![Honda CBR900RR (1996-1998) [16/407] Engine](/img/pdf.png)
Honda CBR900RR (1996-1998) [16/407] Engine
![Honda CBR900RR (1996-1998) [16/407] Engine](/views2/1121100/page16/bg10.png)
Содержание
- E e ee eq 2
- Ee ke ee 2
- How to use this manual contents 2
- Symbols 3
- General info 4
- General information 4
- General safety 4
- General safety 1 1 lubrication seal points 1 19 4
- Model identification 1 3 emission control systems 4
- Service rules 1 2 cable harness routing 1 22 4
- Specifications 1 4 u s a only 1 36 4
- Tools 1 17 4
- Torque values 1 13 emission control information labels u s a only 1 39 4
- General information 5
- Service rules 5
- General information 6
- Model identification 6
- General 7
- General information 7
- Specifications 7
- General cont d 8
- General information 8
- Fuel system 9
- General information 9
- Lubrication system 9
- Service umit 9
- Cooling system 10
- Cylinder head valves 10
- General information 10
- Alternator starter clutch 11
- Clutch gearshift linkage 11
- General information 11
- Service limit 11
- Standard 11
- Crankshaft transmission 12
- General information 12
- General information 13
- Item standard service limit 13
- Nchn vvrilll ouor limoiuiv 13
- Battery charging system 14
- General information 14
- Hydraulic brake 14
- Standard 14
- Electric starter 15
- General information 15
- Ignition system 15
- Lights meters switches 15
- Specifications 15
- Engine 16
- General information 16
- Remarks 16
- Torque 16
- Torque values 16
- Engine cont d 17
- General information 17
- General information 18
- Frame cont d 19
- General information 19
- Description 20
- General information 20
- General information 21
- Engine 22
- General information 22
- Lubrication seal points 22
- Engine cont 23
- General information 23
- Engine cont d 24
- General information 24
- Location 24
- Cable harness routing 25
- General information 25
- General information 26
- General information 28
- General information 29
- General information 30
- General information 31
- General information 32
- General information 33
- 4 starter 36
- Atter 97 36
- General information 36
- General information 38
- Secondary air supply system routing california type only 38
- Crankcase emission control system 39
- Emission control systems u s a only 39
- General information______________________ ______________________________________________ 39
- Source of emissions 39
- Evaporative emission control system california type only 40
- General information 40
- Noise emission control system 40
- California only 41
- General information 41
- Emission control information 42
- General information 42
- Labels u s a only 42
- Vacuum hose routing diagram label california type only 42
- Vehicle emission control information update label 42
- Frame body exhaust 44
- Rhaivic duut thnelo tanhuoi otoilivi 44
- Service information 44
- Troubleshooting 44
- Frame body panels exhaust system 45
- Removal 45
- Seat fuel tank 45
- Frame body panels exhaust system 46
- Installation 46
- Pillion seat side cover 46
- Removal 46
- Frame body panels exhaust system 47
- Frame body panels exhaust system 48
- Installation 48
- Frame body panels exhaust system 49
- Middle lower cowl 49
- Removal 49
- Special bolts 49
- Frame body panels exhaust system 50
- Installation 50
- Rearview mirror removal 50
- Upper cowl 50
- Frame body panels exhaust system 51
- Upper cowl removal 51
- Frame body panels exhaust system 52
- Frame body panels exhaust system 54
- Upper cowl installation 54
- Frame body panels exhaust system 55
- Rearview mirror installation 55
- Frame body panels exhaust system 56
- Front fender 56
- Installation 56
- Removal 56
- Torque 56
- Frame body panels exhaust system 57
- Rear fender 57
- Removal 57
- Frame body panels exhaust system 58
- Installation 58
- Removal 58
