plias replace with a new one f necessary SLIDER CHAIN GUIDE n aS 325 ROLLER OR SLIDER GuibE SLIDER coc emi 2 24 Date of Issue Sep 1988 HONDA MOTOR CO LTD BELT CASE AIR CLEANER On scooters with a cleaner element in tha sir inlet to the drive belt case remove the element and clean Wash the element in water and dry it thoroughly before rainstalling FINAL DRIVE OIL LEVEL Check for leakage and proper oil level Remove tha inspectionllevel hole cap from the gear case and check that the oil level is up to the lower edge of the hole It the oil leval is
44. stment 2 10 Date of Issue Sep 1988 HONDA MOTOR CO LTD MAINTENANCE When the lack nut is tightened the clearance may change So be sure to racheck the clearance after tightening the lacknut Adjustmant is properly carried out only when the feeler gauge can be pulled out with a little difficulty If tension on feeler gauge is too great or too little readjust dn the case of valve lifters in direct push type engines change the shim and adjust the valve clearance Refer to the Model Spacific manual for the oporopriste adjustment method ENGINE OIL NOTE Do not screw in the oll cap level gauge when checking cil level Tho oil level cannot be correctly measured if the motor cycle is not supported perfectly upright on a level surface As the ail is gradually consumed it is necessary to periodically check the oil love and replanish the oil volume to its proper lev Ifthe oillevel is too high overall engine performance and the actuation of the clutch may be effected Too litte cil may cause engine overheating as well as premature wear to various parts Ifadifferant brand or grade of oll or low quality oil is mix ed when adding oil the lubricating function deteriorates Check the oil level only after starting the engine and allowing the oil to circulate through the engine throughly It is especially important te run the engine before checking the cil lovel on a dry sump engine due LL 1
45. th the transmission in neutrai then shift the transmission into gear with the clutch laver squeezed Move the side stand full down The engine should stop as the side stand is lowered M there is a problem with the system check the side stand switch SUSPENSION Compress the front and rear suspension a few times On models with exposed suspension springs check for cracks end damage Loose worn or damaged suspension parts impair vehi elo stability and control Repair or replace any damaged components batore riding Riding vehicle with fauity suspension incr of on accident ond possi ble Injury SIDE STAND SWITCH Chack for squeaks in the suspension movement that could in dici ck of lubrication Try to push the swingatm from side o side to check for worn damaged or loose suspension pivot components I any play is detected check for looseness of the swingarm pivot bolt Check also tor wear or damage to the pivot bearings ior bushings It looseness is detected in the up down motion at the end of the arm on Pro link suspensions check far wear or damage to the shock absorber mount pivet point Check for leakage from the oil seals on the fork scratch marks on the working surface of the fork tubes and wear and peeling of the chrome plating On models equipped with rubber boots on the fork legs turn back the boats to allow inspection If the fork is in poor con
46. til the wheel can be moved Loosen the adjuster lock nut turn the adjuster nut or bolt and adjust the play On snail cam types rotate the adj ler plates A scale ia included on the adjuster Be sure that the reading on the scale is the same for both sides CAUTION It the adjustment value is not the camo the wheel is out af alignment and can cause excessive tire sprocket and chain wenr As the rear suspension moves through its travel the distance between the drive and driven sprocket centers varies Therefore it is important to adjust the chain so that it has at least the minimum amount of acceptable slack when the sprockets are farthest apart or when the center of the drive sprocket swingarm pivot bolt and the reer axle are in align ment Tha Model Specific manual provides a proper dimension for each model based on this minimum slack and maximum distance position but it is measured in a much more conve ient suspension position DEPENDING ON MODEL ADJUSTER NUT LOCK NUT INDEX MARK tock wur ADJUSTER BOLT pi 4 Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 21 MAINTENANCE After adjustment retighten the axle nut to the specified torque NOTE Pulling the lower chain row firmly up toward the swing atm when tightening the axle nut helps ensure that the adjusters on both sides are seated against their
47. tions in fuel flow from the carburetor which prevents an ac curate detarmination of the idle speed RADIATOR COOLANT Wait until the engine is cool before removing tho radiator cap Removing the cap while the engine s hot and the coolant is under pressure may cause serlous scalding Radiator coolent is poisonous Take care to avoid geting coolant in your eyes on your skin or on your clothes M coolant gets in your ayes flush repeatedly with water and contact doctor immediataly j lf coolant is accidentally swallowed induce vomitting and contact a doctor immediately KEEP OUT OF REACH OF CHILDREN Coolant evaporates naturally so check it regularly Coolant is both an antifraeze and an anti rust agent CAUTION Be sure to ute the propar mixture of antifreeze and distill ed water to protact tha engine i Use distilled water Tap water may cause the engine to est or corrode 3 RADIATOR CAP THERMOSTAT RADIATOR Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 17 MAINTENANCE LEVEL CHECK Always check the coolant leva with the motorcycle ina ver teal postion on a fat evel surface Always check the coolant level at the reserve tank not the radiatort after tha engine has been warmod up Check to sea if the coolant level in the reserve tenk is somewhere between the upper and lower lines UPPER LINE I the
