![Honda VTX1800C (2002-2004) [11/466] Crankshaft transmission](/img/pdf.png)
Honda VTX1800C (2002-2004) [11/466] Crankshaft transmission
![Honda VTX1800C (2002-2004) [11/466] Crankshaft transmission](/views2/1121072/page11/bgb.png)
Содержание
- Charging system alternator 2
- Clutch gearshift linkage 2
- Contents 2
- Cooling system 2
- Crankshaft transmission 2
- Cylinder head valves 2
- Cylinder piston 2
- Electric starter starter clutch 2
- Engine removal installation 2
- Final drive 2
- Frame body panels exhaust system 2
- Front wheel suspension steering 2
- Fuel system programmed fuel injection 2
- General information 2
- How to use this manual 2
- Hydraulic brake 2
- Ignition system 2
- Lights meters switches 2
- Lubrication system 2
- Maintenance 2
- Rear wheel suspension 2
- Troubleshooting 2
- Wiring diagram 2
- Symbols 3
- General information 4
- Model identification 4
- Service rules 4
- General information 5
- General 6
- General information 6
- Specifications 6
- General information 7
- Fuel system programmed fuel injection 8
- General information 8
- R cooling systfm 8
- R lubrication system 8
- Cylinde 9
- General information 9
- Head vai vfs 9
- General information 10
- Crankshaft transmission 11
- General information 11
- Front wheel suspension steering 12
- General information 12
- Rear wheel suspension 12
- General information 13
- R battery charging system 13
- R hydraulic brake 13
- Electric starter 14
- General information 14
- Lights meters switches 14
- R ignition system 14
- General nfdrma7 om 15
- Torque values 15
- Engine cont d 16
- General information 16
- General information 17
- N frame 17
- Frame cont d 18
- General information 18
- Frame cont d 19
- General information 19
- General information 20
- General information 21
- General information 22
- Lubrication seal points 22
- Engine cont d ___________________________ _ 23
- General information 23
- General information 24
- General information 25
- Cable harness routing 26
- General information 26
- General information 29
- General information 30
- General information 31
- General information 32
- General information 33
- California type 35
- General information 35
- Crankcase emission control system 36
- Emission control systems 36
- General information 36
- Source of emissions 36
- Exhaust emission control system secondary air supply system 37
- General information 37
- Evaporative emission control system california type only 38
- General information 38
- Noise emission control system 38
- An emission control information label is located on the front of the rear fender as shown the seat must be removed to read it it gives base tune up specifications 39
- Emission control information labels u s a only 39
- General information 39
- The vacuum hose routing diagram label is on the front of the rear fender as shown the seat must be removed to read it 39
- Vacuum hose routing diagram label california type only 39
- Frame body panels exhaust system 40
- Service information 40
- Troubleshooting 40
- Align the seat hook with the fuel tank rear bracket and install the seat 41
- Frame body panels exhaust system 41
- Install and tighten the socket bolts securely install the washer and tighten the cap nut securely 41
- Installation 41
- Installation is in the reverse order of removal 41
- Left crankcase rear cover 41
- Release the side cover bosses from the grommets and remove the side cover 41
- Removal 41
- Removal installation 41
- Remove the cap nut washer and socket bolts 41
- Remove the socket bolts and left crankcase rear cover 41
- Side cover 41
- Slide the seat back and then off 41
- Frame body panels exhaust system 42
- Muffler exhaust pipe 42
- Rear fender 42
- Removal 42
- Frame body panels exhaust system 43
- Frame body panels exhaust system 44
- Installation 44
- Disassembly assembly 45
- Frame body panels exhaust system 45
- Frame body panels exhaust system 46
- Maintenance 47
- Service information 47
- Maintenance 48
- Specifications 48
- Torque values 48
- Iihinn 49
- Maintenance schedule 49
- Fuel line 50
- Maintenance 50
- Throttle operation 50
- Air cleaner 51
- Maintenance 51
- Crankcase breather 52
- Disconnect the spark plug cap from the spark plug bases 52
- Inspect or replace as described in the maintenance schedule 52
- Maintenance 52
- Removal 52
- Remove the crankcase breather hose from the air cleaner housing and drain deposits into a suitable container then install the hose securely 52
- Remove the socket bolts and spark plug cap cover 52
- Remove the spark plug using the equipped spark plug wrench or an equivalent tool 52
- Spark plug 52
- Check the following and replace if necessary recom mended spark plug page 3 2 insulator for damage electrodes for wear burning condition coloration 53
- Check the gap between the center and side electrodes with a wire type feeler gauge 53
- If the electrodes are contaminated with accumulated objects or dirt replace the spark plug 53
- If the gauge can be inserted into the gap replace the plug with a new one 53
- If using a new plug install as follows install and hand tighten the new spark plug then tighten it about 1 2 of a turn after the sealing washer contacts the seat of the plug hole 53
- Inspection 53
- Maintenance 53
- Make sure that the 1 mm 0 4 in diameter plug gauge does not insert between the gap 53
- Reinstall the spark plug in the cylinder head and hand tighten then torque to specification 53
- Replace the plug if the center electrode is rounded as shown in the illustration 53
- Specified spark plug ngk ifr6l11 denso vk20prz11 53
