onda Stroke Mopeds wners orkshop anual by Mervyn Bleach Models covered: PFSO Graduate Introduced into UK April 1970 Discontinued February 1974 PFSOR Amigo Introduced into UK February 1974 Discontinued February 1975 PFEU DXR Nuviu introduced into UK February 7975 Currentiy in production PC50K1 . introduced into UK April 1970 Currently in production All models 4900 capacity Nate: This manual covers only mu ohv engined mopeds and not the one or uwu-srrnke variants. ISBN 085696 317 8 min/3H © J H Haynes and Company Limited 1977 Ali rlghts reserved. No pan or mls bnuk may be reproduced nr transmitted in any form or by any mnans, eleclranic or mechanical, including photocopying, recording Dr by any informaflan sloruge or retrieval syswrn. without permission in wrhing from me copyrlgm holder. Printed in England J H Haynes and Company Limited Sparkford Veovil Somersel England distributed in the USA by Haynes Publications Inc 9421 Winnetka Avenue Chalsworth California 91311 USA “macaw..." 'l JHW ill)" V l‘fiTiTIC’PS t t :xiefiefiii i Aéjpowl;dgements Our grateittl thanks are due to Honda (UK) Limited for the technical assistance given whilst this manual was being pmpaled and Fat permission to reproduce their drawings, Win A. Vincent ol Vincent and lerrpm Limited, Taunmn and Mr. N, G, Preston, oi Preston‘s (Yeovili Limited, piovided additional technical advioe based on their experience as Honda agents. The FCSDKl model used in most at the nhomgranhic sequences was kindly loaned try the Vuovil RACIACU LuamL-r Training Scheme. 3 ri Horslall gave the necessary assistance with the overhaul and (levtsed the ingenious methods used tor overcoming the leak at service tools. Les Brazier arranged and About this manual The author or this manual has the conviction that the only way in which a meaninolul and easy to lollow text can on written is tirst to do the work himself, under conditions similar to those round in thc average household. As a result, the hands seen in the photographs are Ihose oi the authur. Even the machines are not new: examples that have covered a consideraole mileage were selected so that the colldtlluns encountered would be typical or those lourid by the average owner. Unless specially mentioned, and thareiore consideicd eswnlial, Honda service tools have not treeti used There is invoriahly some alternative means or slackening oi removtng tome vital component when service tools ate not available and risk oi damage has to be avoided at all posts Each of the six Chapters is divided into numbered Sections. Within the Sections are numbered paragraphs in consequence, cross raicrence throughout this manual is both straightforward tank the photographs, JL-lf mew edited tilt; text and Tim Parker planned the layout of Each page, Finally we would like to acknowledge the help oi the Avon Rubber Company, who kindly supplied the illustrations about tyre fitting, of the champion Sparking Plug Cnmpeiiy Li d, for providing the illustrations about plug maintenance and electrode conditions, and ot Renold Limited luv advice about equivalent British-made chains. We would particularly like to thank Arthur Vincent, oi Vincent and Jerrum Ltd, East Reach, Tauiiton, who provided the machine for the front cover illustration and inglcal. When a relcrenco is made See Section 5.12' it means Section 5. paragraph 12in the same Chapter, If anmhdl Chaplur were meant, the text would read 'Scc Chapter 2, Section 5.12. All photographs are captioned Wllh a Section/paragraph nvmoor to which they rotor and are always relevant to the Chapter text adjacent. Flguve numbers (usually IlnE lllustraliunsl Eppt‘al In nuritciicul order, within a given Chaptev. Fist. l.l therefore raters to the first figure in chapter t. Lclbh'drld and right-hand descriptions oi the machines and their component parts refer to the light and tan at a given machine when the rider is scaled normally. Whilst every care is takcn tc ensure that the tntorrnatinii in this rnanval is correct no liability can bl: accepted by the authors or puhiisticrs tor loss, damage or injury, caused by any errors in or omissions from the information given, Contents crlaerer Section Page Inlmdumurv Secliuns Model dimensions Recummended lubricants Ordering spare pans Rauhflfl maimznancp GPnElal repulr inloimarion 1 Engine, chm-ii and reduction gear Spemficalians Engmclredumion gear remnval Lnglne/Yedllcfion gear dismanlling Engine/ruducllun gear renmailon Clutch rEnDilaIlon Engine Nassumblv Engine/reduclmn gear refining Faull diagnDslS 2 Fuel system and lubrical'mn Speeiricallons Palm-I Kink Carhll'EHDI Air cleanel Exhausl system a Lubricatlun syslem Oil pump Fault diagnosie 3 Ignlliun svnem SPEcHlC' Generami Coil Conrad breaker Condenser Timing Spaik mun Fauil diagnusis A mel.‘ and lurks 5 Wheels, makes and tyres s Elemicel sysmm Spaei ca From lurks Frame assembly Rear suspensian Cefl ire “and Seat Cleaning me meenlne Faull dlagnosis n5 Sperificaliuns From wheel me brake assemblv Spuedomelev eirlve gears Rear wheel Rear wheel snrnckm Biukns: aeiuslmem Final drive chain Tyres: removal and replacement Fault diagrmsis Speeliieerions amrery Lumps Wiring diagram Faun diagnosis Alli ‘Spem‘ficanons’ and 'Genemi descrrprian' are yII/Ell at me beginning 0! each Chapler, and 'Fault diagnasir’ar the and a! each Chapter. Mc‘rll.‘ earwersian (ables Index Introduction to the Honda 4-stroke ohv mopeds The Henda everneed vulva engined mopeds were firsl lnlroduced imo me Uniled Kingdom in April 1970 (u repleee inose fined with an overhead eamsnair englnE. Tne change In engine design was due to the lam that an overhead valve engine will produce pewer at a lawer speed men an overhead earnsnan engine, which, when enunled will an aurumatic rransrnissian sysxerrn enables a more rracieble machine m be produced, The mopeds were designed iur me eernmmer, not lhe sparring emhusiasl, se me additional [on speed at the overhead camshalt Model dimensions engine was nur ulilised as me machines were governed m eornply wilh ulnar Eurnpaan caunlries' own legrslsnon, By definition in me UK, a maeed rs a machine lined wnlr an engine of less man 50cc capacity, lhifl has pedals. Then: is {imposed legislalion [a iimil me [up speed of niepeds in me UK is bring them in line with Common Markel countries, bul an the Honda mopeds already eunlorrn ro Khe Ennllllmllul yustricll’nns. no elmralicns will be necessary. Overall length Overall widm Overall nelgm Wheelbase ..i Ground clearance Kerb weight: PF50 PFSUR FCSDKI PF models PC models 1638 mm (64.5 in) 1755 mm (692 ml 535 mm (25 0 ml 500 mm (23.5 in) 1067 mm [42.0 in) 1035 mm (4&7 ml 1067 mm [42,0 in) 1130 mm [44.4 in) 127 mm [5.0 mi 140 mm (6.5 in) 45.5 kg (99.1 lbs) 48‘s kg (106.9 lbs) 50 kg (1102 lbs) Honda PCSDK1 moped Hanna PFSD mnpod Ordering spare parts When ordering spare parts {or any of rhs Hnnda models, is is advisablv w deal dimer with an affic'lal Honda agent, whn should be sale in supply most irems e mck. Pans cannor be Obtained lrnrn Hnnda lu Kl Limireu direct; all orders must be routed via an approved agent, oven ll rm, pans requlred are nnt held