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TYPE CODE
Throughout this manual, the following abbreviations are used to identify individual model.
CODE AREA TYPE
NR NIGERIA
BU BURKINA FASO
PE PERU
A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also
damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and
the reliability of the vehicle. Any error or oversight while servicing a vehicle
can result in faulty operation, damage to the vehicle, or injury to others.
For Your Safety
Because this manual is intended for the professional service technician, we
do not provide warnings about many basic shop safety practices (e.g., Hot
parts–wear gloves). If you have not received shop safety training or do not
feel confident about your knowledge of safe servicing practice, we
recommended that you do not attempt to perform the procedures described
in this manual.
Some of the most important general service safety precautions are given
below. However, we cannot warn you of every conceivable hazard that can
arise in performing service and repair procedures. Only you can decide
whether or not you should perform a given task.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise.
This will help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
Improper service or repairs can create an
unsafe condition that can cause your customer
or others to be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt
or killed.
Follow the procedures and precautions in this
manual carefully.
Date of Issue: April, 2005
©Honda Motor Co., Ltd.
INTRODUCTION
This addendum contains information for the NF100MN/MB/MSH-5. Refer to NF100M Shop Manual (62KRSFM3) for service
procedures and data not included in this addendum.
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messages
and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards
associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
• Instructions – how to service this vehicle correctly and safely.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.
Honda Motor Co., Ltd.
SERVICE PUBLICATION OFFICE
24-1
24. NF100MN/MB/MSH-5 ADDENDUM
MODEL IDENTIFICATION···························· 24-2
GENERAL SPECIFICATIONS······················· 24-4
LUBRICATION SYSTEM SPECIFICATIONS 24-5
FUEL SYSTEM SPECIFICATIONS··············· 24-5
CYLINDER HEAD/VALVES
SPECIFICATIONS········································· 24-5
CYLINDER/PISTON SPECIFICATIONS······· 24-6
CLUTCH/GEARSHIFT LINKAGE
SPECIFICATIONS········································· 24-6
ALTERNATOR/STARTER CLUTCH/
CAM CHAIN TENSIONER
SPECIFICATIONS········································· 24-6
CRANKSHAFT/TRANSMISSION/
KICKSTARTER SPECIFICATIONS ··············· 24-7
FRONT WHEEL/BRAKE/SUSPENSION/
STEERING SPECIFICATIONS······················ 24-7
REAR WHEEL/BRAKE/SUSPENSION
SPECIFICATIONS········································· 24-7
BATTERY/CHARGING SYSTEM
SPECIFICATIONS········································· 24-8
IGNITION SYSTEM SPECIFICATIONS ······· 24-8
ELECTRIC STARTER SPECIFICATIONS······ 24-8
LIGHTS/METERS/SWITCHES
SPECIFICATIONS········································· 24-8
STANDARD TORQUE VALUES ·················· 24-9
ENGINE & FRAME TORQUE VALUES ······· 24-9
CABLE & HARNESS ROUTING ·················24-12
EMISSION CONTROL SYSTEM·················24-18
FRONT TOP COVER ···································24-19
MAIN PIPE SIDE COVER/LEG SHIELD······24-19
HANDLE COVER·········································24-20
REAR FENDER ············································24-21
MAINTENANCE SCHEDULE······················24-23
AIR CLEANER ·············································24-24
SECONDARY AIR SUPPLY SYSTEM ········24-24
AIR SCREW ADJUSTMENT·······················24-25
SECONDARY AIR SUPPLY SYSTEM ········24-26
CHARGING SYSTEM INSPECTION···········24-29
ALTERNATOR INSPECTION ······················24-30
REGULATOR/RECTIFIER SYSTEM
INSPECTION ···············································24-31
IGNITION SYSTEM INSPECTION··············24-31
IGNITION CONTROL MODULE
REPLACEMENT ··········································24-33
TURN SIGNAL LIGHT·································24-34
BRAKE/TAIL LIGHT ····································24-35
WIRING DIAGRAM ·····································24-37
NF100MN/MB/MSH-5 ADDENDUM
24-2
NF100MN/M B/MSH-5 ADDENDUM
MODEL IDENTIFICATION
The frame serial number is stamped on the seat stay.
The engine serial number is stamped on the lower left side of the
crankcase.
FRAME SERIAL NUMBER
ENGINE SERIAL NUMBER
NF100MN/MB/MSH-5 ADDENDUM
24-3
The carburetor identification number is stamped on the intake mani-
fold side of the carburetor body as shown.
The color label is attached on the fuel tank as shown. When ordering
color-coded parts, always specify the designated color code.
CARBURETOR IDENTIFICATION NUMBER
INTAKE
MANIFOLD
SIDE
COLOR LABEL
NF100MN/MB/MSH-5 ADDENDUM
24-4
GENERAL SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS Overall length 1,870 mm (73.6 in)
Overall width 715 mm (28.1 in)
Overall height 1,050 mm (41.3 in)
Wheelbase 1,208 mm (47.6 in)
Seat height 750 mm (29.5 in)
Footpeg height 266 mm (10.5 in)
