SIIflP MANIIAl HONDA ncso express NAsoexpress 11 mean ’77—’82 ‘ NAso ’79-’18]! IMPORTANT SAFETY NOTICE WARNING Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed. CAUIION Indicates a possibility of personal injury or equipment damage if instructions are not followed. NOTE: Gives helpful information. Detailed descriptions of standard workshop procedures. safety principles and service operations are not included. it is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all con ceivable ways in which service, whether or not recommended by Honda might be clone or of the 9055» ible hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Any- one using service procedures or tools, whether or not recommended by Honda must satisfy himself thorough/y that neither personal safety nor vehicle safety will be jeopardized by the service method or tools selected. é HONDA ‘ ‘ NCED - NAED FOREWORD This shop manual describes the technical features and servicing procedures for the HON DA N050 and NASO. Refer to the add-endums at the back of the shop manual for 1979 and subsequent' model years ser- vice information. HONDA MOTOR CO., LTD. Service Publications Office ALL INFORMATION, ILLUSTRATIONS, DIREC‘ TIONS AND SPECIFICATIONS EXCLUDED IN THIS PUBLICATION ARE BASED ON THE LA- TEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR COT, LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITH» OUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. N0 PART OF THIS PUBLICATION MAY BE RE- PRODUCED WITHOUT WRITTEN PERMISSION. Date of Issue' November 7980 _: American Honda Motor (20., Inc. 1980 ~ An Ram: Reserved V HONDA mcso - NAso TABLE OF CONTENTS TECHNICAL FEATURES FEATURES .................................................................... .....1-1 2-STROKE ENGINE FUNDAMENTALS .................................................. 2-1 ENGINE .......................................................................... 3.1 STARTING SYSTEM/POWER TRANSMISSION SYSTEM . . . 4-1 LUBRICATION SYSTEM .............................................................. 5-1 CARBURETOR ..................................................................... 6-1 SERVICING PROCEDURES SERVICE PRECAUTIONS ................... . . .7-1 INSPECTION/ADJUSTMENT .......................................................... 8-1 ENGINE REMOVAL/INSTALLATION ................................................... 9-1 Engine CYLINDER HEAD/CYLINDER/PISTON ........................................... 10-1 Engine OIL PUMP ....... . . 11-1 Engine A.C. GENERATOR ............................................................ 12-1 Engine L. COVER/STARTER .......................................................... 131 Engine CLUTCH/FINAL DRIVE GEAR .................................................. 14-1 Engine CRANKCASE/CRANKSHAFT. . , . 151 Engine CARBURETOR ............................................................... 16-1 Frame HANDLEBAR/FRONT FORK/FRONT WHEEL ...................................... 17-1 Frame REAR SHOCK ABSORBER/FUEL TANK ......................................... 19-1 ELECTRICAL ...................................................................... 20-1 SPECIAL TOOLS ................................................................... 21-1 MAINTENANCE SCHEDULE ......................................................... 22-1 TORQUE SPECIFICATIONS ......................................................... 23-1 SERVICE DATA .................................................................... 24-1 TROUBLESHOOTING ............................................................... 25-1 SPECIFICATIONS .................................................................. 26-1 WIRING DIAGRAM... ............ 27-1 '79 NA50 ADDENDUM .............................................................. 28-1 '80 N050 ADDENDUM .............................................................. 29-1 ’80 NA50 ADDENDUM .............................................................. 30-1 ‘81 N650 c NA50 ADDENDUM . ’82 N050 ADDENDUM .............................................................. 321 Data of Issue: September, 1981 © Amencifl Honda Mater Co., Inc, 1981 - AII Rights Reserved I 2 3 4 TECHNICAL FEATURES . FEATURES . 2-STROKE ENGINE FUNDAMENTALS . ENGINE . STARTING SYSTEM/POWER TRANSMISSION SYSTEM 5 . LUBRICATION SYSTEM . CARBURETOR Date of IssucI September, 1976 4?: HONDA MOTOR CO'. LTD. 1 HONDA hfl=5Cl FEATURES The Honda NC 50 is powered by a 24troke, 49cc, crankcase scavenged gasoline engine with two reed valves incorporated in the intake port. This model is designed on the basis of a ”maintenance-free” phiiosophy in that the maintenance items are limited and service procedures are simplified to a great extent. A new design is employed in the starting mechanism for simple and easy starting with the use of a starring spring which stores power for cranking the engine, starting is remarkably easy for every one. @The power main is enclosed in the left crankcasewith an oil bath to lubricate the compartments The engine and L crankcase swing up and down as a unit, with a pivot in the pipe frame. ® The rear wheel is suspended by one rear shock absorber on the left side in combination with the L crankcase. @ Since an independent lubrication system is employed, fuel and oil are separately filled in the gasoline tank. (5) A high-performance plunger type pump is utilized for lubrication purposes. Date of Issue: Septembets 1976 1 - I if; HONDA MOTOR co., LTD. HONDA 2 N050 2-STROKE ENGINE FUNDAMENTAL In most 2-stroke engines, the mixture is first drawn into me crankcaw and men forced into the cylinder by the pressure buildup which results from the down movement oi the piston, thereby, forcing the exhaust gases cut through the exhaust Dom Unlike a Invoke engine, when firing ocwrs in the cylinder, some of the exhaust gases still remain mixed in the fuel mixture, Therefore, the engine performance of an 2-stroke engine is mainly dependent upon the timing of absorbing the mixture into the crankcase and the scavenging efficiency of the exhaust gases bv the pressurized iuei UlleLlre. (Z-STROKE CYCLE PRINCIPLE) SCAVENGING PORT a EXHAUST PORT DIRECTION OF ROTATION \ (I TOP DEAD CENTER $0994.: 483‘ 11) COMPRESSION STROKE (Mixture forced into cylinder) (2) POWER STROKE (Mixture in crankcase Compressed) INTAKE COMPRESSION POWER SCAVENGING EXHAUST (3] EXHAUST STROKE {Mixture in crankcase still compressed) i4) EXHAUST/SCAVENGING STROKE Dale ol‘Issuc’ September. 1976 HONDA MOTOR CO” LTD 2' I HONDA 2-smuu: ENGINE FUNDAMENTAL NCEO IPORT TIMING] Twu‘cche port liming Is determined by the Iocations of the ports In the cylinder. 0n N050, rha imake port is provided wirh a pair of reed valves shaped to give an optlmum port Iiming throughout me enn‘re speed range. The use of the reed vaIve prevems reverse flow of mixture from the crankcase Into the carburetor and assures improved performance even at modev are and Iow speeds (REED VALVE CONSTRUCTION) INLET PIPE REED VALVE (LOCATION OF PORTS IN CYLINDER) Opening and Closing angles in terms of N650 TWO~STROI\ \,\ (EXHAUST) ISCAVENGING) \ _(EXHAUST)V _ 430° BOTTOM DEAD CENTER D' cc of Issue: September, I076 2.2 I HONDA MOTOR CO” LTD fl\ HONDA 2 % NCSD 2mm ENGINE ruunAMENm 1. 2-STROKE PORT AND VALVE ARRANGEMENT 2.5mm port and valve arrangement comes in zhrae types; 1) Reed valve, 2) Piston valve, and 3) Rotary valve. On the N050] a pair of mm need VaWes is milized {or each §ntake porL Opening and closing of the exhaust pens are made by the DISIO" as it moves up and down in the cylinder. NCSO PORT AND VALVE ARRANGEMENT EXHAUST PORT REED VALVE V (1) REED VALVE TYPE Thin plate opens and closes the intake new when dif- ferential pressure Kakes place across the imake passage-2nd SCAVENGING PORT engine crankcase‘ INI'AKE PORT EXHAUST PORT i 1 1 (2) PISTON VALVE TVPE (3) ROTARY VALVE TYPE The intake ports in me A “7er disc plate wuh a cvnnder wail ale opened and gun closes and opens the chased hy the piston as H intake port in the crankcase wan. In some inslallafiuns, the crank web '5 used to open and close the pew moves up and down. Dam onssue Septembcn l976 HONDA MOTOR (0., LTD, 2 . 