• SHOPM XL35

HOW TO USE THI S MANUAL Follow the Maintenance Schedule (Section 3) recommendations to ensure t hat the veh i- cle is in peak operat in g co ndit ion and the emission levels are with in the standards set by the U.S. Envi ronmental Protection Agen- cy and California Air Resources Board. Per- forming the first scheduled maintenance is very important. It compensates for the ini- tial wear that occurs during the break-in period. Sections 1 through 3 apply to the whole motorcycle, while sections 4 through 18 describe parts of the motorcycle, gr ouped according to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most secti ons start with an assembly or sys- tem illustrati on, general instructions, specifi- cations, torque va lues, tools a nd tro uble- shooting for the section. The subsequent pages give detailed procedures for the sec- tion. If you don't know the source of the trouble , go to section 19 . w 2 " 2 w ..J ~ u a: .... u W ..J W CONTENTS GENERAL INFORMATION LUBRICATION E MAINTENANCE E FUEL SYSTEM ENGINE REMOVALIINSTALLATION =-- CYLINDER HEADIVALVES lIS; CYLINDER / PISTON CLUTCH / OIL PUMP / KICK STARTER ALTERNATOR CRANKCASE/ CRANKSHAFT / BALANCER TRANSMISSION FRONT WHEEL/SUSPENSION/STEERING REAR WHEEL/BRAKE /SUSPENSION HYDRAULIC BRAKE REAR FENDER / EXHAUST PIPE BATTERY /CHARGING SYSTEM IGNITION SYSTEM SW ITCH ES /HOR N/ L1 GHTS TROUBLESHOOTING 61KU01

GENERAL SAFETY SERVICE RULES MODEL IDENTIFICATION SPECIFICATIONS TORQUE VALUES TOOLS WIRING DIAGRAM CABLE & HARNESS ROUTING EMISSION CONTROL SYSTEM 1. GENERAL INFORMATION EMISSION CONTROL INFORMATION LABELS 1-1 1-1 1-2 1-3 1-5 1- 7 1-9 1-11 1-14 1- 15 GENERAL SAFETY (4id;liliiitj If Ihe engine must be running to do some work, moke sure the area ;s well· ventilated. Nellf!r run the engine in a closed area, The exhaust contains poisonous corbon m onoxtde gas. h'i/.l@@' The battery electrolyle contains sulfuric acid. Protect your eyes, skin and clothing. In case of contact, flush thorough- ly with worer and call Q doctor if your eyes were exposed. SERVICE RULES Gasoline is extremely flommable and is explosi ve under cerrain conditions, Do not smoke or allow {/Qmes or sparks in yo ur working area. 'CI;i!i!ii1 The battery generales hydrogen gas whi ch CfIn be highly ex- plasi,,€!. Do not smoke or allow flames or sparks near the ba ttery. especially while charging it. 1. Use genuine HONDA or HONDA·recommended parts and lubricants or their equivalent. Parts that do not meet HONDA's design specifications may damage the motorcycle. 2. Use the special tools designed for this product. 3. Install new gaskets, O .... ings, cotter pins, lock plates, etc. when reassembling. 4. When tightening bolts or nuts, begin with the larger-diameter or inner bolts first, and tighten to the specified torque diago· nally in 2-3 steps, unless a particular sequence is spec ifi ed . 5. Clean parts in non-flammable or high flash point solvent upon disassembly. Lubricate any sliding surfaces before reassembly_ 6. After reassembly. check all parts for proper installation and operation. 7. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners. The use of incorrect tools and fasteners may damage the motorcycle. 8. Route all f'lectrical wires as shown on page 1·11, Cable & Harness Rout ing, and always away from sharp edges and areas where they might be pinched between moving parts. 1-1

GENERAL INFORMATION MODEL IDENTIFICATION The vehicle identification number (V IN) is on the left side of the steering head. , The engine serial number is stamped on bottom of the left crankcase. 1-2 rz n ~ cover. ,\ The frame serial steering head. , ,. is attached to th " T.;;;;~ 0;;;,,,,,;; identification number·is on the right side of the carburetor body.