- Seat rail 58
- Frame body panels exhaust system 59
- Installation 59
- Muffler exhaust pipe 59
- Removal 59
- Frame body panels exhaust system 60
- Installation 60
- Frame body panels exhaust system 61
- Maintanance 62
- Maintenance 62
- Service information 62
- Maintenance 63
- Torque values 63
- Maintenance 64
- Maintenance schedule 64
- Fuel line 65
- Maintenance 65
- Throttle operation 65
- Air cleaner 66
- Carburetor choke 66
- Maintenance 66
- Spark plug 66
- Inspection 67
- Maintenance 67
- Replacing a spark plug 67
- Reusing a spark plug 67
- Inspection 68
- Maintenance 68
- Valve clearance 68
- Maintenance 69
- Exhaust vaives 70
- Maintenance 70
- Adjustment 71
- Maintenance 71
- Engine oil oil filter 72
- Maintenance 72
- Oil level inspection 72
- Oil viscosities 72
- Sae 10w40 72
- Sae 20w 50 72
- Engine oil filter change 73
- Maintenance 73
- Carburetor synchronization 74
- Maintenance 74
- Maintenance 75
- Engine idle speed 76
- Maintenance 76
- Radiator coolant 76
- California type only 77
- Cooling system 77
- Maintenance 77
- Secondary air supply system 77
- Drive chain 78
- Drive chain slack inspection 78
- Evaporative emission control 78
- Maintenance 78
- System california type only 78
- Adjustment 79
- Cleaning and lubrication 79
- Maintenance 79
- Maintenance 80
- Replacement 80
- Sprockets inspection 80
- Maintenance 81
- 3 cracked 82
- Brake fluid 82
- Front brake 82
- Maintenance 82
- Rear brake 82
- Brake pad wear 83
- Brake system 83
- Front brake pads 83
- Inspection 83
- Maintenance 83
- Rear brake pads 83
- Brake lever adjustment 84
- Brake light switch 84
- Brake pedal height adjustment 84
- Headlight aim 84
- Maintenance 84
- Clutch system 85
- Maintenance 85
- Front suspension adjustment 86
- Front suspension inspection 86
- Maintenance 86
- Side stand 86
- Suspension 86
- Maintenance 87
- Rear suspension inspection 87
- Maintenance 88
- Nuts bolts fasteners 88
- Rear suspension adjustment 88
- Front rear 89
- Maintenance 89
- Steering head bearings 89
- Wheels tires 89
- Lubrication system 91
- Lubrication system diagram 91
- Bibl tm 92
- Kiuaiiu 92
- Lubrication system 92
- Service information 92
- Lubrication system 93
- Troubleshooting 93
- Lubrication system 94
- Oil pressure inspection 94
- Inspection 95
- Lubrication system 95
- Oil str al n er pressu r e relief valve 95
- Removal 95
- Installation 96
- Lubrication system 96
- Disassembly 97
- Lubrication system 97
- Oil pump 97
- Removal 97
- Inspection 98
- Lubrication system 98
- Service limit 0 5 mm 0 14 in 98
- 3 pump shafi 99
- Assembly 99
- Lubrication system 99
- Installation 100
- Lubrication system 100
- Lubrication system 101
- Oil cooler 101
- Removal 101
- Inspection 102
- Installation 102
- Lubrication system 102
- Lubrication system 103
- Fuel system 106
- Njtlöybltm 106
- Service information 106
- Fuel system 107
- Specifications 107
- Torque values 107
- Fuel system 108
- Troubleshooting 108
- Air cleaner housing 109
- Fuel system 109
- Installation 109
- Removal 109
- Carburetor removal 110
- Fuel system 110
- 1 nuts 111
- Carburetor separation 111
- Fuel system 111
- Air funnel 112
- Carburetor disassembly 112
- Fuel system 112
- Diaphragm vacuum piston 113
- Fuel system 113
- Starting enrichment valve 113
- Caution 114
- Float and jets 114
- Fuel system 114
- 2 valve seat 115
- Fuel system 115
- Carburetor assembly 116
- Fuel system 116
- Fuel system 117
- 2 spring 118
- Diaphragm vacuum piston 118
- Fuel system 118
- Starting enrichment valve 118
- Air funnel 119
- Fuel system 119
- Fuel system 121
- Fuel system 122
- Fuel system 123
- Carburetor installation 124
- Fuel system 124
- Fuel system 125
- Idle drop procedure 125
- Pilot screw adjustment 125
- Fuel system 126
- High altitude adjustment 126
- U s a only 126
- California type only 127