in stock. Always quote the engine and frame numbers in lull, particularly if parts in? required for any of mu earlier models. The lraml: number l's stamped on the lehvhand side Ell the flame, shave the engine on the PCSDKI YIIDdD], and is slampad on the righ Hw‘dnd slda of (he (tame just (a the rear of [he engine on the PFSU mudels. The engine numbcr ls stamped Dn ma left- @csoE—D EBOO‘H hand crankcase, ilmnndlalely below me flywheel ulzneramr cover. Use unlv parts or genuine Honda inanuracurre. Panem pens are available, some of which milllllam rrurn Japan mu} are packaged (a resemble me originals in many insrsne 125:: parts will have an adverse ellect on perrnrmanco and/u! r ab Same at "w more expenualsle pnrrs such as spark plugs, \\ bulbs, tyres, oils anu greases elc” can be obialnea Flom accessm'l} sharps and muwr rectors, who have convenlevll opening hours, charge lower prices and can alien be found nm lar lronl nurne. II is also possible in oh‘ral plans on a Mail Order hast: lrmn n number at specialists who advertise regulnrly m we mom! cycle magazines, / ”an...“ - FSOE'L xwlz Engine number location on the PFSD models l f l Routine maintenance Periodic routine maintenance is a continuous process that commences immediately the machine is used, It must be carried out at specified mileage recordings ur on a calendar basis it the machint! is net used treniiently, whichever the snunest. Maintenance shauld be regarded as an insurance policy, to help keep the machine in the peek at condition and to ensure long, trouDlErlree service. it has the additional benolll at giving eatly warning at any lauits that may develop and will act as a satety check, to the obvious advantage or hath rider and machine alike. The various maintenance tasks are described below, under their respective mileage an calendar headings. Accompanying diagrams are provided where necessary. it should he renitirnhered that the interval between the various maintenance tasks senrcs only as a guide. As the machine gets older or is used under particularly adverse conditiens, it would be advisable to rarilice the period between each check, Nu special tools are required ler the normal routine maintenance tasks, The tnois contained in the tunl kit supplied with every new machine are very limited and will need m be mlrlPd tn ll (ht) awnEr WlSHUS to flu ally maintenance, When buying tools, it lsworth spendinga little morn than the mvnimllm to ensure that goud quality tools are obtained. Snml- nl the nheapor tools are 100 50f! D! flimsy N) do an adequate tub. it is inltuiating tn have tn stop part way thrcuph ii ml) been“. a spanner has splayed open or broken. and a mplat‘t‘mnnt must by Inunl‘l A tie p ruoied knuwledgc cl engineering principles is py no nit-uric necessary nature the ane . undertakes his or her own maintenance teal/n blll lemriiarity with a low at the more commonly used lclms and D ban: knowll’rlg? Elf haw m use tools will help. The lolluwirlg list nl ioois will stirtice to undertake the iridium maintenance tasks described in this Section but where ruleience is mddu tu uriulhux Chapter tor the dismantling iireeediire additional tools may he required. A tym pnissnrr: gal/g0 A tyre ptirnp A 10 mm spark plwr spanner A final metric 11ch em'mi spanrrers from 5 min In 17 mm A pair ciphers A crass'head screwdriver A small L‘Iarllical SCMWdriVEr A set nr led/er gaiiynr An adjuxrab/E spanner (this mall to be uxcr/ only at a last rornnl. Wealtiy er every 2m miles lazo km) 1 Cher the I‘ll/t} pressure: The tyre prcwuyes should be 25 psi lur the horn tyre and 28 psi lot thu ice,» tyre when the tyres- are cold. FlCV'llll/e ml: (Just cup, lllclt il'lL‘ valve tit! [tr blaw out any dlrl or water and push on Illt) plussurv gmlgni ll the pressure is top law, pump up the tyre with the pump or a garage airline, to the correct pressure. It the pressure is too high, push the valve centre ta release the air until the correct pressure is reached. Replace the dust cap as it ls a second seal. 2 check the engine oil level. The engine ciil capacity is 0.75 litre (1.3 pintsl contained in a wet sump, and normally SAE2lMI/50 but in cald cllmattas SAElDW/GO should he used. Place the machine on its centre stand on level ground, lr the machine hasjust bun run, allow tltt: oil to settle for 5 minutes betore checking the level. Remove the plastic filler cap with its integral dipstick. Wipe the oil off the dipstick. Replace the dipstick without screwing it in. remove it and check that the oil level is between the upper end lower limit marks on the dipstick. Add oil ir necessary, to bring the oil to the correct level, and replace the filler cap cunt dipstick alter ensuring that the sealing Owing is in peed condition. 5’ Oil and art/'11:! the brake cab/es. The standard brake cables should be lubricated wlth alight machine oil, but it nylon lined cables have been titted url nu account use all on them. Similarly, the cable nipples and rlivut points should be oiled unless plastic levers have been titted. Nermally, rain and the washing of the machine will provide sufficient lubrication for the nylon and plastic parts. aererc the winter sets in each year, it is advisable to rernoiie the cables completely and thoroughly lubricate them, as shown in rhe accompanying sketch m ensure troublefrae riding during the more arduous conditions to be lound in winter. The brake: need adjusting when there is too much movement an the levers ie; when the brake lever comes class to the handlebar when Ine brake ' ilpplledt To adjust, either cable, turn the adjusting nut until the hrake just slarte to rub when the wheel ls spun. Slacken back the adjusting nut until the brake stops running. Ensure that the adjusting nut cutouts arc seating correctly on the lront brake cable stop and the rear brake operating arm on the PCSOKI model and that the locknuts are tight (m the PFSO models. 4 Check, adjust and lubricate me final drive chain. Flam: the machine on its centre stand on level ground. Check the up and down movement an the chain, midway between the two sprockets. Rotate the back wheel until the up and down movement is at the minimum. This is the 'tight sput' on the chain and the up and down movement should be between to mm (0.40 in) and 20 mm (0.79 in). ll the play is greater than 20 mm (0.75 in} the chain should be adiustcd as lollows: Slacken the wheel spindle nut so that it is lingemight. Make sure that each adjusting nut is turned the same amount to keep the wheels in line until the play is reduced to within the limits. Tighten the wheel spindle nut and recheck the amount ul play on the chain. When the wheels are properly aligned, both the adjusters Should match the frame or swinging arm markings. An SAE 90 oil or Chain Lubrlcant should be spread on the chain for lubrication. The latter is applied from an 8 Routine maintenance aerosol Pack. to make application easier, 5 Check the lights and horn. Check that all the lights are working properly Renew any detective bulbs and if any lighss are dim, clean the connections and earthing points so testore the lights to their original origlttness. Check that the horn works, again one kntg the connections ii the periorrnance is paw. 6 Visual inspection Give the whole machine is close visual inspection, checking tor loose nuts and tirsings, ireyeo control cnhlcs or missing parts which may have tallen oli or been stolen, Monthly ar evlly 1000 miles (1600 km) Check the tyres orakes. lights and horn as described in the weekly/zoo mile service and then catty out the rollcwtng additional tasks. 