Page 1-1

1. GENERAL INFORMATION


GENERAL SAFETY1-1
SERVICE RULES1-1
MODEL IDENTIFICATION1-2
SPECIFICATIONS1-3
TORQUE VALUES1-5
TOOLS1-7
CABLE & HARNESS ROUTING1-9
EMISSION CONTROL SYSTEMS1-16
EMISSION CONTROL INFORMATION LABELS1-18

GENERAL SAFETY

WARNING

If the engine must be running to do some work, make sure the area is well-ventilated.  Never run the engine in an enclosed area.  The exhaust contains poisonous carbon monoxide gas that may cause loss of conciousness and lead to death.

WARNING

The battery generates hydrogen gas which can be highly explosive.  Do not smoke or allow flames or sparkes near the battery, especially when charging it.

WARNING

Inhaled asbestos fibers have been found to cause respiratory disease and cancer.  Never use an air hose or dry brush to clean brake assemblies.  Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA designed to minimise the hazard caused by airborne asbestos fibers.

WARNING

WARNING

Gasoline is extremely flammable and is explosive under cartain conditions, work in a well ventilated area with the engine stopped.  Do not smoke or allow flames or sparks in the work area or where gasoline is stored.

WARNING

The battery electrolyte contains sulfuric acid.  Protect your eyes, skin, and clothing.  In case of contact, flush thoroughly with water and call a doctor if electrolyte gets in your eyes.

WARNING

Do not remove the radiator cap when the engine is hot.  The coolant is under pressure ans severe scalding could result.  The engine must be cool before servicing the cooling system.

CAUTION:

Used engine oil may cause cancer if repeatedly left in contact with the skin for prolonged periods.  Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil.

SERVICE RULES

  1. Use genuine HONDA or HONDA-recommended parts and lubricants of their equivalents.  Parts that don’t meet HONDA’s design specifications may damage to the vehicle.
  2. Use the special tools designed for this product to avoid damage and incorrect assembly.
  3. Use only metric tools when servicing the vehicle.  Metric bolts, nuts and screws are not interchangeable with English fasteners.
  4. Install new gaskets, O-rings, cotter pins, and lock plates whe reassembling.
  5. When tightening bolts or nuts, begin with the larger-diameter or inner bolts first.  Then tighen to the specified torque diagonally in 1-5 steps, unless a particular sequence is specified.
  6. Clean parts in non-flammable or high flash point solvent upon disassembly.  Lubricate any sliding surfaces before reassembly.
  7. After reassembly, check all ports for proper installation and operation.
  8. Route all wires as shown on pages 1-9 through 1-14, Cable and Harness Routing.

Page 1-2

MODEL IDENTIFICATION

Page 1-3

SPECIFICATIONS

ITEMSPECIFICATION
DIMENTIONS
Overall length
Overall width
Overall height
Wheelbase
Seat height
Foot peg height
Ground clearance
Dry weight
Curb weight
2,085mm(82.1 in)
750mm(29.5 in)
1,075mm(42.3 in)
1,430mm(53.3 in)
778mm(30.6 in)
355mm(14.0 in)
155mm(6.1 in)
168kg(370.3 lb)
184kg(405.6 lb)
FRAME Type
Front suspension, travel
Rear suspension, travel
Gross vehicle weight rating
Maximum weight capacity
Front tire size
Rear tire size
Twin tube diamond, aluminum
Telescopic fork, 130 mm (5.12 in)
Swingarm, 120 mm (4.72 in)
291 kg (642 lb)
156 kg (345 lb)
110/80-17 57H Tubless type
150/70-17 69H Tubless type
Cold Tire Pressure Up to 90 kg
(200 lb) load
Front
Rear
225 kPa (2.25 kg/cm2, 33 psi)
225 kPa (2.25 kg/cm2, 33 psi)
Up to macimum
weight capacity
Front
Rear
225 kPa (2.25 kg/cm2, 33 psi)
250 kPa (2.50 kg/cm2, 36 psi)
Front brake, lining swept area
Rear brake, lining swept area
Fuel capacity
Fuel reserve capacity
Caster angle
Trail length
Fork oil capacity
’88