48. tire deflation CAUTION OF uneven Tire pressure specifications differ with each model Refer to the Model Specific manual for the correct pressures RIM BOLT AxuNuT COTTER iN AXLE HOLDER NUT Check oscillation by changes in the SPOKE WRENCH NY Riding with incorrect tire pressure can affect and impair Date of Issue Sep 1988 HONDA MOTOR CO LTD MAINTENANCE Check for cracks and damage to the tire tread and walls and replace the tire if nacessary Chack far naifs pieces of metal and stones etc which may have become lodged within the tread or embedded in the tires Tread depth can be observed directly or by use of the depth gauge M the tread depth is below minimum tread depth the tire should be replaced WEAR LIMIT Replace the tire if the wear limit indicator can be observed INDICATOR Check also for uneven wear of the tiras NOTE Wear indicators A are distributed et severe locations __around the tire s side wall for ease of inspection STEERING HEAD BEARINGS Securely support tha vehicle from benaath the frame with the front wheel off the ground Turn the handlebar from left to Tight and chack that the movement is smooth if the operation Ie not smooth or tha handlebar snags or has a haavy feel in cer sin locations chack that thera is no interference from cables
49. ulation ELEMENT AIR CLEANER SEPARATOR DRAIN TUBE DRAIN PLUG Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 7 MAINTENANCE SPARK PLUG Noe Clean around the spark plug seat with compressed air before removing and be sure that no debris is allowed to enter the combustion chamber Remava the spark plug cap and then ramove the spark plug and inspect or replace as described in the Model Specific manual maintenance schedule inspection Check the following and replace it necessary insulator for damage electrodes for wear burning condition coloration dark to light brown shows good condition excessive lightness shows faulty ignition tir mixture or lean REUSING A SPARK PLUG ark plug electrodes with a wire brush or special Chock the gap between the center and side electrodes with a re type faelar gauge If the gap is not as specified bend the side electrode to adjust Replace the spark plug in the cylinder haad and hand tighten Torque to specification CAUTION J Make sure thera is no dirt or debris on the seat of the spark plug hole before insarting the spark plug To provant damage to the cylinder head hand tightan tha spark plug before using a wrench to tighten to the spacitied torque 1 REPLACING A SPARK PLUG In the casa of new spark plugs set the gap with s wire type feolor gauge Instal
50. ura the reflector plate is clean withia the light Adjust the rear brake light switch so that the brake light comes be n just prot to the brake actually being engaged If the light fails to come on adjust the switch so that the light comes on at the proper time NOTE REFLECTOR The brake light switch on the front brake lever cannot be PLATE adjusted If the front brake light switch actuation end brake engagement are off either replace the switch unit or the malfunctioning parts of the system Make all raat brake light switch adjustments after the height adjustment and the brake pedal free play adjust ment have been made _ 2 30 Date of Issue Sep 1888 P HONDA MOTOR CO LTD MAINTENANCE Tum the adjusting nut on the brake fight switch and nat the Switch bady and wires to make switch actuation adjustments Be sure to hold the switch body firmly while turning the ad justing nut CAUTION Allowing the switch body to tum during adjustment can break tha wires in the switch After adjustment recheck to be sure the brake light comes on at the proper time HEADLIGHT AIM To make a vertical adjustment loosen the headlight mounting bolts matching the punch mark on the case and the bracket by moving the headlight up or down Some motorcycles have an adjusting screw on the bottom of the headlight In this case turn the screw to make the vertical adjustment For those
51. y lubricate the throt e cable and avarhaul and lubricate the throttle grip housing If the throttle grip still does not return properly the cable may need roplacement With the engine idling turn the handlebar all the way to the right and left to ensure that the idle speed does not change If idle spend increases check the throttle grip tree play and the throttle cable connection mpm h a damaged or abnormally bent or kinked throtue THROTTLE GRIP TYPE cable can prevent propor throttle slide operation and may FREE NN s lead to a loss of throttle control while riding Throttle tree play should be checked and adjusted as follows Throttle grip free play is correct if there is a prescribed amount ol play on the outer circumferonce of the throttle grip flange Throttle lever free play is correct if there is a prescribed mount of play at tha tip of the throttle lever FREE PLAY Minor free play adjustments can be made with the adjuster on TYPI the throttle grip sido ICAL Loosen the lack nut and turn the adjustar to obtain the desired amount of free play Tighten the lock nut after the adjustment has been made If the adjuster has a boot reposition it properly att ment is made adjust Lock ur ADJUSTER Major adjustments are made on the carburetor end of the cable with one of the adjuster types shown here ADJUSTER ADJUSTER With a forc
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