Ground clearance 130 mm (5.1 in)
Curb weight 104 kg (229 lbs)
FRAME Frame type Back bone type
Front suspension Telescopic fork
Front axle travel 80.2 mm (3.16 in)
Rear suspension Swingarm
Rear axle travel 80.5 mm (3.17 in)
Rear damper Single effected tube type
Front tire size 2.25 - 17 33L
Rear tire size 2.50 - 17 43L
Front brake Mechanical leading trailing
Rear brake Mechanical leading trailing
Caster angle 26° 30’
Trail length 69 mm (2.7 in)
Fuel tank capacity 3.8 liter (1.00 US gal, 0.84 lmp gal)
ENGINE Bore and stroke 50.0 x 49.5 mm (1.97 x 1.95 in)
Displacement 97.1 cm
3
(5.92 cu-in)
Compression ratio 8.8: 1
Valve train Multi link chain drive and OHC with rocker
arm
Intake valve opens at 1 mm (0.04 in) lift 2° BTDC
closes at 1 mm (0.04 in) lift 25° ABDC
Exhaust valve opens at 1 mm (0.04 in) lift 33° BBDC
closes at 1 mm (0.04 in) lift 0° TDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Air cooled
Air filtration Paper filter
Crankshaft type Assembled type
Engine dry weight 22.8 kg (50.3 lbs)
Cylinder arrangement Single cylinder inclined 80° from vertical
CARBURETOR Carburetor type Piston valve type
Venturi diameter 15.9 mm (0.63 in)
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Automatic centrifugal type
Transmission Constant mesh, 4-speed
Primary reduction 4.058 (69/17)
Final reduction 2.571 (36/14)
Gear ratio 1st 2.833 (34/12)
2nd 1.705 (29/17)
3rd 1.238 (26/21)
4th 0.958 (23/24)
Gearshift pattern Left foot operated return system
(rotary system; only when the motorcycle
is not running)
- N - 1 - 2 - 3 - 4 (- N)
ELECTRICAL Ignition system Condenser Discharged Ignition (CDI)
Starting system Kickstarter with electric starter motor
Charging system Single phase output alternator
Regulator/rectifier SCR shorted/single phase, half wave rec-
tification
Lighting system Alternator
NF100MN/MB/MSH-5 ADDENDUM
24-5
LUBRICATION SYSTEM SPECIFICATIONS
Unit: mm (in)
FUEL SYSTEM SPECIFICATIONS
CYLINDER HEAD/VALVES SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Engine oil capacity At draining 0.7 liter (0.7 US qt, 0.6 lmp qt) –
At disassembly 0.9 liter (1.0 US qt, 0.8 lmp qt) –
Recommended engine oil Honda 4-stroke oil or equivalent motor
oil
API service classification SE, SF or SG
Viscosity: SAE 10W-30
–
Oil pump rotor Tip clearance 0.10 – 0.15 (0.004 – 0.006) 0.20 (0.008)
Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014)
Side clearance 0.07 – 0.11 (0.003 – 0.004) 0.15 (0.006)
ITEM SPECIFICATIONS
Carburetor identification number VM16B
Main jet #72.5
Slow jet #15
Jet needle clip position 2nd groove from bottom
Air screw opening See page 24-25
Float level 18.2 mm (0.72 in)
Engine idle speed 1,400 ± 10 0 min
-1
(rpm)
PAIR control valve specified vacuum 67 kPa (500 mmHg)
Throttle grip free play 2 – 6 mm (0.1 – 0.2 in)
ITEM STANDARD SERVICE LIMIT
Cylinder compression 1,177 kPa (12.0 kgf/cm
2
, 171 psi)
at 600 min
-1
(rpm)
–
Cylinder head warpage – 0.05 (0.002)
Valve,
valve guide
Valve clearance IN 0.05 (0.002) –
EX 0.05 (0.002) –
Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965) 4.92 (0.194)
EX 4.955 – 4.970 (0.1951 – 0.1957) 4.92 (0.194)
Valve guide I.D. IN 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)
EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)
Stem-to-guide clear-
ance
IN 0.010 – 0.037 (0.0004 – 0.0015) 0.08 (0.003)
EX 0.030 – 0.057 (0.0012 – 0.0022) 0.10 (0.004)
Valve seat width IN/EX 1.0 (0.04) 1.6 (0.06)
Valve spring
free length
Inner IN/EX 32.41 (1.276) 30.9 (1.22)
Outer IN/EX 35.25 (1.388) 34.0 (1.34)
Rocker arm/
shaft
Rocker arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.10 (0.398)
Rocker arm shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390)
Camshaft Cam lobe height IN 26.503 – 26.623 (1.0434 – 1.0481) 26.26 (1.034)
EX 26.318 – 26.438 (1.0361 – 1.0409) 26.00 (1.024)
NF100MN/MB/MSH-5 ADDENDUM
24-6
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS
Unit: mm (in)
ALTERNATOR/STARTER CLUTCH/
CAM CHAIN TENSIONER SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder I.D. 50.005 – 50.015 (1.9687 – 1.9691) 50.05 (1.970)
Out-of-round – 0.10 (0.004)
Taper – 0.10 (0.004)
Warpage – 0.05 (0.002)
Piston, piston
rings
Piston mark direction "IN" mark facing toward the intake side –
Piston O.D. 49.980 – 49.995 (1.9677 – 1.9683) 49.90 (1.965)
Piston O.D. measurement point 18 mm (0.7 in) from bottom of skirt –
Piston pin bore I.D. 13.002 – 13.008 (0.5119 – 0.5121) 13.055 (0.5140)
Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) 12.98 (0.511)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.020 (0.0008)
Piston ring-to-ring
groove clearance
Top 0.015 – 0.045 (0.0006 – 0.0018) 0.12 (0.005)
Second 0.015 – 0.050 (0.0006 – 0.0020) 0.12 (0.005)
Piston ring end gap Top 0.10 – 0.25 (0.004 – 0.010) 0.5 (0.02)
Second 0.10 – 0.25 (0.004 – 0.010) 0.5 (0.02)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 1.1 (0.04)
Cylinder-to-piston clearance 0.010 – 0.035 (0.0004 – 0.0014) 0.15 (0.006)
Connecting rod small end I.D. 13.016 – 13.028 (0.5124 – 0.5129) 13.10 (0.516)
Connecting rod-to-piston pin clearance 0.016 – 0.034 (0.0006 – 0.0013) 0.08 (0.003)
ITEM STANDARD SERVICE LIMIT