after ’88

Fork oil level
’88

after ’88
Hydraulic single disk, 262 x 2 cm2 (40.6 x 2 sq in)
Hydraulic single disk, 200 x 2 cm2 (31.0 x 2 sq in)
12.0 lit (3.18 US gal, 2.64 Imp gal)
2.0 lit (2.10 US qt, 1.76 Imp qt)
27°
111 mm (4.37 in)
497 cc (16.8 US oz, 17.4 Imp oz)
502 cc (16.9 US oz, 17.6 Imp oz)
133 mm (5.2 in)
128 mm (5.0 in)
ENGINEType

Cylinder arrangement
Bore and stroke
Displacement
Compression Ratio
Valve train
Oil Capacity

after disassembly:
with oil filter:
after draining:

Coolant capacity

Coolant change:
Total system:

Lubrication system
Air filtration
Cylinder compression
Intake valve

Opens:
Closes:

Exhaust Valve

Opens:
Closes:

Valve clearance (cold)

intake:
exhaust:

Engine weight
Idle speed
Water cooled twin, 4 stroke SOHC (Single Over Head
Camshaft) engine
2 Cylinderts 52° V
79.0 x 66.0 mm (3.11 x 2.60 in)
647 cc (39.4 cu-in)
9.4 : 1
Silent, multi-link chain drive and OHC with rocker arms

2.8 lit (2.94 US qt, 2.46 Imp qt)
2.3 lit (2.43 US qt, 2.02 Imp qt)
2.2 lit (2.32 US qt, 1.94 Imp qt)

1.6 lit (1.51 US qt, 1.41 Imp qt)
2.2 lit (2.32 US qt, 1.94 Imp qt)
Forced pressure and wet sump
Paper filter
1,324 ± 196 kPa (13.5 ± 2 kg/cm2, 192 ± 28 psi)

10° BTDC at 1 mm lift
40° ABDC      "

40° BBDC      "
10° ATDC      "

0.15 ± 0.02 mm (0.006 ± 0.0008 in)
0.20 ± 0.02 mm (0.008 ± 0.0008 in)
80 kg (176 lb)
1,200 ± 100 rpm

Page 1-4

ITEMSPECIFICATIONS
CARBURATION Carburator type
Identifcation number
Pilot screw initial setting
Float level
Constant velocity dual carburator
VDGKA [VDGLA]
See page 4-14
9.2 mm (0.36 in)
DRIVE TRAIN Clutch
Transmission
Primary reduction
Final reduction
Gear Ratio I
Gear Ratio II
Gear Ratio III
Gear Ratio IV
Gear Ratio V
Gear shift pattern
Cable Operation, multi-plate, wet
5-speed
1.888 (32/68)
2.750 (16/44)
2.769 (13/36)
1.882 (17/32)
1.450 (20/29)
1.174 (23/27)
0.965 (29/28)
Left foot operated return system, 1–N–2–3–4–5
ELECTRICAL IgnitionDigitized full transistor ignition
Ignition timing "F" mark10° BTDC at idle
Full advance31° BTDC at 7,000 ± 200 rpm
Starting systemStarter Motor
Alternator240 W/5,000 rpm
Battery Capacity12V 8Ah MF Battery
Spark plugNGKND
 Standard:DPR8EA-9X24EPR-U9
For cold climate (below 5° C, 41° F):DPR7EA-9X22EPR-U9
For extended high speed riding:DPR9EA-9X27EPR-U9
Spark plug gap0.80-0.90 mm (0.031 - 0.035 in)
Firing orderFront - (232°) - Rear (488°) - Front
Fuse/Main fuse10 A x 6, 15 A x 1 / 30 A
LIGHTS Headlight (high/low beam)
Tail/brakelight
Front turn signal/running light
Rear turn signal light
Instrument light
Oil pressure warning light
High beam indicator
Turn signal indicator
Neutral indicator
12 V - 60/55 W
12 V - 2/32 cp x 2
SAE No. 1157