3 2-STRUKE ENGINE FUNDAMENTAL NCED HONDA 2. SCAVENGING Tlvoe methods of scavenging are m commonly used. The N850 millzes loop scavenging with thvea scavenglng port; SCAVENGING PORT “V" EXHAUST PORT SCAVENGING PORT 6/; EXHAUST PO RT \I‘ SCAVENGING PORT (1) LOOP TVPE SCAVENGING In Scnnuerle rvpe, the mlxlure dlscharged into the cvl» lndel through the scavenging ports ls, by the angle oi lhe port outlets, lnrown against the wall oppaslu‘ from the exhaust port and bounced back, lhus forcing me exhaust gas out of the non. {R‘— ~—. (2) CROSS SCAVENGING TYPE The specially deslgned pmon crown or dcflecmr acts as a guide m allow the mlxture to flow upwards and then down- wards to the exhaust non ln the oppcslze Slde of me cylinder. NC 50 SCAVENGING lg SCAVENGlNG PORT SCAVENGING PORT fifi ”‘— EXHAUST PORT \Rf SCAVENGlNG PORT HONDA N050 EMPLOVS SCHNUERLF TYPE] ONE OF LOOP METHODS, BUT THREE SCAVENGVNG PORTS lNSTEAD OF TWO ARE PROVIDED IN ORDER TO ASSURE STEADY SCAVENGING EFFECT‘ (3) UNIFLOW TYPE SCAVENGING One openlng interconnects the two combusnon chambers a1 top. Scavenging port is provided in one cylinder and exhaust part In the other cylinder so that the scavenging flows runs in one way without Entanglement, 2-4 Dale oflssue: Septemben 1976 HONDA MOTOR CO.. LTD 3 ENGINE 1. CYLINDER HEAD Two cvcie engines run hotter rhan iour-cvcle engines since each upward movement of the pismn is a compression stroke and each downward move» ment, 3 pcwer Stroke. The cyiindei is a sturdy, one-piece aluminum casting with rows of fins to dissipate excess heat. \ CYLINDER HEAD HEM |SPHER|CAL COMEUSTiON CHAMBER is /// t _. / PISTON SOUISH AREAS A niearance, called squish area, is prowded all the way along tha crrcumference of the chamber between the piston or TDC and cylinder haadl where rhe mixture is under pressure higher than the other area. This causes the mixture in Ihe squish area to rush toward the center, thus making me burning steadier, assuring high burning efficiency and also minimizing carbon formation Dale or issue: September, 1976 6: HONDA MOTOR C0.. LTD. 3.1 3 HONDA. ENGINE NCSD Z. PISTON ROUND HEAD Two compression rings are fined tn the piston. No oil control rings are used since the engine is lubricated by oil mixed with the fuel. Irma“ piston with "EX" /toward EXHAUST \ PISTON PIN FLOATING TYPE The piston skirt has cutawavs to comet opening and claslng of the scavenging pom. HSTON RING DOWEL A piston ring dowel is press fitted to each ring groove to loca‘e the ring in place. After «##rv fitting the ring in the ring groove, check to make sure that the dowe! engages the ring A and gap properlvv TOP RING PISTON 2nd R|NG RING EXPANDER Expander assures uniform ring contact and reduces slapping sound. RING END GAP Dale of Issue: Semember, 1976 3 .2 to HONDA MOTOR 00., LTDc HONDA 3 NCSD ENGINE 3. CYLINDER The cylinder block is designed such that maxrmum rigidity with minimum dismrtion characterisrics are accomplished in an aluminum casting, The block employs a dry liner which is in full-face conlactwith the block for good conduction of heat. The ports in the cylinder are arranged to provide most elfecxive breathing and easien exhaust gas explosion. LINER The dry liner :5 machined to very close tolerances for good conformity with me plsron and minimum distonion due to hear. SCAVENG lNG PORT \ \ COOLlNG FINS .V. BARREL SCAVENGING PORT EXHAUST PORT 4. CRAN KSHAFT/CRANKCASE The crankcase is of airtight construction with least resistance to mixture flow, It is designed to offer effective scavenging to blow out remaining exhaust gases in the cylinder and to provide mixture for the next cycle effectively. sczavemsms PORT , ,# _ /SCAVENGING PORT g: . // OlL SEAL The nglu and len oil seals are E OlL SEAL made of special material an , r E resist oil for improved sealing, : l CRANKSHAFT 7' The crankshaft is a sepame type 55 ' . :5 and is made 0? high carbon steel. ‘ W» The right and left shafts are press fined ta each other. CRANKCASE The crankcase is of a split type and is divided into righl and left halves. Radius of curve in me scavenging passage plus Unique shape of the crankcase mmbine to achieve im- proved scavenging. CRANK WEIGHT The weight is machined to close toler- ances to lower resistance to mixture "°‘”- CONNECTING ROD The big end bearing uses a needle teller bearing for redhead resistance and longer service life. Date oi issue' September. 1976 a, HONDA MOTOR co.. LTD. 3 .3 l 4 HONDA % STARTING SYSTEM/ NCED K POWER TRANSMISSION SYSTEM The motorcycIe is not equipped with a transmission, Starting is accomplished by a foot pedal located at the left side of the motorcycle. The entire starting system consists mainly of the foot pedaI, starter spring, starter drive and driven sprockets and starter chain. These are bathed in oil in a sealed case. (BEFORE STARTING] Starzer pedal *‘Starter ratchet “Starter drive sprocket +Starter chain #Starter driven sprocket ~Starter spnng wEnergy stored in StaI can spring (motorcycle is ready for starting) (STARTING) Rear bzake lever -* Brake cabIe ->Starter lever -Start2r arm —>Starter spring (releasing stared energy) —>Starter driven sprucket #Drive mate *Engine crankshaft QStart — BEFORE STARTING — STARTER RATCHET STARTER SPRING Winding up STARTER PEDAL STARTER DRIVE SPROCKET STARTER CHAIN Dale of Issue: Septembct, 1976 0NDA MOTOR CO'. LTD 4-1 HONDA smmm: svsma/ N050 PflWER InAusmssmu 3mm {POWER TRANSMWTING SVSTEM) Crankshaft ADrive plate *Clutch ~>Drive chaén —>Driven sprocket T’Final Gear #Rear wheel — POWER TRANSMITTING SYSTEM - CLUTCH D R IVE PLATE —- STARTING — DRIVEN SPROCKET PULL 1N REAR BRAKE LEVER REAR BRAKE LEVER DRIVE PLATE Release / STARTER ARM STARTER DRIVEN SPROCKET STARTER SPRING STARTER LEVER CRAN KSHAFT DRIVE CHAIN FINAL GEAR Date of Issue: September. 1976 7 HONDA MOTOR (70., LTD. 4-2 4 , manna 3mm; HONDA. POWER musmssmu svsml NCED 1. STARTER DRIVE SPROCKET The stnrter drive sprocket transmits energy to the starter spring through the starter chain. It also keeps the spring com- pressed until the rear brake lever is pulled in lor starting, {OPE RATIDN) EWort exerted on the starter pedal is transmitted to the starter drive sprocket as described above. The starter ratehet then holds the spring compressed even if the pedal is released. The purpose of the starter drive sprocket is twofold: 1) To trans~ mu energy to the starter spring through the ratchet, and 2) to keep the spring compressed until the rear brake lever is pulled in, As the starter spring is released, it causes the starter drive sprocket to turn until it bears against the stopper. The starter stopper damper absorbs shock on the stopper when the spring is released. STARTER PEDAL STARTER DRIVE SPROCKET LOCKED HERE T L \ ’\ STARTER RATCHET \ STARTER STOPFER STARTER STOPPER DAMPER Z. STARTER SPRING . 0n the NC50, the engine is cranked by releasing energy stored in the starter spring The spring is held in place with a sus- taining plate and special screws and cannot be disassembled in the field. Notice that the springwill pop out in a dangerous manner when disassembled STARTER SPRING ‘4’ SPECIAL SCREWS ,_\ Date of Issue: Septclnben 1976 4 . 3 , ”EHONDA MOTOR cor. LTD. HONDA swarms srsrmr’ 4 NCSO PBWER musmssmu svsrm . 