* *hts SERVICE MANUAL mm mm a . “SERVICE cutawfir W'mnlponflble for the upkeep of the HONDA CB-CL’ZOO. It is compiled into six sections and summarizes the . procedures for disassembling, inspecting. repairing and rcassemblin; the components of the machine, Strict adherence to the instructions given herein will result in better, safer service work. This SERVICE MANUAL is based on C3200. with added explanation and photos on CLZOO except for minor differences. All information. illustrations and specifications contained herein are based on the I973 model. HONDA raserves the right to make changes at any time without notice and obligation. HONDA MOTOR 60., LTD. Service Publimiom Office g. E i PPT'FP'.‘E".“1' Ill. Breaker point up And ign on tuning Carburetor ....... . t . Throttle grip play. Clutch . . Cm chain Elfin! oil . . . . . Front disc blah . Front drum brake Rnr bake ..... Air cleaner. . . Oil filter Fuel filter ' Spark plug . . Drive chain ........... Front wepenrion end wildel . Rear suspension and wheel Headlight beam ....... ouwaammmauuuuu— 0n.ll‘).‘ 3. CARBURETOR Make udiuttrtieiilt with the engine “mined up. it Set the engine at an idle :peetl of 1.100 rpm by turning the throttle stop mew. Rotation of the throttle itop screw in n clockwne direction mill increase the idle speed. and Ht‘t‘ \'C|'Sll Tum the .iir \LR‘W ciilier m or out to ohtniii the hlgllval idle \peed tttirreti idle >pccd will be ohtdiiied by turning the on screw .ill the my iii .iiid ilieii lint‘klng it i 3 till! l'.- iiiiiisl ll' idle speed l\ tllt’lt‘flhk’tl itr dt'trtntwd Jlltwe or helm» the specified ht’lllllx, teiitliutt hi. the tlimllle \‘lnp Wrew. Specified idle speed‘ 1,200 rpm 4, THROTTLE GHIP PLAV ] llie llltlllllc imp mould he .idliistetl to have 107 150 pl:i\ .ii the grip mums“. Tn .itlliiii lniiten itit- ltltl Illll ind tum lllL‘ trip pm dulllhlt‘l either in Mr out at iietemri, ADJUSTMENT 3 Fig. 2-4 (I) (iciicrttlot rotor {It rimk (3) Index mark (-0 Advance niqik \t n Fig. 2 S (I) BAN? plate locking xcrvw t1) lime plate (3) Test lamp ,. Q Sltip mew (2t Fig 177 ill l3) (invnluitttlitnlt-r 1 oil out 76’” ll. INSPECTION AND .1 Check the throttle cable for twisting or tnterl‘erence wlth adjacent parts: also for proper routing. while tum- mg the handlebar between twu extremes 5. C LUTCH 1. Check the clutch lever for free plat ul us up. Specified play: 10720mm (0.4703 in.) To udlufl the play loosen the lock nttt and tttnt the upper ndtustcr Ill lllt‘ dtrccttotl ".‘A‘ all the way unttl tt Wlll no longer g0 3. Turn the lower adjuster in the dtrccltmt “A“ as far as tt Wlll get This loosens the cable. 4‘ Remove the clutch saver and loosen the dutch ad]l|5lk‘r luck nut Tttnt the udtustet tn the dtrectmn "A“ unttl .1 reststnnce H lell. .tnd lhvll b'JLk ll uul IJ—irlt‘l lunl: 'ltghten the lock nut tu \ccurc thc uthtutmcnt : Rutult' the clutch (.thle Inwet .ldllhlEt unttl the pl ' the (up M the tlutch lutt-r ts IO‘ZOmm 10.47034“! 'ltttJllcn the luck nut h Mttmt adjuslmclll ls dune by turnlltg the [lulkh cable upper autuucr After thc udtustrttcrtt ha: been made, check tn see that the clutch IS nut tllpptng and llul lllc L’lllhill IS proverb dlwngnglng 1 When the luck starter n used~ the eltglne hnllltl :lurt mmulltly 4nd grudttullv uttclcrnlc \l \ ADJUSTMENT Fig 2— 9 (1) Clutch lever at Free play Fig.2elo (I) Clutch will: upper mum-r luck nut t2) (‘lutch cnhle upper atltustet Ut Cltttth table luwur Adjmlt‘r (4t (‘Iulch unble luwu .tdltlstn luck llul Fig. zell ll) 11) (lutchadjuttet tglutclt adjuster luck nut ll. INSPECTION AND ADJUSTMENT 5 6. CAM CHAIN 1. Stan 1h: engine and removc the generator cover. 1 Rome lhe generator rulox counterclockwise so as lu align the "T" mark with the index mark 3 lnmen the lock nut and the cam cham lensiunu selling bnlL The cum chain will be automatically tensluncd properly when ll": scmmg boll is lumcllcd 4. Tighten lhe setting bull and secure with the lock nul, [-15.2713 [ll lensmnc: yslung hall (I) Luck mll 7. ENGINE OIL (hecking uil Iml l. Insen lhc ml level gpuge ml fillcv cap) mm me nghl engine crankmsl‘ In determmc the ml level m the mmlme nu should be up to me uppurlcvcl mnk ull llw mugc II' [he level Is low. .ldd ml In Ihe crankcnc. In» nut \ru“ m m gauge when mmuring me ml level Changing uil l qu up the engine ilnp the cngmc 4nd muuvc [he ml mm up I Remnw lllC dmn plug lmm lhc unumn nf the engmc uunlumse- Uperulc lhc luck mum >evrru| (mu-x m «1mm all 0.] Much may he Iell m llu: .unkmxc Fig 144111 lvllermp a) llpperlcwl mm x Releu' mam.“ pluand renuwuh lhcxpcg’lficdtillup m anerlevel nulk (u Ilw pmpcr lcml Ca l'HiIerlthSqll Spec led oil viscmlty (n'm' mu lcnlpel'ulun‘s SAE IOW4IJ urSAE IOWJO Mlmmr' Am) SAE 30 m In sum: me u. [SOC] SAE 20 u! 20w llcluw , .005 SAE law Al’l ('lawlfiulmn 5L Fig. 2715 m ('mmmplug 6 ll. INSPECTION AND ADJUSTMENT 8. FRONT DISC BRAKE Brake pad I. Check the bmkt pads for excessive wear. Discard if worn down re the rod wear line. Always replace hath brake pads ifeirher Is unscrviceabler Adjuslmcm No anl brake adjustment is necessary as the brake is self adjusted thn [he brake pads are [u be replacld wilh nuw ones. however, lhe fulluwmg slaps should be observed: 1. Th:- firsl lhmg necessary is (o ‘ake up possible slavk in rhr- brake rahle Thu- can he done by luming rhe brake «able adjufilillfl bolr out. Do nor lnnsen rlw bull mare Ihnn rnmuur ro take up slack. runner tum nul rhe hull _~, § lurm and nuns with rhc luck nuL NOTE: [)0 nor confine “cable slack" with "fret play" normally measured at [he lip of the hrakr lever, Note Ihat loose brake cable will prcvcnl the lever to be mlumcd fully when mlcngcd. _ ()rwmlr‘ Xhe Hrnku lcmr Jhoul ll) mun In thc the mm» “H mmxeh [he {ever mu hm .. props! 111.1} m :n anluch l11".).unnmalrcnlly. X «\Her :nlwnmcnl. put the ”th hunt mar thr- abh- .uiluirmg huh, th 1hr rmm th'cI mncd rill 1hr- xmund, nuke mm lhrn Ihe “heel mule: rreel) mmuul dram. 9V FRONT DRUM BRAKE 1 L‘Imk 1h.- trum herc 1cm pm Smndard plzw' 20730mm1087117in.) Fig. 2—16 (I) [Ink]: culipcr (3) Brake pad (3) Wcul hue (led) (4) Brake dm; Fug 2 I7 1H Frum hruLL‘ cabin Mummy hull (3 Lack nut Mg 1 Ix 1erer «cl! .Ithrm-JVH Mg 2 W (H lwm mu Imm (:r I-m- pm ll. INSPECTION AND ADJUSTMENT 7 1 Mnjor adjustment of the front brak: can be made with the from whee| adjusten To adjust. loosen the lock nut and tum the adjusting nut either in or out at necessary. Rotation 0f the adjusling nut in the dircction (A) de- creases th: plny. and vice versa 2710 (I) Lock mu (2) ant brake adjusting nut w Minnr adjustment IS done by lurumg the from brake cable 41.11“!ch al lhc from brake lever. Tu adjmt. [omen lhz‘ lm’k run and turn (h: adjuster in the dive-:tinn (A) to decremc the pla): Turning the adjusler III the dvreclinn (B) mcreases the play. Fig. 2 2| (I) lock mu my Mum brake cable adjusler 10. REAR BRAKE (“heck Ihe brake pedal play, Standard play: 2073mm“ [0.84.27 I) In «dlust the play. loosen m: Inck nut and adpm thc pcdul I‘m: hcudu \V‘Il'l the bmkc pcdal )lupp" hall. I; Fig 27:: m km mm pedal (ll Fm: pm 0. Pedal sluppcv boll m Lmk mu 3 AdIml the brake pedal pm by [mnmg [he mm ,cJuulmg nul mum in up mu .1‘ nrccmryv I‘n drtrcusc the plux, rnlulc the nut m lhn‘ duecrmn (M and we \em ll. lNSl‘bL'TlON AND ADJUSTMENT 8 11. AIR CLEANER 1 Remove the rig)“ .md lefl an cltanex cuvcu 0n ('LZOO. rcmuvc the 12“ Am cleaner cover ul’lcr taking nut the muffler, 2 Remove the nut and (JkL‘ uul the m cleaner case. 3 kemme [he lmln .Iml stcnnnccl [he cunucumg zuhc Inmg (hp. Luke 0|” the mmmg element. 4 Shake dml md dm uff [he elemcm and blow from (he remer m the clnnunl Imlwuld. Figv 2724 m Air Cleaner cast 121 I‘m mounnng nul Fig. 2 25 m An cleaner elemem 12) Fate: elemelu amchmx 1mm ‘1) Funnecmlg lube flunk lllp 12‘ OIL FILTER ‘» 1 1)!qu Ills cugme Ihnrmlghh l Renmvu Hu- rlghl lun' w thfler 1(R:t)(hm]y>.md km mum rum : Remm‘u [he mew ml ”kg nu! ma ngm mimkcmc mver lugL‘thr mlh me mm 4 1mm .1 :h; N Hwy mu 1mm m “‘1 mm mm mm mm Hg 1 21m m lenznmgfl mm mm mm SkIL'L‘H WIN II. INSPECTION AND ADJUSTMENT 9 S. Remuvc all dust and other foreigt particles from the center M the tutor. 