Manual clutch Disc thickness 2.92 – 3.08 (0.115 – 0.121) 2.6 (0.10)
Plate warpage – 0.20 (0.008)
Clutch spring free length 25.7 (1.01) 25.2 (0.99)
Clutch outer guide O.D. 20.959 – 20.980 (0.8252 – 0.8260) 20.91 (0.823)
Clutch outer I.D. 21.020 – 21.041 (0.8276 – 0.8284) 21.09 (0.830)
Centrifugal
clutch
Clutch drum I.D. 104.0 – 104.2 (4.09 – 4.10) 104.3 (4.11)
Clutch lining thickness 1.5 (0.06) 1.0 (0.04)
One-way clutch drum I.D. 42.00 – 42.02 (1.6535 – 1.6543) 42.04 (1.655)
One-way clutch roller O.D. 4.99 – 5.00 (0.196 – 0.197) 4.97 (0.196)
Primary drive gear I.D. 19.030 – 19.058 (0.7492 – 0.7503) 19.11 (0.752)
Crankshaft O.D. at primary drive
gear
18.967 – 18.980 (0.7467 – 0.7472) 18.92 (0.745)
ITEM STANDARD SERVICE LIMIT
Cam chain
tensioner
Push rod O.D. 11.985 – 12.000 (0.4718 – 0.4724) 11.94 (0.470)
Spring free length 111.3 (4.38) 109 (4.3)
NF100MN/MB/MSH-5 ADDENDUM
24-7
CRANKSHAFT/TRANSMISSION/KICKSTARTER SPECIFICATIONS
Unit: mm (in)
FRONT WHEEL/BRAKE/SUSPENSION/STEERING SPECIFICATIONS
Unit: mm (in)
REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Crankshaft Connecting rod side clearance 0.10 – 0.35 (0.004 – 0.014) 0.60 (0.024)
Connecting rod radial clearance 0 – 0.008 (0 – 0.0003) 0.05 (0.002)
Runout – 0.10 (0.004)
Transmission Gear I.D. M2 17.016 – 17.043 (0.6699 – 0.6710) 17.10 (0.673)
M4 17.016 – 17.043 (0.6699 – 0.6710) 17.10 (0.673)
C1 23.020 – 23.041 (0.9063 – 0.9071) 23.10 (0.909)
C3 20.020 – 20.041 (0.7882 – 0.7890) 20.10 (0.791)
Bushing O.D. C1 22.979 – 23.000 (0.9047 – 0.9055) 22.93 (0.903)
Bushing I.D. C1 20.000 – 20.021 (0.7874 – 0.7882) 20.08 (0.791)
Gear-to-bushing clearance C1 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Mainshaft O.D. M2, 4 16.966 – 16.984 (0.6680 – 0.6687) 16.95 (0.667)
Countershaft O.D. C1, 3 19.959 – 19.980 (0.7858 – 0.7866) 19.94 (0.785)
Gear-to-shaft clearance M2 0.032 – 0.077 (0.0013 – 0.0030) 0.10 (0.004)
M4 0.032 – 0.077 (0.0013 – 0.0030) 0.10 (0.004)
C3 0.040 – 0.082 (0.0016 – 0.0032) 0.10 (0.004)
Bushing-to-shaft clear-
ance
C1 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Shift fork I.D. 34.075 – 34.100 (1.3415 – 1.3425) 34.14 (1.344)
Claw thickness 4.86 – 4.94 (0.191 – 0.194) 4.60 (0.181)
Shift drum O.D. 33.950 – 33.975 (1.3366 – 1.3376) 33.93 (1.336)
ITEM STANDARD SERVICE LIMIT
Minimum tire tread depth – To the indicator
Cold tire pressure Driver only 200 kPa (2.00 kgf/cm
2
, 29 psi) –
Driver and passenger 200 kPa (2.00 kgf/cm
2
, 29 psi) –
Axle runout – 0.20 (0.008)
Wheel rim runout Radial – 2.0 (0.08)
Axial – 2.0 (0.08)
Wheel hub-to-rim distance (WITH SPOKE WHEEL) 11.5 ± 1 (0.45 ± 0.04) –
Brake Brake drum I.D. 110.0 – 110.2 (4.33 – 4.34) 111.0 (4.37)
Lever free play 10 – 20 (0.4 – 0.8) –
Fork Spring free length 329.9 (12.99) –
Tube runout – 0.20 (0.008)
Recommended fork fluid Fork fluid –
Fluid level 84 (3.3) –
Fluid capacity 62.0 ± 2.0 cm
3
(2.10 ± 0.07 US oz, 2.18 ± 0.07 lmp oz)
–
ITEM STANDARD SERVICE LIMIT
Minimum tire tread depth – To the indicator
Cold tire pressure Driver only 225 kPa (2.25 kgf/cm
2
, 33 psi) –
Driver and passenger 280 kPa (2.80 kgf/cm
2
, 41 psi) –
Axle runout – 0.20 (0.008)
Wheel rim runout Radial – 2.0 (0.08)
Axial – 2.0 (0.08)
Wheel hub-to-rim distance (WITH SPOKE WHEEL) 10.0 ± 1 (0.39 ± 0.04) –
Drive chain Size/link 428/100 –
Slack 25 – 35 (1.0 – 1.4) –
Brake
Brake drum I.D. 110.0 – 110.2 (4.33 – 4.34) 111.0 (4.37)
Pedal free play 20 – 30 (0.8 – 1.2) –
NF100MN/MB/MSH-5 ADDENDUM
24-8
BATTERY/CHARGING SYSTEM SPECIFICATIONS
IGNITION SYSTEM SPECIFICATIONS
ELECTRIC STARTER SPECIFICATIONS
Unit: mm (in)
LIGHTS/METERS/SWITCHES SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Capacity 12 V – 5 Ah
Current leakage 0.1 mA max.
Voltage
(20° C/68° F)
Fully charged 13.0 – 13.2 V
Needs charging Below 12.3 V
Specific gravity
(20° C/68° F)
Fully charged 1.270 – 1.290
Needs charging Below 1.260
Charging
current
Normal 0.9 A/5 – 10 h
Quick 4.0 A/0.5 h
Alternator Capacity 85 W/5,000 min
-1
(rpm)
Charging coil resistance
(20° C/68° F)
0.2 – 2.0 Ω
Lighting coil resistance
(20° C/68° F)
0.1 – 1.0 Ω
Regulator/rectifier regulated voltage Charging output 15.5 V/5,000 min
-1
(rpm)
Lighting output 12.6 – 13.6 V/5,000 min
-1
(rpm)
ITEM SPECIFICATIONS
Spark plug Standard CR6HSA (NGK) U20FSR-U (DENSO)
Optional CR7HSA (NGK) U22FSR-U (DENSO)
Spark plug gap 0.60 – 0.70 mm (0.024 – 0.028 in)
Ignition coil peak voltage 100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Alternator exciter coil peak voltage 100 V minimum
Ignition timing 15° BTDC at idle
ITEM STANDARD SERVICE LIMIT
Starter motor brush length 12.0 (0.47) 4.0 (0.16)
ITEM SPECIFICATIONS
Bulbs Headlight (High/Low beam) 12 V - 35/35 W
Position light 12 V - 5 W
Brake/tail light 12 V - 21/5 W
Front turn signal light 12 V - 21 W x 2
Rear turn signal light 12 V - 21 W x 2
Speedometer light 12 V - 1.7 W x 2
Turn signal indicator 12 V - 3.4 W x 2
Gear position indicator 12 V - 1.7 W x 5
High beam indicator 12 V - 1.7 W
Fuse 10A
NF100MN/MB/MSH-5 ADDENDUM
24-9
STANDARD TORQUE VALUES
ENGINE & FRAME TORQUE VALUES
• Torque specifications listed below are for important fasteners.
• Others should be tightened to standard torque values listed above.
