'; SIIflP MANflAl HONDA $90 0l90l. 090 m. 6L9!) 0090 GT90 FOREWORD Thls shop manual Is a reference and a gulde book lor Ihe propel seNlcing ol ma Honda 90 series molurcycle. The inlermulion comained herein is based on lhe S 90 wrlh equal applicabilily lo lhe CL 90. CL 90 Li CD90, C90 and CT90. When no reference is made lo my speclflc rrlodelr lho inIovmalion shall be common lo all models Inlumanorr perllnem lo any speal‘lc model will be norad. The ml is prepared in several difieranl pans lor convenience and ease in localan rho parli- mlar lnlomraliom All wvicmg inlormariorr including drscrswrrbly, reassembly and mspecllorl procadures are ocnloined in lhe respecllve sections for qulck relevance. All HONDA products are pvecisionly wheeled wilh pveclse lolerarrce (or opllmum parlormanco. fheteiore, lhe procaine: oulllnad :hould be followed my clasely and any repairs or raplocamarrrs made when the serviceable limil is exceeded. Fulher, Illa special tools specified my be used in older lo parlorm rho repair or servlce In a salislocvory rrlclrrrrer. For pvcfiloble mice operaliorr, all work should be compleled pvomplly and lo lhe sallsIaclion oI lhe cuslomer. this requires a complete line 0! anliclpaled veplocemsnl pcrls readily available. HONDA MOTOR co.. L'I’D. SERVICE DIVISION ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HWDA MOTOR CO.. LTD. RESERVE THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGAUON WHATEVER. N0 PART OF THIS PUBLICATION MAY BE REPRO- DUCED WITHOUT WRITI'EN PERMISSION. CONTENTS I. mrunss .................................. I I. I ENGINE. 1 I. 2 HIM/5.. I 2. SPECIFICATIONS AND momncss ..................................... 2 2. I SPECIFICATIONS... 2 2. 2 PERFORMANCES... I0 :I. ENGINE ................................................................ 20 a. ENGINE DisaImON ............ 3. rows: TRANSMISSIm SYSTEM. 3‘ ENGIBE REMOVAL.” ........... 3. ENGM NSTALLMION. 3. CYLINDER HEAD ..... F?~opp??wpnffl?ypn??opn??m~un— Cmvmcvion ........... . ........ Dlmly lelindor Hand Blockt. InspchLon and Repair ............. BMW , ‘ CYLINXR. Discs-unbly . . . lmpecllon ..... humbly ............ CAM CHAIN TENSIOf‘fl Constantly! ............. Dlmsamhly . . . Inspacvion. Raasslnbly. . CLUTCH ..... Consomclian ‘ . , Disassembly . . . Inspxlion. Remunbly . . OIL PUMP . . . . ConsnucIion. Dimbly . . . I‘é CONTENTS 4. 4. 3.0.0 papyzpnsn? n OFFSPOF? PPGZP 31 Qrwpfiw? FRAME .............. POP? GEAR SHIFT MECHANISM ............ CONIMHOII . . . DIM)! lnspocflon. I . Roomy” CRAFKSHAFT” Comlncllon. .. Dlsamnbly . Inspecflon. .. Roossmbly . . .. TRANSMISSION 0015"th . . . Dlmmmbly . lnspecticn . I . . Rmmbly .......................................................... 60 CRANKCASE I. Communion . ., Dimsuvhly . lrspocnon. Recmmbly” KICK STARTER AND GEAR INTERLOCK MECHANISM. POSl-TORQUE MECHANISM [CT 901 ....... . ..... Commotion ................................. Disastemhly . . . CAMTOR , I Cmmion ................ Fmficn of Each Cam" . Adusimenl ........ . ........ mm» (at Hm. Spud ..... Adlusmml Io: Immiatn Spud. Adiustmam for Slow Spoed.. Adiusling Ihe Fuel level ................................................ 71 STERING HANDlE .. lmpecflon “realm ladle)... . . My. ......................................................... 79 CONVENYS PDWPmPflPPmF>u90w>mPOP?MPDF?»POF>QPOW>N . IO REAR FORK AND CUSHION DAMPER . STEERlNG STEM .................................................... BO Comiruciion . H ‘ . 80 Discssembly . . a] lnspedion. ., 82 Rsassembly ............................. H 82 FRONT FORK. ‘ ‘ B3 Consiruciion , .. . 83 Disassembly ...................................................... Bl lnspedion. , . 88 Reasssmbly‘ ‘ B9 FUEL TANK . B9 Construciion .......................................... . 89 Disassembly . , 89 Inspection. . 90 Reassembly 91 FRAME BODV ......................................... . 9| Conshucqion , . . ‘ 9| Disassembly . . , , 9| Inspeciiofl .......................................................... 92 Reassembly ................................. . 92 SEAT . ‘ ‘ . . 92 Conshucfion‘ . 92 Disassembly ..................................................... 92 Inspection ......... . 93 Reosyembly ...... 93 BRAKE SYSTEM . . . 94 Consmlcvion .............................. 94 .94 97 H 97 . 97 Disassembly MUFFLER. Comm-mm Disassembly ......................... Inspecfion. . 97 Reussembly. . 97 AIR CLEANER ...................................................... 9B . 9a 9a Impedion... . 99 Reossembly ....................................................... 99 100 . 100 100 Consirucvion ................ Disassembly . A. Conslrwion. E. Disassembly . CONVENYS 6. 9 BRAKE SYSTEM .. _ l4: 6. 9 [XIVE CHAN. . . I“ 7. WIING DIAGRAM .................................................. ”5 8. SUPPliMENY 10 590110 .............................................. 153 9. SUPPLEMW‘I' Y0 CT9OK2~K6 ......................................... I” 10. SUPPLEMENT T0 CTWKB (77).. V I7] 1. FEATURES l . l ENGINE The englnes Used on lhe HONDA 90 series are basically ldenlical wiili lhs maior difference in iliul llie 590, CL 90. CL 90L and C0 90 are equipped wilh a mniully opened clutch and ilie C90 and CT90 havlna an autocratic clinch. A. Chain driven warhead eunlhufl The canshoii Is driven by a caesium lemlon chain. melts quiei opevniien and precise valve limim. Furlher, ii enables greater power wipul due lo mulldalllly of hl§ier opemlng RPM. I. OHV lid semi-spherical combustion chamber The overhead valve duigi provides amulet clr lnrdre Inio ihe cylinder and a uomequenl higher vuluiieivlc efilclmcv‘ The semisphericul combuslion climber assures a smooih llane propagation which Is luriher enhanced by the lncorpormion of a special swish area. C. Double oil l'llier The all system lncorporcles a the mew screen filler and a cenirilugal filler io supply the engine wllh a hidily clean oil. This minlmizes Ihe wear lo lhe wine components. reducing minimize and exiending ila lile ol ihe arable. 0. Clutch Rid“ eciiori clinch lever is employed on ihe 590, 0.90, €1.90 L and CD90, wlih auiomailc cluIch Installed on ihe C90 aid CI'90. E. Trcnunluien All M on consimi meshed lo provide smooih gear changes. The $90, Q90, CL 90L and CF90 have low [award speeds whereas the C90 has lhree speeds. Furlher, the CT90 is equipped wilh a pasi—ioiqu. mechanism Ior selecting Ilia low speed il/z redisciionl range. I . 2 FRAME A. Rigid lighrwelghi frame The im of lhe 590, 0.90, CL 90L md c090 are mode ol pissed slsel shes! cl monocoque design, Frame ol lhe C90 aid CT 90 ls a Mien ol pressed sieel sheel with a large diameier steel pipe suppening ihe sleeriro head. These desiyu alve rigid lighlwelghl frame of hidi strength. 5. Rear suspension Swing arm suspension ls provlded wllh u iwo siege cushion oil damper lo provide comicrluble riding under minus loodifu and road oundillons. C. From uusperulen Telescoping iype iron! (ushions are empluyed on lbs 5904 CL 90, Cl 90L and CT 90 models [from from serial No. OODOOIA). Bottom lid: types are used on Ihe C904 CD 90 and C790 models (lrom lrune serial No. lOOOOll. D. lreke Trailing leading lype no lode hides are used on both lhe iron! and rear wheels. The right hurdle lever epemies ihe lroni‘hrulre and lhe tight fool pedal opemles ihe rear flake. The CT 90 Is equipped in oddiiion wiili a leh hard lever lo operate lhe rew broke. 2. SPECIFICATIONS AND PERFORMANCES 2. I SPECIFICATIONS \\Wel Type I Molouydc Dulgnmbn Dir-mutant Overdl I-nuth Ovucll wldqh Ovuall leghv Whulbasc Min crowd chum: Wolgh! Waigm Empty Brdrlng dismnca Fool (:an CIIrrbmg ability S 90 CL 90, CL 90 L Honda 90 Honda 90 I,B90 mm LBEO m (74.47 In] (72.1 IN 650 mm BI D m (25.6] in) ISL? W 950 mm 1,050 m (38.6I In) (“.3 In! 1,195 mm I,200 mm “7.06 inl (47.2 Inl 145 run 160 m (5.71 In) I63 InI 86 5 kg 920 kg ”90.73 lbs! [202.9 lbs] Moan 7‘01" av 35 km/h 122,960" at 21.75 mile/hi 75 hull of no km/h ll 76 mile/U. 5‘ 9d. 2‘. 85mile/hl IB° Max. IBM or 50 km/h [47.6 II ® 3ImIIa/hl 80 bn/l at 40 km/h II 38 Nile/US. 9d. (9 25 mill/h] 20° 2.1 SKCIFICAVIN CD 90 Honda 90 (.795 mu (70.72 h) 6‘0 m (25.22 In] 955 m (37.63 In! Ll 62 run (45.39 in) 130mm (5.12M! Max. 6.75m 0' 35km”! (22.14" © 21.75mlle/h) sum/I u! 35km/h (l86miln/U.S. gal. @ 21.7mfle/m l9“ C90 Honda”) 1.830!!!" (72.10%! 640 m (25.22 in) 995 mm ‘ 39.20 lnl l.l90 mm (46.39 in] '(30mm (5.l2|nl 85.0 kg (1 87.00 lbs) Max. 6.9m a! 35 (rm/h (22.630) (2| .75 mile/M 80 km/l m 30 Ian/h (l 88 mile/U5. gal. (D 18.64 mile/11) .980m ‘ 1,133."... ‘ “6.51 in! ‘ I37mm C190 Honda 90 1.00011": (70.92 (N 650 «In (25.6] W (38.61 in) (5.40 in) SI .5 kg (l 79.30 lbs] Max. 5.5m at 30 km/h ((3 ('1 [l9 "Illa/h} 75 km]! a! 40 (rm/h (l 76 mile/U5. 90L i) 25 mile/h! High rmge 15° Low mugs 25° 0'90 (from F. No. DOOOOIA) Honda 90 ! .870 mm (73.6 in! 680 Inn (26.8 In) Low mm (4 l .0 Int (.2l 5 mm (47.9 In) I75 mm (6.9 it“ 9| kg (200 lbs) Max. 5.5m a! 30 km/(I (I8 M ((9 mile/III 75 Ital/I or 10 km/h (176 mill/U.S.ga1. ® 25 mile/h) High range 13° Low rungs 25° 4 1. SPECIFICA'IONS NO KHOIMANCES \Model Typo \\\ Corburolor No. and type Mumfoclurer Alr filler lype Mawfoclum Fuel lmk capacity Lubrlcalinn System leriwfing molbcd Type m Type oil filler luhrlcallon syxlem capacily PW20H (or UM20l-ll, I uch Kalil" Selki lMthmi Kogyol Dry filler element Tokyo Roki 7’ (5:32 545‘ 57‘) Pressure lype Trochoid type Screen and mlrlluwl filter 1.90 us. pr. 0'“ (1.55m. pl. S 90 CI. 90, CL 90 L l Mln. lumlru radim 1.950mm LBWmn [76.830 In) (74.4 In) Engin- NanlandModol ‘HondaS9OE mam: Typo fuel used 1 Gasoline Scum as Mr Typ- suglne Alr cooled 4 stuck. cycle Sam a: M! No. 01 cyllnder and Gammon! Slnglo cylinder, filled lorwud 75' Sun. a lo" Valve (3le Owl-sud valve Sam :3 Ion Tolul pislon dkplccsment 59.6 o: 89.6 0: (5.47 cu. In! (5.47 cu. in! BoroXSrroka 50X45mm 50X45.6mn ll.97Xl.77lnl (l.97)<345mm [17.90XH.03><13.59W (31.7Xll.2>(13.6inl Sam a: It" 24kg (52.5 b5) 24 kg (52.8 lbs) 25 kg (551w Sane as loll Sane a: I." Sam as In" Sane as In" Sam. as loll Sane es lo" 5cm 0! lo" Sane n: leh Pisvon valve M». I each PW ISHAI, I ooch Pislon valve type, I each Same as to" Koihin Seikl Kelhln Seiki Kolhln Sell Sane as Inf! Sam. as Iafl Sane as lefl Sam as MI Same as Ion Same as to" Sane as Ieh (5.0 U. 5. pI. (1.6 U. 5. m. (3.7 U. 5. p'. I 6U. 5. gal 7‘“ (12.3lmp. p1.) 5'51 ( 9.7 Imp. m.) ‘4“ (11.4 Imp. pl.) 6‘“ (I 3mm! ) Prawn Iype Pm Iypc Pleasure typo Sana as left Trochoid type Trocllold typo Trodxold mp Sam as (ch Sam cs (eh Same as lo" Sane as lel'r Sana as lefl (.9 U. 5. M. (.9 U. 5. pl. (.90 U. 5. F1. (.9 U. 5. pl. ”1 (1.6m pl.) 0'" (1.6 Imp. pf.) 0-“ (1.6m n. ) 0'“ (1.61m pr.) 5 2. srscmcmous AND mas M‘TYP'l s90 CL9o,cL9oL \ (i 7 lgnmon Sylhm Ignition Method Bowery lgnlrlon Sane as leh Type (gnillon Coil 5265 29700-l0l-0 ST 65 l 39700-1014) Mumfaclvrer Kokvson Donn f Nam Dense Kolmsun Denld , NMn Dem Type Spak Plug D—6 HW D-6 HS X 20 F5 Mmflaclurer NG< Spelt Plug Col, W. W Spuk . Nppon Dense Plug Co., Ltd. ! Ekflrlcal Synon- Ballery No. md type MA36A or 336-6, 1 each Sane us Iel’) Vol! and AH 6-6 6-6 Maillot»: Yuma Devil Sane a left Typo gamma 37000-0264)5 EG2I 37000-026- Mawlochnr Power Tranmlulon Syn-m Prlma'y reduction mlhod Reduelion ratio Clutch type Typo iranunision 690’ chance melhod Goa relic. Isl gear Gn ratio. 2nd 99a Goa who, 31:! get: Gear ralia. Alh 9w Sub minim Secondary rednellon molhod Reduclion rolio valna Synhm Sowing handle vumlng radius Steering handle Wldll‘l Caster Trdl Tlre. from Tim, (our Brake Sync-n Type bake, from Nippon Duso l Kokusm Dori! Gm 3.72 We! mulllple disc type Constant meshed seas [ell loo! operated relum type 254 l.53 1.09 0.86 Chain 3.2l 43° 620 mm (24,428 In] 65" 75mm (2.955inl 250-”! (4 PR) 250-18 (4 PR) Imomol nxpaxding shoe 1 Nippon Dense Kokmm D-nkl Sun- as (all 3.72 Sane a left Same as (en San. a: l-(I 2.54 1.6] 1.19 0.96 Sun. as loll 3.21 43° 770mm [30.3 ("I 64° 73 mm (2.87 In) 2.6046 M PR) 275-” (4 PR) Same as (an 2. I SPECIFICA'IONS co 90 c 90 c1 90 l Sun. as 1.11 5"“ ‘3 '°" Sun. a. 1.11 51' 7s 5. 79 Kalcwun Donki Kolrwnn Denkl 0—6 HS 1m x40 rs D“ ”W 0-8 H5 W 591* N990" NGK Spak P1149 Co.. lid. NG< 5pm Plow Co., Lid. Plug 00., lld.[ Demo 3100-5, 1.31. “7" ‘r ‘°°°" 337-5 A, 1m 5-5 “6 5—5.5 Sun. a: 1.11 5"" °‘ "" Sane as 1.11 370011—0550 Mippon Dense Sun. a Ml Sun. a la" Same as loll 3.72 3.72 3.72 5.“. a, 1.3. Autumn: war awhlplo Sam- as loll dsc :ennlfogd lype Sun as 1.11 5m as 1.11 5a... ... 1.11 5m. .3 1.“ Same us In" Sane us lull 2.54 2.530 2.535 14.1350 1.51 1.555 1.511 13.0013'1 1.19 1.000 1.190 1222211 0.95 0.9515 11.7390 1.000 11.35721 Sane as loll Sun: as Iell Sane as 1511 3.00 2.1157 3.000 43° 43" 45° 540 111111 125.22 inl 530 111111 124.522 1.1 515° 53° 535° 75 mm (2.955 1.11 75 mm (2.955 11.1 75 mm 12.9551 250-17 14 121 250-17 14m 250-17 150-17 149121 2.50-17 14 m 2.75—17 Sun. as 1511 Sun. as 1411 Sam 13 1511 CT 90 (from F. No. MONA) Sane as lelv Sun- “ lull Sana as lell Same as loll Sam as Iell Sam: us Isl! Sum a lull Sane as loft Sums m In" Sam :5 lull Sana as [all 3.722 Sane as lcll Sun as lell Sam- cs loll Sane os loll Sane as lefl Sam! as lull Sane as lell Sun: a: [all San as lull Same as Is" Same as I'll Sumo us lell Same as |ol1 2.7547 MFR] 2.75—17 (4 FRI Same as lell 2. SPECIFICATION Am rams \‘\~r~ “959'? "P" E s 90 c1. 90. CL 90 L Type hydra, rear Inlerml expanding shoes Sane as [all Melhod of applicmlon, Trout Right hand lover operated Sane es la“ Memod oi appflcmlon. rear Rig" loo! pedal operand Sane us left Superman Syllem Suspension mound. hem Telescopic type Telescopic lype Superstar method, rear Swing can type Sum- us let! Dunpeninu system. from Hydraulic Same 0: Ian Dampenivg eysiem. rear Hydraulic Same a! loft Frame Type Badtone type Same as Ian ngMlng Syflem Headlign lyp- 6-0l09 Mamflaclmev Slmley Electric. Kolto soledmsho Stanley Electric Hoodlid" roIing 6 V—25/25 W 6 V—25/25 W Twilight ruling 6 V—2 W 6 V—5 W Talllomp oowbinm'uon wilh License lighl Sane ox loll Slop light raring 6 V—6 W 6 V—17 W Tum signal type Moonellc. heath-g element Same as Ieh, Turn signal Ming 6 V—B W 6 V—18 W lmmmwnr Horn type Electric (lot type Sane a: left Manufacturer Mltaba Denial SWIM Typo W/odonmer W/odomeler Mcmfaclwer Nippon Seikt Reflex reflector lype RR 30 W/ralllmp RR 30 W/Iuillamp ManMocIurer Simley Eleclrk: Same us let» 2. I SPECIFICAYIO'G cu 9° c 9° '3 9° (1mm 7. 