GENERAL INFORMATION SPECIFICATIONS AC' California model DIMENSIONS Overall length 2,175 mm (85.6 in) Overall width 840 mm (33.1 In) Overall height 1,225 mm (48.2 in) Wheel base , ,415 mm (5 5.7 in) Seat height 840 mm (33.1 in) Footpeg height 360 mm (14.2 in) Ground clearance 260 mm (1 0.2 in) Dry weight t 22 kg (269 Ibl FRAME Type Semi·double cradle Front suspension, travel Telescopic fork 220 mm (8.66 in) Rear suspension, travel Pro link 205 mm (8.07 in) Tire size Front 3.00-21-4PR Rear 4.60-17-4PR Tire pressure Up to 90 kg (200 Ibl load Front 150 kPa (1.5 kg/cm 1 , 21 psi) 90 kg (200 Ib) load to Rear 150 kPa 11.5 kg/cm 2 • 21 psi) vehicle capacity load Front 150 kPa (1.5 kg/cm l , 21 psi) Rear 150 kPa (1.5 kg/cm 2 , 21 psi) Vehicle capacity load 150 kg (330 Ib) Front brake, swept area Dual piston caliper 342.8 cm 2 (53.1 sq·in) Rear brake, swept area Internal expanding shoes 86.3 cm 2 (13.3 sq·in) Fuel capacity 11.0 lit. (2.9 U.S. gal., 2.4 Imp. gaLl Fuel reserve capacity 2.0 lit. (0.5 U.S. gal., 0.4 Imp. gal.) Caster 30° 30' Trail 120mm (4.7 in) Front fork oil capacity 4'1 cc (13.90z.J ENGINE Type Gasoline, air-cooled 4-stroke Cylinder arrangement Single cylinder inclined 15° Bore stroke 84 x 61.3 mm (3.31 x 2.41 in) Displacement 340 cc (20.7 cu·in) Compression ratio 9.5 : 1 Valve train OHC, chain driven, 4-valve Maximum horsepower 30 BHP/7,500 rpm Maximum torque 2.9 kg-m/G ,SOO rpm Oil capacity 1.9 l it. (2.0 U.S. qt. 1.7 Imp. qt.) Lubrication system Forced pressure and wet sump Air filtration system Oiled polyurethane foam Cylinder compression 1,400 kPa (1 4 .0 kg/cm 2 , 199 psi) Intake valve Opens 7.5 0 (BTOC) } 8, 0 )BTDCI } Cl oses 27.5° (ABDCI , mm lift 122 0 (ABDC) . Exhaust valve Opens 37.5° (BBDC) at 1120 (BBDC) at a 11ft Closes 2.5" (ATDC) 98° (ATDC) Valve clearance Intake 0.05 mm (0. 002 in) Exhaust 0.08 mm (0. 003 in) 1-3

GENERAL INFORMATION CARBURETOR Type PISTON VALVE 1.0. number PH80A AC PH81A Main jet Prj # 112, 2nd #1 10 Air screw See page 4·11 Float level 18.0 mm (0.7 1 in) Idl e speed 1,300 ± 100 rpm DRIVE TRAIN Clutch Wet multi-plate type Transmission 6 -s peed constant mesh Primary reduction 2.708 Gear ratio I 2.923 Gear ratio II 2.000 Gear ratio III 1.550 Gear ratio IV 1.273 Gear ratio V 1.080 Gear ratio V I 0.926 Final reduction 2.857 Gear sh i ft pattern Left foot operated return system ELECTRICAL Ign ition C.D. 1. Ignition timing Initial a O BTDC at 1,300 rpm Full advance 28° BrDC at 4,000 rpm Alternator 337W/ 5,OOO rpm . ' Batte ry capacity 12V- JAH Spark plug { STANDARD] OPR8EA-9 (NGK) X24EPR· U9 (NO) Spark plug gap 0. 8-0 .9 mm (0.031- 0.035 in) Headlight 55/ 60 watt Tail/stoplig ht 3/ 32 cp (S/27W) SAE 1157 Turn sign al light 32/ 32 cp (23/23W) SAE 1073 Speedometer light 1 cp (l .7W) Neutral i nd ica tor 2 cp (3AW) SAE 158 Turn signal indicator 2 cp (JAW) SAE 158 High beam in dicator 1 cp (1 .7W) 1-4