3. CLUTCH A wet, centrifugal rtlulch with drive plate couples and uncouples the engine to and horn the power train. The drive plate incurporares a set of ratcher pawls and cl'urch weights to which the shoes are allached. (OPERATION? To srart the engine, the starter pedal should first be depressed several times. Thusl when ‘he rear brake lever is pulled inl this acnon releases energy stored In Ihe starter sprung, causmg rhe driven sprocket to rotate. When the driven sprocket turns, the ratchet pawls engage [he sprocket teeth. Slum the drive plate is a fight taper fir to the 5m: end of the crankshaft, the crankshaft Is rotated es the pawls engage the sprocket teeth; that Is, the engine .; started. ‘As the engine sratts, cenrrifugal force on the ratchet pawl: causes them to fly outward away from the drive sprocket. An equilibrium between the centrifugal force and the spring force is reached when the engine rotates at about 600 rpm, keeping the clutch off even at idle speed. Oh me other hand, as the crankshafr rotates, the Clutch weights are also flung radially outward and con-.e Inro contact wtxh the Clutch outer. Power from the starter spring is then transmitted to the drive chain via the drive Sprocket. 1 g 2 IN 2,700 rpm 1 < r 7;; _ ____ r e : ‘ é l LOCK r 3,400 4.3,eompm ' O l 77k 77.4,... r g ‘r 55 l OFF 2,500rpm 1, l ‘ , my“ ’ IDLE SPEED 3,800 rpm CLUTCH WEIGHT DRIVE CHAlN CRANKSHAFT ---——-—-9 ENE SPROCKET ~x— CLUTCH OUTE R RATCHET PAWL ’ RATCHET PAWL SPRING// STARTER DRIVEN SPROCKET DRIVE PLATE Date of Issue: Sapternbcr, 1976 lONDA MOTOR Cot, LTD, 4 4 4 manna smm,’ HONDA @é? Puwmmusmssmusvsum NCEO J 4, Tm; drive and fmai gears are of helical design for Smomher, quieter operation over me entire range of speeds and loads of the engine (Redumiun I'aIIOZ 73/11). The gears are bathed in oil stored in the L-crankcase to require least anemmm The case also serves as a war fork that is integrated with ‘he angina and is capable of swinging up and down to absorb shocks or vibl aUDnS when the rear wheel encoumers bumps or irregularities m the road 0 FINAL GEAR DRIVE GEAR Daw of [55113.1 Septcmlier, 1976 4 . 5 :23 HONDA MOTOR (10., LTD. HONDA 5 3% N650 LUBRICATION SYSTEM 'l. LUBRlCATION SYSTEM OF 2-CVCLE ENGINE Twolcycle crankcase scavenged engines have no storage space to hold the oil that is to be circulated (wet sump). True lubricating system most commonly used on two~cycle crankcase scavenged engines may be dependent on "mixed" lube OII with file! or on oil supplied through an independent channel into the crankcase. Honda N050 employs the separate lubrication in that all bearings and moving parts are supplied with oil led into the crankcaw, lrom a separate tank. (1) SEPARATE LUBRlCATlON (2) ”MIXED” LUBRICATION All bearings and moving parts gain lubri- cation by oil fed into the crankcase from an independent oil tank. Oil pumps are used to lorce oil from the oil tank into the crankcase and to control the amount delivered. Lube Oil is mixed with fuei in the iuei tank in a designated proportion (usually 15:1 to 25-1). The above mixture then encounters and mixes with air moving through the carburetor to form the final air-fuel mixture. The mixture containing air is forced mm the crankcase and goes through the crankcase bearings. con- necting rod large ends and cylinder, there- by lubricating each componentt 2. NCSD LUBRICATION SYSTEM The separate lubrication system used on the NCSO is operated by a crankshaft driven plunger pump. The pump forces oil from the oil tank into the aankcase in exact proportion to the engine speeds and loads of the engine. This means reduced oil consumption and less carbon buildup in the combustion chamber. Dale uHssue: Sepia. «at, 1976 r.‘ HONDA MOT0li . , LTD. 5-] 5 HONDA Luamcnnou svsrm N350 @j 3. OIL PUMP The pump ts mounted at top of the crankcase with a screw. The [Hump drive gr:at,wh>ch 1s press fitted to the entyna mank- snait, rotates the (1: ive shaft (Reductt‘on ratio: 1/4). The cam dnvu gear at the other end or the deG shaft rotates the cam gea' mm a reduction ratio of #22. The pump IISEH consists of a Hunger, a valve, a pump body and springs. Two stage cams, mssde and outwde, are formed on the side mutant: of the cam gear. The inside cam is for the plunger and the outside for the valve. (See next page for detail} Tlm valve and plunger are held against the cam surfaces by means 01 the springs so that they move up and down in the pump body as the cams rotate according to the rotation of the cam gear. CAM GEAR CAM DRIVE GEAR To prevent gears from weanng, grease is packed between the drive shah and outer pipe, CHECK VALVE INLET PIPE DFHVE SHAFT (OUTER PIPE) GEAR PUMP DRIVE'GEAR ‘0’ 1 1 (FEATURES) g I . I - Least affected by changes In ml vrscosity (temperaturet, assuring 3 30— g ;. » . / steady deliverv over the entire range or engine speeds and toads o! i the engme through use of small diameter plunger and valve g 20» - . ‘ - . Lung, trouble-(nee hfe due ta use of sintered cams on cam gear 3 - Ccmpactand llghtweight construction '0' ‘- w I ‘ ‘ o I “2" 3 4 5 s ——> Engine RPM (x 70'! Dun: v.14 us: September. 1976 5.2 '1 IHCC.‘ mom»: Co. LTD. Pu mp housing Cam gear (SUCTION STROKE) Iniet port Valve is al bottom dead denter. DiS‘ charge port and pump pan are blocked by valve. LUBRICMIUN SYSTEM —- OPERATION — 1L GEN ‘ E (2 ® Intake port opens. AI and of intake Oil flows into stroke. valve stem pump housing due rising in body, to vacuum as Inlet port is mock- plunger goes down‘ ed‘ W “mum I 's‘fi (9 As valve rises fur- ther. pump how ing is span to dis~ charge port. (DISCHARGE STROKE) 2 g Check va‘ve liliWHlliiHliH @ Plunger is pushed up by cam. Oil is forced into iniet pipe over- coming check valve spring fovcei Date of Issue: Sepia; it; HONDA MOTO‘ :1, 1976 )., LTD. 5-3 LUBRIBATIIIN SYSTEM HONDA N650 (LUBRICATING OIL FLOW) —- OIL “w- MIXED OIL OIL TANK OIL FILTER OIL PUMP CHECK VALVE INLET PIPE " ,4 CYLINDER CRANKSHAFT PISTON 1 PISTON PIN ‘ 1 CONNECTING ROD SMALL END 3 (INTEFIIOR OF CRANKCASE) I 5-4 Date or '31:; September, 1976 11:} HON MOTOR CO LTD 5 CARBURETOR The carburetor is of a pismn iype thai is equipped with a choke vaivei The choke valve provides a very rich mixlure when the engine is being cranked. (CHOKE CIRCUIT) Pulling ihe choke lever in causes the choke valve to own. Thus, when rhe engine is cranked with (he throttle valve iuiiy closed, a high vacuum is developed 371 the air horn on ‘he engine side of me throme Vaive, This vacuum causes the choke valve m discharge a heavy stream of fuel to produce the rich air‘fuel mixture needed for starting the engine. CHOKE VALVE THROTTLE VALVE OPEN FULLV CLOSED ENGINE SIDE THRO'I'I’LE VALVE CHOKE VALVE /’( COMMON PASSAGE FOR STARTING AIR CLEANER SIDE GASOUNE Dave of Issue. Sep , If} HONDA MOTOP‘ B-i HONDA IWCED MEMO Date 5735149: September, 1976 (3 H01“ MOTOR minim. HONDA N650 SERVICING PROCEDURES 7 .SERVICE PRECAUTIONS 8 ,INSPECTION/ADJUSTMENT 9 .ENGINE REMOVAL/INSTALLATION IO.EngIne CYLINDER HEAD/CYLINDER/PISTON II.Engine OIL PUMP 12.Engine A.C. GENERATOR I3.Engine L. COVER/STARTER I4.Engine CLUTCH/FINAL GEAR 15.Engine CRANKCASE/CRANKSHAFT I6.Engine CARBURETOR I7.Frame HANDLEBAR/F'RONT FORK/ FRONT WHEEL 18.F'rame REAR WHEEL/REAR BRAKE 19.Frame REAR SHOCK ABSORBER/FUEL TANK 20.ELECTR|CAL 21 .SPECIAL TOOLS 22.MAINTENANCE SCHEDULE 23.TORQUE SPECIFICATIONS 24.5ERVICE DATA 25.TROUBLE SHOOTING 26.8PECIFICATIONS 27.WIRING DIAGRAM Me 0! Issue' Scp‘ " " ma 11mm “on '11 u SERVICE PRECAUTIONS I!()1\II)Z\ NEED cause lmzardl lllaelnne semcrng, make sure «ha: slarxer spnng 15 released by depmssrng pedal and squeezing rear brake lever. 1% 3??“ mm nm lvandwmate genera- [or mxar clockwwz - Never Fall to obey the following cautions dul‘mg servlce operation, sum» the 5mm Sprmg may lsl pa nor depress slumw halal unless necessary I Always replace whenever reassembled COTTER PIN O’RING © I Wash clean engine parts with solvent. Lubricate their sliding surfaces with 2-cvcle oil whenever disassembled. / SOLVENT ' / I Txghmn iasveners, beginnrng on cenrer or larger d.a. bolls to specs, where sequence rs not specv hurl, in a X pattern, I Grease by caatmg or filling when: specified as such. ‘ - Use HONDA or HONDA-recommended pans and lubrlcanls. w; M» I Alter reassembling, check avely possible pan for proper installallon, movnmenl or operation, / “H r 5 I Use specral tool where so specified I Always check mutual safew when wnrklng wllh partner. l , SYMBOLS - These symbols an: used (hroughout the manual to show sueufic kinds of operanon, sequence of semce procedures, etc. 07,5) ® n , :lndicazes ‘equence or service I metvoflh Apply cal. Apply Dream. 