33000000!” Sano as loll Sane cs loll Sam as loll Same as loll Sam (3 loll Sana as loll Sane as loll Sam I: loll Sana as loll Sun: as loll Rinhl fool podol and loll Sumo as loll llmd lever opera/led Bolton! Ilnk lypo Sano as loll Bollom link lypo Telexopk: Typo Sun as loll Sane as loll Sana a: lull Same as loll Sun- as loll Sun- us loll Sane w loll Sumo us loll Soho as loll Sumo as loll Sano us loll Sane as loll Sana as loll Sana us loll Suns a: loll Sam 0: loll ASS-ll ASS-ll Sun as loft Slanley Eloclrlc Sana as loll Sumo as loll 6 V—25/25 W 6 V—25/25 W 6 V—25/25 W Same as loll 6 V—3 W 6 V—5 W Sun as loll Sanoosloll Sumousloll Sanoasloll Sunoosloll 6V—10W 6V—IOW 6V—l8w 6V—I7W Same as Ml Sum- a: loll 6V—lOW 6V—OW 6V—18W loplionl Sun as loll Sam on loll Sun- a: loll Sumo as loll Mllwba Solkl 0" Nippon Sana as loll Donso Mogulimlly drivun Same as loll Sumo o: loll Nihon Solki or Nippon Sumo as loll Dunno RR 30 W/lalllanp RR 30 W/laillmp Sam. 5 loll Sun. a lull 2.2 PERFORMANCES z. SPECIHCA‘IIONS AND PERFORMANCES MODEL 5 90 45 Stan oulpul m N o 2. 2 PERFORMANCES S90 PERFORMANCE CURVES Dvivmg speed (Km/n: S90 ENGINE PERFORMANCE P \. Torque xgm) .0 o- .0 u: ' 400 \ é Fuel cmsumplion .Gly'W‘HI \_I_I_I_J.__L___J_J 3 4 5 6 7 8 9 10.1. 10I Englne speed {R‘ P. M) Dyiving lame (Kg) MODEL CL ‘70 r: sun abut 7 2, 2 KIFOIMANCES CL90 PEFORMANCE CURVES on10‘ fl 8 S 40?. A x E I g ”E F'- E x5 .2 m 3 30.5 '5 .5 Dvivin Spud (Km M) CL 90 ENGINE PERFORMANCE CL 90 L ENGINE PERFORMANCE l. 'E.‘ .. , ~ . 75 A E i ,6: ' . s c v A ‘ a 5 g 1* E W N I! §§ I m A. — M §§ mg I” ‘ Elih- ID‘IM 03PM) ‘ ’ ”x“. "I. Eml- and (um) ruin-lumi- (a'm) hm- (nu-man) (tun) 2‘ MCIHCAYIONS Am PIIVORMANCFS MODEL CD 90 PS Shah uutpuk 2. 2 PERFORMANCES CD 90 PERFORMANCE CURVES l0X10‘ «kg :ngme speed RPM? u‘ 50 _ Driving speed LKm/Hv: CD 90 ENGINE PERFORMANCE . .0 .0 as u on Tovque{Kg-m) '0- § " Fuel consumption (GI/P8411) 6 7 0X10 Eulm spud (R.P.M) 8 Driving Iovce :Kg‘, I5 ‘ SPECIFK‘JYKONS AM.) PERIORMANCES MODEL C 90 PS7 Shah nuluul m 3 2. 1 PERFORMANCES C90 ENGINE PRFORMANCE 5 7 3 21min. Iplld (R.P.M) 9 C90 PERFORMANCE CURVES 5° . Dnvmg speed (Km/Hr) «)0 § (Gr/P541!) Fuel cmsumplion § ——I__n_._;_.___‘__. [OXID' I7 Driving (one (Kg) II 2‘ SPECIFICAHONS Am FEEfOEMANCKS MODEL CT 90 Prier Do CT 90 F. No. ”2550 Pall-fugue (F. No. 122551 and Iubnquon!) “aa “vs: , AA 5 2, 1 PERFORMANCES Poui-lorqu- (F. No. 00”” and wbuqunm) CT 90 ENGINE PERFORMANCE PS7 6 MA E, r 52 “1.1 ‘06 g E , E :1 ‘ A05 ; 2 ‘ a; m ‘ u. 4‘ n. a 4005 1 '3‘”; 3- \/I § ‘ _ .2003 a ' a 9x101 5 a i Emma med mm) C190 PERFORMANCE CURVES ---------- Indkui- um L rung. n and. mo , S Dmng mm (m 3. ENGINE Tool: Nmary for Dhuuunbly and Rows-ably >—==—-)— ‘T/ —— w —_ x5) ——_. ‘5) l I I — '1) (I) ‘E O O t a J) a} [0 m It 3) ® I] on n, I - m as a TOGS NSQSSMV m DISANNQLV AN) WWW 2| {D TOOL NO. DESCRIPTIONS 0702240001 Drive SIXOCkOI holder 07024-0H01 Clinch ovier holder 07036~0300| T-hundio box wrench, 161ml 07046~2l601 Valve guide driver 07047—04001 Valve guide turnover 07046432801 Valve guide driver 07008-0010] Valve glide leumer 0703i—2000I Valve Mm 07081—0010] Tappet odiusiing munch 07087—00l01 Tappu lock rm soda! Mandi 07024-03401 Clutch outer holder 07007—02801 Valve seal CUNM holds! 07003-0280I Inlet valve not wince seat umer 07004—0280] Exlnusl valve flu! suvioco seal cutie:- 07001—0280] Valve ml miter, 90 deg" 07005-0280i Inlet Valve intuit: seal cutter 07006-0280] Exhwsl valve Interior mi cultev 07032—0330l Piston ring mr 07057—0330l Oil seal guide 07038—0330i Ckndl disassembling & assembling lool 07011-2000I Dynamo roior puller 07033—03301 Piston bum MOM-0280] Timing Inspection cover ©3®8©®®®®©®®®®®O®®©®®®9 J. ENGINE HI. 3.1 mm clumsy um (:90. c1 90. c1 9n n ® Valn rock-v um G) AC. gun-mar role: (2) Cum man a; cum my (9 Spark Wu 0 Can rah a) Cylindu ma o3 1mm». min m. (9 Cthu 63 anuh- town: mun ® ram. 3 am am" dun m on. cm a m um- .plna. m ®Cn¢hahltuhmr own-mew as I ENGINE lXSCIIPTION 3. I ENGINE DESCRIPTION All oi "to models Incorpovale the O, H. C design driven from lhe lei! side of Ike engine by u lighi- weight endless chain, This provides the engine with high speed and higt. power ouipui due to the elimination oi the reciprocating movemenis and mechanical losses, and reduction In Wm. Furlher the chain Is always miniained in a camianl tension by the oil piessme and spring operated cinematic tensioner to mm quiet operation <7er precise valve timing at all speeds, The lubricaticn syslenl utilizes n trochoid lype oil pump driven though the com chain guide sproclei io provide lubrication under pressure to oil of lite primary moving pan: 0! the engine and in cmjunc- tion, a ween end a centrIIugal filter are incorporated in the system to assure Ihut only highiy purified oil is circulolad within me engine to minimize the pans wear and attributing to the extanded engine life. (Fig. 3‘ I) 3.2 POWE! TRANSMISSION SYSTEM The energy produced by lhe combustion of the tool mixiure in the cylinder is applied to the top of Ihe pislon. this is transmitted to connecting rod—b cioldi drive pluIB —> civtch outer—r friction disc -—>clulcl\ center—> primry drive gear—> primary driven gear—> iransmissian main slian —> main shaft gear —» comter shah gear —~» counter shall —» drive sprocket —> drive chain —> driven sprockel—> to the rear wheel. prev gressiveiy in succession. (Fig. 3. 2) 3. 3 ENGINE REMOVAL S 90, CL 90, CL 90 L, CD 90 I. Remove the step bar. 2. Remove lha muffler. 3‘ Remove rile Iail crankcase rear cover and lxt~ hook the drive chain Irom ihe sprockois (Fig. 3. 3) NOTE : Tia 3 piece 0’ who lo bolh ends of We chain to preveni lhe ends from being drawn Into me chain cases This will iaciliial‘e the work during engine Installulion. (s 90, ca 90) 23 Model cw rim 5.: lemming me drive (Min (D Drive chain 24 3, ENGINE 4‘ Disconneci Ibo clinch «his 6) from the clutch lever iii, (Fig. 3.4) 5. Discomoci Ibo air inler pipe av m cylinde! head and 0‘50 remove We high imsion cord lrom mo spark plug. 6. Remove ihe baiiavy cover and disconneci vhe baneiy lead from ihe baliery. Fig. 3.4 Discmmcling no ciuldu cable Q) Civlch cab). ® cum lover , 7 Unhook me bvuko pedal splingi Remove me nuts mourning Me engine (3 for 590, CL 90, CL90L. 2 for CD 90) and Mia roar engine under boin Pull Du) Ma Ma 10mm hex bolv, and ihe engine can be sepavated from me heme. (Fig, 3, 5) C 90, CT 90 1. Remove from cover (C 90), rumova mudguard (c190). Remove "is main We covar [CT 90 model horn home No. OUUOOIA) 2. Romvs me slap ban 3. Remove Ihc lofl crankcase rear cover and le- move "in chum io'ml chn i0 diacunnoci me dwo chain, NOYEx Tie a piece oi win) lo boih ends oi who chain Io pmvcni ihu ands from being dmwn inio mo Fig. 3.0 Run-ovlng m nun pipe chain case. This will {comma xho wotk dining 0) Ininl pip! (2) Hum mmiina WV engine insioiiaiion (C 90). 4. Ramove Me muffler. 5‘ Disconnect inn a}! inioy pipe oi lhe cylinder head. (Fig‘ 3.6) 6, Disconnect ma clocrricai loads 0! Inc con mums. 7. Remove in» high mien cord rm me spark plug a. Unhook ma bvako pedal spllng. 9. Remove lhe 2 engine rimming nuis and men pun oui iho your engine under boii and your engine hunger bolt. “m 3-7 Emir» exumbly (C90! 10. The engine can bu mrwvad. (Fla. 3. 7) ’ ,r-\ 3. n ENGINE INSTALLATION Generally, the engine installation is petlotmad in the reverse otdat of removal. I. Set the engine on a block and :llde ll under the lrame. Route the engine wire harness up into lho baltaty box whom the engine and harm, and lampotutily insert a sctewdtlvet a: a rod at appropriate dicmotot to suspnnd tho engine. 2. Insofl the engine mounting bolls from the lelt side. also replace the screwdriver and Install md torque lha rms. Hook the brake arm return spring on the lower mounting bolt. 3. Connect all oleclricul loads to the win! harness. 4. Connect the battery leads to the battery terminals, push the wire bundle w lnto lhu lop at the banmy box where it will not interlere with battery installation, lnstull buliery and chad to make sute that the wires cle not buittg pinched, 5, Route the battery vent ltbe through the floor of the battery compartment std rrnke sure that the Mae is not pinched er kinked. preventing ptoper venting. 6. Reconnect the clutch cable to the clutch lever. 7. Install the inlet pipe on the carburetor and bolt to the cylinder head. install the high tension cable hold down clip under lhe right inlet pipe mounting bolt. Make sure that the O ring is installed betwoon lho cylinder head and Inlet pipe. 8. lnslall lhe mufilef. 9. Loop the drive chain over the drive invade! and connecl the chain. The open end of the chain ioint clip must be Installed facing in the opposite direction of the chain movement. (Fig. 3. B) )0. install the chain cusp. the tear crankcase cover and the loctresl bar, 11. Adiust the chain with the chain adluster nuts on both sides of the tear whacl so that there is u slack of 1~2 cm l0.4~0.5inl when checked with fngon on the bottom leap at mid- poinl belween the sprockols. (Fig. 3.9) 3, l ENG"! lM'ALlMION 25 [t / “W M w. @—u H rt. 3.: Swing dltacllon oi chuln cllp f?) Dmttcn at relation (2) Dvlvl etrain rs) Chnln tom (4) Chnln tom rlw plan (5) Chnln lulu! cup fig. my Adruxllng rt. chum 2‘ 3, Hue 3.Io Cylindu md f "iv a. ll Squhh mu figr 3. I2 Removing Mo swim minnlbly (g Sluiw mwnbly Fig. all: Moving IM rotor ® lotnr ® Rover wlar ENGINE 3. 5 CVLINDER HEAD A. Construction The cylinder head is made oi lighiweigm cast aluminum alloy lar good heat dissipciion and in. corpovuies the camshaft, cum sprocket, voivesl valve rocker arms. spark advancer and breaker assemblyi The Overhead camshah is driven by the cum chain through the cam sprockel, Conbvsllon chamber is of semi spherical design for belier cooling and increased conbuslion efficiency. (Fin. 3. l0) (Squlsh Ann) m: is an area provided berween Ibo pislon md cylinder head to further cowpress port of the fuel air mixture at the end of the corrpression slroka Io creme 0 Imbalance 0' lhe main luel mixture. The swiril'ng he! mixture is direclad toward the spark plug where it is igliiod. The flan» propogo~ tion is uccelemtedi allowing the leaner than non-cl fool olr ratio or the slower burning iuel mixlure to bum smoothly, iuther, decreasing me lendeocy (or knocking, (Fla 3.1!) a. Dimuembly (Cylinder Head Block) L Remove lhu poinl cover and than the ion crankcase covav. CAUTIONx Oil my flow on! when removing the left crankcase cover. 2. Remove lira stator ossenbly (D. (Fig. 3.12) 34 Remove Ihe rolor in Using a dynuma rolor puller l2] (Tool No. 0701 l rzoool ). (Fig. 3. l3] CAUTION: When removing the rotor, cwlron no! lo apply excessive (nice so as to bond the cronkxhoit. ’\ a. 5 CVLIWEI HEAD p 4. Remove the locker arm side cover, 5‘ Remove l‘le comm? breaker 0530le [V end disconnect the loud wuo J, (Fly. 3. H) 6, Remove lho spank advance: by lemovlng lhe hex bell and lemme the 3 «5‘2 dowel pl". 7, Remove lho pom! base ll by lakmg of! lhe lhveo mounlmg screws. (Fig. 3.15) 8. Revels ma crankshuh go lhal woodmll key T7 is aligned wilh the 3x 5.2 dowel pin hole in the cumshull and lhen lemon: Ihe camsmll by unscrewing (me two balls. (Fig. 3. l6) CAUTION: Pcrfmm llvc cmlmn ulymlrluy ulld assent-M mm m cyllndor and hell ms llghlened. 9. Remove me cylindav head cover md me Cyllrldei head. ll me bond l5 llgm. lap avomd me punlng mince ol lbe cylmer head ligllly wilh a sell loco hummer. l0. Dlsoswmbla lbs valves uslng a valve [illev ll) 0 lToaI No. 07031 2000M. [Fig‘ 3.17) fig. 3, IA [alloying m. cmlncl byoulu mummy (T; Coma hmolu numm Hal 5. Is Romov'mq m. po‘lnl bus. Fig. 3. u Rumovlng mo cumshlfll (ll wmlun Imy l’?‘ Dow-l pm ml. Fin. 3. l7 nmumllmg m valve! (2) had wile (D Pm base (l) Vulvo mm 27 Hg. 3. II Checking :ylmdev head wapagn ® Cylindm ma (2) Bluing or m: loud m. 3.19 hpcivmg wupopl cylind-r me (D cylmw ma (2) send pm. my 120 Gatling in. mm was Glfimnmr (D Cyhndu mu Sr ENGINE cl Inspeuian and Repair The cylinder head m is Oxposed lo lhe high pressure md lomperulure resulring from the combos» iion of ihe fuel mixmm: (when when lhe cylinder head is unevenly lovqued ivmay develop cracks or wavpcge end Will be me cause oi delectivu soalmg between we head and me cylinder and resuli in gas leak air sucking, will. consequent" drop in com pression. The wurpugo of Iho cylinder head does nor develop suddenly md i: may be overlooked, lham‘ fore, cuuiion should be exercised during reassembly since the uneven iorquing of lha cylinder head is u very common (null. To Inspect for wurpage or lhe cylinder hood T. apply a lhin coal at bluing ar red lead l2? on a surface pkzla and work mo miing surioco of the cylinder head on lire sullcce plum; mo warpcge can be deierminod by me lronsfer 0! mo bluing on '0 mo cylinder hem (Fig. 3.19) To correct me wuvpage, lap ma cylinder head on me sulloce plain wuh a £200 smdpwor, finally Finish by using a 3400 sudpcpor and men lnspecr again win the bluing. (Fig. 1m I. Inspect mo :ovrbuslion chamber, inlet and exhaust pom [or cracks. 2‘ Cylinder Mod oombuslion chanbot. ham 1 Standard yulr. Hand vol in. iii—.1“ n lwiln llmym pi“ nmnllra- ll.ova~i i72cu.ln) 3. Inspect lhe vulva wide and valve slam. Vain danmmv ‘ S'unduid mlw ‘ “Yr?” 1‘ m u ail-.0 03 mm om mm ‘ la DUU4~QUOIZWV :0 002m: g m ' oaa~o usmn DJ «in ‘ “‘ lCI‘DUlZNO mm am m 0032 lnl Cher): Iha valve guide dicmelev cl lhe top corner and bollom in bari- ihe X and Y axes, using a precision cylindol gauge 6). Chock the valve slam wllh a niamiev. (Fla. 3.20) 4. lnspsci vulva glide Volw wido. lnlu . Swimm- and uhumv 5mm" m'“ llmn i . i I00055~l 0.065 _ OW" ”m' i lu.3957~0,3ws ini o,un~n ass |mellelln 23:51:5‘: m. 3.35 Nan-ulna mm" Ind damn ( ‘ ' ' a) c-nm O Mummy 54 3, ENGINE L Rucku- mm (Fig. 3.36) ll-m Slvdms a: u I 5.. mm. Mm ‘ ‘ Nlp‘url l' Dir © Mu. 1“l'l10l ¥ a: IA nonml sum um Inuu~locl§ Roman W cm -\1.‘lv37~u:lvn .nl lal IO‘IDIM r.» \4 Ha. :lu mm am 8) Sllputt [no <9 Small hm ‘f‘ ‘ w ‘1 5, Rocker elm man (Flg. 3.37) Ilrm ‘ S'u'uimdwlw ‘5. mm V VI'I~9 96] hm"! ll v- 5'"'" ‘1“ m Jm~n mum Mm m :mu Shall Mia—0.013 nylon ll om claw-c. m.nous~o mu! m: 0 ml :0 coal all M nu. 3.37 tau. um Ihull A D‘ Rcunambly I. Apply ouglm oil Io fill: valve mm below assembly inlo um cylinder how. 2. Assamblu lockol mm at! locker am shall lo the cylinder hand md hula“ rodmr arm side cover. 