FUEL SYSTEM (Programmed Fuel Inje Route the throttle body sub-harness properly and connect the injector connectors and TP sensor connector. SUB-HARNESS Install the throttle body to the air cleaner case (page 5-55). INJECTOR INSPECTION Start the engine and let it ile. Confirm tho injector operating sounds with a sound- | ing rod or stethoscope. If the injector does not operate, replace the injector. REMOVAL Remove the throttle body (page 5-58) Remove the bolts and fuel rail assembly. Remove the injectors from the fuel rail. ae naASee ony INSULATOR 5-62FUEL SYSTEM (Programmed Fuel Injection) 4 INSTALLATION 0 Lanes onies Fepiece *n@ O- Apply oil to the new O-rings. ‘ings with new Install the new O-rings and being careful not to dam- oes 258.582 age the O-ring, Remove the O-rings. INJECTOR Install the fuel injectors into the fuel ral, being careful not to damage the O-rings. INJECTOR Install the fuel rail assembly onto the thrott careful not to damage the O-rings. Install and tighten the fuel rail mounting bolts to the specified torque. body, FUEL RAIL ASSEMBLY TORQUE: 12 Nem (1.2 kgfem, 9 Ibf-ft) Install the throttle body (page 5-68). Bours PRESSURE REGULATOR REMOVAL/INSTALLATION NOTE! Do not apply excessive force to the fuel rail. PRESSURE REGULATOR Hold the fuel rail securely, remove the pressure egulator mounting bolts, then remave the pressure regulator.FUEL SYSTEM (Programmed Fuel Injection) Disconnect the vacuum tube from the pressure regulator, GB ORG | [PRESSURE REguLATOR Install a new O-ring into the pressure regulator body. Install the pressure regulator onto the fuel pipe. ‘Connect the vacuum tube to the pressure regulator. Hold the fuel pipe securely, tighten the pressure regu- PRESSURE REGULATOR lator mounting bolts to the specified torque. TORQUE: 10 Nem (1.0 kgfem, 7 Itt) STARTER VALVE CABLE/THROTTLE ‘STARTER VAIVE CABLE STOP CONTROL KNOB REMOVAL CONTROL KNOB Donot tum Remove the cable stay mounting screws. the thrtto stop contro! kecb. Remove the starter valve cable end from the link arm, Remove the cable stay/throttle stop control knob. CABLE STAY ‘SCREWS INSTALLATION ‘STARTER VALVE CABLE Connect the starter valve cable end to the link arm. CONTROL KNOB Install the starter valve cable to the cable stay and tighten the cable stay mounting screws securely, 5-64FUEL SYSTEM (Programmed Fuel Injection) STARTER VALVE DISASSEMBLY Romove the fuel rail and injectors (page 5-62). STARTER VALVE Turn each starter valve adjusting screw in, counting the number of turns until it seats lightly. Record the number of turns. ‘STARTER VALVE ARM Remove the starter valve cable/thrattle stop control knob (page 5-62). Remove the starter valve arm screws and starter valve arm. VALVE ARMS. LINK ARM LINK ARM Remove the screws and link arm. Remove the starter valve shaft end three collars.FUEL SYSTEM (Programmed Fuel Injection) Loosen the lock nut and remove the starter val assembly. STARTER VALVES o not sly com- Clean the starter valve bypass using compressed air. mercially avaleble carburetor cleen- 2°10 the inside (of the throttle bore, which oatod with ‘motyodenum. ASSEMBLY FUEL RAIL VACUUM TUBES. 11 Nem (0.09 kgfom, 0.7 Ibeft) PRESSURE REGULATOR, b \ s THROTTLE stor CONTROL NOB sagt \ aR, INJECTOR ‘STARTER VALVE THROTTLE BODY BY-STARTER VALVE CONTROL NOB INSULATOR 5-66FUEL SYSTEM (Programmed Fuel Injection) CCheok the starter valve and spring for damage. STARTER VALVE Install the starter valve assembly into the valve hole. Tock NUT Tighten the starter valve lock nut to the specified torque. STARTER VALVE TORQUE: 2 Nem (0.18 kgfom, 1.3 Ibf-ft) Install the starter valve shaft and three collars. COLLARS ‘SHAFT LINK ARM LINK ARM. Install the link arm to the starter valve shaft and tight- en the mounting screws to the specified torque. TORQUE: 1 Nem (0.09 kgf-m, 0.7 Ibf-ft)FUEL SYSTEM (Programmed Fuel Injection) ‘STARTER VALVE ARM Install the starter valve arms onto the starter valves. Install and tighten the starter valve arm mounting ‘screws to the specified torque. TORQUE: 1 Nem (0.09 kgfom, 0.7 Ibf-ft) Install the starter valve cableithrottle stop control nob (page 5:64), ‘Turn the starter valve screw until it seats lightly, then back it out as noted during removal. Install the throttle body (page 5-66). STARTER VALVE SYNCHRONIZATION NOTE: ‘+ Synchronize the starter valve with the engine at the normal operating temperature and with the trans- mission in neutral + Use a tachometer with graduations of 60 rpm or smaller that will accurately indicate 50 rpm change. (Open and support the front end of fuel tank (page 3-15). Romove the No.1 and No.4 vacuum tubes from the ‘throttle body. Connect the tubes to the vacuum gauge. Connect the tachometer. 5-68 VALVE ARMS ‘STARTER VALVE ‘VACUUM TUBES VACUUM GAUGEFUEL SYSTEM (Programmed Fuel Inje Disconnect the PAIR air suction hoses from the reed valve covers and plug the cover. AIR SUCTION HOSE PLUG Start the engine and adjust the idle speed. IDLE SPEED: 1,200 = 100 min* (rpm) The No.2 starter Adjust each intake vacuum pressure with the No.2 valve cannot be eylinder. adjusted itis the base starter valve. Remove the plugs and connect the PAIR air suction hoses to the reed valve covers. Adjust the idle speed if the idle speed differs from the specified speed. IDLE SPEED: 1,200 = 100 min’ (rpm) Remove the vacuum gauge from the vacuum tubes. Connect the pressure regulator vacuum tubes to the Seway joint. Connect the No.1 and No.4 cylinder vacuum tube to the throttle body.FUEL SYSTEM (Programmed Fuel Injection) MAP SENSOR OUTPUT VOLTAGE INSPECTION Connect the test harness to the ECM (page 5-8). Measure the voltage at the test hamess terminals (page 5-9) CONNECTION: B7 (+) ~B1 (+) STANDARD: 2.7-3.1V ‘The MAP sensor output voltage {above} is measured under the standard atmosphere (1 atm = 1,030 hPa), ‘The MAP sensor output voltage is affected by the dis ‘tance above sea level, because the output voltage is changed by atmosphere. Check the sea lavel measurement and be sure that the ‘measured voltage falls within the specified value. © 500 1000 18002000 »m (1850) 2300) (4960) (6600) oot MAP SENSOR REMOVAL/INSTALLA- CONNECTOR TION Remove the fuel tank (page 5-49). Disconnect the MAP sensor connector. Disconnect the vacuum tube from the MAP sensor. MAP SENSOR Remove the air cleaner housing (page 5-53). Remove the screw and MAP sensor from the air cleaner housing. Installation is in the reverse order of removal. 