6. Remove the screen filter and wash in clean solvent. Fig. 2728 ll] oil filter mtor 12) Screen filter 7. Align the tab nithe fillet cap with the mark an the filler rotor; press the cap mm place tn the FOCOL 2L Install :tll rcmuved parts in the reverse order of the removal Replace the crankcaae cover gzsskcl tt‘tound m be worn too badly beyond use. Fig.2 2‘? (H lndemmxk (.3) 14b I3. FUEL FILTER | Pmttttm the fuel valve in "S" ‘_ Inuwn lhc fillet cap and remove the cap. O-nng and screen filter from the fuel Valve, Fig. 2730 m Pmmnn "\ 3, Wash the screen filler .tttd ltlter captn mlvcnl and tnalull tn lhclr rupeettve pmttmm 4 Iurn the fuel \‘ule‘ la the "ON" pmmtm. hemg sun: that Ull‘ [UN 1; not leaktng (I) (2) (3) Fig 2 3| Hy Ftltcr are?" 11] (lung 1;) I‘ll?! ttltet [4p I0 14, 15. ll. INSPECTION AND ADJUSTMENT SPARK PLUG Remnv: the spark plug cap from the spark plug. Unscrew the plug, using a xpark plug wrench, and tcmuve the spark plug from the cylinder head. Check the >pat‘k plug {or depmitx and electrodu crusiott A spark plug with hunted electrudes or hlisturcd tmulatur should be replaced with a new one. Fouled spark plug can he cleaned m Spark plug cleaner or wttlt a wire hrutlt . llstltg 1t feeler yltge, adlust the gap to spacificutiun. Specified spark plug gap: 0.6707mm (0.024—0DZX-inJ To adjust. bend the «do clectrodc onlyv ('lezttt the plug seal and mew the plug mm lht: lhteaded hnle tn the cylllldet head DRIVE CHAIN Checking drive chain tension '1. n l lighten the tear lulu nut Rntse the ruar wheel all the ground with the Ittztin stand. Shtft the trunsmmiuu tntn nelllfllll Check the tcnston of the drive chnln. This can he mudt by applying a thumb preuurr at -.t poll‘ti midway her tween the tpmckett and measurtng the my, Specified sag: 20mm mun.) 7 To uthusL pry out the cuttet pm. luuscn lhe rear axle nut and luck nlflht and turn thu adtushng hultt m or nut as necessqr) The index mark: on the right and lctt thwa chntn udtusters should he alttuled with the same “Oldies in the stile scalet on tltr rear 9':er lnwrt the cutter put Wflh the end through the rule and secure With the lock nut V Check the rear brake pedal play and. lfnut'cssury. ttdlux't ' chain lubrication , lung plltts. remnvc lltc {Cltlltlltlg tltp trout the sham mutt luht‘ lull the chant from the mttlukett the n-tttuvetl clmtn tn \UIVL‘IH and dr) \Hlll .t mmmcwzd an l‘hccl‘ I‘ur cweww ol Abnormal \u‘ur In tho chum tll‘ll :wncke'x Ruplacc “It!“ A ltvv. utle tt worn at duttugull ttm badly heulntl uvc [ul‘lleL‘ the thaw wtth luhmtmtx l RUuhLl“ the Arm chant Make utrc tlut the dwelt and of Ilw rclummg clip l> ltt lllt‘ nnrmal dtrctttuu ul’ mutton Autuxt tllv cltttul [Pnflltn Stdu clcctrudc Fig. 2 34 ll) (3) lntlt'\ math 1-H IF) luck nut to) (film put l1) “Pl" .t\h> nut SAJIC tltvttll Adulttmg bolt Fig. 1735 II» (M Rnlnltllx tltrutltmt Retutttlng t-tlp ll. INSPECTION AND ADJUSTMENT ll 16 . FRONT SUSPENSION AND WHEEL Checking L erh the l'runl brake applied, check rhc action of the shock absorbers This can be done by jouncmg lhc shock ahmrbcrs up and duym several limes by hand. Also check for lculu. rwisrs or bends. replacmg purl: found with any of above lou badly beyond rcpnir, .. (‘heck rhc from fork and handlebar muurmng bDIts fnr lameness , Check the {rum wheel for wobblcl 4. Chuck llu: tire pressure. Specified pasture: 1.8 kg/cm2 [26 psi) 5. Check the lrrc for cracks. EXCEXSIVC wear or any orher defer-L by (link the tube valve fur Mr IEukx J 94 Changing fmnl fork nil 17. l Remove [he drain plug: from I’mlh lurks. Grasp the handlebar and Juunce up and down :everul uxncs In aid m removal of the rmmmug nil. Replace the drain plug\ Place a sulrahle :rund under lhe cngune rn rmc [he front wheel off the ground. V Remnve the oil filler plug and pour lhc specified umuunl of ATF (premrum quahry automanc lmnsnus~ nun mud] mm rhe \‘ucanl hole: ('apncily : llSAIIch {3.94.0 n1) NOTE: Specified amount of fluid will he requircd to fill one fork whenever dimsfiemhlcd. Specified capacily: I28~132 cc [4.3 45 oh) 4, Replace rhe filler plug‘. ,4 REAR SUSPENSION AND WHEEL I Ran: lhv mt wheel off [he ground. (‘hcck lhr‘ rcur lurk I1llihlng\. If any mrundroul play rs named when rhc lurkx are moved :rdeways. leplmie. .‘ (heck rhe mam ~md srde “and spnngs for damage Krplace II damaged too badly beyond user ,1 Chuck the suspension mnunllngs (m 100mm; 4 Flrcck the rear whcul lur wobble < (‘lrcck me me prmme Specified pmmrc: 2.0 kg/cml [28 psi) r» l‘hecklhe [Irv I’m um, wear m ulhrr delerrx 18. HEADLIGHT BEAM I Vurludl Adjllsllllelll I: made In pmmng lhc headlight “1w UH m mmmung bolrs : IIun/unul mummy” .5 nude by mmmg rhe ndjmlmg m“ lnuulcd ml the headlight mu $3 L u '1. 4‘ 1 Fig. 237 H) mm lurk ml drum plug Fig,273fi m ()IIIIIIcrpIug Fig 2 39 m til Mmung mew Hemllrghv mmmrmg hull 12 [II . ENGINE 1. ON-VEHICLE SERVICING Pub m be "MM REL page: Oil pump and all films! 19 Clutch 22 Gearshift mechninn ’ 24 CII’MIBIOI' 7-" W V 34 r 7 Electrical system (senor-mt. conlul;oWfi—Gjlfir J Z. ENGINE REMOVAL AND INSTALLATION The pnlimimry works for the engine removal are shown in the dingram below. Proceed in the numerical order drawn. To inslall‘ reverse rhe removal order. I. Full Ink 3. Starting motor able 4. Muffin (CLZW) “219' W. i Step burs (CBZWH Wt 93!! Fig, 3-1 Ill. ENGINE '3. cvuuoen‘ HEAD, CAMSHAFT, CYLINDER AND PISTON Fig. 3—2 (163(‘3‘3310‘ .4" (17)»@ . (18) (19) pruLkl‘l ronanl rhe ugh! NOTE: lluld the cam chain wilh a “ire or the like [0 prevent rhe chum from falling in rhe cranks»: while opernrion I; Rcrlluw the \pnrk plugx kcmm‘c [he rylmder heal I5 kemme the Icnw‘lnm‘rrmsh lm r—fi (l) (‘nmihutl (ll Sprmkvl 1F) (ulncham lll. ENGINE 16. Disnssemble the cylinder Mad. it Using special tool “Valve Lifter“ (Tool No 079577 3290000), compren the valve spring and remove the valve cotter: Release the tool and rcrnuve the valve spring b. If it is necessary to remove the valve guides because of excessive clearanoe between the valve stem and valve guide, drive the guides from the cylinder Mad using "Valve Guide Remover" t‘lool No 079427 3290100). 17. Remove thc 6mm cylinder hold-down bolt and take out the cylinder. is. Pry the pill \lep from the and til the piatun pin in the piston: withdraw the pin and remove the piston NOTE: Place a waste or rag under the piston to prevent the print clip from falling in the «sultan lmpectiun Cunsh-(t end cylinder head 1. Check the point base and cylinder head cover for ex- ccssivc wear or damage to the camshaft bearing surface, 1. Check the clearance between the rocket arm and rocker arm shaft. Standard veluc: Dolsroflflmm (0.0005—0.00I 7-in.) Service limit: OJ (0.00394n.) Maurine the height nl’eauh unml Fig. 34‘ (I) Valve guide remover Standard value: Intake ; ZS.DSRmrn[0.92l6S-‘in,) Exhaust: 24.872 mm (037924!” Service limit: 'lntake : MfimmlODROJ' Exhaust: 24.7mm (0.972fl- .) 4, Check fur wear or damage to the oil seal (ontact surface of camshaft Measure the valve seat width. Coal the valve seat mlli Pnhsian hlue‘ (lien set the valve in place. Rotate the valve onc liirri WIIII light pretsure If the Fruxuan hliic shows a hand of uniform thlth till the way around both mat and valve, the valve contact is normal it cmrtnet is ImprUPL‘l’. lightly lap the valve with a linen guide lapping cmiipuund. Rentiwc .ill the cuiupmind Litter the lappingupemliuu II 5““ defective. (l) hm," pm “I“, Mitre the vulvt‘ at‘rlt with a valve \eul grinder. Model ‘1, Wm" pm til Pinon (W. 7:74, recummcndcd hv HONDA *7 77 Standard value: Lo lAmm (0.0394 O‘OSSHtLl Service limit' ”hum 10.0709-inJ NOT When using a valvt' :t'al grinder. he sure to tullovv the invtructinm gvclt by the timl manufacturer. Fig.377 (l) Valvelifter y. ( hifilflllf the nutxidi- diiinetei til the vilw :lL‘lll Standard value: Intake: $434.49.