1 Change the Engine oil. As stated lesions. the engine on canoclw is 075 litre (1.3 pints) oi SAE zow/sos Place the machine on its centre stand on level ground. Run the engine tor a low minutes so warm up the oil so that it will run out casier. Place a container under the engine and remove the drain plug, which is situated on the underside ol the engine. When all the oil has drained, replace and tighten the drain plug, ensuring that thc sealing washer is in good condition. Helill the engine with oil oi the correct viscosity, checking the level as described in the weekly check. 2 Remove, clean and lubricate the final drive chain. As the ilnel drive chain is not sully enclosed, the oil and grease lubricant on the chain will tend to pick up dust and grit, so every month it is advisable to remove the chain item the machine lor thorough cleaning. To remove the chain, place the machine on its centre stand on level ground, and rotate the tear wheel until the spring link is in a convenient position. preferably on the rear wheel sprocket. Use a pair oi pliers so remove the spring clip and then remove the side plate and the link plate, thus disconnecting the ohain. Connect to one end or thc chain o second chain, either an old worn out one or e brand new one which is kept in readiness ior listing to the machine, Pull the tires chain oil the machine, leading the second chain on, until she iirst chain can be disconnected irons the second chain, lithe second chain is usable, reconnect is, ensuring that the closed end or she spring clip is (racing the direc on oi travel oi the chain. Adjust the chain as described in the weekly maintenance Section. The chain which has lusl lacen removed should be washed thoroughly in petrol or oarsilin to remove all the dirt and grease. To check whether she chain is due tor renewal, av tt lengthwise in a straight lute and compress it so that all play is taken up. Anchor one end and then pull en use other end so take up the play in the opposite direction. if the chain extends bv more than the distance between two adiacent links, it should lee renewed in conlunction with the sprockets. The chain should its lubricated isy immersing it in a molten lublicanl such as Linklyle or Chainguard end thcn hanging it up to drain, This will ensure good penetration oi luorioant beorveen the pins and rollers, which is less likely to he thrown all when the chain is in motion. Ta relis the chain to lhe machine, connect it to the second chain, poll the second chain and leed the lists chain back onto the machine. Reconnect the chain ensuring the spring clip is correctly listed as stated colors. is is easier to reconnect the chain it the ends are listed onto the rear wheel sprocket whilst the connecting link is inserted. Adlust the chain, using the weekly maintenance procedure. , , 3 Check rhesnsrlt plug. The adlusters should match Ali NGK type Co‘lHS spark plug is titted as standard equipment so the Honda mopeds. The recommended gap on / i the item marklngs im ealzh side ; I ‘ § Lubricming me final drive chain 4n» Ensctilblic§ in an orderly mariner whore ihey are unlikely to he disturbed. The use cl 3 good workshop will give me salisiuclinll oi work done in cornlort and without haste, where there. l5 little chance oi the rtiochinc being dismantled and reasshmhled in anvihiug other than clean surroundings. Unfortunately, ihesc ideal working conditions are not always practicable and under these latter circumstanclls when rnrprnunrrtiuii is called lur, extra cure and iiine Will be needed. The other essential rl'uulmmcm is a comprehensive set ol good quality tools. oirnlity is or urimo importance rice cheap tools wril prove expensive in the long run it they slip or break dill] llamr'igli ihu contourinnis in which thlzy are applied A good iiuoliiy tool will}! last u long inns, and morn than justlly the cost. The basis nl any tool lot is .r col 0? opcnrended spenners, which can be iiserl on almost rrny part oi the machine to which there is ludiuitahlp amass. A set 01 ring spenncis makes a irseiul addition, since {my can he used on nuls ihai am very tight or where access is resirrintu. Where the cosl has to be kcpl within retrson-rrlilt~ pounds, a compromise can he ellecied with a set ul toinlriitatinn spanncrs ~ open-ended at one end and having a ring or the same size on the other end. Sncknl spanners rnay nlsu he iisidered a good iiivesirnpni, aoas ‘Cl/B or 1/2 inch drivi? kl! Comprismg is much“ handlc and a small number nl socket Mails, il money is limited, Additional Ot7 mm l0.024-0.028in) [1.3 0.4 mm [0.012 r0316 in) Mitsubishi 6 volts AC Mitsubishi soc/20.000 2s degwes betore to» dead centre lit: weak spark and dIchull starting cause lk pcrtormancc tn be suspect, il should be tested by an Euloelcclrical expert. A iaulty cni! must bu rnplacetl; It ii not practical to eilecl a mpa . 2 Tu detach the cull the engine/gearbox unit must first be removed as described in Chapter 1.5 The coil is manned Inside the frame and Is retained with a single mu, 3 Feasts-mun, is Ihe reverse oi the removal nl’olmdura Contact Izmir-r: udiustrncttt I To gain access to the contact breaker assemtily, misc on the flywheel generator cover with a screwdriver. Thl: cuntact hrcakar palms can he VlEWEd through one or the apertures in (hr‘ flywheel mtcr. 2 Rotate the Englni‘ until the contact breaker polnB are in the fully open Dusitlon, Examine II]? has all the contacts. H llwv ad or burnt it will be nerzssarv to rcmm/e them full further attention, as described in Section 5 at this Chapter. 3 The normal ccntact hrcaker gay), when the points are fully open is 043 - 0.4mm (0.012 - 0.016in)t ________—_.———— 5 Contact broakar paints: Vlflmllt renovatinn unit replcccm-nt I ll \hu contact hreeker paints are burned, pitted or hstlly worn, they should be removed hsr dmsslnu. If it is necessary to 56 NMM‘MNN Himhanu crankcars Gasket Left-[land clankcau German)! mm Carma! masks] Lubricating wick Scmw ’0 H 12 13 Fig 11. Cranknm and 99mm: 511(in washel Wash” Primary cail assembly Gene/aw! assembly Flywheel Coils Grommet Clip for wire: Hal: Nur Sealing] washer Washer Washer Drain plug Screw (3 all] Sm-w (3 an! 5cm" Dowel {3 0m chapter 3: lgniticln system 57 5 23 Remove the rmur It) gain access remove a substantial amount of maIFnal aelore the faces an be restored, new replacements shoulol he lltterl. 