Category Archives: ANUAL SERVICE M

CYLINDER HEAD/VALVES SPECIFICATIONS

Unit: mm (in)

ITEM

STANDARD

SERVICE LIMIT

Cylinder compression

402 kPa (4.1 kgf/cmJ, 58 psi) at 360 rpm

Cylinder head warpage

0.05 (0.002)

Decompressor clearance

’05-’07

Ex valve clearance + 0.35 mm (0.014)

Valve and

Valve clearance

IN

0.16 ±0.03 (0.006 ±0.001)

valve guide

EX

0.28 ± 0.03 (0.011 ±0.001)

Valve stem O. D.

IN

5.475-5.490 (0.2156-0.2161)

EX

4.965 — 4.980 (0.1955 — 0.1961)

4.96 (0.195)

Valve guide I. D.

IN

5.500 — 5.512 (0.2165 — 0.2170)

5.552 (0.2186)

EX

5.000 — 5.012 (0.1969 — 0.1973)

5.052 (0.1989)

Stem-to-guide clear­

IN

0.010 — 0.037 (0.0004 — 0.0015)

ance

EX

0.020 — 0.047 (0.0008 — 0.0019)

Valve guide projec­

IN

16.1 -16.3(0.63 — 0.64)

tion above cylinder head

EX

17.9-18.1 (0.70-0.71)

Valve seat width

IN

1.1 -1.3(0.04-0.05)

2.0 (0.08)

EX

1.3-1.5(0.05-0.06)

2.0 (0.08)

Valve spring free length

IN

40.68 (1.602)

39.7 (1.56)

EX

42.82 (1.686)

41.9 (1.65)

Rocker arm

Rocker arm I. D.

12.000 — 12.018 (0.4724 — 0.4731)

12.05 (0.474)

Rocker arm shaft O. D.

11.967 — 11.975 (0.4711 — 0.4715)

11.92 (0.469)

Rocker arm-to-shaft clearance

0.025 — 0.051 (0.0010 — 0.0020)

0.10 (0.004)

Camshaft

Cam lobe height

IN

36.890 — 37.130 (1.4524 — 1.4618)

36.890 (1.4524)

EX

35.063 — 35.303 (1.3804 — 1.3899)

35.063 (1.3804)

Valve lifter O. D.

25.978 — 25.993 (1.0228 — 1.0233)

25.97 (1.022)

Valve lifter bore I. D.

26.010 — 26.026 (1.0240 — 1.0246)

26.04 (1.025)

CYLINDER/PISTON SPECIFICATIONS

Unit: mm (in)

ITEM

STANDARD

SERVICE LIMIT

Cylinder

I. D.

96.000 — 96.015 (3.7795 — 3.7801)

96.025 (3.7805)

Out of round

0.010 (0.0004)

Taper

0.010 (0.0004)

Warpage

0.05 (0.002)

Piston, piston ring

Piston mark direction

"IN" mark facing toward the intake side

Piston O. D.

95.970 — 95.980 (3.7783 — 3.7787)

95.94 (3.777)

Piston O. D. measurement point

5.0 mm (0.20 in) from the bottom of skirt

Piston pin bore I. D.

19.002 — 19.008 (0.7481 -0.7483)

19.03 (0.749)

Piston pin O. D.

18.994 — 19.000 (0.7478 — 0.7480)

18.98 (0.747)

Piston-to-piston pin clearance

0.002 — 0.014 (0.0001 — 0.0006)

0.04 (0.002)

Top ring mark

"R" mark side facing up

Piston ring-to-ring groove clearance

Top

0.065 — 0.100 (0.0026 — 0.0039)

0.115 (0.0045)

Piston ring end gap

Top ring

0.25-0.31 (0.010-0.012)

0.45 (0.018)

Oil ring (side rail)

0.20-0.70 (0.008-0.028)

0.90 (0.035)

Cylinder-to-piston clearance

0.020 — 0.045 (0.0008 — 0.0018)

0.085 (0.0033)

Connecting rod small end I. D.