“... (02157 octet—inn Ethan“: 5‘46—5A72mm must) 0.2154tiu,i Service limit‘ Intake: 5.42mi“ (0,2l34—in7) ‘ ExhaustrsAOmm l0.)l2(>in.l Fig. 340 Valve mi 16 Ill. ENGINE 7‘ Measure the valvc»ttrvalve guide clearance. Standard value: Intake: 0015—0035an (EN—0.00! tin.) ExhustIOBSJ—oDSSmm (0.00l3—0.0022—in.) Service limit: Intake: 0.08m (0.0032-in.) Exlurtst:0.lmm (0.“)39-in.) 8, Check the free length at each valve spitng, Standard value: Inner : 33.25mm (I 3091411.) Outer 2 3535mm (1.37%.) Service limit: lnlwl : 32.0mm (I .2598‘i'n.) Ont": 34.5mm(1.3583—in,) Cylinder and piston Oversize phIOIl and piston nng tmtt .4 Measure the inside diameter ofeach cylinder. Measure the bore at the top. middle and bottom with an accuratt‘ cylinder yuge placed at rig)" angle (Y) and parallel (X) lu the centerline of the crankshaft. If the wear is so great that the service lirmts are ex» ceeded. tllc cylindcrs .shnultl be rebored and nversize ptsmns and ptston rtngs installed. The folluwtng {out oversire pistons and piston rings arc available as servtce parts: Stu: tu which cyltnder ts to he tehored mmtin.) 55335.7(»(3949 1 “$537), mm t: um :05!) E32“: 1146 2.1150), 55.5]1: 13-34 1‘24?“ LOU 55.507555lmml 21850 2.1854-In.) 55.6 mntll.lR9(Hn.) Standard value. Service limit: . Meaxure the minute diameter at the putnn at ii: sktl’l Slandardvalue: 55.47 55.49mmt2.lx3972.l846-in) Service limit: 5&4me [1.I8l9-iu.) . VIcaturc the Inside (ilamck’r ut’ the ptalutl put ttulc m the ptstutt Standard value: ”.002 [5.002imm 10 590670590911) Swim hmit: IS,0$mm 10.5925.th Mcusttrc the utttmtc titimlclcl’ ut the Phltm pm Standard value. ”.9947! 5.000mm [0.5903405906-inJ Service limit' l4 9mm [0.5866-inJ Chm the tlcmnu- between the puttm ring ind ring groan; Standard value: Top . 0,0-I40Vm5mm (0.00l670.0030—in.l 1nd : 0.0257006mm l0 00I0~ 0,0024 I.) Oil : 0.015 70,045mm t0.0006 Doom-in.) 0.!5mm10.00504in ] Chet-t tttt- pmnu ring and ng mm): .t t‘cclcr Mtg: Standard Value 0.15 0.35mm10.0059 0.0I3ELiIt.) Service limit’ 0.75mi“ 10.0295-inJ Servin- limit. Fig. 34 | Measuring valve stem-to-valve guide clearance Fig. 3712 Measuring cylinder bum Fig. 37 l3 Mcasurtng Plait)“ ttttg mid gap Fig. 344 t I l Pmutt mtg m.» "tam“; lll. ENGINE .7 Anemhly Pinon ring 1. Use the piston ring ofthe same marking in a set Install the ring to the piston so that the markings are facing upward. when a new ring is used. check it for smooth fit in the piston ring groove. it should slide freely around the entire ri'ng circumference without binding, 3, Position the rings so that their gaps of the top second and oil rings are staggered 120", each being apart from the direction at right ranges to the piston pin. NOTE: Do not install the top and wound ring con- versely. ,4 Vb ‘ \ 3% Top ring " 2% 2nd ring EON ring Piston I. Install the piston with the arrow mark facing toward the front (exhaust ride) of the engine. 2. Assemble the piston. connecting rod and piston pin with new piston pm clips» NOTE: Put a rag or the Like in the cylinder bore of the crank case to prevent the clips from falling In the crankcase Fig.3—15 (l) PRIOR head mark (2) hstonpm (3) Pn‘lunpirlclip Cylinder I. install two knock pins and cylinder gasket to the cylinder surface of the upper crankcase. 1 Place “Piston Buses" (Tool N0. 0795872500000) bet- ween the pistons and crankcase. Passing the cam Chain down through the cylirider.slowly lower lhc cylinder over the pistons. Hold the piston rings with "Piston Ring Compressors" (Tool No 07‘354 3230000) while lowering the cylinder bores Remove the piston hascs and piston ring compressors when the rings enter the cylinder bores. NOTE: Liberally apply clean engine oil to the piston ring; before installation Fig. 3716 (l) Piston hurt (I) Piston ring compressors (3| Cylindcr (4) Cam chain Cylinder head 1 UM: “Valve Guide Urn-er" (Tool No. 0794271180100) when drivrng a new valve guide, Aim drrvrng, rum to awe with “Valve Guide Reamer" (Tool Nu. 079847 IKXJOUDOl Inttall the valves so lhdl lhe narrow-pitch Ends of the valve springs are on the valve spring scat side ,4 Fig. 3—l7 (I) Valve guide driver 18 [IL ENGINE 3, Install the tensioner push bar in place in the cylinder head. Secure the installation with the setting bolt After pressing the bar all the way in until it will no longer 30. 4, Place n new cylinder gasket on top of the cylinder. Be sure to install four knock pins and two O—rings at the same time NOTE: Do not damage the pike! surface of the cylinder head end pike! when installing ”IkEL anve “min I, Rotate the crankshaft so as to align the “T“ mark on the generator rotor with the index mark on the right crank- CISC cover. to V Install the cum chain tn the cam sprocket so that lltc matching lines on the cam sprocket are Ill alignment with the upper surface of the cylinder head. 3 Positron the sprocket in place on the flange end of the cam shaft with tlte spark advance! knock pin facing upward and the matching lines placed ltunmntnlly, Tighten the sprocket n. [he flange with two knock bolts Torque specifications: 170-230 kgvcm (I2,3—|6.6 lbs-fl) 4. Ltmcn the tensioner selling btilt lllld check to he sure that the cunt eltzin is properly tensmnctL Cylinder head cover 1. Place lllt: cylindet head cover in place on the cylttttlcr head thh the gasket inserted in between. Install and rtghlen the cylinder head cover hold~dnvm cup nuts in the wquencc a: glow“ tn th, 3-21. Torque specifications: 180 220 kgutlmg >ptot‘kel selling plate. remuve the \pmckcl. chum and Mulllllg motor aptocket together, [lemme the ml filter. L‘lulC'l and ml pump (\ thh the upper crankcare factng down. "mere“ mne t-mm bulls and nuns 8mm boll: munng lltt‘ {me In Ir place. Rumm- lhc luwcr umkmc wlulc diwmugtttg the I...» nl the gear shift arm from thc gem \lttll drum Figt $759 11 I SLuvmg mntnr spruckct 1:» ('lmn My Slurllngxpruvkcl l4] SemngpLue 32 Ill. ENGINE 7 Remove lhe crankshaft from the uppel crankcase. Inspection I Check the craukzlmfl fm runnuL Measurement: should he made With a dual nldu‘nml and by mmtmg the shnfl one full tum Flue [he shall In V blocks ul bulh cud bump and measure ulnoul a! A. N. C. D, F and F, Slandnrd Value: A, B. (land I.) 0.02mm (DBMS-in.) max. ‘ E and r 0.05mm 1 (0.002(Hn.) max. \ Service limit: A. n. (and D : 0.15mm (0‘0059Ainvl ‘ Fig. 34.1 3. Check me flde dcurance uf Ihe cunnecung nod bug cm]. Standard ulna: 0.07-0.33mm (o‘oozxioouo-m Strvioe limit: 0.6mm [0‘02364JIJ Figv 3762 m (‘nnnecung rod (2) Feelel gwgc humbly When InKmHIng Ihc cranbhnfi. he sun: to hue up the dowelslmur) m the crankcase (uddlck In lhc holes m the bcmnp To Lmhme mi: npemnnn. each heanng him :In allgxung Hunk The dowel mu hole wnll allgn when lhe mark n Hum wllh the {we uf the upper umkuusc Fig 3 61 ll} ngmng nmk lll, ENGINE 11. CRANKCASE fig. 3—64 l Uppfl crankcase ) Lower crankcase ) Dowel pin A [IO X 14mm) ) on “punter ( 5 ) Oil wpamcr sel bar (6) Cable Cllp B ( 7 ) Cable clip A (8) 0»rmgl33.5 x 3mm) ( 9) Drain plug ( l l ( bun..