2 it Is necessary tirst to withdrawthc flywheel maoneto rotor heldte access can he gained. instructions for the removal of the rotor are given ”1 chapter 1,5ection 10, The fixed contact IS removed by w'llhdmwlng the screw which holds the asetnlaly w the stator plate ol the generator. The moving Contact is detached by releasing the circlio front the end ol the pivot pin and by treorrrrr lhe lcat return spring lrom as point at attachment close to the lower coil. 3 The polnls should he dressed with an oilstone or line ernery nlnth.Keep(h0l1l absolutely square during the dressing operation, otherwise they will make angular contact when they are replaced and will bum away rapidly as a result A Replace the contacts bv reversing the dismantling procedure. Take nartrenler care to replace any Insulating washers ‘ln tholr norro sequence, otherwise the points will he isolated electrically and the ignition system will not fullmiam Lightly grease the nrvnt ant bL-Inm 1hr; moving oontac: is replaced and check that there is no oil nr grease on the suriaoos oi the aornts, 5 Replace the llywheel rotor atter greasing the internal contact hrooknr earn. it rs also arlvisahle to add a few drops at light oil to it 5.2b .. the luoncatlrtg wick which rubs on the contact hrealter earn, if the wick has a dry BDPEBIEHW. B Ruadiusl {ha Contact breaker gap after me flywheel roll)! has oeen locked in petition and the centre retaining oolttiohtened fully ta tha racnmmended tuluue wrench Mining 01 300-330 kg CIT! (21.7-27.5 lb Ml. ____—__._————— 6 tend-mot: removal and rural-mm"! ——_____—_ 1 A condenser |s included In me Contact bunker circuitrv lo prevent arclnq across the contact breaker points a they sepurme. It is Dunnected in parallel with the points and il a iault aavalopt, ignition failure will occur, 2 If the engine is omicult to start, or it misfiring occurs, it is possible that the condemn is at fault, To check whethav the condenser has tailed, remove the flywheel magneto cover and observe the points whilsl the engine is running. I! zxmssiva sparking occurs across the palms and they have a blackened at burnt appearance, it may he assumed the condenser as no lungzr Selvlceatllet 3 The condenser 'ls attached to the tonrtton c011, normnlly 58 Chapter 3: Ignition system rivsrtea in place. hut some spare parts catalaguet give a separalu inimher lar the condenser which suggests this latter campanent may he nvailalrle on its own. 4 Ta replace the condensel, the engine/gearbox unit must he removed as (inscribed in chapter 15, the anal removed as tiescrihei-i in Section 3, the wire iinsoluered and the rivet drilled aut. ,, 5 When lirting the new cundenser, cllsllm that the wire is snldared correctly and that the nut and anlt to replace the rival are a good fit in the rivet hale and securely locked with Araldite ar Lucktim. a Heaaemhly at the coil and engine is the reverse or the dismantling procedure. 7 lgn nliminglidjusflnnnt I If the ignition timing is correct, the contact breaker points will be about lo separate when the ‘F‘ line scribed on the rotor coincides exactly with the cast mark on the crankcase. As a check, when the angina is running, a timing light or alroboscope will show ii the cast maik is coincidental with the scribed line on the rotor. 2 H the timing is incorrect, the contact breaker gap shnuld he either incmnsed ar decreased until the points commence to separate as the timing marks coincide. 3 Adlustment is effected by lackening the screw which clamps this fixed Contact point in was on and moving me Contact nearer ur lurll'lcr away as the case may be, by lavering ‘ln the indentation provided. 4 After checking the timing, rotate the engine and check again herare replacingthe saver. The accuracy at the ignition liming is critics terms of ham engine performance arid petrol consumption. Even a small error in setting can have a natieaanla clfecl. 3.3 The ennrlenser is rivetted to the ignition can a ir, ant-r adillfllmg the cantact breaker poinis tn Eibi’lmve iiir tarrect ignitiaii timing, iiw gap is not Within the recumnvu limits, the points sheulrl he i'encwed as a caninleiu SK“, anti iiiu whole pmccsa repeated. l A 10mm NGK spark plug is llllcd as staiitlaitl. nelcr it; the Spemfirzatiuns SeCIiu" headinriiliis [143er lartiitr muomntcnllud grade. 2 All models use a spark plug with a l2.7mni iuaeh which should he gappeu at 0.60.7mrll (U.O24»0.028in], Always use the grade of plug rcaornineiiuari oi the xam equlvalem in another manuiaeturar's range. 3 Check the gap at the plug points during every mulrmiv 0t 1000 mils: service. To row! "we gap, belitl t , UlEi electrudc tn bring i| closer in the central ulec‘tmrle anti chuck [hill a 0.6mm [H.024in) leelnr gauge can be inserted. Navar bend the central electrode otherwise the insulator will crack, causing engine damage if particles tail in whilst the enginc is running, 4 The sand ion at the spark plug electrodes gnu lnsululot can be used as a reliable guide to engine operating connitioiis. See accompany ig illustration 5 Always carry a span.- spark plug of the uni rccl giants, iii lire rare event or a plug failure it will enable the engine in be restarted. s Navarever-tighten asuurk plug, otherwise there is risk at stripping the lhreacls lrom the cylinder headl particularly those cast in light alloy. The plug should be surliciently light to seat lirmly on the copper sealing washer. Use a spannei that is a gantl iit, atherwise the spanner may slip and break the. insulator, 7 Make sure the plug insulating cap is a guild iii anti lree irorii cracks. This can contains the suppressor that eliminates radio and TV interierenaa. Fault diagnosis: lee page 60 Checking plug gap wim mic, Aiming the plug gap. Now use gauge: at cal/est raal Fig. 3.21 Sunk plug maimenance Blake" palm/airy insulation 51:: trade: bum away due to due to hem Central electrode wrong Ivar vaiua nr chmm‘c prevignirlon $Inkingl whim deposits and damage i in insuiarion indicating overheating Excessive black qcpasirs Mild whim deposim and elar Plug in sound condition with caused by over "0" WWW trade burnt indicating ma iigm gmylsn brown depaiilx ar wrong ”S“ "We weak a my minum Fin. 12b. Splk alum alsc‘rodn :nndifinns GD Chapter 3: Ign on system 9 Paul: diagnosis ignilmnsvmm Symvhnll Cause Remedy Engme w." no! star! No spark at pluq Try Iep‘acemum plug if gar) mm. Check whEmE: cunlact breakEr Faults ave ousnvng and claw \9. am: whether Ihev are clean. Check whethar minis an: wlmn sup-Armed, If 50, mnew condenser Chuck ignition swlth and lymuun coiL Engine shins but runs erranczlily Inmrminam Dr weak spark Try mpiscemenl mug. Check whather pain“ are arcing. ll so, renaw candensor. Check accuvacy of ignition timing Low nuzput ham Hywhnvl magnum) generator ur vmnunent breakdown o1 \gnmon mu. Chapter 4 Frame and forks Contents Gennrnloascnolion 1 Swinging arm raarsuspensianzrernoyal from home II Flam iorks iomnval nom frame' pron models 2 Swinging arm rear suspensinn, renovmlm and reassembly 12 Frantforks remnvalrromlmnte: Pcsuki model :l Hearsuspenslnn units emoval,renova(inrl and reassembly 13 FruliHurks removal lromlrame: centrestah xamina t . Front forks arsmontlingzmsom model .. 