R r

3. MAINTENANCE

SERVICE INFORMATION

3-1

EVAPORATIVE EMISSION CONTROL

MAINTENANCE SCHEDULE

3-3

SYSTEM (California type only)

3-15

FUEL LINE

3-4

DRIVE CHAIN

3-16

THROTTLE OPERATION

3-4

BRAKE FLUID

3-19

CARBURETOR CHOKE

3-5

BRAKE PAD WEAR

3-20

AIR CLEANER

3-5

BRAKE SYSTEM

3-21

SPARK PLUG

3-6

BRAKE LIGHT SWITCH

3-21

VALVE CLEARANCE

3-7

HEADLIGHT AIM

3-21

ENGINE OIL/OIL FILTER

3-11

CLUTCH SYSTEM

3-21

CARBURETOR SYNCHRONIZATION

3-12

SIDE STAND

3-22

ENGINE IDLE SPEED

3-14

SUSPENSION

3-23

RADIATOR COOLANT

3-14

NUTS, BOLTS, FASTENERS

3-23

COOLING SYSTEM

3-15

WHEELS/TIRES

3-24

SECONDARY AIR SUPPLY SYSTEM

STEERING HEAD BEARINGS

3-24

(California type only)

3-15

SPECIFICATION

ITEM

SPECIFICATIONS

Throttle grip free play

2-6 mm (1/12-1/4 in)

Spark plug Standard

NGK

NIPPONDENSO

CR9EH9

U27FER9

Spark plug gap

0.8 - 0.9 mm (0.031 - 0.035 in)

Valve clearance

IN

0.16 ± 0.03 mm (0.006 ± 0.001 in)

EX

0.22 ± 0.03 mm (0.009 ± 0.001 in)

Engine oil capacity

at draining

3.4 i (3.6 US qt, 3.0 Imp qt)

at disassembly

4.2 I (4.4 USqt, 3.7 Imp qt)

at oil filter change

3.7 I (3.9 US qt, 3.3 Imp qt)

Carburetor vacuum difference

Within 30 mmHg (1.2 inHg) Base carburetor:No3

Carburetor idle speed

49 state, Canada type

1,200 ± 100 rpm

California type

1,400 ± 100 rpm

Drive chain slack

15-25 mm (5/8-1 in)

Drive chain size/link

RK

RK50MFO/108

DID

DID50V4/108

ITEM

SPECIFICATIONS

Clutch lever free play

10-20 mm (3/8-3/4 in)

Cold tire pressure

Up to 90 kg (200 lb) load

Front

36 psi (2.50 kg/cm', 250 kPa)

Rear

42 psi (2.90 kg/cm1, 290 kPa)

Up to maximum weight cpacity

Front

36 psi (2.50 kg/cm', 250 kPa)

Rear

42 psi (2.90 kg/cm', 290 kPa)

Minimum tire tread depth

Front

1.5 mm (0.06 in)

Rear

2.0 mm (0.08 in)

Tire size

Front

120/60 ZR 17

Rear

160/60 ZR 17

Tire brand

Bridgestone

Front

BT50F RADIAL G

Rear

BT50R RADIAL J

Michelin

Front

MACADAM 90X

Rear

MACADAM 90X

TORQUE VALUES

Cylinder head cover bolt 10 N*m (1.0 kg-m, 7 Ib-ft)

Camshaft holder bolt 12 N-m (1.2 kg-m, 9 Ib-ft) Apply oil to the threads.

Ignition pulse generator cover cap 18 N-m (1.8 kg-m, 13 Ib-ft) Apply grease to the threads.

Drive chain adjuster lock nut 22 N*m (2.2 kg-m, 16 Ib-ft)

Side stand pivot lock nut 30 N*m (3.0 kg-m, 22 Ib-ft)

Side stand bracket bolt 55 N*m (5.5 kg-m, 40 Ib-ft)

TOOLS

Oil filter wrench Drive chain cutter Link plate holder

07HAA - PJ70100 07HMH - MR10102 07NMH- MW00110

or 07HMH-MR1010B (U.S.A. only) or 07NMH - MW0011A (U.S.A. only)

MAINTENANCE SCHEDULE

Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period. I: Inspect and clean, Adjust, Lubricate, or Replace if necessary. R: Replace, C: Clean, L: Lubricate, A: Adjust

The following items require some mechanical knowledge. Certain items (particularly those marked * and **} may require more technical information and tools. Consult an authorized Honda dealer.