- Fuel system 127
- Secondary air supply system 127
- System inspection 127
- Diaphragm replacement 128
- Fuel auto valve inspection 128
- Fuel system 128
- Fuel valve 128
- Fuel strainer cleaning 129
- Fuel system 129
- Coolant replacement 6 4 132
- Cooling system 132
- General 132
- Service information 132
- Service information 6 1 radiator 6 8 132
- Specifications 132
- System flow pattern 132
- System testing 6 3 radiator reserve tank 6 14 132
- Thermostat 6 5 132
- Torque values 132
- Troubleshooting 6 2 water pump 6 11 132
- Cooling system 133
- Troubleshooting 133
- Coolant hydrometer test 134
- Cooling system 134
- Radiator cap system pressure inspection 134
- System testing 134
- Coolant replacement 135
- Cooling system 135
- Preparation 135
- Replacement air bleeding 135
- Cooling system 136
- Removal 136
- Thermostat 136
- Cooling system 137
- Inspection 137
- Cooling system 138
- Installation 138
- Cooling system 139
- Disassembly 139
- Radiator 139
- Removal 139
- Cooling system 140
- Cooling system 141
- Cooling system 142
- Mechanical seal inspection 142
- Water pump 142
- After 97 143
- Cooling system 143
- Installation 143
- Removal 143
- Cooling system 144
- Cooling system 145
- Installation 145
- Radiator reserve tank 145
- Removal 145
- Engine removal installation 147
- 1 engine installation 148
- Engine removal 148
- Engine removal installation 148
- Engine removauinstallation 148
- General 148
- Service information 148
- Specifications 148
- Torque values 148
- Engine removal 149
- Engine removal installation_______________ 149
- Engine removal installation 150
- Engine removal installation 151
- Engine rem oval installation 152
- Engine installation 153
- Engine removal installation 153
- Engine removal installation 154
- Engine removal installation 155
- Engine removal installation 156
- Engine removal installation 157
- Cylinder head valves 159
- Cam chain tensioner lifter 8 25 160
- Camshaft installation 8 20 160
- Camshaft removal 8 5 160
- Cylinder compression test 8 4 160
- Cylinder head assembly 8 17 160
- Cylinder head cover installation 8 24 160
- Cylinder head cover removal 8 4 160
- Cylinder head disassembly 8 10 160
- Cylinder head inspection 8 11 160
- Cylinder head installation 8 19 160
- Cylinder head removal 8 9 160
- Cylinder head valves 160
- General 160
- Service information 160
- Service information 8 1 160
- Specifications 160
- Troubleshooting 8 3 160
- Valve guide replacement 8 14 160
- Valve seat inspection refacing 8 15 160
- Ö utlilwun nchu vhlvcö 160
- 780 00122ü0 161
- Cylinder head valves 161
- Torque values 161
- Cylinder head valves 162
- Troubleshooting 162
- Cylinder compression test 163
- Cylinder head cover removal 163
- Cylinder head valves 163
- Camshaft removal 164
- Cylinder head valves 164
- Cylinder head valves 165
- Cylinder head valves 166
- Inspection 166
- Cylinder head valves 167
- Service limit 0 0 mm 0 04 in 167
- Cylinder head removal 168
- Cylinder head valves 168
- Cylinder head disassembly 169
- Cylinder head valves 169
- Tool tappet hole protector 169
- Cylinder head 170
- Cylinder head inspection 170
- Cylinder head valves 170
- Cam chain tensioner cam chain guide 171
- Cylinder head valves 171
- Valve lifter 171
- Valve spring 171
- Cylinder head valves 172
- Service limits 172
- Valve lifter bore 172
- Valve valve guide 172
- Caution 173
- Cylinder head valves 173
- Not available in u s a 173
- Valve guide replacement 173
- Cylinder head valves 174
- Valve seat inspecti0n refacing 174
- Valve seat refacing 174
- Cylinder head valves 175
- Cylinder head assembly 176
- Cylinder head valves 176
- Cylinder head valves 177
- Tool tappet hole protector 07hmg mr70002 not available in u s a 177
- Tool valve spring compressor 07757 0010000 177
- Valve spring compressor attachment 07959 km30101 177