5 Speedometer: removal and replacement V _, 15 From Yovkslgcnrral examination: PFEO medals .. , a sneaoentetercablazlnsoection and mainiensnce 15 Front lorks. gemera Steering lack , Steering head bearings: examination and renewal 8 Seal: removal , melotks reassembly A, .t 9 Cleaningthe machinc:general Framrl assemhlv' exummallon and renovation 1U Faul‘d'lsgnosig:framesndfaflgs Specificmiuns Frame Type . . . Ctoen,stenthrnv style construction. PFso models . a . Tubular PCSDlnodel .. Pressed steel Caster angle 65° Maximum stealing lock Rear suspension FFSD PFSDR anrl DXR PCEO From suspension PFSU models PCEU model .. 1 General ductiptinn When we l-londa moped was first introduced as the PPS!) it had a tubular open or s‘ep-thm’ tyw name, teleseo Vurks ano nn rear suspensien. The tolnsmniclarks are not hydraulically damped bu| contain a small amount ol oil to prevent corrosion. Tm: men was a great imorevement as 'l\ harl swinging nrm rear suspension although nnt hydraullcallv rianrorsu. The rnonwl was given a new image by moving rhe oerrol tank to make the PFbflDXH ban the lmme and lorks remained unchangedi Tire PC50I<1 has always had a pressed sieei 0pm or Stun-(hiu' tyne lrarne wrtn swinging arm rear suspension and leading linlt lmm furksv The susnansion is ag undampedt 2 Front lurks: removal homlram PFsohnodaIs I It is exrramely unlrkely that the front forks will need to be 65° each side of mantle None Tubular swinging arm Pressed steel swinging arrn Telescopic forks Leading link forks removed tram the name as a unit unless the steering head bearings giva trouble or the forks are damaged in an socioent. 2 Commenea operations by removing the front wheel, following the instructions given in Chapter 5.3. Remove the steering head lock out and washer, the two buns and washers an the top at the folk legs, anal carefully move the handlebars, with the top Voice and headligm attached] to allow access to the steering head. Make a hore of each cable and wiring more so that when the machine is reassembled the controls operate smomhlv and the wiring rs not trapped or it will chefs. a Remnve the steering head adjusting oene, liit out the caged oallraoe and slide the forks clear. Remuvs the swarm: caged osllrace and bearing cone from the steering stem. 4 If tanner dismantling is necessary, rne frunt mvrlgvara can be removed, when the falks have been drawn, by undomg the foul retaining bolts. Hg, :5 I. From lmk assammy , PFbD medals Comp/eh: from Vurk 135:2!"va Stu/i719 head auzmbly Hrghrrhand 1m leg comp/Ely Left-hand folk leg assembly Fork leg gaiter , 2 w Chmme band - 2 a” Spring register - 2 of! mm . 2 gr! Was/w — 2 of} m Her/mar muummg , 2 an 11 Ref/00ml unit - 2 off mmwtnuw§wm- F... 42‘ Frame mmbly - Pan mum-d model 1 Ipnitloncai/ 5 cn-mad/umr/zam 9 Hull 13 Wammzum 2 Plugn‘ap 6 Prams 19 Bolt 14 Lockwixher 3 Wiringllames: 7 Namep/fle H Nut 15 Cab/”lam 4 Glummctlzufll a Nameplate 12 Nuuzm/ ’3 !' Onllavlls’ rerun -Hrcmmlme- l‘CSDK'l medal ‘ ll 2: arllmmnly ll llll-tly’ rum. ills, fmn' lvrlu mil mm m nu rammed lro n mu frame rm unlr unless. rl by , hem) lyrrll 7. ‘l‘mblr rrl lhn luvks firedal‘taylzd flll Willem. n mom .lpwaylum rw mlrllzvmg m mm wilNl, rollnwing 1H. ll"lu‘ill‘ll‘. gl'l/El" l-l mrarrtarr 3. Maxim/“overlie l‘andlcl'dl: arm ulna“ rnllm pm inn Tlmy raslrlnn hvalxruw Elexu ndn lllal : ol'lrfas 'll‘l umpire .~ in willull ilul s L‘nllg linen?! mlllmm run llir‘ lznll in WC mnrre nl rim, llanrllchlus. mm mm: nmrrlfll llr \li w‘u zrmlzl Silnlitnnn‘ inn lwllnsnrl mrvlnnw» in .rlmyrlmr wrllr .: rllaWholt assembly and lrrmliglw a. l)» ll‘lNll‘ llu Jenny luau lucklng nut to lawn} llle sinusu .rlyrrmlnr, mun. rlrnrlrsrrrrr lirrrulrl be mddu ml calming [hr‘ Jul l-all [Mr-lungs, 21 in me ml; race and 25 m llrulmnom 17:56,?! [mill nl w. l Unsruuw mp adlllsl‘lng mire whllsl supporiing ll’lu lurks in rrmnlnn, Thu mu rm 0! ball beavlngls can rlrarl he removed erh r alum m a qrnassu screwdriver. a As lhn lnrlrr arr, lowm Hhe halls in me lower race will bu displazl‘d and once “Iesr: have been cnllzclpd, rlrn fork assembly can he pulled clear of me 'rflmfl. 6 The lrcrlt mudguard can be removed by undoing me two nails and ma retainlng nuls and pulling the mudguard clsar, 4 From lurks: dismnmllng: PF50 modal: 1 it only me Fel‘k legs are to be removed wilhom disturbing rile lmml mass, n ma Th: from wheel 3 described m Chuptsr 5r , mun n’move rim 1mm mudguard by unduing me [our lelalml’lg mm. 2 Prise ll‘l9 chrome band livid urr rubblar {mot nrr inn upper lnlk log 3mm the bull and waslllzl from me lap of mu lurk [24} ml pull the balmm leg assembly clear. The bullunl leg Fig 4.3. Fran» 3534me - PFE'HJ R models Patrol mp Wiring harness Frame Imblzllr stun Ointl‘exiflnd :ma brad‘s! Rear mudguard Engine car/arr Rear light bran/r5! Was/w {QWVUlUlAQN‘ assembly consisls or me leg, the sprlng and ills two spring legismrs, none of which are avallabln as Spam Bar's. an altlmugh the spring unscrew: from (he ragisiers and removal of lire snrlnrr nin renames llle rngistrr and we leg. 1! comnlnle leg BSSEHXblV links ‘5: hr», bmlgh: 2| any (l (5 are lmmrl. a The Chlorml hand aim ml: .r bnul nr. min. in a- , 5n slmuld bl: rerlluwrzl l’or nilnclnn , 4 Fennel [he nmccduni In: llw m fol k led» 5 Yhi: upper fortf rum an welded in (N ha :nrrlrlllfln rlsaembl‘d mu m mncwed ll Ii ‘ls damaged. am, nrv Vale and «he 5 Sum lurks; (lismamflng. PEEK“. mud-ll 1 If onlv (In: lurk lll’lka‘ an? In hr: remunr-a‘ without disrurhing LlVl' ham! races, remnuexhz fromwheel Lu. ascribed lrl {Eliamer 5.3. 2 Remove the iwo nuts and washer: to release the bulmm 0‘ me mudguard and muvc the mudguard our cf rm.- wzu. Pull out (ht! plvm bolls, remove the run UH Ihr; top sprrrlg Riyals-(er and pull the lurk link ussemblv clear, 3 Remuva the plvm hon and mu m release we spring assembly from the link assembly. The spring unscrews From me wring leglsters. The spacers and bushes are a good m in the linls and can be rapped Dr pr‘lsed out. 4 The fork legs are at Dressed steel construction and if damaged, an exuemely dll‘licull to repair m should be rengwed when necassarv. 6 From favks: gen-u] naminulinn: PF50 mod-ls l The ‘lelescuplc type Iron: forks llmd lo the PFEU models have very new spare pans available hence if any wear is found i‘s will nacsssimo are buying ur large assemblies and in axneme Eases, a complete set of forks. 2 Visual examination wlll Show whelher the [op yoke is :ShmymmAQNN SERGE 17 Flue 4.5 mm forks and Iagshialds . ecsom mad-l Ham assembly Tap healing cup Enrmm bearing cup Front fork assembly Rebound rubber (2 am Top bearing can: Balm/n bearing cons Steering lack Fran! mudguald rnruer washer Franz numuer plate [not required In UK) Legenielu: Wire clip Rival (2 or” mine! (2 off! Nameplate Adjusting nut 18 Anchnr nut 12 nffl 19 Special washer (1a of!) 20 Bait 2 am 21 Bolt 22 Ban (2 am 2.? Screw 24 Screw (2 off] 25 Screw (2 off} 26 Screw (2 off) 27 Nur (2 ml” 28 Nut (3 an; 2.0 um 12 am Wamer 14 um :1 Warner (2 am 32 Spring washer {2 am 33 Ballbealiny 116 Eff mp, 19 all thml Fig‘ 4‘4. Fran! suspension! - PCSOKI model 1 Hiymhandsuxpsnsian my 2 Bush M of” 3 Lay: [rand suspension arm 4 Bush (4 off! 5 Prvot pin (2 am 6 Surya-mica unir 12 am 7 Top swing reg/em (2 am 5 Hana/n spring register (2 am 9 Spring (2 am 10 Shack abmlbing rubur-r I2 off) 1 r snau/deredbo/r {2 alfl 12 Nut (4 uffl 13 Wathsl (2 am 14 Spling washer (2 of” 15 Grease nipp/L‘ 12 um chapter 4: Frame and terkt 65 rlistnrterl or ii the upper terk leg assembly ls bent. It is rarely possible [0 eilect a sallsfatlorv repair and mnewal is slrohgly recommended. 