Rozdział 1 - Rutynowa obsługa i serwis,

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Chapter 1
Routine maintenance and servicing
Contents
Air filter - replacement .................................... 24
Battery - check and removal ......................see Chapter 9
Brake caliper and master cylinder - seal replacement ........... 32
Brake fluid - change ..................................... 25
Brake hoses - replacement ................................ 33
Brake pads - wear check .................................. 4
Brake system - check .................................... 15
Carburettors - synchronisation ............................. 12
Clutch - check .......................................... 5
Cooling system - draining, flushing and refilling ................ 26
Cooling system - check ................................... 13
Crankcase breather - draining .............................. 1
Cylinder compression - check .............................. 29
Engine oil and oil filter - change ............................ 11
Final drive oil level - check ................................ 14
Final drive oil - change .................................... 27
Front fork oil - change .................................... 28
Fuel system - check ...................................... 7
Headlight aim - check and adjustment ....................... 16
Idle speed - check and adjustment .......................... 3
Nuts and bolts - tightness check ............................ 23
Side stand - check ....................................... 17
Spark plug gaps - check and adjustment ..................... 2
Spark plugs - replacement ................................ 9
Stand(s), lever pivots and cables - lubrication .................. 22
Steering head bearings - freeplay check and adjustment ......... 20
Steering head bearing - re-greasing ......................... 30
Suspension - check .....,............/...................18
Swingarm bearings - check ................................ 19
Swingarm bearings - re-greasing ........................... 31
Throttle and choke cables - check .......................... 8
Valve clearances - check and adjustment ..................... 10
Wheels and tyres - general check ........................... 6
Wheel bearings - check ................................... 21
Degrees of difficulty
Easy, suitable for
|k
Fairly easy, suitable |k
for beginner with
Fairly difficult, |k
suitable for competent ^
DIY mechanic
Difficult, suitable for |k
experienced DIY
Very difficult, ^k
suitable for expert DIY 5j
or professional
novice with little
^
^
3^
experience
g^
some experience
gS
ISS
mechanic
gS
SS
Specifications
Engine
Spark plugs
Type
Standard ............................................. NGK DPR8EA-9 or Nippondenso X24EPR-U9
For cold climate (below 5°C) .............................. NGK DPR7EA-9 or Nippondenso X22EPR-U9
For extended high speed riding ........................... NGK DPR9EA-9 or Nippondenso X27EPR-U9
Electrode gap ........................................... 0.8 to 0.9 mm
Valve clearances (COLD engine)
Intake valves ............................................ 0.13 to 0.17 mm
Exhaust valves .......................................... 0.18 to 0.22 mm
Engine idle speed
600 engine ............................................. 1200 ±100 rpm
650 engine ............................................. 1100
±
100rpm
Carburettor synchronisation
Maximum difference between cylinder readings ................ 40 mm Hg
Cylinder compression ....................................... 192
±
28 psi (13.25
±
1.9 Bar)
Maintenance & servicing
Miscellaneous
Freeplay adjustments
Throttle grip ............................................. 2 to 6 mm
Clutch lever ............................................. 10 to 20 mm
Tyre pressures (cold) .......................................
Front
Rear
Solo rider............................................... 33 psi (2.3 Bar)
33 psi (2.3 Bar)
Rider and pillion ......................................... 33 psi (2.3 Bar)
41 psi (2.8 Bar)
Torque settings
Spark plugs ............................................... 14Nm
Crankshaft end cap ........................................ 15 Nm
Timing mark inspection cap .................................. 10 Nm
Valve clearance adjuster locknuts ............................. 23 Nm
Valve cover bolts .......................................... 10 Nm
Oil drain plug ............................................. 35 Nm
Oil filter cartridge .......................................... 10 Nm
Final drive oil filler cap ...................................... 12 Nm
Final drive oil drain bolt ...................................... 20 Nm
Side stand pivot bolt........................................ 38 Nm
Swingarm right pivot bolt .................................... 10 Nm
Swingarm right pivot bolt locknut (using special tool) .............. 90 Nm
Swingarm left pivot bolt ..................................... 100 Nm
,
Steering stem nut .......................................... 105 Nm
Steering head bearing adjuster nut ............................ 22 Nm
Top yoke fork clamp bolts ................................... 23 Nm
Recommended lubricants and fluids
Engine/transmission oil type .................................. SE, SF or SG motor oil
Engine/transmission oil viscosity .............................. SAE 10W40
Engine/transmission oil capacity
Oil and filter change ...................................... 2.6 litres
Following engine overhaul - dry engine, new filter ............... 3.0 litres
Final drive oil type .......................................... SAE 80 Hypoid gear oil
Final drive oil capacity ...................................... Approx. 110 cc
Brake fluid ................................................ DOT 4
Coolant type .............................................. 50% distilled water, 50% corrosion inhibited ethylene glycol antifreeze
Coolant capacity
After draining ........................................... 1.6 litres
Total capacity ........................................... 2.2 litres
Fork oil level*
J model ................................................ 182 mm
K, M and P models ....................................... 123 mm
S and T models .......................................... 106 mm
Fork oil capacity
J model ................................................ 405 cc
K, M and P models ....................................... 466 cc
S and T models .......................................... 482 cc
Fork oil type .............................................. ATF
"Fork oil level is measured from the top of the tube, with the fork tube compressed and the spring removed.