- Cylinder head installation 178
- Cylinder head valves 178
- Camshaft installation 179
- Cylinder head valves 179
- Cylinder head valves 180
- Cylinder head valves 181
- Cylinder head valves 182
- Cylinder head cover installation 183
- Cylinder head valves 183
- Torque 10 n m 1 kgfm 7 ihf ft 183
- Cam chain tensioner lifter 184
- Cylinder head valves 184
- Removal 184
- Cylinder head valves 185
- Installation 185
- Cylinder head valves 186
- Clutch gearshift linkage 187
- Clutch gearshift linkage 188
- General 188
- Right crankcase cover installation 9 16 188
- Right crankcase cover removal 9 3 188
- Service information 188
- Service information 9 1 clutch 9 4 188
- Specifications 188
- Torque values 188
- Troubleshooting 9 2 gearshift linkage 9 11 188
- Ulu i un utanbnlf i lin k abt 188
- Clutch gearshift linkage 189
- Troubleshooting 189
- Clutch gearshift linkage 190
- Clutch lifter inspection 190
- Right crankcase cover removal 190
- 2 dus1 seal 191
- Clutch 191
- Clutch gearshift linkage 191
- Removal 191
- Clutch gearshift linkage 192
- 96 97 49 mm 1 3 in 193
- Clutch gearshift linkage 193
- Inspection 193
- Clutch gearshift linkage 194
- Attachment 37 x 40 mm 195
- Clutch gearshift linkage 195
- Clutch outer needle bearing replace ment 195
- Installation 195
- Clutch gearshift linkage 196
- 4 clutch pi atfs 197
- Clutch gearshift linkage 197
- Clutch gearshift linkage 198
- Gearshift linkage 198
- Gearshift linkage removal 198
- Clutch gearshift linkage 199
- Gearshift linkage inspection 199
- Shift drum shift fork removal 199
- Clutch gearshift linkage 200
- Shift drum shift fork inspection 200
- Clutch gearshift linkage 201
- Shift drum shift fork installation 201
- Clutch gearshift linkage 202
- Gearshift linkage installation 202
- Clutch gearshift linkage 203
- Installation 203
- Right crankcase cover 203
- Clutch gearshift linkage 204
- Altern ato k sl ak i tk llui uh 206
- Alternator clutch 206
- Alternator cover removal 10 2 flywheel installation 10 7 206
- General 206
- Service information 206
- Service information 10 1 flywheel removal 10 4 206
- Specifications 206
- Stator 10 3 alternator cover installation 10 8 206
- Torque values 206
- Troubleshooting 206
- Troubleshooting 10 1 starter clutch 10 5 206
- Alternator cover removal 207
- Alternator starter clutch 207
- Alternator starter clutch 208
- Installation 208
- Removal 208
- Stator 208
- Torque 12 n m 1 kgf m 9 ibf ft 208
- 3950000 209
- Alternator starter clutch 209
- Flywheel holder 07725 0040000 209
- Flywheel removal 209
- Alternator starter clutch 210
- Disassembly 210
- Inspection 210
- Starter clutch 210
- 1 one way assembly 211
- Alternator starter clutch 211
- Assembly 211
- Alternator starter clutch 212
- Equivalent commercially 212
- Flywheel installation 212
- Alternator cover installation 213
- Alternator starter clutch 213
- Alternator starter clutch 214
- Crankcase piston cylinder 215
- 1 piston connecting rod 11 4 216
- 2 crankcase combination 11 12 216
- Crankcase piston cylinder 216
- Crankcase separation 216
- General 216
- Service information 216
- Specifications 216
- Troubleshooting 216
- Ukankuaot rlo i un uylinutn 216
- Crankcase piston cylinder 217
- Engine vibration 217
- Torque values 217
- Troubleshooting 217
- Crankcase piston cylinder 218
- Crankcase separation 218
- Caution 219
- Crankcase piston cylinder 219
- Piston connecting rod 219
- Piston connecting rod removal 219
- Piston disassembly 219
- Piston removal 219
- Crankcase piston cylinder 220
- Piston inspection 220
- Service limits 220
- Crankcase piston cylinder 221
- Cylinder inspection 221
- Connecting rod inspection 222
- Crankcase piston cylinder 222
- Crankpin bearing inspection 222
- Crankcase piston cylinder 223
- Crankpin bearing selection 223
- Service limit 0 06 mm 0 02 in 223