5-70FUEL SYSTEM (Programmed Fuel Injection) IAT SENSOR REMOVAL/INSTALLATION Open and support the front end of the fuel tank (page 3-4), Disconnect the IAT sensor connector. Remove the screws and IAT sensor from the sir clean: er housing cover. Chock the O-ring for damage and replace if necessary. TAT SENSOR Installation is in the reverse order of removal. ECT SENSOR REMOVAL/INSTALLATION Drain the coolant from the system (page 6). Remove the thermostat (page 6-6). Replace the ECT Disconnect the ECT sensor connector from the ‘sensor while the sensor. ‘engine i col. Remove the ECT sensor and sealing washer. Install the new sealing washer and ECT sensor. Tighten the ECT sensor to the specified torque. TORQUE: 23 Nem (2.3 kafem, 17 Ibf-ft) “Always replace 2 ‘sealing washer Connect the ECT sensor connector. witha new one Fill the cooling system with recommended coolant (page 65) 5-71FUEL SYSTEM (Programmed Fuel Injection) CAM PULSE GENERATOR 2P CONNECTOR REMOVAL/INSTALLATION Open and support the front end of fuel tank (page 3-4). Disconnect the cam pulse generator 2P connector. Remove the bolt and cam pulse generator from the cylinder head. Install the new O-ring onto the cam pulse generator. Install the cam pulse generator into the cylinder head. Install and tighten the mounting bolt securely. Route the cam pulse generator wire property, connect the 2P connector. er eon Install the removed parts in the reverse order of removal. 5-72FUEL SYSTEM (Programmed Fuel Injection) TP SENSOR INSPECTION Remove the rear cowl (page 2-3). Disconnect the ECM 22P (Black) and 22P (Light gray) ‘connectors. Check the connector for loose or corroded terminals. Connect the ECU test harness between the ECM and main wire harness. TooL: ECU test harness ‘o7yMz2-0010100 (two required) 1. INPUT VOLTAGE INSPECTION ‘Turn the ignition switch ON and measure end record the input voltage at the test harness terminals using a digital multimeter. CONNECTION: BI (+) ~ A22 -) Standard: 45 -5.5V If the measurement is out of specification, check the following: = Loose connection of the ECM multi-connector = Open circuit in wire harness 2. OUTPUT VOLTAGE INSPECTION WITH THROTTLE FULLY OPEN, Turn the Ignition switch ON and measure and record ‘the output voltage at the test harness terminals. CONNECTION: Bt (+) B94) MEASURING CONDITION: ‘At throttle fully open 3. OUTPUT VOLTAGE INSPECTION WITH THROTTLE FULLY CLOSED ‘Turn the ignition switch ON and measure and record the output voltage with the throttle fully closed. CONNECTION: BI (+) ~B9 (-) MEASURING CONDITION: [At throttle fully closed ECU TEST HARNESS 22P (BLACK) CONNECTOR 22P (LIGHT GRAY) CONNECTOR 5-73FUEL SYSTEM (Programmed Fuel Injection) BANK ANGLE SENSOR Do not ciscernact the bank angie curing inspection, 5-74 4, CALCULATE RESULT COMPARISON Compare the measurement to the result of the follow- ing calculation, With the throttle fully open: Measured input voltage X 0.824= Vo ‘The sensor is normal if the measurement output volt- ‘age measured in step 2 is within 10% of Vo. With the throttle fully closed: Measured input voltage X 0.1 = Ve ‘The sensor is normal ifthe throttle closed output volt- Je measured in step 3 is within 10% of Ve. Using an analog meter, check that the needle of the voltmeter swings slowiy when the throttle is opened | gradually. CONTINUITY INSPECTION Open and support the front end of fuel tank (page 3-4) Disconnect the ECM 22P (Light gray) connector and the TP sensor 3P connector, Check for continuity between the wire harness end TP If there is no continuity, check for an open or short cir- cuit in the wire harness. 2P CONNECTOR INSPECTION ‘Support the motoreycle on a level surface. Remove the rear cowl (page 2-3). ‘Turn the ignition switch ON and measure the voltage between the following terminals of the bank angle ‘sensor connector with the connector connected. TERMINAL STANDARD Nis = Gras Red/Green (+) ~ Green (-) ‘Turn the ignition switeh OFF Remove the screws, washers, nuts and bank angle sensor.FUEL SYSTEM (Programmed Fuel Injection) Insta the bank ‘angle sensor with its "UPY mark facing wp. Place the bank angle sensor horizontal as shown, and turn the ignition switch ON. The bank angle sensor is normal if the engine stop relay clicks and power supply is closed. Incline the bank angle sensor approximately 60 degrees to the left or right with the ignition switch ON. ‘The bank angle sensor is normal if the engine stop relay clicks and power supply is open. If you repeat this test, first turn the ignition switch OFF, then turn the ignition switch ON. REMOVAL/INSTALLATION Disconnect the bank angle sensor 3P (Green) connec- tor. Remove the two screws, nuts and bank angle sensor. Installation is in the reverse order of removal. Tighten the mounting screws securely. ENGINE STOP RELAY Check the wire ‘color winen you select the engine ‘stop relay. INSPECTION Disconnect the engine stop relay 4P connector. 60" BANK ANGLE POSITION POSITION 60" NORMAL (approximately) e (approximately) BANK ANGLE SENSOR BANK ANGLE SENSOR ENGINE STOP RELAYFUEL SYSTEM (Programmed Fuel Injection) Connect the ohmmeter to the engine stop relay con: nector terminals, CONNECTION: Red/White ~ Black/White Connect the 12 V battery to the following engine stop relay connector terminals. CONNECTION: Red/Orange - Black ‘There should be continuity only when the 12V battery is connected. If there is no continuity when the 12 V battery is con- nected, replace the engine stop relay. ECM (ENGINE CONTROL MODULE) 5-76 REMOVAL/INSTALLATION Remove the rear cowl (page 2-2) Disconnect the ECM 22P (Black) and 22P (Light gray) connectors. POWER/GROUND LINE INSPECTION Connect the test harness between the main wire har- ness and ECM (page 5-7). TOOL: ECU test harness o7YMz-0010100 (two required) GROUND LINE Check for continuity between the ECM test harness ‘connector A9 terminal and ground, between the A20 terminal and ground, and between the A12 terminal and ground: ‘There should be continuity at all times. If there is no continuity, check for an open circuit in Green/Pink wire and Green wire. POWER INPUT LINE Turn the ignition switch ON with the engine stop switch in the RUN position. ‘Measure the voltage between the ECM test harness connector 86 terminal (+) and ground. There should be battery voltage. If there is no voltage, check for an open circuit in Black White wire between the ECM and bank angle sensor/relay. If the wire is OK, check for the bank angle sensor/relay (page 5-76) ENGINE STOP RELAY BATTERY ECM CONNECTORS: 22P (BLACK) CONNECTOR 22P (LIGHT GRAY) CONNECTORFUEL SYSTEM (Programmed Fuel |i PAIR SOLENOID VALVE REMOVAL/INSTALLATION 2P CONNECTOR Remove the air cleaner housing (page 5-60). Disconnect the PAIR solenoid valve 2P (Black) connector, Disconnect the PAIR air suction hose and air injection hoses. AIR INJECTION HOSES Remove the bolt and PAIR solenoid valve. PAIR SOLENOID VALVE AIR INJECTION HOSES Installation is in the reverse order of removal. INSPECTION 8) ®) Remove the PAIR solenoid valve. (a) Check thet air flows (A) to (B) only when the 12 V bat- tery is connected to the PAIR solencid valve terminals. PAIR SOLENOID Check the resistance between the terminals of the VALVE PAIR solenoid valve Te] \ ‘STANDARD: 20 - 24 (20 °C/68'F) " H the resistane 5-77FUEL SYSTEM (Programmed Fuel Injection) EVAPORATIVE EMISSION CONTROL No.1 TUBE (Fuel tankto-Canister) SYSTEM (California type only) Note: + Refer to the Vacuum Hose Routing Diagram and Cable & Harness Routing (page 1-33) for the tube connections and routing. EVAPORATIVE EMISSION (EVAP) CANISTER REMOVAL/INSTALLATION sonnect the No.1 and No.