Category Archives: ANUAL SERVICE M

OPTIONAL PARTS

ITEM

REMARKS

MAINTENANCE:

Work stand

Pin spanner Air gauge

DRIVE CHAIN & SPROCKET:

Driven sprocket /chain link Standard

Optional

HANDLEBAR LOWER HOLDER:

Standard

Optional

For maintenance

Pin spanner A x 2 For shock absorber spring installed length (preload) adjustment (two required)

51T (Aluminum)/114 50T (Aluminum)/114 52T (Aluminum)/116

3 mm offset no offset

ITEM

REMARKS

FORK ( 05 — ’07):

Spring

TYPE

SPRING RATE

OIL CAPACITY

Light

2 scribe marks

0.45 kgf/mm (25.20 Ibf/in)

Standard

338 cm3 (11.4 US oz, 11.9 Imp oz) Maximum

407 cm3 (13.8 US oz, 14.3 Imp oz) Minimum

311 cm3 (10.5 US oz, 10.9 Imp oz)

Standard

or

No mark (factory products) or 1 scribe mark (after market parts)

0.47 kgf/mm (26.32 Ibf/in)

Standard

332 cm3 (11.2 US oz, 11.7 Imp oz) Maximum

402 cm3 (13.6 US oz, 14.2 Imp oz) Minimum

306 cm3 (10.3 US oz, 10.8 Imp oz)

Heavy

3 scribe marks

0.49 kgf/mm (27.44 Ibf/in)

Standard

335 cm3 (11.3 US oz, 11.8 Imp oz) Maximum

405 cm3 (13.7 US oz, 14.3 Imp oz) Minimum

309 cm3 (10.5 US oz, 10.9 Imp oz)

FORK (After 07):

Spring

TYPE

SPRING RATE

OIL CAPACITY

Light

2 scribe marks

0.45 kgf/mm (25.20 Ibf/in)

Standard

330 cm3 (11.2 US oz, 11.6 Imp oz) Maximum

407 cm3 (13.8 US oz, 14.3 Imp oz) Minimum

311 cm3 (10.5 US oz, 10.9 Imp oz)

Standard

or

No mark (factory products) or 1 scribe mark (after market parts)

0.47 kgf/mm (26.32 Ibf/in)

Standard

324 cm3 (11.0 US oz, 11.4 Imp oz) Maximum

402 cm3 (13.6 US oz, 14.2 Imp oz) Minimum

306 cm3 (10.3 US oz, 10.8 Imp oz)

Heavy

3 scribe marks

0.49 kgf/mm (27.44 Ibf/in)

Standard

327 cm3 (11.1 US oz, 11.5 Imp oz) Maximum

405 cm3 (13.7 US oz, 14.3 Imp oz) Minimum

309 cm3 (10.5 US oz, 10.9 Imp oz)

The standard fork springs mounted on the motorcycle when it leaves the factory are not marked. Before replacing the springs, be sure to mark them so they can be distinguished from other optional springs.

ITEM

REMARKS

SHOCK ABSORBER:

Spring

TYPE

SPRING RATE

IDENTIFICATION MARK

Light

5.30 kgf/mm (296.8 Ibf/in)

Blue paint

Stan-

5.50 kgf/mm (308.0 Ibf/in)

No mark (factory products) or Red paint (after market parts)

Heavy

5.70 kgf/mm (319.2 Ibf/in) 5.90 kgf/mm (330.4 Ibf/in)

Pink paint Silver paint

The standard shock spring mounted on the motorcycle when it leaves the factory is not marked. Before replacing the spring, be sure to mark it so it can be distinguished from other optional springs.

EMISSION CONTROL SYSTEMS

The U. S. Environmental Protection Agency (EPA), and the California Air Resources Board (CARB) require that off-road motorcycle comply with applicable exhaust emissions standards during it useful life, when operated and maintained according to the instructions provided.

SOURCE OF EMISSIONS

The combustion process produces carbon monoxide, oxides of nitrogen and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when sub­jected to sunlight. Carbon monoxide does not react in the same way, but is toxic.

Honda Motor Co., Ltd. utilizes appropriate carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons.

EXHAUST EMISSION CONTROL SYSTEM

The exhaust emission control system is composed of lean carburetor setting, no adjustments should be made except for high altitude setting and idle speed adjustment with the throttle stop screw. The exhaust emission control system is sepa­rate from the crankcase emission control system.