2 -: -: Means me possihllrly of pr» sonal iniuW ro voursell m amersv Mums ma Dosslbrmy a: charm age (a ma machine, ijde; quua mum mu splpral Information for more were.“ md colwemL-m sewn:- mg, Date A; September» 19' Hr , HONDA N650 é INSPECTION/ADJUSTMENT (BRAKE LEVER ADJUSTMENT) Check brake lever play at lever tin, If out of specs” adjust by turning adjusring nut (REAR) FLA! 10 —15mnl HEAH BRAKE LEVER r—RJOA — 0.6 in.) \ ADJUSTING NUT To reset the brake arm, refer to pwe 17-2 (front brake), page 134 (rear brake), BRAKE ARM INDEX ‘ARROW (FRONT) PLAY 10 — 15mm FRONT BRAKE LEVER “My"? : INCREASE PLAY/ ,/ ADJUSTING' NUT (BRAKE SHOE INSPECTION) Reolace shoe if arrow mark on brake indicator allgns with index, when lever is pulled in all the way. Be sure to check the proper starter spring operation, after adjusting rear brake lever free play (page 32). l 8-1 8 HONDA iiiSPEBTlflN/ADIUSTMENT NCED (STARTER LEVER ADJUQ'MENT) This adjustmem is essential to achieve proper starner spring operation. Prior u: this adjusxmem, check relr brake iever free play and adjust if necessary (page 8-1 ). @Depress sxaner pedai 10 — 20mm (0.4 — 0.8 in, and reieaie it STARTER LEVER \O - 20mm (0.; 4mm CLEARANCE 0.5 —1,[)mrn All 4» WW v STARTER PEDAL WWJ . .W W. @Adjust laver-tonut ciearance m o.5—1,omm (0.02 — 0.04m.) from upper most forward position (A). 1I’m DECREASE CLEARANCE , r // TOINCREASE i \ CLEARANCE\\ Vi \ roc'kNuT\~\k1::§ 'p 2‘ VA 9 . (EDStan and stop me angina a few times (more than five times with new rear brake cable) and check thai the clearance has not changed. if necessary repeat steps G) and ®abovav mum'mmben I976 8‘2 {3 ‘RC0 n. > é HONDA 8 P ‘ N850 INSPECTIIJN/ADJIISTMENT (IDLE ADJUSTMENT) AIR SCREW F (D Stan the engine and set it at lowest idle speed by turning the throttle stop screw. (2) Turn the air screw aimer in or out to obtain the highest idle spend 6) Screw the air scram in 1/8 — 1/4 turns. (27 Adiusl the mronle smp screw to allow the engine to run a: an idle speed. Romim of stop screw in a c wisa direction increases speed. IDLE SPEED: 1,800 rpm. , \ock- , (FUEL LEVEL) Check float Iavel height measured from flange with final valve just touching Hm arm mug. Use float gauge to chuck. Float height: 10 mm (0.394 in.) HONDA é mercnuu/Amusmm NCSO (CONTACT BREAKER POINT GAP} (1:; Insert a healer gauge through the role! hole. w/® Check poim gap, Replace if om of specs.. (0.3 — 0.4mm) 0.3 —0.4mm ‘ non—ome' ,) “’3 (IGNITION TIMING) SLACK/WHITE WIRE FROM GENERATOR r LAMP m... ",5, (Use a lamp (II as great a wanage as passibAe} Q}Tum the flywheel coumerclock» wise on!” me "F” mark aligns with the max mark. Do not hanchotate the genevamr rotor cIockwise as the starter spring will w|nd. GROUND CABLE BASE C2) To adjust, loosen the base screw and move the base to get the comet ignition timing where lamp becomes dim with marks aligned‘ 8-4 HONDA. 8 NCEO INSPECTIflN/AMUSTMENI (AIR CLEANER ELEMENT) CAUUON gfiemave air finer element Wash air finer element in clean Stoddard solvent and allow to drv thoyoughly. ®Soak air filter elzment in clean gear oil (No. BO—Nm 90) unlil saturat- ed, men squeeze out excess oilv @Reinstafl air filter elemem, GEAR OIL (SAEED — SAEQO) (OIL FILTER CLEANING) AIR GUN / ‘ PULL DOWN «.TO REMOVE - Empty the on xank behave cleaning ' Bleed the air from the oil line and the oil pump aftei cleaning. O Fill the oil tank with oi! and then bleed (he W from the oil line. Page 8 v 7. 56 (Issue 4- 'ncr. 1976 I IDA L" 1, LTDV 8.5 HONDA msrmmu/Aumsmm NCEO {SPARK PLUG ) To clean, use plug / [cleanav a! steel wire. _ , Replaoe plug‘ with / 7 07mm warn elecmades 24 0.023 in. 1 or damagsd ,, -_ . ,7 insulator / Always use we cormm Check: an ' : zlemoda Wm mark pm; me Ind hm : insumor candition ”"99' : gaxknl condition : prémnw of fouling 1977 MODEL 1973 MODEL «Poms evens max) mus (NGK) avsHs [NGK) BPAHs (NGK) wzoFP (ND) waP (ND) wwrp (ND) W14FP~LKND) - SEAT \~~ LOWER LINE Use ulsmled wamr m use electrolyte level, CAP 7- a g. PULL up — READING SPECIFICVGRAVITY OF ELECTROLVTE - "\ ‘ {1 fl : i NORMAL S.G. HVDROMETER ,. 1.260 — mun/20°C (68°F) ELECTROLYTE <_/ L} \\ \\ \ WARNING 0 Do not sewice the battery while the engine «5 running. Keep the battery away from men flames or sparks. 0 Avoid averfilling the battery. Sulfuric acid (5 very corrosive. k Revised September 1377 © American fiatcr Cu 8-5 HONDA 8 N650 INSPEEIIBN/ADIIISTMENT (BLEEDING OIL PUMP) The oil pump and the 06! km: must m bled to eliminate air whenever. a The 0“ line disconnected. O The oil supply is completely used up. u The engine isvemmed. Am BLEEDING /1 When mo air bleeder cap is removed. earned on will flow out. Continue bieeding until oil {tee of air comes out Before bleeding, make sure more than 0.31 (0.33 US qt) of oil is in tank. ’ V, / / OI L TANK When air-bleedmg more mar- DJE (0,33usm: cl m1 must 190 in the Ian k. OIL PUMP l OILTUBE / GLASS JAR (L. COVER OIL REPLACEMENT/LEVEL CHECK) PAGE 13 — 2 of Issue. Septemhen I976 N‘DA MOTOP L, LTD, 8 .1 ENGINE REMOVAL/ INSTALLATION AH semce operations excepx crankshaft work may be performed with the engme in the frame. (11‘, REAR SHOCK ABSORBER BOLT/ENGINE MOUNTiNG BOLT/ REAR WHEEL/MAIN STAND NOTE 400 a 500 kg - cm (28.9 a 35.2mm {MUFFLER - a“ Tvglmm iastly ax assem‘my. 9-1 300 » 400kg A cm (21.7 7 2891b5-ft) @: REAR BRAKE CABLE \ Adjustment: Pages 8» 1 and 87 2. \ \\// Date of Issue: September, 3 HON KOTOR C0,; HON DA. % N050 ENGINE 9 REMDVAL/INSTALLATIUN Keep fue! cock dosed during disassembly, ’7 CARBURETOR/NR CLEANER CAUHON Bleed air after assembly, Page a - 7 "BLEEDING OIL PUMP.” :9} PRIMARY WIRE Connect color ‘\ (ocular. ©RIL STEP covsns ate oflssuc: September, 1976 Q HONDA MOTOR C . LTD. 9 --2 H] HONDA ‘ Engine NCSD a CYLINDER HEAD/CYLINDER/ PIS TO N wwus Before operahunl make sure thal Halter sprmg ,5 mneaaed Duung uperafiun, do run depress n. i-REAR SHOCK ABSORBER / LOWER BOLT PISTON PIN cups NOTE Ar assnmhly, ‘ 5» install new wrist V pin clip. immusr HEIGHT so THAT 5 CYLINDER HEAD CAN BE REMOVED. Péaoe Mock here to avmd mmng ahead é ,._\ ' CYLINDER \ NOTE . Remace when _ - > , , , disassemumd w“. > 3 .. Be sure mat the paston (ings move fleet»: v before instamng the piston into me mlw’ cylinder. 90 7 120k? an (5.5 A gyms-m Install cylinder head with ,fi "E toward EXHAUST. mm of Issue. Septembs: 10-1 x-Hov AMDTORCO 'Engine HONDA CYLINDER Huu/ N850 CYLINDER/PISTON mussmm III ASSEMBLY (PISTON) - DISASSEMBLY/ASSEMELY \ InsKaII piston wim the "Ex" mark t faclng toward me EXHAUST PORT, Place a :59 over the crank case opening to prevent the WIISI pin clip from M- ling imo the crankcase, (PISTON RING) . DISASSEMBLY Aways remove piston ring as shown above. 130 not forget m CAUTION install expander. Be careful not to damage piston durmg operation Avoid scoring or watching the piston. o ASSEMBLV mm" the puswn rings with their markings facing quard. When» evev the rings are mplaoed ensure ma‘ the proper rings are in- stalled. N: NIPPON PISTON RING T: TEIKOKU PISTON RING Top ring: IN at 1T 2nd ring: 2N or 2T Dam of Issue: September, 1976 f mem MOTOR Co., LTD Engine m CYLINDER mm HONDA msrmmu cvuummsmu NEED 6% (CYLINDER HEAD DECARBONIZING) pre clean aflev decarbwwwg. Avoid scvalching HlSIUE xhe smfaces. Pg—fi SCHAPER <§, (EXHAUST PORT DECAR BONIZWG) WIDE clean after decarbomung. (( <———~ SCRAPER (PISTON/PISTON RING CLEARANCE) 2nd ng ,7, _ _ _ _.__‘ i 0.025 7 0.055mm (0.0010 7 0.0022 in.) I Service meil: 0.1mm (00039 in) J Date of Issue: September. 1976 "L3 @HONDA MOTOR CO LTD; ingine HONDA CYLINDER HEAD/ 10 NCED CYLINDER/FISH)" INSPECTIIJN (PISTON SKIRT 0.0.) 