é tube from the EVAP canister and remove them from the clamp. Remove the bolts, nuts and the EVAP canister from the bracket, Install the EVAP canister in the reverse order of removal. No.3 TUBE (Drain) No.2 TUBE (Open air-to-Canister) EVAP PURGE CONTROL SOLENOID VALVE REMOVAL/INSTALLATION Disconnect the No.4 and No.5 tubes from the EVAP urge control solenoid valve. Remove the bolts, nuts and solenoid valve from the stay. Disconnect the 2P connector from the solenoid valve. Install the solenoid valve in the reverse order of removal. INSPECTION Remove the solenoid valve. <= (4) Check air flow from tube fitting (A) (input port) to tube fitting (B) (output port. 8 + Air should not flow out. Connect the 12 V battery to the solenoid valve connector. CONNECTION: Battery (+) ~ Black/White terminal Air should flow when the battery is connected. 5-78COOLING SYSTEM SYSTEM FLOW PATTERN UPPER RADIATOR HOSE ss ipHoN TUBE RADIATOR RESERVE TANK RADIATOR LOWER RADIATOR HOSE ware PUMP. 6-06. COOLING SYSTEM ‘SYSTEM FLOW PATTERN 6-0 THERMOSTAT ss | ‘SERVICE INFORMATION 61 RADIATOR 67 TROUBLESHOOTING 62 WATER PUMP 6-12 ‘SYSTEM TESTING 63 RADIATOR RESERVE TANK 615 | COOLANT REPLACEMENT 64 | SERVICE INFORMATION GENERAL A WARNING | 6 | Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you. ‘Always let the engine and radiator cool down before removing the radiator cap. + If any coolant gets in your eyes, rinse them with water and consult a doctor immediately, + if any coolant is swallowed, induce vomiting, gargle and consult a physician immediately, + Ifany coolant gets on your skin or clothes, rinse thoroughly with plenty of water [ NOTICE Using coolant with silicata inhibitors may cause premature wear of water pump seals or blockage of radiator passagos. Using tap water may cause engine damage. + Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system. + All cooling system services can be done with the engine in the frame. + Avoid spilling coolant on painted surfaces. + After servicing the system, check for leaks with @ cooling system tester. + Rafer to section 19 for fan motor relay and coolant temperature sensor inspection 6-1COOLING SYSTEM SPECIFICATIONS rem SPECIFICATIONS Coolant capacity Redlator and engine 32 liter (8.38 US at, 282 Imp qd Reserve tank (0.8 ter (0.5 US at 0.70 imp at) Radiator cap relief pressure a 108 - 197 KPa (1.1 — 1.4 kler, 16 - 20 Thermostat Begin to open 80-840 (176-1637) Fully open 96 (203 °F) vi ‘mm (03 in) minimum Recommended antifreeze Pro Honda Coolant or an equivalent high quality ethylene gly- col antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines [Standard coolant concentration 50/50% mixture with soft water TORQUE VALUES Water pump cover flange bolt 12Nem (1.2 kgm, 9 Ibftt) CT bolt Thermostat cover flange bolt 12.Nem (12 kgm, 9 Ibfft) CT bolt ECTithermo sensor 23 Nem (2.3 kgfem, 17 Ibfft) Cooling fan mounting nut 3.Nem (027 kgfem, 2.0 bfft) Apply a locking agent to the threads Fan motor mounting nut 5 Nem (0.5 kgfem, 3.6 Ib) TROUBLESHOOTING Engine temperature too high Coolant leak ‘+ Faulty temperature gauge or ECTithermo sensor Faulty water pump mechanical seal + Thermostat stuck closed Deteriorated O-rings + Faulty radiator cap Faulty radiator cap + Insufficient coolant Damages or deteriorated cylinder head gasket + Passages blocked in radiator, hoses or water jacket Loose hose connection or clamp + Air in system Damaged or deteriorated hose Faulty cooling fan motor + Faulty fan motor relay + Faulty water pump Engine temperature too low + Faulty temperature gauge or ECT/thermo sensor + Thermostat stuck open + Faulty cooling fan motor relay 6-2COOLING SYSTEM SYSTEM TESTING COOLANT (HYDROMETER TEST) (Open and support the front end of fuel tank {page 3-4). Remove the radiator cap. ‘Test the coolant gravity using @ hydrometer (see below for “Coolant gravity chart”) For maximum corrosion protection, a 50-50% solu- tion of ethylene glycol and distilled water is recom- mended (page 6-4). Look for contamination and replace the coolant if eel RADIATOR CAP |, - \ necessary. COOLANT GRAVITY CHART Coolant temperature ‘C (FP 0 5 1 1% 2 2 30 Coolant ratio % \. 82) (41) 150) (69) (68)_(7)_ (86) 5 “1.008 1.008 1.008 1.008 1.007 1.008 1.005 10 oral vor] 017/101 016 s0¥4ln. 01a os ~~ fre 027.026.025.026 1.022.020 7 1.096 1.035 1.034 1.098 1.091 1.029 1.077 a tone cao ae 2 ~ 1.051.052 1.051 1.047 1.046.065 1.043 1,063, 1.082, 1.080 1.058 1.056 1.054 1.052 © Triana) at eal 1.50. 0801 008 son rare oral vr 1.08 = ne v.08) .000/ 1.077 |n.074|.071 a 1.095 1.093.091 1.088 1.088 1.062 +.079 a 1.10" 1086 7.065 |1.092 1.089" 1.098 1.068 35 40 45 50 (95) (104) (113) (722) 1.003 1.001 0.999 0.997| 1.011 1.009 1.007, 1.005| 1.018 1.016 1.014 1.072] 1.025 1.028 1.021 1.019] 1.049|1.046 1.043 1.040] 1.086 1.053 1.050 1.047] 1.063 1.060 1.057 1.054 1.088 1.085 1.062 1.058) 1.076 1.073 1.070 1.067| 1,080 |1.077 1.074 1.071]COOLING SYSTEM Before instaling the cao in the tester, wet the sealing surtaces. RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the radiator cap (see previous pagel. Pressure test the radiator cap. Replace the radiator cap if it does not hold pressure, or if relief pressure is too high or too low. It must hold specified pressure for at least 6 seconds. RADIATOR CAP RELIEF PRESSURE: 108 ~ 137 kPa (1.1 ~ 1.4 kgf/em?, 16 ~ 20 psi) Prossure the radiator, engine and hoses, and check for leaks. NOTICE Excessive pressure can damage the cooling system components. Do not excaed 137 kPa (1.4 kgflem?, 20 psi) Repair or replace components if the system will not hold specified pressure for at least 6 seconds. COOLANT REPLACEMENT ‘ANTIFREEZE SOLUTION PREPARATION \ + The offectiveness of coolant decreases with the | (ETHYLENE accumulation of rust or if there is a change in the | GLYCOL BASE LOW MINERAL mixing proportion during usage. Therefore, for | SOLUTION) OR DISTILLED. best performance change the coolant regularly as WATER When filing the coolent lov place the motor yee ma verte position ona fi specified in the maintenance schedule. Mix only distilled, low mineral water with the antifreeze. | RECOMMENDED ANTIFREEZE: Pro Honda Coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines RECOMMENDED MIXTURE: ‘50-50% (Distilled water and antifreeze) REPLACEMENT/AIR BLEEDING Remove the radiator cap. 6-4COOLING SYSTEM Remove the lower cowl (page 2-4). Remove the drain bolt on the water pump cover and drain the system coolant. Reinstall the drain bolt with the new sealing washer. Tighten the water pump drain bolt to the specified torque. TORQUE: 12 Nem (1.2 kgf-m, 9 Ibf-ft) Disconnect the siphon tube from the radiator. Drain the reserve tank coolant. Empty the coolant and rinse the inside of the reserve tank with water. Reinstall the radiator siphon tube. Fill the system with the recor through the filler opening up to fil FILLER NECK ” neck. Remove the radiator reserve tank cap and fil the [—FLLERGAB TO) reserve tank to the upper level line. wy ALA Bleed air from the system as follows: 1. Shift the transmission into neutral. Start the engine and let it idle for 2-3 minutes. 