- Torque 18 n m 1 kgf m 13 lbf ft 53
- Inspection 54
- Maintenance 54
- Valve clearance 54
- Maintenance 55
- Adjustment 56
- Maintenance 56
- Maintenance 57
- Engine oil oil filter 58
- Maintenance 58
- Oil level inspection 58
- Engine oil filter change 59
- Maintenance 59
- Maintenance 60
- Cooling system 61
- Engine idle speed 61
- Maintenance 61
- Radiator coolant 61
- Maintenance 62
- Secondary air supply system 62
- Evaporative emission control system california type only 63
- Final drive oil 63
- Level check 63
- Maintenance 63
- Avoid spilling fluid on painted plastic or rubber parts place a rag over these parts whenever the system is serviced 64
- Brake fluid 64
- Do not allow foreign material to enter the system when filling the reservoir 64
- Do not mix different types of fluid as they are not compatible with each other 64
- Front brake 64
- Maintenance 64
- Notice 64
- Oil change 64
- Brake pad wear 65
- Brake system 65
- Front brake pads 65
- Inspection 65
- Maintenance 65
- Rear brake 65
- Rear brake pads 65
- Brake light switch 66
- Headlight aim 66
- Maintenance 66
- Clutch fluid 67
- Clutch system 67
- Maintenance 67
- Notice 67
- Side stand 67
- Front suspension inspection 68
- Maintenance 68
- Nuts bolts fasteners 68
- Rear suspension inspection 68
- Suspension 68
- Maintenance 69
- Steering head bearings 69
- Wheels tires 69
- Caution 71
- Lubrication system 71
- Service information 71
- Service information 4 1 oil pressure check 4 3 71
- Troubleshooting 4 2 oil pump oil strainer 4 3 71
- Lubrication system 72
- Troubleshooting 72
- Lubrication system 73
- Oil pressure check 73
- Oil pump strainer 73
- Removal 73
- Lubrication system 74
- Lubrication system 75
- Oil pipe 75
- Relief valve check 75
- Disassembly 76
- Lubrication system 76
- Inspection 77
- Lubrication system 77
- Assembly 78
- Lubrication system 78
- Installation 79
- Lubrication system 79
- Lubrication system 80
- Fuel system 82
- Fuel system programmed fuel injection 82
- Service information 82
- Fuel system programmed fuel injection 83
- Specifications 83
- Torque values 83
- Fuel system programmed fuel injection 84
- Troubleshooting 84
- Fuel system programmed fuel injection 85
- System location 85
- Fuel system programmed fuel injection 86
- Fuel system programmed fuel injection 87
- If the malfunction indicator lamp mil does not light or blink the system has no memory of problem data if the mil blinks note how many times the malfunc tion indicator blinks and determine the cause of the problem page 5 10 through 5 45 87
- If you wish to read the pgm fi memory for trouble data perform the following 87
- Pgm fi programmed fuel injec tion system 87
- Place the motorcycle on its side stand start the engine and let it idle 87
- Remove the seat page 2 2 87
- Self diagnostic procedure 87
- Short the pgm fi system service check connector ter minals using a jumper wire 87
- Turn the ignition switch to off 87
- Fuel system programmed fuel injection 88
- Self diagnosis reset procedure 88
- Fuel system programmed fuel injection 89
- Peak voltage inspection proce dure 89
- Test harness connection 89
- Fuel system programmed fuel injection 90
- Test harness terminal layout 90
- Pgm fi self diagnosis malfunction indicator failure codes 91
- Fuel system programmed fuel injection 92
- Fuel system programmed fuel injection 94
- Fuel system programmed fuel injection 96
- Fuel system programmed fuel injection 98
- Fuel system programmed fuel injection 102
- Fuel system programmed fuel injection 104
- _______ i_______ 104
- Fuel system programmed fuel injection 106
- Fuel system programmed fuel injection 108
- Fuel system programmed fuel injection 110
- _______ i_______ 110
- Fuel system programmed fuel injection 111
- _______ i_______ 111
- Fuel system programmed fuel injection 113
- Fuel system programmed fuel injection 118
- Fuel system programmed fuel injection 120
- Fuel system programmed fuel injection 121
- Pgm fi mil 23 blinks o2 sensor heater california type only 121
- Fuel system programmed fuel injection 123
- Fuel system programmed fuel injection 124
- Fuel system programmed fuel injection 126
- Fuel line inspection 127
- Fuel pressure inspection 127
- Fuel system programmed fuel injection 127
- Fuel system programmed fuel injection 128
- Fuel flow inspection 129
- Fuel pump 129
- Fuel system programmed fuel injection 129
- Inspection 129
- Fuel filter replacement 130
- Fuel system programmed fuel injection 130
- Installation 130
- Removal 130
- Fuel cut off relay 131
- Fuel system programmed fuel injection 131
- Fuel tank 131
- Installation 131
- Notice 131
- Removal 131
- Air cleaner housing 132
- Fuel system programmed fuel injection 132
- Installation 132
- Removal 132
- Fuel system programmed fuel injection 133
- Throttle body 133
- Throttle body removal 133
- Do not damage the throttle body it may cause incorrect throttle and idle valve synchronization the throttle body is factory pre set do not disassemble in a way other than shown in this manual do not loosen or tighten the white painted bolts and screws of the throttle body loosening or tightening them can cause throttle and idle valve synchronization failure 134
- Fuel system programmed fuel injection 134
- Loosen the band screw and disconnect the water hose 134
- Loosen the lock nuts and disconnect the throttle cables from the throttle drum 134
- N m 0 5 kgf m 2 lbf ft 134
- Notice 134
- Fuel system programmed fuel injection 135
- Intake manifold removal 135
- Fuel system programmed fuel injection 136
- Fuel system programmed fuel injection 137
