Do not reused the removed O-ring in order to prevent leakage of oil. If there are any abnormalities, replace the tie rod end with a new one. Inspect the tie rod end boot for wear or damage. If any damages are found, replace the tie rod end with a new one. The locknuts 2 with a yellow finished surface have left-hand threads. NOTE: When installing the handlebars, make sure that the cable, wiring harness and brake hose routing are proper.
Make sure all the tires are inflated to the standard pressure. Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. NOTE: Make sure that the disc is free of any greasey matter. Remove the brake hose union bolt 1 and disconnect the brake hose 2. If any defects are found, replace the shock absorber with a new one. Do not attempt to disassemble the rear shock absorber.
It is unserviceble. NOTE: Do not turn the adjuster screws more than given position, or the adjuster may be damaged. If any defects are found, replace the spacers with new ones. If excessive play is noted, replace the bearing and bushing with a new one.
If excessive play is noted, replace the bearing with a new one. Do not reuse the removed dust seals. If the runout exceeds service limit, replace the pivot shaft with a new one. Page 4. If any defect are founds, replace the dust seal with a new one.
NOTE: The smaller diameter portion of the boot must face to the axle housing. NOTE: The axle housing bolts are unequal in size. Page Make sure that the brake disc is clean and free of any grease matter. The cable adjuster is located at inside of the fuel tank right side cover.
How- ever, if the battery is overcharged, hydrogen gas may be pro- duced. No accessories Check the battery for current leaks. Measure the current between - battery terminal and the - bat- tery lead wire using the multi circuit tester.
If the reading exceeds the specified value, leakage is evident. Measure the AC voltage between the lead wires of the generator using the multi circuit tester. If the voltage is under the specified value, replace the AC gener- ator with a new one. Check if the starter motor runs when its terminal is connected The transmission is in neutral. Turn on the to the battery terminal Do Clicks Others Engine does not turn though the starter motor runs.
If any damages are found, replace the brush assembly with a new one. If the resistance is not within the specified value, replace the starter relay with a new one. Correct NOTE: The ignition coil peak voltage inspection method is applicable only with the multi circuit tester and the peak volt adaptor. NOTE: Make sure that the spark plug cap and spark plug are connected properly and the battery is fully-charged.
Measure the ignition coil resistance in both the primary and sec- ondary windings using the multi circuit tester. If any abnormality is found, replace the respective switch assemblies with a new one. Never remove the electrolyte container from the battery while there is still electrolyte in the container.
If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper. Worn cylinder. Worn piston ring. Worn valve guide or improper valve seating. Repair or replace. Excessive valve chatter 1. Excessive tappet clearance.
Weak or broken valve spring. Worn camshaft. Worn or burnt camshaft journal. Noise seems to come from the piston 1. Worn gear. Worn or distorted gearshift fork.
Weakened gearshift stopper spring. Worn gearshift pawl. Engine idles poorly. Tappet clearance out of adjustment. Carbon buildup on piston crown. Insufficient amount of engine oil. Check level and add. Defective oil pump. Clogged oil circuit. Float chamber fuel level too low. Adjust float height. Improper front wheel alignment. Insufficiently lubricated. Low air pressure in front tires.
Tie rod ends tending to seize. Bearing : 60 N. Swingarm pivot nut 9. O-ring : Apply thread lock to the thread part. Removal 1 Remove the engine sprocket cover 1. IH 5 Remove the engine sprocket 6 with drive chain. Install the rear sprocket in the reverse order of removal. Pay attention to the following point.
Rear sprocket flange Inspect the rear sprocket flange for damage and wear of spline. NOTE When positioning the joint plate 10 on the tool, its stamp mark must face the joint plate Drive chain roller 3. Replace the drive chain control Removal roller bearings if there is anything unusual. Refer to 1 Remove the rear sprocket. NOTE The rear axle housing bolts are different length. If any defects are Installation found, replace the boot with a new one. BH Removal 1 Remove the rear axle housing.
Do not use or mix different types of fluid, such as silicone-based or petroleum-based. Throttle cable 5. Starter cable 6. Reverse gear cable 6. Worn pads or disc. Oil adhesion on friction surface of pads. Clean disc and pads. Worn disc. Page 4A-7 Brake Control System and Diagnosis: 2 Attach a hose to the air bleeder valve, and insert the 8 Fill the reservoir with brake fluid to the upper mark of free end of the hose into a receptacle.
BF: Brake fluid DOT 4 4 Connect a clear hose to the air bleeder valve 1 and insert the other end of the hose into a receptacle. Reservoir cap 6. Brake lever : Apply silicone grease. Diaphragm 7. Brake lever pivot bolt : Apply brake fluid. Disassembly 1 Remove the reservoir cap 1 and diaphragm 2. IH Assembly Assemble the master cylinder in the reverse order of Brake pedal 5. White mark : Do not reuse.
BH Removal 1 Remove the right footrest mud guard. Reservoir tank 6. Brake hose union bolt 7. Removal 1 Remove the fuel tank cover. Rubber parts Inspect the primary cup, secondary cup and dust boot for wear or damage. Front brake caliper 8. Piston seal 9. Brake pad spring : Apply thread lock to the thread part.
Page Front Brakes: 4B-7 Brake caliper piston Brake caliper holder slide pin Inspect the brake caliper piston surface for any Inspect the brake caliper holder slide pin for wear or scratches or other damage. If any damage is found, damage.
If any damage is found, replace it with a new replace the piston with a new one. Rear brake caliper 8. Front brake disc : Apply thread lock to the thread part.
