ANUAL SERVICE M

TORQUE VALUES

Crankshaft bearing set plate torx screw

('05 - '07)

10 N-m (1.0 kgf-m, 7 Ibf-ft)

Apply locking agent to the threads (Pro Honda Hondalock 3 or equivalent high strength locking agent)

Apply locking agent to the threads (Pro Honda Hondalock 3 or equivalent high strength locking agent)

Apply locking agent to the threads Apply locking agent to the threads Apply locking agent to the threads Apply locking agent to the threads Apply oil to the threads Apply locking agent to the threads Apply oil to the threads and seating surface

(After '07)

20

N-m

(2.0

kgf-m,

15 Ibf-ft)

Balancer shaft bearing set plate bolt

10

N-m

(1.0

kgf-m.

7 Ibf-ft)

Countershaft bearing set plate screw

10

N-m

(1.0

kgf-m.

7 Ibf-ft)

Gearshift drum bearing set plate bolt

10

N-m

(1.0

kgf-m,

7 Ibf-ft)

Mainshaft bearing set plate bolt

10

N-m

(1.0

kgf-m,

7 Ibf-ft)

Balancer shaft nut

44

N-m

(4.5

kgf-m.

32 Ibf-ft)

Cam chain tensioner bolt

12

N-m

(1.2

kgf-m,

9 Ibf-ft)

Transmission oil drain bolt

16

N-m

(1.6

kgf-m,

12 Ibf-ft)

TOOLS

Remover weight 07741-0010201

Bearing remover set, 20 mm 07936-3710600

Bearing remover set, 17 mm 07936-3710300

TORQUE VALUES

or 07936-371020A (U. S.A. only)

Attachment, 72 x 75 mm 07746-0010600

Driver

07749-0010000

Bearing remover handle 07936-3710100

TORQUE VALUES

Attachment, 37 x 40 mm 07746-0010200

Attachment, 52 x 55 mm 07746-0010400

Attachment, 62 x 68 mm 07746-0010500

TORQUE VALUES

Pilot, 30 mm 07746-0040700

Pilot, 20 mm 07746-0040500

Attachment, 32 x 35 mm 07746-0010100

TORQUE VALUES

TORQUE VALUES

TORQUE VALUES

Gear holder, M1.5 07724-0010200

Pilot, 25 mm 07746-0040600

Pilot, 17 mm 07746-0040400

TORQUE VALUES

TORQUE VALUES

or 07724-001A200 (U. S.A. only)

Extension bar 07716-0020500

Lock nut wrench, 20 x 24 mm 07716-0020100

TORQUE VALUES

w

TORQUE VALUES

or equivalent commercially avail­able in U. S.A.

TROUBLESHOOTING

Excessive noise

• Worn crankshaft bearings

• Worn or damaged connecting rod big end

• Worn or damaged connecting rod small end

• Worn balancer shaft bearings

• Improper balancer installation

• Worn, seized or chipped transmission gear

• Worn or damaged transmission bearing

Transmission jumps out of gear

• Worn gear dogs

• Worn gear shifter groove

• Bent shift fork shaft

• Broken shift drum stopper arm

• Broken shift drum stopper arm spring

• Worn or bent shift forks

• Broken gearshift spindle return spring

Hard to shift

• Improper clutch operation

• Incorrect transmission oil weight

• Incorrect clutch adjustment

• Bent shift fork

• Bent fork shaft

• Bent fork claw

• Damaged shift drum guide grooves

• Bent shift spindle

Engine vibration

• Excessive crankshaft runout

• Improper balancer timing

ANUAL SERVICE M

TROUBLESHOOTING

ENGINE DOES NOT START OR IS HARD TO START 1. Fuel Line Inspection Check fuel flow to carburetor. Does fuel reach the carburetor? IMO - • Clogged fuel hose or …

WIRING DIAGRAM

WIRING DIAGRAM WIRING DIAGRAM

STARTER SWITCH

INSPECTION '05 - '07: Remove the front visor. - '05 -'07: (page 3-5) - After '07: (page 3-6) Disconnect the starter switch 2P (Black) connector. STARTER SWITCH Check for continuity …

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