1. Apply a locking agent to the threads.
2. Apply engine oil to the threads and seating surface.
3. U-nut.
ENGINE
MAINTENANCE
LUBRICATION SYSTEM
FUEL SYSTEM
CYLINDER HEAD/VALVES
CYLINDER/PISTON
FASTENER TYPE
TORQUE
FASTENER TYPE
TORQUE
N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)
5 mm hex bolt and nut 5 (0.5, 3.7) 5 mm screw 4 (0.4, 3.0)
6 mm hex bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.6)
8 mm hex bolt and nut 22 (2.2, 16) 6 mm flange bolt (8 mm head) 10 (1.0, 7)
10 mm hex bolt and nut 34 (3.5, 25) 6 mm flange bolt (10 mm head) and nut 12 (1.2, 9)
12 mm hex bolt and nut 54 (5.5, 40) 8 mm flange bolt and nut 26 (2.7, 19)
10 mm flange bolt and nut 39 (4.0, 29)
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Oil drain bolt 1 12 24 (2.4, 18)
Valve adjuster hole cap 2 30 12 (1.2, 9)
Valve adjuster lock nut 2 5 9 (0.9, 6.6)
Centrifugal oil filter cover screw 3 5 4 (0.4, 3.0)
Clutch adjuster lock nut 1 8 12 (1.2, 9)
Spark plug 1 10 12 (1.2, 9)
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Oil filter cover screw 3 5 4 (0.4, 3.0)
Oil pump mounting screw 3 6 8 (0.8, 5.9)
Oil pump cover screw 3 5 5 (0.5, 3.7)
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Carburetor strainer cup 1 22 4.9 (0.5, 3.6)
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Cylinder head cover cap nut 4 7 14 (1.4, 10)
Right cylinder head side cover bolt 2 6 10 (1.0, 7)
Cylinder head mounting bolt 1 6 10 (1.0, 7)
Cam sprocket bolt 2 5 9 (0.9, 6.6)
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Cam chain guide roller pin bolt 1 8 10 (1.0, 7)
Cylinder mounting bolt 1 6 10 (1.0, 7)
NF100MN/MB/MSH-5 ADDENDUM
24-10
CLUTCH/GEARSHIFT LINKAGE
ALTERNATOR/STARTER CLUTCH/CAM CHAIN TENSIONER
CRANKSHAFT/TRANSMISSION/KICKSTARTER
LIGHTS/METERS/SWITCHES
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Shift drum stopper arm bolt 1 6 10 (1.0, 7)
Shift return spring pin 1 8 30 (3.1, 22)
Shift drum stopper plate bolt 1 6 17 (1.7, 13)
Centrifugal clutch lock nut 1 14 42 (4.3, 31)
Clutch lifter plate flange bolt 4 6 12 (1.2, 9)
Change clutch center lock nut 1 14 42 (4.3, 31)
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Crankshaft hole cap 1 30 3 (0.3, 2.2) NOTE 2
Timing hole cap 1 14 1.5 (0.2, 1.1) NOTE 2
Cam chain tensioner sealing bolt 1 14 22 (2.2, 16)
Cam chain tensioner pivot bolt 1 8 16 (1.6, 12)
Flywheel flange nut 1 10 40 (4.1, 30)
Starter clutch outer mounting screw 3 6 10 (1.0, 7)
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Shift drum bolt 1 6 10 (1.0, 7)
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Gear position switch bolt 1 6 10 (1.0, 7)
NF100MN/MB/MSH-5 ADDENDUM
24-11
FRAME
MAINTENANCE
ENGINE REMOVAL/INSTALLATION
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
REAR WHEEL/BRAKE/SUSPENSION
OTHERS
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Air cleaner housing cover screw 4 5 1.1 (0.1, 0.8)
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Engine hanger bolt Upper 1 8 34 (3.5, 25)
Lower 1 8 29 (3.0, 21)
Drive sprocket fixing plate bolt 2 6 12 (1.2, 9)
Main footpeg bar mounting bolt/washer 4 8 22 (2.2, 16)
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Steering stem nut 1 26 See page 12-33
Steering stem top thread 1 26 See page 12-32
Bottom bridge pinch flange bolt 4 10 74 (7.5, 55)
Handlebar holder special nut 1 10 59 (6.0, 44) NOTE 3
Front spoke nipple (WITH SPOKE WHEEL) 36 BC 2.9 3.2 (0.3, 2.4)
Front axle nut 1 12 49 (5.0, 36) NOTE 3
Brake lever pivot bolt 1 5 1 (0.1, 0.7)
Brake lever pivot nut 1 5 4.5 (0.5, 3.3)
Front brake arm nut 1 6 10 (1.0, 7)
Fork bolt 2 20 22 (2.2, 16)
Fork socket bolt 2 8 20 (2.0, 15) NOTE 1
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Rear axle nut 1 12 49 (5.0, 36) NOTE 3
Rear axle sleeve nut 1 17 44 (4.5, 32)
Rear spoke nipple (WITH SPOKE WHEEL) 36 BC 3.2 3.7 (0.4, 2.7)
Driven sprocket UBS nut 4 8 32 (3.3, 24) NOTE 2
Driven sprocket stud bolt 4 8 20 (2.0, 15) NOTE 1
Rear brake arm bolt 1 6 10 (1.0, 7) NOTE 3
Shock absorber mounting nut Upper 2 10 24 (2.4, 18)
Lower 2 10 24 (2.4, 18)
Swingarm pivot nut 1 10 39 (4.0, 29)
Drive chain case mounting bolt 2 6 7 (0.7, 5.2)
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Side stand pivot bolt 1 10 10 (1.0, 7)
Side stand lock nut 1 10 29 (3.0, 21)
NF100MN/MB/MSH-5 ADDENDUM
24-12
CABLE & HARNESS ROUTING
FRONT BRAKE CABLE
THROTTLE CABLE
LEFT TURN SIGNAL
LIGHT WIRE
CHOKE CABLE
HORN WIRE
RIGHT TURN SIGNAL
LIGHT WIRE
HEADLIGHT 4P CONNECTOR
NF100MN/MB/MSH-5 ADDENDUM
24-13
CHOKE CABLE
THROTTLE CABLE
SPARK PLUG WIRE
IGNITION COIL
PRIMARY WIRE
CARBURETOR AIR
VENT HOSE
RIGHT TURN SIGNAL
LIGHT WIRE
CRANKCASE
BREATHER HOSE
CHOKE CABLE
THROTTLE CABLE
CARBURETOR AIR
VENT HOSE
GROUND WIRE
NF100MN/MB/MSH-5 ADDENDUM
24-14
THROTTLE CABLE
CARBURETOR AIR
VENT HOSE
FUEL FILTER
PAIR CONTROL VALVE-TO-AIR
SUPPLY PIPE HOSE
CHOKE CABLE
SPEEDOMETER
CABLE
FRONT BRAKE CABLE
LEFT TURN SIGNAL
LIGHT WIRE
SPEEDOMETER
CABLE
FRONT BRAKE
CABLE
TURN SIGNAL
WIRE
IGNITION
SWITCH WIRE
HANDLEBAR
SWITCH WIRE
CARBURETOR DRAIN HOSE
PAIR CONTROL VALVE
VACUUM HOSE
NF100MN/MB/MSH-5 ADDENDUM
24-15
PAIR CONTROL VALVE-TO-AIR
SUPPLY PIPE HOSE
CHOKE CABLE
PAIR CONTROL VALVE
VACUUM HOSE
AIR SUPPLY HOSES
STARTER MOTOR CABLE
CARBURETOR
AIR VENT HOSE
NF100MN/MB/MSH-5 ADDENDUM
24-16
REAR BRAKE LIGHT
SWITCH
MAIN WIRE HARNESS
IGNITION COIL
PRIMARY WIRE
SPARK PLUG WIRE
FUEL HOSE
MAIN FUSE 10A
SPARE FUSE 10A
STARTER RELAY
MAIN FUSE 10A
MAIN WIRE HARNESS
REAR BRAKE LIGHT
SWITCHBATTERY BREATHER
HOSE
SPARE FUSE 10A
BATTERY POSITIVE
CABLE
STARTER MOTOR CABLE
NF100MN/MB/MSH-5 ADDENDUM
24-17
TURN SIGNAL RELAY WIRE
SECONDARY AIR
SUPPLY HOSE
CARBURETOR DRAIN HOSE
ALTERNATOR WIRE
GEAR POSITION SWITCH WIRE
REGULATOR/
RECTIFIER WIRE
IGNITION CONTROL
MODULE
FUEL HOSES
FUEL UNIT WIRE
LEFT TURN SIGNAL
LIGHT WIRE
RIGHT TURN SIGNAL
LIGHT WIRE
FUEL HOSE
NF100MN/MB/MSH-5 ADDENDUM
24-18
EMISSION CONTROL SYSTEM
EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR SUPPLY SYSTEM)
The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the
exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in
the exhaust system. This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable
amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor.