’05 — ’07

19.016 — 19.034 (0.7487 — 0.7494)

19.04 (0.750)

After ’07

19.016 — 19.038 (0.7487 — 0.7495)

19.04 (0.750)

Connecting rod-to-piston pin clearance

’05 — ’07

0.016 — 0.040 (0.0006 — 0.0016)

0.06 (0.002)

After ’07

0.016 — 0.044 (0.0006 — 0.0017)

0.06 (0.002)

CLUTCH/STARTER CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE SPECIFICATIONS

Unit: mm (in)

ITEM

STANDARD

SERVICE LIMIT

Clutch lever freeplay

10-20 (3/8-13/16)

Clutch spring free length

44.7 (1.76)

43.7 (1.72)

Clutch disc thickness

2.92-3.08 (0.115-0.121)

2.85 (0.112)

Clutch plate warpage

0.15 (0.006)

Kickstarter pinion gear I. D.

22.007 — 22.028 (0.8664 — 0.8672)

22.05 (0.868)

Kickstarter pinion gear bushing

I. D.

20.000 — 20.021 (0.7874 — 0.7882)

20.04 (0.789)

O. D.

21.979 — 22.000 (0.8653 — 0.8661)

21.96 (0.865)

Kickstarter spindle O. D.

19.980 — 19.993 (0.7866 — 0.7871)

19.97 (0.786)

Kickstarter idle gear I. D.

20.020-20.041 (0.7882-0.7890)

20.07 (0.790)

Kickstarter idle gear bushing

I. D.

17.000 — 17.018 (0.6693 — 0.6700)

17.04 (0.671)

O. D.

19.979 — 20.000 (0.7866 — 0.7874)

19.96 (0.786)

Countershaft O. D. at kickstarter idle gea

16.966 — 16.984 (0.6680 — 0.6687)

16.95(0.667)

Starter driven gear boss

I. D.

36.009 — 36.034 (1.4177 — 1.4187)

36.034(1.4187)

O. D.

45.660 — 45.673 (1.7976 — 1.7981)

45.660 (1.7976)

Reduction gear A I. D.

12.010 — 12.050 (0.4728 — 0.4744)

12.050 (0.4744)

Reduction gear В I. D.

10.045 — 10.085 (0.3955 — 0.3970)

10.085 (0.3970)

Idle gear I. D.

12.010 — 12.050 (0.4728 — 0.4744)

12.050(0.4744)

Gear holder shafts O. D.

11.989 — 12.000 (0.4720 — 0.4724)

11.989 (0.4720)

Reduction gear shaft O. D.

9.980 — 9.995 (0.3929 — 0.3935)

9.980 (0.3929)

CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER SPECIFICATIONS (’05 — ’07)

Unit: mm (in

ITEM

STANDARD

SERVICE LIMIT

Crankshaft

Side clearance

0.30-0.75 (0.012-0.030)

0.75 (0.030)

Radial clearance

0.006 — 0.018 (0.0002 — 0.0007)

0.05 (0.002)

Runout

R

0.03 (0.001)

L

0.05 (0.002)

Transmission

Gear I. D.

M4

28.007 — 28.028 (1.1026 — 1.1035)

28.05 (1.104)

M5

25.020 — 25.041 (0.9850 — 0.9859)

25.07 (0.987)

Cl

22.007 — 22.028 (0.8664 — 0.8672)

22.04 (0.868)

C2

30.020-30.041 (1.1819-1.1827)

30.07 (1.184)

C3

25.020 — 25.041 (0.9850 — 0.9859)

25.07 (0.987)

Bushing O. D.

M4

27.959-27.980 (1.1007- 1.1016)

27.94(1.100)

C2

29.979 — 30.000 (1.1803 — 1.1811)

29.95 (1.179)

Bushing I. D.

C2

27.000 — 27.021 (1.0630 — 1.0638)

27.04(1.065)

Gear-to-bushing

M4

0.027 — 0.069 (0.0011 — 0.0027)

0.11 (0.004)

clearance

C2

0.020 — 0.062 (0.0008 — 0.0024)

0.12 (0.005)

Mainshaft O. D.

M5

24.959 — 24.980 (0.9826 — 0.9835)

24.94 (0.982)

Countershaft O. D.