- Crankcase piston cylinder 224
- Crankpin bearing selection table 224
- Crankcase piston cylinder 225
- Piston assembly 225
- Piston installation 225
- Caution 226
- Crankcase piston cylinder 226
- Crankcase combination 227
- Crankcase piston cylinder________________ 227
- Cranksh aft transmission 230
- Crankshaft transmission 230
- General 230
- I 19 i 230
- Service information 230
- Service information 12 1 crankshaft 12 3 230
- Specifications 230
- Troubleshooting 12 2 transmission 12 9 230
- Crankshaft transmission 231
- Hard to shift 231
- Torque values 231
- Troubleshooting 231
- Crankshaft 232
- Crankshaft transmission 232
- Removal 232
- Crankshaft transmission 233
- Primary drive sub gear installation 233
- Primary drive sub gear removal 233
- Caution __________________________ 234
- Crankshaft transmission 234
- Starter clutch needle bearing replacement 234
- Tool attachment b collar 07964 mb00200 234
- Crankshaft transmission 235
- Inspection 235
- Crankshaft transmission 236
- Main journal bearing selection 236
- C green 237
- Crankshaft transmission 237
- Installation 237
- Main journal bearing selection table 237
- Crankshaft transmission 238
- Removal disassembly 238
- Transmission 238
- Crankshaft transmission 239
- Measure the i d nt each gear 239
- Measure the ld and o d of each gear hushing 239
- Wear or damage 239
- Crankshaft transmission 240
- Crankshaft transmission 242
- Install the dowel pins on the upper crankcase holes 242
- Installation 242
- Torque 12 n m 1 kgf m 9 ibt ft 242
- Front wheel suspension steering 243
- Front wh eel sus pens 10 n steerin g 244
- Front wheel suspension steering 244
- General 244
- Handlebars 13 3 steering stem 13 23 244
- Service information 244
- Service information 13 1 front wheel 13 8 244
- Specifications 244
- Troubleshooting 13 2 fork 13 14 244
- Front wheel suspension steering 245
- Torque values 245
- Troubleshooting 245
- Unbalanced tire and wheel 245
- Front wheel suspension steering 246
- Handlebars 246
- Removal 246
- Front wheel suspension steering 247
- Front wheel suspension steering 248
- Installation 248
- Front wheel suspension steering 249
- Front wheel suspension steering 250
- Front wheel 251
- Front wheel suspension steering 251
- Removal 251
- Front wheel suspension steering 252
- Inspection 252
- Front wheel suspension steering 253
- Disassembly 254
- Front wheel suspension steering 254
- Front wheel suspension steering 255
- Installation 255
- Torque 20 n m 2 kgf m 14 ibf ft 255
- Front wheel suspension steering 256
- Torque 22 n m 2 kgf m 16 lbf ft 256
- Front wheel suspension steering 257
- Removal 257
- Disassembly 258
- Front wheel suspension steering 258
- Front wheel suspension steering 259
- Fork spring 260
- Front wheel suspension steering 260
- Inspection 260
- Service limit 260
- Wmwwwm 260
- 2 back up ring 261
- Compression adjuster 261
- Front wheel suspension steering 261
- 12 fork damper 262
- Assembly 262
- Front wheel suspension steering 262
- Front wheel suspension steering 263
- Front wheel suspension steering 264
- Ih mwwwm 264
- Front wheel suspension steering 265
- Installation 265
- Removal 266
- Steering stem 266
- Front wheel suspension steering 267
- Attachment 268
- Bearing replacement 268
- Front wheel suspension steering 268
- Front wheel suspension steering 269
- Front wheel suspension steering 270
- U s a only 270
- Front wheel suspension steering 271
- Front wheel suspension steering 272
- Front wheel suspension steering 273
- Installation 273
- Front wheel suspension steering 274
- Torque 25 n m 2 kgf m 18 ibf ft 274
- Front wheel suspension steering 275
- Steering head bearing pre load 275
- General 278
- Rear wheel 14 3 swingarm 14 16 278
- Rear wheel suspension 278
- Rear wnttuduortnblun 278
- Service information 278
