HANDLEBAR
REMOVAL Remove the handlebar pad from the handlebar. HANDLEBAR PAD ENGINE STOP BUTTON BOLTS WIRE Remove the wire bands. Remove the screw and engine stop button. Remove the bolts and …
FORK DAMPER INSTALLATION
'05-'07 shown: FORK DAMPER ASSEMBLY Wipe the oil completely off the fork spring. Install the fork spring into the fork assembly. Temporarily install the fork damper assembly into the fork …
INSPECTION
FORK CAP SPRING -RINGS BUSHING Check the fork cap assembly for damage. Check the bushing for excessive wear or scratches. Check the spring for fatigue or damage. Check the compression …
OUTER TUBE AND SLIDER DISASSEMBLY
Be careful not to scratch the slider. Remove the dust seal and stopper ring. Check that the slider moves smoothly in the outer tube. If it does not, check the …
FRONT WHEEL
REMOVAL BRAKE DISC COVER Remove the bolts and brake disc cover. BOLTS AXLE HOLDER BOLTS Raise the front wheel off the ground by placing a workstand or equivalent under the …
FRONT WHEEL/SUSPENSION/STEERING
COMPONENT LOCATION 13 N-m (1.3 kgf-m, 10 lbf-ft) After '07: SERVICE INFORMATION GENERAL • Keep grease off the brake pads and disc. • A contaminated brake disc or pad reduces …
CRANKCASE ASSEMBLY
LEFT CRANKCASE Temporarily install the left crankcase. RIGHT CRANKCASE Place the left crankcase facing down and separate the left and right crankcase halves. Install the oil pump inner/outer rotor and …
CRANKSHAFT INSTALLATION
RIGHT CRANKCASE CRANKSHAFT Clean both crankcase mating surfaces before assembling and check for wear or damage. If there is minor roughness or irregularities on the crankcase mating surfaces, dress them …
CRANKCASE BEARING REPLACEMENT
CRANKCASE BEARING/OIL SEAL LOCATION RIGHT COUNTERSHAFT BEARING (5203U) RIGHT BALANCER SHAFT BEARING (6003) RIGHT CRANKCASE: RIGHT CRANKSHAFT BEARING (30 x 76 x 19) SHAFT BEARING (20x32x 14) LEFT MAINSHAFT BEARING …
CRANKSHAFT REMOVAL
REMOVAL RIGHT CRANKCASE CRANKSHAFT Separate the crankcase (page 13-10). Remove the transmission (page 13-11). The crankshaft can Remove the crankshaft from the right crankcase. be removed with the transmission installed. …
TRANSMISSION DISASSEMBLY
Separate the crankcase halves (page 13-10). Temporarily install the right crankcase. Place the right crankcase facing down and separate the right and left crankcase halves. Remove the shift fork shafts. …
BALANCER GEAR/BALANCER
REMOVAL 07724-0010200 or 07724-001A200 (U. S.A. only) N GEAR Remove the following: - Right crankcase cover (page 11-5) - Left crankcase cover (page 12-4) - Clutch (page 11-7) - Starter …
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 …
CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER
COMPONENT LOCATION SERVICE INFORMATION GENERAL • This section covers crankcase separation for service of the crankshaft, transmission and balancer. • The crankcase must be separated to service the crankshaft and …
LEFT CRANKCASE COVER INSTALLATION
ilfy GASKET Install a new gasket and dowel pins. Apply oil to the engine oil drain bolt threads and seating surface. Install the left crankcase cover and bolts. Tighten the …
COMPONENT LOCATION
SERVICE INFORMATION GENERAL • This section covers the removal and installation of the alternator stator and flywheel. These services can be done with the engine installed in the frame. • …
GEARSHIFT LINKAGE
REMOVAL BOLT Remove the following: - Right crankcase cover (page 11 -5) - Clutch (page 11-7) When removing the Remove the bolt and gearshift pedal. gearshift pedal, mark the pedal …
STARTER CLUTCH