- Intake manifold installation 137
- Fuel system programmed fuel injection 138
- Fuel system programmed fuel injection 139
- Throttle body installation 139
- Fuel system programmed fuel injection 140
- Fuel system programmed fuel injection 141
- Injectors 141
- Inspection 141
- Removal 141
- Fuel system programmed fuel injection 142
- Fuel system programmed fuel injection 143
- Installation 143
- Fuel system programmed fuel injection 144
- Disassembly 145
- Fuel system programmed fuel injection 145
- Starter valve 145
- Assembly 146
- Fuel system programmed fuel injection 146
- Air screw synchronization 147
- Fuel system programmed fuel injection 147
- Baro map sensor 148
- Baro sensor removal installation 148
- Fuel system programmed fuel injection 148
- Map sensor removal installation 148
- Output voltage inspection 148
- Ect sensor 149
- Fuel system programmed fuel injection 149
- Iat sensor 149
- Removal installation 149
- Cam pulse generator 150
- Fuel system programmed fuel injection 150
- Inspection 150
- Installation 150
- Removal installation 150
- Tp sensor 150
- Fuel system programmed fuel injection 151
- Bank angle sensor 152
- Fuel system programmed fuel injection 152
- Engine stop relay 153
- Fuel system programmed fuel injection 153
- Inspection 153
- Removal installation 153
- Ecm engine control module 154
- Fuel system programmed fuel injection 154
- Intake duct control solenoid valve 154
- Power ground une inspection 154
- Removal installation 154
- Fuel system programmed fuel injection 155
- Inspection 155
- Fuel system programmed fuel injection 156
- One way valve 156
- Pair solenoid valve 156
- Removal installation 156
- Fuel system programmed fuel injection 157
- Inspection 157
- Pair check reed valve 157
- Removal installation 157
- Evap purge control valve cali fornia type only 158
- Fuel system programmed fuel injection 158
- Inspection 158
- Removal 158
- Fuel system programmed fuel injection 159
- Notice 159
- O2 sensor california type only 159
- Removal 159
- Caution 161
- Coolant replacement 6 4 water pump 6 12 161
- Cooling system 161
- I notice 161
- Service information 161
- Service information 6 1 radiator cooling fan 6 6 161
- System testing 6 3 thermostat 6 9 161
- Troubleshooting 6 2 radiator reserve tank 6 9 161
- Cooling system 162
- Troubleshooting 162
- Coolant hydrometer test 163
- Cooling system 163
- System testing 163
- Coolant replacement 164
- Cooling system 164
- I notice 164
- Radiator cap system pressure inspection 164
- Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or block age of radiator passages using tap water may cause engine damage 164
- Cooling system 165
- Replacement air bleeding 165
- Cooling system 166
- Radiator cooling fan 166
- Removal 166
- Cooling system 167
- Disassembly 167
- Assembly 168
- Cooling system 168
- Cooling system 169
- Installation 169
- Radiator reserve tank 169
- Removal 169
- Removal installation 169
- Thermostat 169
- Cooling system 170
- 84 c 176 183 f 171
- Cooling system 171
- Heat a container of water with an electric heating ele ment for 5 minutes suspend the thermostat in the heated water to check its operation 171
- Inspection 171
- Install the new o ring on the thermostat housing cover 171
- Install the thermostat into the housing with its hole facing upright align the thermostat flange with the groove in the housing upper surface make sure the thermostat is securely installed 171
- Installation 171
- Mm 0 in minimum at 95 c 203 f 171
- Replace the thermostat if the valve responds at tem peratures other than specified 171
- Thermostat 171
- Thermostat begins to open 171
- Valve lift 171
- Visually inspect the thermostat for damage replace the thermostat if the valve stays open at room temperature 171
- Cooling system 172
- Mechanical seal inspection 172
- Removal 172
- Water pump 172
- Cooling system 173
- Installation 173
- Cooling system 174
- Engine removal installation 175
- Engine removal installation 176
- Service information 176
- ________7 engine removal installation 176
- Engine removal installation 177
- Specification 177
- Torque values 177
- Engine removal 178
- Engine removal installation 178
- Engine removal installation 179
- Engine removal installation 180
- Engine removal installation 181
- Engine removal installation 182
- Eng ne remo val installation 183
- Engine installation 184
- Engine removal installation 184
- Engine removal installation 185
- Engine removal installation 186
- Engine removal installation 187
- Engine removal installation 188
- Engine removal installation 189
- Engine removal installation 190
- Cylinder head valves 192
- Service information 192
- Cylinder head valves 193
- Torque values 193
- Troubleshooting 193
- Cylinder compression 194
- Cylinder head cover removal 194
- Cylinder head valves 194
- Camshaft removal 195
- Cylinder head valves 195
- Cylinder head valves 196
- Cylinder head valves 197
- Camshaft holder disassembly 198
- Cylinder head valves 198
- Inspection 198
- Cylinder head valves 199
- Cylinder head removal 200
- Cylinder head valves 200
- Cylinder head disassembly 201
- Cylinder head valves 201
- Check the cylinder head for warpage with a straight edge and feeler gauge 202
- Cylinder head check the spark plug holes and valve areas for cracks 202
- Cylinder head valves 202
- Do not reuse a removed stem seal 202
- Inspection 202
- Remove the carbon deposits from the combustion chamber to avoid damaging the gasket and valve seat surfaces and clean the head gasket surfaces 202