- Service information 14 1 shock absorber 14 9 278
- Specifications 278
- Troubleshooting 14 2 suspension linkage 14 14 278
- Rear wheel suspension 279
- Torque values 279
- Troubleshooting 279
- Inspection 280
- Rear wheel 280
- Rear wheel suspension 280
- Removal 280
- Disassembly 281
- Rear wheel suspension 281
- Rear wheel suspension 282
- Assembly 283
- Rear wheel suspension 283
- Rear wheel suspension 284
- Installation 285
- Rear wheel suspension 285
- Disassembly 286
- Rear wheel suspension 286
- Removal 286
- Shock absorber 286
- Inspection 287
- Rear wheel suspension 287
- Rear wheel suspension 288
- Shock absorber disposal procedure 288
- Rear wheel suspension 289
- Installation 290
- Rear wheel suspension 290
- Inspection 291
- Rear wheel suspension 291
- Removal disassembly 291
- Suspension linkage 291
- Installation 292
- Rear wheel suspension 292
- Rear wheel suspension 293
- Removal 293
- Swingarm 293
- Rear wheel suspension 294
- Disassembly inspection 295
- Rear wheel suspension 295
- Rear wheel suspension 296
- 0010000 07746 0010200 07746 0040500 297
- 0010000 07746 0010200 07746 0041100 297
- Driver attachment 37 x 40 mm pilot 20 mm 297
- Driver attachment 37 x 40 mm pilot 28 mm 297
- Rear wheel suspension 297
- Assembly 298
- Cover a 298
- Cover b 298
- Rear wheel suspension 298
- Installation 299
- Rear wheel suspension 299
- Rear wheel suspension 300
- Rear wheel suspension 301
- Hydraulic brake 303
- Air bleeding 15 3 brake pedal 15 29 304
- Brake fluid replacement rear brake caliper 15 26 304
- Brake pad disc 15 5 304
- Front master cylinder 15 10 304
- General 304
- Hydraulic brake 304
- Lb nyunaulil bnakt 304
- Service information 304
- Service information 15 1 rear master cylinder 15 14 304
- Specifications 304
- Troubleshooting 15 2 front brake caliper 15 18 304
- Brake drag 305
- Brake grab or pull to one side 305
- Brake lever pedal hard 305
- Brake lever pedal soft or spongy 305
- Hydraulic brake 305
- Not available in u s a 305
- Torque values 305
- Troubleshooting 305
- Bleeding 306
- Brake fluid draining 306
- Brake fluid filling 306
- Brake fluid replacement air 306
- Hydraulic brake 306
- Brake bleeding 307
- Hydraulic brake 307
- Brake pad disc 308
- Front brake pad replacement 308
- Hydraulic brake 308
- Caution 309
- Hydraulic brake 309
- Torque 2 n m 0 5 kgf m 1 ibf ft 309
- Hydraulic brake 310
- Hydraulic brake 311
- Rear brake pad replacement 311
- Brake disc inspection 312
- Hydraulic brake 312
- Disassembly 313
- Front master cylinder 313
- Hydraulic brake 313
- Removal 313
- Hydraulic brake 314
- Inspection 314
- 11 snap hing 315
- Assembly 315
- Hydraulic brake 315
- Install the boot 315
- Install the snap ring using the special tool 315
- Hydraulic brake 316
- Disassembly 317
- Hydraulic brake 317
- Rear master cylinder 317
- Removal 317
- Hydraulic brake 318
- Inspection 318
- Assembly 319
- Caution 319
- Hydraulic brake 319
- Hydraulic brake 320
- Installation 320
- Caution 321
- Front brake caliper 321
- Hydraulic brake 321
- Removal 321
- Caution __________ 322
- Disassembly 322
- Hydraulic brake 322
- Assembly 323
- Hydraulic brake 323
- Inspection 323
- Hydraulic brake 324
- Installation 324
- Disassembly 325
- Hydraulic brake 325
- Removal 325
- Hydraulic brake 326
- Inspection 326
- 2 piston a 327
- Assembly 327
- Hydraulic brake 327
- Hydraulic brake 328
- Installation 328
- Caution 329
- Disassembly 329
- Hydraulic brake 329
- Rear brake caliper 329
- Removal 329
- Hydraulic brake 330
- Inspection 330
- Assembly 331
- Hydraulic brake 331
- Brake pedal 332
- Hydraulic brake 332
- Installation 332
- Removal 332
- Hydraulic brake 333
- Hydraulic brake 334
- Installation 334
- Hydraulic brake 335
- Step guard 335
- Torque 26 n m 2 kgf m 20 ibt ftl 335
- Battery charging system 337
- System diagram 337
- Battery charging system 338