2.Snap the throttle 3 ~ 4 times to bleed air from the system. 3.Stop the engine and add coolant up to the proper level if necessary. Reinstall the radiator cap. 4.Check the level of coolant in the reserve tank and fill to the upper level if itis low.COOLING SYSTEM THERMOSTAT Do not tet the thermostat oF thermometer touch the pan, or vou wil get @ false ceacing, THERMOSTAT REMOVAL Open and support the front end of fuel tank (page 3-4). Drain the coolant (page 6:8). Remove the bolts and thermostat housing cover. Remove the O-ring from the thermostat housing Remove the thermostat from the housing INSPECTION ‘Wear insulated gloves and adequate eye protection. Keep flammable materials away from the electric heating element. Visuelly inspect the thermostat for damage. Heat the water with an electric heating operating temperature for 5 minutes. ‘Suspend the thermostat in heated water to check its operation, lement to Replace the thermostat if the valve stays open at room temperature, or if it responds at temperatures ‘other than those specified. ‘THERMOSTAT BEGIN TO OPEN: 80 - 84°C (176-183 °F) VALVE LIFT: ‘8 mm (0.3 in) minimum at 95 °C (203 'F) ‘THERMOSTAT ‘THERMOSTAT 6-6COOLING SYSTEM THERMOSTAT INSTALLATION AIR BLEED HOLE Install the thermostat housing onto the cylinder head. Install the new O-ring onto the thermostat housing Install the thermostat housing cover onto the cylinder head and tighten the housing cover bolts. TORQUE: 12 Nem (1.2 kgfom, 9 Ibfft) Fill the coolant and bleed air from the system (page 6-5). "THERMOSTAT HOUSING COVER. RADIATOR REMOVAL Open and support the front end of fuel tank (page 3-4) Drain the coolant (page 6-5). Disconnect the lower radiator hose,COOLING SYSTEM Disconnect the fan-motor 2P connector. Disconnect the upper radiator hose. Remove the radiator lower mounting boltinut ‘and washer, Remove the radiator upper mounting bolt. Slide the radiator to the right, then release the upper {grommet from the frame boss. Remove the radiator assembly. DISASSEMBLY HooKS ‘Be caretulnot Remove the radiator grille. ra damage the radkator core RADIATOR GRILLE Remove the bolts and side cover,COOLING SYSTEM Remove the bolts and fan motor assembly. FAN MOTOR ASSEMBLY Remove the nut and cooling fan COOLING FAN NUT Remove the fan motor wire from the lamp. Remove the flange nuts and fan motor from the fan ceNSEGTUH ‘motor shroud. FLANGE NUTS 6-9COOLING SYSTEM ASSEMBLY RADIATOR GRILLE 3.Nem (0.27 kgfem, 2.0 Ibfft) COOLING FAN FAN MOTOR siDE Cover 5 Nem (0.5 kghrm, 2.6 Ib) Install the fan motor onto the fan motor shroud and tighten the flange nuts to the specified torque. ren TORQUE: § Nem (0.5 kgfem, 3.6 Ibfft) Install the fan motor wire to the clamp. 4 Install the cooling fan onto the fan motor shaft by aligning the flat surfaces. 6-10COOLING SYSTEM Apply @ locking agent to the cooling fan nut threads, Install and tighten the nut to the specified torque. TORQUE: 3 Nem (0.27 kgfom, 2.0 Ibf-ft) Install the cooling fan motor assembly onto the radiator. Install and tighten the bolts. Install the side cover and tighten the bolts. Be careful not Install the hook of the radiator grille to the radiator. to damage the Ona NUT ‘COOLING FAN FAN MOTOR ASSEY. BOLTS. SIDE COVER HOOKS RADIATOR GRILLE 6-11COOLING SYSTEM. INSTALLATION Install the radiator assembly, aligning its grommet with the frame boss. Install the washer and upper mounting bolt, then tighten the bolt. Install the radiator lower mout the nut securely, Connect the upper radiator hose and tighten hose band screw securely. 19 boltinut, tighten Connect the lower radiator hose and tighten hose band sorew securaly. Connect the fan motor 2P connector. Fill the system with recommended coolant (page 6). WATER PUMP MECHANICAL SEAL INSPECTION TT tee Inspect the inspection hole for signe of coolant Cm leakage. as If there is leakage, the machanical seal is defective. : Replace the water pump as an assembly. 6-12COOLING SYSTEM BOLTS REMOVAL Drain the coolant (page 64). Disconnect the lower radiator hose and bypass hose # fe from the water pump cover. a WATER PUMP, cover Remove the bolts and water pump cover. Remove the O-ring from the water pump body. Disconnect the water pump-to-water joint hose and il cooler water hase frorn the water pump body. Remove the water pump body from the crankcase. 6-13COOLING SYSTEM INSTALLATION WATER PUMP BODY 12. Nem (1.2 kgfem, 9 Ibfet) Apply engine oil o @ new O-ring and install it onto the stepped portion of the water pump. Install the water pump into the crankcase while align- ing the water pump shaft groove with the oil pump, shaft end by turning the water pump impeller. Install a new O-ring into the groove in the water pump body. Connect the water hose. 6-14COOLING SYSTEM Connect the water pump-to-water joint hose Insta " the water pump cover, two SH bolts and two flange sores bolts. e S Tighten the flange bolts to the specified torque. TORQUE: 12 Nem (1.2 kgfom, 9 Ibft) Tighten the two SH bolts. Connect the lower radiator hose and bypass hose, then tighten the clamp screws. Fill the system with recommended coolant (page 6-5) Install the lower cowl (page 2:5). RADIATOR RESERVE TANK REMOVAL Remove the rear shock absorber (page 14-10), Disconnect the siphon tube and drain coolant from the reserve tank, Remove the radiator reserve tank. Drain the coolant, INSTALLATION Installation is in the roverse order of removal. Install the flange collar and washer as shown. Install the rear shock absorber (page 14-13).ENGINE REMOVAL/INSTALLATION 7-07. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION A ENGINE INSTALLATION 76 DRIVE SPROCKET REMOVAL 73 DRIVE SPROCKET INSTALLATION 7-8 ENGINE REMOVAL 14 SERVICE INFORMATION GENERAL A hoist or equivalent is required to support the motorcycle when removing and installing the engine. A floor jack or other adjustable support is required to support and maneuver the engine. Do not use the oil filter as a jacking point. = The following components require engine removal for service. ~ Crankcase, transmission (Section 11) ~ Crankshaft piston/cylinder (Section 12) ~ Shift fork, shift drum (Section 12) + When installing the engine, be sure to tighten the engine mounting fasteners to the specified torque in the specified sequence. If you mistake the tighten toraue or sequence, loosen all mounting fasteners, then tighten them again to the spec- ified torque in the correct sequence. 