- Remove the stem seals and spring seats 202
- Remove the valve spring compressor then remove the retainer spring and valve spring valve 202
- Retainer 202
- Service limit 0 0 mm 0 04 in 202
- Cylinder head valves 203
- Cylinder head valves 204
- Notice 204
- Using a torch to heat the cylinder head may cause warpage 204
- Valve guide replacement 204
- Cylinder head valves 205
- Inspection 205
- Valve seat inspection refacing 205
- Cylinder head valves 206
- Valve seat refacing 206
- Cylinder head valves 207
- Laritie 207
- Cylinder head assembly 208
- Cylinder head valves 208
- Compress the valve springs with the valve spring compressor and install the valve cotters 209
- Cylinder head valves 209
- Insert the valves into the valve guides to avoid damaging the stem seal turn the valve slow ly when inserting install the valve springs install the spring retainers 209
- Install the spring seats and new stem seals 209
- Retainer 209
- Tap the valve stems gently with a soft hammer to firmly seat the cotters 209
- Tool valve spring compressor 07757 0010000 209
- Cylinder head installation 210
- Cylinder head valves 210
- Camshaft holder assembly 211
- Camshaft installation 211
- Cylinder head valves 211
- Camshaft installation 212
- Cylinder head valves 212
- Cylinder head valves 213
- Front cylinder 213
- Cylinder head valves 214
- Cylinder head valves 215
- Rear cylinder 215
- Cylinder head cover installa tion 216
- Cylinder head valves 216
- Cylinder piston 218
- Service information 218
- Cylinder piston 219
- Troubleshooting 219
- Cylinder piston 220
- Cylinder removal 220
- Cylinder piston 221
- Inspection 221
- Calculate the cylinder for taper and out of round at three levels in the x and y axes take the maximum reading to determine the taper and out of round 222
- Check the oil jet for clogs 222
- Cylinder piston 222
- Inspect the cylinder bore for scratches or wear measure the cylinder i d at three levels in the x and y axes take the maximum reading to determine the cylinder wear 222
- Out of round 0 0 mm 0 04 in 222
- Piston removal 222
- Remove the o ring from the oil jet 222
- Remove the oil jet from the crankcase 222
- Remove the piston pin and remove the piston 222
- Remove the piston pin clip using a pair of pliers 222
- Service limit 101 5 mm 3 78 in 222
- Service limits 222
- Taper 0 0 mm 0 04 in 222
- Calculate the cylinder to piston clearance cylinder i d see previous page 223
- Clean carbon deposits from the piston ring grooves 223
- Cylinder piston 223
- Inspect the piston for wear or damage 223
- Inspect the piston rings for smooth movement by rotating the rings the rings should be able to move in their grooves without catching 223
- Measure and record the piston pin hole i d in the x and y axes take the maximum reading to determine the i d 223
- Measure the diameter of the piston at 18 mm 0 in from the bottom and 90 degrees to the piston pin hole 223
- Piston 223
- Piston piston ring inspection 223
- Service limit 0 2 mm 0 26 in 223
- Service limit 100 1 mm 3 73 in 223
- Service limit 24 18 mm 0 456 in 223
- Spread each piston ring and remove it by lifting it up at a point just opposite the gap 223
- Cylinder piston 224
- Cylinder piston 225
- Cylinder stud bolt replacement 225
- Piston ring installation 225
- Apply engine oil to new o rings and install it onto the oil jet 226
- Apply engine oil to the piston pin outer surface set the piston over the connecting rod with the piston direction and position properly as noted during removal 226
- Clean the gasket surface of the crankcase thoroughly being careful not to damage it and careful not to allow gasket material into the crankcase 226
- Cylinder piston 226
- Install new piston pin clips 226
- Install the oil jet into the crankcase properly as shown jet hole side facing toward the connecting rod side 226
- Piston installation 226
- Cylinder installation 227
- Cylinder piston 227
- Coat a new o ring with coolant and install it in the water hose joint groove of the rear cylinder 228
- Coat new o rings with coolant and install them into the end grooves in the water joint pipe and into the cylinders 228
- Cylinder piston 228
- Install and tighten the bolts securely 228
- Install the cylinder head page 8 19 228
- Slide the water joint pipe in position between the cylinders install the joint clips in the joint grooves 228
- Clutch gearshift linkage 230
- Clutch gearshift linkage 231
- General 231
- Service information 231
- Specification 231
- Torque values 231
- Clutch gearshift linkage 232
- Troubleshooting 232
- Check the fluid level often while bleeding the clutch to prevent air from being pumped into the system 233
- Close the bleed valve and operate the clutch lever if it is still spongy bleed the system again 233
- Clutch fluid draining 233
- Clutch fluid filling air bleeding 233
- Clutch fluid replacement air bleeding 233
- Clutch gearshift linkage 233
- Connect the bleed hose to the bleed valve loosen the bleed valve and pump the clutch lever until fluid stops flowing out of the bleed valve 233
- Fill the reservoir with dot 4 brake fluid from a sealed container connect a commercially available brake bleeder to the bleed valve pump the brake bleeder and loosen the bleed valve adding fluid when the fluid level in the reservoir is low 233
- Remove the screws reservoir cap set plate diaphragm and float 233
- Repeat the previous procedures until air bubbles do not appear in the plastic hose 233
- Turn the handlebar to the right until the reservoir is parallel to the ground before removing the reservoir cap 233