— ‘ Disassemhly l Rcmnve Ihe cylinder head, cylinder and mum. See , . P‘fi‘ l4. ’ . r l Scpamlc Ill: upper and lowcr crankcases and rcmuvc the ' crankshafl. mainsllafr. counlcnhul‘l. gear shift drum and ku‘k «uric! 3‘ Remove the ml reparalur and lake our the set bars. Rcmuve the separator from the lower crankcase. Fig. 3765 (I) Oil repnmlor . (Z) Separator rel bar l lnspccuon (1) 1‘ (hack me nankcase ml puwugc rm clumnp, Assembly 1. Apply a \Imfurm coating orpmpu sealing agcnl m lhe cran ‘ase mulmg surl‘avcg 2, Mala: sure all dowel plm zlrv properly Imlallad In lhelr respecrn'e pox-11mm 3. Trgucn um: 6mm 1mm and rune Nmm holrsfllarllng u rlve center toward ulllsidc II) c ch (Are mm m damagc lhc slarlnlg nmmr cal-11c wlulc lightening Use each hnll m us prupcr pmllmn Torque specinmnons: Mum holl 7071") kgun ) 8mm b0" '22:) 23:01:;2'; rig, go 1 _’ (rmm bolt :2) Xmm boll ' (3t Surnng mowr cub]: (I4.57l8,8 lbs-ft] ”05> I'uulriun 34 ' rrr. ENGINE 12. CARBURETOR Fig. 3-57 t I ) Rubber cap 1 3) Cable zdjuster ( 3 ) Cap (4) Carburetor mp ( 5 ) Top gasket (6) Thmttle‘valve ’ g ( 7 ) Needle clip plat ( R ) Clip ( 9 l Jet need]: not Throttle valve (11) Carburetor body (12) Air screw US) Air screw spring (14) Throttle stop screw I IS) Stop screw spring (to) Needle jet (l7) Needle y‘et holder rm) Main jet 11") Slow jet (30) Valve seat (2]) Float valve (22) Float (23) Floatzrm pin (24) Floral chamber (15) Drain bolt (lb) Overflow tube (27) Choke rod >4 a?» ’4. Dinxsembly 1. Remove the carburetor assembly from the machine Sepnrete the float chamber body r ronl the carburetor. Remote the elow and main lets Pry out the flout arm pin: remove the float Remove the float valve seat. lnxpectiun Ir ("heck the throttle valve for damage or any other defeat which might interfere with proper carburetor operation Blow the mum and slnwjets to check them for clogging . Cheek the I“ needle for wear. r Check the valve plute and valve for correcr reatrng , Check the float level In the float chamber Hold the carburetor with its mam bore in a Vertical puhlllull. :o the float :rm lung wtll Just clusc the float valve, wrthout compressing the spring loaded plunger m the end of the valve, Measure l‘loat height wrth a float level gauge. Float height (distance between the carburetor body and the nppoult‘ edge of the float) xhould be :r 0mm (use? in I when the float valve just closes. rt ndJuKtment u needed, carefully bend the float arm tong toward or away from the float valve until the speutl‘rcd lloat hetght Is nblarncrl, “3- 375° l") Flml ‘3) Flofl arm Replace any damage or lenkrng float. (3) F10“ “Val gauge rather. Fig. 3438 ll] Slow ‘cr (2) Main jet U) H 't (4) Hunt arm (5) Hum .mn pln thlol'J llL ENGINE Ammhly I. II is imporlalu- that all uarhumlur parts he handled carefully since roupl handling will damage [hum easily, 2. Install the mmulc valve will lhe cutaway facing toward ”1: choke valve (‘arhurclur selling table "Ilem (‘8200 (1200 Semng number 008A 0271! Main jet :88 L‘ 95 sum 1!?! z 38 i 35 kl “smile yelling A" grew opening 17 ; Final llelghl (2|mm,‘D)lZ7-in.| MEMO Fig. 3 70 (I) Thruulc valve (2) Quawny 36 1V . FRAME 1. FRONT WHEEL (DISC BRAKE TYPE) Figt 4—I (l ) Cotter pin (3.0 x 28mm) (2) Castle nuttl4 mm) 1 3 t Speedometer gear box 1 4 ) Gear box Ictainct covet ( S ) Gear hm: retalne! ( b l 0-ringt47 mm) 1 7 ; Ball bearinglhloll ( 8) Front axle distance cnllar (q | Front wheel hub (10) Ttte flap 11 | ) Ftuttt wheel rim 112) Front Wheel tube (1}) l'mnt wheel me [14) Front wheel bearing retainer (15) Oil sealtll X 30 X 8mm) (1n) Frunl Md: cullat (l?) anl brake disc (18) Lock wttshet (h mm) ll“) ant wheel axle linsu-mbly I PlZIL'L‘ u tal‘cty stand undet the engine [0 muse the front whucl till the ground 3 Remm: the mung screw securing llK spredumetet cable m plun‘, temnve the cable. 3 Pull ml! the \UllCl’ pin .md remove the cattle nut. The front wheel can then he taken uul h) pullmg oul lhc u\lcv NOI'E: Do nnt apply the brake lever with the front wheel 0" the machine, as thix wuuld abnormally advance the uutomatlc brake ndjustment and cause difficulty in lnxcrllng the brake div: between the brake pads. To correct. remove the caliper cuver and tum out the adjusting bolt as necessary. (One lttll rotation of the adjusting hull increases clearattcc by I mm [0,0394in) After assembly, have the bmkc Sell adjuitcd by operat- in the buke 1m. several times 4 Remove the wheel \Idc cullur (mm (M wheel hub nil Mall 5 Stutgjttcn the lug: m lht‘ lot-k mshcn and loosen off the Huh Remuw the htnke dug item the wheel rig.” m senmgmcw (l) Speedometetcablc (3! [mm wheel axle Fig-173 tl) Stde collar (2} Lock washet 13) Brake dtSC 6. 7. IV. FRAME 37 Removc the speedumeur gear box. Remove the scraws and take out the gear box retainer cover, gear box retainer and O-nng, & Remove the oil seals from the wheel hub and speedo- mctcr gear box. 0_ Using “Bearing Retainer Wrench" (Toul No. 0791K 3230101) ). remove the bearing rcuiner. 10. Remove the ball bearing; and distance collar from the whecl huh Inspection . Check the front wheel rim for [ace runouL , (‘heck the ipukcs for lonsenesw Check the front wheel axle for bending Standard vnlue: 0.01min (0.0004-in.) mar Service limit: 0.2mm (0.0079-in.) (Before disassembling) Standard value: 0,5mm (0.0197-inl mu. Service limit: 2.0mm (0.0787 m Brake rim» lzi Dial gaugc Fig. 477 [ll Imver handle 11> ()Uk‘r buunug dmcr anamnmu 38 tv. FRAME 2 Install the bearing realm" and suite at two places as shown A Figl-t—S (1) Hearing retainer [2) Stukz 3. Being sure that the O-ring is installed in the wheel hub, install the gear box retainer and retzt‘ner cuver with the SCIBWS Fig.4 9 (I) U-rmg {2) Gear box retainer (3) Retmner cover 4‘ Install the brake ms: to thc whccl ltub:secure with new ' lock washzrs 5. Install the speedometer gear box‘ :ltgnmg ll wult 1h: gmm'e m the gear box rcmncr. 0 Check and adytst the brake If neccssary IV. FRAME 39 2. FRONT DISC BRAKE Fig. 4—11 ( I ) Caliper joint ( 2 ) Brake cable boll ( 3 ) Caliper body ( 4 ) Pad grommet (5) O~ring(8.5 x 1.7mm) (b) Caliper pm (7 ) Caliper gasket ( 8 ) Pad B ( 0 ) Pad A (10) U-nnuMZ x 4mm) (11) Disc cover I [2) Adjust plate guide boll (13) Tluusr p‘ate guide H4) Brake arm (15) Cable and pin (lb) Adjuuing tau-hex 117) Ratchev fixing wring (18) Caliper cover I 1“) Front brake disc (20) buck washer (6 mm) Dini‘emhly I WM}: the caliper and brake «by: with clean waler. Puxh up the cable ham to expose the cable Adluzlcr. Turn m m: mum: :11 [hr way until n will nn longer go, : Rcmuve [he [hm- 6mm bolts secunug the :nhprr cover In pluw, wmuvc the cow! Fig.4 I} m (‘nhpermver m hmm mm 40 3 Scpamlc the brake arm from the brake cablc. NOTE: av No funlm dmmbly is necmry when only Ihc brake pads are m be nphccd. b. Wrap (In unloved brake Inn will! I clean clulh m the like to pvtvenl airbome dos! Ind din from enter ing inside. c. Do not diguemhle the brake Inn. 4 Remove the Ihrusr plane gnlde. [mull :1 (mm boll used In «(cure the cnhpcr (mu. m we Ilueaded hole m the bark pluh‘ uf the pad A: rcmnvc lhc pad A mgcum mm the tymm bolt, 5 Place a nland undu [he :ngme m (ruse (he from wheel un‘ Ille ground 0, Rcmuve the pad 8 wlulc prcnlng on ma lock pm urea mm 4 \uuublc >Crcwdnwr “ Ihc p“ U xhuuld he rcmuu‘d 1mm [hr and? (mm which (he pad A w,“ 14km mu. The pm 8‘ hmu‘wr. mu m» rammed hum the Am \Idc when H n vmm duwn m the ICJ [mu Fig.4-” (I) Brake cable (2) Brake arm Fig. 47|5 (It I’m A (I) (mun bu]! ID Thrusl lee guudc Fig 441) 111 Lmk pm .{reJ Lr1)CU Fig,4 1771) m n IV. FRAME 4| 8. Remove the lever boot and disconnect the brake cable from the lever. Pull the cnble toward the caliper to re- move it, NOTE: The lmke cubic an be removed from the hnke Inn 1| the cable crud. 'l'I|ls perm“: sinflc rephumenl of the ahle withoul le‘lnoving the wheel '(1) ugh, Emmi m leverbnol (2 Brake cum: 9 Remove the two hmm bolts and a 8mm hull. dis‘ assemble the disc cover. caliper body. caliper joint and caliper pm from each other. Fig.4—l9 (I) Dmcum (2) Caliper body (3) Cal|peljulnl t4) Cuhpcrpul lnspeclion 4*; 1. Check the pads A and B for exceqsive or abnormal wear. Mag 3‘ ” Discard the pad if it Is worn down to the red~|ine wear \.,_/ Tl limit. 0.5mm ‘ NOTE: (0.02%.) l Replace both pads it any one pad shnwx exeem’ve wear 1 l (1) reaching me ted-line limiL (2) fl CL. ._tu Fig-1720 Ill PM] A (.‘l l’fld ll chmbly NOTE. Avoid oily or greasy substances getting on the pads and disc. as this would affect the proper operation of the brake. Wash them in solvent when oil is walked. I. lmlall me callper may. caliper pm, dun cover and callper quYIL NOTE: Be sun ru install the caliper pin in the proper direction, ‘e Fig 4 21 m ('«Iiperpm 42 1V. FRAME 2 Install the bulk: cab]; Insert the able end in the brake cable bolt and scrcw in the adjusting bolt all the way :g raw—22 (I) cm; and [2) Adjusting bolt [3) Brake cable bolt 1 Wipe clean the pad sliding surfaces of the caliper Solvent may he used to remove accumulalcd dust and am. 4. Apply 0.6 lg lamziuoss 01) ul' silicon gum l'SfilM (same as that used for C3750 and C3500) I0 lhe back plate of the pad B; set the plate in plug on the caliper body. Install the from wheel. 