7-1ENGINE REMOVAL/INSTALLATION SERVICE DATA rem SPECIFICATIONS. | Engine dry weight = ~ 68 kg (149 lbs) Engine oil capacity After disassembly “4.4 liter (4.6 US qt, 3.9 Imp qt) [ Coolant capacity Radiator and engine 3.2 liter (8.38 US gt, 2.82 Imp at) TORQUE VALUES Front engine hanger bolts/nuts Rear upper engine hanger bolt/nut Rear lower engine hanger boltnut Drive sprocket special bolt Gear shift linkage bolt 7-2 50 Nem (6.1 kgf, 37 Ibfft) 50 Nem (6.1 kgfem, 37 Ibfft) 50 Nem (6.1 kgfem, 37 Ibfeft) 54 Nem (6.5 kgfem, 40 Ibfft) 20 Nem (2.0 kgfemn, 14 Ibfft)ENGINE REMOVAL/INSTALLATION DRIVE SPROCKET REMOVAL. Be GUIDE PLATE Ty Loosen the drive chain (page 3-16). Remove the drive sprocket cover bolts and sprocket cover. ‘SPROCKET COVER, Remove the drive chain guide plate. VE CHAIN GUIDE PLATE Wik "@ Remove the drive sprocket, washer and the drive rot sprocket with the drive chain from the countershaft. bots if nacossaryENGINE REMOVAL/INSTALLATION ENGINE REMOVAL FGPreR WATER HOSE Drain the engine oil (page 3-11) Drain the coolant (page 6-4). Remove the following: clutch cable (page 9-3) ~air cleaner housing (page 5-53) ~ radiator (page 6-7) — exhaust pipe/muffler (page 2-5) ~ starter motor terminal nut (page 18-4) Disconnect the upper water hose. Disconnect Pt eheopy nena PLUG CAPS MME LEFT SIDE SHOWN: Disconnect the ignition plug caps. Disconnect the crankcase breather tube. ‘AIR SUPPLY HOSES. Disconnect the following: crank pulse generator 2P connector ~ regulator/rectifier 3P/4P connector = speed sensor 3P connector = oll pressure/neutral switch 2P connector ~ side stand switch 2P connector ECT sensor 3P connector CONNECTORS, CElem pestsior 2 ereaie aENGINE REMOVAL/INSTALLATION Remove the gearshift arm pinch bolt, then remove the {gearshift arm from the gearshift spindle, ‘Support the engine using a jack or other adjustable support to ease engine hanger bolts removal. NOTE: Do not support the engine at the oil filter. Remove the bolts and water by-pass cover. Remove the right side of the front engine hanger bolt, rut and distance collar. Remove the left side of the front engine hanger bolt, ‘nut and distance collar. Remove the rear upper and lower engine hanger bolts nuts. Remove the engine. Note the direction and position of the hanger bolts, nuts and distance collars.ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION + The jack height must be continually adjusted to relieve stress from the mounting fasteners, + Route the wire and cables properly (page 1-23). NoTE: Be sure to tighten all engine mounting fasteners to the specified torque. Carefully install the engine into the frame. Loosely install the rear upper and rear lower engine hanger bolts/nuts. Loosely install the right and left side of the front engine hanger bolt, nut and distance collar. Tighten all the engine hanger bolts to the specified torque. ‘TORQUE: R./L. front engine hanger bolts/nuts: 50 Nem (5.1 kgfem, 37 Ibfft) Rear lower engine hanger bolts/nuts: 50 Nem (5.1 kgfern, 37 loft) Rear upper engine hanger bolts/nuts: '50 Nem (6.1 kgfem, 37 Ibf+t) ‘Tighten the right side of the front engine hanger bolt to the specified torque. j BOLTS/_ nuts BOLTS/NUTS/COLLARS. Vee REAR LOWER ENGINE HANGER BOLT/NUT REAR LOWER ENGINE HANGER BOLT/NUT FRONT ENGINE HANGER BOLT/NUTENGINE REMOVAL/INSTALLATION Install the new O-ring to the water by-bass cover. Install the water by-pass cover to the cylinder and tighten the cover bolts securely. Install the gearshift linkage to the spindle by aligning tho slit of the shift pedal and the punch mark of the spindle, Tighten the bolt to the specified torque. TORQUE: 20 Nem (2.0 kgfem, 14 Ibfett) Install the following: = wire band cam pulse generator 2P connectorENGINE REMOVAL/INSTALLATION ~ crank pulse generator 2° connector ~ regulatorirectifier 3P/4P connector = speed sensor 3P connector ~ oil pressure/neutral switch 2P connector ide stand switch 2P connector CONNECTORS Install the ignition coil caps. Connect the PAIR air supply hoses to the reed valve covers. TEFT Sibe SHOWN: Pour recommended engine oil up to the proper level (page 3-12). Fill the cooling system with recommended coolant and bleed the air (page 6-4) DRIVE SPROCKET INSTALLATION Install the drive chain on to the sprocket. Install the drive sprocket to the counter shaft with the punch mark facing out and align the testh of the drive sprocket and counter shaft. Install the the washer and tighten the special bolt to the specified torque. TORQUE: 54 Nem (5.5 kafom, 40 Ibf-ft) 7-8ENGINE REMOVAL/INSTALLATION Install the drive chain guide plate. » ORWECHAIN GUIDE PATE = ™ 2 Install the drive aprocket cover and tighten the cover | BRPEUISE PLATE Ni bolts securely. sd Rs KO SPROCKET COVER 7-9CYLINDER HEAD/VALVES 10 Nem (1.0 kgfern, 7 Ibfft) & 12Nem (1.2 kgm, 9 lot) 9 12 Nem (1.2 kgfem, 9 Ibftt) ICON S ar BRIEF sl NZS 235 Ibfett) 8-08. CYLINDER HEAD/VALVES ‘SERVICE INFORMATION 8-1 VALVE GUIDE REPLACEMENT 8-16 TROUBLESHOOTING 8-3 VALVE SEAT INSPECTION/ | CYLINDER COMPRESSION TEST 8-4 ee oa CYLINDER HEAD COVER REMOVAL 8-4 COTRDERIHESD ASSEMELY’ aan CYLINDER HEAD COVER CYLINDER HEAD INSTALLATION 8-21 DISASSEMBLY /ASSEMBLY 85 CAMSHAFT INSTALLATION 823 CAMSHAFT REMOVAL 8-6 ‘CYLINDER HEAD COVER CYLINDER HEAD REMOVAL at INSTALLATION eae CYLINDER HEAD DISASSEMBLY 8-12, CAMCHAIN TENSIONER LIFTER = 8-29 CYLINDER HEAD INSPECTION 8-13 SERVICE INFORMATION Ez GENERAL + This section covers service of the cylinder head, valves and camshaft. + The camshaft services can be done with the engine installed in the frame. The cylinder head service requires engine removal. + When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations. + Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection. + Camshaft lubricating oil is fed through oil passages in the cylinder head. Clean the oil pessages before assembling the cylinder head. + Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. 8-1CYLINDER HEAD/VALVES ‘SPECIFICATIONS it Unit: mm rem ‘STANDARD ‘SERVICE LIMIT Cylinder compression 1,275 kPa (13.0 kgflem, 185 psi) _ i - at 360 min" (rpm) _ Valve clearence IN | 0.16 = 0:03 (0.006 = 0.001) — LEX | 0.25 = 0.03 (0.010 = 0.001) = — Camshaft | Cam lobe height IN | 36.040 ~ 36.280 (1.419 - 1.428) 36.07 (1.42) |x| 35.800 - 36.040 (1.409 - 1.419) [3897 G40) “i pe = [00s (0.00 | Oil clearance 0.020 - 0.062 (0.008 - 0.0025) 0.10 (0.004) Valvelifter | Vaive lifter 0. 