- When using a brake bleeding tool follow the man ufacturer s operating instructions 233
- Clutch gearshift linkage 234
- Clutch gearshift linkage 235
- Clutch master cylinder 235
- Disassembly 235
- Removal 235
- Clutch gearshift linkage 236
- Assembly 237
- Clutch gearshift linkage 237
- Inspection 237
- Clutch gearshift linkage 238
- Clutch gearshift linkage 239
- Installation 239
- Torque 34 n m 3 kgf m 25 lbf ft 239
- Clutch gearshift linkage 240
- Clutch slave cylinder 240
- Removal 240
- Assembly 241
- Clutch gearshift linkage 241
- Disassembly 241
- Inspection 241
- Installation 241
- Clutch gearshift linkage 242
- Removal 242
- Right crankcase cover 242
- Clutch gearshift linkage 243
- Installation 243
- Clutch 244
- Clutch gearshift linkage 244
- Removal 244
- Clutch gearshift linkage 245
- Clutch gearshift linkage 246
- Clutch gearshift linkage 247
- Inspection 247
- Clutch gearshift linkage 248
- Clutch gearshift linkage 249
- Clutch gearshift linkage 250
- Installation 250
- Clutch gearshift linkage 251
- Clutch gearshift linkage 252
- Clutch gearshift linkage 253
- Primary drive gear 253
- Removal 253
- Clutch gearshift linkage 254
- Primary driven gears 254
- Removal 254
- Clutch gearshift linkage 255
- Inspection 255
- Installation 255
- Clutch gearshift linkage 256
- Clutch gearshift linkage 257
- Gearshift linkage 257
- Removal 257
- Clutch gearshift linkage 258
- Inspection 258
- Installation 258
- Clutch gearshift linkage 259
- Crankshaft transmission 261
- Service information 261
- Crankshaft transmission 262
- Specification 262
- Torque values 262
- Crankshaft transmission 263
- Troubleshooting 263
- Crankcase separation 264
- Crankshaft transmission 264
- Crankshaft transmission 265
- Inspection 265
- Primary shaft 265
- Removal installation 265
- Before removing the connecting rods check the big end side clearance measure the clearance by inserting the feeler gauge between the crankshaft and connecting rod big end 266
- Connecting rod removal 266
- Crankshaft connecting rod 266
- Crankshaft removal 266
- Crankshaft transmission 266
- Remove and discard the bearings if the races do not turn smoothly quietly or if they fit loosely in the crankcase page 11 25 266
- Remove the connecting bearing cap bolts and the bearing caps bearing caps 266
- Remove the crankshaft from the left crankcase 266
- Separate the crankshaft page 11 4 266
- Service limit 0 8 mm 0 11 in 266
- Turn the inner race of each bearing with your finger the bearings should turn smoothly and quietly also check that the bearing outer race fits tightly in the crankcase 266
- Connecting rod bearing inspection 267
- Crankshaft inspection 267
- Crankshaft transmission 267
- Oil clearance inspection 267
- Connecting rod bearing selection 268
- Crankshaft transmission 268
- Crankshaft transmission 269
- Main bearing inspection 269
- Connecting rod installation 270
- Connecting rod selection 270
- Crankshaft transmission 270
- Crankshaft transmission 271
- Removal 271
- Transmission 271
- Crankshaft transmission 272
- Disassembly 272
- Crankshaft transmission 273
- Inspection 273
- Crankshaft transmission 274
- Assembly 275
- Crankshaft transmission 275
- Crankshaft transmission 276
- Installation 276
- Crankcase assembly 277
- Crankshaft transmission 277
- Crankshaft transmission 278
- Crankshaft transmission 279
- Output gear 279
- Removal 279
- Backlash inspection gear tooth contact pattern check 280
- Crankshaft transmission 280
- Crankshaft transmission 281
- Crankshaft transmission 282
- Crankshaft transmission 283
- Case bearing replacement 284
- Crankshaft transmission 284
- Installation 284
- Crankcase bearing replacement 285
- Crankshaft transmission 285
- Left crankcase bearing 285
- Crankshaft transmission 286
- Crankshaft transmission 287
- Right crankcase bearings 287
- Crankshaft transmission 288
- Final drive 290
- Final drive removal 12 3 290
- Service information 290
- Service information 12 1 final drive gear 12 5 290
- Troubleshooting 12 2 final drive installation 12 18 290
- Final drive 291
- Troubleshooting 291
- Drive shaft removal disassembly 292
- Final drive 292
- Final drive removal 292
- Removal 292
- Universal joint removal 292
- Backlash inspection 293
- Final drive 293
- Final drive inspection 293
- Final drive gear 294
- Ring gear removal shim replacement 294
- Final drive 295
- Oil seal 295
- Remove the oil seal from the ring gear 295
- Remove the ring gear bearing using the commercial ly available bearing puller 295
- Remove the ring gear from the gear case 295
- Replace the ring gear shim 295
- Final drive 296
- Ring gear installation 296
- Final drive 297
- Case cover warpage can occur if the cover is not heat ed properly 298
- Final drive 298
- Notice 298
- Final drive 299
- Gear tooth contact pattern check 299
- Final drive 300
- Pinion gear removal shim replacement 300
- Final drive 301
- Final drive 302
- Pinion gear installation 302
- Final drive 303
- Final drive 304
- Case bearing replacement 305
- Final drive 305
- Breather hole cleaning 306
- Final drive 306
- Gear case assembly 306
- Drive shaft assembly installa tion 307
- Final drive 307
- Final drive installation 307
- Front wheel suspension steering 309
- Handlebar 13 3 steering stem 13 33 309
- Service information 309
- Service information 13 1 front wheel 13 8 309
- Troubleshooting 13 2 fork 13 14 309
- Front wheel suspension steering 310
- Torque values 310
- Troubleshooting 310
- Disconnect the clutch switch connectors remove the bolts master cylinder holder and clutch master cylinder from the handlebar 311
