(c) 4-Stroke.net .. .f/.- .:.. ,. ...... ... ~ 1; ~]: . bt:+..l . Hbrldcl' .SS50 ~ -Y. ~ ! - b.\ .. ·~ J~i . ~\! (p ';. ,(. t1 . \ '"' ' . I~-> r .. 'Sixteeher' ®WnerS . WorksOOp ManLJCil . - .· . I by Stewart W. Wilkins ~ . Teh (with an e.tra Chapter I"!'- s--ed mOdels by Mansur o...lington) Models covered : SS50ZE. 49cc 4-speed model. May 1973 to September 1975 · SS50ZK-2E. 49cc 5-speed model. Octob"r 1975 to December 1975 SS50ZB-2E. 49cc 5-speed model with front disc brake. January 1976 to July 1977 ISBN 085696 167 1 © Hc:ynes Publishing Group 1980, 1985, 198 8 All riglm r-rved. No part of this book may be repod~ or transmitted in form or by any meant, elec1ronic or mechanical, including photocopying, 'r.arding or by lilY information storage or retriev;l syst em, without permission ln writing from tfle copyright holder. "'rnv (c) 4-Stroke.net ' Printed in England (t674N3) Haynts Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes Publications, lnc 8.61 Lawrence Drive Newbury Park. California 91 320 USA .. Title page Acknowle~mu · I ntrodlK'tiori Ordeflng $p:'• ~ Safetv firsu Routine maint~ 1ce Recommencb1 lu 'Jric.nH ~ter S~cations 1: Engine, clutch 1r1d lhrbo:K 8 ' .' e' , , .., .. ~xaminto and renqvnion Rea'Membly , Stlll'ting and rui'IOII"g aht• rwbuil, Fault diagnosis· e'1gil'e , . Fat~ ' ;~ iagne»s · clutct- . · Qeath' " rf · Distl..,tling •\ --------------------------------------- • oepter 2: Fuel l'fltem end lubricetion :,.f":.... \ •\. ll ~'· ~- Specifications Petrol tank -; Car'1urettor Exhaust system Fault d iagnos;. ~ 16 28 50 50 60 57 59 60 60 60 60 Specifications Contact breaker Alternator Ignition coil Co. ·dPnser Spark plug Fault ~iagnosf • 61 61 .. : • Front f~t, SteerinJ r.ead s~ Cha .w 5: Wh•ls; brelces end ty,. \ ~'- • ., ,_... . ., 1 '! (c) 4-Stroke.net Specifications ~ /~. Front wheel a~ brakes Bearin!JS and rear wheel Final drive chain Fault d~si ' :J .. "s ,/ Bttterv .•. 'Lights· Wiring rliagfam Pault diagnosis •• \ ·~. Routine maintenance Comparison with 4-speed model Engine: dismantling , exa"'lination and rea111mbly Front forks Front wheel disc brake Wiring di!I!Jtm '· 63 67 67 67 13 71 78 78 80 83 . .86 87 87 87 88 6 : Electrical equipment -~ Chap!er 7 : · wpplement covering the 5~ 62 Reur suspension Speedometer Fault di~nos J -..n. ~'" -1 larm 35 49 r 49 91 92 -4 ~ • 93 93 95 95 95/98 • 99 - ~ ·~4 (c) 4-Stroke.net ' ~ ~ ._;~ __.......:.. .....!..........______ ___: ___::_.:__.., v·•• , 1 • tre:w . ........___ .... . Introduction to the Honda SS50ZE I110p8(l The Honda SS'50Z moped wes introduced into this country in.Miry 1973 to meet public damaod created after legillation that ' r8$tricted six~ year olds on a moped of 50cc capacity. The bike is ba*'d on the SSSO motorcycle w!Jch had been introduced earlier. The engine has been slightly detuned and diffel'ant o119rafl gearing uted from that of the SSSO. Pedals have al.o been in1roduced to make the nttorcycle legally a moped. The pedal drive can be diiCIOnnected end the pedals lotked into . position, and thus ued as con~Wtial type footrests. The moped can be started with the pedllla locked in position by u!8 of the kicknarter. . An outnending feature of this model is itl very low rate of petrol contumption. Sooo aft• Its inception, a rider journeyed from Loi10:Jn to Manchester and still had IOme petrol left over from the initiirl fill up. ·' ~ -:-. .... .. ·-.. ,~ ~ Ordering spare 9 artS' . When ordering spare J*'tlfOr any of the Honde 50 cc\nodltls • it is ldvi~ to deal direct .Mth en official Honda egent, who should be able to supply most hams ex-stock. Paru cannot be o~ined from Honda (UK) Limited dhct: all orders must be roullld via an IPPfOved agent, even if the pans required a,. not held in ltock. Always q~ the -.gine end frame numben in full, per· ticularly if paru are required for eny of the •rlier models. 'The frame numllar is aamptd on the leff.fland side of the frame, U• only pent of genuine Honda pfacture. Pattern paru • •e avaHal:lle, tome of which origlna~ Japan, but In many .., .. initances they rnrv hlvw . . ad_.se Erffect on performance and/ or iability. Honde do .not operate a 'service exchange' scheme. Some of the more expendable parts such • spark plugs, bulbs, tYres,_ oils and '{III!8S8S etc.• can be obtained from accessory shops and rnttor tacfors: who have convenient opening hours, charge lo-r,llri&• aond ,can often be found not far from home. lt is also pdllble lO obtain pans on a Mail Order basis from a number of tpeei&liJts who advertise regularly in the motor cycle magazines. "I (c) 4-Stroke.net ... '' r Safety fi~ ... ~ ' Professional motor mechm(c's are trained in safe working procedures. However enthusiastic you may be about getting on with the job in hand, do take the time to ensure that your safety is not put at risk. A moment's lack of attention can result In an accident, as can failure to observe certain elementary precautions. There will always be new ways of having accidents, end the following points do not pretend to be a comprehensive list of ell dl.!ngers; they are intended rather to make you aware of the a safety-conscious approach to all work risks and to encoura~ you carry out on your vehicle. Essential DOs and DON7s -- DON'T start the engine without first as.certaining that the transmission is In neutral. DON'T suddenly remove the filler cap from a hot cooling system - cove r it with a cloth end release the pressure gradually first, or you may get scalded by escaping coolant. DON'T attempt to drain oil until you are sure it has cooled sufficiently to avoid scalding you. DON'T grasp any part ofthe engine. exhaust or silencer without first ascertaining that it is sufficiently cool to avoid burning you. DON'T allow brake fluid or antifreeze to contact the machine's palntwork or plastic components. DON'T syphon toxic liquids such as fuel, brake fluid or antifreeze by mouth, or allow them to remain on your skin. DON'T inhale dust- it may be injurious to health (see Asbestos heading). DON'T allow any spilt oil or grease to remain on the floor wipe it up straight away. before someone slips on it. DON'T use 111-fittlng spanners or other tools which may slip and ~ use~ • DON'T attempt to lift a heavy component which may be beyond your ~pabilty - get assistance. DON'T rush to finish a job. or take unverified short cuts. DON'T ellow children or animals in or around an unattended , vehicle. DON'T inflete a tyre to a pressure above the recommended maximum. Apart from overstressing the carcase and wheel rim, in e)(treme cases the tyre may blow off forcibly. DO ensure that the machine is supported securely at all times. This is especially important when the machine is blocked up to aid wheel or fork removal. DO take care when attempting to slacken a stubborn nut· or bolt. lt is generally better to pull on a spanner, rather than push. so that if slippage occurs you fall away from the machine rather than on to it. DO wear eve protection when using power tools such as drill, sander, bench grinder etc. DO use a barrier cream on your hands prior to undertaking dirty jobs- it w ill protect your skin from infection as well as making the dirt easier to remove afterwards; but make sure your hands aren't left slippery. Note that long-term contact with used engine oil can be a health hazard. DO keep loose clothing (cuffs. tie etc) and long hair well out of the way of moving mechanical parts. DO remove rings, wristwatch etc. before working on the vehicle - especially the electrical system. DO keep your work area tidy - it is only too easy to tall over articles left lying around. DO exercise caution when compressing springs for removal or installation. Ensure that the tension is applied anc' released in a controlled manner, using suitable tools which preclude the possibility of the spring escaping violently. DO ensure that any lifting tackle used has a safe working load rating adequate for the job. · DO get someone to check periodically that all is well. when working alone on the vehicle. DO carry out work in a logical sequence and check thet everything Is correctly assembled and tightened afterwards. DO remember that your v&hicle's safety effects that of yourself and others. If in doubt on any point. get specialist advice. IF, in spite of following these precautions, you are unfortunate enough to injure yourself, seek medical attention as soon as possible. Asbestos Certain friction. insulating, seallng. and other products such as brake linings. clutch linings, gaskets, ate - contain asbestos. Extreme care must be taken to avoid inhalation of dust from such products since lt is hAzardous to health. If in . doubt. assl..'me that they do contain a~'lesto Fire Remember at all times that petrol (gasoline) is highly flammable. Never smoke, or have ony kind of naked flame around. when working on the vehicle. But the risk does not end there - a spark caused by an electrical short-circuit. by two metal surfaces contacting each other. by careless use of tools, or even by static electricity built up In your body under certain conditions, can ignite petrol vapour. which in a confined space is highly explosive. Always disconnect the battery earth {ground) terminal before working on any part of the fuel or electrical system. and nev ~ risk spilling fuel on to a hot engine or exhaust. lt is recommended that a fire extinguisher of a type suitable for fuel and electrical fires is kept handy in the garage or workplace at all times. Never try to extinguish a fuel or electrical fire with water. Fumes Certain fumes are highly toxic and can quickly cause unconsciousness and even death If inhaled to any extent. Petrol (guoline) vapour comes into this category, as do the vapours from .certain solvents such as trichloroethylene. Any draining or pour!:;s o: such ·1olatile f!ui:!s .;hyufC.: be done in a well ventilated area. When using cleaning fluids and solvents, read the instructions carefully. Never use materials from unmarked containersthey may give off poisonous vapour&. Never run the engine of a motor vehicle In an enclosed space such as a garage. Exhaust fumes con tain carbon monif you need to run the: oxide which is extremely pol~s; engine. always do so in the open air or at least have the rear of the vehicle outside the workplace. The bettery Never cause a spark, or allow a naked light, near the vehicle's battery. lt will normally be giving off a certain amount of hydrogen gas, which is highly explosive. Always disconnect the battery earth (ground) terminal before working on the fuel or electrical systems. If possible, loosen the filler plugs or cover when charging the battery from an external source. Do not charge at an excessive rate or the battery may burst. Take care when topping up and when carrying the bllttery. The acid electrolyte, even whtn diluted. is very corrosive and should not be allowed to contact the eyes or skin. If you ever need to prepare electrolyte yourself, always add the acid slowly to the water. and never the other way round. rubber gl011es and goggles. Protect against splashes ~wearing (c) 4-Stroke.net \..._.. __ __. Mains electricity When using an electric power tool. Inspection light etc which wor'ks from the mains, always ensure that the appliance is correctly connected to its plug and that, where necessary. it Is properly earthed (grounded). Do not uae such appliances in damp conditions and. again, beware of creating a spark or applying excessive heat in the vicinity of fuel or fuel vapour. Ignition HT voltage A severe electric shock can result from touching certain parts of the lgnltion system, such as the HT leads, when the engine is running or being cranked. particularly if compOI'Iems are damp or the insulation Is defective. Where an electronic ignition system is fitted, the . HT voltage is much higher and could prove fatal. · . ~· . -~ ..... .. .. ' ..., . . r • ,. ·. .. '· .. .,.,,: • •. ft ' \' ·"• Routine maintenance Periodic routine ITWim.n.nce il • continuous procea that m~Mdiltey the ITWIChlne la used. lt must be carried IPCified mileege recordlnga or on a ~lendr basis If the machine 11 not ua.d tr.quently, whlc:fleo4r the toonttt. •• en lnauralCe policy, to help Maintenenoa ahould be reg~dt k•p the machine in tht peek of condition end to enan long, troubla·frte 111rvice. lt hla the additional benefit of givtnu early w•ning of any feuka that nwv de¥elop end will act •• a aafety cflck, to the o1Mou1 ~of both ridilr and machine alike. The various mlintenance tllb are dtseribed below, undlr thllr rt~Peciv mile~g end calendar heeding&. Aa:omP'nyinu dleorama 1r1 provided, when nec. . .y . lt thould be ..,_mbertd tt111t tM intlrvel..........., the various main1enence . . . . 