C1 bearing

18.987 — 19.000 (0.7475 — 0.7480)

18.94 (0.746)

C2 bushing

26.959 — 26.980 (1.0614 — 1.0622)

26.94 (1.061)

C3

24.959 — 24.980 (0.9826 — 0.9835)

24.96 (0.983)

Gear-to-shaft

M5

0.040 — 0.082 (0.0016 — 0.0032)

0.13 (0.005)

clearance

C3

0.040 — 0.082 (0.0016 — 0.0032)

0.082 (0.0032)

Bushing-to-shaft

clearance

C2

0.020 — 0.062 (0.0008 — 0.0024)

0.12 (0.005)

Shiftfork, shift

Fork claw thickness

4.93-5.00 (0.194-0.197)

4.8 (0.19)

fork shaft

Shift fork I. D.

С

10.989 — 11.011 (0.4326 — 0.4335)

11.011 (0.4335)

R, L

12.035 — 12.056 (0.4738 — 0.4746)

12.070 (0.4752)

Fork shaft O. D.

С

10.969 — 10.980 (0.4319 — 0.4323)

10.969 (0.4318)

R, L

11.966 — 11.984 (0.4711 — 0.4718)

11.950 (0.4705)

CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER SPECIFICATIONS (After ’07)

Unit: mm (in)

ITEM

STANDARD

SERVICE LIMIT

Crankshaft

Side clearance

0.30-0.75 (0.012-0.030)

0.75 (0.030)

Radial clearance

0.006 — 0.018 (0.0002 — 0.0007)

0.05 (0.002)

Runout

R

0.03(0.001)

L

0.05 (0.002)

Transmission

Gear I. D.

M4

28.007 — 28.028 (1.1026 — 1.1035)

28.05 (1.104)

M5

28.020 — 28.033 (1.1031 — 1.1037)

28.07 (1.105)

Cl

22.007 — 22.028 (0.8664 — 0.8672)

22.04 (0.868)

C2

30.020-30.041 (1.1819-1.1827)

30.07 (1.184)

C3

28.020 — 28.041 (1.1031 — 1.1040)

28.07 (1.105)

Bushing O. D.

M4

27.959 — 27.980 (1.1007 — 1.1016)

27.94(1.100)

M5

27.959-27.980 (1.1007-1.1016)

27.94 (1.100)

C2

29.979 — 30.000 (1.1803 — 1.1811)

29.95 (1.179)

C3

27.979 — 28.000 (1.1015 — 1.1024)

27.95 (1.100)

Bushing I. D.

M5

25.000 — 25.021 (0.9843 — 0.9851)

25.04 (0.9858)

C2

27.000 — 27.021 (1.0630 — 1.0638)

27.04 (1.065)

C3

25.000-25.021 (0.9843-0.9851)

25.04 (0.9858)

Gear-to-bushing

M4

0.027 — 0.069 (0.0011 — 0.0027)

0.11 (0.004)

clearance

M5

0.040 — 0.074 (0.0016 — 0.0029)

0.12 (0.005)

C3

0.020 — 0.062 (0.0008 — 0.0024)

0.12(0.005)

C2

0.020 — 0.062 (0.0008 — 0.0024)

0.12 (0.005)

Mainshaft O. D.

M5

24.959 — 24.980 (0.9826 — 0.9835)

24.94 (0.982)

Countershaft O. D.

Cl bearing

18.987 — 19.000 (0.7475 — 0.7480)

18.94 (0.746)

C2 bushing

26.959 — 26.980 (1.0614 — 1.0622)

26.94(1.061)

C3 bushing

24.959 — 24.980 (0.9826 — 0.9835)

24.96 (0.983)

Bushing-to-shaft

clearance

M5, C2, C3

0.020 — 0.062 (0.0008 — 0.0024)

0.12(0.005)

Shift fork, shift

Fork claw thickness

4.93-5.00 (0.194-0.197)

4.8 (0.19)

fork shaft

Shift fork I. D.