- I tny uhanülnü öyöieivi 338
- Battery charging system 339
- Specifications 339
- Battery charging system 340
- Troubleshooting 340
- _________________________________________ 340
- Battery charging system 341
- Battery overcharging regulated voltage too high 341
- Battery 342
- Battery charging 342
- Battery charging system 342
- Installation 342
- Removal 342
- Voltage inspection 342
- Battery charging system 343
- Charging system inspection 343
- Regulated voltage inspection 343
- Battery charging system 344
- Current leakage inspection 344
- Alternator charging coil 345
- Battery charging system 345
- Inspection 345
- Regulator rectifier 345
- System inspection 345
- Battery charging system 346
- Removal installation 346
- Ignition system 347
- System diagram 347
- After 97 348
- Ignition system 348
- Caution 349
- General 349
- Ignition system 349
- Ignition system inspection 17 4 ignition timing 17 11 349
- Service information 349
- Service information 17 2 ignition pulse generator 17 7 349
- Specifications 349
- System diagram 17 0 ignition coil 17 6 349
- Torque values 349
- Troubleshooting 17 3 throttle sensor 17 10 349
- Ignition system 350
- No spark at all plugs 350
- Troubleshooting 350
- Ignition coil primary peak voltage 351
- Ignition system 351
- Ignition system inspection 351
- Ignition pulse generator peak voltage 352
- Ignition system 352
- Ignition coil 353
- Ignition system 353
- Removal installation 353
- Ignition pulse generator 354
- Ignition system 354
- Removal 354
- Ignition system 355
- Installation 355
- Ignition system 356
- Ignition system 357
- Inspection 357
- Throttle sensor 357
- 100 100 rpm 358
- California type 1 200 100 rpm 358
- Continuity inspection 358
- Ignition system 358
- Ignition timing 358
- Ignition system 359
- Electric stater 361
- System diagram 361
- Electric starter 362
- Electric stater 362
- Service information 362
- Electric stater 363
- Normal 363
- Troubleshooting 363
- Electric stater 364
- Normal 364
- Disassembly 365
- Electric starter 365
- Removal 365
- Starter motor 365
- Electric starter 366
- Inspection 366
- Electric starter 367
- Assembly 368
- Electric starter 368
- 1 bhush 369
- Electric starter 369
- Electric starter 370
- Installation 370
- Connect the starter relay switch connector 371
- Continuity inspection 371
- Electric starter 371
- Ground line inspection 371
- Operation inspection 371
- Starter relay switch 371
- Voltage inspection 371
- Electric starter 372
- Inspection 372
- Installation 372
- Removal 372
- 11 speed sensor 373
- 2 ignition switch 373
- 3 combination meter 373
- 4 front brake light 373
- 5 fan motor switch 373
- 6 neutral switch 373
- 7 side stand switch 373
- 8 oil pressure switch 373
- After 97 373
- After 97 1 clutch switch 373
- Blnsuh 373
- Brake light switch 373
- Lights meters switches 373
- Sensor 373
- Switch 373
- Ycj ov 373
- Lights meters switches 374
- Service information 374
- Lights meters switches 375
- Specifications 375
- Torque values 375
- Lights meters switches 376
- Speed sensor speedometer 376
- Troubleshooting 376
- Bulb replacement 377
- Headlight 377
- Lights meters switches 377
- Bulb replacement 378
- Lights meters switches 378
- Position light 378
- Removal installation 378
- Bulb replacement 379
- Lights meters switches 379
- Removal installation 379
- Turn signal 379
- Bulb replacement 380
- License light 380
- Lights meters switches 380
- Tail brake light 380
- Combination meter 381
- Lights meters switches 381
- Removal 381
- Bulb replacement 382
- Disassembly 382
- Lights meters switches 382
- Lights meters switches 383
- Assembly 384
- Lights meters switches 384
- Assembly 385
- Indica tor 385
- Lights meters switches 385
- Installation 386
- Lights meters switches 386
- Sensor inspection 386
- Speedometer speed sensor 386