11rv11 only " a guide. As the mechine geu older 01' is u•d under perticularfy tdwf• conditione, it would ba edviJable to ', ' " ' - thtl*'lod ~WIl-Ch dlck. Some of the tes•u - . described In ~ai l, where they are not ~ntloed fuly as a routine malntenence item in the text. If a specific Item 11 !TWntioned but not described in deteil, it will be co~ertd fuly in the approprilte OMpter. No ~Petial tools are required for the normal rOU1int maintenence tMkL The tools comeined In the kit aupplitd with every new machine will prow ldtqulte for eacl'l task, but If they ere not available, the tools found In d'ut awraut houMhold should IUffic:e. omenc~ out M AM 1 Check oil level frequently and top up v.twn nec_.ry (c) 4-Stroke.net w..ldy, o r wtry 200 ,..._ ...., ) ~ ... . Cheek the sump oil level and top up if neces111ry. Always _ . 1ha machine on the levtt ground, using the centre stand. If the engine is werm, allow five minutes for the oil lawt to llftfe, befo re checking. The dipnic:tc .. locmd on the right·hend lidt of the enQine, at the rear of the crankca• eating. lt hes an lntep cep 1nd screws into the c:.tin9, to ••I off the oil filler openlne. Remow the dipstick ~rd add oil untjl tne upper IIYII rNrk of the dipstick le reached. Do not overfill. For checki1'41 ~·. tha dipstick should be rested on ''- edge of the filler oPiflintt and not SC~TVWd ho!TW. Check the tyre prltiUriL Alweys check witn the tyres cold. ueing a pt"tsaure gauga known to be IICCUI'IIta. O.C:k the lwel of elec1rolyte in the blrttery. U• only d~ tii!N w~te r to top up, unlet& there his * n 1 definite epiiiiiiJI of .ad. Do not overfill • Give the whole machine a clo• vlauat lnsp~tio, chtcking for loo• nute end fittlnge, frayed control cablas etc. Make sure !M lights. horn and t raffic indicators function correctly. ' . .. ., AM 2 Battery is hidden •-Y · do not overlOOk ·.. 8 Routine Maintenance place or if the tread depth is close to the statutory minimum , replace as a matter of urgency. Oleck condition of return spring on centre stand. Oleck hor n and speedometer for correct functioning, bearing in mind thst the efficient operation of the former is a statutory MDnthly or """V 1,000 milt .. Complete all the checks listed in the -kly/ 200 mile wvice, and the following item: Ctlange the engine oil. Drain off the old oil whilst the eogine is still warm to enture complete and rapid draining. Just over a pint will be releallld. If the machine is ulld for a suo::essjon of wry short journeys, il 11 preferable to halve the period between oil changes, to offwt the effeets of conden•tion, Six Monthly Of' re~J.i-mnt . y_.ty or every 6,000 miles every 3,000 miles Complete all the checks listed under the wa.icly and monthly '-fings, then carry out the followinu aditiorial tasks: Check valve t11ppet clearances and lldjuat if necesSiry Cl tin and adjust or replace the tperkinu plug Ctleck the ignition timing and adjust if nec.essery Clean the air filter element Check throttle for correct amount ot fre. play Oleck fuel tap gauge and clean if nectiSIIry Check fuel tank and fuelli"es for leeks air locks or llldiment. 01-=k dutl:h operatton and adjust if neceuary Adjust and lubricate final drive chain. If worn, replace in conjunction with aprockE!ts Check action of both brakes and adjust if nec-y EJG~mine both wheels for dented or buckled rims 1nd loose tl)okes. Check tread on both tyres . If uneven wear has taken Again complete all checks listed under the weekly, monthly and six monthly heads, not only il they are not directly connected with the tasks listed below. Then complete the following: Change the engine 011. When the old oil has drained off remove the right·hand crankcase cover and c lean the oil Uter screen by washing with petrol. CC 50, S50 and SS50 models only have this filter). Remove the air filter element and fit a new replacement. Remove both wheels and check condition of front and rear brake shoes. Replace if linings are thin. Check actiOn of tront forks. Olack steenng head baartngs for "'-cknm, with mach ine on centre stand. Do not overttghten . Check operation of steering head lock. Capacities data 0.7 lttres (1.2 Imperial pints) (1.5 US pints) Lubrication svuem c~ity (Engine and gearboK tn unit ) Recommended lubncants Below OOC (320f) ooc - tsoc 132oF. 590Fl Over t5°C ( 590F ) 0.002 tnch Tappet clearances (engine cold) Con tact breaker gap Spark plug gap ... Tyre pressures Front fork oil capacity: At oil change ... After reassembly SAE10W SAE 2(JN SAE 30 0.012 · 0.016 inch 0.024 - 0.028 inch 22 psi front, 28 psi rear Inflate rear tyre to 32 psi if pillion passenger carried 95 cc (3.3 fl ozl 100- 105 cc 13.5 · 3.6 fl oz) (c) 4-Stroke.net ., . .Recommended lubricants COMPONENT TYPE OF LUBRICANT ENGINE Multigrade 20W/50. To API SE specification Multigrade 10W/JO Normal temperatures below freezing point FINAL DRIVE CHAI N Mult igrade engine or graphirad grease ALL GREASING POINTS Multi-purpose hi~ based grease Note: The engine oil should be changed every 1000 mil#ls. In wint~r. changed every 300 miles. t• meltong point lithium or when the machine is used for short JOUrneys only, the otl must be ..• ... : • J .. ..,. Chapter 1 Engine, clutch and gearbox Contents General descrip ti on Operations with engine/gearbox in frame Operat ions wit h engine/gearbox removed Removing the engine/gearbox unit Dismantling the engine/gearbox • gene ral Disman tling the engine/gearbox · removing the cylinder head and cyl inder ... Dismantling the engine/gearbox · removing the p iston and pist on rl ngs .•• Dism antl ing the engine/gearbox - removing the vaives and rocker Dismantli ng the engine/gearbox- removing the alternator roto r ... Di smantl ing the engine/gearbox· removing the stator plate Dism;:,nt ling th e engine/gearbox· removing the camshaft chain 'tensioner Dismantling the engine/gearbox· removing the final drive sprocket Dismantli ng the engine/gearbox· removing the clutch operating mechanism and the right hand engine cover Dismantling the engine/gearbox · ~ emoving the clutch and primarv drive Dismantling the engine/gearbox - stripping the clutch Dismantling the engine/ gearbox · removing the gear selector mechanism, kickstarter return spring and oil pump Dismantling the engine/ gearbox -separating the crankcases Dismantling the engine/ gearbox · removing the kickstarter ratchet and gear cluster Dismantling the engine/gearbox- removing the crankshaft assembly Examination and renovation· general Big-end and main beari ngs· examination and renovation ... Cylinder barrel - examination and renovation Piston and piston rings· examination and renovation Cylinder,.head ·decarbonisation and examina tion Valves, valve seats and valve guides· examination and 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 renovation Rockers and rocker snafts- eJ/ to accomplish this is to put the clutch into a vice fitted with soft jaws and carefully compress the clutch unit, using its primary drive gear and then remove the large circlip. On releasing the pressure the clutch plate can be remo~ to expose the clutch Springs. 2 The clutch transmission shock ablorber springs can be removed by prising them out with a 5Crewdriver. 16 Disman tling the Engine/Gear box· Re moving d w gear selector 21 8ig4nd and Main Bearing~· Examination and Renovation mechanism, kick start return spring and oil pump 1 Remove the gear selector positive stop pivot bolt and lift out the stop arm and spring. 2 Unclip the gear selector operating arm and pull out the whole selector complete with the gear lever shaft, spacing collar and return spring. .. - ... .,. _ ...... 1 Failu re of the !big-end beering is invariably accompanied by a knock from within the crankcase that progressively becomes worse. Some vibration will also be experienced. There should be no vertical play in the big-end bearing after the old oil has been wa1hed out. If awn a small amount of piiP>/ is evident. the bear ing is due tor replacement. Do not run the machine with a - · - ~ .. . 13.3 The Mtting plate' and operating lever with screw removed 13.4a Lift otf the engone <:oveo .... 14 1 Remove the <:lut<:h <:over (c) 4-Stroke.net 14.2b The improvised <:lut<:h nut tool ... I . • • ··--------------- • .- '• ,. . 14.3b The clutch pnm3ry drive and ... 14. 3c Its bronze bush (c) 4-Stroke.net 14.4b Loft off the driven primary gear end •.• ." ........ . 14.4c F inally the crankshaft spac;er. Note the large flange is innermost I 'l ..;,......-.. .....~ ' . -. 14.2d Note the spelial beYwlle<$-llh!lf i" (c) 4-Stroke.net . ... .. . .. ' .. .. ...• • .. (c) 4-Stroke.net 16.7 Removt tl l lft · ~d - stdt ge•r •ector dn.om bolt .. .. ... .. y,.,. .• . '. ·..,.. .• •.. ?" : t.. 1' 26 ... Chapter 1 / Engine , clutch and gearbox - - -~ - 4 ~ ~ ... 11 J 0 9 ' ,. 9 5 i I , - -- ~ 11 I I ) I -- ' • l"' •. j. . 5 CyUnder head com~re 6 G#sket 7 0 /p 9 s ;{Jt • 10 RtibbOr sw J 1 O·ring , 8 Scud 12 Rubbers..,, .. f (c) 4-Stroke.net worn big..nd bearing. otherwise there is ritk of brteking the ..,.ble connectitlt rod or crankshaft. 2 lt is not to separate the f lywheel -mbly in order to repllce the bearing becaua the parallel tided crankpin is p,....d into the flywheels. Big-end repair shq~,ld be entrusted to e Houdl agent, who will heve the n~ ' repl or replacement fecllltill. 3 Fe1tu111 of the main bearings is usu•Hv .vident In the form of 1n audible rul11ble frpm the oottorn end of the engine, aca:>m· penled bv vibrltion. The vibrltion will be mott notioa-..,.e tnrough the p~l s. - 4 The cranksheft main bearings are of the bell journal type. If - r 11 IYident in the form of pley or if tbe bearlnga feel roultl • th-v ere rotatlld, replacement i1 nec:eaary. To remo~ the mein t.rings If the appropriate ~ toOl Is not eveilable, ·, insert two thin Stilet wedgas, one on each sidl of the bearing, and wlltt th• clamped in e vic:a hit the end of the crankshaft IQUifely with 1 rawhide mallet in .en attempt to drive the crank· · IMtt tt1fough the t.ering. When the beerine h• moW<~ the innial emount, h lhould be poSij;)le to ineert e conventiontl two or thi'M lelltld aprocket pulle(, to IX1f'l1)1ete the drawing- 1Nl cproc ket is recested to accommodate a puller. 1 The u~ i~' of a bedtv worn cylinder berrel end piston are~sov oil consumption and p iston slap, a metellic rattle thS..oecun wtutn there is little or no load on the eil9ine. If tha top 1.< the bore of the c,4inder barrel is 11111mined cerefullv, it will be found thet there isa ridge on the thrust side, the depth ot which will vary according to the amount of ·weer that has taken place. This merks the limit of trawl of the uppermost pistOn ring. 2 Mleture the bore d iameter just below the ridge, using 1ft internal micrometer. Compere this reading with diameter et the bottom of the cvllnder bore, which has not been aublec:t to If the d ifferenc:a in readings exceeds 0.005 inch it it ~V to heve me cylinder n~bored end to f it an oversize piston enct rings. 3 If an interne! micrometer is not weil eble, .the emount'Of CVIinlder bore we• can be measured b'( interting the pil1on -t. ·~ -• " Chapter 1/ Engine, clutch and gNrbox .- ~ - . .. . ! •; 2 3 ... .. ~ ~ ~() !"~ ...., 11 ~ . 9 ..... ""' l' ,. ·. I I ...., f : ~ .~ . ,.~ I 12~ _:_4/f! 12~:"' • 3 ~ 13 (# - U Fig 1.3. Camsh1ft 1nd valvu r < 3 4 5 • CttmshtJ ft Rochr arm Rocker shaft In/at Jta/Jtt Exhaust ~ 6 7 V a/1111 stem seal Va/11t1 stfm seal CliP 8 Pi#Jfe sprmg outer •• 9 70 Top collar T7 lnMr 11al11t1 JPrmg u.r 12 Collets 13 Ta(JtJit adJUSting screw 14 TIIPPt:t adJusting screw - loci! nut Val11a wring mner without ng~ 10 that it is appc-o•imately '~ inch from the top of the bore. If it it po.,ble to inwt a 0 004 inch feeler gauge between the piston and the c:ylindtr wall on the thrust side of the piston, remed11l action must be taken •· 4 Check the surface o f the cylinder bore for sc:ore marks or any ot h• dai'Tlltge th8t IT'IIY heve resulll!d from en earlier engine •lzure or disphtc:ement of the gudgeon pin. A rebore will be neceel8ry to remove any deep indentations, irrespective of the amount of bore weor, otherwite a compression leek will oc:c:ur. 5 Check that the elCternal cooling fins ere not clogged with oil or road dirt; oth•wi• t he engine will overheat. When cleen, a coeting of trlltt cylinder bleck will help impro\1111 the heet radiation. 0.006 inch for the oil contro l Tlng, the pirton is due for replace ment . lt it unu.uel for this amount o f _ , to occur on its own. 5 Ptlton ring weer is measured ~ removing the rings from the piston and in~trlg them in the c:ylmdtr bore using the crown of the piston to locate them approxtmettly 1 ~ inches from the top of the bore. Make sure that they rest square with the bore. Measure ttw end gap with a feelor gauge; if the gap e•ceeds 0.012 inch they requira replacement, ::.numing the cylinder barrel is not in need of a rebore, and that the ringJ - e gapped correctl y in the first place. (c) 4-Stroke.net .. 