This model has the pulse secondary air injection (PAIR) control valve and PAIR check valve. PAIR check valve prevents
reverse air flow through the system. The PAIR control valve reacts to high intake manifold vacuum and will cut off the sup-
ply of the fresh air during engine deceleration, thereby preventing afterburn in the exhaust system.
No adjustment to the secondary air supply system should be made, although periodic inspection of the components is rec-
ommended.
EXHAUST GAS
FRESH AIR
CARBURETOR
PAIR CONTROL VALVE
PAIR CHECK VALVE
SEPARATE AIR FILTER
EXHAUST PORT
NF100MN/MB/MSH-5 ADDENDUM
24-19
FRONT TOP COVER
REMOVAL/INSTALLATION
Remove the two mounting bolts and the number
plate bracket.
Remove the front top cover screw and two front top
cover rear screws.
Remove the front top cover and rubber cushions.
Installation is in the reverse order of removal.
MAIN PIPE SIDE COVER/LEG SHIELD
REMOVAL/INSTALLATION
Remove the front top cover (See above).
Disconnect the turn signal light 2P connector.
Remove the three main pipe side cover/leg shield
mounting special screws.
First release the hook on the main pipe side cover/
leg shield from the main pipe cover, then carefully
remove the main pipe side cover/leg shield from
main pipe cover.
Installation is in the reverse order of removal.
DISASSEMBLY/ASSEMBLY
Remove the three screws and separate the leg
shield from the main pipe side cover.
Assembly is in the reverse order of disassembly.
BOLTS
BRACKET
SCREW
RUBBER CUSHIONS
FRONT TOP COVER
REAR SCREWS
SCREWS
2P
CONNECTOR
MAIN PIPE
SIDE COVER/
LEG SHIELD
Left side shown:
MAIN PIPE
SIDE COVER
LEG SHIELD
SCREWS
NF100MN/MB/MSH-5 ADDENDUM
24-20
HANDLE COVER
REMOVAL/INSTALLATION
Remove the rearview mirrors.
Do not damage the
headlight/position
light wire.
Remove the two front screws and three rear screws,
then separate the handle front cover from the han-
dle rear cover.
Disconnect the headlight 4P (White) connector.
Remove the two screws from the front side and the
special screw/collar from the back side.
REARVIEW MIRRORS
SCREWS
SCREWS
HANDLE FRONT COVER
4P (WHITE)
CONNECTOR
HANDLE
REAR COVER
SCREWS
COLLAR
SPECIAL SCREW
NF100MN/MB/MSH-5 ADDENDUM
24-21
Remove the throttle housing (page 12-4).
Remove the throttle cable from the handle rear
cover hole.
Remove the two speedometer mounting screws,
then remove the handle rear cover.
Installation is in the reverse order of removal.
REAR FENDER
REMOVAL/INSTALLATION
Remove the fallowing:
– Tail cover (page 2-4)
– Body cover (page 2-4)
– Utility box (page 2-7)
Remove the dust cover from the connectors.
Disconnect the brake/tail light/turn signal light 6P
connector.
Remove the two bolts and brake/tail light unit then
disconnect the rear turn signal light wire connec-
tors.
Release the rear inner fender bosses from the rear
fender holes, then remove the rear fender.
Installation is in the reverse order of removal.
THROTTLE CABLE
HANDLE REAR COVER
HANDLE REAR COVER
SCREWS
BOLTS
REAR FENDER
6P CONNECTOR
WIRE
CONNECTORS
BRAKE/TAIL
LIGHT UNIT
DUST COVER
BOSSES
NF100MN/MB/MSH-5 ADDENDUM
24-22
DISASSEMBLY/ASSEMBLY
Remove the nuts, rear turn signal light units from
both sides of the rear fender.
Remove the bolt, clamp, washer and turn signal
light bracket.
Assembly is in the reverse order of disassembly.
NUTS
BRACKET
TURN SIGNAL LIGHT UNITS
WASHER
CLAMP
BOLT
NF100MN/MB/MSH-5 ADDENDUM
24-23
MAINTENANCE SCHEDULE
Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require
more technical information and tools. Consult your Honda dealer.
Honda recommends that your Honda dealer should road test your motorcycle after each periodic maintenance is carried
out.
NOTES:
1. At higher odometer reading, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. Service more frequently when riding OFF-ROAD.