25.978 — 25.993 (1.0228 - 1.0233) 25.87 (1.022) Valve lifter bore LD. 26.010 ~ 26.026 (1.0260 ~ 1.0266) 26.04 (1.025) | Valve, Valve stem 0.0. IN| 4.475 ~ 4.480 (0.1762 - 0.1768) 4.465 (0.1758) salerguide EX | 4.465 ~ 4.480 (0.1758 - 0.1764) 14.485 (0.1754). [Valve guide LD. INIEX | 4.600 4.512 (0.1772 - 0.1776) | 4540 (0.1787) | Stem-to-guide clearance ‘| IN | 0.010 -0.037 (0.0004- 0.0015) | 0.075 (0.0030) EX | 0.020 0.047 (0.0008 - 0.0018) 0.085 (0.0033) Valve guide projection above | IN| 14.5- 14.7 (0.57— 0.58) — eylinder head EX | 148-15.0 (058-059) = Valve seat width "INIEX | 0.90 1.10 (0.035 - 0.043) a) Valve spring free length IN| 40.9 (1.60) 40.08 (1.578) Cylinder head warpage EX | 40.9 (1.60) 40.08 (1.578) 0.10 10.008) TORQUE VALUES Cylinder head mounting boltwasher Camshaft holder flange bolt Cylinder head cover bolt Breather plate flange bolt PAIR reed valve cover SH bolt Cam sprocket flange bolt Cam chain lifter mounting socket bolt Cam chain tensioner pivot socket bolt Cylinder head stud bolt (exhaust pipe stud bolt) 48 Nem (6.9 kgfem, 35 bf) 12. Nem (12 kgm, 9 Ib) 10 Nem (1.0 kgfom, 7 Ibfft) 12. Nem (12 kgfem, 9 lb-ft) 12. Nem (12 kgfem, 9 IbFf) 20 Nem (2.0 kgfern, 14 Ibe) 10 Nem (1.0 kgfem, 7 IDFA) 10 Nem (1.0 kgfem, 7 IDF) See page 114 Apply molybdenum disulfide oil to the ‘threads and seating surface Apply oil to the threads, Apply a locking agent to the threads CT bolt CT bolt Apply a locking agent to the threads Apply @ locking agent to the threadsCYLINDER HEAD/VALVES TOOLS Compression gauge attachment O7RMJ-MYS0100 Equivalent commercially available Valve spring compressor 07757-0010000 Valve spring compressor attachment 07959-KM30101 Tappet hole protector o7HMG-MR70002 Valve guide driver 07743-02000 Valve guide reamer, 4.508 mm Valve seat cutters (O7HMH-MLoO101 ~ these are commercially available Seat cutter, 275 mm (45° IN/EX) (07780-0010200 Flat cutter, 27 mm (32° EX) 07780-0013300 Flat cutter, 30 mm (32° IN} 0780-0012200 Interior cutter, 24 mm (60° INEX) (07780-0010600 Cutter holder, 4.5 mm 07781-0010600 TROUBLESHOOTING + Engine top-end problems usuelly affect engine performance. These problems can be diagnosed by a compression test or by tracing engine noises to the top-end with a sounding rod stethoscope. + Ifthe performance is poor at low speeds, check for white smoke in the crankcase breather tube. If the tube is smoky, check for a seized piston ring (Section 12). Compression too low, hard starting or poor performance at low speed * Valves: = Incorrect valve adjustment = Burned or bent valve = Incorrect valve timing = Broken valve spring = Uneven valve seating + Cylinder head: ~ Leaking or damaged head gasket — Warped or cracked cylinder head + Worn cylinder, piston or piston rings (section 12) Compression too high, overheating or knocking + Excessive carbon build-up on piston crown or on combus tion chamber Excessive smoke + Cylinder hoad: = Worn valve stem or valve guide — Damaged stem seal + Worn cylinder, piston or piston rings (section 12) Excessive noise + Cylinder head: = Incorrect valve adjustment ~ Sticking valve or broken valve spring ~ Damaged or worn camshaft = Lease or worn eam chain = Worn or damaged cam chain Worn or damaged cam chain tensioner = Worn cam sprocket teeth + Worn cylinder, piston or piston rings (section 12) Rough idle + Low cylinder compression 8-3CYLINDER HEAD/VALVES CYLINDER COMPRESSION TEST Warm up the engine to normal operating temperature. Stop the engine end remove all direct ignition coil/spark plug caps and spark plugs (page 26) Open and support the front end of fuel tank (page 3-4). Disconnect the fuel pump/reserve sensor 3P ‘connector. Install a compression gauge into the spark plug hole, TooL: Compression gauge attachment O7RMJ-MYS50100 (Equivalent com- mercially avail- able) Open the throttle all he way and crank the engine with the starter motor until the gauge reading stops rising. To avoid cisoharg. The maximum reading is usually reached within 4 ~7 ing the battery do seconds, not operate the ‘mare han soven ‘seconde, Compression pressure: 1,275 kPa (13.0 kgf/cm?, 185 psi) at 350 min* (rpm) Low compression can be caused by: = Blown cylinder head gasket ~ Improper vaive adjustment ~ Valve leakage — Worn piston ring or cylinder High compression can be caused by: ~ Carbon deposits in combustion chamber or on piston head CYLINDER HEAD COVER REMOVAL Remove the following: = Ignition coil (page 5-62) = Spark plug cap (page 3-6) Remove the crankcase breather tube. Disconnect the PAIR air suction tubes from the PAIR reed valve covers. COMPRESSION GAUGE,CYLINDER HEAD/VALVES Remove the cylinder head cover bolts and rubber- washers, BOLTS/WASHERS CYLINDER HEAD COVER = Remove the cylinder head cover. Remove the cylinder head cover packing, CYLINDER HEAD COVER CYLINDER HEAD COVER DISASSEMBLY/ASSEMBLY Remove the bolts and PAIR check valve cover. Check the PAIR check val replace if necessary. for wear or damage, Installation isin the reverse order of removal. TORQUE: 12 Nem (1.2 kgfm, 9 tbF-ft PAIR CHECK VALVESCYLINDER HEAD/VALVES Remove bolts and breather separate and gasket. Install the new gasket to the cover. Install the breather plate. Apply the locking agent to the bolt threads and tight- en it to the specified torque. TORQUE: 12 Nem (1.2 kgfom, 9 Ibe) CAMSHAFT REMOVAL Remove the cylinder head cover (page 8-4). Avoid damaging the cam pulse generator while removing the camshafts. Remove the bolt and cam pulse generator from the cylinder head. Romove the timing hole cap and O-ring. O-RING 8-6CYLINDER HEAD/VALVES Inisrot necessary toremove the ‘cam sprocket trom the canshatt except nen replaong the camshaft andor cam sprocket Be caret not to ‘dp the cam sprocker bots ‘nw the crankcase Turn the crankshaft clockwise, align the “T" mark on the ignition pulse generator rotor with the index mark con the right crankcase cover. ‘Make sure the No.1 piston is at TDC (Top Dead Center) fn the compression stroke. Remove the cam chain tensioner lifter sealing bolt and sealing washer. ‘Turn the tensioner lifter shaft fully in (clockwise) and secure it using the following tool. This tool can easily be made from a thin (1mm thick- ness) piece of stool. 