3 Check tor play between the mp and bottom idrk leg tubes. li‘ it is exensstve, replacement uf the worn assembly is essential. 4 The springs should be checked to ensure that they are llnhmkrm and ti nnssihle compared with it new one lo determine ll any teduetlun ul iree length has eccured warranting renewal as a matched wait. 5 Examine the rubber boots for signs at perishing or cuts. nenew where necessary. 5 || should he remembered that some indication oi the extent or wear ul the fork tubes can be gained belere the machine is disntanrlerl. it the tram wheel is gripped between the knees and the handlcbars ranked in and fro, the amount at weer will In! inngni red by the leverage at the handlebar ends. Cross-check by applying the lrent brake anrl pulling and pushing the machine backwards and inrwards. Do not eoniuse the mnyemunt with that which will result from slack steering head bearings. 7 Front lurks: general examination: PcSoKI mudel l The Ieadinglinklype irent terksiittedtnthe PCSOKl model have all pans eveilaule as spares. 7 Visual nxamlndtidn will show whether the pressed steel lurk legs are damaged 0t bent, necessitating renewal. 3 Check that the bushes are a need tit and secure in the link arms. Cheek lor play hetwean the bushes and due p'lvm belt or sueeer, renewing the worn parts il play is Excessive. 4 The spnnqs shuuld be checked to ensure that they are unbroken and it pnsslhle Enlnnared with a new one to determine ii any reductiun in lree length has securedwarranting renewal as a matched nah. 5 ltshmile be remembered that some indication of the extent oi wear ul [he lurk bushes can be gained batare the machine is dismantled, it llw lrurlt wheel is gripped between the knees and the handlebars incited re and lrn, the amount at wear will be Fig. 4.6. Frame assembly s FLEOK1 mudal Blanking plug Candenmr lym'n'on cei/ Plug cap Wiring names! Grommet (2 am Frame Grammar Blanking plug (2 off! 10 Nameplate I 7 Bali 12 Belt 1.? Nut 14 Nut (2 am 15 Washer 16 Washer I2 am wwymmnwwu magnified by the laverage oi the handlebav ends. Do not confuse the movement from that which will result (mm slack steering head bearings, 8 Steering hand hclrim‘ls: axlminnion and ramwal 1 Before summer! 9 to reassamble lhe forks, inspect (hi: steering head races. The ball bearing tracks should be palished and free from indentations and cracks. lfsigns ol wear or damage are evident, the cups and cones must be replaced. They are a tight press fit and need to be drilted out at pnslllon. 2 Ball bearings are cheapy and sheuld be leplsced witheut questian ii the originals are marked or disbeleured, To hold the ball hearings in place whilst the forks are rte-attached, pack the bearings with grease, ___._—_—_— 9 Front tents: reassembly l TD reassembm the front forks, fallow lhc dismanlling procedure in reverse, ensuring that 5 small amount of oil is put inte each teleseo r: leg to prevent corrosion and that the leading llnk bushes are lllDrDughlv gleaned. 2 Tighten the steering head carelully, so that all play is eliminated without pla g undue stress an the bearings. The adjustment is current ll all play is ellminmed and the handlehafs will swlng ta full lDEk of their own accord when glven a push on one end. a It IS possible to place several tens nressure an the steering head bearings it they are overtlghlerled,1he usual symplom er overtiglrt bearings is a tendency let the lnach'lne te roll at law speeds, even though the handlebars may appear to turn quite lreely. 4 it, after assembly, it is found that the lurks are incorrectly aligned or unduly stilt in action, loosen the lront wheel spindle nutst The forks shduld man be pumped up and down several times to realign them. Hzliglllen lhc {rum wheel suindle nu‘is 5.2a Romuve the mudguard mammg nms ., 5.2:: , and pull m2 vork Imk assembly dea- 5.3;: Remove p'wok buns w scparuw me spring assembly fish The spring unscrews from me mgisters 5,3c Remuve the spacers 5 36 ,. and mu buslms frnm the lmks (:7 F19, 11,7. Slssring head and from mudguard - PFSU mndal‘s 1 Hum 14 Blanking cap 2 Hearing cup (2 am 15 Ban {2 am 3 Tim bearing :me 15 Bolt 12 am 4 Hmmm bmn’ng L'onr? 17 Bolt (2 fo) 5 Caged ball 751:2 (2 or!) 18 Screw 12 am 5 Steelmglock 19 Screw 12am 7 Fran! mudguard 217 Nut (2 am a From com 21 Waxher 14 am 9 Packing lee 22 Washer 16 ufll 10 Emblem 23 Washer 12 um 11 Fla/11 numbcrplala‘ 24 NM 12 am 12 Washer 25 Spring washer [2 cm 13 Steering mend nut ‘ not required In UK 68 chapter 4: Frame and fork; 1D Frama lssambly: mmination Ind ranuvnlan 1 The lrarne is unlikely to need any special attentiun unless the machine has been invalund in an accident or has ccuered a very large mileage. Small welding and straightening jobs are passibie. but care nrusr be taken to limit lhe amount of heat used and the area ta be beaten because the land mrrving properties diminish when lhe metal is heated excessivelv. 2 Frame alignment shanld be checked when lhc machine is complete. The aceumpanying diagram shows how a board placed each side at the rear wheel can be used as a guide in alignment. it is, all Donne, necessary [0 unsure lhat hum wheels are centrally disposed within their respectwe rarks below carrying put this check. 3 Serlous damage is net repairable because tnu purchase er a new rrnrne is invariably cheaper than the oust or attempting to straighten a damaged irame, especially when the nece§ary rigs tor correct alignment are not available. _——__ 11 Swinging arrn raar suspansicn: r-maval rrarn rrama ————.———— ! Alter an extended gelled all service (he Silentbluc type swinging arm bushes will wear and need renewing. 2 Remove the rear wheel :is described in Chapter 5J1. a Release the chainguara by removing the swinging arm pivot bolt nut and the rear fixing bolt. 4 Remnve me nuts or balls from the helium of the rear suspension units ta release the rear or the swinging arm. 5 Withdraw the swinging arm pivot bolt and pull me swinging arm clear, in butlom of s 12 swinging arm rear suspension- ranayation and reassembly w“ 1 The Silenlblcc type swinging a-rn bushes can be tapped out of the swinging arm and the new ones tapped in but care should be taken to tap only the purer metal or the bushes or damage to the rubber and its bonding will result. 2 Ta reassemble the swinging arm, reverse the removal prcccuure ensuring that the chain and rear brake are properly adjusted. Ia Rut mmnlinn unit . emmai, ranauatlan and rcassambly .—__—_—____ 1 To remove the rear suspension unit; if Var any reason they are suspect, commence operatians by putting lhu machine on the centre stand. 2 Romuve the nut pr bait irom the bpttam of the suspension unit and the nut and washer rrarn the top. The unit will \hen slide a" the machine. 