5. Replace every 2 years. Replacement requires mechanical skill.
6. Replace every 3 years or 24,000 km (16,000 mile). Replacement requires mechanical skill.
FREQUENCY WHICHEVER
COMES FIRST
ODOMETER READING (NOTE 1)
REFER TO
PAGE
X1,000 mi 0.6 2.5 5 7.5
X1,000 km 1 4 8 12
ITEMS MONTHS 6 12 18
* FUEL LINE III 3-4
* FUEL STRAINER SCREEN C C C 3-4
* THROTTLE OPERATION I I I 3-4
AIR CLEANER NOTE2 C C R 24-24
CRANKCASE BREATHER NOTE3 C C C 3-6
SPARK PLUG IRI 3-6
* VALVE CLEARANCE I I I I 3-8
ENGINE OIL R EVERY 3,000 km
(2,000 mi): R
3-9
** ENGINE OIL STRAINER SCREEN C 3-11
** ENGINE OIL CENTRIFUGAL FILTER C 3-11
* ENGINE IDLE SPEED I I I I 3-12
* SECONDARY AIR SUPPLY SYSTEM NOTE6 I 24-24
DRIVE CHAIN NOTE4 EVERY 1,000 km (600 mi): I, L 3-12
BATTERY EVERY 2,000 km (1,250 mi): I 3-16
BRAKE SHOES WEAR I I I 3-17
BRAKE SYSTEM I I I I 3-18
* BRAKE LIGHT SWITCH I I I 3-20
* HEADLIGHT AIM I I I 3-20
CLUTCH SYSTEM I I I I 3-20
* SUSPENSION I I I 3-21
SIDE STAND III 3-21
* NUTS, BOLTS, FASTENERS NOTE4 I I 3-22
** WHEELS/TIRES (WITH CAST WHEEL) I I I 3-22
** WHEELS/TIRES (WITH SPOKE WHEEL) NOTE4 I I I I 3-22
** STEERING HEAD BEARINGS I I 3-23
* Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is
mechanically qualified. Refer to the official Honda shop manual.
** In the interest of safety, we recommended these items be serviced only by an authorized Honda dealer.
NF100MN/MB/MSH-5 ADDENDUM
24-24
AIR CLEANER
Remove the main pipe side cover/leg shield (page
24-19).
Remove the four screws and the air cleaner housing
cover.
Remove the air cleaner element.
Make sure the rubber seals are installed in position
and are in good condition.
Replace them if necessary.
Clean the air cleaner element using compressed air
from the carburetor side, or replace it according to
the maintenance schedule (page 24-23).
Installation is in the reverse order of removal.
SECONDARY AIR SUPPLY SYSTEM
• This model is equipped with a secondary air sup-
ply system. The pulse secondary air supply sys-
tem is located above the cylinder.
• The secondary air supply system introduces fil-
tered air into exhaust gases in the exhaust port.
The secondary air is drawn into the exhaust port
whenever there is negative pressure pulse in the
exhaust system. This charged secondary air pro-
motes burning of the unburned exhaust gases
and changes a considerable amount of hydrocar-
bons and carbon monoxide into relatively harm-
less carbon dioxide and water.
Remove the following:
– Main pipe side cover/leg shield (page 24-19)
– Right side cover (page 2-3)
Check the PAIR control valve-to-air supply pipe hose
and pipe between the pulse secondary air injection
(PAIR) control valve and exhaust port for deteriora-
tion, damage or loose connections.
Make sure the hose and pipe are in good condition
and replace if necessary.
SCREWS
COVER
ELEMENT
RUBBER SEALS
TORQUE:
Air cleaner housing cover:
1.1 N·m (0.1 kgf·m, 0.8 lbf·ft)
ELEMENT
(CARBURETOR SIDE)
AIR CLEANER
ELEMENT
PAIR CONTROL VALVE-TO-AIR
SUPPLY PIPE HOSE
AIR SUPPLY PIPE
NF100MN/MB/MSH-5 ADDENDUM
24-25
Check the air supply hoses for damage or loose con-
nections.
Disconnect and check the air supply hoses.
If the inside of the air supply hoses are carbon
fouled, check the pulse secondary air injection
(PAIR) check valve (page 24-28).
AIR SCREW ADJUSTMENT
• The air screw is factory pre-set and no adjust-
ment is necessary unless the carburetor is over-
hauled or the air screw is replaced.
• Use a tachometer with graduations of 50 min
-1
(rpm) or smaller that will accurately indicate a 50
min
-1
(rpm) change.
IDLE DROP PROCEDURE
Remove the left main pipe side cover/leg shield
(page 24-19).
1. Turn the air screw clockwise until it seats lightly,
then back it out to specification given.
This is an initial setting prior to the final air screw
adjustment.
2. Warm up the engine to operating temperature.
Stop and go riding for 10 minutes is sufficient.
3. Stop the engine and connect the tachometer
according to its manufacturer’s instructions.
4. Disconnect the vacuum hose from the intake
manifold, then connect the vacuum hose to the
vacuum pump and plug the hose joint.
AIR SUPPLY HOSES
Damage to the air
screw seat will
occur if the air
screw is tightened
against the seat.
INITIAL OPENING: 1-3/4 turns out
AIR SCREW
THROTTLE STOP SCREW
VACUUM HOSE
NF100MN/MB/MSH-5 ADDENDUM
24-26
5. Apply the specified vacuum to the PAIR control
valve vacuum hose more than 67 kPa (500
mmHg).
6. Start the engine and adjust the idle speed with
the throttle stop screw.
7. Turn the air screw in or out slowly to obtain the
highest engine speed.
8. Lightly open the throttle 2 or 3 times, then adjust
the idle speed with the throttle stop screw.
9. Turn the air screw out until the engine speed
drops by 100 min
-1
(rpm).
10.Turn the air screw clockwise to the final opening
from the position obtained step 9.
11.Disconnect the plug from the vacuum port, then
remove the vacuum pump and connect the vac-
uum hose to the intake manifold.
12.Readjust the idle speed with the throttle stop
screw.
Install the left main pipe side cover/leg shield (page
24-19).
SECONDARY AIR SUPPLY SYSTEM
SYSTEM INSPECTION
Start the engine and warm it up to normal operating
temperature.
Disconnect the air supply hose from the separate air
filter (page 24-27).
Disconnect the PAIR control valve vacuum hose
from the intake manifold and plug the hose joint.
Connect the vacuum hose to the vacuum pump.
Start the engine and open the throttle slightly to be
certain that air is sucked in through the air supply
hose.
If the air is not drawn in, check the air supply hose
for clogging.
With the engine running, gradually apply vacuum to
the PAIR control valve vacuum hose.
Check that the air supply hose stops drawing air,
and that the vacuum does not bleed.
If the air is drawn in or if the specified vacuum is not
maintained, install a new PAIR control valve.
Install the removed parts in the reverse order of
removal.
IDLE SPEED: 1,300 ± 100 min
-1
(rpm)
IDLE SPEED: 1,300 ± 100 min
-1
(rpm)
FINAL OPENING: 3/4 turns in
IDLE SPEED: 1,400 ± 100 min
-1
(rpm)
VACUUM HOSE
VACUUM PUMP
PLUG
SPECIFIED VACUUM: 67 kPa (500 mmHg)
PLUG
VACUUM PUMP
AIR SUPPLY HOSE
VACUUM HOSE
NF100MN/MB/MSH-5 ADDENDUM
24-27
SEPARATE AIR FILTER REMOVAL/
INSTALLATION
Remove the following:
– Main pipe side cover/leg shield (page 24-19)
– Right side cover (page 2-3)
Disconnect the air supply hoses from the separate
air filter.