15m 190m as MATERIAL THICKNESS: 1.0 mm you plan to replace the camshaft and/or cam sprock- et, loosen the cam sprocket bolts as follow: — Remove the cam sprocket bolts from intake and exhaust camshafts, INDEX MARK. SEALING WASHER BOLT STOPPER TOOLCYLINDER HEAD/VALVES. ‘Suspend the cam hain with 2 place of wire to provent the chan from faling into the crankcase, 8-8 = Turn the crankshaft one full turn (360), remove the other cam sprocket bolts from the camshafts. ~ Remove the bolt. — Remove the bolts and cam pulse generator rotor. Loosen and remove the camshaft holder bolts, then remove the cam sprocket, cam chain guide B, camshaft holder and camshaft. NOTICE From outside 10 inside, loosen the bolts in a crisscross pattern in several steps or the camshaft holder might break. Do not forcibly remove the dowel pins from the camshaft holdCYLINDER HEAD/VALVES Remove the valve lifters and shims. VALVE LIFTER + Be careful not to damage the valve lifter bore. + Shim may stick to the inside of the vaive lifter. Do not allow the shims to fall into the crankcase. + Mark all vaive lifters and shims to ensure correct, reassembly in their original locations. + The valve lifter can be easily removed with a valve lapping tool or magnet. ‘+ The shims can be easily removed with twoozers or a magnet. INSPECTION ‘CAMSHAFT Check the cam and journal surfaces of the camshaft for scoring, scratches or evidence of insufficient lubrication. Check the holes in the camshaft for clogging. ‘Support both ends of the camshaft with V-blocks and check the camshaft runout with a dial gauge. SERVICE LIMIT: 0.05 mm (0,002 in) Using @ micrometer, measure each cam lobe height. SERVICE LIMITS: IN: 36.01 mm (1.42, EX: 35.77 mm (1.41 in} CAMSHAFT HOLDER Inspect the bearing surface of camshaft holder for scoring, scratches, or evidence of insufficient lubrication. Inspect the oil orifices of the holders for clogging, CAMSHAFT HOLDERSCYLINDER HEAD/VALVES CAM CHAIN GUIDE B ia CHAR UIDES inspect the cam chain slipper surface ofthe cam chain CAM CHAIN ‘uide for wear or damage. CAMSHAFT OIL CLEARANCE PUASTIGAUGE Wipe any oil from the journals of the camshaft, cylir der head and camshaft holders. Lay a strip of plastigauge lengthwise on top of each camshaft journal. Do not rotate the Install the camshaft holder onto the camshafts. camshaft wien Apply enging oil to the threads and seating surfaces using plestgeuge. of the camshaft holder bolts. Install the twenty holder bolts with th washers. ight sealing ‘The camshaft holder have the number “1 thru. 207 Temporarily tighten the four bolts of the center area gradually in the sequence 6 - § - 8 - 7 until the dowel pins on the camshaft holder inserts into the pin holes in the cylinder head (the clearance between the hold- er and head is 1~5 mm). Next, tighten all the holder bolts in the numerical corder east on the camshaft holder (1 thru. 20) in several steps, then tighten them to the specified torque. TORQUE: 12 Nem (1.2 kofem, 9 Ibfft) Remove the camshaft holders and measure the width of each plastigauge. The widast thickness determines the oil clearance. ‘SERVICE LIMIT: 0.10 mm (0.004 in) When the service limits are exceeded, replace the camshaft and recheck the oil clearance. Replace the cylinder head and camshaft holders as a set ifthe clearance still exceeds the service limit. 8-10CYLINDER HEAD/VALVES CYLINDER HEAD REMOVAL Drain the coolant (page 6-4) SOCKET BOLTS Remove the camshaft (page 8-6). Remove the cylinder drain bolt and sealing washer. Drain coolant from eylinder head and cylinder block. Check that the sealing washer is in good condition, replace if necessary. Reinstall the sealing washer and drain bolt. Remove the socket bolts, sealing washers and cam chain tensioner lifter and gasket. Romove the cap nut, sealing washer and cam chain tensioner. WATER HOSE Disconnect the water hose. Remove the thermostat housing cover and thermostat, CAP NUT Loosen the 9mm Remove the ten 9 mm bolts/washers. bots ina crssoress pattem in2~8 steps. Remove the two 6 mm flange bolts.CYLINDER HEAD/VALVES CYLINDER HEAD DISASSEMBLY Remove the cylinder head. DOWEL PINS Remove the gasket and dowel pins. Remove the right crankcase cover and ignition pulse generator rotor (page 17-7). Remove the socket bolt, cam chain guide and collar. Remove the cam chain and timing sprocket from the crankshaft. ‘BOLT/COLLAR/GUIDE ‘TAPPET HOLE PROTECTOR (<) Romove the spark plugs from the cylinder head. Install the tappet hole protector into the valve lifter bore, Tool: ‘Tappet hole protector o7HIMG-MR70002 ‘An equivalent tool can easily be made from a plastic 35 mm film container as shown.

before checking clearances. Insert the reamer from the combustion chamber side of the head and always rotate the reamer clockwise. TooL: Valve guide reamer, 4.508 mm 07HMH-ML00101 ‘Measure and record each valve guide LD. ‘SERVICE LIMIT: IN/EX: 4.540 mm (0.1787 in} ‘Subtract each valve stem O.D. from the correspond- ing guide I.D. to obtain the stem-to-guide clearance. ‘SERVICE LIMITS: IN: 0.075 mm (0.0030 in) EX: 0.085 mm (0.0033 in) fotace the vate the stem-o-guide clearence is out of standard, seats whenever determine Ifa new guide with standard dimensions the valve would bring the clearance within tolerance. If so, guides © replace any guides as necessary and ream to fit. nihtet Whe stom to guide clearence i out of standard with the new guides, replace the valves and guides. 8-15CYLINDER HEAD/VALVES VALVE GUIDE REPLACEMENT Chill the replacement valve guides in the freezer sec- tion of a refrigerator for about an hour. Heat the cylinder head to 100 ~ 180°C (212 - 300°F) with a hot plate or oven. NOTICE Do not use a torch to heat the cylinder head: it may cause warping. VALVE GUIDE DRIVER | ‘Support the valve guides from the combustion chamber side of the cylinder head. Toot: Valve guide driver o7HMD-ML00101 Drive in the guide to the specified depth from the top of the cylinder head, TOOL: Valve guide driver (07743-0020000 ‘SPECIFIED DEPTH: IN: 145 ~ 14.7 mm (0.57 - 0.58 in) EX: 148 ~ 15.0 mm (0.58 - 0.59 in} Use cutting o'on Let the cylinder head cool to room temperature. MATE SUSE REAR the raamer cing tns operation Ream the new valve guide after installation. Insert the reamer from the combustion chamber side of the head and always rotate the reamer clockwise, TooL: Valve guide reamer, 4.508 mm O7HMH-MLOO101 Clean the cylinder head thoroughly to remove any ‘metal particles. Reface the valve seat (see following steps) 8-16CYLINDER HEAD/VALVES VALVE SEAT INSPECTION/REFACING The valves cannot be ground. Ifa valve face is ‘umes or badly worn or iit con tacts the seat revert, repice the valve. Clean the intake and exhaust valves thoroughly to remove carbon deposits Apply a light coating of Prussian Blue to the valve seats. Tap the valves and seats using a rubber hose or other hand-lapping tool. Remove the valve and inspect the valve seat face. Inspect the valve seat face for: + Uneven seat width: = Replace the valve and reface the valve seat. + Damaged face: — Replace the valve and reface the valve seat. * Contact area (too high or too low) = Reface the valve seat. The valve seat contact should be within the specified width and evan all around the cireumnference. STANDARD: 0.90 ~ 1.10 mm (0.035 0.043 in) ‘SERVICE LIMIT: 1.5 mm (0.06 in) Ifthe seat width is not within specification, reface the valve seat (page 8-18) HAND-LAPPING TOOL JL DAMAGED FACE UNEVEN SEAT WIDTH Too Low TOO HIGH ’ : e at ‘SEAT WIDTH 8-17CYLINDER HEAD/VALVES Follow the rafec- ‘ng manufciur er operating 8-18 VALVE SEAT REFACING Valve soat