23 Piston end Poston Ringa · ExaminatiOn end Reno..tion rebore is n - - v , the e~lsting poston and rings can be diwegar~ becaue thev Will be reptec:ed with their oll8nize e~.uvlntr1 a maner of c:our•. . · 2 Remove all treats of ca'bon from the piston crown. using a soft tcraper to .,-.sure that the surtece is not marked. Finish ott by • pohshll'lg the crown, with me1a1 polish. so that carbon does not · • .! adhtfa 10 eastly tn the future. Never u• emery cloth. 3 Piaton wear usually oc:c:urs \11 the skirt or lovo.er end of the piSton end takes the form of vertical atreaks or score marks oo the thi'\Jst 11de. There may al.:> be .:>me variation in the thick· n - of the skirt. 4 The piSton nng 9fOOves may also become enlarged in u•. al1owmg the piston rings to have greeter aide float. If the cleerence e~cds 0.004 inch for the tv.o l:Ompreaion rings, or 1 If 1 ; 1 Remove 1lrtrecee of Qrbon from the cylindlrr heed and valve ports, using, l wit tcr•P• . Extreme care ~Id be taken to ensure that the combullton c;hambe'r end valve - t s are not marked in any w.y, otherwtte h ot spots .,-.l.lleaktges ITIIY oocur. Finish by polist'ltng the combustion chember 10 that carbon dole not adhere 10 enlly in the future. Use metal polish and NOT emerv clom. . .• 2 Check to INke sur• that the valve guidH era tr.e from Qrbon or any other forttgn mnutr that ITIIY ctuse the valves to sttck. 3 lvleke sure me cyhndllr head fins ere not clogv~d wnh oil or roed dtrt, otherwue the engine wtll overheat. If nec-v, ute a wire brush. When the fins and outer .urfecec •e ct11n, • CXMting of matt cylindtr black will help improve the hell l'lldl•lon. • ·• .. • .• (c) 4-Stroke.net . .... . ., .. -·. : 30 2b Ordu of 30.21 Order of auembly of the gearbox mainshaft • ) .. .. • assembtV of the g!~Mbox mainsl\al t ~ · ~ • .. .. Chapter 1/Engine, clutch and gearbox Before reauembly is commeneed, the various engine and gearbox components should be thoroughly cleaned and placed close to the working area • 2 Make sura all traces of the old gaskeu have been removed and the mating surfaces are elean and undamaged. One of the be.t ways to remove old gasket cement is to appjy a reg $08ked in methylated spirit. This acts as a solvent and will enwra the cement is ramo-wd without r&sort to scraping and the tonse· quent risk of damage. 3 Gat her together all the necessary tools and have allllilable an on''can filled with dean engine oil. Make wre that all the new gaskets and oil seals ere to hand; nothing is more frustrating than having to stop in the middle of a reassembly sequence because a ·Atal ga~ket or replacement has been overlooked. 4 M~ 'sure the reauembly area is clean and that there is edequa& working ~PCce . Refer to the torque and clearance seti~ ~erv they are given. Ma')Y oft~ smaller bolts are easily sheared' if they are over-tightened. Always use the correct size scre'Wdrive bit for tha cross haad screws and ne'ller an ordinary screwdriver or punch. 5 Rerno11e all oil teals if in doubt about their condition. After replacing them grease :heir tealing tips to facilitate !haft insertion Without risk of damage . (c) 4-Stroke.net ;;e ~ obtained:- ;.· ~· •• 2:7 Troi~d .....- , ·~ ~ ~·' -. ~: oil pul'n~emova, Aefer to Chaptet'2 ·Section 13 for details of tile oil pump. • ., ) 1.\ • < •." ·,~ faJtllll · Examination and Renovation, • Check •the condition of the clutch drive to ensure that none . ' ~.:_ :._.,. ~ ...· ~ . . -.£------._ -------------------------------------' 31 Enginei.Gearbox reas.embly ·.Joining the cnnkcaM hal:,;"J, Examination and Replecemant • ,. 29 Engine Re-mbly · General 30 ji ng~.tlearboK r-mbly - Replacing the crankshaft,lf'arJ and IHcklt(rter .. # - -........;.- - - ; . _ - - - - - - - - - - - - - - - - 1 Fit!l;h ' cranksh;Rt complete with bearings into the left·hand • \, crankc alf. · · .~ • 2 ASMlmble the gears onto their respective shafts in the correct ~ ~~ order. Do riOt forget any of the thrust wamers or spacerS~ ~ ~ ·· 3 Refit the selector forks onto the selector drum making suni . ~ ·. ·~ ~? :fbe roc'et .e nd ~S liNe~r 1s excessive ·~ eplacmnts will have' to be shaft and replace th1s 10 the crankcase. a• ·. . one. ,... 4 Examine the condition of the val~ collets al)d the groo119 on ... the valve in which they seat. If there is any sign of. damage, new replacements should be fitted. If the collets worfc loose whilst f the engine is running. a valve will drop in and cause extensive damage. •· -: · 6 Measure the valve Stems for wea'f, making reference to the tolerance values given in t he Specifications Section of this Chapter. Check al$0 the valve guides. If wear is evident. the cylinder head will need to be replaced if it is of the cast iron type. In these cylinder heads, the valve ~J.ides are an integral part and cannot be replaced. Alloy cylinder heads are fitted with detachable valve guides, which ~ eai't be removed by heating the cylinder head in an oven then U:Sing a two diameter drift to drive them out of position. The initial diameter of the drift must be a !J!)Od .fit int the valve guide stem. Replace with the new valve guides whilst ttle cylinder head is still warm. .• 6 Check the<*'" length of the valve $prings against the list of tolerances in the Specifications. If the springs are reduced in leng1h or it•there is any doubt about their cond!tion, they should ~ be re n e~ . :~ .•.. ~ .... ··•· •• • ·· ; ·{ ~6 RO~s and Rock• Shlifts. -EKamination ·~ .. I .tQI'te4. After cleaning the valves to remove all traces of carlxH)f examine the heads for signs of pitting and burning. Examine all:> ~ the valve seats in the cylinder head. The exhaust valve and its seat will probably reQuire the most attention because these ere the hotter running of the t\1110. If the pitting is slight, the marks can be removed by grinding the seats and valves togeth!M", using fine valve grinding compound. 2 Valve grinding is a si~le task, caHied out as follows. Smear a traci! of fine valve grinding compou.nd !carborundum paste• on the seat face and apply a suction griflding tool te) the head of the valve, or use a screwd river in the slot in tbe valve head. With a semi·rotary motion, grind in ttle valve ~d to its saat: using a backward and forward - action . lt j1 advisable to lift ttle valve occasionally, to distribute the grinding ·compound evenly. Repeat this operation until un unbroken ring of light grey matt finish is obtained on both valve •and seat. This denotes the grinding opehtion is complete. 'Before passing to the neKt operation, make quite rure that ull traces of the grinding compound have been removed from both the valve a.nd its seat and that none has entered the valve guide. If this precaution is not observed, rapid wear will take place, due to the abrasive nature of the carborundum paste. .. 3 When deeper pit mark ~ are encoutil'~d, it will be necessary to· use_a valve refacing machine al)d also·a valve seat cutter, set to · an angle 'of 45°. Never resort to excessive grinding because this will only pocket the valve and lead to redu~ engine efficiency. If t here is any doubt about the condition of a valve, fit a new t l J ot(he teeth are chif,ped, broken or badly worn. t G~ .-th. plain and the imer'ted clutch p lates a wash witn a pantfi~I'Q mix and check that th~y are. not butkled or dlsRemove ail traces of dutch ilmert debris, otherwise a .•grad\.rdl buiid-up wi ll affect clutch action. · ' • 3. (/isual ii'ispeetlon will show whJ~ter the tongues of tha clutch ~ate$ haiie become burred and Whether . in~taos have fbrmed in the slots with· which they engage, Burrs should be ' removed with a file, which .can also be used tO dress the slots, provided the depth of the indentations is not too great. 4 Clleck the thickness af the friction liningS in the inserted plates. it' the linil'lgs have worn the plate should be replaced. Worn linings promote dutch slip. 5 C~k also the free length of the olutch springs. Do not attempt to stretch the springs If they have compressed. They must be replaced when they reach the setViceable limit, as a complent set. To reassemble revn~ the procedure in Section 15 of t~lhepr. 25 Valves, Valve Seats and Valw Guides · Examination and Renovation .. 29 Meke sure. that both the gasket faces of the crenkcase halves are clean and apply a thin coating of gasket cement. 2 Check that the hollow <;lo~ pins are in position, Fit a new gasket end lower the right-hand erankcaM on to the left·hand one. The tWo halws should locate together without force . 3 RepiKe the eight 6mm crosshead scr•ws and tighten them ' ·' .. .,. r I l 30 Chapter 1/Engine, dutch and gearbox diagonally and In an 111en manner. Note that there are thrH lengths of tcrews. 32 Engine/Gearbox r-ambly · Replacing the geer _.lc:IDr mechanism 1 Replace the two end plates and four pins of the 91111r ~alector drum. The four pins are of equal length, but one will protrude further from the eelaetor drum to act as a locatiniiJ pin. This arrangement ensures that the cam plate on the end of the drum is correctly registered. Turn the engine over and f it the 6mm bolt ard washer in to the other and of the •lector drum. Replace the rubber !Baling plug. 2 Refit the gear • lector mechanism and gear leller shaft complete. L91tly grea• thalhaft before r ea~bly . 3 Replace the positill'll n ap levvr, roller and spring by screwing in its 6mm pivot bolt to the crankcase. 36 Engine/Gearbox re-mbly • Replacing the. ea m shaft chain and tensioner !< 1 Refit the camshaft tensioner wheel by screwing its piiiOt bolt into the crankcate. Fit the camshaft chain . . 2 Replace the tensioner pushrod with ita machined f lat side 'facing outward from the engine 81'1d screw in the lock screw so that the rod cannot be pushed out further than the mark made on it wh.n dismantling. Lock the adjuster screw with its 6mm locknut. 3 Rttplace the two tensiorler springs (the lightar spring Is interted first) and raew In the tensioner adjuster screw. Replace the plug bolt and wathtr. :n Engine/GeMIIox reawmblv · Fitting and Piston end Cylinder Blrrel 1 Assemble me piston nn me connecting rod, with the arrow on the piston crown facing downwards. lt may be necessary to helt 1he piston in warm water to enable the gudgeon pin to enter the piston bosses. Replace the gudgeon pin cirdips, cheki~ to eNUre that both circlips are located positively in their grool/9$. Always f it new circlips - ntvef re-u~ the originals. tt is advisable to oover the mouth of the crankcase with rag during this operation. If a cirdip falls in, it may be necessary to di$nlantle the engine again! '!" : with the Specifications and 2 Check the p iston ring -mble the rings in their respective gro~lef, checking ro make sure that the TOP merklng on both comt)ression rings faces up· wards. The chrome ring is carried in the top groove of the piston. J Before the piston is interted into the cylinder_.berrel the camshaft drive chain must be fed through the tunnel cast in the cylinder barrel. The chain guide roller should also be fitted et this stage and located by the pin an '0' ring sea l that screWI into the left·hand side of the cylinder berrel. 4 Fit a new cylinder ba• g11sket and oil the piston end the cylin~ oore. Slide the cylindt!r berrel down the long holding down studs and with the piston 1n a convenient position lo._. the barrel over the piston whilst compressing the piston rings with the finget"s. Check thet the ring geps are staggered and not in line with each other, to cut down compression loss. Special care i1 needed whilst the rings ore being cr;>mpraslled and inll!rted into the barrel because they are brittle and will break very easily • 33 Engine/Ge•box r•-mblv · Refitting and tan11oning the kickstarter return aprlng • 1 Slide kickstarter !pring on to the shaft followed bv the splined retainer. Turn the shaft clockwiee until the and of the spring retainer abuta egainat the crankcase stop. Loop the end of the return spring round the crenkceae lug whilst holding the lhaft in the fullv clockwi• position. 2 Fit the retaining c~rel_, and check that both the kickstarter and the gaarchange mechanisms function correctly. lt will be necessary to re\/Oiw the gearlhafts to facilitate the checking of the ~alector, mechanisms. "'ps 34 E nglne/Geerbox ra-mbly · Replacing the oil pump, prim..-y ~ive and clutch Replace the oil pump using a new gasket and tightan down the three 6mm retaining croslhead screws eventv. 2 Replace the specer on the crankshalft with ita large flange pointing innermost. Fit the primerv drive pinion o nto the gear· box shaft and teeure it whh iu cirelip. 