3‘ Inslnll lhl cyllndm hood. (Fly. 3.38) NOTE I Exorcisa can) to male sulo lhul Ike cyllm hood gasket cyl‘mdol slud pastel md cum chum guskol ls lrula|lod plapcvlv lo plavem all look; 7:; all. Aumllllrg ma (yh'lduv Mod {1) Cyllm Md ll) Cum mom: L5) Cm emu. A 4. lnslcll lho cylinder head cover and llghlou lhu mls diagonally and mllovmly m 150~200kg~cm (H.5~18.l lb"). lupmpar lclqving WlU cause all leak. (Flo. 3.39) m. a.” law. name. 0! cvlllldlv ma JJ CVLINDER 53 5. Position mo :rmkxhull 10 mm iiie woodmfi key ii i: on we cylinder (Miami‘s and in ma d-iociimol Me cyimdm hood Nign inc ”0” "mi 1‘ m the cam spiockni in tin index mail: on iha cy-indm hood (iim sprodvi iroumrg boli halos wnl ha in iino wiiii i“) cylinder canveilino) aid iron :cmcci me cum ciiuin _.,_ (Fig, 3. 40) (v. Siido Hm cumshall ‘l inln Hm cylindov hood iimigii me spuxlm! wiih Mia pin hole lowurd Ihn head com. Ina valve aid lhn pision me in 1h: iop-dood :misr position of Ihu mission shake. lFlu. 14]) 7. Amrroia 1}» pain! bas- iii on live commi- miionsiun using on oil soul guide iool flool No. 07057 0330“. (Fla. 1‘2) Dam}! in iiio oii mi may main ii Iooi i, noi used. wwiimg in oil limit. A, lnyiull II»: 3 “5.2 gum pln rnd assumio mo mi udvuntcr. 9, Asmmble I'm cmiacr mum umnbiy um! cmmi «no imam. io, Ammbio Iho A, C. gunovuior on ma cronhhnin ii. venom. lqpcl clwrmcu adjualmaril and im'» Hon liming. 12. lmiali Iiin poini com and mo Iah clunkcaso (Oval. 3. 6 CYLINDER A. Cannrucllon m cylirdni is made cl 59% u. (as! iloll, Tm imido cm» mu. unlo- a v. on g; mum. n! mg '9 (mm plan b ”won 64;: #4, on» prac- I cum Ipmu g) Chum cum 1;. Mm mu mm N am. dam: w.” cu lam hack M '6 Ohlev ‘6. wlvid‘ is usxumblod vc Iha ddva plum mvough Iho clmch swing :I. n apomlod by 510p ping on me gem change podul. av mapping on m. gem chum): pedal. me clulch com plate 8' is ucmred. comm) the plus- suvu lo be upphod against the mm: 0qu and diwngug‘mg Illa clutch, sza IN change pedal is diuocdy connected lo Iha clulch can dam IM :Mch disengage: beiom Vhe gaur change 15 afiecved. mung gear changing Io be ”Nam smooihly bolh up and down wimouv difficuhy‘ a. Disnmmhly I. Remove the clutch cover. 2. Ram ma Iigh! crunkcusa cover. 3. Ram :91- cknch Mar cover. (Fla. 3.65) 5’ Clutch mm am: finial «3 Clara Nln um. 02‘ .5 m um: lan M woo NI! mm»; '10 We. [Ill-v an on mm mm uy cm lhrw‘ I). am Mm um. '56 mm lmp rm] :‘L leu Im. Ip‘ng Q C‘ulu» ‘Ivlr hmmlw KM mun cum :wu © Chm ml- mm 5) aura m1- 4‘ J. 71.. J.“ Roaming m clvldi tummy (D Chum cm. a) It... last m 1' 1pm (1) 16m lock M (D Child Mu hold" 3.0 Dmmumhly mu mm (I) cum ammbw nod mumhhrq low Q) Clvlch My m. a.“ lmpodldg IN chm mm 1]) Swing mI-r ® Sumo (NGINE 4, Un‘ock lhe Yémm lack washer and unscrew who Iémm \ock nu! m, yhv :Mch assembly 1!" can bu removed u) a mm. (Fig 3.66) Use IN clutch (Mar holoev 3‘ IToo: No‘ 07024 ‘ 0! ID!) to lucid Iha slum: and vemovo the lock ml with ”m Iém box wvench 2, float No 07056—0300l L 5, 1M wmk 0| dlmsso'nblmu Ibo :Mch ammbly our! be manned by we use cl special Iool Ll (Tool No. 07038 0300” (Fig. 3.67) NOVE- When uxlnu mo mom] loci, avoid the drlvo pIOVO‘ dam snrlng rarmm olncrwlsu ma duvo piqm mm! bu mmvcsmb. C. lnlpullon l. Clulch swing (Flu. 3.68) —Inm w'mhh “rm ‘ M'w‘iml Vuhm hm" 5” m. M M“ «magnum-4 Cl 90 Mann \' ”5M m‘ ”0231"“ mm 20.1L-22 mu m IMM CD V0 7": 00 ”5153—15343 lb! av a we w "M 7, " lopkxyzllounduv mm M,» I ‘: 0mm u MIA-m cno noun 1.; m 15m... \ ”"W'l m~71v4um cm In} ‘ NOI'Ex Use coil aptinq mater mm No. WIM- 99901) (0: twin; Ihe vulva sauna unslom 3.5 CLUrcH ‘7 2. Mom disc and clulch plum (rag. 3.69) ncm 5mm“: "um. I Sputum!» mm mun-my 7N~2Vm 24m dlc <0l|07~0 H“ M HHNUW I-whvoh BY 1 VJ~7 Dr' mm f'F‘l‘lllgé‘LJWb' mm plolo .0 OMD~D (ML! m lD 073 VI Wapuua c“ 0 2mm 0 5 mm ywnlu ’0 uO/V ml ‘D (”76 -N Clulch ouluv m1 duve plale o: cluith plum. Hm sumac val-J Sam-ow. mu name-n mm. a! m. mm. plum °'2 ‘°'°“‘ ’"‘ 0.7 10,036 m mum . laplnrl 44 cut mum on: 0" '0 onn "" n 7 to nab m‘ 1. Clurch comm fluids (Fly. 3. 70) m- S‘cnmud whm ' sum-mm. hm nuns-acuw‘ mm. H aw" ""“’ ”W" many-.0 anlvmi a us In ueu an Cmnmnh m ‘ emu-am. ‘ 5. anmy dnvo on: (Fig. 17]] um. [ f-Immud ml». ‘ Souluublu mm uou~2o.u2m mum. u mm ""‘d' 4““ mms~a m 24.»: mm m: RnPurx »l m“: u.” mm (mm amm.[ I33A~13 95m FX'. 3.» II-Ipocvlrg m chm you (D Chm plnll @ om flavo- Ii'. 1.70 Clmcn cum wldv nclou 3 mm Iro,un~o.ssn4m luau» D. Roanembiy I. mm "m :fulzh ouvor. month mu clutch 5pm, dylvn plum. hicncn diac and clulch plums. and mm comm: ma drive plum m accordmca wirh lbc procodmu In secfion 8—54 and Inslall [he sax ring: also Ins!!!" clutch «new 5pvlng. 2. Assemble lhs dvive 99a, clmch camar was logeiher mm tho cluxch umb‘y m the crank shah. Torque the lock nu! Ia 360~450 kgxm [5£~M lbl. "I NOTE 1 The Vock Washev ID nus! be locked by hem ding the rub char Iorquiug the NI: ll rho dds :2! me nu! does nor ahgn wim ihs tab, llghmn m nm fume: vo pelmil locking. do not loom. (Hg. 3. 72) 3. Assemble me cluvdl 009m covor. 4. Install my righv cvunkcuse covet. 5, 1mm“ the clutch cove: tom-r wivh the clutch um: In! all quid; (ms 4 mm} fig. 3.“ 'v-my 4m gm Fla. 3.71 and up m M on lock «my (2) Lock um II J. ENGINE 3.9 Oll. PUMP W1 I\ fl fly. 3.73 How a! Murmur. an (D Omhhull :9 mm mm- (a 7mm. mm" (a m. cm :1) WI 0 a. a» 5.9 0H PUMP A. Communion m Honda 90:: movozcycla aqEna airplay: a 99m lype on pom lo: Ihe eaflier models and lrcchold *ypu iar the lam models m Varnish on under pressua to an moving pom V0 pvevant seizvva and minlm'z- wear. The OAI whim has been dmwvl w horn the sunw is passed though "as swim md is div-med in Iwo directions. Om min: "1. oil is sum ”Hugh the monk mung“) and In Ihe ltarwnisslon Mara ”a coup!) nan: pmlolvhnnhmh®mdfhcmhr Aha" @ m Mal-mold. Th9 9M mun: an all I: piped much du- W in who vlw eaten» and Ibo oar-tame cave: when 1! is 1mm: blanched so mu! one of me mule lubricate: lb: cronkshdt and camper-on! polls. md the olhet is tooled lo the hollow m we musk)“ whm ma muvirg puns mm «m cylindu had such as the rodrar arm (A). camshafl ‘EJ. md llbriams th- cum chum @ an its way back 10 tho sump, The moving pans smh us gears, beatings Mich an m Mylar-d by film an lubricated by all splash and way. (Fig. 3.73) I. Dlununlsly l. Emu tho clutch «us-«Hy a a uni! In accor- deI will! 3:?va 3. ER 2. Thu 011 paw cm b0 vomovud by mmwinfi Ibo Ihm 6mm mm (D and nodal Max ball (3). (Mg. 3.74) NOTE x All angina- uhnqwnl lo lh ham rmlbnr shown below on equipped wilh a single place dam aankoull cont. F. No. S 90-674103 CL 90-] 200! 5 C 201-1660“ (CD 9DI n.. nu amen m (Dar-noun“: (1)59th m 5.1. Mg. 1.1" magic on m bill m In»: ‘1) 590cm nu hon 4° "j. 5. 75 A Q) "I. 3. 7! I 3, ENGINE 3. The mml ol 1h: lwo 5mm «new: will d1» assemble the all gimp. (Flu. 3.75) C. IIIIPKNM 1. The normal equally ol "IQ oil puma Is 1200:: I73.22cuinl/mimnc Q!) 4000mm; If lhe mlly loll; balow I000m|61,02culnl, Ihom is o dul- gav cl duvoloplng will: snlzlxe. "melon, llle pom: should bu "paired ov veplmod. Urodzoid pump; HOOcc $5.43 cu lnl/mln Q) 8000 rpm] 2. Clourunm: cl ovum-m puns Gear Typo "Ill standard VIII“! I 50"“. UM" Ewlul |' MO! 0.09.91” 5‘" "‘ "°"“"' vonozuwmu In! Hi “50"“, [LDNO~0,I u ROPIIBI II M- lumswown w ° 3° Gum bncllrnh . m In 15ml Tmlnld Typo ll-m ‘ Slanduld m. DloT~Dlol 0'" ‘° ‘°“"'“ lagoon-vow”: rum—rm" ' n.l~0lll m WV © .. “ M". l moose mom: fan-0N- mm 109‘“. ll on: CI I2 mm" In) mum ll my 0‘! “MID" lnl D. Inlmbly l. Amnble If. all m and lnsloll on Io "l. rlalll :rmkm. 2. Illsldl lho clmch My and Ill. dull awh- cosI cm In accordance wllll proud»- ou- Ila-d h mum 3. m ' 1m GGAI SHIN mm 3. l0 GEAR SHIFT MECNANISM A. Conmvcflon m gear mm '0“: z: moved Imoully by IN rovary mvmnv of mo pat sum o'mm. Wham lhn goo: shin pedal is dopveswd, Illa gou- mm :pfirdu, Imam rho may shill um, coma: the shit: dnm Io mom oilhnv nu ma clockwise or com"! clockwlw dnoclicn, depending upon Wham-r m- lorwavd o: Fig. l" 5w mm M'mnnhm G Gun charg- mini (2 Gto- mm windi- ® 5001 shlll an WI lD'hfl @ cw mm - 69 6-0 mm mm var-w plan 6) Goa mm mm: M (D an mm M (i) Guy mm an. 5) 5, :. ENGINE rear of ma pub! is doprassvd. Th dill! leak: on Mad cm "in shlll dual and guid-d In H: Um: mam! by me common the surface cl rho :hilr m inla which we lurk guide: pins are immlod. Romllou a! lbs dmm slums lhe forks lo lho 139mm loll whlch in mm pale-ms ll» gear shilling. A goo: shin relun suing mums ma goar dumps pedal to I): will pmillm allay such gear cw sucks. (Fig. 3.76) a. Dimsemhly ii..:.7r [moniv‘lwlhf‘rmy Mme”: I. Ramova the clulcll assembly in mandates ® mm“: m wivh action Ma 8. 2 Roam. Ilw primary drivcn gear (D by remo- ving the 20m clrcl'p. (Fla. 3. 77) 3. Removn lho will can slower, Pull on! no goar shin Ipmdla mm the and cl lhn shall mm «Wyn; lbs shm drvm hold in vho dxroclion ol wrow. (Fig. 3. 78) C. lupuvlon I. Impacl mo poor shill spmdls. gear slulv am and near shill lurks lor MS: or bend. 2. Imp-cl me your still dvum and wide pin for .. 0mm. wear. (- K Fig. a." naming m. m mm ma. 3. Check me spring lo: bracing- and ptopor Ian- 0 Goa: .m: u in D. Instantly I. Assemble Iho mar shill splndlo In Ilw rovnm otdev ol Illa soquance described in Illa dimmin- bly secllm 3 ohm. Mm manly. ml. sum mm m: opemllon is preps:- and fill” mo ma ma INN mum sprlng pln is not born. 2. Install 1h shill chum flapper G) and lhovl nmblo 0M drlvan new. (Flo. 3.79) 3. lmvoll the chuck mi! and the vial“ crankcmo fl com ln madam with ”cum 3.80. m. an Ann-Ming man a... um (1) am nun my»: a: sum tu- mpp- plan J, H GAMSNA" J, I I CRANKSHAFT A. Conflmfluu 1m crmkahah i; consmmod oi hrgh strength calbon sync! and vagmlm: with ma connocling :01, convcv's rho rcclpvocuh'ng rumba 0! mo pinion vo m: voluvy mum and. In addulon. poz‘uvms Ibo fumvion a! Iho flywheel by uhsochmg Mu: 0-mon- ling Xorquu. The nghl 0rd \olr crmkshuh ccmpenanbs on: press fined Io Ihu nickul chrome mulybdemm cmnk pin wivh tho conmcliw rod assembled. The liming splodel which drives Iha cum chum is shlmk fined In tho 19h crankshaft. Ccunlrshuh 05mm is 5.5311th m we painls by know My mu beatngs. Tho vighl :vmkcosu Incorpolulns a comet oil passage Ihrough which ml undo: pressure passes 9c: Vhe cmripin Io lubricate ma large and 0! ma con- nechng rod (Fig, 3.30) a. Dimsemhly l. Removu Vhe :Mch assembly in oczovdmcu wivh BB and ”I9 gear 5M) sc‘ndie in exudate with 10.5. 2. Remove lhe lei! Umkcme. 3. Remove Ibo cvlindm had in occotdanco wilh 5.8 W Iho cylinder :n accondmm will» 6.8. 4. Remove me 6 A I6 hux ban and wpcralu "In Mr Umlccss. The cronkshafl and immissim wlll be com- mcvely expound. 3. Thu cmnkshnfl assorrbly Ix" can be mmovod [mm me lvh czmkcaso. .E‘ (Fig. 3.3!) C. Inspection I. amen me Ciur‘ksmfl 'L on V blocks ‘4' m bolh bearings and measms the amount of man. (Fig. 3. 87) 1mm... m. 3:?“ My mm o m 5 Ewluc' u w.) IMO m ' 9'!" 35m u .379 m ““7"“ "“ 0.1mm): m 10ml 7 , 'W by» mm; DOIS 1.94m u Nob I“. G1 10 no“ h) 011-! um ”377m ' mom: w m. a. In Gunman Fin. 3." Emu-g Vh- ambit“! (D Clmhlah 6) t. annual. Hg, 3." Mwmng comm: avg‘mm | Cmniiuh a] Dial pug: g» Y block 51 SA 3, ENGINE 7. The claalunco In mu boom-g is measured by hing lha crunlzllull w. (calm: and movlrlg ms Loam, ill llc mlul u-vl lullml dlrafillm (Fig. 3.83) lm— 9an ma. [mm m. Iv- A. al a l.’l~n m .m .l mm c mm. ‘m (allwa! r ll mm; lrl l (Innlllmn llxlllll llmlnne ll om mml -a :l ln~nl‘,ll4 .ll ll «ls lunuyml \Nhan 1h. :lnuranco ln 'Ixo Oluul Jllocllorl HI. 3." max-mg am: Ll...”- ri) Cranium" , . , . l?) mam: WW. sldo re 51:50 when engine I: “1"!an and ploduca (I) v bled: undonlrublo misus as wall as omm‘ng unevan wool lo ll-a cyllrldor, plslnn and lhn llmm 9w. ll wlll also skylon Illa Illa of lhe :Iulch. ll lhu clemmco ls loo small. il will cum 0 decrees: ln mo power oulpul md :homm lho u m “I,“ Mn nl lhu clumhull. «Lilian 0.55244" 3. Connecting rod wul. and bow, (Fla. 3.84) Slundulu vullln l4 0l2'lfl 078 (0.55l [-0.5573 lrll Sorvlconhln Ilml: Eoplnca ll oval 14.05 30.551“ lnl bocnms oxcosslvo, lln :lurhllull wil| move hem fig. 3. u Com-«mo ma D. Ranuembly l. Assemble ll‘o clumzmll mammlv Inlo me lo” Cinnkcnw. 2 Asganmle mo nJ'll cumcuea ll m rm lo" uurlkmau. l' (Fig. 3.85) Cannon» rm ml lager lo mml lm lwo Lluwul pm. a (Fig. 3. as) 3. lnzlnl ma cam mull- gmua sp-ockm. 4. Anne/'lbfo Cyl-lldcr :u Ma omlcusn n (12:01- dance wnr semen 3,60. and me cylinuav ‘mud and cover .n accmozvlce wllh aocllon 3.50. (0 a. who“ 5. Assemble mo gear slllll spindle l" uccovdanca (I) L. cur-lame wlm socliul SJOD. Assemble lhu dumb and @ Dowtl an»: Inn; lhe cmkcaso and inslull me (199" Cmnlcuse cove: ln accctdmca will: mllon 3 6D. 3. 12 TRANSMISSION A. Connmcoion The vunmiaim mca'wos lbw vmulv power ham "v crankmn and through a mic: cl gum. changes u lo who das rod speed on! Ihon umsmns ix Io mu mm. (mm spam :0 mm: m roar wheel. the: Ivmzmlsaicn on ma 590, (190. (190 L. CD 90 and C190 Pas bur womb. C V0 has mm speeds. NI Mo gems om canslurd mom, assuring smooth goo: chemo. The low ”1'on Ivunsmission on the c190 is «nipped wllh o sub-hummissiun which has a low spud mm;- ulacmbimy, m socllon 3. 15. TM uimy roduchon mllo Yo: ‘20 cc: 1777. (Fig. 3.56) l. Opevunm (590, CL 90, CL 90 L, CD90 C7 90D Lew. (Fig. 3.53) My pawn! 1va the crmkshuh I; nmsminod Ihvough Ihu duck ID lho sp‘Jnn fixed dnvou gear on OM lrmsmiuim muin shah. 1‘ Tm rowor from rm lrtms'msum nun mun u nummlr'od Pom ma mm :‘nfl era 9m: m r'un henly mmlmg (comm :mh Jaw gm: « However, Ira ccm'm mu sorc-nd gm! ‘n Mm. is sphno-J In W.- Lower 211'! and is nmau 09.11"“ mg m gay ‘4 by me 5me lurk and .3 mm by mean 0! a dog, (ammo on Wegml um! wnh the cowwshan re Vransml :‘ne dmirg (arcs in the dlive spcockar mounkud on me Me and of [he counts: shah. I. I: "ANWHSStON 53 (D (2) My 3.“ Imam. on: may. mnm (I) Dunn gm (1) pm 9.“. 10 my ‘II 25 12 ‘19 22 mg; ”as "9. 