cuttorsigrinders or equivalent valve soat refacing equipment are recommended to correct worn valve seats. If the contact area is too high on the valve, the seat ‘must be lowered using a 32’ flat cutter. If the contact area is too low on the valve, the seat must be raised using 2 60° interior cutter. Use a 45-degree cutter to remove any roughness or irregularities from the seat. Toots: Seat cutter, 27.5 mm (45° IN/EX) 07780-0010200 Cutter holder, 4.5 mm (07781-0010600 or ‘equivalent commer- cially available Use a 32-degree cutter to remove the top 1/4 of the existing valve seat material. TOOLS: Flat cutter, 27 mm (32° EX) _07780-0013300 Flat cutter, 30 mm (32" IN) __07780-0012200 Cutter holder, 4.5 mm 07781-0010600 or ivalent commer- cially available ‘CONTACT TOO HIGH > CONTACT TOO Low > ‘OLD SEAT cau is a Lp sear OTH er ROUGHNESS OLQ SEAT WIDTHUse 2 60-dagree cutter to remove the bottom 1/4 of the old seat. TooLs: Interior cutter, 26 mm {60° INEX} 07780-0010600 Cutter holder, 4.5 mm. (0781-0010600 or equivalent commer- cially available Using @ 45° seat cutter, cut the seat to the proper width. ‘Make sure that all pitting and irregularities are removed, Refinish if necessary. After cutting the seat, apply lapping compound to the valve face, and lap the vaive using light pressure. [NOTICE | + Excessive lapping pressure may deform or damage the seat. + Change the angie of lapping too! frequently to pre vent uneven seat wear. + Do notallow lapping compound to enter the guides. After lapping, wash all residual compound off the cylinder head and valve. CYLINDER HEAD/VALVES (OLD SEAT WIDTH 1.9. mm (0.04 in) as 7 HAND-LAPPING TOOL 8-19CYLINDER HEAD/VALVES CYLINDER HEAD ASSEMBLY INTAKE VALVE SPRING VALVE LIFTER Poe \ Som ote ‘SPRING SEAT VALVE GUIDE E EXHAUST VALVE STEM SEAL INTAKE VALVE Blow through all oil passages in the cylinder head with compressed air. "TAPPET HOLE PROTECTOR Install the tappet hole protector into the valve lifter bore. TooL: Tappet hole protector ‘07HMG-MR70002 Grease the Install the valve spring seats. cotiers fo ease Install the new stem seals. instalation Lubricate the valve stems with molybdenum oil solution. Insert the valve into the valve guide while turning it slowly to avoid damage to the stem seal ge Aa, E man” SPRING SEAT COTTER 8-20CYLINDER HEAD/VALVES ‘Sogoon the oyin- Install the valve spring with the tightly wound coils er head above facing the combustion chamber. the work bench surface 10 prevent possible vaive damage. of Install the vaive spring retainer, RASS COURSE Install the valve cotters using the special tool as shown, NOTE: To prevent loss of tension, do not compress the valve spring more than necessary. TooLs: Valve spring compressor _07757-0010000 Valve spring compressor attachment (07959-KM30101 Tap the valve stems gently with two plastic hammers, {as shown to seat the cotters firmly. LES Install and tighten the spark plugs. TORQUE: 12 Nem (1.2 kgfem, 9 Ibftt) CYLINDER HEAD INSTALLATION Install the timing sprocket by aligning the wide teeth between the crankshaft and sprocket. Install the cam chain.CYLINDER HEAD/VALVES Install the cam chain guide and boltiwasher. * > cu cKencue ae, Su KK Bou Install the washer, cam chain tensioner and socket bolt. Tighten the cam chain guide bolt to the specified torque. ‘TORQUE: ‘Cam chain guide bott 12 Nem (1.2 kgf-m, 9 Ibf-ft) Install the ignition pulse generator rotor and right crankcase cover (page 17-7). Install the dowel pins and a new cylinder head gasket as shown, Install the cylinder head onto the cylinder block. Apply molybdenum disulfide oil solution to the threads and seating surface of the 9 mm boltsiwash- (rs and install them. Install the two 6 mm flange bolts. Tighten the 9 mm bolts in a crisscross pattern in 2-3 steps to the specified torque. TORQUE: 48 Nem (4.9 kafom, 35 Ibf-ft) 8-22CYLINDER HEAD/VALVES Tighten the 6 mm flange bolts. mm BOLTS Install the cam chain tensioner onto the cylinder head, WATER HOSE ca Tighten the nut to the specified torque. TORQUE: 10 Nem (1.0 kgfm, 7 Ibfft) Connect the water hose. = Camshaft (see below) CAMSHAFT INSTALLATION Install the new gasket and cam chain tensioner onto the oylinder. SOCKET BOLTS Install the new sealing washers and tighten the sock- TORQUE: 10 Nem (1.0 kgfom, 7 Ibfft) Install the camshaft (see below). instal the shims Apply molybdenum ol solution to the outer surface of ‘and valve liters inthe each vaive lifter their enginal face. ‘ions. Install the shims and valve lifters into the vaive lifter bores.CYLINDER HEAD/VALVES IF the cam sprockets are removed, install the cam sprockets onto the camshafts Insta the cam NO." CYLINDER CAM LOBES pulse gene‘tar + Install the intake cam sprocket withthe timing mark ‘rotor with the (IN) facing outward and the No.1 cam lobes facing No.t camshaft yp and out as shown. loses ecg JP. Ingtall the exhaust cam sprocket with the timing ae mark (EX) facing outward and the No.1 cam lobes oa acer up arc an cho Clean and apply a locking agent to the cam sprocket, bolt threads. Install the cam sprocket bolts. Clean and apply a locking agent to the cam cam pulse generator rotor threads. SCOTT Mae Install the cam pulse generator rotor and mounting bolts. ‘Turn the crankshaft clockwise and align'the "T" mark y TOE HAR on the ignition pulse generator rotor with the index tf mark on the right crankcase cover. 8-24CYLINDER HEAD/VALVES Bo sure the dowel pins inthe ‘camshaft holder ign property with the holes in the ‘vind nasa Apply molybdenum oil solution to the camshaft jour- nals of the cylinder head and camshaft holder. Install the cam chain over the cam sprockets and then install the intake and exhaust camshafts. + Install each camshaft to the correct locations with the identification marks. IN": Intake camshaft "EX": Exhaust camshaft ‘+ Make sure that the timing marks on the cam sprock- ets are facing outward and flush with the cylinder head upper surface as shown. Apply molybdenum oil solution to the camshaft holder as shown. Install the camshaft holder onto the camshafts. Apply engine oil to the threads and seating surfaces of the camshaft holder bolts. Install the cam shaft holder B and holder bolt (color: silver) from the front side of the cam sprackets. Install the twenty bolts to the cam shaft holder. Finger tighten the bolts. ‘The camshaft holder has the number "1 through 20 cast into it Gradually tighten the #6, #5, #8, and #7 bolts (in that order) 1/4 to 1/2 turn at a time to draw the holder down evenly until the clearance between the cylinder head and the holder is 2~3 mm all the way around. If the holder tikts toward the #1 cylinder during this process, readjust bolts #6, #5, #8, and #7 as necessary to keep the holder level. When the holder is parallel with the cylinder head, resume tightening the bolts in the sequence specified above.