3 Oil and replace the clull:h bnring and fit the clutch primary drive geer. Replaoa the clutch fol<»~ed by the special domed washer the correct w~ round i.e. 10 that the marking "out.ide" can be read with the walher in position, then the tab wlllhar and finally the clutch nut. Tighllln up the nut. The engine will have to be locked by plecinQ a bar through the nnall end of the connection rod, not forgening to u• protective pecking between the bar and the gasket face. Knock owr the tab$ of the tab washer. 4 Replace the clutch oover pi alii using a new !J8$kat. 1 r.; j I I .• 38 Engine/Gearbox Re-mbly • Fitting the Cylinder Heed 1 Before the cylinder haad can be fitted to the engine it mu11 be fullv a!ISembled. Although it mav appear possible to replace the rockers when the cylindllr held is bolted down, this is not so in practice. The rocker spincles ere retained by the lon111 holding down studs thet pass through the cylinder head and cannot be rttmoved or replaced unless the cylinder hell(! is lifted. , 2 Lllwer the cylinder head onto the cylinder berrel, taking care to feed the camshaft drive chain through the tunnel cast in the bOttom of me head. lt is necessary to loop the ~ha in around the large camshaft sprocket during this operation, passing both through the tunnel. They can be kept together by passing a wire through the centre of the sprocket so that they are retained in c lo~e proximity to the camshaft, whilst the head is bolted down. The cam5haft i5 fitted· from the right·hend side of the cylinder heod, wh8f!1 there is sufficient clearance for the cams to pass through. 3 Note that there is a full gasket between the cvtinder barrel and head and not just a copper ring seal. 4 Fit the finned top 00\Mf of the cyl.nder heed with gasket, and pull down evenly until the racommendeo torque settings are achieved 16.5 - 8.7 ft lbl. Alwavs tighten ill a diagonal sequence. an essential requirement becau• an alloy cylinder head will distort easily. There is a separate bolt on the left·hand side of the cylinder head, just below the circular oemsh11ft sproclet aperture, (c) 4-Stroke.net I 35 Engine/Gearbox .--mbly · ReP!f!Cing the left·twnd cover end dutch operatinl mKhlnj,m Fit me ohwy. guide and ·'!>ring -mbly into the clutch centre. 2 Rept;,::e the clutch puahrod into the right·hand side cover locating the tang into the hole provided. 3 Fit a new gasket. replace, and tighten the eight 6mm croiShl!lld screws !three different lenghts) in a diagonal and even ~equnc. 4 Replace the clutch operating lever complete with its adjusting tcrew and locknut folloMd bV the ~eting plate which is retained by one 6mm countersunk cronhead tcrew. 6 Gretll! and inll!rt the opereting arm and spindle complete with the new 0-4"ing. Replace the clutch stop pin. 6 The inapection cover can bl replaced at this stage, if dlnired, but it mey hew to be removed egein later to adjust the clutch. See Section 44 of this Chapter. . .. '"" • • .. . -, . . . ., ,r .. 31 Chapter 1/ Engine, clutch and ge1rbox . • <; • 8 15 (· ID I& tJ ..' • 11 20 12 11 r 11 1J ' .. ,. . .' Fig. 1.4. Pect.l drive lnd left hind lfl(llnt cover Lt~f-hlnd .. 2 3 ; . cr•nkc- cover Driw •procktlt 12Tor 13T Drillfl sprocktlt 12Tor 13T 4 Pedal sprocket • 5 Sliding dog 6 Selector fork 7 Spring 8 Spring : \- 1 ·. 10 Lever 1 1 Poin tt cowr 12 Gnkltt 13 Spllntd wuhtlr 14 Circlip 15 Circl/p 16 17 18 19 Dowel Scntw SctWW SctWW 20 SctWW 21 CirclltJ (c). 4-Stroke.net 9 SeiiiCtor fork shaft _,..": end below this, 1 bolt et the b - of the cylinder bl~n. t must bl tighttnld. .• Both sprock1t. Fit the three bolts thtt cltmp the IPf'OCktt to tne camshaft end check ._;n thtt ell the timing positions core~PQnd eKtctly w1th thJ'cantrt line. 4 The need for accuracy ctnnot bt overstr.-d. Even 1 ~mal errOf' in the valve timing will hiYe a very m.rkld etfect on me pertormanct 1nd general running of the engine. 5 If the •cond c:htck pro.,.. •tisflctory, fit the two side coven to the cylinder '-cl Md1 with a new guket. The right· be finld -hand cov.r 11 held by two cron hHd terews 1nd tim . A Iona bott through the cantrt of this cf this Chapter. Do n:.: forge\ to fit a new exhaust pipe gaskllt. ~ .... 44 Engine/Gearbox Reaiaembly · Completion and Final Adjustments {oncludinq clutch adjustmen1l. Replace the sparki(lg "lng a \ter checki ng that ot os gapped at 0.024 onch . .;_:! • 2 Replace and tighten -the crankcasa drain plug. Refill the sump with clean engine o(l bf the redommended viscosity. The capacity is 0.? litres_. just'over OSie..flnperiel pint. Check With the dipstick to make. SUfl t!~e oil is tPie correct lev"L 3 Adjust the clUtch lever tree play to 1.0- 2cm at the ert,d. Tbe adJustment is made by the screw antllocknut located utlder the ri!Jht·hand chror'l'led engine insP.Sction cover. 'j 1 _e ·.), 32.2 Replace the gear selector mechanism I ar • f (c) 4-Stroke.net .. \ 45 Starting and Runni"' ''!ml Rebuilt Engine When· the initial ~uq, is made, ru'l the engine gently for the first few minuwtJn order to allownhe •oil to circulate throughout all part'i of~ engine. Rern~bf that if a numbe r of new Par-ts have been fitted Qf if the engin.e has been rebored, iJ w!IJ be necstl~y to .f"i.low tb4 original running-in instructions 'llo that thP new 'Parts h&li& aml"'e opportunity to bed-down in a satisfactory manner: Check for oil leaks and/or blowing gaskets before the machine is run on the road . ' . .. .. . ,,.;. ~ .. .· , =.~ ·~ ·. 32.3 Refit the positive stop mechanism "I ..;· .,, e ,. . '1 ' · ~ r t 36 . \ .. _ ·• .· ir __.. . ·. "· •.;:\-t' .' .\ • ' ,"-~ - ~· :,, ···)-.:. '/ / u .l»t-~i t .i .. • . "'· I-: ..' •\ ~· ZO--l() ·~ I 21---(S · ~to · ,____, Q----,8 ~16 _ ..... ,. '. ' (c) 4-Stroke.net Fig 1.6. Camshaft chain and tensioner 1 ca~h sf tsp rocket 2 Chain 3 Tensioner arm 4 Sprocket roller 5 Pivot bolt 6 Spring 12 Roller , 7 Spring 8 9 TO 11 Tension push rod Adjusting bolt Adjusting bolt Rubber push rod cap .,., 13 Roller pin . 14 'CJ!ain guide sprocket 15 Oil pump drive 16 Bolt . .... ·= .. 17 Bolt • , .• 18 Sealing washer ' · 19 Washer 20 ()-rim;~ 21 Nut ·.-. .. • . 34.1 Replace the oil pumJI· 34.2b Replace the retain1n9 c~ri'P 34.2o Refit the crankshaft spacer, large flenge 1nnermost .. 1 of the primary driven gear 1 (c) 4-Stroke.net 35.2 Locate t he clutch push rod tang into 111 hole ·. ... • .- ., t 35.3 Replace t.a side cover 35.4 Screw up the clutch operetrng mechanism 35.5 lrMrt the clutch O(lertting erm and spmdle followed by the ttOP pin • 35.6 Replacl the inspection cover ,. (c) 4-Stroke.net r •• Je.1 Fit the camshaft chain 1nd tensioner ~I ' .' -. ........,. ·,. ' 36.3a Note the order of the Sl)rongs ·. 37.1 Arrow on piston must face downwards ,• 37.3 Refit the chain guide roller (c) 4-Stroke.net .. .. . ' 38.2a Feed the ch11in and sprocket into the head as it is slid etong the studs • ) 40 5 ' I 20 2& 24 3 4 / 21 (c) 4-Stroke.net Fig 1.7. Right·hand engone cover 6 Right crankcase cover Gdskcr Clutch cover Gssker Combined filler plug/ dipstick Clutch lever l Spring 1 2 3 4 5 I I I I ~ k_ 8 Clutch lever stop pin 9 Clutch push rod 10 Clutch fitrer plate 1 T Clutch lift!Jr S!Jtting plate 12 Clutch adjusting screw 13 14 15 16 17 Distance piece Sprmg CJp Oil seal 0 11 sosl 18 O·nng 19 O·ring 20 21 22 23 24 25 26 Screw Screw Screw Screw Screw Nut Dowel . , : lI 41 11 ) . 13 I 11 8 ,.. 9 8 ·~ 1 I r' (c) 4-Stroke.net Fig 1.8. Clutch 1 Clutch outer 2 Clurchcover pressure plate 3 Gasket 4 5 Clutch centre bearing Clutch friction plare 6 Clutch pressure plate 7 Plain clutch plate 8 Spring 9 Damper spring 10 Circlip 11 Spring collar 12 Primary drive gear 13 Clutch drive gear 14 Lock nut 15 Lock washer 16 Lock washer 17 Cirr::Jip 18 Screw 19 Spl/ bearing _.__) 38.2b Replace the cemshaft 38.3Note t~e .full head 11esket. Do not forget the rubber oit seals t r ,. 38.4 TorQUing sequence for th8 cylinder head nuts. Note the plain nut on the bonom right-hand side. 38.5 Do not forget to t ighten the (c) 4-Stroke.net ·' 39.1 Align t he timing merits 39.5 Replace the finned cover twO bolts 1 : • I 40.1 Replace the sfator. Do not tor{l(t 1 new O·ting 40.3 Replace the woodruff key -40.4 Do not 42.2 Setting the tappets fOI"get to repiiCe the -sher bi'fore tightening down (c) 4-Stroke.net 43.1 Use 1 n - !ll"ket when replacing ----· .. ·-·~, '- th1 IIChllust P•PI ...:) .. 44 •. I r t , I (c) 4-Stroke.net r I Fig 1.9. Crankcase and oil pump 1 Right crsnkcsstl 2 Gasktlt 3 Left crsnkc/1$e 4 Left crsnkctlltl 5 Gasktlt ~- 6 Oil pUmp complete 14 Oil filter 15 Stud 16 Stud 11 S8aling washtlr 18 Dowel 8 Oil pump cover 9 Gasktlt 10 Inner rotor 1 1 Outer rotor 12 Oil pump crive sh8ft 19 Bolt - 21 Screw 22 Scrtlw 23 Screw 24 Screw 25 Screw 26 Spring washer ~ I ,-~ 45 ~ 9 1 & 5 z 15 ~t ~ 11 ~ .. ' ._-..' :~ · · .. "' l ' (c) 4-Stroke.net Fig 1.10. Gear selector drum and shaft 2 3 4 5 Gur sttltte tor fork 2off Selector lork gutde 2off ~lt1cor fork guidll pm clip 2 off Selector drum Posimte stop plate 6 Select or 7 4off Selector pin plate Positive stop lever 8 9 Spring , 10 ~M change spindle Collar 12 Sprmg 13 GPar lever rerum qmng 14 Gearleverrewm spring pin 15 Neut,.l swttch cont«tf 16 Neut,.l SWitch 17 NIIUt,..l switch fixing plate 18 O.ring 19 Pivot bolt 20 WMher21 Rubber plug 22 Oil seal 23 Bolt 24 Screw 25 Screw (c) 4-Stroke.net ... ' /:'~ I·~ ._,_ , . ·.t·" ·. ~ · ~'1; 1 ·. .• . - ·~ .: , ~ I,'"" .·- ~~ ,. l V ., l• ,I ~ \· i I ~ • l ,l .I ~ I 2 ~ I .(" ~ ~ .... . •I • .. 10 12 , i• I. 1, . _, ... . ..... -:.• r '~" I /~ 3 4 I ~\.1 .f " I 1 < iolo . • ( 11 I g .. ' . .... . ... ..'t 4' \ .; .. ., ... . ' • I 13 .- .i~ I .. .:·. l ~' ' 1 Pinion 24T 2 ~tcM spri ng 3 Sprin~ 4 Spindle '- : ... 5 Spring ,.~iner 6 SpFing retelner 7 Kick sterrer return spring . ,. 8 Kick starter 1"8tum 9 Thrust WBihttr 10 Washer ~- ---- ..... .;. "' . • ...... 1 I Circlip 12 Circfip 2 off 13 Circfip " ..,. ~ J··· ( I ~ :~ ~ . •. ~~ I i . 1 . 12~ft!IU" ..... • I Fit ~'" ,· 1 5 6 ; f .· (c) 4-Stroke.net ,•. ~ ~! ~ . ".. ,. ,. ~ A ...., ._ ~ - - ~ ~ :! .- •··- ~ ·- ~ : 4 . ,· 14 r i6J 13 - _J r 16 r 8 b~, ~ r ~ / ~· (__ _ ___ Q f 5 (c) 4-Stroke.net I 6 3 Fig 1.13. Crankshaft and piston Crankshaft assembly complete 2 Crankshaft assembly complere 3 Piston ring set 4 Piston 10 11 12 13 5 Gud{Jf!on pin Gud{Jf!on pin circlip 2off 7 Connecting rod 8 Roller retainer 9 Right hand fly wheel 6 Left hand flywheel Left hand flywheel Crankpin Valve timing sprocket ______ ____ ............................ ~ _.... ____ _.. 14 Woodruff key t 5 Big end roller 22oft 16 Main ball bearing ___ ...... _..__ ------- ----....~ - -- -"' -• Chapter 1/Engine, dutch and gearbox 49 46 Fault diagnosis · engine Symptom Cause Rtmedy Engine w1ll not turn over Clutch slip Check and adjust clutch . Engine turns over but will not start No spark at plug No fuel reiiChing engine Too much fuel reach ing engi ne ContiiCt breaker gap incorrect or points dirtY Remove plug and check. Check fuel system. Check fuel system. Check contact breaker. Engine runs but fires unevenly Ign ition and/or fuel system fault Check systems as thou~ engine would not start. Check and reset. Check comp ression. If none, remove cylinder head and exl!mine. Leak should be visible. Liff cyl inder head and replace gasket. Check timing marks for accuracy of setting. Incorrect valve clearances Burnt valves Blowing cylinder head gasket Incorrect ignition timing Lack of power Incorrect ign1 t1on timing Fault in fuel system Incorrect valve cl earances Burnt valves Blowing cylinder head gasket Badly worn cylinder barrel and/or piston See above. Check fuel system. Check and reset tappets. Check compression. See above. Examine piston and cylinder barrel. Check with list of tolerances. Hi!tt oil consumption Oil leaks from engine/gear unit Cylinder barrel in need of rebore and o/s piston Worn valve guides Identify source of leak and rectify. Fit new rings and piston after rebore. Failu re of lubncation system Wrong valve clearances Worn cylinder barrel !piston si8PI Worn big end bearing (rattle) Worn crankshaft bearings (rumble) Stop engine and do not run until fault located. Re-adjust. Rebore and fit o/s piston. Fit new crankshaft assembly. Fit new journal bearings. Symptom cause Remedy Difficulty in engaging gears Gear selectors not indexed correctly Gea r selector forks bent Check that pins engage fully with selector drum . Renew selector forks. Worn dogs on ends of pinions involved Selector pawl spring broken Renew worn pinions. Renew spring. Kickstarter does not retu rn when engi ne turned over or started Broken or misplaced return spring Renew spring or tension correctly. Engine, speed increases but machine does not respond Clutch slip Check clutch adjustment for pressure on push rod, or free pi ay at handlebar lever. Check depth o f linings. also frH length of clutch springs. Replace if serviceable limits reached. Difficulty in engaging gears. Gear changes jerky and m8Ch lne moves forward, even when clutch full y withdrawn Clutch drag Check clutch adjustment for too much free play. Check for bu rrs on cl utch p late tongues or indentations in cl utch housing slots. Dress with file. Check tightness of retaining sleeve nut. If loose, fit new tab washer and retlghten . Excessive mechanical noise Recondition as appropriate. 