С

10.989-11.011 (0.4326-0.4335)

11.011 (0.4335)

R, L

12.035 — 12.056 (0.4738 — 0.4746)

12.070 (0.4752)

Fork shaft O. D.

С

10.969 — 10.980 (0.4319 — 0.4323)

10.969 (0.4318)

R, L

11.966 — 11.984 (0.4711 — 0.4718)

11.950 (0.4705)

GENERAL SPECIFICATIONS

ITEM

SPECIFICATION

DIMENSIONS

Overall length

(’05 — ’07)

2,180 mm (85.8 in)

(After ’07)

2,179 mm (85.8 in)

Overall width

821 mm (32.3 in)

Overall height

1.273 mm (50.1 in)

Wheelbase

(’05-’07)

1,483 mm (58.4 in)

(After ’07)

1,480 mm (58.3 in)

Seat height

963 mm (37.9 in)

Footpeg height

431 mm (17.0 in)

Ground clearance

345 mm (13.6 in)

FRAME

Frame type

Twin tube

Front suspension

Telescopic fork

Front suspension axle travel

279 mm (11.0 in)

Front suspension cushion stroke

315 mm (12.4 in)

Rear suspension

Pro-Link

Rear wheel travel

313 mm (12.3 in)

Rear damper

Decarbon type with nitrogen gas filled

damper

Front tire size

80/100-21 51M

Rear tire size

110/100-18 64M

Tire brand (Dunlop)

(’05-’07)

Front: D742F

(After ’07)

Front: D742FA

Rear: D756

Front brake

Hydraulic single disc

Front brake swept area

334.5 cm2 (51.8 in2)

Rear brake

Hydraulic single disc

Rear brake swept area

391.1 cm2 (60.6 in2)

Caster angle

(’05-’07)

27°10′

(After ’07)

27°03′

Trail length

(’05-’07)

110 mm (4.3 in)

(After ’07)

114.7 mm (4.52 in)

Fuel tank capacity

(’05-’07)

8.6 liter (2.27 US gal, 1.89 Imp gal)

(After ’07)

7.2 liter (1.90 US gal, 1.58 Imp gal)

Fuel tank reserve capacity

(’05-’07)

1.4 liter (0.37 US gal, 0.31 Imp gal)

(After ’07)

1.6 liter (0.42 US gal, 0.35 Imp gal)

ENGINE

Bore and stroke

96.0 x 62.1 mm (3.78 x 2.44 in)

Displacement

449 cm3 (27.4 cu-in)

Compression ratio

12.0:1

Valve train

Chain drive and OHC with rocker arm

Intake valve opens

at 1.0 mm (0.04 in) lift

10° BTDC

closes

at 1.0 mm (0.04 in) lift

45° ABDC

Exhaust valve opens

at 1.0 mm (0.04 in) lift

50° BBDC

closes

at 1.0 mm (0.04 in) lift

15° ATDC

Lubrication system

Forced pressure and wet sump

Oil pump type

Trochoid

Cooling system

Liquid cooled

Air filtration

Oiled polyurethane foam

Crankshaft type

Assembled type

Engine dry weight

32.3 kg (71.2 lbs)

Cylinder arrangement

Single cylinder, inclined 6° from vertical

CARBURETOR

Carburetor type

Piston valve type

Venturi diameter

40 mm (1.6 in)

ITEM

SPECIFICATION

DRIVE TRAIN

Clutch system

Multi-plate, wet

Clutch operation system

Cable operated

Transmission

Constant mesh, 5-speed

Primary reduction

2.739 (63/23)

Final reduction

3.923(51/13)

Gearratio 1st

2.230 (29/13)

2nd

1.625(26/16)

3rd

1.235 (21/17)

4th

1.000 (19/19)

5th

0.826(19/23)

Gearshift pattern

Left foot operated return system.