39,955 7 39.!)75mm (1.5731 7 1.5739111.) w 39.35mm (1.5689m) Measurements should be {akeu at pain! 4mm (0.16 in} from button). (CYLINDER LD.) W .. - ,#.i 40.00 »-40.01m¢n (1.574s-1.5752m ‘ Service Limit: 40.05mm [1.5758II1J Dale of Issue. September, 1976 2: HONDA MOTOR (0., LTD. ")4 Engine III cvunnm um,» HONDA msmnou mmnmrlsmn N350 (PISTON RING END GAP) Push me vings down squarely into the cylinder bore usmg the piston head (PISTON PIN 0.0.) 9994 — 10,000mm [0.3935 7 0.3937 NLI ‘t Sen/Ice Limit: 9.97mm (0.3925in.) ‘ ”’1 7‘ fi—,__,._#_.fl — _._,., ——-. 10,002 , 10.008mm (0.3938 — 03940 In.) I Scrwce eriV: 10.03mm “13949 :n.) Date of Issue Sepmnbcg 1976 1 0.5 HONDA MOTOR (70.. LTD. N650 . Engme OIL PUMP me all tank (I, OIL TUBES / Ensure (hm no dust gels . into pans upon reassembly To mm pipe Bleed all pump and all lube aha! 35'sembly. Page a . 7V “'25 GI L PUMP ' *‘ "* ‘KIDFHVESHAFT » At assembly, handv \ ‘\ ,/ rozamthe crankshau to ensure (hat all / » pam have been prop- erly assembled. ,1— Do nG‘Horgel la install. O INSPECTlON CHECK FOR OlL LEAKS. CHECK GASKET FOR DETERIQRAT‘DNl , Date 01' Issue: September. 19% L * _- HONDA M0T0R.C0., LTD. 1 1 _ I , e 12 Engine A.C. GENERATOR Never mm flywheel clock @- AL FLYWHEEL GENERATOR wxse during disessembly Disassembly/ assembly, and reassembly page 12 - 2. \ \ CAUTION NOTE During disassembly and installation, check the in- 9) ROTOR FLANGE 300* 35°k9~cm side to ensure that no D‘sassemva/assembly. (21.7 — 25,3 lbs~m foreign particles have page 12 A 2‘ \adhered to the magnet. \ 1 a! Disassemby,pa9012 2. ’QTSTATOR Prior to installing. mute the generator cable through the hole in the case. I PAGE 8 ~ 4 FOR IGNITION TIMING ADJUSTMENT AFTER ASSEMBLING. . Dam oi’lssue: Sepwmber‘ 1976 I 2' 1 15 HONDA MOTOR CO.‘ LTD. HONDA Engine DISASSEMBLY ‘2 NCED LC. summon ASSEWLY (FLYWHEEL DISASSEMBLY/ASSEMBLV) FLWVHEEL HOLDER (No. 079250010001) 5 TOOL ' 0 DISASSEMBLY ' (ROTOR FLANGE) I IN T I N ACG. FULLER ATTACHMENT 3 ALLAT 0 (No. 07931-1 4701 00) PU LLER (CONTACT BREAKER D lSASSEMBLY) After installation. check and adjust the paint gap and me ignition timing if required, page S - 4‘ on: or issue; September, 1976 ; v“ HONDA MOTOR (70., LTD. I 2. 2 L, 12 Engine HONDA ,m M. summon NCSO K/ INSPECTlflN (CONTACT BREAKER POINT) Polish me contacx points with a point me ii they are burned, oxidized or aux of alignmem. OUT OF 3 ‘ FOU LED Date ol’lssue: September, I976 f7 HONDA MOTOR CO . LTD. 123 HONDA I 3 NCSO Engine L. COVER/STARTER Pm" [u difiassembiing, My release the Starter spring by pulling in the rear brake mm. (L. COVER DISASSEMBLY WITHOUT OIL RENEWED) r"" a’x’] BATTERY ~ ~— WARNING Check for signs of leaks. , 5 Lay on gmund with Leaver up. NOT _ 7,49 /- ’ , ,AssmaLY; _ “ Pour 0.75 liters (0.79 qt.) of oz! in case beiore insxalling hoover. :évHEMOVE L-COVER l PAGE ‘3 ‘ 2 FOR OIL REPLACEMENT.' Dzue of issue: Seplambcr, i976 2v HONDA MOTOR CO, LTD, INDEX l3 mum Engine HONDA sruusucz L. cum/31mm NCEO (L. COVER DISASSEMBLY WHEN OlL RENEWED) STARTER LEVER Keep the lever turned all the way in the 3mm direc7 tion when installing the L7 coverl lnsmll lhe L~covev while hand roxaxing the flywheel in arrow direction, 1/: / Cl'leck for damage or other delect. During reassembly, use cannon to keen pans assembled m place, Avoid gening oil on the brake linings. OIL FILLER After assembling, adjust the oil level to lower brim af the filler opening Fm Leaver lnstallalion and oil refilling, see page 134 But, lo! perlcdical change as prescribed in malmenance L COVER DRAIN BOLT schedule, follow Ihe proceduve - as below: NOTE 1. Stand the motorcycle up- l Only about 0.6K (066 right ‘ us qsl 0! oil is drained - - NOTE - 2, Dram the case all - . cu! from the drain bolt 3‘ Pour oil and adjusl level Place an all pan hole‘ up to lower brim of oil under the tease and fuller hole power train. Dam oflfi'uc: Septzmber. l976 QHONDA MOTOR (70., LTD. 13:2 mun: HONDA Engine mum ‘3 NCEO L. cflVER/STARTER SEflHENEE (STARTER DISASSEMBLY/ASSEMBLY) SE . ‘ “ " ’ ¥ ' 1 ' ' U SpE‘C a! iool STAND as descrwbed on page 3 4 AX assembly, "15m“ “an” pedal so the tip is wilhin ”A". SUSTAINING PLATE {STARTER SPRING) WARN‘NG DANGER !! NEVER D'SASSEMBLE, REPLACE TOGETHER W|TH L- COVER AS AN ASSEMBLY. {3:1 STARTER PEDA L \ ’ l HST/AMER STOPPER \ ARM SPRING WARNING \ NOTE Make sure ma \ the spring is Prinr m disassembling, \ \ hooked secu rely rend relauve tome under \ \ on me arm during STARTER STOPPEH \ \ assembly. DISASSEMBLY on page \ é‘, STARTER ARM 13 - 4. \ " \ @STARTEH DBWE SPROCKET Disassembly and assembly, pages13A4 and 13- 5‘ Dill? of Issue. September, 1976 'k,‘ HONDA MOTOR CO“ LTD. HONDA N050 l3 DISASSEMBU Engine ASSEMBLY L GUVER/STARIER (STARTER DISASSEMBLY/ASSEMBLY) ~STARTER STOPPEH DISASSEMBLV _ 2“ Make SUl‘e that SIEVYEY sprocket (3;STARTER STOPFER Remove the stunner with the starter pedal held. After assembly, check for proper operation [ST/ARTE R RATCH ET is locked by starter arm secu'sly Do not permit your hands to touch the chain ’ and the starter arm. When installing the L cover to the L case, wind up the starter spring until the punch mark an the starter sprocket alrgns with the tip of the starrer srm. Lightly tap the L cover while rotating the flywheel, and never ran the L case. j TA , , STARTER SPROCKET STARTER SPRTDCKET , .i ‘ PUNCH MARK w , , P}/4,: V \ STARTER ARM l ‘ ’13Temparalily install the starter pedal in the prop- ' er position and mute until there is a clearance gig?“ D‘SASSEMBL'NG between the starter stapper and the sprocket dogt (No 07965: M70001) :3 / — STARTER DRIVE SPROCKET DlSASSEMBLY —- Install the drive sprocket with the marks aligned, J SPROCKET ASSEMBLY \ Al assembly, avoid damaging all seal, LVCOVE R BASE (NoVD7965-1470001)\ lL—COVER (53 Release the stepper arm by rotating in arrow direction .. The starter spring is released by ramming the pedal gradu~ ally in due arrow direction. Date of Issue' September, 1976 ~15" HONDA MOTOR CO, LTD. HONDA Engine ASSEMBLY 13 NCSD L. cnvm/smmk INSPEETWN (STARTER DRIVE SPROCKET ASSEMBLY) marks. (STARTER ARM/SPRING INSPECTION) S FOPPER :\ Rtrplacc If damaged DAMPE R w , 7 Replace :r damaged SPRWG DAMPER CAP , ,ir Replace If damaged Remact- x: weakened Date of Issue. Sipu‘mber, [976 HONDA MOTOR (10.. LTD. 13:5 1 3 Engine HONDA m INSPECTIflN L CUVER/STARTER N350 « (DRIVE SPROCKET) SPINDLE BEARING RETURN SPRING Replace a weakmw ..\ Replace if the ratchet pawl: or fieplm ‘f unusuaHv stretched splines are damaged. RATCHET SPRING ‘ »'\ Date of Issue; September‘, 1976 i 3 -fi QC) HONDA MOTOR co” LTD. N850 Engine mCLUTCH/FINAL DRIVE GEAR lBALL BEARING /- Replace with a new hearing, f Page 14 - 2 for reassembly. 'éw/ @TENSIONER SPRING /OlL SEAL Replace wilh a new ’/ "'\®FINAL GEAR @DHIVE SPROCKET/DRIVEN SPROCKET Remove or install wilh chain engaged / 300 — 350 kg , cm W/DRWE PLATE (21.7 — 25.3mm Disassembly and assembly, page 14 - 2. / L-COVE R BASE (CHAIN TENSIONER) (No.07965-1470001) After assembling, check the chain tension. Replace me spring if weakened bane of Issue: Septembe}: 1976 HONDA MOTOR co., LTD. 14-1 seal when disassembled. M msnssmsu Engine ASSEMBLY CLUTCH/FINAL DRIVE GEAR (DRIVE PLATE DISASSEMBLY/ASSEMBLY) 51:7 Remove the nut while the tool is engaged with the mchex pawls. FLYWHEEL HOLDER (No. 079250010001) CLUTCH PU LLER // (No. 079353050000) (BALL BEARING ASSEMBLY) To install. drive outer race squarely (o outer race. J J x "/1 Date of Issue; Septembex, 1976 © HONDA MOTOR CO., LTD‘ 14-2 HONDA Engine ‘4 N650 cwIcH/HNAL DRIVE GEAR INSPECTION (INSPECTING DRIVE AND DRIVEN SPROCKETS FOR WEAR) DRIVE CHAIN "‘ _ FINALGEAR DRIVE SPROCKET DRNEN SPROCKET O x! J gégJL/égi REPLACE (BALL BEARING LOOSENESS) EXCESSIVE LOOSENESS (RENEE) EXCESSIVE LOOSENESS (Replace) Date of Issue: Semembet, 1976 “7 HONDA MOTOR (30., LTD. 14-3 1 4 gm“ HON DA msvmmu cwIcu/Fum nmvt sun NCSD (CLUTCH SHOE WEAR) (CLUTCH SPRONG TENSION ) AS-KNSTALLED LENGTH 35 mm (IABBinJ [_._.____. .___.____.__m..__ 15kg/35mm (33.1 ‘bs/LSS in.) Serwce Limit: 13.5kg/35mm (29.8lbs/1.38 in.) ‘ ___,, ., \ I Date of Issue: September. 1976 4 4 CD HONDA MOTOR CO.. LTD HONDA . 