47 Fault di..noSts ·gearbox and clutch Machine jumps out of gear (c) 4-Stroke.net Clutch p lates worn and/or clutch housing Cl utch assembly loose on crankshaft splines Operating action stiff Damaged, frayed or trapped control cable .. .. . Check cable and replace if nace$$81)'. Make sure cable is lubricated and has no sharp bends . ~- ~ .. •... .. .. .. . -~ ' ~ .. . ·, . •' .. fl' · · . ::r.•'t. :--- ~ • Chapter 2 Fuel system ~nd ·. lubr~tion . . Contents Fuel system and lubrication · general descri13tion Petrol tank· rern011al and replacement · Petrol tap · remO\Ial and replacement Carburettor· general description Carburettor · rem011al and replacement Carburettor · dismantling and reassembly Carburettor· adjustments 1 2 3 4 5 6 7 Throttle cable and twist grip· removal -and replacement Air filter· cleaning Exhaust system· cleaning •· Engine lubrication ·genera description · • ···,.. Oil filters· rem011al, cleaning and replacement Trochoid oil pump- removal. examination and replacement Fault diagnosis · fuel system 8 9 10 11 12 13 14 Sp«:ific:etions Fuel tank capacity 7.0 I itres 11.54 Imp gal) Lubrication IIYJtem capacity 0.7 litre (1.28 Imp pin't s) Carburettor Main jet Pilot jet 58 or 70 35 Keih in Seiki General dltlc:rl ption The petrol from the petrol tank is grsvity fed via a tap having an intl!grel filter to the flollt chamber of the Keihin carburettor. The carburettor is of the fixed choke type with a cylindrical throttle slide. A manual choke lever is fitted for cold starting. Air is filtered by a paper element located underneath the seat. Before the petrol tap can be removed the tank has to be drained. 2 The filter bowl is threaded to 1he petrol tap body and can be removed by using a 10 mm ring or tocket spanner. The petrol tank does not have to be drained to clean the filter, provided the petro l tap is closed. 3 Lift out the synthetic rubber sealing wash81' and the filter gauze. This will reveal the crosshead screw that retainsthe tap. A synthetiC rubber sealing washer is titted betWeen the body of the tap and the petrol tank. 4 Remove the two crosshead screws from the plate that retains the tap lever. 1f the plate and spring wasner are removed, the tap lever will be released. The rubber gland washer fitted between the tap body .and the tap lever should be renewed, irrespective of whethlll' it appears damaged. 5 During ..-eassembly, the top side of the gland washer should be lightly $meared with vaseline, to aid the smoothness of the tap operation. Do not overtighten any of the componentl during reassembly, otherwise there is risk of permanent damage to the synthetic rubber washers.. (c) 4-Stroke.net 2 Petrol tank • Removal and replacement lt is unlikely thet the petrol tank will need to be removed except on very infrequent occasions, because it does not restrict access to the engine unit. Before the petrol tank can be removed the dual seat has to be detached. 2 Slacken and remove the tY\110 8 mm bolts at the rear underside of the seat and lift the seet off, in a rearward direction. 3 Turn off the petrol and remove the petrol pipe from either the tap, or the carburettor. Pull back the rubber tank cltp at the rear ot the tank and lift the tank off in a backward direction. The tank is secured at the front by twO rubber buffers which locate in the frame. 4 To replace, reverse tlle above procedure. Carburettor - General description The carburettor works in a semi-downdraft position and is of the fixed choke type. Mixture control is obtained by a conventional fixed main iet with a cylindrical throttle slide and 3 Petrol tap • Removal and replacemem l 4 . -. • 2.2b Lift the Mat off I j 2.3 Pull back 1~ rubber tank chp 3.2 Remove the filter bowl (c) 4-Stroke.net 3.3a Remove the filter gauu .no sea11ng retaon ing sera"" .. __ • 52 14 _.:::::o-- 21 (c) 4-Stroke.net Petrol tan k anc:t up Petr of tap complete 2 Filter bowl 3 Le1111r .. reramm9 4 Le~tr Plate I . g wesher 5 Seam 1 6 Spring Flg2.1. 7 Petrol filcerher 8 Sellltng was 9 O·ring 10 Petrol tan 11 Spacer k 12 Buffer 13 14 15 16 . Rubber clip Petrol cap I Petrol cap sea Emblem 18 Screw l9 Screw . 20 Petrol P1P" 21 Clip 11 Screw ~ . . ,. 53 l 11 I 15 -_!_j 8 1%-1 i / / ~ I t \ l o-1\\ 1j \ \ \ \ \ (c) 4-Stroke.net Fig 2.2. Cwburettor r 2 3 4 G•lcer ~ NHdlt1 valve 115SMTib/y complete Nt1edlt1 end selt 11swmbly complettt Float 5 6 7 8 Ca~bureto rop comp~re Fl011t bowl complete Throttle srop and pilot scrttw assemblies complertl Thro ttltl valve IHtd spring 9 Carburttttor comp,.re TO Cartxlrttror complete TT 12 13 14 Rubber e a~ sltlfl,.. Nt1edlt1 se.r Jtlt Ptltrol pi/Je Clip 15 Main Jtlt 68 or 70 16 Main ittt 68 or 70 17 Pilot Jilt 35 18 Float pivot pin ' 0 ( 3.4e Lift out tt1e tap lover. Note the rubber gland 3.4b Lift out the lever washer 5.1 Disconnect the petrol p1pe 5.3 Pull the car1Jurettor out of the hole .' (c) 4-Stroke.net 6. 1 Remove the floet bowl. No te the jets 6.2 Remove the float ... ••. ~- A ... •. 55 Chapter 2/Fuel system and lubrication adjustable height needle. For .mall throttle openings tl)e petrol is fed through a fixed pilot jet and the air and thus t"- mixture is controlled by a tapered scre~ . The fuel level is controlled by a dual float and rapef3d needle and seat valve. Access to t>oth the jet$ end the, ftoat is by removal of the float bowl which is retained by \.wire c lip to the underside of the carburettor. An overflow tu~is fitted in the float bowl to nop the engine from being flooded-if the float needle niclls open. •• 5 Carburettor • Removal and r19l1c:.mtnt 1 Turn off the petrol tap and disconnect the fuel pipe . .. 2 Unsc~w the carburettor top and care~u!l · phdraw the thronle si ode end needle. · · ·?-· 3 lt easier to remove both the inlet manifold·~ carburettor aa a unit than ju~t the ~rbueno. The inlet manifold doti not interfere with any servicing o r maintenance to the carburettor and therafore can be left anached. Unclo the two 6 mm bolts at the cylinder head end o l the inlet manifold and pull the carburettor out of the rubber ho• on the air filter side. 4 To replace reverse tha above procedUre not forgening to renew the cylinder heat/inlet manifold gasket. 6 Carburettor · Dismantling and rea•embly 1 Remove the float chamber assembly by prising off the spring clip at IJ\e base of the carbunenor mixing chamber. A synthetic rub~ ogasket seals the joint be""'"n t he float chamber and the carburettor mixing chamber • • 2 Remove the hinge pin on which the float as•mbly pivott. The floats can then be withdrawn and the float n!Mdle lifted from its seating. 3 The needle jet can be displaced after the jet holder has been removed, bY pushing in a downward direction. 4 Do not u1e wire or any other t hin metal object to cleer a blocked jet, beceuse the holo can easily become enlarged or misshapen, which will seriously affect the flow of petrol. To clean the jets blow them out with compressed air eg. foot pump. 5 To remove the needle, push the cable nipple down t he slide and remow it from the slot. push the needle into the slide which • in turn will push the retaining spring clip out, leaving the needle free. 6 Further dismantling is not recommended or usually required. To reaswmble, reverse the above procedure. after checking t he neadle for trueness and that the throttle slide and carburenor body are not badly worn. 7 6.5b The spring retaining clip (c) 4-Stroke.net Carburettor • Adjussmenta' All adjustments should bo made when the engine is at normal working temperature. 2 To adJust the slow running, at the throttle stop screw so that the engine runs at a fan tick·()'.ler speed. 3 Screw in or out t he air scnew until the engine runs e.,.enly, without hunting or misfiring. Reduce the engine speed by unscrewing the throttle stop md re-a~ust the air screw, if necessary. Do not arrive at a S&tting where the engine ticks over too slowly. otherwise there is risk that it may stall. when the throttle is closed, during normal running. ~ 4 As a rough guide, the air screw should be positioned from one to one and a qua. ter complete tu rns out from the fully closed position. Screwing the air screw in makes t he mixture richer and vice versa. 5 The amount of throttle slide cutaway, size of main Jet, size of neede jet and size of slow running jet are pre-determined by the manufacturer and should be correct for the model in which they are used. Check with the Specifications. The throttle needle position cen be varf!cj1, be removing and replacing the needle c lip. Under normal circumstances, the needle sho uld be positioned in .. -....... ... . ,. 56 I .. . - .~ .. . Fie 2.3. Air ei•Mr 1 2 Filter IJI•nwnt Filtwr eltt"""t CO'"' 3 Induction 1/lnc~r J 7 Screw 5 Hoseclip 6 Cover 4 Oip . (c) 4-Stroke.net 2 Fit. 2.4 1 l. Centri fu,.l filter 2 Lubrt~ ion Oil filttr ~uze JYstem 3 Trochotl oil pump ' .... Chapter 2/Fuel system and h1bric:ation .:-. ''2.'1 ; the second or third notch, measured from the top. Dropping the needle w ill weaken the mixture ond vioe versa. 6 The slow running Jilt control• engine speed up to approx· imately 118 th throttle end the degree of throttle slide cutliWay from 1/8th to V. thronle Thenaafter the net!dle jet takes OVIII', up to ~ throttle, end the am1n Jilt siu control• the final % to full throttle. These stiQeS are only approx1mete, there is a certain amount of overlap lug . 4 Block up the llngone to that the front wheel is clear of the ground. Reroow the front wheel spindle nut split pin and reroow the nut. W1thd'aw the spll'ldte, notong the spacer on the roght·hlnd •de and lift the wtM91 clear. 5 Draon both the fork tubes by remov1ng the drain plug in the bottom of llch fork sl1der. 6 Remow the front mudguard bv u nsc:rew ong its four 6 mm bolts. 7 Remove thl tour 6 mm bolts in the handlebar clamps and lift off the handlebars 8 Remove both the fork top bolts and unscrew the steering head stem domed nut. Lift off t he top fork yoke. 9 Remove the sroering head adjuster nut with a suitable Sl ide the ru bber ge1ter off the front fork tube . The fork spring and guides are w1thm the gaiter. To remove the spring, extract the top spr1n9 retainer from the gaiter and pull out the spring, noting the order o f the components and the attitude of the spring since it is of the dual rate type. 2 Ramow the circlip in the front fork slider and pull out the fork tube. which will also br1ng with it the oil •al •nd top bush. 3 To remow the piston bottom bush, the circlip at the bottom of the fork tube has to be rerooved, allowing the bush to be alld off. 4 Check the bushes for wear ond the fork tube for JCOring. Renew If necessary . Alto c heck the condition of the oil ••1, particularly since it c.n be damaged by removal. The sprint should be checked for even wear and over ell length. Renew as a pair if nect$$arV 5 Reesaemble the forks 1n the rever • manner to the above making sure that evet"ythong os clean and lightly oiled. Repltct the d rain bolts and washers and refill the forks with the rtcom· mended quantity of A TF, see page 8. Front fork leg~ • Oosnwnthng, eqmination and r-.nbly (c) 4-Stroke.net ._.___.., ~- -· - -~ 5 Front forks • Rtpa.cement 11 1S assumed the fork tubes alone are being replaced, but if the whole fork unit has to be refitted the neri~ head will 1 110 have to be reassembled as ducribed in the following Section. 2 Slide th e fork leg a . .mbly , prefilled with d amping oil, into -·---·-- • A 2.211 Disconnect t he electrical connectors 2.3 Unclip the brake cable$ fro m t he lug 2.2b Remove the head Iight bolt 2.4a Remove the split p in and •.. (c) 4-Stroke.net 2.4b ... with# J ' 13 ..... 14---[\ 25 ' r! 4-Stroke.net (c) 70-4 20 -d 23 Fig. 4 .4. Frame -mbly 1 Sealing plufl 2 3 4 5 6 Framt~ Frame F111me F111me Battery box 7 Helmet lock 8 Helmet lock retllnfng plate 9 &tt11ry side covtJr 10 &ttttry side cover 11 Thumb screw 12 Nllmfl plete 13 Embl1m i4 Registretron number plate 15 Bettery caution label 16 Heln»t holtkr label 17 Lower rwr engine bolt 18 Upper rt~e bolt engine 19 Screw 20 Rivet 21 Bolt 22 Nut 23 Nut 24 Spring -lh•r 25 Spring t~rWhe . 1 15.2 Tht~Pfedomr dri11e •sembly 17.411 Slec:ken the cotter nut 17.5 The pedal shaft IISMI'nbly (c) 4-Stroke.net 17.61 Remove tht left·hand bush and ... 11.6b ... the right-hand one --.....-·.....