Release the separate air filter from the frame clamps
and remove it.
Check the separate air filter, replace it if necessary.
Installation is in the reverse order of removal.
PAIR (PULSE SECONDARY AIR INJEC-
TION) CONTROL VALVE REMOVAL/
INSTALLATION
Remove the left main pipe side cover/leg shield
(page 24-19).
Release the fuel hose from the clamp.
Disconnect the vacuum hose from the PAIR control
valve.
Disconnect the PAIR control valve-to-air supply pipe
hose from the PAIR check valve cover.
Remove the two bolts, disconnect the air supply
hose, then remove the PAIR control valve body.
Installation is in the reverse order of removal.
SEPARATE AIR FILTER
AIR SUPPLY HOSES
FRAME CLAMPS
This separate air fil-
ter has a direction
mark.
SEPARATE AIR FILTER
DIRECTION MARK
To the
PAIR
control
valve
VACUUM HOSE
PAIR AIR SUPPLY HOSE
BOLTS
PAIR CONTROL
VALVE-TO-AIR
SUPPLY PIPE
CLAMP
FUEL HOSE
NF100MN/MB/MSH-5 ADDENDUM
24-28
PAIR (PULSE SECONDARY AIR INJEC-
TION) CHECK VALVE REMOVAL/
INSTALLATION
Remove the PAIR control valve (page 24-27).
Remove the two screws, check valve cover and
check valve from the PAIR control valve body.
Check the reed for damage or fatigue, replace the
PAIR control valve if necessary.
Replace the PAIR control valve if the check valve
rubber seat is cracked, deteriorated, damaged or if
there is clearance between the reed and seat.
Installation is in the reverse order of removal.
AIR SUPPLY PIPE REMOVAL/INSTAL-
LATION
Remove the left main pipe side cover/leg shield
(page 24-19).
Disconnect the PAIR control valve-to-air supply pipe
hose from the air supply pipe by releasing the band.
Remove the three bolts and the air supply pipe.
Remove the gasket and clean the both mating sur-
faces.
Check the injection pipe for crack or damage.
CHECK VALVE COVER
SCREWS
CHECK VALVE
REED
RUBBER SEAT
BOLTS
PAIR CONTROL
VALVE-TO-AIR
SUPPLY PIPE HOSE
AIR SUPPLY PIPE
BAND
GASKET
NF100MN/MB/MSH-5 ADDENDUM
24-29
Install a new gasket to the air supply pipe.
Install the air supply pipe and bolts.
Tighten the bolts in the specified sequence as
shown.
Connect the PAIR control valve-to-air supply pipe
hose to the air supply pipe and set the band in posi-
tion.
Install the left main pipe side cover/leg shield (page
24-19).
CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE INSPECTION
Turn the ignition switch “ ” and disconnect the
battery negative (–) cable from the battery.
Connect the ammeter (+) probe to the battery nega-
tive (–) cable and the ammeter (–) probe to the bat-
tery negative (–) terminal.
With the ignition switch “ ”, check for current leak-
age.
• When measuring current using a tester, set it to a
high range, and then bring the range down to an
appropriate level. Current flow higher than the
range selected may blow the fuse in the tester.
• While measuring current, do not turn the ignition
switch " ". A sudden surge of current may blow
the fuse in the tester.
If current leakage exceeds the specified value, a
shorted circuit is likely.
Locate the short by disconnecting connections one
by one and measuring the current.
GASKET
AIR SUPPLY PIPE
3
1
2
PAIR CONTROL
VALVE-TO-AIR
SUPPLY PIPE HOSE
BAND
CURRENT LEAKAGE: 0.1 mA max.
NEGATIVE(–)
TERMINAL
NEGATIVE(–)
CABLE
(–) PROBE
(+) PROBE
NF100MN/MB/MSH-5 ADDENDUM
24-30
CHARGING VOLTAGE INSPECTION
• Be sure that the battery is in good condition
before performing this test.
Warm up the engine to normal operating tempera-
ture.
Stop the engine, and connect the multimeter as
shown.
• To prevent a short, be absolutely certain which
are the positive and negative terminals or cables.
Restart the engine.
With the headlight on Hi beam, measure the voltage
by the multimeter when the engine runs at 5,000
min-1 (rpm).
• B V = Battery voltage (page 15-5)
• C V = Charging voltage
LIGHTING VOLTAGE INSPECTION
• Measure the voltage with the headlight connec-
tor connected.
Remove the handle front cover (page 24-20).
Connect the voltmeter positive (+) probe to the
headlight 4P (White) connector Blue terminal, and
negative (–) probe to the Green wire terminal of the
wire harness side.
Start the engine first.
Turn the lighting switch " ", and select Hi.
ALTERNATOR INSPECTION
• It is necessary to remove the stator coil to per-
form this test.
Remove the body cover (page 2-4).
Disconnect the alternator 4P connector.
Check the resistance between following terminals.
Replace the alternator stator if readings are far
beyond the standard.
Refer to page 10-3 for stator removal.
Do not disconnect
the battery or any
cable in the charg-
ing system without
first switching off
the ignition switch.
Failure to follow this
precaution can
damage the tester
or electrical compo-
nents.
Standard: Measured B V < Measured C V < 15.5 V
REGULATED VOLTAGE:
12.6-13.6 V at 5000 min
-1
(rpm)
4P CONNECTOR
STANDARD:
Charging coil (White-Green (Ground)):
0.2 – 2.0 Ω (at 20° C/68° F)
Lighting coil (Yellow-Green
(Ground)):
0.1 – 1.0 Ω (at 20° C/68° F)
ALTERNATOR 4P CONNECTOR
NF100MN/MB/MSH-5 ADDENDUM
24-31
REGULATOR/RECTIFIER SYSTEM
INSPECTION
Remove the body cover (page 2-4).
Remove the regulator/rectifier 4P connector, and
check it for loose contact or corroded terminals.
If the regulated voltage reading (see page 24-30) is
out of the specification, measure the voltage
between connector terminals (wire harness side) as
follows:
If all components of the charging system are normal
and there are no loose connections at the regulator/
rectifier connectors, replace the regulator/rectifier
unit (page 15-11).
IGNITION SYSTEM INSPECTION
• If there is no spark at the spark plug, check all
connections for loose or poor contact before
measuring the peak voltage.
• Use commercially available digital multimeter
with an impedance of 10 MΩ / DCV minimum.
• The display value differs depending upon the
internal impedance of the multimeter.
• If the lmrie diagnostic tester (model 625) is used,
follow the manufacture’s instruction.
Connect the peak voltage adaptor to the digital
multimeter, or use the Imrie diagnostic tester.