1-N-2-3-4-5

ELECTRICAL

Ignition system

ICM (Ignition Control Module)

Starting system

Electric starter motor and kickstarter

Charging system

Single phase output alternator

Regulator/rectifier

SCR shorted/Single phase, half wave

rectification

Lighting system

Alternator

LUBRICATION SYSTEM SPECIFICATIONS

Unit: mm (in

ITEM

STANDARD

SERVICE LIMIT

Engine oil capacity

At draining

0.67 liter (0.71 US qt, 0.59 Imp qt)

At filter change

0.70 liter (0.74 US qt, 0.62 Imp qt)

At disassembly

0.87 liter (0.92 US qt, 0.77 Imp qt)

Transmission oil capacity

At draining

0.65 liter (0.69 US qt, 0.57 Imp qt)

At disassembly

0.75 liter (0.79 US qt, 0.66 Imp qt)

Recommended engine oil

Pro Honda GN4 4-stroke oil (U. S.A. and Canada) or equivalent motor oil API service classification: SG or Higher JASO T 903 standard: MA Viscosity: SAE 10W-30

Recommended transmission oil

Pro Honda GN4 4-stroke oil (U. S.A. and Canada) or equivalent motor oil API service classification: SG or Higher JASO T 903 standard: MA Viscosity: SAE 10W-30

Oil pump rotor

Tip clearance

0.15(0.006)

0.20 (0.008)

Body clearance

0.15-0.21 (0.006-0.008)

Side clearance

0.05-0.13(0.002-0.005)

FUEL SYSTEM SPECIFICATIONS

ITEM

SPECIFICATIONS

Fuel tank capacity

’05 — ’07

8.6 liter (2.27 US gal, 1.89 Imp gal)

After ’07

7.2 liter (1.90 US gal, 1.58 Imp gal)

Carburetor identification number

’05, ’06

FCR04A

’07

FCR13A

After ’07

FCR13B

Main jet

’05-’07

#142

After ’07

#145

Slow jet

#45

Jet needle

’05, ’06

NCVU

’07

NHTU

After ’07

NNEU

Jet needle clip position (Standard)

’05, ’06

2nd position from the top

After ’06

Fixed position

Pilot screw initial opening

’05 — ’07

1-1/4 turns out

After ’07

1-1/8 turns out

Float level

8.0 mm (0.31 in)

Idle speed

1,700 ± 100 rpm

Throttle grip freeplay

3-5 mm (1/8-3/16 in)

Hot starter lever freeplay

2-3 mm (1/16-1/8 in)

PAIR control valve specified vacuum (’05 and ’06 California type, After ’06)

56 kPa (420 mmHg)

Throttle position sensor (Blue — Black) resistance (at 20°C/68°F)

4-6 m

COOLING SYSTEM SPECIFICATIONS

ITEM

SPECIFICATIONS

Coolant capacity

At change

1.21 liter (1.28 US qt, 1.06 Imp qt)

At disassembly

1.45 liter (1.53 US qt, 1.28 Imp qt)

Radiator cap relief pressure

108 — 137 kPa (1.1 — 1.4 kgf/cmJ, 16 — 20 psi)

Recommended antifreeze

Pro Honda HP Coolant or an equivalent high quality ethyl­ene glycol antifreeze containing silicate-free corrosion inhibitors

Standard coolant concentration

1 :1 mixture with distilled water

SERVICE RULES

1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may cause damage to the motorcycle.

2. Use the special tools designed for this product to avoid damage and incorrect assembly.

3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fastener.

4. Install new gaskets, О-rings, cotter pins, and lock plates when reassembling.

5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified.

6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.

7. After reassembly, check all parts for proper installation and operation.

8. Route all electrical wires as shown in the Cable and Harness Routing.

— ’05 -’07: (page 1-25)

— After ’07: (page 1-32)

MODEL IDENTIFICATION

’05 — ’07 shown:

SERVICE RULES

SERVICE RULES

, VEHICLE IDENTIFICATION NUMBER (VIN)

The Vehicle Identification Number (V. I.N.) is stamped on the right side of the steering head.

SERVICE RULES

The carburetor identification number is stamped on the left side of the carburetor body.

NAME PLATE (U. S.A.) OR SAFETY I CERTIFICATION LABEL (Canada)

SERVICE RULES

The name plate (U. S.A.) or Safety Certification Label (Canada) is,. „ л,

attached on the right side of the frame. U b A — shown:

SERVICE RULES

SERVICE RULES