3.17 Nunbur a! gear ml». I )lmflcml c090 m. a. u m. W (1) Immwsslon ”mm (3} ton am a) Yrunumnlon :wnlumlu Q) Cwmouhah low gm G) Cmmmnu ascend glar 3‘ a, ENGINE Socond: [Fiq‘ 3,99) ihr: mm cm!» Wt (law . Much .». uulmo gm [mac 1: Mn mu— . l I 5 mated by lhc 5hr“ luv: m ‘06 w»: mo 5am"! gm: 3 I'w mmm ‘Jn 09 powa' 1mm ‘he mu :Hull 10 "o comm :hah x by o? 0 no; mus pmmvfirx; mu mum "Im'mn m.» mum mm m u gout win We whnud v Mme la Iqu W: cmn'ov mnh znmnn (w, ”Mm Fig. I.” Snead 90m @ [vanadium m‘nlbah (3‘, Mammal! mcewd M: (n; Maqull mm m. a; vavnlulon comm-mm“ G) Com-mum. mmd mm mm: (Fig, 3.90) Th9 poww [mm m: lionzmlcnmn mn‘m won 1‘ u honxmmod 10 Inc LOMHOI shah mm 9mm by momma w‘m mo 1mm new I» J 90m 1' , Ho counlm She"? Wort! goat 1!: which 4: spin: sldn flnod I momd by IM mm Ind to Lock mm lhu va vofiuhng Ihud sou! l‘ by mom 0' a dog, rm; coma-J me cwru» man W In rotme and m vum duvns In: weaken r:., 3.0!: mm qtuv zi‘ Ivanmwmn nml'lslah (i Mmmcn mm pm < Maxim-Jinn (cum-"Ml! a) Chum-um” mm com Cowl-"MN Locond mu: Tap: [Fiq‘ 3‘91) H's mm shun mm gem w [5 mm by when m: ‘:~vk m lock war the [we roluling tap your " by manna o! :1 mg, was pavmmmg In: nun» msslon o! powm {1011 IN: mom shah "n to ma comm shall by moshhg the NM shn‘I mp gum 5.: wnh vha med cmnlur uuh to am: mo spmckm m. 3.91 lop gm. <1) hunumuwon ”mm. (2) Mammah lop new a) Amwan Wrd alul @ nun-mm ‘amlulhoh (9 van and: 3, l1 "ANSMISSION Neutral: (Fig. 3.92) Thu gears am no! Ioclmrt The main shah low 99w 2D is mashed wim 9h: comm shun low gear (33 and the mum shah rhird 96m in i: mashed mm counter shah mild gear ‘1‘. however. Iha counter shah gears more haelv and thatch"! no powor is delivered In 1h: drive spvxkcl. 2. Opmurim (C 90) Low: (Fly. 3493) Thu powur from Ibo crunkshcfr ls immmod Ihreugh the clmch lo the spline fixed Ewen gnu (D on the rmlssion min 55us C2) The power hum Ibo "mission main she“ I: namminad lrorn ma main shalt driven gear to who freely oounlor shah low gaar (3‘. However. the scum shah mend your CD which Is splined lo we comm shah and I: moved against me low gas: by the 55m lork and Is locked by means of a dog, 19mins m Inlagrul uni! wi1h IN Ccm'er shall (5.) lo )runmlil lhe driv'ng (arc: m the drive sprockm (a) moaned on me lo" and of mo counter ML Snendr (Fla. 3.94) Tn: main shah lqa m7 Ci) ls moved by me shill led: to lock with mu (m rolulim second new (3) by man 0' a dog. 1h); pumming 1h. trumission cl power from rho m‘n shall (D to rho mumer MI (0 by making me main shah mend gear (2: wnh the cow!" wrnlxm gear -'s lo drive me uproar-L Top: (Ha. 3.95) The comm ihafl mood your CD ix moved by »- shlfl 'ork to m m. up gear @by means of a dear 1h powor As unnamed from me min :hull lop gear ('51 and to tho oomuor shah mp your ® md Io m. drlvu sprockel. Hg. 3. 92 N'unnl Hz. a. u up 9». a J ENGINE I. Dilouombly l. Rmvu Elm cylinder Mod In accovdonco whh snuim 3. 5 8. 2. Remove cylmdev m otcovdmo wFFh mum 3.6 B, 3. Ram-m1?» cm». assembly In accountants wim wch'cn 3.8 8. 4. Remove who gear L'II'V lovk m uncovdunco w-m :achon 3.10 E. 5. Sopdmvn Hm ngm and Ioh c-un‘tcmo m accor- dance wilh melon 1H3, ma Ivmsmksim compo- (2) hum-um" mum mm mm M“ I” ”"WM‘ ,5. ”MM” “In,“ mm 6. Pull on! the luck s-quer guild‘s. ’1‘ (‘4‘; Cam mu aw (Fig. 3.96) Hg. 3.“ Emma m. .m nun-v w mile :1, Kick “an" 10'de 7. Remove mo wuin shah "i , tom’s! shah cm the gnu: :hi‘l drum 4‘ from the Ian crank» case a: mammal assembles. (Fla. 3.97] rig. 1.91 3.113va m gum G} Trmmlmkm min mu (g) honminm «mm may. Ii) Geo. mm mm. 5. Emma Ihe 99¢! shih guide pin chp ‘T1 and pun on! he gem 5'an kxk guide pm; "a gear 9am lork =-1 can bu dvsassemblod hum m: gear shin drun (Fly. 3.98) m. 3." I-mwng mo 9-.» my Ion (y Gin: my am- pm my. Q; Gum N. In 3. I! "Mm I. C. Imam“ I. Main man we min shall any clams. (Fig. 3.99) Iran I Slade!!! vol»! Souk-d- Ilnul U.0l‘~n.fi$7m Ilia:- II M 3"“ "an no.uon¢~o.oczom 0.1.... 10.0mm 0.0M~0.°51I—| hula:- .v w- '°’ W’w I0 aooo~nn02mnn 0.1m mom: 2. Count: id! 90 comm My gear doom:- (Flg. 3. mo) Ila Slaw! who 5-:le II-v o.°”~°.052'l “M II M W "‘3 ro.oau~o,aozow 0.1-..- IOJIO‘ m "Mtg :Kb‘géfo‘mn {$1303} 3. Tm mar buckled Simdnrd vdvex 035941170 I0.0034~0.0l365 W Sowmlo Ilmlv : Ropkxa if over 0.2 m 10.008 lnl. 4. Shall lo bearing chums In: ma Wk. SIM III-IV Djlsrvflfifllllm huh-1. I! M M 1M" In Ml a. l0.0006~0.DM:n 0 III- 0.0I6~0.fl$2mm balm hl M Cm than» M a“ mmoo~mm£l Mam 5. Shift [at k; lhlh dmm charms Siudwd vulun 0»025~0.075nm (0.0m D~D.0030 In! smviclcblo Hmlh 0.15m l0.0060|nl, mluco 6. Band In shill fat W V01“): 0.05m [0.0020 h) Strv'ludfle limit: 0.2mm (0.008in), raping 7. Shih dm mm (Fig. 3.10” SW vulux 6.1~6.2nlm (0‘2‘01 ~°.24U In! Sonic-dd. lit-in Boploca If ova 6.4 m (0.256 In! D.0l6~0m2 Fig. $.97 Mun mu m w charme- (D Main III!" and a... (I) Mnh man my gun E'E gE Fig. 3. In Own-v man In par dumm- ® CM!" IN!" low my Q7 Cam-v mul- mlm on Ian. 3J0! am dun you-- (I) all: tun gm rig. 5.107 A on film In any MI 1m marl Geur mu rak G) Gee! IN" I'll!" Hg. 3.10: Imwnhlqu H. "mm“ (Ti Yuma/Mme" muh 1M?! ('3 ‘hununm‘m cww'av aha" (.11 Gem m I: am . - n . H]. 3. I04 (Mdlna m um: M: an: 3. ENGINE D. Ruuucmbly I. lnmull Iho your 5M: [mks ‘3' on the gear shin u‘mm W. Iman "10 rov shit gwrm pins and m in p‘nco by saving me chp. CAUTIONx Wm. msonhmg 'hv gnu: 7m 5m”, mam no! lo :D'mrw Ibo LH and Ike RH lofts. Tho RH your shlh .‘cuk IS marker! "R” 1‘. Ahoy rm usmmh‘y, crock Fm oporullm. (5.9. 3.102) 7. In who assembly of Iho hmmluion gem, mum gums wh‘ch cm fixed «1 mum wxm mu shah she” be Fn'cd Io Ibo splines will care and muse which om hoe maxim mm In: mslallod wlm 1h: mm! woshms. A-sz - asmmbly, chock lo: plcpcl opormlon. a, Insla" mo lvmzmiszion main shun. coumm shah, gum 5m" drum :5anth on Ihe \alr crankcase. (Fig. 3. 103! 4. Insmn who km src'fov :pind‘n. 5. Asmio "to UI and RH undone: 'm uccovd- nvzo mm 50::le 3.110. 4,. Imuan {'4'} goat ah ;. :pwdlv: um mu driven gear in occuvdunm wuh sccnon 3.10 :1 and 0m cluvch assembly 1»: RH cmn|caso cover 2.. occotdumo with mum 3.8 D. 7. [Mia]! the cylinder \n accordance with section 3.50 and Inn cylinder hood in accordance wwm soclion 3.6 D. B. Inswfl Iha (pear shill spindle In the raverso ovdor 0' seam 3.]28. CAUTION : When cascmblying. chad. for uveu "4|" upon:- Lon and also deck We sh‘h [alum spying pm [or bend. (Fig. 3.104) 9. lnz'nl. mo shah dmm Mapper um um duvun goal, IO. lmlun mu all vamp. mun rho clutch assem- bly 1n occovdanm wish sacnon 3.3 D. Install who lock washm, lock ml and lock ms nu! by bow ding ma washer vab. lnslull me clmch ovlur covey ad "we fight cvmkcuso cover. 3. I3 MUSE 6| 3. l3 CRANKCASE A. Construction The crankcase 1: on imwml W. 0! (he "my mission made M Ma rig!“ md Ieh halves 1mm axmunum alloy use casfinp. (Hg. 3.105) The cy‘inde! Ix noun?” a! rho 5mwnd and and NH in plot: by me cylinder hood stud baits wwsd inm Ihu crankcase. A bummer mum: and o bramher passage cra imrporated m on: upper season 05 both aunt. cm halve: Io dissipum 'hc pressure builup h Ihe amen. A can chain lmsloner is 1mm“! Into who hit crmkcm he”. In lhe Imwmd lowev section of Ihu righfi cumicam is Included m ail ”minor and whlth oognlhar with ma cunmrugul film puril‘u lho Marlcmion oil whldv ls pmssum («d Io lhe vc-iow componanls o! Ihn angina. lBREATHERSY The hlefior 0' Phi Claims: is cumin-Jolly Ink: valng Fumes, bull! w by lb. rocfpmcuflm 9350011. In addition. Dho umbcow is filled wilh "I: was from 1h: blew-by o! the plslon ad the was m. mos lercam q) Le" cannon. {2) mm marina-is ill. 3. IN Canteen (D l. aunhm G) I. «aka. a) l. Menu cm fl 3, ENGVNE no. 3.107 mm I». wanna». "5mm mm a mid. MM Fw- (9 Cumm- (g mum. m HI. :Lm rm sum-1 manna 6) no vumr «Ma'- 6, my mm mm (a) my mum mmv mm. (9 Kmi mm W4. 6) Kid: "and pawl mm Q) Gum- mun \ow nou- woducad by me haul of thu umkcusa. Fm rhis melon, Ihu duzomnmuion o! In. all looks a! lhv can pawn" men is Manned. The rumba: A; dsngmd um incorpovavad 1n m can! '0 0mm" Iho pom In m: outside and also In mmmom a mum»: pvassmo within mo crank- cmo. (Fla. 3.106) a. Dlsauombly l. leovo :vimdlr Mod, "[91 lo suction 3.55 2. Rnrnovo cylindm. role lo 506506 3.6 E. 3. Ramove clulch 055:"th as a «M. Ma: lo adieu 3.5 B. 4. Retrieve your shit spiudhu. mloy Io ”cum 3.”) B. 5. Super". the right crankcase from «he leh. Info! #0 saclian CLUB. 6. Ihmvo Iho main shah and comm man. Ida Io seclion 3128, The gm:- mm loll: osmmbly and 0.. Ha» swarm: can be unmoved. The cmnksmfv can be runovcd m a my lav disassemblv. 7. ‘lhe ugh! cvtnkcuse will have We oil silninet and the Ooh cmnkcusa Will have who cam chain lensiomv md igmion coil mun-d. Tho oil mm screen can bu vmvod hon: Ihc fight cronkouss. C. Impecflon I. Check Ia doings: especially around nu ma- ancd muting surfams since even a small dofac? will cause 0” lesz. The mung smlacus should be Ila! lo within 0.05 mm 10.0mm Mums mm a mkkness gouge. (Fla. 3. I07) 0. lion-nbly 1. Asamln in ma "mm ordev of mm 3.13 B /’\ :Lu KICK slum AND 5m malocx MEflmsM 3. H KICK SI’ARYB AND GEAR INTILOCK MECHANISM In lhh system. where m- kid: amorpmionfiz) ls uwdlovhaMwQDJIn-klckonmlm i: lidnaidoay.ardvhlmofrhlruwfiulon mar Induce: lhl posibilily of "cubic. As shown In Hg, «.103, who" the kid: sinner Iplndlcm I: remind by and. uh- kick slaw ral- chel Hangs ®. I: rotated Ilmlmouly. Tho shalt of IM Hdl nun-1 vuichm 0mg. slid“ dawn (m m- klcksm ram mid-(bond I: mud to "I mm of the kid: mum: pinion by m. M! nprlw Q. Pwu I; Imsminod lo "I counmhon Iw you © lrom Ihl kid um pm. (2) WM 1h. kick am W0 mums aim kicking as shown In Flu. 3.|09 n.- klck :Iurlur mocha! “mg- I: proud back by lhv Hammer spying. he the" 716.: on tho kick manor midi-l midi and lho lack slum pinion is hand. v . d m Flu. :.no show; the m lundodx hem m- "' ’ m ” "°"" "' V‘W \kL/W m. 1. no Gm wanna mm [lei Hull mm Cam: My law any (D Man an Minty «am out hwy am on: Fifi. :I. II: (aII-ov n: IoeI comm Irma. Io 0' N r, Nu, I71 . I m mm mm moan II (2) 'IIvI dvmn wad-I a From 7. no I2255I and nccnmA I Ngm‘Iau "mod mwm m. 3.": Ina mud um- I ENGIN( cmnksIn-‘u hem thch Ihe IoIquon dmcIan and poswions 06 5mm my be seen. 3. I5 POSI-TORQUE MECHAN'SM (CT 90) A. Connlucvian The: CTN. modaIs H'rc-n homo MI 122551 and DDOODIAI are eqvnppeo WM 0 msmovquo Io xelocv belwoan me my. am low spud my), In lieu ol Ioplacing Inc spvockon o; in Ihe nurhar sauna. Iv pIcwdo gouvcv drlvmg power in Iha foul dwn u! a Induced spuod. The imovpommn oI we pomquu. mquims only In. epomnon o! Iho hIgh,'lcw mod tango seIecror Io change In. dnvlng speed a guaI IImo savmg ovet Inc owl-er mugs thch muimd Ibo ImIing oI Inn Iago sprocko: am changing I). long"! 0? Ihc chain‘ (Fig. 3‘ III, 3. ll?) POWLR TRANSMISSION IN IIIL POSl-TORGLI MECHANISM - Low wood Iungn. (Hg. 3.113) In Ihe low spnnd range, Ihs wIacIcr sl‘des IN splmod pcsmcvme hIgh gear 1"." lo mosh wim me driven gem of Iha posmorque calmer shaft (,3). The: power ham lbs counlav 51'an (I: is nuns. mined Io Ihe posi-lolqoe counrer shah 13/ and men Io Inc has Iozonng sprockeI dnva gsar unII £4) wheve the speed Imam Iukos place. The chain ‘E I: driven by Ibo splecko! which IquIns al a spend Iess mun Ire counIer shah, ’fi 3,15 CARBURE'IOR - ngn speed ralge (Fig. 3.1141 In rhe high speed mugs. mo soloclor sildus who splvned posirlorque hig‘w gear a. lo lock wilh the bee roln‘mg sprocket dme gem uni: ll. Tlo powm lrom the «may shalt ll is nonwi'md from me soy-torque ng gem dlrec'ly yo me (me romhng sprockel drive gear um! y lo ddve 'Mx special or the same spsed as the com'cr slm’l. a. Dimnambly l. Removo llae lour, 6mm screws and lake of! Mo posI-lovqle cover. 2. Remove the posi-lorqae low gear and who counler pea! assenbly Iogelhee w-vh lhe mums: shall. 3. To dlscsmble m posivlorque high 9001. remove IN: 20 run :ivclip and Iho splincd washcr‘ A. The [en crankcase coral nus! bu lemowd and the chain unheated lrom lho splaclor lo dlsassombla lhe dlive sproaev. 3. l6 CARBURETOR A. Conflrudlon (ll ‘lm am when ln iuom "l0 uir Llama, anlurs um Inlet s-do (l) of llx: carlmclor u; a main uu lbw. passes undo! no nuomo val-m lol and lhon leave me cuvbuvclov ough pimugo lBl In he mien mo Iho engmo 7m; flaw 0| r).r cumlos n mgmwo prossmo crawl m noo'fla jol Ml cm twins ”‘0 [ml in ma llcul chumbuv :21 lo I»: uvuwn w lluwgll ma mm ml um, um nuodlu icl lm‘Jov l3l whom .I l: rum wilh mu ui m2 :5 Ida" In at alr |el |5l and onlavs lhroug'l me on olocd hole: l9! localod would lhe noodle lol holder l3l, and 2; Ihun Ill:- chcvgod bemoan mo 1qule in! MI and iol noodle l7l locumd dlroclly below ma Ihvolllo vn‘vn lél. Tho dlschuvgod qul ls mlxad wim Mu mam niv new and alomlma harem being Idon mm Inc onglncl In oscillou, lo voguluvo mo luol mixmc av small Iluolllo oponl'ng‘ lhc air lulu)" in lvom cutbuiolor inle! lll pawns by lhe openmg (l2l ol the air screw [IIL enlers the slow lat (131 by Ihu way cl lho blood halo, and lhcn ls lllllw wirh Ibo [val dis chatgod lrom mo bola locuwd undo! [he Ihionle ml" to produce a rich lwl mixture. This dlschurgod [ml mlx'ura ls mixed wilh lhe main inlet air now and Iolnonlnlo me Mglm. The {vol mixluve odusl- Fig. 3. In my. quud long. 1.9. :L H: 4*m|....vu u :, [NGINE ml cl "a slow tyslem I: mod. by "allowing the air scrow U U. Turning Ibo alt 1cm clockwlso wlll pvoduce a rich mixluw Tuning vha air screw couvlor clock- wiu will pvodm a In: mlxnn. I21 Float Chiba Tho now produces (ml mixme whlch is "a. 5. ll‘ Clan-indium! vilw ol auburn": m w" m. «:1 "hum Q‘, “out 0mer (3) max. 1.: hold-v (9, MM:- 1e! 1;) Alv lo! (I) "you!- WM (7) m m6]- ® 0mm .14. of cuvhnkx ® My blua mm a Mam in o]: All mm a Op-nlnq n! n- air snow 9 Slow in ® rm pung- ® Va!“ Ma! Q Hm vain «3) Hum 03 new am 0 cm "ow pi). tuned la "la mm”. openlrc ad «on speed. However. lor lhol purpose, It Is my to keep lull level comical In lbs cerblnlor. Thu I: per- lonned by lhe float theater. The luel Ivon- Ill- luel talk passes Much the pew IH), between valve sum ”5] ad "evolve (16L and "ion was rho 110m chum (2|. TM float ll7l bocorrl: bwyanl as Fuel enleu. raises lhe "out valve (lb) Waltheflomwmadwhichmn Ihe flout vulva inlo lhe valve ml lo nap the new of the fuel. Whenluelinllve MIME-scum“ and the luel level drops. "’09 Heel ”7), Iowevolow will! lhe luel level. Charm. bomeen the valve (I6) and the valve sea! ”5!. allow: fuel to enter um um dumber. fly repeating Ihlx, no lml I. always nn'mlu'med «Install. A swing is filled lnlo tho sullen of lhe valve (l6l which convocu ll- 000! on» (Isl, md prevents lho valve lromoocllla nirv‘ When Ihe vehlclc i: an a god. or when dirt is lodged between me valve and war. we. wlll over flow and anion the cylinder. Th-nloro, lor pnvmfim the hpl from «sire dame a carol-1 level. an overflow ll». ls Walled. (Hg. 3. "6) l3) Choke When-mine ls colder 1h- Ionpumuro I: low durlm slaw, a rich luel mixtu- 13 many requlncL Thi; cm be had by the use of the choke. When the choke lover ls pulled up, the choke 00) Is fully closed. The opening (219 Is nonldly cloud by he lellof valve 12”' lewd/er, durlvc slam!) when the lhvcllle is meimmly U4 ad Ihe kick slam operated. Ihe "egalive pressure croalod in ll. cyllndot will (we. "I yell-l valv- (2l) Io open by the proper em! ldamd section 24) and perm" alr lo pas: 9W the met; this flow ol air draws the fuel em 0! Illa needle iel (4| :0 wide on air luel mlxm Ideal lor nul- ing. All» the endu- slam, Ill. idol newlive plume inn-met ad canes lhe mild valve 12" no open campeedinglv Wider lo own a wlktln mixk". Thus. me openingel "I relief valve 12]) changes acceding Io lb. opening 04 the lhrofllc valve (6). mlion (25). (Fly. :l.ll7) I. Fumllons cl Each Component ll) Mail Jel II: mnln wpose is Io abluln u ptopu fuel mime rollo by oommlling ll. new 0' Incl whm ”I OW!!