- Front wheel suspension steering 311
- Handlebar 311
- Left handlebar switch housing 311
- Release the wire bands 311
- Removal 311
- Remove the attaching screws and the left handlebar switch housing from the handlebar screws 311
- Front wheel suspension steering 312
- Front wheel suspension steering 313
- Installation 313
- Front wheel suspension steering 314
- Front wheel suspension steering 315
- Front wheel 316
- Front wheel suspension steering 316
- Removal 316
- Front wheel suspension steering 317
- Loosen the left axle pinch bolts pull the front axle out and remove the front wheel 317
- Loosen the right axle pinch bolts loosen the axle bolt 317
- Raise the front wheel off the ground by supporting the frame securely 317
- Remove the axle bolt 317
- Remove the bolt caps from the right and left axle pinch bolts 317
- Remove the side collar from the left side of the wheel 317
- Remove the side collar from the right side of the wheel 317
- Disassembly 318
- Front wheel suspension steering 318
- Inspection 318
- Assembly 319
- Front wheel suspension steering 319
- Front wheel suspension steering 320
- Front wheel suspension steering 321
- Installation 321
- Front wheel suspension steering 322
- Removal 322
- Front wheel suspension steering 323
- Right fork disassembly 323
- Front wheel suspension steering 324
- Hold the damper rod lock nut with a spanner then loosen and remove the fork cap from the damper rod 324
- Loosen the lock nut as shown while pushing down the spring collar remove the spring seat stopper 324
- Pour out the fork fluid by pumping the fork pipe up and down several times 324
- Pour out the remaining fork fluid by pumping the fork damper rod up and down several times 324
- Remove the fork spring 324
- Remove the spring collar 324
- Front wheel suspension steering 325
- Hold the fork pipe in a vise with soft jaws or shop towel 325
- Remove the dust seal 325
- Remove the fork damper and centering plate fork damper centering plate 325
- Remove the fork socket bolt and sealing washer with a hex wrench 325
- Remove the stopper ring 325
- Socket bolt sealing washer 325
- Front wheel suspension steering 326
- Left fork disassembly 326
- Front wheel suspension steering 327
- Hold the rod lock nut with a spanner then loosen and remove the fork cap from the rod remove the rubber stopper from the rod 327
- Pull down the outer pipe so the inner fork bolt is visi ble remove the inner fork bolt 327
- Remove the fork cap from the outer pipe slide outer pipe down onto the axle holder 327
- Rubber stopper pull down the rubber stopper 327
- Tool lock nut wrench 36 x 44 mm 07vma mz0010a 327
- Front wheel suspension steering 328
- Front wheel suspension steering 329
- Inspection 329
- Front wheel suspension steering 330
- Front wheel suspension steering 331
- Front wheel suspension steering 332
- Right fork assembly 332
- Front wheel suspension steering 333
- Front wheel suspension steering 334
- Front wheel suspension steering 335
- Front wheel suspension steering 336
- Left fork assembly 336
- Front wheel suspension steering 337
- Front wheel suspension steering 338
- Front wheel suspension steering 339
- Front wheel suspension steering 340
- Installation 340
- Front wheel suspension steering 341
- Removal 341
- Steering stem 341
- Front wheel suspension steering 342
- Bearing replacement 343
- Front wheel suspension steering 343
- Front wheel suspension steering 344
- Installation 344
- Front wheel suspension steering 345
- Front wheel suspension steering 346
- Front wheel suspension steering 347
- Front wheel suspension steering 348
- Steering head bearing pre load 348
- Rear wheel suspension 349
- Rear wheel 14 3 350
- Rear wheel suspension 350
- Service information 350
- Service information 14 1 shock absorber 14 11 350
- Troubleshooting 14 2 swingarm 14 12 350
- Rear wheel suspension 351
- Troubleshooting 351
- Loosen and remove the rear axle nut remove the rear caliper stopper pin bolt 352
- Move the rear wheel to the right to separate it from the final gear case and remove the rear wheel 352
- Pull out the rear axle then remove the rear caliper from the brake disc 352
- Raise the rear wheel off the ground and support the motorcycle firmly 352
- Rear wheel 352
- Rear wheel suspension 352
- Removal 352
- Remove the bolts and license plate bracket 352
- Remove the exhaust system page 2 3 352
- Inspection 353
- Rear wheel suspension 353
- Disassembly 354
- Rear wheel suspension 354
- Rear wheel suspension 355
- Assembly 356
- Rear wheel suspension 356
- Rear wheel suspension 357
- Rear wheel suspension 358
- Installation 359
- Rear wheel suspension 359
- Inspection 360
- Rear wheel suspension 360
- Removal 360
- Shock absorber 360
- Installation 361
- Rear wheel suspension 361
- Removal 361
- Swingarm 361
- Inspection 362
- Rear wheel suspension 362
- Installation 363
- Pivot bearing outer race replacement 363
- Rear wheel suspension 363
- Rear wheel suspension 364
- Rear wheel suspension 365
- Rear wheel suspension 366
- Hydraulic brake 368
- Caution 369
- General 369
- Hydraulic brake 369
- Service information 369
- Specification 369
- Hydraulic brake 370
- Torque values 370
- Troubleshooting 370
- Brake fluid draining 371
- Brake fluid replacement air bleeding 371
- Connect a bleed hose to the front caliper lower bleed valve 371
- Connect a bleed hose to the upper bleed valve 371
- Front turn the handlebar to the left until the reservoir is level remove the screws reservoir cap diaphragm plate diaphragm and float 371
- Hydraulic brake 371