5. Put the Gains on the pad A, In like manncr at nlmve. apply (15; (00: oz) of the same ullcun gmm' KSblM In the 8!"er urcumfuence of the pad A lmtall the pad A wulll llle matching marks on lhe caliper budy pmpcrly aligned NOTE: Be sure tn me a new (king, IV, FRAME 43 (x Connect lht: cable end to the brake arm and tuxtall the thrust plate guide in position ram—26 t1) Brnkearm r2) Thrun plutc gum 7. Disengage the ratchet from the brake arm. Using a standard screwdriver‘turn out the adjustlnlt holt until u is lightly opposed by the Slnpper. Make sure that the adjusting bolt rotates freely with light pressurc.(thh the brake pads worn down to the red-line wear limit, the bolt will be shipped when rotated I I turns) NOTE. Damp“ this opention when only the bnke able is replaced. 8 Instztll the ratchet and check for proper OPCRIIKWL 9 Install the brake arm In the caliper. 4-27 (1) Standard :(rcwdrttcr (ll Ratchet H1 ltntail the Elllpfl' cover wrth the gasket under it. install three hmnt butts in the hole: In the Cttvcr and tighten wrnrely NOTE‘ Be (lire to replace the gasket. Fig.4 28 m L'ttlipt‘rcuwrgttskt‘t ll It) nwtre cumplclc rututtttttg (it thc brttkr lu'er, tint lwhdlt the hmke cable adjusting bolt all the way Then. turn in the .tdtusllng tmlt until it is In the fully released ptmtrun Finally. turn nut the hull I In 3 full turn: and mute Wllll the 10d; nut, Fig 4 19 [It (‘Jblc Adlllsllllg hult {.‘l Lmknur 44 IV. FRAME ll Operate “I8 brake lever :boul I0 film In have the bnke self adjusted. The level will have I proper play of 20—30mm (n 8 l. 2 in) automatically. [3. All" adjustment. put [he cable bool over the cable ndjuning bull. With the from wheel raised off th: floor. make sure Ihll Ill: whegl rotllei freely withom drag MEMO lVr FRAME 3. FRONT WHEEL AND FRONT BRAKE (DRUM BRAKE TYPE) Fig. 4—32 45 ( l ) Frunl whtcl ax]: ( 2) From wheel side collar ( 1 ) (3) Oil seal (26427) (4 ) Ball bearing (6302) ( 5 ) From axle dixlanne collar lb) Front wheel hub (7 ) From wheel lure ( 8 ) From wheel lube ( 9 1 Tire flip (10) Front wheel rim (1 I) From brake ‘llnc (12) From brake shoe spring (13) anl anchm pin washer (14) From hrakc cam B (15) From brake cam A “6) Oil sen] (53667) “7) Speedometer scar (Isl Front brake panel (19) Brake cam dust seal 120) Plain washer ( 14 mm) (ll) Lock washer (8.2mm) (22 Frunl brake arm (23) Frnnl hmkc arm return spnng (24) From brake arm B (15) Front brake arm A (26) Castle nulll4mm) (27) Caner pin [)isassembly v 3. w Place a sunable supporl under rhe engme to raise the from wheel oflthe gmund Loosen ml the :cl .wrcw and unconnecl lhc \pccdu- meter cable l'ry on rhe Cotter pm: separate vhe from brake cahle lrom lhc brakc arm Loosen the luck rm! and lake our lhe blake cable l'rum the brake paneL Slmghu-n llw tab of lhB luck washer and remove [he hull. lm‘ lllr nuke xlnppcl mm llum lhc brakc panel Rcmm‘c the caller pm and loosen MT the caitle nuI WIKthflW [he front wheel axle Thc whccl can then he um um may ”,4 33 Fig/1734 [I] Speedeelercmble (3] Brake :lupper arm ll) Flnl'll wheel ml: 46 IV. FRAME 7. Remove the wheel side collar from the riyit side of the front wheel ti Disassemble the hrakr: panel as an assembly from the from wheel 9. Loosen off the lock bolts (mm the brake aims: take out the brake arms together with the return spring l0 Remove the dust seals from the brake paneL Fig.4735 (I) Fruntbrzike arm (1) Lock bolt ll. Pull out the cutter pins and remnve the washers, and ihen remove the bake shoes. shoe spring. and brake cams from the brake paneL ll Rumm'c ilir: uil seal. ball bearings and distance collar from the front wheel hub. inspection ]. (‘lieck ilic lrnnt wheel axle for bending. Standard Value: 0.0] mm (0.0004—in.) max. Service limit: 0.2mm10.0m9a‘n.) (hack the bull hearings for ex cemve play Standard uial play: 0.05mm (0.0020—in.) max. Service limit: 0.|mm 10.00394") Standard radial play: 0.03mm (0.00I2»irr.l max, Service limit. 0.05mm (0,0020-inJ Check the nm for true l’llnuul. (Bciurc dls‘dhkk‘lllbllllgl. Standard value: 0.5mm (0.0197-in.) max. Service liiliit: 2.0mm (0.0787-IIIJ .(‘heuk ilie >pukt‘8 for lnoseriess. bend nr ntherwrse breakage, . Check Ill: ml seals for wear or damage, Chuck the brake drum [or wczir or any ivllier damage Standard hmke drum I,D..‘ I607I603inm 16.299276.“ I0»ili i Service liiiiit: lblflmiii [films-in.) . (heck the l‘mku lining for CXCCESIVL‘ wear Ur any niher detect Standard hrrikc lining thickness: 4.54.7mm l0.l772 lllsSO—in.) Service limil.‘ 2,0mm 10.7X7~in.) . Check the brake pzinel inr \lJHIIIgC hr and. Assembly 1 r4 Hum] pad ilic wheel hearirigx .irii] wheel huh \\llll grease lhinir "Bunny Driver Aiirrclmierii“ 1|qu \0 mm Mimi)!” and "anr llaridiu" ‘TiNll N.» 704‘) 0110000). dllVl‘ fit the hearing in the “heel huh ihruugh the distunu‘ wllur NOTE Install the hearing with the seal ~idc Inward ilit Ollhldc. Do not .mgie the distant: collar while driving Dru? .i we“ UII )i‘fll in the wheel huh iiniil it. is ihnh mm rm- huh ciid Du rim angle rin- seal while driving, Fig. 4‘36 Fig 4. 37 Fig 443 (ll (Kl (Si ll) 1]) ii) Cotter pm (1) Brake shoe («H Brukc (uni [hike drum 4:) lwill \‘r'lUk‘l llll“ (hi \l'Jl Wash: r Shoe spring Calipers ill hill hearing 1v. FRAME 4-, 3. lnslall the brake cam: wilh 1h: punch mark on the end face toward the mxidc, 4. Sparingly apply grease m the brakc cams beforc instal- ling [he brake shoes NOTE: Avoid gust gening on lhe bnke lining and bake drum. 3: lhk would nffecl the proper openliull of the brake. 5‘ Install ‘he brake arms with the matching maxk on the braku Mm lintd up with this! (111 [he brake cam Fig. 4—39 (1) Punch mark (1. Connect the brake smppcx arm [0 the brake panel; secure wilh new lock washer. 7, Adjusl me brake. Fig. 4—40 m Brake stopper arm 12) lock wmher (3) Huh MEMO 48 IV. FRAME 4.3 EAR WHEEL AND REAR BRAKE ) Rear bnke panel side collar l Rear brake Irm ) Plain washer (l4 mm) ) fink: cam dust seal r S ) Rear brake panel (6 ) Rear brake shoe (7) Brake shoe spring 1 B ) Rear brake cam Ball bearing (6303) ([0) Rear axle dlxurlcu collar Rear wheel axle (Ill Dnve chain adjuslcr 113) Dme chain adjusting bolt Rear wheel huh ( lS) Rear wheel rlm (Io) Tire flap (l7) Rear wheel lube Rear wheel me (10) Snap mg 147 mm. (20) 0:1 51:11] Rear wheel damper bushing 12:) Drrven sprukel fixing hnlr 113D Dnrc chum Drive chain juml 1:5. Dmv )prucktl 12m Spruckvr )idc plarc Lock wmhcr (25) Snap nngflflmm) Rear srdc collar (30) (3511!: nul [lbmml [3]} l’oner pm Dimswmbly . erlnlun the ruar whccl rule ()n ([1100. rtmuw lllc "lumen, Drsmnnecr the rear brakc rm] and rear lwrake “upper arm Luuwn llw Imk mm wluch :ecure lhc dnw chum lulnmmg hulls. loosen the adjusnng bnlrr I'ull nn' rhu curler pm and mmuve rhe mule nut Kemm‘e the rlnvc than! from llw final Jrncn \pruckrl m mummg the return W :n |hc rhuln Mm nu: permlfl remnml of Ilw war nlrccl, Ark-r rcrmmng rho map ring. pr) llm \pmclur ml! of plum- llum lllL‘ {L‘JI “hEEl Ming 3 prcw nl‘ mmd as >ln~\\n NOTE, :1 «My: handle the final driven :prucktl and fixing boln M a w! I; Nu removal of the lock umher |\ nccmwry Be sure [u rentu rhe mnher whenever disaw’mbled. <2) Dm‘c clrmn adjurrrng [-0 Curler pm Rear wheel 1qu Lock nnr a) Drug clum ad1l|sler (5) (ml: nut to) Fig 4 42 m [2) Plr‘u‘ ul‘ ' Fig. 443 m Final driven spvmkcl IV. FRAME 49 8 Remove the side cnllar {turn the oil ml 9, Remove the tear brake panel assembly in With the oil seal removed, take out the map ring, bearings and distance collar. ll. Remove the rear brake arm and dust sea] from the rear brake panel l1 Pry out the cutter pin; remove the brake shoes. bnke cum and