- 1H CAIIUIEIOI Ii; 3. m cm. (I ha, Jill! Hg, 3‘ in mi 3.120 fig. 3‘ III Main in (I) Ail in Meni- In :ni male 6) Nu“ cila Q Jo! needle 5. ENGINE is fully Opened (opoioling cl Ike maxim spoodi. Howevei, lhc iuei lulio is infiwnced down lo around one half ihroillo opening. (Fig. 1 Ila) (2| All Jo! To pvevenl lilo mixoc gas hum becoming rich ql Mg» weed. m1 loan cl low speed, air is loud in ll!) needle lo? holcol. The luncliou of Illa all iel is is conviois tin wow oi on. Al 0 cmslam lhonlo opening. me IGVQOI the air lol. lilo smuilvl will be live diflnrence in luol new bolwcm high and low speeds, and a consoqucnl luduciion in incl flow, (Fig. 1”?) [3! Noodle Joi Tho noodle lei covlllols 1M incl whic‘v hull boon Miamd by lhc main iali betweon me inlornlndiaiu aid lull lluoillo. The conirol is peiicimod by vary- ing lilo :iearancu huiweon lhc noodle fci and ;.i nuodlo desclibod in who Following soclim. Hole in lie needle in! ix mado wim my. dogrel el pled- sion is cssvlu accurate luel Cm'loli (Fig. 3. 120] Ml Jol nocdic Tho icl needle, in conimlign wilii "ll! ubovu mcnlionud needle inl, con'lols "IO iwl mlxlmo mlio ul inlermedinle meme cpmlng [mainly balwm 1/4 lo l;‘7l. lho long loomed lul modlo is lined ln rho comm hole oi ll’o lhlcllle valve wiln lilo iapomd and inscriod mio lbs needle iov. Tm VDV’ICOI mave- menl oi lha molilo valve cmlospuximgly nova: vile lapemd |ul Modlo wiliiin rm needle 19!, my ing mo clearance bclwcon lllo needie and lie ' s. and in lhis way, ”i9 proper Fuel mixiuvo is obluinod in mlulcnca io lhe position oi lhc manic vuive, Then: me five ciip groove mail-on: on ills head 0! "la in! Medici lilo luol mixiu’o bosom; lichen as iha clip is moved iiom "so my (room ilopi iowwd the film gloove. (Fig. 3‘ l2!) (5) Throllie valvo The lhionio valve logulaic‘s no umoml oi air lake» Inlo lho engine, this ossonllclly :mVlols the engine speed as wall as ihe power ovipul, in od- dilion, lilo livollia vaive paiovms olhw inwlonl cmllol 'unClimL The skin ol we li-onle valve is :ul 0' an angle on the iniol side ; lho size oi liils culcwuy Is do» signaled by mu cuiawuy number which is desclihed in succeeding secllon E 2‘ By changing [M valve will! a diflueni sire cuiawcy, ihe nowlivc pressure in lb. vlciniliy of "to noodle Iol is Chung“, afloa- irq ih fuel flow aid cmuquemly changing iho fuel ’\ J.” CAIBUIH‘OI nixluo Hallo, This change I: efiocflvo In lin slow spend longs bemoan idlim ax! l/4 mam. 0pm in; and has no afiocl :2;vo 1/2 ihroul. opming. (Hg. 3. I22) .6» Slow in» The flow in! melon Ibo flow o! "in [vol al idling aid in me slow speed (wipe. md mus lhn lull lo be ulomizod by mixing in wilh rho air iukui in hem Ibo air blaod bolus. (Fly. 3. I23) 17) Air :crow The air straw :09»th lilo mourn oi air calming lbs slow speed syslom. The air which pow by lha all screw mixu wllh Iha Fuel [ram Illa xlow 5.1 and is dischugod In the proper mlxlue, producilv a spray in mslsv vqaorireflom (Flo. 3.124) C. Adlmmm In order for the carbonic: In prod):- iho nu:- lrmrr parlorm oi lhl wine's WNW I! m! be adlusvad so mat a propcr MI mam in ovoil- cblo over vh- couple’s spud larva from idlllu lo the mxlmum speed‘ and iurlhor, be able la main- lain this cordilion. Thl: carbuulor has but! do- slgnnd and Waived lo wiisiy mess conditions by "$6 pmcision madaciuro oi lho commas and specially in vhe we or aperior quellly wear rosislunl materials. Yin in! Medial noodle lol, lhrol- lie valve and lhe flow valv- balm mcmvibh re wear. hm been made oi mlarials pesscsslru 90cc wanting chalcflavisllcsl procisionly mmflocrwad and surface nomad lo give man-Sod salisiuclcry service wilhoul Che-vi: lo parlovmmca. The ndiuslmenls or. mummy and. and per- (ormmc. dado-d by boih "I "attach"! and lociory primal lo assure when the zanlro oi lhe various pads on pmiu. minim. wllsn making my udiuslmanls. parlorming engine repair or roplw iru wompmx. 91v. pailcnlur mimicry to the (ol- lawiw poinls. ® M. an that "is mine is odlmlsd In mcordmca with the specifications. ® Chad: in see Ihal lhem an no air lads: m rho comma: Hamlin Hunt. (3 When th- ocmrollllu comm" bum worn, rnplace will: m puts. Hg. 3. m Throm- vain m. s. m Slaw w W H]. mm Air mm (D Air wow (g) Air mow nap mug rim 3. In Mail: in ® Mail in r1..o.m 1mm. vain. Air mu 0 mom. wm (1) Au Ian: 5A ENGINE D. Adllmmuni hr High Spud 1h: cmlrol oi "a fuel mix": bemoan 1/2 mm": yo lull mollle opening is Ihe fimlion of lhe main iel. (Fig. 3. '25) The dolurminaiion of he find mixture talk) I: made by tho followlrv mlhod. (l) A! full ihmnle, if lha engine speed Inc-eons what! lho clinic is sliyllly closod‘ ii is m In- dlcallau oi lean mixlu-I. Progresively tapioca I}: nn'n Del and hole 1h. psrfomlmcei [main lots on Wed In W of 5‘! (2| lflhqevvmspuddropiwimlhocmis slldllly closed. I! Nicolas Oh)! the main M is oithar of ma prepai- sin a Ila ll may be too Imps, in which also, porform on. ‘OIIUMN chuck Io undo the domlnullon. to! If the min [er had been of apropor sizo‘ mo unolno lpoed will dtop Man the min is! is upland wirhoneof a senallor slzo: rho apood will increase If rho choh I5 slightly closed. In such case, in: ovioiud in! we: 0! "In proper size aid Din-dov- should be roimlulled‘ Ibi Ii Ibo main M iodboonloo largo, "pine. andnlulhaqu-uwllh not do Muller flu Ml lb. carillon In H abov- ls land ad men "mull lhu wow :In in. l. Min-Omani fa Wm Spud Tho fuel mixm odiullmom In the inmmodlulo Ipud moo bolwoon I]! to NZ "IONIO M II mode by mlcmling Ill. is! noodle pailionina clip and rcplochg ihc memo Volvo wllh Ml ol 5 d“- luoni sin cutaway. However, changing m- vlvolilo valve will a» chat "is operavirv condition bolow rho spud mm. of We Iiuonh oponing, Ill-micro. n I: my dlfiiculv lo adlvsl lor imovmdim wood by Wm! 05 the lhrolllo vulva only. It Is rmnnmdtd llm the odiusvml low oh. lmumodloio apocdbomodoby Ibo 101M,andxiaywimn ll. w o! oecsplablo ace-lamina Momma. um (NI would am a lunl mile-11MB Mich lowll. (Hg. 3. ”6) III hr medic lal Block mob mind from the ”has! on or Humidiulo Ipud II a! Micah of loo rid! a fuel mlxnn and kccmclcdby J. l‘ CAIIUIIVOI ndlusllm lln it? needle lo a [mm pndllon lbl Flol spot (Illllhr to NM ninlrol Willa oculcrulim at cl lnrumdiulo speed ludi— cale: lhol Wm luel mixlure i: loo Iemmd 13 Wed by adiuling the in needle lo a my." pounou. [2! Theme valve lcmawuyl The ll-vlllo valve Is MW so lhol m. 1m rho warped mbov size, loam the luel mime will be. When chaulru he lhvolfle vulva, llnmlbomldued Mdow mood wlll be afiecled as W] as the Imam-elm: med. F. “Iv-hm for Slow Spud The 511mm.“ ol “I. luel mlxm belwoeu l/B ”1'0"ka Idling is flabby file all screw and lb. cutaway 01 Mom. volvo. (Fla. 3. IN) (I) All wow The lual mlxue udiuslmenl or idllm spud la made by the air Icrew‘ Tumlm Ila new in the dodwllo dlmlon wlll produce a rldl mlx- unzelomndxmncmb-lndbywmlnglh w In IN mm clodmln dmllcm Hw- mnluldoxrwlsmaulyloaslwm who slam all-"Hon Mulwbodm lolli- lmlllen ptlod from Elihu to mom. outing. h Mlle! words. n» luel mixture lo pmlde lhe smooth walla- m the polar when mom. ls opened 5|le bvyond ll. idle speed. 6. Adiullng th- Fuel Lml Smcv il is dimcul to man. the actual high! 0' [be fuel level, "I. Mum-moi mhlflll d Ill. floor vdve is nude which, will wrlspond In Me lucid" cl lho luol. floor minim mllmd (a! Ten the flea! lifillly hem I." la lid“ with the Page: and local. lhe poslllon when llle lip OHM "out valve iuslburolyoanle ‘n 1| m. mm mm...” cl «.1 u. m «on gum (I) Flour an L2) Heal mu ”ma um:- 71 8. ENGINE coulocl willl 0' a claims 0' 0.1 m (01104 lnl exlsl bemoan rh- floor arm [bl In lhls posillonl "so dium belween lhe bow of lhe neat and lllo cwburorm body ® should mama 2L0m (0.827inl. ll udiuilml ls loquilod. :aclully bond lhn "on! firm by lhu m! ml. CAUTION: A lprina lx Monaural-d In the bow- pl lhl "out valve. lh-rofon I! lhe float mm is passed ogulnll the valve, lhe mung will rICIdI inlo lhn valve and true Indioullon will ml be oblalned. Careful obeervalian mull bounds lo accurately delecl lhe pain! ol conlacl helm lhe llool arm and lhe floor valve, (CT90 Model From Frame No. MOO”) All alliludo nllclol knob ls lllcorpotulcd ln "Io (whoever O! "5' CT 90 model slwllng wllh flame serld Ncl C1 9D-ODOOOlA/engine wiul No. CY9UE—OODOOIA. This makes available oplimum :urblnlo: perlomnonce for nominal or hldl allilvde mololcycle overalion. Pull lhe knob one let lidlng nl ellllme of 6.000 (eel above sea level. Thls will provide uddllienai amply of olr ID lhe needle lel Iran lhe meln or: supply passage Al lhe some llme, oddilional ls also unplled lo llow [el Irom lhe slow mm olr portage, lo loan but the Fuel mlxlue. Pushing In lhe knob will clole ofl lhe all supply In bolh lhe slow and main syslems. (D‘ /0 A} 0 . . 0 . . : : g . 5 a) Mlle eeele odlwu o Mulll [u (o w.» 0 Ihmlll who 0 Au new 6) Heel (a mu . Yul" o Mber up 0 near a. pin 6) Noodle all. plane 0 Tee 0 Heel vulv- L5) 0 mg a To: Waller a War we a) a. :n. a M 8 and m. m Jul needle 8 Noodle It! a Call urine 0) Slaw w a o m 0 halal en. a) new m be» 0 0 I'm 0 w: m SHNG TM 5e: 7 a a 7 - <2. 19...} in“ is alive. R7. 3. 3. 7 2. a... 1... 1: 7 <32... 7 it... a; 7 44.“: a.» fig. 3 _ 2 «us. a. _ _ . 3 .21 E _ 3 6:. 1! SE , r ‘ ‘a 7 _ « _ ,u a. dd 3 a.— 3 3 I: I! 1 W3 ‘3 «x2. .3 «x3 3 «x2 .3 «x: 3 «1:. 3 «x2. 3 ‘ x .2‘ a; ‘ 5. 1.5.... «x3. .3 5.: 3 «x; .3 «x3 .3 w «x2 .3 «x: 3 «x3 .3 «x3 .3 $3.. .>n.>._ «3:... $95 .593 w E: § 313:? 13.5.3 233.; 293%! 3%“ m «.2 9.: 3. 3— 32 la: uflnulanfl. trial—:6: uluuliu. .Uu«l=«= 3'. l 3de 2x3.« 3x3 $5.3 3x5 1 .182 1 h lrkln x 1. o M567“ o «x3 w 7- «x8 ~ r mm? - w «x; u 7! n N «x; n 7“ «x2 » ~ «x3 n M 33.9 _ a W 52.9 1M 7- «x? u . «x3 « 13.3 «x3 4 «x2 9 _ «x; n 526 _ 3x37» «x3 _ «x? n .56 H on; 3; ‘ B; a: 7 1 3 2. a. a. a. 7 1i: Bin—I8... Slam—I8... Sufi—I68. 7 31.38 It 2.88926“... 62.. Ru 7 35 3.6 .86 in 7 11: 4. FRAME Tech Nummry {a Dlmnmbly and Romumbly @639 @®@® n {-1 9 TOOL No. 07045-033“ 37035 -0330 I 07063- 0300 l 07048-0300 I 07072-00 l D I 07071 4500] 07782-99925 07054-0280 I 07790—02801 DISCRIPHON Rolurn pin tech! wrench Rea anhleu (£anng 5 (mumbling Owl Sum um socket wrench Boating driver Pin Spamv, 36 mm Main swlldl pin spanner Snap my plior: Ideal hon! lovk oil sol driver Tool case 4, I 9:5ch HANDLE 75 4.] STEERING HANDLE A. Commxlion The naming harm: or u‘! "'0 model 90 mover- (N cyc‘os whh mo cxcepflon of C90 cvo mode of finned sled p.99. They ova mourned Ia We hon! lork by being :‘nw‘md bolwean me. upper and lower hmdlo mp. hokzms and bound '0 mo Fovi lop budge plme‘ Tho Roofing handla 0| ihc C 90 is made 0' [Messed n shoal smul Mm a continuous slcel pipe yip wol- Fig. LL: cmo‘ clvuL mumu 'v'wl'u dad (or rciniacomonn Mom up. hnmlm wu M: n a x farm-L9 L\ W} ”WM” a 1 2 upmnm‘a mum run 4 pa 3cm. .1 cm {[vg a v 1' Fame mu . CV 90 MPH :v urn-ma. A p My. 4, L1 ca 90 mm, mm. A F‘ r... Lu cm mm, mm‘u I ‘ HI. A.I.l $90 "0qu mm. III. A.I.5 c190 llwlng um!- a, Dinuuembly (s 90, CL 90, CL 90 L) L Hold rhe how brain um " boi- uwd unsc'uw no udymng m 1‘ (Fig‘ 4.2) Fig. A.: w: 7, m2. admin)» :r B: . (Kilm‘vl w ‘1‘ mo. o‘m 7. Dixonnocu rho chuck cable m lower md horn um um” lover 2‘. (Fig. 4.3) CAUTIONx n. qu-c‘rse cum ml 30 aulwuu mo cyumr and mm” Mod nm whorl mmovng "‘6 mm. h. The mu rim to si-nplfmd by box-mug ma ceilusflrg wow u! Hm humlu luvcr and um nuconm: mg; mo mum. r m mu 3 Disconnect ‘Jyo "wot-Io cuhlo av the rhroMa vulvo Ji“ by unscvewmg mo caubmevor cap. pulhrg ou' the vhuonto vulva and man unhookmg the lhvomo COMO (Fla. 4.4) W mm. m. lvm mum/Nev mm (a; cw. «a A. Renown m mm, mm mm! m-I mmmar swlch Iced H by ioosen'mg ‘ho screws cl My Mom 06 m hemhw cum‘ and ascarnocling m. connocwvs wilhiu Iho bcodl‘gm cuw‘ (F19 L5) m. 4.5 Disxoummn mmmv lauds (9 (lumen! loud: A. l slams HAND“ 77 5. Remove lho lour hox boll: mulling llro handle pipe belwoerl the upper and lower holders ald remove rho sreermg handle‘lll Iogulhur wilh mu conrrol mhlos. (Fly. 4.6) 6. lho lork lop bridge (i! is romovod logolhcr wllh lho mm signal Ilghls by romowrrg lbs lrorrv lcrk bolls lLl‘ and I‘m flooring slam nul L2}. mg. 4. 7) Use slam ml Sockol wrench lll (Tool No, KNOBS-OSOOH lo loom lhu slum mu 7. In mdar lo remove Ibo clulch and brdre cnblax lram rho hadln lam. loosen lhn cable udiusllng bolls (:3). align llro lock ml J} lo lhu groove and “parole lrorrr mo handle levar. Romy: rho cdale end from the lever, (Hg 4. 8) 8, Remove rho lwo 5mm screws to separate rho null: llcndlo grip brudror. rum szgml swilch assembly. lhrollle grip pipe and Iherl disconnecl lha lhrorllo cable (0 from lhe lhrovrle cable hinge (21. (Fig. 4.9) 9. Emma mo hex slem run lo dlsmsomble lhe handle pipe lowor holdor. handle cushion upon and lower rubbers and handle cushion soul lrom lbs 10p bridge plnle. NOTE x When lemming lhe handle papa lower holder from me lop bridge, loosen the l0mm hex ml before mmmlng Ibo handle. This will prevent lbs holdu ax! nul lrom lumlllg and facililulu ml. r... 4.5 Rmvlng we» plan (D Harrdll ulna Hm 4.7 lmwrv «r. lop w”. plalo sr-rr run loch! erMh (2) Srn ml Fm- larl w. (r) rm lop wo- rlg. 1.3 Rumovlrlg brake and clulch tabla: 5) Led rm (23 (an. ud'mrer Fig. 4.9 . lmmg mm. m (D mom. mu. ® 1mm cam. lulu;- 7| 4 FRAME (C 90, CT 90) ‘ l. Romvo me how (mm. (C 90) 2. Uncoup-‘o Ibo speedomeler cchlo l: and dls- connocl lllc flml make coho 2‘, (Fig. A. l0) Mo lull handle level 0! llo CT 90 ls me Elrulle lever lot the Incl blew, Hemovo lilo cable 017.1 from live Made lever, Loosonlrg lllo udluslor ml n! "m law when: will simplllv We mskl 3, Dlxonnocl mu lhlolllu cublo (:l M lhlollle valve by rnsl mlxlowmg rm carburetor cap ll", pulling on! Illa llvolfla Volvo and men who xx cling ma lhloltle came. J) (Fig. A. ll) ¢. Remov- mg hoodllgnl mounllng screw and pull all me Modllghl unll, Dlxonmcl lho hom, mm slgnql and mo dllllmcl )wllcn lends l1) cl tho cmmclols w-lllin Ina hmdllgm case. (Fig. 4. 