15 NGED Engine CRANKCASE/CRANKSHAFT _ Take care to torque fight. ‘2 R:CRAN KLASE Use caution to avoid scaring and \Dvsassemblv, pas215'2- scrambing of pans, since on: crankEase must be pressure tighL Repiaue with a new gasket upon reassembly‘ (I) INLET PiPE 90 v SZOkg'cm g (6.5 - 8.7ihs-m OIL PUMP DRIVE GEAR "‘ / CHAN KSHAFT NOTE ® L-CRANKCASE Replace Dali bearing, oil sea! Disassembwl page 15-2. and pump drive year when overhauling the engine. I PAGE 15- 2 FOR CRANKCASE AND OIL SEAL ASSEMBLY. Date of Issue: September. 1976 1; HONDA MOTOR C0..LTD. 15] “.4. I5 msussmau Engine HONDA ASSEMBLY CRANKEASE/CRANKSHIFI NCED (LCRANKCASE DISASSEMBLVI (RvCRANKCASE DISASSEMBLYI CASE PUL LE R (No. 079334470000] (CRANKCASE/OIL SEAL ASSEMBLY) \ I,/ / / Use collar when assembling the crankcase. OIL SEAL ASSEMBLING TOOL (No. 079534470000) — L-OIL SEAL INSTALLATION DIMENSION -— — RDIL SEAL INSTALLATION DIMENSION ~ 172mm 5 3 - 4 mm (0‘04 - 0.03 in.) a; ‘ "W ”(0.12-0.16m.) V Dale of Issue; September. 1976 1 5 .2 @J HONDA MOTOR Co” LTD. HONDA Engine '5 N050 CRANKCASE/CRANKSHAFT msrmmn (CHECK CONNECTING ROD SMALL (CHECK BEARING LOOSENESS) END BEARING LOOSENESS) FL :T Over 1,5mm [0.06 ml (Replace) UNUSUAL LOOSENESS UNUSUAL LOOSENESS (Repiace! (Replam) (MEASURE CONNECTING ROD BIG (MEASURE CRANKSHAFT RUNOUT) END BEARING SIDE CLEARANCE) V BLOCK _ . ‘ , 60 mm 60 mm 3 (2.36 in} (2.36 in.) PDXNT A 81 B '——‘—1 .0161 in, i 0.05mm (0.0020 in.) MAX. ' E Service Limit: 0.15m"! (0.0059 in) [ V ._._ . (MS—0.41m“ (0.0059— = Serwce Limit: 0.6mm (0.0235m.) ‘; L_* ,_J Date of Issue: Sepwmber, 1976 * HONDA MOTOR co., LTD. I 5_3 I B HON DA Engine _: CARBURETOR ”CED Turn off fuel valve befove draining. (4‘: CHOKE CABLE ~\ f3: THROTTLE CABLE /A’§; CARBURETOH Disassembly and reassamblypagv 5AM? CLEANER / NOTE wmm msramnq carburetor, m su re to fasten the ground cable. ’DROTATE SCREW TO DRAIN. Date 01 lssun’ Scpiembn. 1970 I 6 ' 1 tC‘HON'DA MOTOR CO.. LTD. Engine msnssmm "i cmunnnn ASSEMBLY (AIR CLEANER) (i! E LEMENT COR E (2; AIR CLEANER ELEMENT ,’ Cleaning, page 8 - 5. {woven Hoax level and MI: adgustmenls, page B - 3. (CARBURETOR DISASSEMBLY/ASSEMBLV) AIR SCREW 3%? «w ,4? F LOAT VALVE Use curu Smce they are vaslly 5:0qu or scratched :2) F LOAT »"’ F LOAT CHAMBER DRAIN SCREW Dale of Issue: Sepmmbcr, me : HONDA MOTOR 00., LTD. 16.2 1 6 Engine HONDA INSPECTIflN cARBunmn NCED (MAIN JET/SLOW JET CLOGGING) (FLOAT VALVE OPERATioN) Check that nnfices are open and not clogged sewage if nox rammed smoothly. by blnwing. (THROTTLE/CHOKE WIRE FRAY OR DAMAGE) (CHOKE VALVE/THROTTLE VALVE DAMAGE) (Replace) SCRATCH 0R SCORE (Replace) Due ofls§ue: September, 1976 I 6 - 3 (a HONDA MOTOR (30., LTD. 17 Frame HANDLEBAR/ FRONT FORK/ FRONT WHEEL » ~-- «fiHEADLIGHT CASE (43,4 — 65A lbs-ft) MES} *' i" NOTE 600—900 kg-cm 0.] a?» \ 1x2; HEADLlG HT STAY PIN SPANNER (No. 079160440000] | "(L TOP CONE RACE LGEFRONT FORK At assembly tighten w‘uh Vorce ‘ 1 f 1 men back a" ‘A mm ‘\ -,.>§ (a) FRONT WHEEL Disassembly and assembly, page 17 » 2. @61 NOTE 300 — 400kg -cm (21,7 — 28,9Ibsrft) ' BALL RACE DISASSEMBLY AND ASSEMBLY. PAGE 17 - 3. Date oflssue. Septembcr, 1975 :4“. HONDA MOTOR co.» LTD, 1 7 .1 Frame 1 1 BISASSEMBLY HANDLEBAR/ HONDA ASSEMBLY mm roux/mm WHEEL NCED (FRONT WHEEL blSASSEMBLY/ASSEMBLY) NOTE FRONT BRAKE CABLE 40 _ 70 k Adjustment after assembly, SPEEDOMETER CABLE Mm NOTE (2‘9 — 5,1 lbs-m page 8 -1. / ‘ Check for smooih opelation after 9’ assembly. /- / Avoid any or greasy auhsxances / geningonlinings, Align punch marks as assembly‘ (FRONT BRAKE ARM READJUSTMENT ) Once the omer cable and reaches the pain! shown in the picture due to shoe wearing after adjusting the front brake lever free play, reset the bake arm posifion (punch mark) by turning the bake arm by one serration counterclockwise. This adjustment is only enough wnh one time resetting. Date of Issue: Septembex, 1976 1 7 -2 :3 HONDA MOTOR co. m), Frame museum HONDA HANDLEBAR/ ASSEMBLY 17 NCED mm FllRK/FRBIIT WHEEL msmnnu (BALL RACE DISASSEMBLY/ASSEMBLY) — DISASSEMBLV — — ASSEMBLY — 3‘7 wag, BALL RACE DRIVER (No‘ 079533330000) EXCESSIVE LOOSENE§ (Repiace) EXCESSWE LOOSENESS (Replace) (CHECKlNG FRONT WHEEL AXLE BEND) ‘ 0.05mm (aoozom MAX. 3 Service Limit: 0.1mm 0.0039 In,) L, pm of Issue: Septemben 1976 HONDA MOTOR cov. LTD. 1" _3 Frame 1 7 HANDLEBAR/ HONDA msrscnuu mm roux/mm WHEEL NCSD (WHEEL HUB LD.) 80 780.2mm (3.150~3,158 in. Service LimiK: 81.0mm (3.189 m.) {BRAKE LINiNG THICKNESS) 3.5mm (0,138 in.) ‘ Sewice Limit: 2.0mm (0.079iu.) 1‘ ..... _____.7 ,,,,, (FRONT WHEEL WOBBLE) Service Limn: 20mm (0.079 in!‘ 1:,05mm (ODOZOEVL) MAX. ‘ Check for damage or nails embeded in the me treads. — SPOKE LODSENESS — Retighten or reapair as necessary. Date of Issue: September. 1976 1 1 -4 <0 HONDA MOTOR co,. LTD. 18 Frame REAR WHEEL/ REAR BRAKE (fig D) REAR BRAKE ARM RESETTINGS ' 7#_ 'V " Bt'ore arrow on ma: bake indicator aligns to index on L crankcase, brake arm resetting is necessary :wo times according to shoe wearing. <29,- A), , "LS-,3); may) mam mmuw Aumuufl A Mm A W \ __ J Dim oi regeilings mu «m: w RTOE h No—E —‘Fzm reseaiaf—Secm reséiling wig-eon ep am new w an m , 500k? cm disassembled. n n ma brake arm reaches the point shown in (fig. D), when ‘28-9‘351'b“ ’ brake lever is adjusted with adiusling nun reseI arm in Accovdance with (fig. A}, And under the same conditipn, if arm is in the same again, reset like (fig. BL REAR WHEEL When instailing new shoe, fallow with (fig. C). REAR BRAKE INDICATOR 1 REAR BIRAKE ARM REAR BRAKE CAM ;' % Q 40 —~ 70 kg—cm Avoid oflv or greasy (2‘9 — 5.1 ibs-fl) substances geuing GREASE on linings, ‘ . \ L. CRANKCASE I PAGES 8 - 1 AND 8- 2 FOR HEAR BRAKE CABLE ADJUSTMENT AFTER ASSfiMBLING. Date of Issue: September, i97§ c HONDA MOTOR Co.. LTD. a, I 8 _ i ] 8 Frame HONDA INSPECTIUN REAR WHEEL/nun BRAKE N350 (CHECKING BALL BEARING LOOSENESS) UNUSUAL LOOSENESS (Replace) UNUSUAL LOOSENESS (Replace) (MEASURE WHEEL HUB LD.) 1 80,0v80.2mm (3‘150~3.1581n) ‘ ! Service Limit: 31,0mm (3.1mm \ (MEASURE BRAKE LINING THICKNESS) gr 35mm (0.133m.) V j ‘ Service Limn: 2.0mm (01mm) 5 L‘". . ___4 Dam of Issue: Septembcr‘ 1976 1 8'2 “\N‘ HONDA MOTOR CO“ LTD. HONDA W %> ”(:50 Frame —~———REAR SHOCK ABSORBER/ FUELTANK /,.@GASOLINE/OILTANK NOTE 1 \ \ 3007 400kgrcm (21‘7--2aV9Ibs-m \ /,,. '5; CONN 5cm R STOP/TAILLIGHT REAR SHO’CK ABSORBER “ NOTE 200—300kg-cm (14.5 A 21.7 lbszt) (REAR SHOCK ABSORBER DISASSEMBLV) 9 After assembling, check operation 3 \ 00 @ \ STL REAR SHOCK ABSORBER COMPRESSOR (No 079593290000) a? Daxe of Issue: Sepxember. 1976 - 1‘s“ HONDA MOTOR ca; LTD 19.] 20 ELECTRICAL HONDA N050 (ELECTRICAL ACCESSORIES AND THEIR LOCATIONS) 1. IGNITION SVSTEM 2. BATTERY CHARGING SYSTEM 3 LIGHTING SYSTEM AND omens CONTACT BREAKER AC FLYWHEEL GENERATOR HEADLIGHT IGNITION COIL RECTIFIER STOPKTAILLIGHT CONDENSER BATTEFW HORN SPARK PULG CONDENSER BATTERYJ' IGNITION con. I _‘ MAIN SWchlij-v—>0I g SITOP/TAILLIGHT M" ML -/ CONTACT BREAKER ' Inspection, page 84 I I SPARK PLUG and 12-3 I — Inspection, . iA.C. FLYWHEEL GENERATOR page a _ a. “LIGHTING COIL) 20-1 Daze of Issue: September, 1976 (C? HONDA MOTOR C0,, LTD. NCED ELECTRICAL mspacnnu [IGNITION COIL) Check m: cominuity as Shawn (LIGHTING COIL) Check lor cuntinully by anaching one last probe to yeuow connector and the other to ground. Norma) if there is conti- Normal If continuous only in arrow direction. Replace If continuity exms in reverse direction, nuity. Dale of Issue: Scpwmbex, 1976 : , HONDA MOTOR C0.. LTD. 2 _ IHIHW NH! 1 Ill! 1 14:! ESE 20 INSPECTIBN ELECIRlCAL HONDA Mesok Battery inspemicn. page B - 6. (BATTERY CHARGING) Keep away spark s and open fl ames from battery while charging. (MAIN SWITCH) BAT Load color BLACK] WH‘TE GREEN BLACK RED (DlMMER/HORN SWITCH) Connect chmgfir nusmw m (Brmmsl l0 bflflPW DONUVI: ‘ Count-Hing terminal. method Comm charmr negalwv 1—» (ermmu‘ to baltcry nuqanv? ‘erminal cm my my on Inspecnan Cominua chmgmg unrll suc- cm: granny 9105“ch ekgclrw 2sz ‘s 1.187 1 23 mm CL Gases m formed on plate sup ram vigmausly m and or ‘ Chyglng xzme cnavm, .