REMOVAL SHAFT Remove the following: - Right crankcase cover (page 11-5) - Clutch (page 11-7) Remove the reduction gear shaft and reduction gear B. REDUCTION GEAR В GEAR HOLDER PRIMARY …
KICKSTARTER
REMOVAL KICKSTARTER SPINDLE SNAP RING/ і ASSEMBLY Bl THRUST WASHER I t % « «« '-s Remove the following: - Right crankcase cover (page 11-5) - Clutch (page 11-7) Remove …
CLUTCH SPRING
Clutch springs should be replaced as a set if one or more is below the service limit. Measure the clutch spring free length. SERVICE LIMIT: 43.7 mm (1.72 in) CLUTCH …
RIGHT CRANKCASE COVER
REMOVAL WATER HOSE JOINT/O-RING Remove the following: - Brake pedal (page 16-24) - Right engine guard (page 3-5) Drain the transmission oil (page 4-23). Drain the coolant (page 7-7). Remove …
COMPONENT LOCATION
Ibf-ft) SERVICE INFORMATION GENERAL • This section covers service of the clutch, starter clutch, kickstarter and gearshift linkage. All service can be done with the engine installed in the frame. …
PISTON INSTALLATION
When cleaning the cylinder mating surface, place a shop towel over the cylinder opening to prevent dust or dirt from entering the engine. Clean any gasket material from the cylinder …
PISTON REMOVAL
Place a clean shop towel over the crankcase to prevent the clip from falling into the crankcase. Remove the piston pin clips with pliers. Press the piston pin out of …
COMPONENT LOCATION
SERVICE INFORMATION GENERAL • This section covers maintenance of the cylinder and piston. These procedures can be done with the engine installed in the frame. • Before disassembly, clean the …
CYLINDER HEAD COVER INSTALLATION
Check the plug hole seal is in good condition, replace it if necessary. Apply oil to the circumference of the plug hole seal. Install the plug hole seal. "UP" MARK …
CAMSHAFT INSTALLATION (After ’07)
Apply molybdenum oil solution to the outer surface of each valve lifter. VALVE LIFTERS DOWEL PINS Install the valve Install the valve lifters into the camshaft holder. inters in their …
CYLINDER HEAD INSTALLATION
Install the dowel pins and a new gasket. Install the cylinder head onto the cylinder. Apply oil to the cylinder head nut threads and seating surface. Be careful nol to …
CYLINDER HEAD ASSEMBLY
VALVE COTTERS SPRING SPRING RETAINER SPRING SEAT INSULATOR ІІПг STEM SEAL VALVE GUIDE 3? O-RING After '07: WATER HOSE JOINT INTAKE VALVE EXHAUST VALVE Blow out all oil passages in …
VALVE SEAT INSPECTION/REFACING
Clean the intake and exhaust valves thoroughly to remove carbon deposits. Apply light coating of Prussian Blue to the valve seat. Tap the valves and seats using a rubber hose …
CYLINDER HEAD INSPECTION
CYLINDER HEAD Disassemble the cylinder head (page 9-27). Use care not to Remove the carbon deposits from the combustion scratch the chamber and exhaust port. combustion с^еск the spark plug …
CAM CHAIN TENSIONER/CAM CHAIN GUIDE
CAM CHAIN GUIDE REMOVAL Remove the following: - Cylinder head (page 9-24) - Left crankcase cover (page 12-4) - Flywheel (page 12-5) Remove the cam chain guide.
CAMSHAFT HOLDER BEARING REPLACEMENT
Drive out the bearing. Install a new bearing into the camshaft holder using the special tools. TOOLS: 07749-0010000 07746-0010200 07746-0040500 Driver Attachment, 37 x 40 mm Pilot, 20 mm After …
CAMSHAFT REMOVAL (After ’07)
Remove the cylinder head cover (page 9-7). Remove the crankshaft hole cap and O-ring. “Д" MARK PUNCH MARK Turn the crankshaft clockwise to align the punch mark on the primary …
INSPECTION
If the camshaft contact surface of the rocker arm is damaged or abnormally worn, check the cam lobes for damage (page 9-12). Inspect the camshaft contact surface of the rocker …