12) 5. Unsc'ew rho two mp budge mllmg bolls ‘Jl [rem wllhln ‘ho Moullgll cum and lomove m lwo 6mm Mlldlu Gel ml: ll. [C 90) (Fig. 4.13) 51d llh OH We handle: lngnlhm wllh mo 00th and leak. " 6. Remove mo l'oul 6mm hon Lollu lc 9090mm rig. {:il «.mvng mem- (;l. hm cullmlalcv 'h" m” '5‘” “W” "Um" mm W” °"” m Cab-Mal run (i; haul-l. van. 0) men» mm. lm slewing llmdlo l. Iagelhav wnn mo cables A 7 and clcclllcul leads (Fla. 4. IA) (CD90 8. C190) Fig. mo Imam-cl mm: and m (I) smamm (col. f!) than cum! (CY?!) Modal hem meo No. ODOOOIAI l. Ramove Illa from brake adlnxl nu: and haul bldle cabla from me (mm arm llrcnl Make cable may I» dizmnncclad (VD'fl lhc bloke level). 2. anovu Illa mm [nuke cable {mm lhu mar bloke level. 3. Emma me calbuvelor cop and asuswnblo lbs lhrollln vulva 1591:er wilh ‘ho Ihlollle cable (mm lhe cal'norelol. hm M, Dam“, “mm mm my", 4‘ Remove lhe heudagm and dlsconnecl Illa m- m [Ilcmml lend: specllve leads. A 5. Unscrew lhe {our male namring bolts and remove Illa handle hcl, C. lmpoulon [nearing handle) I. |rlspocl "to lmonle, cfulzh Iron! make an?! "\ lea! bloke (c1 90) cables lo: W001 and duru- gas. also chock lot smoolhness oi opsrmim. 2. Check lbs handle levers lo.- smolh apoval'lon. 3. lnsoecl lhe handle plpe lor deformllon and VWIS'. 4. Check a" me switches [or paper operalion /\ "'5 .22??? :m 33"?“de boll and lnspecl the aleclrical loads (a rlanogns. 4 l $lEEIING mm: D. leauembly L Assowtln m: handle pipe lcwur holder. handle cushion uppw and Iowa: rubber. lmn s-grnl llghls urd handle cushion seal '0 who lop b':dgo plow. (K 2. Auomha ma memo and hen: brake cmlas, mmnla gnp and swivclu 05le to tho slowing hunch. NOTE 1 u‘ Apply grouse on born the mm and omnde of mo ptpu whore mo Imonlo gvip ls lo be F lmiallad‘ lhxs is lo macaw me women! of Ibo vmenlo gvlp t2) and us compononl pants. (“9‘ 4. l5) 1:. cm mo ptopax cpemuon ol all cables. 3. Ammuu llu: fork mp budge plate on ma iron! lo:k um mslall me Mom lmk bolt and Slocum slom nm. 1.. Posnlon we CUUU) and ulccmcul leads m llxou plow! luwuon and clamp me 51mm hadlo In its {wopei pas-lion balwoon ma upper and lower handle papa holder wilh "10 low "mn- mg bolls. NOIE x f.‘ a, mum mo Iwo forward bolls mu, u».- should be a cinema 0! 0.2 to 0.3mm \O.UUB~0.0101nl clearance bemoan lho holders U! "to your balom llvc your bolls om llghmnud. b. 1m senanons on we handle man should be locmod a! who comm of Ihu holdws, c. l’mnion mu pundl ullgnmum mum on lho bundle plpo lo the porllrg ”lacs oi m. holdovs. a, Tovquo mo balls 10 80~ll0kgun (5.5~ &Dll,lbl. P 5, Comocl all 1h- elocvnocl laud lo the loodx 0' who mma color wiihln the hoodllm case. 6. Insmll and comocl Ibo lhvollle cable '0 lhe Ihmnlv valve and screw on me carbumlar cap. Adjus! the cable lav propel emu: cl play. 7. Cannot! Ihe clulch cable to the clmch arm f‘ and odiusl Inc play allot lmlallalion Io IO~ 20m (0.40~0.80 in) cl lroo Ivavol cl mo and of Ibo clurch levav. [S 90, L 90, CL 90 L, CD 90) NOYEI The odiustmwv of the clulch lava lm Ivuvol can be mu: 0! both clutch cable upper odinsler 0) (Fig. 4.16“ end U1 the clutch odfla (‘ mm (1) mg. 4.1m r... Lu l-mvlna )lnrlrv lmdlo ICD 90 a cum (I) Hundlu boy Fig. A, Is Ammbllna "not". m (D mam bay (1) mom. W {I} m. A. I“ ® Clvlch «blo app. Mum: m, L In (D cm- :ubl. ud|uu¢r a mm m 77 la 4. fIAME m. m7 ~1ng hunl mm (1) mm w.- ud‘mmg m! <9 mm mm :cb‘. 5. Com! the (ram bralo cub‘n and make Ihe (xi‘u'nenv Mm mo miwstmg nm' No! the brake mm A'iwn :0 my mom .-, 10 mm ‘0 20 mm [0 AU~OBOm: 0' (me novel 0! Me hum: [cu/m, (Fig. 4. I7) 4. 7 STEERING STEM A. Conmuchon Mo Mooring 5mm I5 mo pivm pom! foe who from Wool and is supponed m m harm hood p7pn by [we ms 0! com races and sml bails. n is noon at high 5"»th haul nomad sml vo wivhslmd We shock Imposed by vcwh load: and (1‘50 rho mgw lroqooncy wbrarion which {ends in long» It»; mulal. Fig. l. u A sum ug "on floor u‘navnm mu, Ct 90. CL9C u 6) rum [:1 Cor-I m (i) fou'x mp mm. 91w: @ 35 steel ball Q) swam mm m Q) Stunting mm © swaying mu m lhund re.‘ 4. III S'oamg my» mnwu dmum u: my (D Slowing ma mm m G) Fevk top m». g) Slwlng mm (9 ram lmk henna We. A 2 SVEEKINU 51w II a. Dhauembly (S 90, CL 90, CL 90 L) I. Duoszomblu mu Mndle nm We 709 (hion plulo I‘ in accordance wivh 4 | B. (Fig.4.19) m. A," mama lm lop bridge p'ml G) rod mp hiduo plot. 7, Dsunnmlfla I'm from cwhlon 1T} In accordance wllh 4111 (Fig, 4,20) 3. no ham cisumbly :2 wow hem ma lovk mam bridge by mum»; me Mr: 6- 12 hex bolt!” mm born my be mmm mmm below 0! chm um mmmnl or the slanting new! Fig. L20 wen-mug Ivan (”Man I!) hm mm 4. 921cm: 1M nearing head lop ":me 2 using a 36mm hook cm! ‘4 lloo. Nav 07072~ 00101) urd pml Me steevirg mm our we bonam. (Fig. 4‘ 2y) CAUTION: Do not drop our me :6 sveel ball: during the sleeving stem removaL fig‘ til ”mm Alanna Had my mm (D as um um mm (2) S'uu‘rg ma Yup mam: I! l. FRAME (CD 90, C 90, C190) I. For dmnbly. ruler ro rho mpocrivo from fort rmval lor CD90. C90 and CY 90 in 4.3.B. CAUTION: When removing rho lronl fed. carrier: no! 10 drop sroel balls lmralrod In rho XVI-ring hood. (Hg. 4. 22) (CT 90 Model From From No. 000001“ ‘ 1. Remove Ibo handle lever \n occardarza wivh "m 1.22 5,... w, action 4. LB [CT 90L (D N rm: balls 2. Unscrew the Iwolronrfork bolls endure sIoerIng slam run md rormm the fork top bridge. 3. Unscraw rha rwo marry“ mourning bulls and remove 1h: hoodliyrl and Ihen rho left and righl 010333") 5.0m lurk my... 4. Remove Iha Iron! fender. 5. Raise the from wheel and plot: a slum! under Ihe engine Unscrew In. hem am mr, pull 00! Me ax|e and remova lhe front wheel. 6. Loosen m. from cushion mowing ball on Ihe hon! fork honom bridge and drop m- hom fork assembly. 7. Loom lhe sreerang hood lop ”ma using me 36mm hook spanner and mnve Iha smar- ing srarn our the honour. Nola - Exerclsa core no. to drop Oh. stool balls when removing rho steering slem. rig. A.” srur hulls C. |mpo0ch. (5 90. CL 90, CL 90 L) Remove lho rmfilon {For CL 90 and CL 90 L vamovul of W will ml raq-Jide Remove lhe brake podol spvlng an and lho :Iop ugh! springm from lho bvoio pedal m). (Fig. 4.60l Remove Iha 3mm Co‘ICI pin Q3 From Iho mar hunks paw pip. (Flu. 4.6l) Rumvc Ihe roar mu ndiusling nm and roman the but: rod from lho roar bmko mm. MIWI MW ll '0 remove lho LSX 15 con-r pln at tho roar brako padul mo‘ rear bucks rod 101an The veer bvcko padal can be rmved by pushing the rear btako pivot pipe ime the hell by lqnplng with a rod ad a lrommcn (CD90 a C90) Runovo lhe mulflov. Remove me bvuka pedal spung and Iho slop um spring lrom mo bvcko pedal. Remove me racy brcxa udiusling nul and realms lhe bvake rod “on: [he brdm urrn. Remove me 6 mm m! from me year brake and we: btdxa pzvcn pipe and remove the comx pin horn the opposite end. [The removal can be padovmad more easily with the dive chain case lower hull la mover“ By moving Iho rear brake pm: pipe, me bails pedal can be rmvod‘ CAUTION: The ma bate pivot plpo A commonly used Ia Mo main slmd, lhecelore. balms removing me rear brdta plvol bolt ploce u snilcble staid under Ille engine. Roar whool disussombly [valor lo mlion 4J3] The row whuol cm bu disassembled In 0.: some mam: as wivh S 90, Pig. 4.62 [why an brak- red hon rm: hula "m (CT 90) G) lmh calming nul ®Imham l. Bdapodoldimrbly lll lZI Renme the bake pedal spring and vhc slop Hm: 5pm; From the but: pedal. Remuvc ma larch cdiusfing nut (D and le- mon Iho rear back: vod Iran- the roar bunk. arm @. (Fig. 4.62) A u MUIHn f\ Ial Remove mo ma bvdm some :li rm we broke rod ‘2. (Fig. 4.63) I4) Ramovo Ihu Hmm lam ml l'lorn Iho roar bvo'm pipe and mum "av coIIor pin al lhu oppomo and. By pll‘ling can we rear mam papa, me p Luuke pedal can he rammed '69-)th wilh Ina bmke W1 2. Rom wheel disassemb‘y III For disassmblng mo '8‘.“ whanl, min: In fiction 4.13. P‘ 4. a MUFFLER A. Consnmk-m In mum" and 0mm Dlpe have been made We un magical will by Weldmg IO grm'Iy lrmvavc IM silencing o-Teclweness of um mu-Tlan Ilse miss ls Iurlha: reduced by me incmpmanon oI a dimmer pips nl she muffle: 0mm. I. Disosnmbl y (all model) I. Remove Ihe MO flmgo nnunllrg mls from me 1 exhaust p1.” flange at the cylinder head, 7” Remove lhe mm mulching lha (rumor bvodals Io lbs flame or several poinls. The Ioculion of lhu blockels will very bemoan llle diflocanl models. 3_ Thu dlfiuser pipe cm be removed by unsaow- irg Iho 6 A 5 hsx boll, however. me dlflusal pipe is nol vennvdnlo cu Ihe USA expovl models. (Fm 4.65) C. Impulion l. Inspoci lhe mfler and exlmsl pipe (or buml Ihmugh xm‘s, Imge deals which may efiecl Dev- l’\ mm, 7 Top I've mrrm all would Ilghlly mm a wooden rod 0er we on ma |oosened carbon purliclos. n. Reassembly A I, Fashion lho mu‘flev mil in placal "ding sun lhul IN guskeé ls inslulled, and fnsl lnslall Ibo oxhaw pipe flame Io IM cyllndor hood lompo rarily. 2. Iighlul Ibo blade! bolls and the finally lighlen me Gar-gt. Fig. 4.9: lamina Ina ml. ashl- (D hur mn- :ablo 6) arm. rod ri.. 4‘54 5 m a.) w». rial Lu Wing allus- pip- Q) Dllluw plpa ® 6X5 m boll 97 9! Fig. A.A6 Ail Chane: (3 901 (D All mum rig. 4.37 imam-J mr c‘num wwm nor:- |> My (1) A: claim" mm mm (a) An cJ-um- momma boy: "v. 1.67. ham/Ina an chum (5 90A (1) Au chum nlmm (D All any». cm 4.9 All CLEANER A. Conmumon 1m a. cleaner coma-m u pupc- “Nor 0mm whch IS co'uguvod Vo yxowdc the maximum 0! film. ing surface. I! ‘5 damned to provide vha curburo'or wrh the women vclumo of air and a lens! mom! 9! dusv. 053mm; maxim/m powm 0mm and enduv» unca horn ”no angina The uxr cleunar m suppozlod on "in humu and enclosed so mm A u adoqumely pended km "13 min. dus! and ovhor odvorso slums-1's. On vhu 590, CL 90 and CL 90 L, "19 mm is Iocatod 0! the come: of the home below vho loo] talk (Fig, 4. 66), lar lhu CL) 90, mo Nor is locavod on [he Inf: m humv comm. F01 lhu C90 and CY 90 the mm: ‘5 located in me vucmlly of mo momma 5mm. 5. Dimumlfly (S 90, (190, CL90 L) I. Remove me or moano' Coho cow: “New; one each or. Iho Ham and lot: mo and lake on Iho cove: ‘ . Unscmw me air cloumv anllhg holy w. (Fig. 4.67) 2. Remove me two air claw cuso moummg utews, upper md' lower, and detach m. an clams: case, 3. Romovo tho air cleaner connocrmg lubn clam horn cl lho cleaner and (New). me at! clounev conmcmg mo groove. Free me an cleaner moment by pushmg voward mo your and who" d-sangogod from M tuba, suds the atom! in) om of the case (Fig. 4‘65) 4. 9 All CLEANER Remove um or! flower case cover (D momled on rho rigm side er rho corner at rho (mm. The air cleaner element may be removed by unscrewing rho crunching screw ('3). (Fig. 4.69) (C 90, C1 90) Unscrew the cop rm ®. remove the cover (5) on: W" our We aim! ermr. (Hg. 4. 70) c. lmpotflon L Replace my element which A; deformed or damaged 2. Creun me elemenr (D by rm rapping lightly 'o loosen rhe dusl or! men blow off the dust by applying dry compressed 01'! From me inside. [Fig. 4. 7|) CAUTION n An loose euu musv be removed comprerery Gr else He duel wiH be when inlo me cyl-nder and cause wear. 0. Rnaumbly Perform the reassembly in Ihe reverse order of A dlmerrbly. Hg. 4.69 mm err elm ran 90: 0 Ah slum m (D Alr dmu e— (3 Armrm raw Hg. 4.70 M err deem-r (cm. (:1on ® Cup run (9 A» clean: mu rig. 4.7: Chandra a? charm (i) Arr m than 0 M B- I00 4. Fug. 1.71 ha! 101: (1) am (when 3 hm m Hg, 1.7: Humming no: Mall (1) any mm Fla. 4m imurura \awm Law 9 lam :m 51 '21 Fear mm" mm m .1) hr." lav: 'iu‘ 4.75 mum; "a mu (D In lurk ® in (wt plvo' ban FRAME 4. IO REAR FORK AND CUSHION DAMPEl A. Connruulon 7m; mm iork u n swmgmg arm lypu cesgn sunpmlM by r. mung cusmon (mm 0! Ms root and hngod ul mo ham '0 mo mm harm: mombcv, chw me :our wivu'fl r. m mohon, "-9 [mi pn-av mm m; mm mm. Tm. mm mm m croso maugh vo mo chem drwo smockov n-cx mo movement 01 Mo whoo‘ has vevy mun oflocl cn mo chain Ionsion. a. Diwuombly I ' r «no fl'u'orcycm up on mo mum svand and rcmuvu I‘m) mm wheel! ”aim in sachet! 4.1313). Remove me deo cho‘m 50:0 on we model which um 50 chippud J Rumovo Mm mu “who" dumpcr lower be" and detach 'hc du'npm 4mm 2m may (on. A. Rumovu we vmr lmk mm m and wpuvulu mu lork from ma ‘mm c. Impcdion L Damage} 01 wow dvive chem case gasket should be vL-p‘uced. 2. Chen film veer fork plvo! :uhbev bushwng 104- umugo. excessive won: and 0911 Him :ldmlmd mlm Sculcuah‘l Y J 5507c} 90‘ >2 u~vz 2 ’ 70 90L m U7~Luwm , ( m o c 9c (1 m7 ‘ 3 Check me ,on 'ka Io: ahgnmmh replace .1 1mm gram mm 1 m (0,040inL D. Roolnmbly 1, Assemble Fork in IN rmevse Older of (150:- mbly. 2 \naluJ Ihu when} um «Awe cram. and odml me chem lemon. 4\ A. ll ISM ran: DEMON DAM!!! A. II REAR FORK CUSHION OWE A. Commefion Tho m fovk cushion dumps is aooil type wlm a doublo cylinder all typo damper. Tho shod: i: modvedbyrhdmwwd lhelmbnisdh- sipuved by the all damper. The oil dunner com Ooh: 30cc. of SAE ‘30 shod" min-d lpnrafl‘ld 031. The specified alum? is lmportml, sine. (b shack dammedislimvhcrmdor dhl‘nHlediI propmim to the ma! NH. (Fig. 4.76) H'. 4.7‘A 5-:in via-1 M Mr Min (590. Q90. CLWl) Ohmmwmm @Mtumlflvbflmmfl {nmumm ©Mcmvmmvlm ©Mnnlmsmw ©Mrcmwvcw ®hamlockml (DI-ammmbvmwk- (DI-nammwhhvhnh alum-gunm- @lmmma- ,,.___ calm J Tniuzsznn) "I. 4.”. Row mam (CW, CTN) (0 m. mum was! um (i) 2: mm mmm (a) Row emhlm «pp-v mu nuv ® Iou sumo» “opp" man. (I) an: anion 11va em 0 km up" «an mom. 0 My mum and sta- (D but am all u! ® My mum calla O now down. tad pum- io um «um «band ”can" mung 0 My Won bonm can 0 low :ulhlon loving gm- 0 My cum lama 0 be: amen bollun "val mum. 0 Mr anhlu 1m. up 1M l0: 4. NAME a. Disauembly 1, Remove rm 8mm upper and Iswer cap rm: ‘1‘, Ramve me year cushion assemmy 2]. (Fig. 4.77) fig. 4. 