ANUAL SERVICE M

THROTTLE OPERATION

Check for smooth throttle grip at full opening and automatic full closing in all steering positions.

Check the throttle cables and replace them if they are deteriorated, kinked or damaged.

Lubricate the throttle cables if throttle operation is not smooth.

Measure the freeplay at the throttle grip flange. FREEPLAY: 3 - 5 mm (1/8 - 3/16 in)

Throttle grip freeplay can be adjusted at either end of the throttle cable.

Minor adjustments are made with the throttle side of the adjuster.

Remove the dust cover from the adjuster.

Adjust the freeplay by loosening the lock nut and turning the adjuster.

After adjustment, tighten the lock nut to the speci­fied torque.

TORQUE: 4 N m (0.4 kgf m. 3.0 Ibf ft)

Install the dust cover.

Recheck the throttle operation.

If the adjuster cannot reach the correct free play, turn the adjuster all the way in and then turn it out one turn.

Make the major adjustment with the carburetor side of the adjuster.

Major adjustments are made with the carburetor side of the throttle cable.

Remove the fuel tank (page 3-8).

Adjust the freeplay by loosening the lock nut and turning the adjuster.

After adjustment, tighten the lock nut to the speci­fied torque.

TORQUE: 4 N m (0.4 kgf m, 3.0 Ibf ft)

Recheck the throttle operation.

Install the fuel tank (page 3-8).

HOT START

Check for smooth hot start lever operation and lubricate the cable if necessary.

Inspect the casing for cracks which could allow moisture to enter.

Replace the hot start cable if necessary.

Measure the hot start lever freeplay at the lever end. FREEPLAY: 2 - 3 mm (1/16 - 1/8 in)

Hot start lever freeplay can be adjusted at the hot start cable.

Remove the dust cover.

Adjust the freeplay by loosening the lock nut and turning the adjuster.

Tighten the lock nut.

Install the dust cover.

Recheck the freeplay at the lever end.

AIR CLEANER

Open the air cleaner housing cover.

Remove the air cleaner retaining bolt.

Remove the air cleaner assembly while turning it as shown.

Remove the air cleaner element from the element holder.

Thoroughly wash the air cleaner in clean nonflam­mable or high flash-point cleaning solvent.

Then wash the element again in a solution of hot water and dishwashing liquid soap.

Clean the inside of the air cleaner housing.

After cleaning, be sure there is no dirt or sand trapped between the inner and outer layer of the cleaner.

Wash again if necessary.

Allow the air cleaner to dry thoroughly.

After drying, soak the air cleaner in clean Pro Honda Foam Filter Oil or an equivalent.

Apply air filter oil to the entire surface of the air cleaner and rub it with both hands to saturate the element with oil.

Gently squeeze out excess oil. It is important not to over-oil, or under-oil the element.

Apply a thin coat of Pro Honda Filter Grease or an equivalent to the sealing surface.

Assemble the air cleaner element and element holder.

Hook the element hole onto the holder tab.

After '07: Apply 3.5 ± 2 g grease to the air cleaner assembly contacting area of the air cleaner housing.

Install the air cleaner assembly into the air cleaner housing.

Carefully position the sealing flange of the element to prevent dirt intrusion.

Align the air cleaner tab with the "Д" mark of the air cleaner housing by rotating the air cleaner counter­clockwise.

Install and tighten the retaining bolt securely.

NOTICE

If the air cleaner assembly is not installed correctly, dirt and dust may enter the engine resulting in wear of the piston ring and cylinder.