FREQUENCY

O

ODOMETER READING (NOTE 1)

X1,000mi

0.6

4

8

12

16

20

24

X 1,000km

1

6

12

18

24

30

36

page

EMISSION RELATED ITEMS

*

FUEL LINE

1

I

1

3-4

THROTTLE OPERATION

1

I

1

3-4

#

CARBURETOR CHOKE

1

I

1

3-5

AIR CLEANER

NOTE 2

R

R

3-5

SPARK PLUG

1

R

I

R

1

R

3-6

VALVE CLEARANCE

I

3-7

ENGINE OIL

R

R

R

R

3-11

ENGINE OIL FILTER

R

R

R

R

3-11

*

CARBURETOR SYNCHRONIZATION

1

I

1

3-12

*

ENGINE IDLE SPEED

I

1

1

I

I

1

1

3-14

RADIATOR COOLANT

NOTE 3

1

I

R

3-14

»

COOLING SYSTEM

1

I

1

3-15

»

SECONDARY AIR SUPPLY SYSTEM

NOTE 4

1

I

1

3-15

EVAPORATIVE EMISSION CONTROL SYSTEM

NOTE 4

I

1

3-15

NON-EMISSION RELATED ITEMS

DRIVE CHAIN

Cvery £>00mi (800 krri> 1, L

3-16

BRAKE FLUID

NOTE 3

1

R

I

1

R

3-19

BRAKE PAD WEAR

1

1

I

I

1

H 1

3-20

BRAKE SYSTEM

1

1

I

1

3-21

BRAKE LIGHT SWITCH

1

I

1

3-21

*

HEADLIGHT AIM

1

I

1

3-21

CLUTCH SYSTEM

1

1

1

I

1

1

1

3-21

SIDE STAND

1

1

3-22

*

SUSPENSION

1

1

1

3-23

*

NUTS, BOLTS, FASTENERS

1

1

^ »

1

3-23

**

WHEELS/TIRES

1

1

3-24

STEERING HEAD BEARINGS

1

1

1

1

3-24

* Should be serviced by an authorized Honda dealer, unless the owner has the proper tools and service data and is mechanically qualified.

** In the interest of safety, we recommended these items be serviced only by an authorized Honda dealer.

NOTES: 1. At higher odometer readings, repeat at the frequency interval established here.

2. Service more frequently when riding in unusually wet or dusty area.

3. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill.

4. California type only.

FUEL LINE

INSPECTION

Remove the side cover (page 2-2).

Check the fuel lines for deterioration, damage or leakage. Replace the fuel lines if necessary.

For the tube routing, see page 1-20.

THROTTLE OPERATION

Check for any deterioration or damage to the throttle cables. Check the throttle grip for smooth operation. Check that the throttle grip returns from the full open to the full closed position smoothly and automatically in all steering positions.

If the throttle grip does not return properly, lubricate the throttle cable, overhaul and lubricate the throttle grip housing.

For cable lubrication: Disconnect the throttle cables at their upper ends (page 12-3). Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a light weight oil.

If the throttle grip still does not return properly, replace the throttle cables.

Awarning

• Reusing a damaged or abnormally bent or kinked throttle cable can prevent proper throttle side operation and may lead to a loss of throttle control while riding.

With the engine idling, turn the handlebar all the way to the right and left to ensure that idle speed does not change. If idle speed increases, check the throttle grip free play and the throttle cable connection.

Measure the throttle grip free play at the throttle grip flange. Free play: 2-6 mm (1/12 - 1/4 in)

Throttle grip free play can be adjusted at either end of the throttle cable. Minor adjustments are made with the upper adjuster.

Loosen the lock nut and turn the adjuster to obtain the free play.

Tighten the lock nut and reposition the adjuster boot properly after the adjustment has been made.

(1) FUEL LINES

(2) ADJUSTER

Major adjustments are made with the lower adjuster.

Remove the air cleaner base (page 5-4).

Loosen the lock nuts and turn the adjuster to obtain the free play.

Tighten the lock nuts after the adjustment has been made. Recheck the throttle grip free play.