- Install the bolt remove the reservoir cap diaphragm plate and diaphragm 371
- Loosen the front caliper lower bleed valve and pump the brake lever stop operating the brake when fluid stops flowing out of the front caliper lower bleed valve 371
- Loosen the upper bleed valve and pump the brake lever stop operating the brake when fluid stops flowing out of the upper bleed valve 371
- Make sure the master cylinder is parallel to the ground before removing the reservoir cover 371
- Once the hydraulic system has been opened or if the brake feels spongy the system must be bled when using a commercially available brake bleeder follow the manufacturer s operating instructions 371
- Rear linked remove bolt and the reservoir cover 371
- Tighten the front caliper lower bleed valve securely 371
- Brake fluid filling air bleeding 372
- Hydraulic brake 372
- Hydraulic brake 373
- Hydraulic brake 374
- Hydraulic brake 375
- Hydraulic brake 376
- Brake pad disc 377
- Brake pad replacement 377
- Hydraulic brake 377
- Hydraulic brake 378
- Brake disc inspection 379
- Front master cylinder 379
- Hydraulic brake 379
- Removal 379
- Disassembly 380
- Hydraulic brake 380
- Hydraulic brake 381
- Inspection 381
- Assembly 382
- Hydraulic brake 382
- Hydraulic brake 383
- Installation 383
- Front caliper 384
- Hydraulic brake 384
- Removal 384
- Disassembly 385
- Hydraulic brake 385
- Assembly 386
- Hydraulic brake 386
- Inspection 386
- Hydraulic brake 387
- Installation 387
- Hydraulic brake 388
- Rear master cylinder 388
- Removal 388
- Disassembly 389
- Hydraulic brake 389
- Assembly 390
- Hydraulic brake 390
- Inspection 390
- Coat the master piston and piston cups with clean dot 4 brake fluid install the spring onto the primary piston cup install the spring primary piston cup into the master cylinder 391
- Hydraulic brake 391
- If the pushrod is reinstalled adjust the pushrod length so that the distance from the center of the master cylinder rear mounting bolt hole to the center of the joint pin hole is 65 mm 2 in after adjustment tighten the lock nut to the specified torque 391
- Install the piston boot to the groove on the rear mas ter cylinder body 391
- Install the pushrod piston into the master cylinder install the snap ring using the special tool 391
- Snap ring pliers 07914 sa50001 391
- Torque 18 n m 1 kgf m 13 ibf ft 391
- Hydraulic brake 392
- Installation 392
- Hydraulic brake 393
- Rear master cylinder reservoir 393
- Disassembly 394
- Hydraulic brake 394
- Rear caliper 394
- Removal 394
- Hydraulic brake 395
- Inspection 395
- Assembly 396
- Hydraulic brake 396
- Brake pedal 397
- Hydraulic brake 397
- Installation 397
- Removal 397
- Hydraulic brake 398
- Installation 398
- Pcv proportional control valve 398
- Removal installation 398
- Caution 400
- Charging system alternator 400
- Service information 400
- Charging system alternator 401
- Specification 401
- Torque values 401
- Troubleshooting 402
- Battery 403
- Battery testing 403
- Charging system alternator 403
- Installation 403
- Removal 403
- Voltage inspection 403
- Battery charging 404
- Charging system alternator 404
- Charging system alternator 405
- Charging system inspection 405
- Current leakage test 405
- Battery case 406
- Charging system alternator 406
- Charging voltage inspection 406
- Removal installation 406
- Charging system alternator 407
- Regulator rectifier 407
- Removal installation 407
- Wire harness inspection 407
- Alternator 408
- Charging system alternator 408
- Inspection 408
- Left crankcase cover removal 408
- Charging system alternator 409
- Charging system alternator 410
- Left crankcase cover installation 410
- Stator removal installation 410
- Charging system alternator 411
- Charging system alternator 412
- Ignition system 413
- Ignition system 414
- Ignition system inspection 17 3 414
- Service information 414
- Service information 17 1 ignition coil 17 5 414
- Troubleshooting 17 2 ignition timing 17 5 414
- Ignition system 415
- No spark at spark plugs 415
- Troubleshooting 415
- Ignition coil primary peak voltage 416
- Ignition system 416
- Ignition system inspection 416
- Ignition pulse generator peak voltage 417
- Ignition system 417
- Front ignition coil 418
- Ignition coil 418
- Ignition system 418
- Ignition timing 418
- Rear ignition coil 418
- Ignition system 419
- Electric starter starter clutch 421
- Service information 421
- Electric starter starter clutch 422
- Starter motor will not turn 422
- Troubleshooting 422
- Electric starter starter clutch 423
- Starter motor turns when the transmission is in neutral but does not turn with the transmission in any position except neutral with the side stand up and the clutch lever pulled in 423
- Disassembly 424
- Electric starter starter clutch 424
- Rear cover 424
- Release the rubber cap and remove the terminal nut to disconnect the starter motor cable 424
- Removal 424
- Remove the bolts and starter motor 424
- Remove the o ring from the starter motor 424
- Remove the starter drive gear page 18 12 424
- Remove the starter motor case bolts and rear cover 424
- Starter motor 424
- Electric starter starter clutch 425
- Inspection 425
- Electric starter starter clutch 426
- Electric starter starter clutch 427
- Assembly 428
- Electric starter starter clutch 428
- Install the following o ring insulators washer nut 428
- Set the collar on the brush terminal set the brush terminal on the brush holder install the brush holder onto the motor case 428
- Align the index lines on the front cover and motor case 429