- • Chapter 4/Frame and .f orks 73 12 Footresu • Examination end renovation 16 Dual aNt· Removal 1 The footrest bar is attached to the bonom of the crankc_, of the engine unit by four 8 mm bolts and washers. The bar is malleable and is I ikely to become bent if the machine is dropped. 2 To straighten the ber first remove it from the machine and detach the footrest rubbers. lt can then be bent straight in a vice, using a blow lamp to warm the tube if the bend is sewre. Never attempt to straighten the bar whilst it is still attached to the crankcue, otherwise -ious damage to the crankcase casting may result. The dual seat is held by two 8 mm bolts 1t the rear and after these have been removed it can be lifted off in a rearward direction. 13 Speedometer- Removal and replecement 1 The speedometer is of the magnetic type and al110 includes the mileage recorder (odometer). lt is illuminated and contains the neutral indicator lamp. 2 To remove the speedometer, disconnect the speedometer drive cable by unscrewing its knurled nut. Pull out the two bulbs and holders and remove the two 5 mm securing nuts noting the order of the rubber washers etc. The speeckjmater head can now be lifted off its bracket. ~ · 3 If the speedometer malfunctionsiirst check the gearbox and drive cable. If all is correct the tpeedometer hftd will have to be removed and repaired by an instrument repair specialist. 4 To replace the speedometer, revena the above Pr'QCedure. )I lflou ld be noted that although e speedometer is not legally re(J.Iirad on a mllchioe of less .than 100 ccs capacity in the U.K. if one is fined it must be in good working order. 17.9 Remove the shaft circlip lt is advisable to detach the speedomatar drive cable from time to time, in order to check whether it is adequately lubricated and whether the outer covering is comprasaed or damaged at any point along iu run. A jerky or siuggilfl $p88dometer movement can often be attributed to a cable fault. 2 To grease the cable, withdraw the inner cable. After removing the old grea•, clean with a petrol 110aked rag and examine the cable for broken strands or other damage. 3 R~greas the cable with high melting point graa•, taldng care not to grease the last six inches at the point where the cable enters the speedometer head . If this precaution is not oblerved, grease will work into the speedometer head and immobili• the movement. 4 If the speedometer and the odometer stop working, it i$ probable that the speedometer cable has broken. Inspection will show whether the inner cable has broken: if so, the Inner cable alooe can be renewed and re inserted in the outer oovaring after greasing. Never fit a new inner cable alone if the outllr covering is damaged or comprened at any point along its run. (c) 4-Stroke.net 17 Pedlls and drive· Dismantline. inspection 8fld rea-mbly 15 Speedometer drive gearbox · Location and examinatioo The speedometer drive gearbox is attached to the brake plate of the front brake assembly and is driven internally from the hub. The gearbox rarely gives trouble unless it is not lubricated reg.~lay, in which case the drive may become stiff or part of the drive mechanism lflear. 2 The gearbox is retained in position by the front wheel spindle, which passes through the centre. When the spindle is withdrawn, the gearbox will pull free of the brake plate. The drive ring that engages with the revolving hub will be found in !i de the boss cast in the centre of the front brake plate, from which it can readily be withdrawn. Inspection will sha.nt whether the two projecting tongues that take up the driw are broken or damaged. For removal of the front wheel, refer to Section 2, paragraph after first disconnecting the speedometer drive cable and front brake cable from the brake platll. 1 1 The pedal drive follows bicycle practice In construCtion. The pedllls drive the rear Wheel by using the gearbox output shaft and sprocket as a countarshaf t. Little can go wrong and only periodic lubrication of the Chain and pedal shafr Is normally required. 2 To remove the assembly firstly detach the pedal chain guard bV slackening the three 6 mm crosshead screw~ and lifting the guard off and over the pedal crank ann and pedal. 3 Remo\18 the chain spring link and allow the chain to drop. There is no need to remove it completely i1 only the pedals are being detached. 4 Slacken the 6 mm nut on the crank pedal coner pin and hit the nut with a hide faced hemmer to free the pin. Remove the nut and pin and pull the pedal and crank off the shaft, noting the order of the washer$ and seal etc. 5 The shaft can be pulled out by pulling the right-t.nd pedal. • --- ----...-........ 74 21 l . :' I II . , ~, l 21 19 24 ~ 11 3 ... Q (c) 4-Stroke.net ..... 11 Fig. 4.5. Swinging arm and chainguard 1 Chainguerd 2 3 4 Rear brake torque arm Spring Left pillion footrest bar 5 Right pillion footrest 6 bar Pillion footren rubber 7 Pillion foorrcst rubber 8 Swmging arm 9 Swinging arm 10 Swinging arm bush 11 Sealing cap 12 Tyre caution plate 13 Tyre caution plate 14 Swinging arm pivor bolt 15 Torque arm bolt 16 Self locking nut 17 Bolt 18 Bolt 19 Nut 20 Washer 21 Washer 22 Warner 23 Split pin 24 Spilt pin 25 Lock pin 26 Pill ton footrest bar 27 Clevis pm 28 Wasi/Or (c) 4-Stroke.net f 76 r { I 15 33 22 u • 3 ..... n 30 ~ ~ r 21 ~ 30 tO Ji, (c) 4-Stroke.net 20 11 u 30 Fit. 4.7. Pedal and crank auembly T Chsingusrd 2 Rubbers!lpper 3 Rubbtlr chain {1Jid6 4 Righ t crank srm 5 Locking/ever 6 atisher 7 8 9 L Clevis pin Right hand pedal Pin 10 uh crank arm 1T Chsin 12 Laft hand pfldal 13 Ped81 shaft 14 Cotter pin 15 Spring 16 Spring plate 17 Collar 18 Dunsesl 19 Dust cover 20 Spring link 21 Pedal shaft bush 22 $Baling washer 2:1 Thrust washer 24 Washer 25 Circfip 26 Bole 27 Screw 28 Screw 29 Nut 30 Washer 31 Spring washer 32 Spring washer 33 Circlip 34 Circlip ------77 Chapter 4/Frame and forks Again note the order of the shaft components. 6 Check the condition of the shaft bushes located in the swinging arm and renew them if necessary. 7 The pedllls can be removed from the crank ann if required, by unscrewing them using the ~ pane r flats provided. 8 Check the chain and lub"icate it as deso-ibed in Chapmr 5 Section 9. Check the condition of the twO rubber chain 11 ippers and renew them if they are badly worn. 9 The driven sprocket on the gaarbox output shah ir retained by a circlip. Behind it is the engagament dog. When removing this , note the order of the thrun washer and spring. 10 The engagement lever i$ housed in the left·hand engine ouUir cover which haa to be removed if it is necessary to strip it down. The mechanism is held in place by a circlip at the lever end of the operetill9 rod. 11 To reassemble, raverte the abovv procedure not forgettillg to grease the pedal engagement mechanism and fit the spring link with the cloaed end in the direction of travel. Note that there is no provision for chain adjustment. 18 Ounlnt- c;.n.e1 1 Ahe<' remov;ng all surface dirt with a rag or sponge thllt is washed frequently in clean wnw, the application of car polilh or wax will give a g,o od finilh to the cycle paru of the 11'11Chine, eher th IIV have driled thoroughly. The p llted parts lhould require only a wipe oYer with a damp rag. 2 If po•ible, the mechine should be wiped over immadlet:11ly after it hla been u•d in the wet, 10 that it is not g~r.ed In damp conditions that will promote rusting. Make sure to wipe the chain and if neceuary r11-0il it, to preYent Wllter from enmring the roll en and causing hllrllhneu with an IICCIDmpanying rapid rete of w•r. Remember there la little ct.nee of weter entering the control cables. If they Ire lubrlcettd regul•ly, es recommended in the Routine Maintenance IIIC1ion. 3 The plastic parts sum as light len• and duel•t are best cleaned with hoiUtehold dBtergent and water which ahould remove any dirt, oil or IJ'Iall!. 19 Fault di19nosis · frame and forks Symptom Cause • Mach ine is uncl.oly sensitive to road surface irregularities Fork and/or rear suspension units damping ineffective Mach ine rolls at low so l:thf i.~N t /aver in close proKimi ty to tyre val..-e Use two levers to wnrk bei'C or-er the edge of rim When first be11d •• ·:II!Dr of rim, temo..-e tyre as shown. Fig. 5.4b Tyre fitting D E F Inflate inner tube and insert in tyre Lev tyre on rim and feed valve through hole in rim Work firil bead oYer rim, using lever for final section •. .J ~86 Chapter 5/Wheels, brakes. and tyres H G H l.h• 1imilar trK:hniquo for second bead. Flnith at tyre volve position Push Vlflve and tube up into tyre when fitting fi11al section, to avoid trapping bead of the tyre ove;- the edge of the rim. Finish with the aree close to the valve, pushing the valve up into the tvre until the locking cap touches the rim. This will ensure the inner tube is not trapped when the last section of the beed is edged over t he rim witn a tyre lever. 13 Checlc thlrt the inner tube is not trapped at any point. ReInflate the inllef' tube, and check that the tyre is seating correctly eround the wheel rim. There should be· a thin rib moulded around the wall of the tyre on txlth sides, which should be equidistant from the wheel rim at all points. If the tyre is u~ evenly located on the rim, try txluncing the wheel when the tyre is at the recommended preSSlJte. lt is probable that one of the beads t.s not pulled clear of the centre well. 14 Alw.vs run the tyres at the recommended pre~a.s and neYer under or over-inflate. The correct pressures for 10lo use are 26 psi front and 28 psi rear. If a pillion passenger is carried, increase the rear tyre pressure o nly to 32 psi. 15 Tyre replacement is a ided by dusting the side walls, particularly in the vicinity of the beads, wttn a liberal coating of french chalk. Washing-up liquid can also be used to good effect, but this has the disadvantage of causing the inner surfaces of the wheel rim to rust. 16 Never repl.e ce the inner tube and tyre without the r im tape in position. If this !)(8Caution is overlooked there is good chance of the ends of the tpOke nipples chafing the inn• tube end causing a crop of punctures. 17 Never fit a tyre that has a damaged tread or side walls. Apart from the legal aspects, the;-e is a very great risk of a blow-out, whlcl't can have serious consequences on any two-wheel vehicle. 11 Fault diagnotlt · wtteels, brakes and tyres Symptom Causa Handlebars oscillate at low speeds · Buckle or fl at in wheel rim, molt front wheel Tyre not straight on rim pr~y Remedy Check rim alignment bv spinning wheel. Correct by retensioning spokes or haYing wheel rebuilt on new rim. Check tyre alignment. Machine lacks poww a nd accelerates poorly Brakes bi nding Worm brake drums provide be'U evidence:' Re-adjust brakes. Brakes grab when applied gently Ends of brake shoes not chamfered Elliptical brake drum Chamfer with file. Lightly skim in lathe (special ist attention needed). (c) 4-Stroke.net L Brake pull-off sluggish Brake cam bi ndi ng in housing Weak brake shoe spri ngs Free and grease. Replace, if broke springs not displaced . Harsh transmission Worn or badly adjusted chains Hooked or badly worn sprockets Adjust or replace as necessary. Replace as a pair. ,I ' • .... ... ' I"'j.,' . .' ... . Ill.· ... '\ ~ : . .. . . ' ..· ' 7• • . • Chapter 6 Electrical equipment Contenu General descnption Alternator · check1ng outpu t Battery • exeminauon and mamtenence Battery • chargmg p rocedure ... Fuse • locatiOn and replacement Selenium rectlhtr ·general detcr1pt1on Selen1um rect1htr ·locatiOn and replacement Selenium rect1 f1er · testing Headlamp removal and replacement ... beam het~ Headlamp • e~ustmg Stop 1nd tail lamp replacement of bulbs Sp~Ki f lc:~ 1 ·~ 2 3 •• J.,.......... •1, ,. 4 5 6 7 8 .9 10 11 Flashing indicators· replacement of bul bi Flasher unit · location and replacement Neutral indicator and tpeedometer bulbi · replacemen t Horn· locat ion and replocement Stop l~t switch· location and adjustment ... Neutral indicator switch ·location and replacement Handlebar switchts • remov.a ... Ignition and lighting switch Wiring · layout and txamlnlltJon Fault d1agnosis • electrocal equ1pment ... ..... 12 13 14 15 16 17 18 19 20 21 n ions Battery llNd acid. 6 Yolt l Type ... Capacity Earth ... FuM ratmg l 91t ing Headlamp Ta1 l/stop Flashong 1ndicator NAU trlll indocator Speedometer bulb Yuesa6N4·2A,.. 6v 4amp hr l\legatiV11 .· 15amp .. I 6v 26/ 25W 6v 5/21W 6v8W 6v 1.6W 6111 .5W (c) 4-Stroke.net The Honda SSSOZE 11 f1tted w1th a sox-volt negative earth electrocal Jystem, the supply of which IS provided for by the comb1nat1on of the bettery and rectifier. The load consists of the ltg hts horn, and flaShing 1nd1cator lampS. The battery is charged by the alternator, ¥18 the selenium rectifier. 