CARBURETOR CHOKE

STARTING ENRICHMENT (SE) VALVE

The choke system uses a fuel enrichening circuit controlled by an SE valve. The SE valve opens the enrichening circuit via a cable when the choke lever on the handlebar is moved back.

Check for smooth operation of the choke lever. If the operation is not smooth, lubricate the choke cable, overhaul and lubricate the choke lever. For cable lubrication: Disconnect the choke cable at the upper end (page 12-6). Thoroughly lubricate the cable and its pivot point with a commercially available cable lubricant or a light weight oil.

Remove the air cleaner base (page 5-4). Move the choke lever all the way back to the fully open position. Make sure the SE valve is open by trying to move the choke lever on the carburetor, there should be no free play.

Adjust the free play by loosening the choke cable clamp on the carburetor and moving the choke cable casing so the choke lever is fully open. Tighten the clamp.

Push the choke lever fully closed. Make sure the SE valve is fully closed by checking for free play in the cable between the lever on the carburetor and cable casing.

Install the removed parts in the reverse order of removal.

AIR CLEANER

NOTE_

• The viscous paper element type air cleaner cannot be cleaned because the element contains a dust adhesive.

• If the motorcycle is used in wet or du&ty areas, more frequent inspections are required.

• Replace the air cleaner and sub air cleaner as a set.

Remove the fuel tank (page 2-4).

Remove and loosen the air cleaner housing cover screws. Remove the air cleaner housing cover.

Remove the air cleaner and sub air cleaner.

Replace the air cleaner according to the maintenance schedule (see page 3-3).

Install the removed parts in the reverse order of removal.

SPARK PLUG

Remove the left and right maintenance covers (page 2-3).

Remove the spark plug caps and clean around the spark plug bases.

NOTE

* Clean around the spark plug bases with compressed air before removing, and be sure that no debris is allowed to enter the combustion camber.

Remove the spark plugs using the spark plug wrench. Inspect or replace as described in the maintenance schedule (page 3-3).

INSPECTION

Check the following and replace if necessary (recommended spark plugs: page 3-1).

• insulator for damage

• electrodes for wear

• burning condition, coloration

- dark to light brown indicates good condition.

- excessive lightness indicates malfunctioning ignition system or lean mixture.

- wet or black sooty deposit indicates over-rich mixture.

(2) SUB AIR CLEANER

(1) AIR CLEANER

(2) SIDE ELECTRODE

(3) CENTER ELECTRODE

(1) INSULATOR

(3) CENTER ELECTRODE

(2) SIDE ELECTRODE

REUSING A SPARK PLUG

Clean the spark plug electrodes with a wire brush or spark plug cleaner.

Check the gap between the center and side electrodes with a wire-type feeler gauge. If necessary, adjust the gap by bending the side electrode carefully.

CAUTION

• To prevent damaging the cylinder head, hand-tigten the spark plug before using a wrench to tighten to the specified torque. _

Reinstall the spark plug in the cylinder head and hand-tighten, then torque to specification.

REPLACING A SPARK PLUG

Set the plug gap to specification with a wire-type feeler gauge (see above).

CAUTION

• Do not overtighten the spark plug.

Install and tigten the new spark plug, then tighten it about 1/4 of turn after sealing washer contacts the seat of the plug hole.

VALVE CLEARANCE

NOTE

Inspect and adjust the valve clearance while the engine is cold (below 35°C/95°F).

Remove the cylinder head cover (page 8-5).

INSPECTION

Remove the ignition pulse generator rotor cover cap.

(1) IGNITION PULSE GENERATOR ROTOR COVER CAP

Turn the crankshaft clockwise, and align the T mark (notch mark) with the index mark on the ignition pulse generator rotor cover.

Make sure that the timing marks ("IN" and "EX") on the camshaft sprockets are aligned with the cylinder head upper surface and facing opposite each other as shown. If the timing marks ("IN" and "EX") on the camshaft sprockets face each other, turn the crankshaft clockwise one full turn (360°) and realign the T mark (notch mark) with the index mark.

Remove the cam chain tensioner lifter sealing bolt and sealing washer.

Turn the tensioner shaft fully in (clockwise) and secure it using the stopper tool.

This tool can easily be made from a thin (1 mm thickness) piece of steel using the dimensions shown below.

15 mm 19 mm

15 mm

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