- After 97 387
- Connection black red green black standard repeat 0 to 5 v 387
- Connection pink green green black standard repeat 0 to 5 v 387
- Lights meters switches 387
- Output signal inspection 387
- Lights meters switches 388
- Removal installation 388
- Wire harness inspection 388
- Lights meters switches 389
- Removal installation 389
- Speed sensor 389
- After 97 390
- Connection black yellow and ground 390
- Inspection 390
- Lights meters switches 390
- Peak voltage 10 v minimum 390
- Tachometer 390
- Coolant temperature gauge sensor 391
- Inspection 391
- Lights meters switches 391
- Lights meters switches 392
- Thermo sensor unit inspection 392
- Cooling fan motor switch 393
- Inspection 393
- Lights meters switches 393
- Removal installation 393
- Inspection 394
- Lights meters switches 394
- Oil pressure switch 394
- Ignition switch 395
- Inspection 395
- Lights meters switches 395
- Removal installation 395
- Handlebar switches 396
- Lights meters switches 396
- Brake lightswitch 397
- Clutch switch 397
- Lights meters switches 397
- Neutral switch 397
- Inspection 398
- Installation 398
- Lights meters switches 398
- Removal 398
- Side stand switch 398
- Torque 10 n m 1 0 kgfm 7 ibf ft 398
- Broken ground wire 399
- Inspection 399
- Lights meters switches 399
- Turn signal relay 399
- A о o 400
- Wiring diagram 400
- Z mas 6700 400
- Д b c d 400
- О о о о 400
- О оо 400
- О р ю 400
- After 97 401
- Wiring diagram 401
- Z mas a000 401
- Engine does not start or is hard to start 402
- Engine does not start or is hard to start 21 1 402
- Engine lacks power 21 2 poor handling 21 4 402
- Poor performance at high speed 21 4 402
- Poor performance at low and idle speed 21 3 402
- Trouble shooting 402
- Zl inuubltônuuiinü 402
- Engine lacks power 403
- Possible cause 403
- Troubleshooting______________________________________________________ 403
- Poor performance at low and idle speed 404
- Troubleshooting 404
- Poor handling 405
- Poor performance at high speed 405
- Possible cause 405
- Troubleshooting 405
- Service information 407
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GENERAL INFORMATION TORQUE VALUES FASTENER TYPE TORQUE N m kgf m lbf ft 5 0 5 3 6 10 1 0 7 22 2 2 16 34 3 5 25 54 5 5 40 5 mm hex bolt and nut 6 mm hex bolt and nut 3 mm hex bolt and nut 10 mm hex bolt and nut 12 mm hex bolt and nut TORQUE FASTENER TYPE N m kgf m Ibfft 5 mm screw 6 mm screw and flange bolt SH type G mm flange bolt 8 mm head 6 mm flange bolt 10 mm head and nut 8 mm flange bolt and nut 10 mm flange bolt and nut 4 0 4 2 9 9 0 9 6 5 9 0 9 6 5 12 1 2 9 26 2 7 20 39 4 0 29 Torque specifications listed below are for important fasteners Others should be tightened to standard torque values listed above NOTES 1 Apply sealant to the threads 2 Apply a locking agent to the threads 3 Apply molybdenum disulfide oil to the threads and flange surface 4 Apply grease to the threads 5 Stake 6 Apply oil to the threads and flange surface 7 Apply clean engine oil to the O ring 8 U nut 9 ALOC bolt replace with a new one ENGINE ITEM MAINTENANCE Crankshaft hole cap Spark plug LUBRICATION SYSTEM Oil drain bull Oil filter cartridge Oil pump driven sprocket bolt Oil cooler boss COOLING SYSTEM Waler pump coverbolt Coolant temperature sensor FUEL SYSTEM Carburetor assembly bolt 5 mm 6 mm Vacuum plug for synchronization Roost joint for fuel valve Carburetor insulator band screw _____ Insulator band screw tightening CARBURETOR SIDE 10 5 0 5 mm Q TY THREAD DIA mm TORQUE N m kgf m lbf ft 1 4 45 10 18 1 8 13 12 12 8 7 1 1 1 1 12 20 6 20 29 3 0 22 10 1 0 7 2 15 1 5 11 64 6 5 47 NOTE 6 7 NOTE 2 NOTE 2 3 1 6 PT1 8 13 1 3 9 4 10 1 0 7 2 NOTE 1 1 1 3 1 5 6 5 5 5 5 0 5 4 10 1 0 7 2 3 0 0 30 2 2 2 5 0 25 1 8 3 REMARKS NOTE 4 See below
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