2 Alternator • Checking th t output between the upper or1d lower marks on the case by topping the cells up with distilled water. If spillage has occurred, it should be topped up with •ul phurlc ocid of the correct specific gravity. If, when fully chargod. rho specific gravity of the acid in the battery is not within tho ranqe 1 26 • 1 28 measured at 2ooc. replace it with fresh ~cid of the correct specific gravity. 2 If the mach1nc hos not bl!on used for some time the battery should be rocharged o...ery six wef'ks or so, to prevent deter· ioration If the battery 1S allo.wd to remaon in a discharged state the plates w•ll sulphate thus r!'nderong it Inoperative. The output from the alternator used can be checked only with speciol1sed list equ1pment 1t Is unlikely that the average owner/roder w1ll ha1111 access to this equipment. In consequence, if the performoooo of this or.nerator •s suspec1, 11 should be checked by a Honda agent or an electrician 3 Bettery • Inspection tnd maintenance The electrolyte level of th~> bllttery should be main tained A normal charging rate of 1 amp should be used. Note although thP standard voltAge of the battery is 6 volt immed•ately alter chargong 1t w1ll be approximately 8 volts off load. ·r . .;, 88 Chapter 6/Eiectrical equipment I ~ I> f 5 Fuse· Loc:ation and replacement 1 A 15 amp fu• in a plastic case is found on the positive side of the battery. lt is to give protection from sudden overload (i.e. sh~ circuit). 2 If a fuse biOII't$ 'ltle electrical circuit should be checked for a fault before replacing it with another. 3 When a fuse biOII't$ whilst running the machine and no sp•e is available, a "get you home" dodge is to remove the blown fuse and wrap it in silver paper before replacing it in the fuse holder. The silver paper will restore the electrical continu ity by bridging the broken fuse wire. Thit expedient should never be u.ed if there is evidence of a #lort circuit, otherwise more serious damage will be cau~d. Replace the bloW~" fui! at the earliest possible opportunity, to restore the full circuit protection. 6 Selenium rectifier· General description The function of the rectifier is to convt~r olternoting current to direct current. lt allows the current to flow in one direction but not in the reverse. In cne Honc:E SS50ZE e selenium rectifier is used. r I I 3.1 The electrolyte level in the battery should be m 8tntained between the marks etc 7 Selenium rectifier· Location end replec:ement 1 The rectifier is located within the frame, ne• the battery. lt is accessable from below and is held in position by a tingle nut located to tfle left of the battery. 2 Applying a reverse currant to the rectifier fore long period of time will W!!aken it, therefore running the machine w ithout a battery for any period of time (which cauteS a h igh voltogel should be avoided. 3 On no account bend, scratch or damage the wafers in any wev as this will impelr the service life of the rectifier. 4 If the rectifier is melfunctloning, a replacement w ill h - t o be obtained. .. 8 Selenium rectifier -Testing The rectifier can be checked bv connecting it as shown in 1he accompanying diagram in ~eris with the battery and a light bulb. 2 For testing in the normal direction connect the positive (+I side of the battery to the white lc=ad of the rectifier via a bulb ~nd the negative (.) side to the red lead. The bulb should light up if the rectifier is functionong propenv. 3 For testing in the rever1111 direction connect the negative ~ide of the horn Ieeds at the connectors end unterew the two mounting bolts. 3 To adjust the horn volume, Wrn the screw on the back of the horn body but not more than half a turn in e ither direction or the dial)hragm insi de may be damaged. Tune for maximum volurr.. Note: if the horn does not .work, c heck for continuity of the light ween wire between the horn and the horn button on the left·hand handlebar switch. 16 Stop light switch· Location and adjustment 17 Neutral inckcator switch- Loattion and replacement ~ 1 This is mounted on the end of the gear change d nJ m and, operates the neutral pilot light. 2 To· gain access, untcrew the cross head screws retaining the left crankcase rear cover and remove the cover. Unscrew the· switcfl mounting &ere'NI and remove from the gearshift drum. 3 If it is not functioning correctly (after checking the neutral bultl is not at faultlreplace. • Th l1lsa pull switch operated bv the brake pedel. '18 Hanc(leber switches · Removal To remove. d osconnec t the battery to prevent a short c ircuit ,.( • • .. • 1 .. I .... ' . ..· . 91 IIPif•• end by removing the two croaheed tcr- thet c:~ the tWo helves together on the handebars. • 1 Th• wiring herness is colour coded 1nd will correapond to the ac:compenying wiring diagram. 2 Visuel inspection will show whether any bretks or frayed outer cowrings are giving rise to short circuits. Another IOUrct of trouble may be the $1lap connectors where the connector h• not been pushed home fully in the outer housing. 3 1ntermittent short circuits can often be treoed to a chaffed wire that pes- through or dote to a mete! component, JUdl as 1 frome member. Avoid tight bends in the wire or 1i1uations . where tht.were can become trapped between casing~ 11 ltnitlon endllahcintlswitch 1 The lgnrtion afld lighting switch is combined In one uflit. lt is operettd by' key, which cannot be removed when the ignition is Mltched Ql'l. • 2 The Ignition switch is located on the frame, beneath the petrol t1nk. 3 The number ltlmped on the key will match the number on the lock. This will 1id obtaining a replacement if the original key Is lo•. 4 The lvnition key alao operetes the neereng heed lock. 5 lt it not pn~eticl m repeir the .witch if it metfunctions. lt should be repl8ced with another lock end key to match. ~ . ..., . 21 Feult dillgnoset • _elec:tral equipment Symptom .. Complete elec:troc:el failu re Blown fuse Cht!Ck wiring and electrical components for short circuit befor.e fit ting new 16 amp fuse. D•tcherged battery" Recharge bettery with battery charger. Check whether generetor is giving correct output. Vibration, poor earth connection Check security of bulb hol'*' Check ear1h return connections. ~ Dim lights and horn enopereteve • Constantly blow~ng bulbs -~ • ........ ' • ' . (c) 4-Stroke.net . •. ... .' .. • • .. ,· • • , .. I -~ l .... .•.~ '.. .. • • .... . .. - J o .. ~ .. ·~- ;.. V ~ .. .. i •.;,, - .\" ·~. ... .. . ©7 :rE1IJi]H .. ~· ; l • . r' - ~- • •· .....,. . ..... G ~LG .O.C.IGH ,. .:. ~ ~ . - ... ... ' ... - "";..: • ,.... . ., .:, ... " .. ... -: ;: : -=- " .. . ... .. ~. .. r _,.. -~ •. .' . ~ ~ .. »EAIXJGtT BEMI CQITR!l SWITCH ARA-MENT ........ HB lB Tl •c, C1 SE H8 f- I* ~ ON lB - ~ .. .; .... .t' .: ..... -:- , ... ··- -:..v ' ' .. (Jf, ,. ·.. ,~ • _ _.._ . ' - ~ 4.. ;,. • ·:-; •[..,, ;' - ..: - - - ~-:=1 J I .... .: ;w. ~PUXi ..· 1 COl ' K'ltJ~ ·.: ~ .~ ~; ~ • ':· :~ - .: :~ ~ ... t«lRH TI.IIH SIGNAL SWITCH . .. ;. ..... ..., ..,.- ~- RREAR TURII SQ!Al lOO 6VI8W t ····. B ::;'"J~ .~ -,- . _,~ ·~- .. . . . ... ..... . (c) 4-Stroke.net .... sow. oon 6Vtsr 0 ~ . . LfRC)IT Juflfl __ _ W-IIAII .. • : , \, \$ f :~ L ., ft .. 11 I • I ~ ~ • SWUOf ·..... - .. . c: . .- ·t ... ·.. ,. .. .... . - ~ REAR ST ""'Oralwe . .. -.p......, . ·:-., , ._ .. ' - . ... ~ ., ... ·' I'· • • ~· l!ngte 4. • • ;'\ I ti,.., . unit and cycl'it ~i!rts: dtsmantltng, examin~o and;· reas$$nbfy .. ... •. .··· ~. ~ Engine unit· dismCinlling llfld reassemb!Jng the geariJOl< • <.. ' 2 Front forks~ t'cmoval from' frame .... 3 · .. Speedometer drtve gearbox: location a" d examinetlon 4 . •; • 'Fron~ y,;hecl .. .:di~c brake. assembly: examination, dismantlin'g; ·, renovatton anu reassembly · •.. 5 • < ·.... , . ,, ,. ' • _.._..!iPKm~ . ••.;. ., . . . . ·. ·~ 6 7 8 9 ~ .-! .... • .. .• .. Front brake di'IC: §mi!VIIII', examination ind replacement and repl-ment ... Wheel bearir)gs; exqmineed ·.model: . · COmpariSon with t~ . earlier four-speed vers1on . ; . ( . ·During earlv ·1!h6, improved ver~ions of the orig tnel SS50ZE model were an.,ounced, t he maii'l dofern~; being the 'use of a Jive-speed gearbox. TW<~ verstons were evailoble, the SS50ZK·2E • wh •ell wa~ fitted with conventional drum br'nkes, and' the • • " S50Z~ · 2E , which ·had a cable-opecatk! front wheel di~ b raka. Both 'mqdels benefmed from a useful boost in power output, • • • ach•eved by ~emoving the fO mm res\rtctor jrom the 12 mm . , chokl! K,eih in c,arburettor art!! re~uctny the length of the over.:" • ' long ,thrott,le $ol~e. AJ'I inc:tebt in COQ"pore~sin rat10 also helped.,• ... •::r- ... to .- . improve performance, albeit at the expense of a slight increase in the rate of fuel consumption. • Owners of earlier models ore warned against modifying their machines to bring them more in lioe with the revised spet:ifk;ation. Th.is appltes in porticular to reducing the length of the throttle slide. If the slide ts not cut absolutely sQuare, it will · inevitably ·iatn in the wide open position and create a very dangerous situatio'!. • ' .. ·. . · r { r l I 141 N G) f N I.a c 0 :J: & "ot CO ,... ... Cl) (c) 4-Stroke.net .. .:: ;- Chapter~ ~ : Su(lplement covering the 5 -speed models 1 Envine unit and cycle paru: d11m.,ding. examln81 ion and mb ly ' r- 1 Although the 5-speed models are s1m ilar in most resp~c ts t o ( hi! · SS50ZE mOdel described in the preceding Chapters, reference should alw!IYs be m ade to this Chapter first in view of • • J ttlt! . -d to follow a revtsed procedure when certain componenu • ~ to be rein011ed and replaced. Where no informatiOn is given 1n this Chapter, 1t moy be assumed the procedu}'e is 1dentical to ~hat given for the SS50ZE modi'! I jn earlier Chapters. . #'' 2 Routine maintenance procedure closely foll ows the schedules already described in the earlier Sect10n at this Manual. The only exception occurs 1n the case of the SSSOZB-2 E disc brake model, ·.• where the brake requires a d ifferent form of attention. Re fer t o the Rout ine Maintenance Section of this Chapter. · 2 .. Engine. unit: dism.,tllll9 end re11•11mbling the gearbox Although the same proCedure described in SeCtiOns 18 and 30 of Chapft: r 1 can be employed, the gearbox cont&tm t wo extra pinions. Refer to the accompanying tine illustration show111g the method of assembly of tiJ_e 5-spe~ !jear cluster. 4.1 Speedometer dnve gearbo)l is on right-h and aide of hub ... 3 Front forks: re moval f rom frame \. Follow the p rocedure described in Stetibn ~ of Chapter 4 in the c8se of Models fitted with a conven,tion at fro nt wheel drum brake. On disc brake models, the speedometer drive gearjlox is a separate, self-contaoned unit, fi t ted on t he right-hand.en\:!'bf the wheel hub. The driv11 c~ble can b& disconnected using the drum brake method. , 2 On dose brake mOdels, there os oo necessi ty to d isconnect the " bruke operating cable from the callper end. If the two ltblts that retain the !eh-hand mudguard stav are remo11ed, this will free the upper .mount ing ot':the b rake caliper. If the lowe r bolt is t hen withdrawn, th~ caliper ·un it can be lifted a way ~ t he forks as a complete un1t. • 4 SpMdo metlf drive geatbox: locatron end examinatio n 1 The speedometer drive gea rbox is fitted o n t he nght·hand eiv:J of the front .....,ee l hub in t he case of the disc br ~ e models and lorins an inte!)ral pert of the front brake plate aSS41mbly on the case of drum front bra ke models. In either case, the gearbox rarely giws trouble unless it is not lubricated regu larly. A neglected speedometer drive gearbox will prove stiff tQ..turn and in ·111'1 extreme case, part of t he drive mechanism mav sheur. • 2 . On disc brake models the spredometer drive georbOK con be • pulled off the end of the front wheel hub atter t he front wheel has been removed from the forks. On drum brake models the speedometer drive assembly can be Withdrawn from ins1de the front brake plate after remO\ral of the front wheel from the forks. In bo th cases. care must be taken to ch'eck that the drive engagement dogs align with the dogs on the hub, during reasscrnbly. Check the cond ition of both sets of dogs to ensure they are not badly worn or broken , and also the condition of the drive pi'nions. • . (c) 4-Stroke.net 5 Front wheel d isc: brake assembly: examinetion, dismant ling, renovl'tion and reassembly Oisc brake models have the brake usscmbly operated by cable. TM cable actuates a quick thread worn Withi n the brake caliper assembly and it is this that presses the peds ega1nst the · disc when the brake is apptll!d. ' 2 Each pad has a red line inscribed around ats periphery , which denotes the limit of wear. lt is usually poss1ble to see t he red line '• .. 5.2 Brake pads have lnsc:nbed tine t o show wear li mit . .. ~ ~ - I - .~ ~· - ._ - .- .... ··- -""- ~ ~ "!' -- 1 . .. .. • ' - - ' Y" l ' \ .I ""' ~ ~ ,- i .. , g_ vl) 16 ~ 24 ~., I m' 'f" ~ I 5 ~ ~ _._..