77 Rem-um my (9 a m (up mu (9 m. (”man 7 Compass the rear cusmm upper case mm a special me! (D (tool No. 07035—0330” and mks oul vho ma cushbn lock nut (53]. Remove Iho uppor cm. (Fig. 4.75) MW , rat" I m m ml ("v dw'r-wrr y 0M mummy u»: 1) m, run} I... u m uuHm vm. nu 3, Remove mo rec! cuxhlon canponoms pm; T :0 ‘i' ‘ (no. A. 791 (5} 5 ‘ 4 H... 4,77 Compnncn' pan: 0! mm my. an (I) um. (um. uppw can (I) ha cumm map" we! (a) In sumo» mm a) he anion rod Loan «9 hey cuNon [MAW ml Q) M, cuhkm bomm ml I.” mmmma C. Ion-punct- L DUI-vim WIN Mm I new»; many Dumping Md Cum. lwh sum no WaugtfikIfl/efimfa n.1,“. Sumac on no 3:: 19:41: mgr“: an mm CL 70 .c; m 7 7 : . m" ”’3 :31: 3 53A mu m 7 cm 7 uIfii‘WiiS/Ww i m 13;: 1 mi;— 51.2 .1... h, C” émfidfim. ’ m“ $31“ 333% ‘1‘ M" c‘" (attfirgmm. " m‘ fi" 35:}: cu mm £02sz fismm - z: :2: 23:35:. «m 2. Mmhionm to» sum mm W [lam ugh— Tim} rm laugh WM [6.1" [III Ham: "4 Inn—Inn. 5 9" u“ [175: mm“ um —' 7:» Wm" w “W“; W u u. in. lm I721 [6.7574 b. I57} “‘2' hi no nun/I014 a. 90 w ~‘ ”.5 kg __ c1 ,0 1 mm wzzao n, ”In?! an F... Iuph' 21! «um» “$937715": ‘ loan-mow _ CD” u“ litany-[mam m | Wilfil I: MW," ~- m- m‘ 2|: mum first? “"In.5n-/12Mg" —‘—_ ‘— c vo lead ’55, ML!“ m rm | Win" La' ”9““; a" r... Im an (Mum 'g'filflf: nu "1157.5 I, cm W tum www- TIII Wm» Lb‘ ”k?“ ®luumcn "l- 4.00 Maud mun 6' an am 4. NAME 4.12 FRONT WHEEL A. Council” Fig. 4." CW»! pom ol hour who! 6) from who: on. (1) mn owl ml (3) no: I Dell Inorhv © Divan“ collar (i) from Wm: M. (a) how: wml Mb ® 63D! I ma mm Q) Why noun (9 use! on nul Hg. 4J2 Prawn». moving @ want no Q Imh pun-x a hen! hvulln can 03 am- M. Q In“ m- lerw 0 ham who pond 0 Ron! wh-Ql um collar 0 Am m 0 Mm bah on. (9 6x25 m w The Iron! whool axle and Ibo uxlo ml amnblu the alumina» alloy hub, lion! brdil poml mining of rummmwobuu bum-adam- mam your. (Hg. 4.“) The roaclion force aovtod by bruklrv ls trau- minad lrom vho brute ml dlflecl lo Iho [ram 'ovk. For lho CD 90, (:90. CT 90. Iho love- ls "my mlnud '0 the [mm {at by mean cl IN lurquo llnk. mum. Io Wlde wav-vpvoolina and dust woof-lg lemme: la Ibo hon! wheel hub md bvuka ml, 6 labyvlnlh has been deslmed lnvo ll. hb. (Fla. 4. B2) m 5 l2 "ONT thEL I” a. Dhanembly (S 90, CL 90. CL 90 L) I. New u :Jppovl ulmk undu' ma Munflu‘ ?, Remove we ltcw: L'u'vu (must-u t-ul (ljl and dlacngago the btcio ccnle l! {rm 'hn Irony lttoke a-m. (Hg. «33) :l, Dneonnect tho imodo'tolnr ctlhloli Item the hon! brake purcl, (Fig‘ 4,33) 4, Remove the “OM wheel axle nut and dtcw out "l8 uxlc. 5a The wheel ml :1: awn haul the hem fork, “9- ‘~“ “MW “N” [ca 90, c 90. c1 90)“: Y 8 2:2; :2: :51“ M tll Place a wppofl block wdet the engine. (a) Swan-m ccblv 01 Remove the hem bmko odiusting ml and dxsongugc the male cable '7) Item the from bruko ante I3l Becomes: the speedcmela! cable Tl hem the brdta pmel, Ml Remove the castle ml -Ilt and pull out lho panel steppe: bolt ('5. :51 Loosen lhe twoamm belts suspension arms. lel Remove tI—e heat axle nut md pull out the axle.’3 theftmtwhoel will drop away he.» t Ihe (vent the hem Icrk, . (all model) M "5 5:233:3ka . . 6e Sepamle the front brake parol (2) hem the a) men. cable 1mm wheel ma @4 rsmova the speedomclet goat 8 "W W" . l Cum: nut une dlsassenbla the brake can heal rte ml. (9 mm, “W be” (r... 4. 35) 4‘) 5.... M M" 7. The {make shoes we held ln place by springs (D4 lherefore spread the shoes opal! to dis- mantle hem the brake panel (Fig. 4.86) B. Dtsmsemble the bmke com from lha ltont brake panel, 9‘ Remove lhe otl seal from the from b'aka panel lot Remove the sldo collar ard lhs cil seal Item the hem wheel hub. 11. Romevo lho ball beating and we axle dislmce collar hum lho from hub. 12. Remove the lite {D Item the tln with lhe tlre ' lever (g) and pull out the M‘s lvem the casing. \ V 1 (Fly. £. 87) Fig. 4.:5 50ml. m. pun-I Q) Fro-ll whul m G) hem mu ml c. Inxpetlinn L Check We um {01 bclh verlvcal cwj sdo rmA OUL mm -d nh-u J 7~ a ”a “m" now—«a mo nu v um um. Rm, yr My nan-A 0,320 1‘ 1.0 mum v.1 2. Check lhe front axle lo: wow and bond, (Hg. 4‘ a?) fig, L36 D‘mmH'ng mm mm (D Ema: m. snvi-vg :2) Emu m 'MI imam mm, Samoan“ mm D ‘ ?;v5;5mc§n' """' ‘" m 19A~n an. m j . . a and 02 m main: ‘ Lafil'n'flg” 3. Check broke shoe swing . » i‘n‘nrn ‘1 mm 1 n- \rnum ‘57U131un SIC ‘I 31rd 4, Check we broke areas, (Fig. 4‘90) r-m :nnqqit' mu .. ‘ . , ‘ , ~‘ m- m. 1m” Oden {mu-r mm mm m“, Fig. I." lama-4M1: m {D lim (3‘; 1“; In“. ‘ , leomca a mud-V ‘ “5’5"“ Mummy; 5. Check me Ihlcknau cl Ibo hem bruko cum. Svandond value: 6mm “1736 inl Sorvicoablo Hams: Replace a! excessivaly warm, do‘ommd or damaged, 6. Check me spokes [or lighuncss, Rolmqm my spokes [and loom 4~21 kg~cm 1U 3~‘5 ‘L lst 7. Insnoci Iho who by looks by mt‘nving, submavga in wulnv. and check (0: bubbles. Hg. J." Mouluqu whac‘ mm 3. Impact we :iro mm on ma 'matdu u: wo‘l as ‘ ‘ lhe wsida ‘nr n'rnoms and irrbodded nails, m n; mum“ Hg. 4." M-umw ma 0' an. (I) horn on. ('1) Dan gang. (5) v blacl mm»; we a! n.1- [a [x Q. lz now WleL D. Reunembly l. lns'cll lhe rim bald so lhal ll wlll complalely com Ihe spam nipples. (lo‘el lo leuv whool loamnblyl 2. Assenble me lube belween llla rim and lire, inl‘zlle llle lme wllh a small am.“ of air and Iowa lhe we bead lr‘lo lhe .lml NOTE: a. Aller lllc llle is assembled on lhI! ml, in. (lala mo lilo lo Us the normal pressure 1.6 ~l,8|\ /"\, 5 I: am WKEL ‘W 34 Diwnembly 1, Ramova ifs [9‘9 crmkcasa mu: cover, discon- red me dnve chum. “’13. (Fig. 4‘94) 17,.Unsc'aw ‘hu 6‘~ ID mrr hex be": and remove MD c'r‘cin £05167 3. Remove "-0 mumcv. 4. Remove Ihc roar brake Iovquu lrk boll and semvara ‘ha mrqua lmk (mm me brake ML 5. Unscrew the rec: broke mpsmg my and d-s- canned me tear bunks rod hon lhe bmko mm. 5. Unscmw the your uxlu nu! and draw out the fig. 434 {ramming a». drum axis to lemova I‘ve chcin udiusxm and (ha side 6) am chum collar «09mm 7. Remove the mar when). (Fig. 4.95) 5 Roman: vhn "xv <1on slcovo my and mew Ic- v-vwo the fiml dun" smodo' nnd Tra‘ drwen flange as a complaln unit. 9. Dow wt Ehn mu! ux!a flcuvo [10m I‘ue le dn'ven flange, unlock the 8mm mogou wuslvur (3‘ and remove We dnvm spmc‘m: sct'ms; bol: ‘ Diwssembla lha rm: dwm sfiocko! r; 0rd (Hg. 4.9a) n.‘ 4.0: Ramovlna not Mm (I) in wind £9.49 (in. I.“ imvirg whack-v (1) 5m mnmod um- ® swing m G) rum dIlv-n Wu: G) Final dllwn flang- LI) llllm M Q) n m T—hmdlu mam. no A. NAME ,/\ . lo, Remove mo ioai axlu sleeve collar hem mo ‘ CD (3) incl um" flmgei o‘il ml loll ml No. 23406 used on lmm. N03. S90--l11565~590-l42498 ? and S90-4244B7~590493162 and lube» (5) twat“, and all wul No. 27406 m on 5mm: r No.59D-493162i home No. 59044275“ "W 4) and mimmi ball bearing 6203 2. (Fig. 4. a (C1901 On heme numba prim lo c1 90‘ 122550, ihe Final dilven spuockm A, B. an - mud on he final driven Dmge. Remove m: n; 4,97 cm.” porn 0! final dvlvln napa- Iour rimming bolls lo dlwssombh lbo final dliven I“ g 3:: 3;: 33;" may a lion. spr-ocllat A. (Fig. 4. in) Q m“ h." mm, The sub-nammlnlon lopkmed tho daibio Ip- G) on ml rocker fur chiming iii. speed range, lmrmm Q) Ila flxl. XVIIVI talk: No. CT 90-]2755'. (6) m. mi. shew ii. Retrieve iiis 40.5x3 "o" ring homlho rear wheel hub, rent wml mi. 630] bull hum- lng, I8377 oil seal and lecruxle disiunce collar )0 lemme me real wheel. 12. Remove iiie hicks shoe mini "is no. bids panel by upmding vii. 5m rmolnlng spring. Remove me brake com iiom the bake panel. 13. Disassenbla lhe «is and who liom Ibo mu by using Ihe lire level. i H C. Imoeuion 1. Check tharh'orbmhvevlioolmdsidemw. i “2- L” Rumba Mr? dim" wrath! ll.- 'i swam mlu. } Suvicml. llnu ‘ (D niiui an»... imam n —_ h (9 Final dllvon my A 0.7~l,fl maxi ll om @ swam mum {on 5““ "“°"‘ l lo.m~o.omini LO inmoinl Velma! ‘ luvulr I! am “mm! ‘ °-5""“‘°-°7°"" I.o £0.0‘0Inl 2. Check the m axle lei mi and band. ‘ min | smauiavulu. [animal-iii." ILNI~I2357 ‘ WW ‘ WW" I io.472~n.sl 5 ml 1 — . mu n.s "1320 iii and l 0.2 «moral War-plum: ‘ fin. 4.99 lmlulllng iii. band 1 G) lliii band a) m: mini m I ; 1: REM! WHEEL III 3, C'aci l: -.- 1n:.vl,‘u -‘/r«"‘mi I. ‘ I ,- a; Lan‘ 4 u «M H w ‘ -w-x :v, Ilw (~h ( .x mm,“ m ”an HI:'-‘,1~Il wy H mm ‘ 7sz ,n mum ‘ Z‘DJWBE : Crack 'bo ih‘clnos: of Ihc your hm?!) mm. mm “3336 m! 1- \mV: sup (n 4! mm ‘mmmd who: 6 lu‘rvmo': (H flu ca Vr'c Ludm 1w vghlvv-c: (OA~IA:’1-lm xwmqm my mm 2",! L :54: H /‘ lnzmo ch um luv] by mime whmh'ge n wa‘L-v unu Lhuu 'DV buhhm FL IIISLI:C‘ H'c ‘vu {mm rm Mn WW: 1:: m.“ us w.» w'wu lp- du'mvjm (M wt. _ m mm, o. Reonembly 1. menu Ihn Mu i; J 1 a3 rm: n Cnrrn‘flm‘y 0‘ (Fig. 4.99) cm no ,1, ya me vi'n '1'; covers lr‘c :znlo r ’1. Aswmhlu the IA: Ly infinl‘mg the nu; shghuy so 2m: i' hold; me grape, mace msirie me we (m: mun insvml the Mo on Ike rm. (Fig. 4. I00) CAUTION u. Nlcr Hm li'o ms been imlcl‘oi on he (My u'nq'fi Bo nprx'cxi'rlmol,’ 1‘3 “er :\ Muszuru 41.5~2‘m5‘:~.-; é~ m3; "I m then Hg'fly 13p m w: UH IM: NJ] ”13.01 mm a mum to u, - my be p m h. The ma who you. «mu m r- n! leak my 4: . 3. Dim vha mu bomb; We the Fnzl driven flange, and {nz'cfll I’o 0'1 seal an! the (our ax‘a alcove cclur. (Fig. 4. IO” 4. Assamua um («5| driven sprac'rm 101m Fm! dnvcn new lussmb‘e rm (1 1 flcngc A and B on CT 90 F. No‘ 122550 and omliorl and in- Hg. moo numb 1;, Hum m: m I'm '0"! x) mm mm m Fig. 4.101 m dzrq m: 1mm; Hunv'ev wlrg mm In 4. IIAME =9-—@ 71.. A. m Chum clip ductile:- 9 Damn llakage and mumrv ln hard arming or no starring a! all. b. Chock for Mr Volvo llmlru, Chock lav much in Iho cam chain. :1. Chad lar any slippage oi mu hmmg sprocket. f‘ Iruukor palm nrvlclng and gap adiumnonl a. Romavo Iha dynamo coynv and blookuv poinl cover, lnspocl the wviocws of no bleak-r palm; ll lhay on bum! or paved. arm lho xuloca wilh av ailuana 0' a poll" droning filo so ma: Ibo palm: are making parallol nonvocl. M's! lhI palms huva been dvmd, waah in gasoline or "ichlovoelhylona l0 remove all Iraoo oi all. h. Tum ll» gunralav vole! owl-clockwiu co the paint wine in bmku polnls an at auxin-um opening. Tho ml gapO) I: 0.3 lo 0.4mm (D.0|2~0.016inl. N odlusl- manl is memory, loosen lho Ma breaker arm adiusling new: (2 and mow Iha slallm ary My palm by landing a :cnwdviw lnlo lha adlunlna am to ablaln lha prop“ gap and lhon mighlsn tho scram. (Fla. 5. 5) lmficlam m palm gap: lal The spud: lend Io iingav, Ihal Is the Inlermpr‘m oi lhn primary clrculi I: no! complaiod al ihe palms, Ihurefcxe, 1h- saaondary high volloga buiidmp is mad. lb) Yhe closed duofien oi "l3 points is longer. pmduclnu heat ma mulling ln durum. [cl In canimclion wilh (bl dzavo, lha polnls will be late in opening coming a daIay in lb. lglllicn liming; this will came a drapln panorama-Jr. Excasiva lander pow gap: In} The dmlan not rho painls are closed I: loo short f0 allow for window comm llaw In ll» plmary circuit with a W low Velma m. 5.4 lacking m odluII-ng nu! 0 him much Q am mm. m. 5.: “mm m poml alumnus. (a mm inch: poinn (3 Dual" um odiwlnw 1:104 @ mu... am I” rig. :La Miullbfi rm lyllrion lirrrhn Q "E“ "k Q) Alignml mrlr m. 5.: Mlvlillv in. mum rim odwm (D Tim Ian G) TM 5i PHIOOKC ADJUSTMENV build-up in lho secondary or tho high lenslou volloge circuit. "N‘s condlilon will cause poor angina mum, spark missing or max speed and a cmsaquonl loss oi pom", (bl Eroim oval-incl: merrily. ici The igniiion liming is groally Wadi 4. lgnlrlorr rlmlnu null-maul o. Whuruver lbs brodler poinl gap has been odiuslod, mo igniilorl liming will be ufiecled and illusions il mus! also be rmdiuslodl b, Wivh me dynuno oovur rammed, rolalo who summer rolor cornlerdockwin unlil the "r" morka on me flywheel lines up wilh rho ally-imam mark {2; on lire slaror. (Fig. 5. 6) in lhis posirien, rim branker poinv should iusi cmmlsm ro open. This car be checked with a thin thickness gauge. H od« luslmanr is necessary, loosen the boss piore screws La!) and rulers lhe buss plale (D by insuring a screwdriver Inlo mo odilming :10! lo obruin vhc proper liming. (Fi 5. 7) c. The sluiic ignmon liming Is rolalively uccllule and WI“ give sarislucvory angina poriormance, howeveri the use 0' the service lash! wiil «mum rho mam precise timing. lrelor to service lesler operalionl. When wire a strobe liming light (D lo duck me liming. idle m. angina at 1.200 npm. (Fla. 5. I) If i! is lewd our of iiming, perform rho odiuslmenr in rim sane mama as described daovo. Resulrs of retarded iglirion iimlng: 1. Drop in power umpul. 2. Druslic increase In rue! consunpiion. 3. Emina overhams wilil a possibility of pisVon some. Results :3! advanced ignillon rrnrirg: l. Prelim llnockirv and drop in power output. In sews cases. damage '0 piston, comedic rod, Crabbe" my rear", Mortimer, wimfic bup-clion should be performad. 2. Upon completion oi the pain! gap and Ignition limirv mlmnl, duck for proper oporulicn 0' "'0 wk odvunar wiih "I service tenor. s. l MAINTENANCE INSPECTION In 5. Spark plug adiusrrrlm A dirty or dumped spark pkg. or plug elaclro- do: which on modod will not ml a good wrong spurt. lheraloro. lho spark plugs shank! be inspected periodically ad clemlng ald cdiuslmmls mode. Spark plugs with seory. wm electrodes, or eleclrodes covered wllh depesils wlll pumll the high lensiorl voltage lo bypass lhe gap wllhorn snaking. l. Clemira a. Thameolrlnspark plugdeanrillha recomrmdad melhod ol Chaim me plow. Wen/or, a sarlslacrory cloallrlg em ho performed by using a needle or a still who to remove rho deposits and then wash in gasoline lollumod by dry'ng wilh mmprvssod all, (Fla. 5. 9) b. Adlusl lrla spak gap char cloan‘lng. Sal lha gap lo 0.6~0errl lolou~ 0.0251nl by bordlru Illa Muclrodo on Ibo wound side. (Fly. 5.10) 2. Spud: PM Impoaion a. Chock the quark bunny prodxnd bemoan Mgvdflugramwmemolufl- rods. Blue spark. Good nominal! Red spark Poor wrldillur Cm we lo: 1. Law apply vollaoa 2. Defoclive lgrlllm call 3. Doleclive spark plug 4. No sparking may also be dun lo oom- prouiorl CAUTIONl I. Do rm remove rho dnposirx by burning. 2. Whul lmlulling who spark plug, cloal lbs swung area free of oil or lureigl mil:- ard irulull nnger light below Iorquirlq will. a plug Mandi. 3. The spark plugs an be remd after odilsh ml, wlm "In pkg latter. Wl'h tho hlyl Iowan volvuge unlmuimd ml, my Illa ml dumber pressure and Irwoct the undi- lion 0! lbs spark. H]. 