brake shoe return spring. Inspection I. (‘heck the rear wheel axle [or bend Standard value: 0.0]mni (mama—in.) mu. Service limit: 0.2mm (0.0079-in.) , Check the ball bearings for excessive play. Standard axial play: 005mm (0.0020-Zn.) maxi Service limit: Delmm (0.00391'n.) Stumdud ndi' play: 0.03m (coon-in.) maxi Sewiee limit: 0.05m (0.0020-int) .1 Check the nm for face runout {Before disassembling) Standard value: 0.5mm (0.0197-in.) Service limit: 2.0mm (0.0787-int) 4. Check the spokes for luoseness. bend or otherwise breakage 5. Check the final driven sprocket for excessive wear or Lilly other damage u Fig, 4—45 Checking win: on final driven iprocket 6. Check the brake rhucs [or excessive wear at any other detect Standard brake lining thickness: 4.5A4,7mm (0.!77270.l8$0»in.) Service limit: 1.5mm (0‘059linil 7‘ Check iii: brake panel l'ut damage at crack ti. Check the brake drum for wear or tiny nther damage Standard brake drum LD.: 1400 >140.) mm 15.5] l8- 5,5236-in.) Service limit: I4l.0mm {5.5512—in.) ‘L Check the ml seal: for wear or dumagi: Ammbly l. Hand pack the wheel bearing and wheel hub with grouse. Using “Bearing Driver Attaclunent" (Tuul No. Fig. 4 46 (i, prim liaiidla 0794573330100):md "Dnvcrll2ndle"(Tool Ni; 0794‘) m Beam“! “me, Madmen, *(rIIUOOOL dtive fit the bearing in the wheel huh through the distance collar. Dnve n new ml saul in the wheel hub until it ix flush with the hub and Du llul angle the seal while driving. . lmull the driven ipruckct to the pivut bushing ut the wheel huhe then secure with the 166] ball: luppcr. lx pcx and 1mm 12 pm In each race pmpcrly. Mule rmaung lhc slccnng slPHL lnuld~llgllten the slccnng head (up thread so lhul ll mmes lrccly wllhnu' rulllc \n} Xllglllcfl ulununl m pl.» m :1.\l.‘| almunn can no: he mleralcd here NOTE: (‘lean the Com: races. ball races and slt-cl halls in cleaning solvent and apply a coal of gxease before lnxullauun. Fig-14:0 (I l Tup Llll\€ me (in : \ \ll'cl lull ,4 1m- lurk [on bridge :huuld he mulled mm lcmpwmllh ugluenmg lhc [mm torkx TIghlUll llu- \lccnng «rm nuL Stem nul ligllll’llillg mrque: 8004900 kgcm (57.9 72‘} “‘QJII /('|) Fl: 4 m m Ml luphndgt m lmll ml 54 IV. FRAME 7. FRONT SUSPENSION Fig. 4—62 ( l ) Cover cushion A ( 2 ) Right fork upper cover ( 3 ) me reflex reflecmr ( a ) Refleclol base ( 5 ) Cover cushion B (6 ) From fork boot I 7 ) Right from shock abmrber assembly ( x ) Left fork upper cover 1 9 ) Folk boll 110) Ovring(23 X 2.4mm) (I I l anl shock absorber spring ( l I] linllnm hzsc cover (I!) Dust seal (314510) (14) Snap ring (45 mm) (IS) Oilsedal x 4] x 10mm) (I6) Pislon ring (17) Seal pip: (IR) me lurk plpc (1‘)) Oillnck p1ece (2m Bonom case 121) Sockel bol! ()1 mm) Dimssembly :. 7 .4 Remove Ihe from wheel (See page 50 on disc brake [\pr. or page 45 un dmm brakc lypc) 0n dlSE bmkc ‘ypt. mmuve lhe cahpu assembly lwm we left from lurk (See page 3‘!) . 0n drum brake Iypcv maighmn (he mh< no" me luck wasth The {mm brake sluppcr can be taken mn {mm the left from fork by unscrewmg llvc allachmg bulL ‘ Remove the rm.“ fender hy hac‘ "g of! the allachmg hulls Wuh 1h: [mm rmk hull loosened. rcmm‘e Ihe hulls at [he Iork mp hndgc and steering stem, whwh sccurc (he {wk menmyy Pull (hr (mm (ark memhly mwurd lhc lmuum Drum the from sllspcm‘lon ml. Remove um U" the lmm fork pipe. II any. mm fine cmcry mm Fig‘ 44.3 Fig. 4 (>4 (H lmm Oelnier [1 b I null l‘urk hull (1) [MIX mum”: In: lV. FRAME 55 3. Remove the wcket bull and scpmu Lhz frunl lurk pipe and oil lock pltoe from Ihe honour case. Us: “Allen Head wmnch‘Tl'ool No. 0791773230000) to remove (ha rocker bolL 9. Remov: the l'mru fork bull on lop of the fork vipc; mmnve the from shock absorber spring and bullum pipe. 10. Remove the botlum case cover. dusl seal and map ring‘ and take out thc oil scal. WWW Fig. 4—65 m Allen head wrench ll (‘heck the free lenth of the from shock absorber sprung, Standard valuc: 453.7mm (l7.flb22-lnr) Service um: MSmmllISle‘n) W ' 1 Check the bottom pipe for wear on the pislnn ring 3. Check the from fork piston and barium case for wear, ~. crack or any olher dzfecl. Star-dud honour case 1.0.: 31 mo, 31.039mm . m (I 1205—] lIZZD‘inJ A ; Service limit: JLMmm (1,2264n.) Standard fork pixmn 0.1).: 30325730950mm ~m0 o In (l.2|75—I.2|85-in.| 591W“ limit: 30.9mm (I ,2l65-inJ ‘3 Check the oil scal for wear or damage. Fig. 4 66 Expludcd New 0| [mm mm humbly I. Clean all parts In solvtnt befnu assembly, 1 Apply a coating of ATI' (automatic lrurrsminion fluid) to [he cnhre surface (1! a new ml real Install the ml seal to the bottom case. Dnve fir the seal using "I ark (1) Seal Um!!!" (Tunl Nu 07°47 3550000)‘ NOTE: Ik sure to install the dim cover iecurzly. (2) 3, lnslall [he from muck absorber spring inrn the (rum fork pipe 30 that Lhe rnd wrllr |lu~ Luge lurch n at the humour. 4 Install lhc from lurk pupa (n [he hullmu caw NOTE' Apply liquid nalam tn the xhrcadx or the 8mm socket boll a " Fm mh mm l‘ork bunmn cm with 13x 13: (c ,; Qiil (4.3 4,501.5)anl1 , ‘ , Fig. 44.7 (1: FM ml dnu‘r ~l2) on ml m Fig 443x I‘ll...“ an 56 IV. FRAME B. REAR SUSPENSION Fig. 4-69 1 I ) Rear shock ahxurbcr assembly (2) Rear pipe ( 3 ) Jon“ rubber (A) Upper joml ( 5 ) Spring seat stopper 1 0 ) Rear shock absorber spring upper seal I 7 ) Lock nut {9 mm) ( 8 ) Rear shock absorber srupper rubber ( 9 ) Rear shock absorber spring (10) Rear damper (Ill Sprmgunucrwr (I: Spnllg adjuster (U) Rear fender ([4) Drive chain case {I51 Rear (ark (l6! Dusl seal (17) Rear fork bushing 118) Rear furk collar (10) Rcrn‘ fork dusl seal rubber (:0) Rear lurk prvm bolt [21) Under rubber bushing (1:) Rear mu smppcr arm Drmmrrhry Rear 1 ‘ suwemiou 0n L‘LIDO. remove the mutIlcr (0 [aka nut the 1:01 rear shock absorber Remove the bolts securing the rear pipe in placeLnr [he same time. remove the rear shock absorber anachmg cap nuL Rcmuvc Hu- rear shock rrhmrhcr by rcmovmg the ball 41 [he hnrmm Compress the rm shock absorber usrng "Rear Shock Absorber Compressor“ 1 lnnl No. 07959 3290000) and remove Ihe $pnllg war stoppers Takt our [he spring Wat. rcur shack absorber spring, spring joint, under spnng veal and spnng adiuslcr. ~ M4) Firs. 4*70 m Kuarprpc 1:) km prpc ball up ('aprrur m Bull (1') Fig 4-71 m Rur shuck ahsnrher comprcunr lV. FRAME 57 Folk Remove the rc-r when]. (8:: page 48) Rcmove the rear shock absorber; {Sec pug: Sb) . Remove the bolls securing the drive chain case m place: take out the chain case. r Unscrew Lhe self-locking nut; withdraw thc rear fork pivot bolt. Remuvc the mar fork from the framer . Remove the dim wal cups. dust seal rubbers and rear fork collars [mm the rear fork. ” m . wN_g FiE- ‘42 m Duvccnmnmc 13) Punt mm (21 Sen-locking nut <4) leurr Inspection 1. Check the free length of the rear shock absorber spring, Slandnrd value: l96.7mm (7.744141) Servic: limit: 185mm (7r2835-in.) Check the [car damper fnr dumrtion or nil leak“. (‘heck the rear “ripper nibbcr for cracks or damage , t'hcck the rear fork center callarrtmbushmg clearance Standard hushing L0,: 20.000720.052Inm (0.7874A 0.7894—il1.) Service limit! 20.2mm (01953411.! Slandnrd center Collar 0.1).: l9.927-| 9360mm (3) [0.7845 70.7853-in) Servicr limit: [9.9mm (0.7835-in.) 51w“ hg. 4773 (1) Rear shock «lumber 12) Rear sloppcr rubbcr (3) Rear shtick ahmrlwr wrlllg Membly I Apply a coating nt grease to the rear fork center collar bot'orc installation Install the rear fork to Ihe train: 1 Reaching from the right sidtJnSHH the rear lurk prUL secure with the wlfrlocking nut. Torque specificatiuns: 6007 700 kg cmmmnty as specified below (070) with the swilch wiecmv knnh m m each pusmnn Ierrnmal KB KW ‘ Lead color 4‘ Black Blackx‘vmue l 01‘]: RU; 7 7770—47 ‘ m) i 0H" ‘ l Surfing witch Dmnnnecl lhc terminal uf [he surnng 7 dam-m drum 06 33.950 33.975u.33664.33m 3331411345) 7 Gambit! [01k ID 34000 inns [1.3386—1. 3%) 34 07.» (713415) Gen-Quin fork guide pin 0.I| 0,228 (0.004.340.0090) 0.5(00197) clearance in gmuvc in drum : lsl. 2nd. 0089 —o.17u(u,nn.