CRANKCASE EMISSION CONTROL SYSTEM

The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor.

OPTIONAL PARTS

AIR CLEANER

CARBURETOR

FRESH AIR BLOW-BY GAS

IGNITION CONTROL MODULE (ICM)

MAIN WIRE HARNESS

ICM 6P (NATURAL) CONNECTOR

STARTER RELAY SWITCH

BATTERY

BATTERY NEGATIVE (-) CABLE

TAIL LIGHT WIRE

IGNITION CONTROL MODULE (ICM)

REGULATOR/RECTIFIER WIRE

ICM 6P (BROWN) CONNECTOR

IGNITION CONTROL MODULE (ICM)

CRANKCASE BREATHER HOSE

TRANSMISSION BREATHER HOSES

PAIR AIR SUCTION HOSE

CRANKCASE BREATHER HOSE

PAIR CONTROL VALVE

AIR SUPPLY HOSE

VACUUM HOSE

AIR SUPPLY PIPE

CONDARY AIR SUPPLY SYSTEM (’05 and ’06 California type, ’07)

CONDARY AIR SUPPLY SYSTEM ('05 and '06 California type, ’07)

PAIR AIR SUCTION HOSE

CRANKCASE

BREATHER

HOSES

TRANSMISSION BREATHER HOSES

AIR SUPPLY HOSE

AIR SUPPLY PIPE

PAIR CONTROL VALVE

CABLE & HARNESS ROUTING (After 4)7)

CONDARY AIR SUPPLY SYSTEM ('05 and '06 California type, ’07)

STARTER SWITCH WIRE

ENGINE STOP BUTTON WIRE

ENGINE STOP BUTTON/CLUTCH SWITCH 3P (BLACK) CONNECTOR

THROTTLE CABLES

STARTER SWITCH 2P (BLACK) CONNECTOR

TRIPMETER CABLE

MAIN WIRE HARNESS

HEADLIGHT 3P (NATURAL) CONNECTOR

FRONT BRAKE HOSE

CLUTCH CABLE HOT START CABLE

HOT START CABLE

ENGINE STOP BUTTON WIRE

CLUTCH CABLE

THROTTLE CABLES

CONDARY AIR SUPPLY SYSTEM ('05 and '06 California type, ’07)

20 (0.8 in

STARTER SWITCH WIRE

FUEL TANK BREATHER HOSE

CONDARY AIR SUPPLY SYSTEM ('05 and '06 California type, ’07)

OVERFLOW HOSE

SIPHON HOSE

CLUTCH CABLE

THROTTLE CABLES

CONDARY AIR SUPPLY SYSTEM ('05 and '06 California type, ’07)

HOT START CABLE

FRONT BRAKE HOSE

ENGINE STOP BUTTON/ CLUTCH SWITCH 3P (BLACK) CONNECTOR

STARTER SWITCH 2P (BLACK) CONNECTOR

CLUTCH SWITCH WIRE CONNECTOR

ENGINE STOP BUTTON WIRE

CONDARY AIR SUPPLY SYSTEM ('05 and '06 California type, ’07)

ALTERNATOR WIRE

CRANKCASE BREATHER HOSE

IGNITION PULSE GENERATOR 2P (BLACK) CONNECTOR

HOT START CABLE

RADIATOR SIPHON HOSE

AIR VENT HOSE

RADIATOR OVERFLOW HOSE

0-3 mm (0 — 0.1 in)

ALTERNATOR 4P (BLACK) CONNECTOR

FUEL HOSES

CONDARY AIR SUPPLY SYSTEM ('05 and '06 California type, ’07)

CONDARY AIR SUPPLY SYSTEM ('05 and '06 California type, ’07)

CLUTCH CABLE

TRANSMISSION BREATHER HOSES

CRANKCASE BREATHER HOSE

ALTERNATOR WIRE

CARBURETOR OVERFLOW/ DRAIN HOSE

AIR VENT HOSES

PAIR AIR SUCTION HOSE

AIR VENT HOSES

CRANKCASE BREATHER HOSES

SPARK PLUG WIRE

THROTTLE POSITION SENSOR 3P (BLACK) CONNECTOR

HOT START CABLE

MAIN WIRE HARNESS

CRANKCASE BREATHER HOSE

RADIATOR HOSES

SIPHON HOSE

CLUTCH CABLE

THROTTLE CABLES

CONDARY AIR SUPPLY SYSTEM ('05 and '06 California type, ’07)