12 V - 32/3 cp x 2
SAE No. 1034

12 V - 32 cp x 2
SAE No. 1073

12 V - 3.4 W x 1, 1.7 W x 2
12 V - 3.0 W
12 V - 3.0 W
12 V - 3.0 W x 2
12 V - 3.0 W

Page 1-5

Torque Values

This was coppied directly from the official Honda service manual.  If you have doubts about my transcription, (if it looks funny, check it) check out the scans of the original pages, they can be found here:
page 1-5 JPG
page 1-6 JPG
Note that I changed the note number on page 1-6 so the html reference would match up.  This only affects one line, regarding the thermostatic switch.

The torque specifications listed under "Engine" and "Frame" are for specific tightening points. If a specification is not listed, follow the standard torque values below


Standard torque values


TYPETORQUE N•m (kg-m, ft-lb)
5 mm bolt, nut 5 ( 0.50, 3.6)
6 mm bolt, nut 10 (1.0, 7.2)
8 mm bolt, nut 22 (2.2, 16)
10 mm bolt, nut 35 (3,5, 25)
12 mm bolt, nut 55 (5.5, 40)
5 mm screw 4 (0.40, 2.9)
6 mm screw,
6 mm bolt with 8 mm head
9 (0.9, 6.5)
6 mm flange bolt, nut 12 (1.2, 9)
8 mm flange bolt, nut 27 (2.7, 20)
10 mm flange bolt, nut 40 (4.0, 29)

Engine


ItemThread dia.
(mm)
Torque
N•m (kg-m, ft-lb)
Remark
Spark plug 12 14 (1.4, 10)
Cylinder head cover bolt 6 10 (1.0, 7.2) Special bolt
Camshaft holder bolt 8 23 (2.3, 17)
      8 mm nut 8 23 (2.3, 17)
      6 mm bolt 6 10 (1.0, 7.2)
Cylinder head nut 10 48 (4.8, 35)
      bolt 8 23 (2.3, 17)
      8 mm nut 8 23 (2.3, 17)
      6 mm bolt 6 10 (1.0, 7.2) socket bolt
Camshaft sprocket bolt 7 23 (2.3, 17) NOTE 1
Clutch lock nut 18 130 (13.0, 94) Staked nut.
right crancase cover bolt 6 10 (1.0, 7.2)
left crancase cover bolt 6 10 (1.0, 7.2)
Oil filter cartridge 20 10 (1.0, 7.2) Apply clean engine oil to the O-ring
Oil drain bolt 14 35 (3.5, 25)
Neutral Switch 10 12 (1.2, 9)
Oil pressue switch - 12 (1.2, 9) NOTE 4
Primary drive gear bolt 12 90 (9.0, 65) UBS bolt, NOTE 2
Flywheel bolt 12 130 (13.0, 94) Left hand threads, NOTE 2
Starter one way clutch 8 30 (3.0, 22) Torx bolt, NOTE 1
Oil controll bolt 10 23 (2.3, 17)
Oil pipe bolt 7 10 (1.0, 7.2) Special Bolt
Connecting rod cap nut 8 34 (3.4, 25)
Crankcase bolt 8 27 (2.7, 20) NOTE 2
6 12 (1.2, 9) NOTE 2
Shift drum stopper plate bolt 6 26 (2.6, 19) NOTE 1
Insulator band screw 5 4 (0.4, 2.9) NOTE 2
Timing hole cap 14 10 (1.0, 7.2) NOTE 3
Crankshaft hole cap 30 15 (1.5, 11) NOTE 3
Oil pump driven sprocket bolt 6 15 (1.5, 11) NOTE 1
Valve adjusting screw lock nut 7 23 (2.3, 17)
Cylinder stud bolt 8 mm 8 20-30 (2.0-3.0, 14-22) NOTE 1, Refer section 10.
     10 mm 10 30-50 (3.0-5.0, 22-36) NOTE 1, Refer section 10.