- Apply grease to the oil seal lips and bearing and install the front cover by aligning its lugs with the lock washer tab 429
- Assemble the motor case and rear cover aligning the brush holder boss with the groove in the rear cover 429
- Electric starter starter clutch 429
- Install and tighten the starter motor case bolt to the specified torque 429
- Install the armature in the motor case 429
- Install the insulated washer and lock washer on the armature shaft 429
- Install the seal ring onto the motor case install the shims on the armature shaft 429
- Install the shims on the armature shaft 429
- Rear cover 429
- Seal ring insulated front 429
- Shims lock washer armature 429
- Shims seal ring 429
- Torque 5 n m 0 kgf m 3 ibf ft 429
- Electric starter starter clutch 430
- Inspection 430
- Installation 430
- Starter relay switch 430
- Electric starter starter clutch 431
- Operation check 431
- Removal installation 431
- Electric starter starter clutch 432
- Flywheel starter clutch 432
- Left crankcase cover bearing replacement 432
- Starter driven gear torque lim iter removal 432
- Electric starter starter clutch 433
- Left crankcase bearing replace ment 433
- Starter drive gear inspection 433
- Electric starter starter clutch 434
- Flywheel removal 434
- Starter torque limiter inspec tion 434
- Electric starter starter clutch 435
- Starter clutch removal 435
- Electric starter starter clutch 436
- Starter clutch inspection 436
- Starter clutch installation 436
- Electric starter starter clutch 437
- Flywheel installation 437
- Balancer weight 438
- Electric starter starter clutch 438
- Removal 438
- Starter driven gear torque lim iter installation 438
- Electric starter starter clutch 439
- Installation 439
- Lights meters switches 441
- Service information 441
- Lights meters switches 442
- Specification 442
- Torque values 442
- Lights meters switches 443
- Troubleshooting 443
- Vehicle speed sensor speedometer 443
- Avoid touching halogen headlight bulb fingerprints can create hoy spots that will cause the bulb to break 444
- Bulb replacement 444
- Headlight 444
- Lights meters switches 444
- Notice 444
- Bulb replacement 445
- Front turn signal assembly removal installation 445
- Headlight case removal instal lation 445
- Lights meters switches 445
- Turn signals 445
- Bulb replacement 446
- License light 446
- Lights meters switches 446
- Tail brake light 446
- Disassembly assembly 447
- Indicator box 447
- Lights meters switches 447
- Removal installation 447
- Lights meters switches 448
- Removal installation 448
- Speedometer 448
- Lights meters switches 449
- Output signal inspection 449
- Vehicle speed sensor 449
- Voltage inspection 449
- Lights meters switches 450
- Removal installation 450
- Front brake light switch 451
- Inspection 451
- Lights meters switches 451
- Neutral switch 451
- Rear brake light switch 451
- Removal installation 451
- Clutch switch 452
- Ignition switch 452
- Inspection 452
- Lights meters switches 452
- Removal installation 452
- Handlebar switch 453
- Left handlebar switch 453
- Lights meters switches 453
- Fan motor switch 454
- Inspection 454
- Lights meters switches 454
- Right handlebar switch 454
- Coolant temperature indicator 455
- Lights meters switches 455
- Removal installation 455
- Ect thermo sensor unit inspec tion 456
- Inspection 456
- Lights meters switches 456
- Side stand switch 456
- Inspection 457
- Installation 457
- Lights meters switches 457
- Oil pressure indicator 457
- Removal 457
- Inspection 458
- Lights meters switches 458
- Oil pressure switch removal installation 458
- Fuel reserve sensor 459
- Inspection 459
- Lights meters switches 459
- Removal installation 459
- Turn signal relay 459
- Wiring diagram 460
- Troubleshooting 461
- Engine lacks power 462
- Troubleshooting 462
- Poor handling 464
- Poor performance at high speed 464
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GENERAL INFORMATION r CRANKSHAFT TRANSMISSION ITEM Crankshaft STANDARD Connecting rod side clearance 0 10 0 25 0 004 0 010 0 28 Crankpin bearing oil clearance 0 032 0 062 0 0015 0 0024 0 070 Main journal bearing oil clearance 0 030 0 054 0 0011 0 0021 0 068 Runout Shift fork fork shaft 0 05 I D 14 000 14 018 0 5512 0 5519 14 04 Claw thickness 5 93 6 00 0 233 0 236 5 83 Shift fork shaft O D Transmission SERV Gear I D Gear bushing O D 13 966 13 984 0 5498 0 5506 13 95 M4 M5 31 000 31 025 1 2205 1 2215 31 03 C1 30 000 30 025 1 1811 1 1821 30 03 C2 C3 33 000 33 025 1 2992 1 3002 33 03 M4 M5 30 950 30 975 1 2185 1 2195 30 94 C1 25 987 26 000 1 0232 1 0236 25 97 C2 C3 32 950 32 965 1 2972 1 2978 32 94 Gear to bushing clearance M4 M5 0 025 0 075 0 0010 0 0030 0 095 C2 C3 0 035 0 075 0 0014 0 0030 0 095 Gear bushing I D M4 27 985 28 006 1 1018 1 1025 28 03 Cl 22 050 22 150 0 8681 0 8720 22 17 C2 C3 30 000 30 030 1 1811 1 1823 30 05 at M4 27 959 27 980 1 1007 1 1016 27 94 clutch outer guide 27 980 27 993 1 1016 1 1021 27 97 at C1 21 980 21 993 0 8653 0 8659 21 97 at C2 C3 29 959 29 980 1 1795 1 1803 29 94 M4 0 005 0 047 0 0002 0 0019 0 067 C1 0 057 0 170 0 0022 0 0067 0 190 C2 C3 0 020 0 071 0 0008 0 0028 0 091 Mainshaft O D Countershaft O D Bushing to shaft clearance U CIMAI hOIMC ITEM STANDARD Recommended final drive oil Final drive oil capacity Final drive gear backlash Backlash difference between measurement SER Hypoid gear oil SAE 80 at disassembly 150 cm3 5 1 US oz 5 3 Imp oz at draining 120 cm3 4 1 US oz 4 2 Imp oz 0 05 0 015 0 002 0 006 0 30 0 10 Ring gear to stop pin clearance 0 30 0 60 0 012 0 024 Final drive gear assembly preload 0 2 0 4 N m 2 4 kgf cm 1 7 3 5 lbf ft