| \2—13 hams for balwries ma specific 9mm, below 1.22 (at 20%) GREEN HED E La 1H. v / I O. Lead color BLACK/ WHITE EGHEEN L-zad color WHIYE BLUE VELLOW LIGHT Lead CDIor GREEN GREEN All wtres are rowed iv mmllgm case. Check these switches whr-n main swnch ls to be inspectmL 20-3 Dale of Issue: September, 1976 ((7? HONDA MOTOR CO.. LTD. (2) SPECIAL TOOLS 21 \ if 1 Too! parts No. Description Common to: Remarks Page (D 1 07925421010001 Flywheel homer M Holding nvwhw and drive plate 3 :3 l , (‘2‘- . 079314470100 ACG. pulier machmant N050 Promoting shaft end when disassembhng 12 . 2 J 1 rotor flange {3. 3 079651470001 L-crankcase base NCSO Disassembling L-uankcase cover 13 - 4 (5) 1 079358050000 Clumh puller 6 series Pulling oux drive mm 1412 5 ‘ 079334470000 Case puher N050 Disassembfing crankcase 15 , 2 (6,: ‘ 079534470000 on seal assembfing too! N050 'nstaflins crankcase and crankshaft 0" 5em 15 - 2 (,2? 1 079160440000 Pin spanner - Removing and tightening top corn race 17 - 1 ® | 0795393330000 0211 race driver 033501: Removlns and installing ball race 17 - 3 r\ L Re h k Disassemblmg and ramsembling rear shock ‘ \9, 1 079593290000 mgpswgsco, absofber XL250 absorber 1g 1 Date of Issue: September, 1976 HONDA MOTOR co" LTD. 211 22 HONDA MAINTENANCE SCHEDULE NCED ‘ ‘ 1 REGULAR I MA’NTENANCE SCHEDULE INITIAL I SERViCE PERIOD This maintenance schedule is based upon SAFETV Perform at every indicated average riding conditions Machines PRERIDING , ,NSPECT‘ON mm o, mileage “malt subjected to severe use, or ridden in I INSPECTION ‘ Michmrmmfim unusually dusty areas, require more 1 w , W 7777777 , 77"" ,4 - - ‘ 1 month 12 momhs 24 months “We” ”mm“ 1 200 muss 1,000 miles 2 mo miles TIRES AND PRESSURE ‘CONTACT BREAKER POINTs' i I 'IGNfiiCN TIMING H V W 7 ' N WW 7 THROTTLEOPERAT‘I‘ON 'WHEELTRUENESS AND SPOKES 'NUTS, BOLTS (TIGHTENI ‘ ’BRAKE LININGS V 7 I V ‘ : I “"EXTTERY FLUiD LEVEL ' 7! WEE W Effiwm ,, ' VE W "BATTERY FLUID SPECIFICGHAVITY ., ‘ ' 7 ' ' i ’SPARK ‘AIR FILTER ELEMENT __ 7 N 7 7 ' (EVERY 6 MONTHSI c 'CAREURETOR W." ' 7 7"~_I_W I 7 ’EUELEILTER scREEN '- lc' N c “SUSPENSION OPERATION H < j I i'iCLfJiTr'CH SHOES FOR WEARV I , ,, ,_ ,_ ‘ V i “I- ”TRANSMISSIONOIL __ ‘7 , I R 'DECAREONIZE CYLINDER HEAD AND , ‘ I C MUFFLER ‘ BRAKE OPERATION AND FREE PLAY VOIL AND EUEL LEVEL if? ____ ALL LIGHTS TRANSMISSION CASE FOR LEAKE I-lnspect, ciezn, adjust or replace it necessary H—Replace Ciciean L~Lubricate Items marked‘ shouid be serviced by an authorized Honda deaier, unless the owner has pruper tools and is mechamcaily pmficienn Other maimenanue items may be serviced by the owner. gate of Issue: September, 1976 22 .] C> HONDA MOTOR co., LTD. 23 TORQUE SPECIFICATlONS ‘% Ncso (ENGINE) . - . . Thread dia. Torque ‘ . Rel. No Tighlenmg norm 0 tv mm kgm‘ (ms . m Page 1 Cylinder head holdrdown nuts 6 907120 (65 — 8.7l 10*1 2 AC, flywheel generator attaching nut 10 300—350 (21.7 4 253) 12—1 3 1 Clutch (ddve plate) anaching nut ‘ 10 3004350 (21.7 » 25 3». 144 4 mm pipe attaching nuts I 4 a 96—120 (6.5 — 8.7) 15.; i (FRAM E ) Thread d' Torque l . . .a. . Ref. No. Tnghtenmg palm O [y mm ‘ kg~cm (lbs . l!) ! Page ,_ -v ‘ _ 1 Engine mounting box: 1 m 300—400 (21.7 — 28.9) 1 971 2 Slesrmg stern mu 1 - soc—eon (43.4 7 55.1)3 17,1 l 3 . Front wheel axle nut ; 1 70 i 300—400 (21.7 , 28.9l l7--1 4 ; Reavwheel axle nm 1 1 12 1 400—500 (28.97 saw. 13‘: . , , 5 § From brake avm bolt 1 5 ‘ 40—70 ‘29 — 5.1) 17-2 6 ‘: Rear brake arm bolt 1 5 ‘ 40—70 (2.9 7 5.1) 3 13—1 ‘ l 7 Rear shock absorber Unper nut 1 10 300—400 (21.7 7 28.9? 194 Lower ban 1 5 ‘ 200—2100(14,5—21.7)'l , Standald Torque Specifications Type Torque kg ~¢m (lbs ~ m 6mm bolts 40v70 {2.9 ._ 5.1} 6mm screws sol—x10 (6.5 - 8.0) 6mm bolts 10!)» 140 (7.2 ~ 10.1) 8mm bolts 20!)» 250 [14.5 > 18.1) mm“ bolls 300-400 (21.7 — 2&9) Date oflssue: September, 1976 C7 HONDA MOTOR COU LTD. 23-1 24 SERVICE DATA (ENGINE) HONDA. /\ N050 Unitmm Cm.) mam Assembry Standard Repair Luni‘ Page Pist0n/pismn Eng marance 7" 0702570055 (0001040022); 01 (0.0039) 7 )0: 3 F5310" 510‘ (1D. (11mm from bottom) 39.955739,975 (15731—15739) 39.85 (1.5639) 30 7 4 4000-400) (1 .5748— 5752) 40.05 (1.5760) 10 - a .70“ - ..,A “W, .. __.. .. . ,, .. ,,,,, .Z Pnston ring end gap 0.15*0.35 (0.0059700138) 10 7 5 Pinon pm 00. 0904—10000 (03935703937) 0.97 (0.3925) ; 10 — 5 Pinon pil hale LD. 10002“10.008 (03938-03940) I 10.03 (03949) 1D * 5 Clutch shoe 0.0. 103.87103VQ (408254.0905) 70305 (4)0787) 1477 4 09mm spring preload: Load kg/mm (lbs/in.) 3 15/35 1311/1/30) , 115/35 (ma/1.38) 14 .. 4 Conneciing I'od big and baaring Side clearance 0. 15—1141 (0.0059—0INS1) 0.6 (00236} 15 —~ 3 Left 60mm Z 0.05 max. (0.0020) 0.15 (0.0059) f y C’W‘m‘ ‘ “mm“ Right 60mm 0.05 max. (0.0020) 0.15 (0.0059) ‘5 3 (FRAME) Unitmm ()n.) Hem Assembly Standard Repair Lvmn J Page From wheel axle bend 0.05 max. (00020) 0.1 {0.0039} I 07 7 3 Front and rearwheel hub n.0, 80.0— 30.2 (1150—3168) 51.0 [3.189) I; f: Front and rear brake Dining thicknesses 3.5 (0,138) 2.0 (0.079) . g i From wheel runoux 0.05 max. (0.0020) 0.2 (0.0079) 17 — 4 24-) Dam: of Issue: September, I976 Z3 HONDA MOTOR (30., LTD. HONDA NEED 25 TROUBLE SHOOTING Trouble Probable Cause 2 Remedy Engine does nerstarr 1. Loss or compression l Primary compression leak past all seal 1 Replace Primary compression leak past gasket surface l Repall Leaky cylinder head gasket ' Reriemen er repleee Poorly tightened spark plug , l Renglnen l Worn piston ring or seized piston ‘ Replace l Damaged or defectlve piston Replaee Blown em cylinder head gasker . Rerlgnren or replace Scores or scratches on cylinder wall ! Repair or replace , , , ‘ _ 2‘ No sparks across spark plug gap ‘ Fouled plugar bridging { Clean or replace 1 Wet Spalk plug 1 Clean or replacu l Fouled breaker points 1 Clean or replaee l Improper (mint gap , Adiusr pr replace “ improper ignilion timing Adlust Detective ignition coil Replace lgmtlan coll open or short circuited 1 Replace snprred er derecuve condenser l Replace 3. Fuel not reaching carburetor Clogged fuel tube Clean Clogged fuel cock Clean Deiccrive carburetor lloar valve ‘ Replaci- Fuel tiller cap hole clogged 3 Clean 4. Clutch purerorder r Burned or worn clutch weight shoe ‘3 Replace Weakened eluseh weight spring 1 Replace 5. Starter pedal out oi operatipn t Too little 3 starter lever play ; Adjust Starter arm spring out or proper position or damaged l Repair or replace Starter lever shaft stuck § Clean Wire rusted l Luprleare ‘ Weakened or damaged ratchet spring l Replace ‘ Worn or damaged starter ratchet 1 Replace Starter chain disconnected : Replace l Starter spring out of proper position or damaged L Replace 6. Starter spring not released ) 3 Excessive starter lever play 1 Amos! 3 Drive sprocket shalt seized ‘ Replace Sustaining plate out of proper position or damaged . Repair ol replace Dam of Issue: September. 1976 HONDA MOTOR CO, LTD. 25 _ 1 25 lllllllllLE SllllllTlllli Engine starts but stops 1 1. Spark plug louled Clean or replace soon i 2. Breaker points fouled Clean or replace ? 3. Engine out of lime ‘ Adjusi 1 4. Clogged luel pipe ‘ Clean 5. Clogged carburetor ier Clean 6. Loss of crankcase compression Repair Starter pedal does not 1. Starter arm spring weakened Replace return 2. Drive sprocket spring weakened Replace 3. Starter ratchet out of order or damaged Repair or replace Engine lacks power 1. Worn or seized cylinder or plston ring Repalr or replace . 2. Engine our of time Adiusl 3. Defective breaker Doints Repair or replace 4. Improper spark plug gap Repair or replace 5. Clogged carburetor let Clean or replace 6. improper float level Adjust l 7. Air cleaner clogged l Clean or replace 8. MExcess'lve accumulation of carbon in exhaust muffler Clean Engine overhear: 1. Excessive accumulation of carbon in combustion Clean chamber l 2. Float level too low ((00 lean a mixture) l Adjust l 3. Timing too far advanced Adiust l 4. Excessive accumulation cl carbon in combustion Clean 3 chamber ( 5. Starved engine inspect 1 6. Brake ncll released Adjust ? 