Stopper ring : Apply thread lock to the thread part. BH 8 Apply a small quantity of thread lock to the brake Removal caliper mounting bolts 4. Page Rear Brakes: 4C-5 4 Remove the caliper holder pin 5. NOTE 7 Force out the piston by pushing the piston pin 7.
If there is no abnormal condition, the caliper holder pin removal is not necessary. If damage. If any defects are found, replace the mounting any damage is found, replace it with a new ones. The removed stopper ring must be replaced with a new one. Replace the brake disc if the thickness is less than the service limit or if defect is found.
Special tool A : — Micrometer 0 — IH IH 5 Set the parking brake shaft 6 in neutral position by 10 Adjust the parking brake. Replace countershaft. BH 6 Disconnect the reverse lock cable 7 by remove the Removal rotor 8. Countershaft Reverse driven gear Reverse lock shaft 2. Top drive gear Gear position switch 3. Gearshift cam stopper plate 4.
IH IH 2 Install the reverse idle gear 3 and shaft 4. IH 2. Countershaft 2. After a snap ring has been removed from the shaft, it should be discarded and a new snap ring must be installed. Page Manual Transmission: 5B-9 Gearshift cam bearing Inspect the gearshift cam bearings, left and right for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. IG Gearshift fork groove width Measure the gearshift fork groove width using the Removal Oil seal 1 Remove the transmission assembly.
Refer to Inspect the oil seal lips for wear or damage. Page Manual Transmission: 5B 5 Remove the gearshift cam right bearing 5.
IH 7 Install the oil seal retainer 4. IH 3 Install the bearing retainers 2. Page Manual Transmission: 5B 3 Loosen the reverse lock release cable lock-nut 1 7 Remove the switch contacts 6 and springs 7. IH IH Installation 4 Disconnect the reverse lock release cable 3 by Install the gear position switch in the reverse order of removing the mounting bolt.
Page Manual Transmission: 5B 5 Remove the gearshift return spring 7. IH 6 Remove the gearshift pawl lifter 8 and gearshift cam driven gear 9. The removed snap ring 14 must be replaced : Thread lock cement — with a new one. Inspect the gearshift shaft oil seal lip for damage or 4 Remove the bearing 2 with the special tools.
If any defect is found, replace the oil seal with a Special tool new one. Clutch lever 3. Parking knob : Apply grease. Parking lock 4. Clutch lever position switch Clutch Lever Removal and Installation 2 Disconnect the clutch lever position switch coupler BH 3.
Removal 1 Disconnect the clutch cable 1 and parking brake cable 2. Page 5C-4 Clutch: 4 Remove the screw 5 , washer 6 , parking knob 7 Installation and spring 8. Install the clutch lever in the reverse order of removal. Clutch pressure plate 6. Spring washer Primary driven gear assembly 2. Spring washer seat Push rod 3. Page 5C-8 Clutch: 8 Remove the clutch drive plates 5 and driven plates 12 Hold the clutch sleeve hub with the special tool.
Special tool B : — Clutch sleeve hub holder 13 Remove the clutch sleeve hub nut. IH 9 Remove the spring washer 7 and its seat 8. IH 14 Remove the washer 11 and clutch sleeve hub The concave side of clutch sleeve hub nut 6 2 Apply engine oil to the spacer 1 and bushing of the faces inside.
Three kinds of the drive plate No. IH IH 22 Install the rear brake pedal. Move the inner race by finger and inspect for smooth movement. If any defects are found, replace the Clutch drive plate claw width clutch release bearing with a new one. Stiff Insufficiently lubricated. Low air pressure in front tires Adjust. Handlebar upper holder Handlebars Removal 1 Remove the throttle lever case 1.
IH 6 Remove the left grip 6 and starter lever 7. IH 6 Disconnect wheel side tie-rod ends using the special tool. IH 10 Draw out the steering shaft 9.
Special tool 11 Disconnect each tie-rod ends using the special tool. Replace the cotter pins 11 with new ones. Inspect the tie-rod ends for smooth movement. Inspect the steering shaft bushing for wear or damage. Clamp 6. Clamp Engine sprocket cover : Bind the wiring harness with the clamp.
Clamp 7. Clamp 5. Starter motor : Bind the brake switch with the clamp. Wiring harness : Bind the handlebar switch L , starter cable and clutch lever position switch. Starter motor lead wire 6. CKP sensor : 5. IH 3 Tighten the headlight adjusting bolt 1. BH If any abnormality is found, replace the handlebar Inspect the dimmer switch in the following procedures: switch assembly with a new one.
If the bulb remains lit, replace the unit terminals. BH If any abnormality is found, replace the ignition Inspect the ignition switch in the following procedures: switch with a new one. Fuel tank cover 4.
Side cover LH 2. Front fender : Apply thread lock to thread part. Rear fender 3. Mudguard LH 2. Mudguard RH : Apply thread lock to thread parts.
Removal 2 Pull out the fastener 2. Pull the seat lock lever 1 upward and remove the seat 2. Page 9D-5 Exterior Parts: 2 Disconnect the ignition switch coupler 4. IH IH Installation 4 Remove the reverse selection knob 6 and screw Install the side cover and front fender in the reverse 7. Page 9D-7 Exterior Parts: Rear fender 5 Disconnect the ignition fuse assembly 5 , starter motor lead wire coupler 6 and clamp. Removal 6 Remove the rear fender 7.
IH IH Installation Install the rear fender in the reverse order of removal. Frame 4. Rear grip 7. Battery plate 2. Seat rail 5. Front grip 6. Removal Remove the footrests 1 , left and right. IH Installation 1 Install the footrest 1. Page Prepared by March, Part No.
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