$sr mom; a: (0.0070) Trunsm'nsion gm 3rd backlash 4th. 51h 0.09470. ] 88 (0,0037 0.0074) 0 2 10.0079) w.— , 7.1., fir VI. SERVICE DATA 79 m -eonl'd Unit: mm (m) Ital Ana-Hy Ind-d 8min: Iii-u ennui-n mi :1 mm 002010003) 015(00059) Mada-flail!) IS.OI&-IS.034 (own-0.59:9) 15.07 (0.5933) Comm; rod bi; end Me dell-nee 001—0 33 (00023—00130) 06 (0.0230) Fun: m disc in» mm 005 (00020) 0 20 (0 0079) link: a: bend 005010020) 03(00118) Bake disc minimum 4‘ 9—5.1 (01059—0 2008) 700) I575) Fm: brake “mum-L 4.547011772704350) 10 (0 0737) minimum-nib iso—maumwz—ssuo) 16L0(b,3386) Wheel rim [Ice mm! 0.5 (0.0197), mm. 10 (0.0787) Ball baring axial plly 005 (0.0020):;|;x. V A 01 (0.0039) wmnufiy 003 (0.0012) 005 (00020) anI lea m 0.01 ((176034).max.77777 7 . 0 7 (0.0079) Rm axle bend ‘ 00: (0.0004). flux. 02 (00079) nu link: iii-in. lhickm 4.5—4.7 (01772—01050) W ‘ Ekaoso I) Rmhnkeaiumm Imo—maasns—iszss) ”10(15512) Fro-l shodi slum-her uni-in; (we length 453.7(17.8622) Rut shock .00.... swing he: lenglh l9h7(7.7441) Ru fork pivot mingle-0:11;" collar (445)“75197) (185)(7.283$) 0.0470,I25((100l670.0049) 03(001m dunner: Rut com [milling ID V L 20.00040. (E2 (0 7874—0. 7804) 20 2 (0.7953) Ce'mercollar on 19,9277I9.960((17845 07053) ”3107335) i merorkbommcaéeio 37000731039(1.220.571.2220) 31.|_1o(i.2259) rmmrorkp'peon ‘ 30925 30.950(l.2|75~l.2185) 3090(12105) 0 VI, SERVICE DATA E‘fnouaLE snoo-rme WI- Troble Prob": an: Brandy Erdne wil not “In or fill m Int. 1. lnml‘flciznt crimp-union manure l) Imprvper upper ndjustumnt Adjust 2) Worn valve guides or improper vulva Rtpl-cc or recondi- seltln; lion. 3) Incorrect valve timing 1 Adjust. 4) Worn piston ring: Replace. 5) Worn cylinders Replace. 2. No spark from plugs or on points i) Foul plup ; Clem 2) Wet plus 1 Clean. 3) Foul palms 1 Clean 4) Incorrect point pp ‘ Adjust. 5) incorrect iytition liming Adjust. 6) Defcctive ignition coil Replm 7) Open or short circuit of ignition Replica. cords 8) Short circuit in condcnser Replncr: 3. No gasoline is fed to carburetor. l ) Clogged vent hole in tank cap C lean 2) Clogged fuel cock_ Chan 3) DelectiVe carburetor float Valve RGPIICE. 4) Clogged furl pipe Clean Fagin: stalls frtqurntly. l. Foul plugs Clean 2. Foul points (‘ lean 3. Incorrect ignition timing Adjust 4. Clogggd fuel lines Clean. 5. Clogged carbureturjeu Clean 5. Improper llppcl adjustrmnt Adjlfll lining is noisy. I. Noisy tappets l) T00 large : tappzt claatance Adjflsl 2) Weak vulva spring) chlace 2. Piston knocking l) Worn pistons nr cylinders chlnce 2) Carbon depusils rm combustion Clem chamber wallx 3) Worn piston pint ur connecting chlace md small ends 3. Cam chuin I) blonguted chain Adjust or replace 2) Worn cam sprocket ut timing Replace sprocket 4. Nnixy clutch ll Loose clutch center splines Replace 1i Ex sstve clearance between Replace clutch rncmm an: and teelh of ‘ clutch uutcr huusrng 3i Warped l‘nctrun dim: or clutch Repair nr replace. plates VL SERVICE DATA 8| Elghe -eorrt‘d Trouble Probable came Remedy W! is unity. (cont‘d) 5. Crankshaft I) Loose crankshaft bearinfi Replace. 2) Loose connecting rod big ends Replace 6. Noisy seats I) Worn tnmsrnision gears or inter- Replace ference between pars 2) Worn splines 1 Replace 3) Worn primary gear or interference Replace between gears Chrtdr flips. l. Improper clutch adjustment (no play Adjust in clutch lever) 2 Weak clutch springs Replace 3. Worn or warped pressure plate Replace 4. Warped clutch plates Replace 5. Worn or warped friction discs Replace Clutch dny. l. lmpmper clutch adjustment (excessive Adjust play of clutch lever) V l Unequal clutch spring tension ‘ Replace 3. Warped clutch plates ‘ Translation perm to be drifted I. Deformed shift drum stopper Repair or replace smoothly or hqrrentr'ally. 2. Broken gearshift dntm Replace 3. Detour-led gearshift forks Repair or replace Change pedal fails to return. I. Broken gearshift return spring Replace 2. Interference between crankcase and Repair gearshift spindle Truullnlslion parsdlsenp'e accidentally. I. Worn main shaft or cuunterstraf t Replace shifting gears Z w . Weak gearshift drum stopper spring Bent or wont gearshift forks Repair or replace Replace Engine operation is erratic at low speeds. L O Engine operation is erratic at high speeds. «purest» rer— gm wra— souveni- . Defective valve guides l Incorrect ignition trmlng . Defective points . Weak sparktdefcctive condenser or V Incorrect flnal level , Weakvulvc springs . Incorrect valve timing . Ton small a plug gap (defective nutty . Retarded ignition tuning l Weak point arm spring . Defective ignition coil . Incorrect float ler'cl (too low) Improper tappet adjustment Improper cylinder head valve seat annual Too large a punt gap ignition c l) lmprupcr carburelur arr screw adjustment matic advancerl Clogged alr cleaner clement Adjust Reettndlllun Replace Adjust Repair Adjust Replace Adjust Adjust Replace Adjust Adjust Adiust Replace Replace Adjust (‘learl VI. SERVICE DATA Elli! ~00!“ hull- thhle eule My mmimnum 9. Imumeientpolhlelsfedto c-rbureror Clemoraddguoline (“0"!) A Erin-t gas are very My. L Brcesive engine oil Adjun oil level Recheck willl level DWI? 2. Worn cylinder: Ind piston rings Replace 3. Worn valve guides Replace 4. Scored or scrnlclud cyllnders Replace Engine doe not daddy mfllclent purer. I. Improper nppet adjumnent Adjust 1 Weak valve :pringr Replace 3. Incorrect valve timing Adjust 4 Worn cylinders and piston ring Replace S. Improper vdve seating Replace 6. Incorrect ignition timing ‘ Adjust 7. Defective point: ‘ Reprir or replace ll Incorrect plug gap Repair 9. Clogged carburetor jets Clean Ill Incorrect float level Adjust I l. Clogged nir cleaner element Clean Emilie i: Mellie-ting. l. Cuber: deposits on cylinder head Decarbonize 2 Insufficient engine oil Add to specified level 3. Defective oil pump or clogged oil Clem passage: 4. Too low a float level Adjust 5‘ Advanced ignition timing (knocking) Adjust Frlme Tumble Prob-bl: cluse Remedy Steering is lard. l. Diceuively tightened steering stern Adjust 2. Damaged steering stem steel balls Replace 3‘ Bent steering stem Replace 4. Low lire inflation pressure Adjust S. massively lightened steering cone Adjust Motorcycle pull: to one ride. 1. Unequal tension of left and right Replace shock absorber spring: 1 um from forks Repair or replace 3. Ben! front axle or incnnecr wheel Replace or repair aligylmcnl Front wheel wobble! . I. Deformed rims Re place 2 Worn front wheel bearings Replace 3. Loose spokes Retighlen 4. Defective lire Replace 5. Loose axle and related parts Retighlen Front shock absorbers are spongy. L Weak springs Replace 2. Insufficient damper oil Add VL SERVICE DATA Fun - unn‘l Trouble l huh-He curse Randy Frontshockmlllehd. l. Toohiduehocklbwrberoilviscosity Change 7. brush: damper oil Adjust Plant shock m In noley. I. Interference between shock absorber Replloe one and Ipringu Z Damagd shock absorber stopper Replwe rubbers 3. Inmfficiem damper oil Add A loose connections Retidtten Rear wheel wbhlu. I. Deformed rims Replace 7. Warn rear wheel bearing Replace 3. home spoke: Retighten l 4. Defectiv' e tire Replace Rear diodt IMH .e Iponll’. L Weak xprinp Replace 2’. Improper rear shock absorber adjuster Adjust operation Rear shock absorber: are l. Improper rear shock absorber adjuster Adjust operation Rear shock absorber! Ire noisy. I. Interference between shock absorber Replace case and sprinp 2. Loose connections Relighien Braking efl‘ect is poor. (Frommheel. disc type) I. Incorrect brake fluid level Adjust 2 Worn pads Replace (Front wheel, drum type) I. Improper brake shoe contacl Repair or replace 1 Oil or grease on brake lining: Replace 3. Improper brake adjustmenr Adjust (Rear wheel) I. Improper brake shoe contact Repair or replace 2. Oil or grease on brake linings Replace 3r Worn rod or brake pedal shaft Replace or adjust 4. Improper brake adjustment Adjust Brake me play Is too small. I. Worn brake shoes Replace 1 Worn brake shoe cam Replace 3. Improperly engaged brake arm serration Replace 4. Worn brake cam Replace inks are noisy. l. Worn brake shoes Replace 2. Foreign matters un brake shoe surfares Clcun or replace 3. Hardened brake shoe surfaces Replace 4. Bent or twisted brake shoex Replace Electric-I system Trouble Probable mac Remedy Engine fails to fne ur I'm-s weakly. 