3 The rubber bushes in the em}: of the suspension units can be tapped nut and new one: pushed in. 4 Thr: PFSDR and DXH models have snalud rear suspension mill; which, ii found deiactive, cannot be repaired but must be replaced as a pair. 5 The FCEDKI model has partially strippable rear suspension units but as the spring needs in be compressed to gain access to the locknut, a job inktich requires special tools. ii is best left In a Hunda dealer. There is also a risk cl personal damage if the spring is released inadvertently during the stripping Dr reassembling nperalfions. The recommended course ul action is to renew the rear suspension units as a pair il either unit is suspect or detect 9. I4 6 Ta rem the units follow the dismanlling procedure in 13.2 Remove nut and washer to mluase suspensinn unit revarsa, ensuring that a matched pair is used if renewal has been necessary, mommy“ Chamguard Tapped chamguam Tappad bracket Firm! drive c/mm Spring link Ar/iumr (2 pm 4.3, Chainguald and swinging nrm » PCEDK1 model 7 Swing/”g arm 8 Silentb/oc bush (2 a”) g Mpmlhush 10 Rubber bush (2 off! 17 Spacer tube (2 on; Swinging amv spindle Fin. 4.9‘ Roar Suwansian unils - P650!" modal Rear Juspemiml unit (2 off) 8 Limit stay "1be (2 uffl 9 1:] Rubber bush I2 off) 71 Spacer tube (2 am 12 Shun/dared halt 12 am 13 NH! (2 pm 14 Was/m I4 0”] Spring legisrer (2 am Bottom folk 12 am Top cover I? am Enrram cal/er (2 a!" Namnzwou 15 Bolt 77 NIH Ia Acorn nut 19 Wmherlzofl! 20 or 21 SpringwaxherIZ a") Lack/Hg rm! (2 am 79 Chapter 4: Frame and folks Fig. 4.10. Swinging arttt nu suawnsinn - PF50 R models 1 Chaingua/d 5 Swinging arm 2 Chain 6‘ Rubber hashes is of!) 3 Spring link 7 Silents/ac bus/i l2 am 4 Rubber mounting l2 0”} t9 1“ 14 Centre stand; axlminlfinfl I The centre stand is attaehed to the lower extremeties or the lame unit, m nrovrde a convenient means or parking the maL‘hinu on level ground. it plvoxs on a spindle which is retained in position hy a split pin. A return spring retreats the stand when the machine is pushed lnrward, so that it can he whet-led prior to riding. 7 The condition oil the return spring and the return action should he checked regularly. lithe stand falls whilst the machine is in motion it eould catch irt same obstacle in the read and unseat the rider. m ls Suesdomsler: removal and repleaentunt —————~—___ 1 A speedometer oi the magnetic type is litted to the Honda mopeds. it contains also the odometer lor recording the total mileage covered by the machine. 2 To remove the speedomemr, remove the lrorrt ol the headlamp. Unscrew the cable and pull the speedometer out or the top of the hemflamp. When replacing th speedometer, ensure that the sealing ring is in good eondi on. 3 Although a speedometer on a machine oi less than lunee oapaeity is not a statutory requirement in the UK, rl uflL' is lined it must he in good working order. Reference to the mileage reading shown on the odometer is a good way of keeping in pace with the routine maintenance schedules. 4 Apart horn defects in the speedometer drive or in the drive eahle itsell, a speedometer that maliunetione is driheult to repair. Fit a replaeement or alternatively entrust the repail to an instrument repair specialist. 13 Smumnvr tabla: illsnacliull Ind maintenanc- H i It is advisable to detach the speedometer drive cable from Hmrsuxpensiarl unit [2 off] 12 73 Suit-W f2 05/ i4 Acorn nut (5 um 15 Spring Waslwr a Space! (4 off! 10 Pi'Vmbo/l 71 Washer {10 affl Cup washer (2 oil) time to time, in order to check whether it it adequately lubricated and whether the outer enirering is eoirtnresseii ul damaged at any point along ite run it mitv or eluggisii speedometer mmemcut can eiten he alliibutad to a cattle fault. 2 Tu grease the cable, withdrew the inner aahle. Artur rprnoutng the old grease, clean with a netrpl snakud mg und uxamllil‘ the cable lor broken strands or ether damage, 3 Fla-grease the cable with high melting norm grease, taking care not to grease the last six inches at the point where the tahle enters the speedometer he a. it this precaution is not observed, grease will work into the speedometer head and imrnohriise Ihl,‘ movement. a lithe speedometer and the odometer swl) working, it is probable that the speedometer cable has broken, lilspeclluli will Show whether the inner eahle has broken; ii so, the inner cahle alone can he renuwcd and reinserted hr the outer AZOVLEimg altar greasing. Never lit a new inner oooie alone if the oliwl‘ covering it damageri or eomiiresred at any point along its run. 17 Sleenny lock The steering luck l5 only lined in the Pcsl) model and is mounted bulilnd lite iroiil lurks. It incite the steering iii the lull riglil lock position. Two scram hold Ult‘ luck .rt position. ’i The PFSD mudeis have a pillar mounted sent. When ille- pinch bolt is tilidona,tlte seal wrli slide out of the heme. 2 The PCEOKI model has a pivoting seat that sticks to two rubber suckers. TWO nuts hold the steal to me nivultrig bracket but il the bracket needs removing, the plastic cow! and the petrol tank must be rerritived lirsl, Chapter 2.2 lully rleacrilies the patrol lahic removal. The seat bracket is retained with intir baits. Chapter 4: Frame and forks 19 L Vamvlg me machine: neutral 1 Ann wmnwvg an 3mm mm mm .3 mg orsuuuge washud :mqummv m cm" wam, me anpllcmion a! car polish m wax Wm gm: a quad hnish no me mnchmu. The mam} parts should rr-qum: nmv H mm ow'r with a damn rug, {allowed by puhshmg wull a rirv mq. u, lmwnvur, nmmmon has mkun mam, which may mcur when me mad, 1w mum durlng [ha wimev, a proprietary chmml: cleaner can he umd. 2 Wm mums mluy parts Wm Inga (hair sheen and oxuhsr smw‘v yr Hmy um um polrshed mgulany, 'l m, sparlng usr: or mma‘ mum m Wm: mush such as Solvm Amosm Wm vesmm lhr) unmnm mmh wnh anw a Vow mIHmM labour. 3 The mwmw smmlu be wnpm nw'r .mmmmmly mm n has hvmw ”Sud m We Wm 50 that ix ‘5 nm qaraycdl day damp «,omhlmm whirl! WAN Lauw nmtnw and corrosion. Make sure m sham 15 WNW and u mttrwsalv mm m uruvcnl waver imm mmm (hr: ram-15am causmg harslmr‘ss with .m accumpauying mpul mtv a! view Remnmbm' mm is lime chance ol wmer enlwlng me comm! cnmm u may an: lubricamd legumfly, as mammmded in we Hounne Mamcenanm 5mm, K a ~ . . ‘52 Unscrew the cablu and pull the speedumetar mar Fm, 4‘1 1. Chacking wheel angnmm A and C , Incarrucr 8 7 Current 72 Frame and forks Chapter 20 Flull dimnosis: fruma Ind forks symmom Can-u Rumldy Machine veers to hell er right wslh hands off handlebars Machine rolls at law speeds Mmhineiudden when from make is applied Machine piKChes badly on uneven sur'accs Fork amen suff Machine wanders. Steering imprecisc‘ mar met-2‘ mm to hop Inwnccl wheel alignment Bent forks Twislnd frame Ovemght steering head bearings Slack naming head hearings Inefleuive Forks Ineifectiva mar suspengion units Fork ‘03]: out of alignmam Worn swinginy arm pm Check and re-align‘ Check and venew‘ check and renew. Slacker: and re1esL Tighten until all may 15 taken up. Check and .enew, Check and renew. Slacken {mm whee‘ spinme nuts, Pump forks several mnes men Hyman spxnule nuts. Dismantle and renew bushes and rlivut shafL Chapter 5 Wheels, brakes and tyres contents Gmlvml ileserrmian ... .._ 1 Front wheels. examination and renovation 2 rrarrt wheel. removal 3 Front brake assembly' examination, renovation and reassembly 4 Front wheel hearings: examination and replacement: PFSOmodel . 