Miscellaneous
Wheel bearings ............................................ Multi-purpose grease
Rear suspension bearings ................................... Multi-purpose grease
Steering head bearings ...................................... Multi-purpose grease
Cables, lever and stand pivot points ........................... Motor oil
Throttle grip .............................................. Multi-purpose grease or dry film lubricant
Maintenance schedule 1-3
Note:
Always perform the daily (pre-ride) checks at every maintenance interval (in addition to the procedures listed). The intervals listed below are
the intervals recommended by the manufacturer for each particular operation during the model years covered in this manual. Your owner's manual
may have different intervals for your model.
Daily (pre-ride) checks
H See
'Daily (pre-ride) checks'
at the beginning of this
manual.
Every 8000 miles (12 000 km)
or 12 months (continued)
G Check the swingarm bearings (Section 19).
G Check the steering head bearing freeplay
(Section 20).
n Check the wheel bearings (Section 21).
G Lubricate the stand(s), lever pivots and cables
_ (Section 22).
G Check the tightness of all nuts and bolts
(Section 23).
After the initial 600 miles (1000 km)
Note:
This check is usually performed by a Honda dealer after the
first 600 miles (1000 km) from new. Thereafter, maintenance is
carried out according to the following intervals of the schedule. .
Every 4000 miles (6000 km)
or 6 months
Carry out all the items under the Daily (pre-ride) checks
G Clean the crankcase breather (Section 1)
D Check the spark plug gaps (Section 2).
Check and adjust the idle speed (Section 3).
Check the brake pads for wear (Section 4).
Check the operation of the clutch (Section 5).
Check the tyre and wheel condition, and the tyre
tread depth (Section 6).
Every 12 000 miles (18 000 km)
or 18 months
Carry out all the items under the 4000 mile (6000 km) check,
plus the following:
LJ Replace the air filter (Section 24).
L] Change the brake fluid (Section 25).
Every 24 000 miles (36 000 km)
or 2 years
Carry out all the items under the 8000 (12 000 km)
and the 12 000 mile (18 000 km) check, plus the following:
G Change the coolant (Section 26).
Every 8000 miles (12 000 km)
or 12 months
Carry out all the items under the 4000 mile (6000 km) check,
plus the following:
G Check the fuel hoses and system components
(Section 7).
D Check throttle/choke cable operation and freeplay
(Section 8).
G Replace the spark plugs (Section 9).
G Check the valve clearances (Section 10).
D Change the engine oil and replace the oil filter
(Section 11).
D Check carburettor synchronisation (Section 12).
Q Check the cooling system (Section 13).
D Check the final drive oil level (Section 14).
n Check the operation of the brakes, and for fluid
leakage (Section 15).
Q Check the headlight aim (Section 16).
n Check the side stand (Section 17).
n Check the front and rear suspension (Section 18).
Every 24 000 miles (36 000 km)
or 3 years
Carry out all the items under the 8000 (12 000 km)
and the 12 000 mile (18 000 km) check, plus the following:
G Change the final drive oil (Section 27).
Non-scheduled maintenance
G Change the front fork oil (Section 28).
G Check the cylinder compression (Section 29).
G Re-grease the steering head bearings (Section 30).
G Re-grease the swingarm bearings (Section 31).
G Replace the brake master cylinder and caliper
_ seals (Section 32).