Item Terminal Specification
Battery charging
line
Red (+) and
ground (–)
Battery voltage
should register
Charging coil
line
White and
ground
0.2 – 2.0 Ω
(at 20° C/68° F)
Lighting coil line Yellow and
ground
0.1 – 1.0 Ω
(at 20° C/68° F)
Ground line Green and
ground
Continuity
should exist
4P CONNECTOR
REGULATOR/RECTIFIER
TOOLS:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter
(impedance 10 MΩ / DCV minimum)
PEAK VOLTAGE ADAPTOR
DIGITAL MULTIMETER
NF100MN/MB/MSH-5 ADDENDUM
24-32
IGNITION PULSE GENERATOR PEAK
VOLTAGE
Check cylinder
compression and
check that the
spark plug is
installed correctly.
Remove the body covers (page 2-4).
Turn the ignition switch to “ ”.
Disconnect the 4P connector from the ignition con-
trol module (ICM).
Connect the peak voltage adaptor or Imrie tester
probes to the wire harness side connector termi-
nals.
Turn the ignition switch to " ".
Shift the transmission into neutral.
Crank the engine with starter motor and read the
peak voltage.
If the peak voltage measured at the ICM 4P connec-
tor is abnormal, measure the peak voltage at the
ignition pulse generator 4P connector.
Disconnect the ignition pulse generator 4P connec-
tor and connect the tester probes to the terminal
(Blue/Yellow (+) and body ground (–)).
In the same manner as at the ICM connector, mea-
sure the peak voltage and compare it to the voltage
measured at the ICM connector.
• If the peak voltage measured at the ICM is abnor-
mal and the one measured at the ignition pulse
generator is normal, the wire harness has an
open circuit or loose connection.
• If both peak voltages measured are abnormal,
check each item in the troubleshooting chart
(page 16-3). If all items are normal, the ignition
pulse generator is faulty. See section 10 for igni-
tion pulse generator replacement.
TOOLS:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter
(impedance 10 MΩ / DCV minimum)
CONNECTION:
Blue/yellow (+) – Green (–)
PEAK VOLTAGE: 0.7 V minimum
4P CONNECTOR
4P CONNECTOR
NF100MN/MB/MSH-5 ADDENDUM
24-33
ALTERNATOR EXCITER COIL PEAK
VOLTAGE
Check cylinder
compression and
check that the
spark plug is
installed correctly.
Remove the body covers (page 2-4).
Disconnect the 3P connector from the ignition con-
trol module (ICM).
Connect the peak voltage adaptor or Imrie tester
probes to the wire harness side connector terminal
and body ground.
Turn the ignition switch to " ".
Shift the transmission into neutral.
Crank the engine with starter motor and read the
peak voltage.
If the peak voltage measured at the ICM 3P connec-
tor is abnormal, measure the peak voltage at the
alternator exciter coil connector.
Disconnect the alternator exciter coil wire connector
and connect the tester probes to the terminal (Black/
Red (+) and body ground (–)).
In the same manner as at the ICM connector, mea-
sure the peak voltage and compare it to the voltage
measured at the ICM connector.
• If the peak voltage measured at the ICM is abnor-
mal and the one measured at the alternator
exciter coil is normal, the wire harness has an
open circuit or loose connection.
• If both peak voltages measured are abnormal,
check each item in the troubleshooting chart
(page 16-3). If all items are normal, the alternator
exciter coil is faulty. See section 10 for alternator
exciter coil replacement.
IGNITION CONTROL MODULE
REPLACEMENT
Remove the body covers (page 2-4).
Remove the ICM from the bracket.
Disconnect the ICM 4P and 3P connectors.
Installation is in the reverse order of removal.
TOOLS:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter
(impedance 10 MΩ/DCV minimum)
CONNECTION:
Black/red (+) – Body ground (–)
3P CONNECTOR
PEAK VOLTAGE: 100V minimum
EXCITER COIL WIRE
CONNECTOR
4P CONNECTOR
ICM
3P CONNECTOR
NF100MN/MB/MSH-5 ADDENDUM
24-34
TURN SIGNAL LIGHT
FRONT TURN SIGNAL LIGHT
BULB REPLACEMENT
Remove the two screws and turn signal light lens.
While pushing in, turn the bulb counterclockwise to
remove it and replace it with a new one.
Installation is in the reverse order of removal.
REMOVAL/INSTALLATION
Remove the front top cover (page 24-19).
Disconnect the turn signal light 2P connectors.
Remove the following:
– Main pipe side cover/leg shield (page 24-19)
– Two cover screws and turn signal light cover
– Two stay screws and turn signal light cover stay
– Three screws and turn signal light unit
Installation is in the reverse order of removal.
LENS
TURN SIGNAL LIGHT BULB
SCREWS
TURN SIGNAL LIGHT 2P CONNECTORS
COVER SCREWS
TURN SIGNAL
LIGHT UNIT
STAY SCREWS
COVER
COVER STAY
SCREWS
NF100MN/MB/MSH-5 ADDENDUM
24-35
REAR TURN SIGNAL LIGHT
BULB REPLACEMENT
Remove the screw and rear turn signal light lens.
While pushing in, turn the bulb counterclockwise to
remove it and replace with a new one.
Installation is in the reverse order of removal.
REMOVAL/INSTALLATION
Remove the brake/tail light unit (page 24-36).
Remove the nut and turn signal light unit.
Installation is in the reverse order of removal.
BRAKE/TAIL LIGHT
BULB REPLACEMENT
Remove the two screws and brake/tail light lens.
While pushing in, turn the bulb counterclockwise to
remove it and replace with a new one.
Installation is in the reverse order of removal.
LENS
TURN SIGNAL LIGHT BULB
SCREW
TURN SIGNAL LIGHT UNIT
NUT
BRAKE/TAIL LIGHT BULB
LENS
SCREWS
NF100MN/MB/MSH-5 ADDENDUM
24-36
REMOVAL/INSTALLATION
Remove the following:
– Tail cover (page 2-4)
– Utility box (page 2-7)
Disconnect the brake/tail light/turn signal light 6P
connector.
Remove the two brake/tail light mounting bolts.
Pull the rear brake/tail light unit backward.
Remove the dust cover from the turn signal light
wire connectors then disconnect the turn signal
light wire connectors.
Remove the brake/tail light unit.
Installation is in the reverse order of removal.
• At installation, align the bosses on the brake/tail
light unit with the grommets in the rear fender.
BRAKE/TAIL LIGHT/TURN
SIGNAL LIGHT 6P CONNECTOR
BOLTS
TURN SIGNAL LIGHT
WIRE CONNECTORS
DUST COVER
BOSS
BRAKE/TAIL
LIGHT UNIT
GROMMET
NF100MN/MB/MSH-5 ADDENDUM
24-37
WIRING DIAGRAM
MEMO