1. Defective ignitiun conl Replace 1 [)efeclive spark plugs Replace Contact hrenker pnintx burn l. DEftCIlVE condenser Replace 0-, g; VL SERVICE DATA lurid syner- - m‘d Turtle Prohhle can: Remedy Carbon k W on "It flu; I. Rich fuel-air mixture Adjurt carburetor m. 2. [die weed loo Irifill Adjust carburetor 3. Improper palin- Change ‘. Cloned air cleaner element Clean 5. Uta ofwld type plugs Replace by hot type Plugs fink plum -e {mi ‘ l. Warn piston ring Replace 2 Worn piston: or cylinders Replace 3. Excessive clearance between velve Replace guide and valve Spark [I'll' electrodes overheat or bum. L Use of hot type plug: Replace by cold type plus- 2 Engine overlienting 3. Incorrect imition liming : Adjust 4. Lame spark plug Retigliten '3 5' [en fuelqir mixture Adjust carburetor Generator will not chug! human I. Open or short circuit in wiring. or loose Repair ur rcpl-ce connections Generator charm ;flery inauflicientlyp W l. Defective ynemtor coil due to shon or Replnce open circuit. or grounding 3. Damaged silicon diodes Replace 4. Short u‘rcuit in regulatur lends Repair or replace 5. Regulator voltage under no load is below Adjust rpecification 1. Wiring I Open or short circuit. or loose connections 2. Generator - Short circuit in field coil [Check resistance by continuity tesL) Repair or retighten Replace 85 VI. SERVICE DATA 6. SPECIFICATIONS 11m cm cum DIM Omall 1,935 nun (76.2-1r_i.) ” 1:975 mm 1,965 mm (774111.) Overall no man (283411.) 825 mm (325411.) Ovenll 121.11: 1,060 nIIn(M.7-in.) 1,070 m (42 in finelbaaa 1,290m(50.un.) 1,2 mm 50 Seat height 7n mm (30.7%.) 795 mm (31 3-1...) Gmunddeanue 155 m(6.1:h.) 180mm(7.1-in.) W 132 “(291 lba.) 0' 1331:; Type Sernklouble cnille F. surpenaian. trawl Tchawflc fork, travel 105mm (4.1-in.) 11. mapum'on. travel Swing arm, (revel 67.8m(2.7~1n.) F. are 312, prawn 1754801151)“ R. lire in. procure 3.00~18(41’K)(” 6PR) 325—18 (4P1!) Ehralre Dircbrakn ('Eumbnkej Drumbnke R. brake ' Internal expanding rho: i Fuel capacity 7 , 9.0111. (2.4 us. pi. 2.0’1inp. gal.) Fuel morn capacity 2‘5 11!. (0.7 U.S. gal.. 0.6 Imp. gal.) [ 1.5 lit. .4 U.S. gal.) Caner aule 64' "‘ W” ”— Trail 1&1}: 89 MOS-in) T 90 mm (3.5-in.) ENGINE ' Type Air cooled. “nuke 0.H.C. engine » Cylinder arrangement Twin, parallel §;inclined {ruin venical Bore and stroke 55.5 x 41.0 mm (2.185 x 1.614411.) Displaceml ‘ 198 cc (12.1 ell-in.) ' Companion ralio 9.0 : I Valve train Chain driven over head camshaft Oflgpacity r 1.7 Iii. (1.8 U.S. qt, 1.5 Imp. qr.) inbrlcalinn iyalenl Forced and wet rump Open: A: 5' (before mp dead cer- [make "1“ Close: Ar 35' (filer botIom diad center) Open: Ar 40' (before boumn dead center) Exhaust “I“ Close: Al 5 " (aim Qp'dnd cemer) Valve rapper cleannu: 1N, EX : 0.05 mm (0.002-in.) Idle speed 1,200 rpm muvrs mm 7 Clutch Wei,mulii-plau type Trariaminlorr__ S-cpeed oonilznl mesh ‘ Primary reduction 3.700 Gear ratio 1 2.769 Gear ratio 11 1.882 Gear ratio In {1450 ’ ’ Geur nlio IV [.174 7 Gear ratio V 0.960 iiiiii Final reductiun 2.333 ' , j 2.465 Gearshifl Emem Left operated return sysrem lgmlion Battery and iguliun coil starting sysrem StarriFg motor and kick starter Altemalor AI. generarnr Battery capaciry 12v. 9AH Spark plug NGK muss-i; ND X24123 ’ ‘ Indicates specification of U.K. type " Indicates specificalion of European type d: afiiilufi :‘ 424‘: 3: Sad. 3. 5.. VI. SERVICE DATA , a In 3...: ,,r§~_=!E.u!§5 I: :3 2.! 5:59. I! :3 35¢. ’51 L 1z'wmlm DIAGRAM . wm>h id...— . 87 VI. SERVICE DATA A mm: 1.3 . VI. SERVICE DATA ‘3 . ma: Zamozaw _ V . his 5.. 3.1:: 5.35.» E: a! 3:3! I. S. 5.. «51!: Elm: ii. .539. it! U Vl. SERVICE DATA ( FRENCH TYPE ) m n mum" “mm mm {1‘ v hs‘ 3:: g‘“ 31‘; 12 5’ 9¢Z a 615; g“ 90 QBZOOT 1. FUEL COCK The indicator maxks and their positions on the fuel cock was changcd to a new type. Fi!.T—l (I) Fuclcock (Z) haven 2. MAIN SWITCH The many“ switch, previously offered on the swilch A housing at the right side of the stccnng handlebar. was discontinued Move the mainswilch to "ON" pusinun to turn th: headlight and taillight on and to the "Parking" 0?? position to turn the taillight (parkmg light) on n a? W {kg % n; T42 m Mninswllclt m Headlight 13> Tailllght 3. HEADLIGHT DIMMER SWITCH A new dummcr (wilcll was added to the tum signal and horn swutch housing at Lhc lcfl sud: of the handlebar Fig, T73 11) Dxmmet swnch 11) llvm >wllcll 13) Tum ugnul :wmh CBZOOT ADDENDUM SHEET 9| 4. SIDE STAND Theideatandwasohamdtoamtype withashoek ’ absorbing rubber pad. h-pwdon . 1. Check the entire stand anembly (aide ltand bar, bruket and rubber pad) for installation, defamation or other- wiae exuuive damage. 2. Check the spring for freedom from damage or other defeat. Fig, T—4 (1) Side standbar (2) Spring (3) Rubber pad (4) 6mm bolt (5) Side stand pivot bolt ’ 3. Check the ride stand for proper return operation: a. Wlth the aide ttand applied, raise the stand off the ground by min; the main stand. b. Attach a spring scale to the lower end of the stand and measure the force with which the stand it ntumed to itt original position. c. The stand condition it correct ii the meaaurement falls within Z-Skg (4.4-6.6 lbs.) If the stand requires force exceeding the above limit, this might be due to neglected lubrication. over- tightened stand pivot bolt, worn stand bar or bracket, or otherwise excesive tension. Replace a: neceeaary, Fig. T—S (1) Side stand bat . (2) Spring scale 4 x ‘ . Check the rubber pad for deterioration or wear. when the mbber pad wear in exoeaaive so that it ia worn down to the wear line, replace it with a new one. GOOD Ill ’ Fig, T76 (I) Wenrline ' Rubber pm replamnent 1. Remove the 6mm bnlt; separate the rubber pad from the bracket at the side stand. 2. After making sure the oollnr is installed. put a new rubber pad in place in the bracket with the arrow mark out. NOTE: ' Us: rubber pad having the mark “OVER 260 lbs ONLY". 3. Secure the rubber pad With the 6mm bolt. Fig. T77 tl) Rubbcrpad . (I) Collar 92 C320!" ADDENDUM SHEET 5. MAINTEMNCE SCHEDULE Sum um:- occund In the HANNAH}. mdwfidldenflsmumhnmflluly bolow: MAINTENANCE SCHEDULE Th1: minimum: Mule i: bind upon wens: riding common; Machine: rubjected m never: use, 0r riddm In unumally duty mm, uquIre more frequem servicing. INITIAL SERVICE PERIOD REGULAR SERVICEP’ERIOD Perform It every indic-ted month or mileage inlervrl, whichevzr nccures first 500 mil“ l I 6 12 month , months months month- 500 1,54” 3,000 6.000 ' "Illa mils ‘SIDF. STAND—Check inst-“man, apemiou, afanlmIon. dam and wear. "o IIII'I'II marlwd' should be serviced by Ill authnrlud Honda dealer, unle- lhe owner In: proper took and is mechmicllly proficient. 0mm malnunam Immr are imple to perform Ind may be serviced by the nwrmn W'~--.- wa—W—f — 4... u- CBZOOT ADDENDUK’SHEEI' 6. WIRING DIAGRAM (CW, 85- £5: ; Sula: “E as. S: 58 Si 5:: 5.3.2.: 5:: i=5 5:353 IS; 58:: nun—:6: gal: 35 ,, 85: 5: :5.“ i: is: _ _ _ _ _ 5...: a... La: 1% g_!!:!. ll‘f ,_ ,.\. 35:2 32:: 5.5 , :8. 85:: .5. x! .47: Z _ “W 1/ 1,, L, J , .aE=S_SsRiE.s:._ ‘I. § i! I" . / :2: i 3.1!: 2525“ PE. :3 2:93. .53 S. 5.2. E! 5.5!:- .536: 5:5 .Eh.§__5 .125! 55 mmmmm wan-ummmuwmumwmmmmmmm-muj mmwhmwmmmnam huh- amummmmmu u) bub Wrflmhm Emhdumaflnmdnpulndondulndmm ummflumpddhwumm mmmammm‘Mu-hmmm A: mmhmmm.mmmmimmfl. Ihawfth-hdnn-hlunhlflmml. 010(1ka bnkeitoumddnmformumdmlltbeum Brahman! ‘ - Grumman Ind! i: “needed. ¢ icabh mm models and Frame ” “(3' 200 CBZOO-IOIOIIG Ind whequml "L.“ U) Bun mind 4%. L drum‘wom B. 1—8 (I) (2) (3) I. (4) (5) link: um Bnkl indicalot Flute Wm limlu