GENERAL INFORMATION TORQUE VALUES ENGINE ITEM a'TY THREAD OIA . (mm) TO ROUE N·m (kg-m, ft-Ib) Kick starter ratchet guide bolt 2 6 10- 14 11.0- 1.4,7- 10 ) Cam chain tensioner bolt 1 6 10-1411.0-1.4,7-10) Clutch center lock nut 1 18 60-70 (6.0- 7.0, 43 - 50) Alternator flywheel bolt 1 12 100- 120110.0-12.0,72-871 Cylinder head cover bolt • 6 10- 1411.0-1.4,7-10) (Small head bolt) 12 6 8- 1210. 8-1.2.6-9) 1 8 24-30 (2.4-3. 0,17 -22) Cylinder head bolt • 10 47 - 53 (4 .7-5.3, 34-38) Cvlinder bolt ( 10 mm) • 10 47-5314.7-5.3,34-38) (Smm) 2 6 10- 14 11.0- 1.4,7 - 10 ) Rocker arm shaft 2 I. 25-30 (2.5-3.0, 18 -221 Subrocker arm shaft IN 2 I. 25-30 12.5- 3.0, 18-221 EX 2 12 20-2512.0-2.5, 14- 18) Cam sprocket bolt 2 7 17- 23 (1.7-2.3, 12-17) Valve adjuster loclt nut • 6 15- 18 11.5-1.8, 11 - 13) Shift drum stopper arm bolt 1 6 10-1411.0-1.4 , 7-10 ) Oil pass pipe bolt 3 7 8- 12 (0.8-1.2,6-9) Shift drum stopper plate bolt 1 6 10-14 (1.0- 1.4, 7- 10) Crankcase cover bolt 21 6 8- 12 10.8- 1.2, 6-9 ) Dram plug 1 12 20-30 (2.0-3 .0 , 14-22) Dr ive sprocket bolt 2 6 8-12 (0.8- 1.2, 6-9 ) Primary drive gear lock nut 1 18 60- 70 (6.0-7.0, 43 - 501 Crankcase bolt I. 6 8- 12 10.8-1 .2, 6-9 ) Oil pump bolt 3 6 10- 14 (1.0- 1.4, 7-10) Pulse generator bolt 2 3 8- 12 (0.8- 1.2, 6-9) Alternator stator bolt 3 6 10-1411.0-1.4 , 7- 101 Carburetor intake pipe bolt 3 6 8-12 (0.8- 1. 2,6-9) Neutral switch 1 10 35- 45 (3.5-4.5, 25 - 33) Spark plug 1 12 15- 20 (1.5- 2.0, 11 - 14) FRAME ITEM O' TY THREAD DIA. (mm ) TOROUE N ·m (kg-m, ft -Ib ) Steering stem nut 1 2. 80- 120 (8.0-12.0, 58- 871 Handlebar holder bolt 4 8 18-30 (1.8-3.0, 13-22 ) Front fork pinch bolt (upper) • 8 18- 30 ( 1.8-3.0, 13-22) (lower) • 8 30- 35 13.0- 3.5 , 22-25 ) Front axle 1 12 50- 80 (5.0-8.0, 36 - 58) Fro nt axle holder n ut • 6 10-1411.0-1.4.7- 10) Engine hanger bolt 3 10 45- 55 14.5-5.5,33-40) Engine hanger boll (front - upper) 1 10 35-45 (3.5-4 .5, 25-33) (top) 1 10 35-45 13.5- 4.5, 25- 33) Engine hanger plate bolt 6 8 23-30 12.3- 3.0, 17- 22) Rear axle nut 1 16 80- 110 (8.0- 11.0, 58- 80) Final driven sprocket bolt 6 8 24- 2812.4- 2.8,17 - 20) Front brake ca li per bracket mount bolt 2 8 20- 30 (2.0-3.0, 14 - 22 ft -Ib) 1-5

GENERAL INFORMATION FRAME (Cont'd) ITEM O'TY I-rHREAD DIA.(mm TORQUE N·m (kg-m. ft -Ib ) Rear shock absorber mount bolt (upper) 1 10 40 -50 (4.0-5.0, 29- 36) (tower) 1 10 40-50 14.0- 5.0, 29-36) Shock rod pillot boh 1 10 40- 50 (4.0-5.0.29-36) Shock. arm pillat bolt (swing arm side) 1 12 90- 120 (9.0- 12.0, 65-871 (shock rod side) 1 10 40- 50 (4 .0-5.0, 29-36) Swing arm pivot bolt 1 ,. 80- 100 (8.0-10.0, 58-72) Steering adjustment nut 1 26 1-2 (0.1- 0.2.0.7-1.4) Aight foot peg bolt 2 10 55- 6515.5-6.5,40-47) Gearshift pedal pinch bolt 1 6 8- 12 (0.8- 1.2. 6- 9) Kick starter pedal pinch bo lt 1 8 20- 35 (2.0-3.5, 14-25) Muffler band bolt 1 8 15-25 (1 .5-2. 5, 11 - 18) Muffler bracket bolt 1 8 20- 30 (2.0-3.0, 14-221 Brake disc nut • 6 14 - 160.4 - 1.6. 10- 12) Brake pipe 1 10 30-40 (3.0-4.0, 22-29) Brake hose joinl 2 10 12-15 (1.2-1.5, 9-11) Caliper oil pipe boh 1 10 30-40 13.0-4.0, 22-291 Side stand pivot bolt 1 10 35-45 (3.5- 4.5, 25-33) Brake pedal pivot bolt 1 10 35 - 45 13 . 5-4.5, 25-33} Torque specifications listed above are for the most important t igh tening points. If II specificat ion is not listed follow the stand· ards below. STANDARD TORQUE VA LUES TYPE TORQUE N·m (kg·m, ft·lb) TYPE TORQUE N'm Ikg·m, ft·lb) 5 mm bolt, nut 4 .5-6.0 (0.45--0.6, 3.3-4.3) 5 mm saew 3.5-5 10.35-0.5, 2.5-3.61 6 mm bolt, nut 8-12 10.8-1.2, 6-91 6 mm screw, bolt with 8 mm head 7- 11 (0.7 -1.1, 5-8 ) 8 mm bott, nut 18-2511 .8 -2.5, 13- 181 6 mm flange bott, nut 10- 14 (1.0-1.4, 7-10) 10 mm bolt, nut 30-40 (3.0-4.0, 22-29) 8 mm flange bott, nut 24-30 (2.4-3.0, 17-221 12 mm bolt, nut 50- 60 (5.0-6. 0, 36- 431 10 mm flange bolt, nut 35-45 (3.5-4.5, 25- 33) 1-6