G Replace the brake hoses (Section 33).
i.4 Component locations
1 Rear brake fluid reservoir
2 Battery
3 Valves and spark plugs
4 Air filter
5 Front brake fluid reservoir
6 Steering head bearings
7 Fork seals
8 Clutch cable lower adjuster
9 Engine oil filler/dipstick
10 Swingarm pivot
11 Crankcase breather tube
12 Rear brake light switch
1 Radiator pressure cap
2 Engine idle speed adjuster
3 Carburettors
4 Coolant reservoir
5 Fuel filter
6 Brake calipers
7 Final drive oil filler/level plug
8 Final drive oil drain plug
9 Engine oil filter
10 Coolant drain plug
11 Engine oil drain plug
12 Rotor inspection cap
Introduction i.
£
1 This Chapter is designed to help the
home mechanic maintain his/her motorcycle
for safety, economy, long life and peak
performance.
2 Deciding where to start or plug into the
routine maintenance schedule depends on
several factors. If the warranty period on
your motorcycle has just expired, and if it
has been maintained according to the
warranty standards, you may want to pick
up routine maintenance as it coincides with
the next mileage or calendar interval. If you
have owned the machine for some time but
have never performed any maintenance on
it, then you may want to start at the nearest
interval and include some additional
procedures to ensure that nothing important
is overlooked. If you have just had a major
engine overhaul, then you may want to start
the maintenance routine from the beginning.
If you have a used machine and have no
knowledge of its history or maintenance
record, you may desire to combine all the
checks into one large service initially and
then settle into the maintenance schedule
prescribed.
3 Before beginning any maintenance or
repair, the machine should be cleaned
thoroughly, especially around the oil filter,
spark plugs, valve cover, side panels,
carburettors, etc. Cleaning will help ensure
that dirt does not contaminate the engine and
will allow you to detect wear and damage that
could otherwise easily go unnoticed.
4 Certain maintenance information is
sometimes printed on decals attached to the
motorcycle. If the information on the decals
differs from that included here, use the
information on the decal.
Every 4000 miles (6000 km) or 6 months
I
1 Remove the plug from the bottom of the
crankcase breather tube located behind the
side stand
(see illustration).
Allow the
deposits to drain into a suitable container,
then fit the plug back into the bottom of the
tube.
Note:
The crankcase breather should be
drained more often if the bike is ridden
frequently in the rain or at full throttle, or if the
bike is washed or has been dropped. Drain the
tube at any time when deposits are seen in the
clear part of the tubing.
6 Inspect the electrodes for wear. Both the
centre and side electrodes should have
square edges and the side electrode should
be of uniform thickness. Look for excessive
deposits and evidence of a cracked or
chipped insulator around the centre electrode.
Compare your spark plugs to the colour spark
plug reading chart at the end of this manual.
Check the threads, the washer and the
ceramic insulator body for cracks and other
damage.
7 If the electrodes are not excessively worn,
and if the deposits can be easily removed with
a wire brush, the plugs can be regapped and
re-used (if no cracks or chips are visible in the
insulator). If in doubt concerning the condition
of the plugs, replace them with new ones, as
the expense is minimal.
8 Cleaning spark plugs by sandblasting is
permitted (though not recommended),
provided you clean the plugs with a high
flash-point solvent afterwards.
9 Before installing the plugs, make sure they
are the correct type and heat range and check
the gap between the electrodes (they are not
pre-set on new plugs). For best results, use a
check and adjustment
I
I
1 This motorcycle is equipped with two spark
plugs per cylinder. One plug is located on the
side of the engine, the other is located within
the valve cover (there is no need to remove
the valve cover to access the plug for
removal)
(see illustrations).
Make sure your
spark plug socket is the correct size before
attempting to remove the plugs - a suitable
one is supplied in the motorcycle's tool kit.
2 Remove the seat and disconnect the
battery negative (-ve) lead.
3 Remove the fuel tank (see Chapter 4).
4 Clean the area around the valve cover and
plug caps to prevent any dirt falling into the
spark plug channels.
5 Check that the cylinder location number is
marked on each plug lead, then pull the spark
plug caps off the spark plugs. Using a socket
type wrench, unscrew the plugs from the
cylinder head
(see illustration).
Lay the plugs
out in relation to their cylinder; if either plug
shows up a problem it will then be easy to
identify the troublesome cylinder.
1.1 Remove the plug and allow any
deposits to drain from the
crankcase breather
2.1 a Each cylinder has a spark plug on the
side of the engine ...
2.1 b ... and one within the valve cover
2.5 Remove the spark plugs using the tool
provided in the tool kit or a
deep plug socket
1 Crankcase breather -
draining
2 Spark plug gaps -
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Rozdział 1 - Rutynowa obsługa i serwis,

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