5 Front whalel bearings: examination and replacement Peso model 5 sraoadometer drive gearbox: examination: PFSO moi-leis 7 Speedometer drive gearhux: lucdtinn and examinminn: PCSO model ... a, 8 Front wheel: replacement 9 Rear wheel examination and rcnovalmn .. 10 Rear wheel: remuval . ... ... ... 1' Film brake assembly: examination, rcnuvmizm and reassembly 12 Rear wheel bearings: examination and replacement 1: Rear wheel sprocket: removal, L‘xaminuuon and replacement 14 Rear wheel: reassembly . Front and rear brakes: adiustment Final drive chain: examination and lubrication Tyres: removal and replacement Fault diagnosis: wheels, hraltes and tyres Wheels and tyres Front wheel .. Rear wheel Tyre pressures Frunl neat .. Brake Final drive sprocket Chain length I General description 1 0n the PFSO medals both wllcllls are of 17 inch diameter. Iitrud With 100 rneh section tyrasl They am not interchangeable as the rear wheel has a helmn linal drive sprocket, 2 0n the Pesto model the wheels are oi 15 inch diameter, fitted with lwo tIillmerrt size tyres. 3 Each hub contains an internally expanding brake. The hunt brake Ilnckplate also carries the speedomfler drive gears an the Past) model. 4 It IS necessary lo delatzli the final drive chain belore the rear wheel ran he removed irom the frame. 2 Front wheel: examinallnn and renavatiert 1 Place the machine on the renrre stand so that the tram wheel is raised civill at the ground, Spln the wheel and check the rim alignment. Slimll irregularities can do mrmclud by tightening the PFso Inndals 100 x 17 inch ZOO x 17 inch Peso models 2130 x 19 Inch 2.15 x 19 inch 1.8 kg/sq cm 2th kg/sq cm (26 mi) (28 psi) 1.9 kg/m cm 20 kg/sq cm (27 mil (23 psi) Internally expanding 26 teeth 29 teeth PFSD Belinks PCSO BBlinks FFEOR 8t DXR 58 links spokes in the affected aree,although a certain amount oi experience is necessary If evar-mrrection Is to be avoided. Anv ‘ilais' in the wheel rim should be evident at the same time. These are more dirtieult to remove with any success and in most cases the wheel will need to be rebuilt an a new Vlmt Apart from the eliect an slabi|ilv, there IS greater risk of damage to the tyre bead and walls if the machine is run with a deformed wheel. 2 Check lor loose or broken spokes. Tapping the spokes is the best guide to tension. A loose woke will produce a quite different note and should be tightened by turning the nipple in an antiolnckwise direction. Always check for run-our by spinning the whee| again. 3 If it is necexary to turn a spoke nipple arr excussive amount to restore tension, it is advisable to remove the tyre and lube so that the and of the spake that nnw protrudes into the wheel rim can he filed flush. II this precautian is nul taken, there in danger of the spoke and chafing the inner tube and musing an eventual puncturel 74 \ Fioe 5.1. From wheel ammblv - P050K1 modal wnee/mmale Spacer Maul [lull Bear/n9 spacer Whealrl’m Tyre Tube Rfm mp9 Speedometer warm lo Speedometer gear 11 Drive piece :2 rlmm washer (2 am 13 Blnk: backplate 14 Blake shoe (2 off) 15 Emk: cam is Blake rem-n spring 17 Blake arm 13 What 19 Oil teal 20 DH ml 21 01']me 22 Bolt 23 NH! 24 Se/Hackl’ng nut 25 Jamal ball baa/[n9 l2 um 25 Spoke mm; 27 Spoke (15ml mmumumcanm Wheel complete with brake ammbIY Braks and wheel :pmdle mommy Wheel spindle anembly Duke numb/y thel spindle Adjustable calm 12 of" Span” Hub Can: Iackmlr [2 off} 10 anknur [2 of” 1! Dust cover 12 off] 12 Ball bearing: 13 links backplale mmeumw m Fig. 5.2‘ From wllnal assembly , PF5n modem Blake :hoe (.7 all; Return spring 12 am Nut far [Mammy speedometer arm, VEdAIL‘liDn gear Wlme/ spindle nut 12 am mmer (2 alll Spacar Speedometer mm- reductmn 98.?! Wheel camp/m we: bearing: and brake Tyre Inner lube Rim rape Spake [36 off! Chapter 5: Wheels, brakes and tyres 75 3 Front wheel: removal l Comrllenrc uporalluns by plasma the machlne on the centre stand, 2 Dlscnnnt‘cl the c Ca: 05: :gzm 9,..on E 90 EEG an“: 52:; a: fl Wu M.“ w‘ G 3“: 3%: use: v =5 55;. .3 I“. g .355 .520 9.63:; 355:5 ,ui 323$ I" 5:; =3: rag/L { :5 Eu E; 32.2.3 32,; . In. E :2... :5 E 2 553...,15 Jhfi :35 @U ~ IIIIIIIIIIIIIIIIII L _ E .5. =55 .lllll\llllllll\\1l|l|I!|I\IL $.sz SEE O: N 55:: O a 2.. a _ y '0 w I 5 a... 3 E 5%: N n; .d 5.5.; a Ea: F 19:26 9558: m: demSm 25.; 325 a a; ESE: Index A Adjusting mpnels 10 AW Ml?! , 49 B Barrels 13,20 Big-end bearings , 27 Brake atlinstrnent a 75 Brakes , spcclliwllnns » 73 auibr , 84, 14 C Cam lulluwery 20, 33 Cainshalt ~ 27, 33 Carnshalt chain tensianer A 33 Capannies a 45 Cartturettnr , 45 Centie stanu- 7n Chain 71 Cleaning. 7i Gluten -d manning - 24, 33 Clulch anemhng mechanism , 33 Clutch - soeeiiieetions - IS Condenser , 57 Connecting rod . 27 Games! bmaker ~ adlustmant - 55 Craltknase - 27 Crankanalt - 27 Cylinder barrcl~18429 Cylinder head e 18, a: Dncarbonizing - 33 Dry wzlghl A a E Elzcn'lcal system . specifications , 34 Englni! examination - 17 Enginc "13550th , 34 Engine speclflcallons >18 Engine mmnval - 17 Exhaust System - SI Exhaust valve . 20, 32 Fault oiognasi clutch - 43 Fault diagnosis - electrical system - 58 Fault diagnosis , engine , 43 Fault diegnasi » Frame and lork assembly .72 Fault diagnosis - fuel system - 53 Faull diagnosis , (reductionl gear - 44 Fault diagnosis » lgnislon system e so Fault dlagnusl rwhenls, brakes and final drive - 83 Final driue - 24, at) Flywheel generator 155,84 Footrests - 15 Frame assnmblv > 68 Frame number , 6 Front brake , inspection ~ 75 Front forks - 51 Front wheel . inspection » 73, 77 Fuul system - specifications - 45 Fuel tank , 45 G Guflrbnx - 27 Gear cluster -16 General repair inletrnatlen - 13 Generator removal , 20 Generator A 55, 84 Headlamp . a4 Horn - as ignition coil ~ 55 |gniliun system ~ specific ignition timing e 59,11 Inlet valve , 20, 32 Length - 4 Lighting switch - 36 Lubricants — ‘3 (1mm 92 Main bearings - 27 Mainsmm ammbly - 27 Maintenanne . 7 Model range ~ 4 on arrange , 7 Oil pump 7 27, as, 53 Oil seals . 27 Overall langm - 4 Overall wialn - 4 Pedals - l5 Penal tank - 45 Pam-ll tap - 46 Plsmn >1s‘32 Pinon rings . 32 Plastic moulding - 71 Rear brake r inspection . so Rear chain . so Rear suspensinn units 7 as Rear wheel - 77 Rear wheel sprucknl , ED Rings- 32 Rockars — 33 Rockm hnx . 33 Rocker shalt: ~ 33 Seat . 70 Index Sparking plug » 53 Speedometer » 7o Speedomeler cable 2 7o Speedometer drive gearbox . 77 Sprocket sizcsA 73 Sleering head bearings - s5 Steering head lock - 7o snap and «all lamp , B4 Swinging arm - 6: Tail lamp » 84 Timlng - 58 Tools - 75 Trochuid oil pump - 53 Tvm removal and runlacumenl - 81 Tyre sizes . 73 v Valve grinding , 33 Valve guides - 20, 32 Valves , 20, 32 Valve seats - 32 Valve springs - 32 Weight 4 thelbas! - A Wheel bearings . 76 Wheels - specifications - 73 h , 4 Wiring diagrams - 39, so Wlnng harness , as Walking chdilinns and muls , 15