5.9 Spark m clmr 0 sun plug ® seal plug clean 0.6~0.1mrn (Mm-#02550) HI. LIB Mnhllng wk w "I 5, PulooIC ADlUSlMENY Fig. 5. II Full totl [Oval (1) ml cock law. (2) Fvul ma um (91) ml 5. m Cluanlnu lwl mum. l590, two] CLWL. cn 7m (D "o" ylng (17 5am (g ml mm. m Q) 1'3) Fig. 5. I2I CV’WID Vlnl wumv H: 90. Cr Vol (I) ill-I mall-M cup (5 "on m G) 5m... 6. Fuel :upply tythm Roslncllcn m lha luel supply syslem wll maven! sumcmn' fuel flow lo the corbue'ov and cause engme lo spmer dwing naelemllm or lha engine may svull al mg» Speed 0, Check lor s-ficlanl supply oi fuel ln the kink b, Disconnocl "In lual leed lube 2 lrum me cal- harder and chedl me lusl now wuh We he cock ll In Me (N ov me R pofillflfl. (F' . 5. H) c. ll the luel flow :5 insufi‘uclem, lemme lhe luel cock, disassemble and clean. When the flow is 5%" inodeqnlel remove lhe fuel tank from me home body and clean lnlemally. CAUTION: m The msmciem luol flow mov be cal/sod by m: plugged venl hole In me filler cap as wall as he voslricflon in lhe luel line. (g) The luol cmk :s swllchsd In R (rmrve) («om we ON posing“ when the MI lawk bocwus .3le 7. Fun] malner (loanlna The folalgn Lubsmnces remained in IM fuel posscs Waugh M lunl I‘m '10!" My fuel lunk and alloy: lhc slva‘lnov cup Yho lomlgl abalone»: and womb il nol moslod, will onlm lho cyllndot and can” angina falllmz. 1. Cleallng a, Sal lhe luel cock lover lo lha 5 poxilicnl b. Remove lho slloimr CVD and War :clcar. c. Cloun lha s-muuv cup and Fllor scum", (Fla. 5. l2) NOTEx C 9!]. CI 90: Iho iusl sun-Mr is ‘mcotpovclved lho may and ol mo carbwvol. s. OH filter Iueon cloanlng 1M mom oll ls mlomd Ihrmgh a syslom oi doublo fillols mime l’ ls s,lpnlloc1 OM~LML5~H F'on' ML. unw- lmk ma m u ~4CUIg-(w, 2L7~15,3m.n~, M‘ En M mm" rm |2DD~253‘ -:va H.5~‘5lhs-H GE! ‘0‘)! [ml {my my mno~zaowm g Rem um WM lZflC-~EEOIJ-: IA, 5~I5 lbs-"l a nu' H. 5~Ifllbs~hl 5‘ I‘fllOD‘C ADDSVWNT m, 5. 43 ill 5,“ Taupmg pa 1-: u (u Ilundlu lm'uvmhan nu‘x \90~HCI‘g-Ox>>> moo GmZmnl. mkuOn... 11m ii .I ...... is! 3.3:: 8.325.. :23 m «o c. m. >. mxwow... 11m 85-5: 35. =3. 5.: :1..- an m. . as... .5. mi: oo 3; saw" . . .5 x55 \ . a i 52;: 5 C3: I.“ xi? 5.. =3. : WVEWKU SNIHIM 'l 2x2 2022. 20.030» 9% $52 5:32. 2228» 0.00 22mm»... meOx... ._.<_vm 222.5250: $3.8: \ Mmr mzaz amozrm a 5% 2.2 81:20 5: £32 mxsozflmm \ a an; a»: 22:: 5% 2 a: z :31 2% a, @L WM @ 3% 2:2 \Llr eiué . 6;, all: a a as: @flfiflwfiwo L. an: 22% [9/ g _ ( :F as 3% 5% 2: 9 gigs: - . 1 fl :2 r mm; a: a. 5m 55% 2 was; 5% 2% Es :2: e .282 8; 233% 22 mzwaz 8.6 825sz g}: 3:2 ‘ e a, ; 52:20 5; 2.22.5232 2:2. m , , 222229 £222ng 222% :32ng mg; 38.. u./: s ‘ 1 a x : p 2 mm a: a r 285. w W 22;: £8: a li a»: 225 c w; .\ A m o 6 A: , 2% as: F _ . 040 a»: mi: :82 ; ‘./_l 0 2:8: 22:2 82:2 :3; 93mg»? 6 9......05 06 13 Q. a? 9.00 r Fm. >. mxwog «(wm 5...! ”In. wig I: «a... .Eai! isms... .: .. . in a. s s magi .3»: max: :9: 25:. «2:2! :25: .335 a; 2:: x x O _ o . 0900 Cd . . _ _ 0.990 FE . H = 129.4 kam mqov Ian 5) an») mx>xn 11 45% “2:2 2% :2. “52 \III 1 mull . At , 583:: :5 E; I v in {mama _ . E. .5. s .5. ‘ W VJ “ ,mexpximmg 2 I— ‘ _ ‘ . r .................... . L 21919 r: ...L . . p w» __ I W! I . 1L __ a . A QM _ _ 7 9% x2... :2: a. an? a :52 . r32: 3:: 225. :9: WM 933 fi' 5... 3:2 =3: 22... 1—3 5: ES: i... 5.32 83 sin: #52 5:5 «2:2 :3. 2:2. :52 BM wwsma SNIIIM 'L no 00 #5:: as?» Asa—x2: 53:3 our .53: E... 2;: $.52... 3.: 2.5. :2: :5 as: A 559.5: m a m m n :2. I I u m .w m m :p :2. 3:: u is. as. 2 Sign: . H we... 2.5 9.5. .EE ES“: :9. E; 0mg: 2.52 Mm win! an m: 0 e 5;; :5 is El. mgr 5:1 {gage SE: 3-: x3 “1:? X 5.: 2:25 :25": 35:; «3‘9. 3; .23: m ‘ \ .23: sag—.5 :53 2:23 ”2:55 . ‘ , a: Fuomv _ . N 0 o 0 $92; .23 :3 L. 333: a 8.3: 0633 6" Em: £022, 53:523.. :85 ms; Aw; Emz $23. 253; noo mmrsz: mmnzrmx 2mm 33 2 1.31m» mmi H53 as flow 5:.“ 92:0: 32 1 IIIIIIIIIIIII J g _ , m a; 22:: :5. o a» 2 _ , e: a; 2: wIE W .1 | L on n. 3 u n a .7 n g s: a; h z (I Sr £8 :2: ‘ U: II lllllll _ 52:62 N a 03st r 8:. c o a; a m E H :5 :QEQUSEV a x :32 , _ m _ m w w a as: 22:; :iv m ¥ _ .1 o a PM: mm; E as; 3% a $2 , , r I I x 6 lguw +9“ _r_~ 2223» 22;: 2:? ¢ I 1 1 6 2x2 waz: 5% _ I_ E: 32: m5 . I nSEzéoz 22:01 5%. can: ii, an 6:1 :22. 3:52;.» ,<< w in; xm=oi “EB. :22 u 1022 E: 32 2mg :21 2:2. Lu. Brzézmz z .wqoé: 5;} 3m 20:1 :22 92: £5 «13: 8:1 :22 ”a :3. 3:6 6:1 .33.. 25 :2. am in: .32: 3cm :3. «1—0: 63; .331 :m Oil '1 wvaovm onM x .33. .322 202).. :05. m<\ Es zmcgz. 3.3 :2.» 23%: mummuo 35m» 5.: 22.“: :5: mm»: _ 25 .w 2 A S 20:: 2:32 332 $92? 2:32 .252 292: 25H 5% 23: \J.\ Julzms :05. me n« 00 Emm G» 75km: wm;< mg L‘ max MES: : .. ”dd. 2. “4.: 2. am; Ex: £022. CE: 2: 5.2 n g a \l h v “““““““““ 2:31 :2: E 2 <5 0 _r m< Emmy <0. 923:8 5.5.2. 2:2. 3 3535252: _ OI-O u 229 _ n 59:20 2:; A|.|V .222: 352: :3 59:35 233$ 2:6: 2% >225: Sun In : E a: a. 2 mm zws .OIIOIIO non-O. O. .0 0| .0 go =93 m m E2: .222 22% :2: 97;: 043 .30; 1‘ 20. 880;. «$25: mmflima :91 .WDIHIIIII a; 22:. 253: t I IIIII 5.35: 2.3: . .fl ”531.5 Expznmii 2:5: 2 3.: 22:2. 32 5% m2: _ m: a “3222? ES: 3:3: 3 5% 2.1 _ 2 04¢ 19. mm; “.32: $3., 33 Z; _ 2,: ” “2:2 8:. 22... V . 2:: 5% 23: g _ y _ a _ IIIIIIIIIIII ”£3222. m _ 3 n _ I _ _ rI.eI|H...__ rIwIIwnnnun ”LnumFL fl 1 I I IIIIIIIII IIIII HfiL _ IIIJH. I ~ " _ x mm; Ea. 99.5,. _ h L. E u :9: 92% m no" _ .I n . gTJmnu. " Ease: .3 IDIU I: i < < 2&5“: I I_ r IIIIIIIIIII I. IIIIIIII , 52$” , : c mawflflfvfinfllflln nu r255. «S: 72¢ MW. . 1 mg? :2: 6%. IIIIL a _ _ 1,, IIU w 3:32 233: u 7 :22 @9un #39. 853mm» _. an; we»; 28E. m. a. 35x 33 . :9: 2:2 51:29 2:; a . ..I_ .2; 2:52... 353 ._. Hr .. . 52:5 azxm» .6 onzmiax s 85.2. wag": s: :0: a F E a 2 mm P 3 x wvusma QNIEIM '; 8. SUPPLEMENT TO $902K] O I. CAM CHAIN THISIONER The can chain Damian: was chug“! hum the hydraulic self-adiuniug typo m the WWW ud- hnldib lypu. Il.‘ KLI G) lush-r mm». @ Sum»; war-mum (9 Tasman-hm ® Sudlnq boll (D hum pan (.3 M we had («In (0 1mm pan (9 0-0an rod 3 Q Vim-cm mum"; ball (I) Swine I! m. can M I; mvfly nolly wlm "I m Idling. "in tomb" M [ho cm! duh ll Impmpor and again; odlusvmom. . 1. To adiusv, Mn Nu mums boll In or out as my. Turn "1. mm boll In a cledtwlll dlm- nun who Iha dull: produces a dunerlng noun. (md mm H In a Mavdockwha h mofawiuvinqnoiu.5ormmhg M'Iauwuwwovhmhmbm. mulled. H" KL: (0 MMNV bull m a. SUFFAMNY 10 57:1le Hg. KL: (i) Km mm. ”m. (3) nu ma»: Inv‘ng (a) mum mug 2. KICK STARTER The kick slurry was changed In a new vvpo as shown In Fig; “-3 3. CARIUIETOR Sflrlng Dahl- W?— Mom In i “a New In | “a m Madly “WW I - -2nd. groove | A" mm «mm | 1 - Ill}. “'5 mm In.” mm (W! 2|»... «2,52; m 4. FRONT SHOCK ABSORIEI (FION‘I' FORK) on capacity: 130~l400c (4.4~4.7m.1 OII upocmmnun A‘I’F [Manama Traraululcn PW) nu. Km 5) From fault hall (I) Flu! [at m '9 smug mu I37 mm ® Wash-r unxum: ® rm nu pun-r ID on ml Li) om. xuxz: m ® Fork and- m pig. {:0 in.» Iui pip- ama- (5) no": lmk W cm. a ham mock mam qxuu @ Fran! Ink hem-Mn m. ri; (an we bridge Q Shad: mus lying glifll 9 have cut piuan xiv final low 9.9. 0 Shock «um-r ulna um guldo Q Snap ling ® m 5am. mg. a) amen cm am a PM. no, my 3‘ sumwwr 70 5931:! I55 5. REAR SHOCK ABSORBER (REAR CUSHION) Spvlng Fru ~ng: 173.5mm 16.63] in.l Installed length/Loud: 159.1 rum/19.3 kg (6.764mJ4255Ihx.) ; ,, ~ , .. ” “ (I; ‘ 7 I V \ A A ([4 @873 Mb 9) @QB \9\3J\§/ 52.. KI. s _ hay neck mu” w "my a, My plpe 13 mm. bmmg <01 a: V2) ha snocl mm hone-n mavul ® ub- nap ® mm 5415\ng ‘3) km mock mm «pm-g m Sphng 9mm ® 39;... (mi E ha shock m- m ® non gun» a 04‘ mm m (ma non spun; w Lott M 6. WHEEL AXLE NUT Thu hon! and wheel axle runs were Chang-d to a castle M that I: fixed by a cone! pin. Fi" Km :1 Wm! uxl- ml a; Calla M 156 7. MAINTENANCE SCPEDULE B. SUPPLEMENY YO $90211 Sarvlco Eeqdnd ,wa Km #5357 Hrs 20 30 Mom}: or Mllas. Mmr 00cm first Mum-r7 l Second Thkd ‘7 7, 773,000 5 mo ‘3 , o g 3.0m 6.000 5,000 1 10,000 i a Emile Owl—m El rug—3.: Souk Plugs—clam md adiw or Tan Can Chain-um}: 7 7 Cam and. Points—check or m 7|y|l1lon Timing—duck or aim _Ve|vu Tapper Change—duck or 7am 7 Air Chat—clam and , "9““ Throflle Quotation—duct Camreror——m;&' J m Fuel Vdve grim—m Fuel Tank aid rmi Linu—dCck Chm—cm a odiusv bu». Chuln md Wn~um and who. or union. J mmifiM , 7W F3911! aid Ina Evan. Shots-duck or mph:- Front md I!” M Univ-died O I O 1 O ‘0 OOO‘ OO‘O 55' 88 Every Mllu II .600 Km) 3 OOO O‘OOOO‘O 0100 O o! OJ 0‘0 0 0 0‘0 { Whlul Rim aid Sodas—dud fives—am or rqabn From Fork Oil—anal In “49.7” dmaa Sham Head Earrings—chock or odiuu Steering Ham Lodz—dunk for emotion How‘o|ooi‘ 000 ‘0 0 00010 ‘0 o 010, [0‘ o Slde sound mug—dick amary Eloctrolvh Laval—chad: aid rm w 7 7 Mary 0‘00 0 ‘O O O um, Horn. Susannah—chad: [<17 operation or odiun 001’ 129.55. 82.39: E655 8:3? £22 >§>znmgnza I. mz_§.| xw E 1 F a o mm a 9 Cam 5:22.13. a Q 96 Sim: 3030 0.0 oz 2.21 z. 183 «S: 06 5.3:: 32? :9: . zmgimwl 29: file] «Em E, Eifln .. a: momzz. I 50: x F :4 . w; 2.. mil 5 vmwmmuognfix mvmmuimag :2: 2...? an 3 E2. zmcdazl ”FDA V > I I .0227 Eng :5. 2:: . as? Iol IM>UEmIA 2 $3: _ mum Ba: 4 u n 2.. p as» _ :9: 2.3%: _ _ 2 w. q _ a: m 2% 22:9. amwwwfimfl m 62:52 8F 0 (an r 3024 322% “ file szmx 5.! 3 wazzr :9: u a w 222 . " éumzmmn a 2.5M « _ “‘ “‘ . :2: EE «32).. :9: m1); 155. ‘ Ex: «5:? d T 835.2%: $.40: _ 22:2. F ‘ “2:9. ,I. E 82;: En) ‘ Sunnzmzzon :22 $30: Bizomzmza WVUSVIG ONIHIM ‘9 DIZ ass 0A lNiwilddflS (9| 9. S'ECIFICATIONS 3. WM? 10 SWZK: ‘Cut My? ’ 7 am: Fv-I Rum Cwlny 7 Tm}: Longih ENGINE Typ- Cylindwi Arm! OII Capacity Lmlcuvlon Symp- DRIVE 'I'IAIN Cinch Trammlulcn firm mm .7 Goa flotlo I 7 7 77 ll 77 m i u Iv ' 1 w v 3 Find Mullen 3 Gem 5va Pun-m ‘ , ELECTIICAL 19mm Stating Syn-n All-«ma Merv Cwlw A Spark PIua \ '3'. ,MJPGL swam min mm 1,590"... ( 74.4 m 650nm (25.61.” 980nm I 38.6 In) 1.195"... (47.0 In) 145mg ( 5.7 m 36.5w (190.711). Back bum Tawney: fork Swinging arm 150—18 (5 FR] 250—48 It PR] lulomol «paid-I9 IN). 24 75 ..24 75W ”7.0 III. (I I L4 m. (3.0 u. ,p. 65“ 75mm 0.95 IILI 3,722 _n~_ md Ignition can WV~W _ AC Idol, 0405 lW/éODOrpm §.V-,6.L"L,, NGK was 9. SUPPLEMENT TO C190K2 COMPARISON OF CTWKZ-KJ YO CT90 I. KICK SYAI'I‘IER The kick starry was Charged In a now was shown m Fig. K2-l. 2. AIR CLEANER Thu air cleaner was new lor Ihe revised ml. Gunman! erh VIII: chahgo, Iho malmm pro- codns of mo dunner elammv was changed. Mum-much l, Remove live wirg an ad loosen 1he air clamor connecting mbe clamp, man remove lhn air clearer case lid. 2. Urrsctevw lhe fixing plots boll aid remove the fixing phla. 3. Hr]! oul the air cleaner ml Iran Ihe air clamor cm. 4. Wash Illa air clocmr alumni in clam Sradrhrd solver! I‘d ullcm Io dry Ihorouyrly. WARNING: Gasolina or law flash poinI solvems curs highly “mantle and must nor be used Io clam air cleaner olomenL 5. Sad ma alr clemer olemanI In clear 99:: on [SAE No. 80 or 90) until rammed. than men. om excess oil. 6. Relwull who ali clearer 0mm. 7. Relnilall lh. air cloamrr case lld, CT90K2~K6 (2) WI m Kltk mm splndlo rum-u “aw Fla. :2. l \m xlcr slam spam Hg. :1. 2 " Cumming lulu A (9 Air :Iuaw .l-mni .;u Elmm lmr plp‘ mung plai- : mung plan. hell ' All chm- can. m: n 6) Wm: um i Clam-r can all. n i m. clump Cloomr m. gum ! “mm mm Camlnn Lb. a HO 9. WKEM‘NT Y0 CV 90K2~K6 Flu‘ (.24 (D Am "In (2| Can-l pl» 3. CARIURETOI Soulng “bk um... um ma Main I-I us 5m la us In mm. un-nq — 3rd. groove Av saw mum: lele nun Flam MW lm-D‘ zom- mam“ A. SWING HANDLEIAI CLAMP Th3 marlng handle was charged to unaw typo wllh c hmdkba clamp. Th! mun cm In sol In longitudinal posllion to who loaning spans whm ormsponlvg ”a motorcycle. GWKG I. WHEEL AXLE Thefranmdroawiwolaxlonma were dmgnd loam anaemia 9. mum YD CVVOK2~N l6! C790!“ COMPARISON Of CYWKJ To CTWK3 I. CAM CHAIN TaiSIONER "we can duh lensimev was CW 5mm lhfi hydwllc sall-adiusling lypo lo we mallnllv udiusl- dzh lypa‘ Adiuflmenl Malta lsnslon odiusmnl whlla Ila amine ls Elm ll Loomlhobckmmdloumlhelsmlm udiusting boll uppmxlmulely one lull lum. Fl]. u I 5;- memr mum had (a) Sud-w wailm :3; 1mm- will mu Q) Hm mama hull g laminae: ”lug A (.3 om. :4) twin plug n ® Yon-lunar mum-g my @ Tmm hall 0 Dual ml 2. ll Illa chain is sllll my Evan filler III diml— men! above. loosen lhe Hm scaling boll loculod av lhu Ion bollom slde ol lbs arm-tau». and saw in "l! rum boll le um" I! I! no longer noisy. Mm canplefing lha aqulmall, Hymn lha Mnsionu calming boll lock nu! md 14mm soullng boll manly, Hy, n: u) Tumour boll lo: 9. sUmEMENT TO CV ?DK2~K6 2. RIGHT CRANKCASE COVER A m pruleclor was insfalled to the riuhl ant/cue cover. 3‘ CARBURETOR Mg, m. a 0) man amm- :wvl wow-cm (A) oma ® anm M Q) Clmn odlmmg be" mm.- :9 cum «mung boll (i) mm aunkcml now 71.. ".4 ® Sill-MIN M! Q h. lak and hell (9!“ M Flu. XL! (D ful um ml (3 Hour-u hom- Sofling kilo Bolling 1|wa 556A Mail: I" 362 Shaw w :55 7 Jun nudl- um... . 3rd. groove All wow optnlvm I 2|]: tun ma wan-19am! 20m (Mal-In.) 4. ml FORK The row lovl: pivol bolv “curing run was churned lo a haw all-Why ml. 5. MI. SUI TANK Amwhflwb'fliwhfiombld‘ku Mdludonihn MHowursld-ollhmhr. thy: 0.5m. (0,2U.$. wl.) 9. wmiwm vo cwoK7—Ka (:wa5 COMPARISON O! CTNKS YO C190K4 I. ENGINE STOV SWITCH A now ugh- nep Mich was oddod to rho hoodlum switch hcuxhv al fin Ilsa side of Iho had-bur. 2. MAKE WEAR INDICATOR 0n the CTVOKS. now wan: Mentors wen pro- vldod In the Iron? and mar broke; Winn Ibo btdta cppllad. an mow. dim!» Io III: but. am moves toward a refm- malt onvhobvdw pawl. The ism beMaan IN cum and III: "sienna: mark. on full mama or m. mtg. Moms but! lining vhldms. 3. REM! BRAKE The mar level bvdw «I the loft xida of ma hum. him» ofierod, wm dlscmvlmad. m. [5.1 ®¢nn|m “up much 3; Manny» mm ”In“ (Dam-pm: @Nm @ tel-om Int (0 mi. I“ A. MAINTENANCE SCHEDULE 9. SUWLIKNT '0 CI 90K2~Kfl m: «alarm schedule I: band men mow Ildlng oondlllonx. mm ubloclod Io lover: Inc. at mid.» In wily dmry cram. muir mac hm! vacIno. MM OIL#CIIW. CENTRIFUGALM OIL SCREN2 I MII. soo mobsoo 100% 4,000 Km Loon Ioooz.soosooolo.ooo 7.1M OIL R ' a VI ‘(INTIIFUGAL OIL FILTER C- ‘9". FILTER SCEEN C, I *coNTACT BREAKER— ms ’ ’17:, ‘IGNIIION TIMEJQ Ji 7 *VALVE TAPPET” em I L , ‘CAM CHAIN TE ION | ’ I i i' 7 Sorww anfy’ ‘ 7 POLYURETHANE FOAM AIR FILTER ELEMENT II mm.“ In My) ‘ _ i 9“”, , _ , gamma 7 v I 7 7 _| 7 JHROWAFEMTQN i fl I , I 7, FUEL FILTER scgecN * c SPARK AMSTOR “BMW, 7 am cg , WHEEL RIMS mes ' ERONT row OIL FRONT ANJ LIE—AR iSUSFENSIONL ‘ um mix §IJSHING 'srssIéI'NG Inn BEARINGS SIDE sum' aAmw UGHTNG EQLIMLNT NJTS. nous (TIGHTEN) I 4mm chm, adII-I a mum ‘Il Men-av E—lwlou C—CIm L—Lumem llm HIM-d ' Md Mantle-“w I» «would W anal-r union III. Mr ML prop. 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