Page 1-6

Frame


Item Thread dia.
(mm)
Torque
N•m (kg-m, ft-lb)
Remark
Front engine bracket bolt 8 28 (2.8, 20)
Front engine mounting bolt 10 40 (4.0, 29)
Rear upper engine mounting bolt 10 40 (4.0, 29) NOTE 2
     —mounting bolt lock nut 22 55 (5.5, 40)
     —mounting bolt adjusting bolt 22 11 (1.1, 8)
Gearshift arm bolt 6 12 (1.2, 9)
Thermostatic switch 16 18 (1.8, 13) NOTE 4 (changed to 4 to match)
Exhaust pipe joint nut 8 27 (2.7, 20)
Muffler band bolt 8 27 (2.7, 20)
Muffler mounting bolt 8 27 (2.7, 20)
Fuel tank mounting bolt — front 6 12 (1.2, 9)
Fuel tank mounting bolt — rear 8 22 (2.2, 16)
Fuel filter bracket bolt 6 22 (2.2, 16)
Front brake master cylinder holder 6 12 (1.2, 9)
Brake oil bolt 10 30 (3.0, 22)
Brake resevoir screw 4 1.5 (0.2, 1.4)
Bleed valve 7 6 (0.6, 4.3)
Front caliper mounting bolt 8 27 (2.7, 20) Flange bolt
Front caliper pin bolt 10 28 (2.8, 20)
Pad pin 10 17 (1.7, 12)
Pad pin plug 10 2.5 (0.25, 1.8
Front brake disk retaining bolt 8 40 (4.0, 29) NOTE 1
Rear brake resevoir mounting screw 6 9 (0.9, 6.5)
Rear brake disk retaining bolt 8 35 (3.5, 25)
     —retaining bolt lock nut 8 9 (0.9, 7)
Rear caliper mounting bolt 8 27 (2.7, 20)
Rear caliper pivot bolt 8 22 (2.2, 16)
Brake torque rod bolt 10 35 (3.5, 25)
Handlebar pinch bolt 8 27 (2.7, 20)
Ignition switch mounting bolt 8 25 (2.5, 18)
Fork pinch bolt (upper) 7 11 (1.1, 8)
Fork pinch bolt (lower) 10 50 (5.0, 36) NOTE 2
Fork tube cap - 23 (2.3, 17)
Fork socket bolt 8 17 (1.7, 12) NOTE 1
Steering bearing adjustment nut 26 20 (2.0, 14) NOTE 2
Steering stem nut 24 105 (10.5, 76) Flange nut
Front axle bolt 14 60 (6.0, 43)
Front axle pinch bolt 8 22 (2.2, 16)
Rear Wheel nut 18 120 (12.0, 87)
Eccentric bearing carrier lock nut 35 165 (16.5, 120) Staked nut
Shock absorber upper mounting bolt 12 65 (6.5, 47) Flange bolt
Shock absorber lower mounting bolt 10 45 (4.5, 33) Cap nut
Shock absorber damper rod lock nut 14 62 (6.2, 45) NOTE 1
Swingarm adjusting bolt 26 15 (1.5, 11)
Swingarm adjusting bolt lock nut 26 65 (6.5, 47)
Swingarm pivot nut 14 65 (6.5, 47)
eccentric bearing carrier pinch bolt 16 75 (7.5, 54)
Sprocket mounting bolt 8 43 (4.3, 31)
Foot peg bracket bolt 8 27 (2.7, 20)
Sub-frame mounting bolt 10 40 (4.0, 29)
Side stand pivot bolt 10 38 (3.8, 27)
Side stand bracket bolt 8 28 (2.8, 20)
Center stand mounting bolt 10 55 (5.5, 40) Using a box wrench.
Ignition switch mounting bolt 6 25 (2.5, 18) T-40 Torx bolt.
NOTE 1 :  Apply a locking agent to the threads.
NOTE 2 :  Apply clean engine oil to the threads.
NOTE 3 :  Apply molybdenum disulfide grease to the threads.
NOTE 4 :  Apply sealant to the threads.