~ - 1 1/ /,1 ~ ~ _: ~ ,. lf I ~r 14 I I a ""'T' Q#o,. 2,0 18 I s l ~Q ~- 15 17 = 3 .o . ~ 111 ~ ~ ~ 1,3 • , 1 1,: · . \ 20 ' ' 4: ! /J /2;1f' . fl ~ _ . I ~ - _ _ ~"'- 2 1 ~' . ' _) - ", '• . ~ -~ . -~ .. (c) 4-Stroke.net ·~ Fig. 7, 1. 5--speed ge•rbox and klckrart 1 Mainshaft 12T 2 Layshafl 3 Layshsft 1st (111/Jf pimon • 36T 4 M81l'1Sh8ft 2nd gear pimon • l'T 5 Layshaft 2nd gear pinion • 30T 6 Main shaft 3rd Bnd 4th geer pmion (20, 22T} 7 Layshaft 3rd gear pinion • 2BT Laysheft 4 th gt1ar pit~un • w 25T 9 MJtnS!lJft 6th gear pinion 24T 10 L11ySh11ft 6th gtJar pinion 23T 8 ·, ,_. . .. . , mbly 11 Kickstlfrt pinion 12 13 14 ratchet spring Kicks tart shalt Ktckstart spring l)nchor gutde, . Kick.· ~ ~ /v~ ~-MaJ_ ... ~ 2 20.. ·.~ - ~ ~ 11 ~ ". ~ -, · :J>A, 1E ... . . •. . ... .. ., .. \ . . ~0/ . 6 19" ""-."'-./ (c) 4-Stroke.net Fig. 7.2. Disc brake caliper as,embly 2 Cafiper pivot upper 5 Cable adjuster scr9w bracket 6 1 8 9 Caliper p i voc pin 3 Discguard 4 Caliper body Cal/per outer cover Ouick·scrcw assembly Outer pad Fixed pad ,...._ · ., · ~-. "" 10 Replacement pad set 11 Thrust plate guide 12 Adjuster screw 13 Cable motion block .."~- ·o· 18 Pivot pin ring- 2 off 19 Outer pad ring 20 Pivot pin lower mounting 14 Ratchet thrust spring . 15 Adjusrer ratchet 16 17 Outer cover gasket ·o· stud Gromm11t tr;: r. ~ .: ~ •.t.C'* . ._,_ . •• _1_.,.. .• .L .... - ~- - 21 · Nut 22 Spring washer 23 Outer cover bolt 3off ~ -j .. / -. • 98 "V Chapter 7: Supplement covering the 5-speed models 5.3 These three bolu retain c:eliper assembly to fork leg .. , on each pad whi lst applying the fro nt brake when the assembly • is still in situ on t he machine w1th the front wheel in place. 3 If the pads are worn the tront wheel must be removed to allow occess, and the pads removed as follows: Remove the three bolts which hold the caliper cover 10 place and detach the cover. Pull the rubber boot off the cable adjuste( and loosen the locknut, Screw the adjuster screw as far 11'1 as poesible. T he eKtra cable length gained w1ll facilitate dcsconnecting. the cable from the qucck screw operating arm. Pull the qu1ck scr~w assembly from position, followed bv the thrust plate guide which lies undemeath. 4 Screw one of the 6 mm cahper cover screws into one of t he threaded holes in the outer d isc pad and pull the pad from position. The inner pad is located in the recess in the caliper unit by a pin wh ich protrudes through to the right-hand side of the cal iper casing. By pressing the head of the locating pin with a suitab le tool the pad can be pushed from position. •' • 5 If either pad is worn down to the red 'wear limit' line both pad s must be renewed. . 6 Before replacing the new pads into the caliper unit make certain t hat it is absolutely clea n. Lightly coat the backing plate of tile fixed inner pad w ith silicone grease su 1table for use with brake assembl ies. Replace the inner pad in the caliper un it. Refit the front w heel into lhl1 forks and tighten the INheel spindle. 7 Pl ace a new '0' ring o n the outer pad end coat the outer circumference of t he pact with silicone grease. Replace t he pad in the caliper un it makcng sure that the punch mark Oil the rear of the pad aligns vv1th the punch mark on the caliper body Reconnact the brake inner cable with the brake actuating arm aod t hen rep lace the t hrust plate guide. Pull the adj uster ratchet from pOsition on the quick screw assembly and unscrew the adjuster, which lies underneat h unti l it comes up against its stop. Screw in the adjuster screw about :4 of one turn so that the screw can rotate freely. Replace the ratchet and check that the q uick screw assembly functions properly. 8 Fi t the quick screw assombly into the cal iper unit and replace the cove r and gasket which is held by three bolts. ,screw the cable- adjuster out until any slack in the cable has been removed. Do not over-loosen the adjuster. Now loosen the adjuster a further tw\a.lurns and tighten the adjuster lockout. Pull the rubber boot"'own into position over the cable adjuner. 9 No front b rake adjustmant as such is necessary as the brake w ill adjust itse lf automatically when operated. Th is can be done by operatirg the handlebar lever about 10 times when the selfedjustment w ill have been accomplished. Check tho:~ the front whee l w ill spin freely and does not drag on the disc pads. 6 Front b rake d isc: removal, examinatio n and replec:ement (c) 4-Stroke.net After eKtended service the front brake disc w ill wear down to a poin t where it cannot function efficiently. T he thickness of the disc can be measured 11t various points around its c~runfe witn t he use of a micrometer. If t he disc wears below 0 .0157 in. 14 mm) it shou ld be replaced. Check the d isc for warpage by spinning the w heel m the fo rks. Warpage of more than 0 .0079 in. (20 mm) measured at the inner radius of the disc w ill reduce the efficiency of the brake and w ill cause juddering and p remature pad wear. 2 The d isc is retained on the wheel hub by four studs and nuts and can be removed after the f.ront wheel has been detaehed from the tront forks. The locknuts are secured in pairs by common tab washers which must be knocked down before the nuts are removed. 1 5.8 Brake cable adjuster is used to remove sleek from cable .:. .... - ............... r Wheel bearings: examinet ion and replacement To gain access to the front wheel bearings on disc brake models, it is first necessary to remove the spedom~tr drive gearboK, which will pull off, the gearbox retainer and the retainer cover. The retainer and cover .are retained by thre~ cross ..... • Chapter 7: Supplement coverint the 5-speed .. .. .~ ..,:;. ..; ,.. .. . .. . · 12 "' ·. .. .. Fig. 7.3. Front w!Mel 8nd br81ce diK 1 wtwl spind'2 Whe f ~ r 3 Front whHI hub 4 Bttaring spacer 5 Speedometer geertJox rtttttinttr 6 SpHdometer ge11rbox reai~ cowr 7 W'-lnm 8 Outttr cotlf':r 9 Inner rube 10 11 12 13 Rimbttnd Speedomerw geNbox Brllke dnc D1sc rer.ining stud · 4 off 14 Wheel spind le CMr.lfltiKI nut 16 Dou bltt ceb weshttr 2off 16 'O'ring 17 Dun cover 18 Str screw • 2 .off • 19 rwsunlc~ 20 Nvr · 4off 21 Split pin 22 61111beering • 2 oH 23 Inner &pob · 18 oH 24 Ountr spolce • 18 off • ,. (c) 4-Stroke.net .. ..~ •• head screws. Prise the oil seal from poSition 1n the left-hand end of the wheel hub. 2 The bearings can then be driven out as descrobed in Section 42 of Chapter 5 and the remainder of the procedure on that Sec tion followed. permitted to - • beyond the red line insc:nbed arou nd thell peripher, a po1nt that 11 easily overlooked If the brake does not require the regular attention of a drum brek11. 9 Wirine dlagrwn 8 Front wheel diec brake: adjustment As mentiOned prevoously. the front ... heel diSC bralte is of the "'f-adtustlng type and will automatu:ally teke up excess p lay as t he dose pads we¥. lt is 1 mper atn~e thet t he pads are not 1 Although the same bes1c wiring d1egram it employed as th• , used for the eCII'Iier SS50ZE matkl, t he colou r coding of the wiring has been changed. Refer to the revosed diegr.m diet accompanies this text. bee page 100) ,... ·~ • ....-...._............, 'Y -•-o ,> T, :e;. cc , •• • .. •' ... ~ ·- . • .... 4< ,_ , - .. • ,. , :c . , . pe ~· "! _ _ _ _ _ _..; l!i '··' g R REAR TUIIII S"'N "' Al LICHI 6 rLB~V REAR SlOP SWITCW ;,. '- -~.!£ _ ~ $_? - ~"L WIIIKE" .• " . ---- /T ,. .•. ~t· ~LG 1111, .. ~ 6~18 LrROt;l TURN SIG/IAL liGIIl J ~~ ... 8• · ·· Brow" 8t " 8~(1 13· ·l'lllt Grttn 0.. · ·Onnge Ct.. " ·C y r~ lt .. -t1 ht 8111 ' ~ ·;. I! .... . ... .. SWITCH ARRAASlii£NI ; I"' I' ft •Y' ..- I r! OPI ../>. •t ·····'·: ., :. : ·" . ,· l_t .. ·~- ~ ~ liGIIT LREAR TURN- SIGNAl 6VI8' 11 . ..... OH .. Fig. 7.4 . Wiring diagram · SS50ZK2,82 (UK model) .~; ·• • •• . I T ~ j -. .·• · 0·1~ Gr .- ~ · IC '•.· l "' ,_ ·1 SPARK PlUG TURN SIGAAl HOI!N SWITCH . ... · 8~t p .. p~· R · ·Rf.002 0.003 · 0.004 0.006 0.008 0.007 0.008 0.009 0.01 0.02 0.03 0.04 0.05 0.08 0.07 0,08 0.09 0.1 0.2 0.3 0.4 0.5 0.6 29 30 31 32 33 23 24 25 26 27 28 29 1 .~ la "'\() 41 42 I 22 1.26884 1.29921 1.37796 1.41732 1.4567 1.4961 1.5364 1.5748 1.6142 1.6635 1.6929 1.7323 36 37 38 43 44 45 17 .sea 1.7717 30 31 32 33 34 35 31 • .. 101-.6 127.0 152.4 " ~ .1 1 ~ 9 10 11 12 13 , 14 15 16 1.220U 35 rs~ • 1.18110 34 0.0762 0.1016 0.1270 0.1524 0.1718 0.2032 0.2286 0.254 0.508 0.762 1.018 1.270 1.524 1.778 2.032 2288 2.54 5.08 7.62 10.16 12.70 15.24 17.78 20.32 22.88 25.4 0.8 0.9 1 2 3 4 5 6 7 18 19 20 21 ·~ 0.0264 O.D608 0.1 (c) 4-Stroke.net .. ' 228.6 254.0 279.4 304.8 330.2 355.6 381.0 406.4 431 .8 457.2 482.6 5011.0 533.4 568.8 584.2 . . .6 636.0 660.4 685.8 711.2 738.6 762.0 787.4 812.8 838.2 883.6 -~ 114.4 • • ,. .. fP ~- t ,t J. l . .. ., ' ~ .,.. .o;. ·• ~ I , .. I t. ' .t a ..t .. .. ... ' ... ' ~ ~ _, .• , ., 11 ~ ... ~- " ~ Index "-·' A .. . ignition system- 62 wheels brakes and tyres • 86 Fuel system- 50 Final drive chain - 83 Five speed models · 93 Footrests- 73 Frame assembly · 67 Frame number · 6 Front forks • 63, 95 Front wh118l • 78 Fuse- 87,88 Adjusting tappets - 35 Air filter· 50, 57 Alternator • 59; 87 .. B •. Battery · 87 Big end and main bearings • 16 Bore· 9 Brakes • 78, 83, 93, 98, 99 f' '~ . '- ~- ; , .,. Carburettor· 50, 55 main jet • 50 ,.. • pilot jet - 50 .... adjustments • $ • Centre stand· 67 Clutch. 10, 14, 24 Cleaning· general · 77 Condenser - 60 Compression ratio· fl, 93 Contact breaker- 59 Crankcase- 16 Cubic capacity - 9 Cush drive assembly· 8) Cylinder head· 12, 30 . la c ~ G Gearbox- 9, 12, 95 Gear ratios- 10, 93 H Ha11dlebar switches- 90 Headlamp· 87, 99 Horn- 90 'I (c) 4-Stroke.net .... ,._ ~ ~:, Ignition system- 59 Ignition and lighting switch · 92 Indicators- 87, B9 IJ .,.-: ~ D Decarbonising· 20 Dismantling engine and gearbox · t ~. Disc brake · 93, 95, 98, 99 Dual seat- 63, 73 ,.~ L Lighting· 87 Lubrication • 50 engine- 58 96. ., N E Engine number - 6 Engine/gearbox· 9, 95 Exhaust system · 50, 57 Neutral indicator · 30, 87, 90 switch· 90 ' Fault diagnosis: eltctrical system · 92 engine- 49 system ·-59 f ramthnd f«!''!s • 77 . uel ~ ~ \ F ' 1. Oil pump· '24, 25 Oil filters • 58 "' 0 • ;. .. '1: p Pedals and drive · ·63, 73 Petrol tank remoyal ·50 tiiP removlll • SO • ·' ... "' -<- ;J .. ., . 103 Index Swtnging arm · 63, 67 nand nngs · 9, 12. 14, 20 t-nmery dnve • 25 T R Rear suspensi'bn • 67 Rear wheel · 80 Rockers· 24 Routine IRI!intanane» · 7, 93 Selenium rectifier· 88 ~ometr • 63, 73, 87. 95 Spares· 5 Spark plug gap • 60 Stop and tail lamp • 89 Stop ligbt IWitch · 90 Steering heed • 63, 6 7 locks - 63,67 StrOke·· 9 ( (• s Tank capacity · 50 Tailltop lamp· 87, 89 Tappet cleerancn · 9 Throttle cable and twi5t grip · 50, 57 Timing c.nshaft · 30 Torque wrench settings· 10 Tyres • 78, 84 V Valves· 9, 24 w WheelS· 78 Wheel bearings· 80, 98 Wiring diagram · 92, 99, 100 • .. (c) 4-Stroke.net • , . . • ~ ,1 •• ., .... I , ~ .. .. .. ... .. ... .. ..... • ... .. .. .. . :• t •. !I .. £ Printed by J H Haynes & Co ltd Sparkford Nr Yeovil Somerset BA22 7JJ England ..~ · (c) 4-Stroke.net } - ..... ., •• ,, ~ Honda SS50ZE 49cc 4 -speed.model. May 1973 t o September 1975 Hond a SS50ZK·2E. 49cc 5-speed model. October 1975 to December 1975 Hond a SS50ZB·2E. 4 9cc 5-speed m odel w ith front disc brake. January 1976 to July 1977 What the press say ,....The c lear. step-by -step illustrated i n~truc t ions C'Oil_er the dismantling. tnspectjPn. repa ir and reftttmg of the engine, ciJJtch and gearbo)(, cooling "SYStem (where fttted), fuel and lubrication systems. ignition and exhaust ..... systems. frame and forks . wheels. brakes and tYres. an d the e!ec tric al system. Routine maintenance, c omplete specifications and detailed fault diagnosts ~ro c edurs are also included . Only Havn es completely strtp and reb't.ild the motorcycle on wh ich each manual is based. Saving you---money from ., start to finish ~ ~ ~ Whethilr you JUSt want to change your oil. repllice yoor plugs:ca;r:;,. o u t a top end overhaul or rebUi ld your gearbox. the Haynes manual will sho you how an d c an help save substantial amounts on servicing and repair bl11s. Helping you make things .go r . a little further ,. ;_.·. . A Haynes manua l can help 9o" stretch your motorcycling budget that little bit further tn other ways too. Regular mamtenance and servici ng will mean that your motorcvcle is safer to ride-whilst g iving you more of t~se precious mpg . What 's more. a motorcycle that is:wellloDked after will • - . . _ hold its price better and last a lot longer. ........., (c)\ -=-4-Stroke.net --- ~· · with help from these published by rnual~ Havnus you can ·bv following step bv· step ontructions perform just anoou f!ve rv maontenance task VO.J 11 ever need to runnong lor year~ i/Ve hear