IGNITION COIL PRIMARY WIRE RADIATOR HOSES

PAIR AIR SUCTION HOSE TRANSMISSION BREATHER HOSE

CABLE & HARNESS ROUTING (’05 — ’07)

CABLE & HARNESS ROUTING ('05 - '07)

ENGINE STOP BUTTON WIRE

FRONT BRAKE HOSE

STARTER SWITCH 2P (BLACK) CONNECTOR

CLUTCH CABLE

HOT START CABLE

MAIN WIRE HARNESS

STARTER SWITCH WIRE THROTTLE CABLES

TRIPMETER CABLE

ENGINE STOP BUTTON/CLUTCH SWITCH 3P (BLACK) CONNECTOR

HEADLIGHT 3P (BLUE) CONNECTOR

HOT START CABLE

CLUTCH CABLE

THROTTLE CABLES

CABLE & HARNESS ROUTING ('05 - '07)

STARTER SWITCH WIRE

ENGINE STOP BUTTON WIRE

FUEL TANK BREATHER HOSE

CABLE & HARNESS ROUTING ('05 - '07)

FRONT BRAKE HOSE

ENGINE STOP BUTTON WIRE

IGNITION PULSE GENERATOR 2P (BLACK) CONNECTOR

ALTERNATOR 4P (BLACK) CONNECTOR

HOT START CABLE

THROTTLE CABLES

TRIPMETER CABLE

CABLE & HARNESS ROUTING ('05 - '07)

CLUTCH CABLE SIPHON HOSE OVERFLOW HOSE

CABLE & HARNESS ROUTING ('05 - '07)

CARBURETOR OVERFLOW/ DRAIN HOSE

GROUND CABLE

RADIATOR SIPHON HOSE

CRANKCASE BREATHER HOSE

FUEL HOSE

RADIATOR OVERFLOW HOSE

ALTERNATOR WIRE

CABLE & HARNESS ROUTING ('05 - '07)

REAR BRAKE HOSE

’05, ’06:

SIPHON HOSE

RADIATOR HOSES

SPARK PLUG WIRE HOT START CABLE

MAIN WIRE HARNESS

THROTTLE POSITION SENSOR CONNECTOR

THROTTLE CABLES

CLUTCH CABLE

IGNITION COIL PRIMARY WIRE

RADIATOR HOSES

CRANKCASE BREATHER HOSE

CABLE & HARNESS ROUTING ('05 - '07)

TRANSMISSION BREATHER HOSE

’05 and ’06 California type, ’07:

RADIATOR HOSES

SIPHON HOSE

SPARK PLUG WIRE HOT START CABLE

MAIN WIRE HARNESS

THROTTLE POSITION SENSOR CONNECTOR

THROTTLE CABLES

CLUTCH CABLE

CRANKCASE BREATHER HOSE

IGNITION COIL PRIMARY WIRE

RADIATOR HOSES

PAIR AIR SUCTION HOSE

CABLE & HARNESS ROUTING ('05 - '07)

TRANSMISSION BREATHER HOSE

’05, ’06:

CRANKCASE BREATHER HOSES

CABLE & HARNESS ROUTING ('05 - '07)

AIR VENT HOSES

CLUTCH CABLE

TRANSMISSION BREATHER HOSES

CRANKCASE BREATHER HOSE

AIR VENT HOSES

ALTERNATOR WIRE

CARBURETOR OVERFLOW/ DRAIN HOSE

’05 and ’06 California type, ’07:

CRANKCASE BREATHER HOSES

CABLE & HARNESS ROUTING ('05 - '07)

CLUTCH CABLE

TRANSMISSION BREATHER HOSES

CRANKCASE BREATHER HOSE

ALTERNATOR WIRE

CARBURETOR OVERFLOW/ DRAIN HOSE

AIR VENT HOSES

PAIR AIR SUCTION HOSE

AIR VENT HOSES

CABLE & HARNESS ROUTING ('05 - '07)

MAIN WIRE HARNESS

TAIL LIGHT WIRE

— ICM 6P (NATURAL) CONNECTOR

REGULATOR/RECTIFIER

WIRE

IGNITION CONTROL MODULE (ICM) ICM 6P (BROWN) CONNECTOR

BATTERY

BATTERY NEGATIVE (-) CABLE

STARTER RELAY SWITCH