Page 1-7

TOOLS

The danger of a typo here is large, hense the JPG.
If someone wants to enter the data and provide hotlinks to the sections, that would be awesome.

SPECIAL



Page 1-8

COMMON



Page 1-9

CABLE & HARNESS ROUTING



Note the following when routing cables and wire harnesses:


Page 1-10





Page 1-11





Page 1-12





Page 1-13







Page 1-14

CALIFORNIA MODEL ONLY:

NOTE











Page 1-15


CALIFORNIA MODEL ONLY:





Page 1-16

EMISSION CONTROL SYSTEMS

The U.S. Environmental Protection Agency and California Air Resources Board (CARB) require manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during ther useful life, when operated and maintained according to the instrutions provided, and the E.P.A. requires that motorcycles built after January 1, 1983 comply with applicable noise emissions standards for one year or 6,000 km (3,730 miles) after the time of sale to the ultimate purchaser, when operated and maintained according to the instructions provided.  Compliance with the terms of the Distributor’s limited Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect.

SOURCES OF EMISSIONS

The combustion process produces carbon monoxide and hydrocarbons.  Control of hydrocarbons 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 it is toxic.

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

EXHAUST EMISSION CONTROL SYSTEM

Except for California:
The exhaust emission control system is composed of a lean carburetor setting, and no adustments should be made except idle speed adjustment with the stop screw.  The exhaust emission control system is separate from the crankcase emission control system.

California only:
The exhaust emission control system consists of a secondary air suoply system which introduces filtered air into the exhaust gasses in the exhaust port.  No adjustments to this system should be made, although periodic inspection of the components is recommended.  The secondary air supply system helps improve emission performance.


Page 1-17

CRANKCASE EMISSION CONTROL SYSTEM

The engine is equipped with a closed crankcase system which routes crankcase emissions through the air cleaner into the combustion chamber.




EVAPORATIVE EMISSION CONTROL SYSTEM (California model only)

This model complies with California Air Resources Board evaporative emission requirements.
Fuel vapor from teh fuel tank and carburetor is directed into the charcoal canister wher it is adsorbed and stored while teh engien is stopped.  When the engine is running and the purge control diaphragm valve is open, fuel vapor in the charcoal canister is drawn into the engine through the carburetor.



Page 1-18

NOISE EMISSION CONTROL SYSTEM

TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

AMONG THOSE ACTS PRESUMED TO CONSTITUTE THE TAMPERING ARE THE ACTS LISTED BELOW:

  1. Removal of, or puncturing of the muffler, baffles, header piples or any other compenenty which conducts exhaust gasses.
  2. Removal of, or puncturing of any part of teh intake system.
  3. Lack of proper maintenance.
  4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.

EMISSION CONTROL INFORMATION LABELS

An Emission Control Information Label is located on the rear fender as shown.  It contains basic tune-up specifications.




EMISSION CONTROL INFORMATION UPDATE LABEL

After making high altitude carburetor adjustment (Page 4-15), attach an update label on the left sub-frame upper pipe.
Instructions for obtaining the update label are given in Service Letter No. 132.


Page 1-19

VACUUM HOSE ROUTING DIAGRAM LABEL (California model only)

the Vacuum Hose Routing Diagram Label is on the air cleaner case cover.  Route the vacuum hoses as shown on this label