7‘ Excessive acmmulation of carbon on piston and plsmn Clean or replace rings Poor englne perlarmance l 'l. ignition timing lnlpruner ‘ Adjust at low speed 2 Defective breaker point ' Repair ar replace ‘ 3. Excessive spark plug gap Repair or replace l 4. Spark too weak due to defective condenser or ignition , Replace l coil ‘ l 5. Float level improper Adjust 6. Carbureror air screw out of specification Adjust Puor engine performance 1. Spark plug gap too little Repair or replace at high speed ‘ 2, Ignition rirning too late Adjust 3. Breaker poinl deleciive Replace 4. Ignition coil at fault Replace l 5. improper lloat level Adlusl l s. Clogged air cleaner element Clean or replace j 7. Loss or crankcase compression 1 Repair i 8. Leaky exhaust pipe or excessive accumulation of 1 Repair or replace l carbon in exhaust pipe 25-2 Date of Issue: September. 1976 i? HONDA MOTOR CO., LTD. HONDA NGED lllllllBLE Sllllllllllli 25 Delecllve clutch Sparks do not jump across spark plug gap 1, Clutch slips Worn or burned Clutch Weigh! shoe 2. Clutch does not disengage Clutch weight not functioning properly 3. clutch engages too early (too late) Clmch spring weakened an or burned clutch weight shoe . Clutch drags ax idling (engine slallsl Idling speed too last Fatlgued Clutch spring Carburetor at lault 1. Defective lgnluon coil . Defective spark plug . Breaker palms fouled or point gap lmproper Replace Repair Replace Replace Adiusl Replace Adlust or replace Replace Replace Adjust or replace Excessive carbon accumu» l 1. Too rich a mixture (carburetor or air cleanerelogaed) Adjust or clean lau‘on en spark plug elec- 2. Spark plug heat range improper Replace trodes : P, ,.._ _ _ ,, .,_ e. A, ,, __. Burned breaker points l. Points out uf alignment or not properly contacted Replace 2, Condenser at fault Replace Spark plug eleclrcdes 1. Carburetor out of adjuslmem Adjust excesslvely fouled 2, Flooded carburelor Adjust Spark plug electrodes ll Improper heat range Replace 2. Engine overheating ‘ See page 74 3. Engine outpl time l Adam 4. Lnosened spark plug in head l Retighlen 5, Mixture mo lean Adjust Heavy steering ‘l, Improper tire pressure l Adjust 2' Loose handlebars l Retighmn 34 Front axle not lightened properly Rellgl’ltel'l 4. Loosened or excessively tightened steering stem nut Retighten or adjust 5. Loosened or broken spoke Reughzen 5, Defarmed rlm Repair 0! replace 7. Excessive rattle ln ball bearing Replace 8. Bound wire or cable Repair Poor braking 1‘ Brake shoe partially contacted with brake drum Repalr or replace Date of Issue: September, 1976 \C‘ HONDA MOTOR cor, LTD. 25-3 25 TRUUBLE SHODTINE HONDA. NCED Poor brakvng Unusuai noxse Loose from shock absorber . A! drive chain or starlet chain Excessive chain slack 0v deflection Wom chain lensionex Worn or starved charn Chain interfering with chain case 2. OHV or greasy Substances on brake lrnlng or drum Clean . 3. Devecme brake cable Replace , 4. Brake out 0! proper adrusrmum : Adlusl Brake unable ro be adiusmd 1 v, Exczssively worn brake shun f Replace ‘ 2. Excessuvelyworn brake cam j Repiace ; 3. Improper insmHatiun uf brake am an brake arm ‘ Replace V swindle (sevrauon) 1 [ I. At from shock absarber ‘ ‘ From cushion starved of gvuase Grease Hangman Admsi or replace Replace Repxace or Subncam Adjust 25-4 Date of Issuc: SeptembeL 197s HONDA MOTOR Co. LTD NCEO 26 SPECIFICATIONS DIMENSIONS Overall length Overall widlh Overall heigm 1,550mm I61in.) 600mm (23.63nJ 1,000mm (39.43n.) Wheelbase 1,050mm [41,3inJ Ground clearance 125mm I 4.9 in.) Dry weiahl 43 kg (94.3 lb.) FRAME Type Back bone F. suspension R. suspension F. me size, pressure R. we size, pressure F. brake R. brake Fuel capacity Fuel reserve capacity Caster angle Trail length Front fork grease Telescopic fork Swing arm 2.25 414 w APR 21p». (Lake/cm“) 2.25 — 14 — 4m zapsi. (2t0kg/cm1’ Internal expanding shoes lnlernal expanding shoes 2mm (0,53 u.s. 93L) 0.: HI. (0.053 u.st gal.) 67“ 72mm (2.8 in.) sec lo.lsozsl ENGINE Tyne Cylinder arrangement Bore and stroke (1977 model) Bore and stroke (1978 made” Dlsplacemem Compression ratio (1977 model) Compression ratio (I975 model) Transmission oil capacity Oil tank capacity Lubrication system Air screw cpemng Intake Open Close Exhaust Open Close Scavenge Open Close lele speed Air cooled, 2-stroke Single-cylinder flat 40 x 39.6 mm (1.57 x1.561n.) 4D x 39.3 mm (1.57 x 1.55 in.) 49 at: (2.99 cu. in.l 6.7 : 1 6.6 : 1 0.75 Iit. (0.79 U.$.al.);10W-40 motor OII 0.8 III. {0.8 Iii. (0.84 U.S. qt.) ; 2 stroke iniector uil Forced and wet sump 2-1/8 Automatically controlled AutomaticaIIy controIled 65° BBDC 65° ABDC 470 EBDC 47° BBDC 1,800 rpm © Amnllnnlw Honda Motor (2a,. Inc. 1977 Revised Septemaér 1977 25 I 26 HONDA é SP£CIFICAIIUNS NCED DRIVE TRAIN cmtch anary reduclion Final reducfion Automanc oemrifugal vm tvpc Chain and gear 14.220 : 1 ELECTRICAL Ignition Slanmg system Genemor Spark plug (1977 model) Spark ping (1978 model) Spark plug gap ignition \iming Bamzvy capacity Fuse capacity Headlight Low/Hugh Yail/smofigh! Speedometer light High beam indicamr light Magneto and banery Tan smarter A.C. generamr 6V 0.053kw/6,000 rpm NGK EPGHS, BPSHS; ND WZDFP, W16FP NGK BPSHS, EPISH57NDW16FP, W14FF~L 0.6 — 0.7mm (0.024 — 0.02Bin.) 18° ETDC 6V ZAH 7 amp. 15/15 wan (21/21 CF) 513/25 wan (3/32 (21’) 117watt (1 CP) SAE TRADE N01 51 1.7wan (1 CF) SAE TRADE No. 51 26 '2 Revised Sepumber 1977 Cc) Amerxcan Honda Moxor can In: 1977 27 WIRING DIAGRAM D Fugue—Hmong is u 3 . ia a; s :5 u g. . is a .5: , s... A as S i: h; a: 1. “I: . mica 6:: is $33 . 9.0. me an 55m .33 21-1 13.1.9 or me Sew, my 19% '5 HONDA MQTOR. CO.‘ LTD, HONDA NASO F0 RWO RD Refer to the base NEED shop manual for service items nol described in this addendum. This addendum contains service procedures and data for the '79 Honda NASO. ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LA‘ TEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FORPRINTING, HONDA MOTOR CO, LTD, RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURR< ING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE RE- PRODUCED WITHOUT WRITTEN PERMIS- SION. HONDA MOTOR COT, LTD. Service Publications Office TABLE OF CONTENTS FEATURES .......................... 28 v SERVICING PROCEDURES ................ 28- 1. . 28 - 2. ENGINE REMOVAL/INSTALLATION ..... 28- 3. Frame HANDLEBAR/FRONT FORK/FRONT WHEEL ............... 28 - 4. Frame REAR SHOCK ABSORBER/FUEL TANK/SEAT ....................... 28 - 5. ELECTRICAL ....... 54 CABLE ROUTING ................... 28 ~ 7‘ SPECIFICATIONS I“ ............. 28- 8. WIRING DIAGRAM .................. 28 ~ Dale of Issue: Sep.. 1978 If HONDA MOTOR CO., LTD. 28-1 HONDA NA5O FEATURES The Honda NASO is powered by a 2~stroke, 49 cc, crankcase scavenged engine with two reed valves incorporated in the in- take port. Limited maintenance isems and simplified service procedures provide a "easy~rnaintenance" model design. A new starting mechanism design simplifies starting (1‘) A starting spring builds power for cranking the engine for easier starting ® The power train enclosed in the left crankcase is oil-bath lubricated. The engine and Ielt crankcase move tagether on a pivot in the frame, {5) The rear wheel is suspended by one rear shock absorber on the left side combined with the L crankcase. G) Since an independent lubrication system is employed, fuel and oil are separately filled in to the gasoline tank (5‘) A high»performanm plunger type pump is utilized for lubri- cation purposes. © Electrical units, fuel and oil filler caps are beneath the seat, Date oflssue: Scp.,1978 28 2 rs. HONDA MOTOR co.. LTDi HONDA NA50 SERVICING PROCEDURES I . INSPECTION/ADJUSTMENT 2. ENGINE REMOVAL/INSTALLATION 3. Frame HANDLEBAR/FRONT FORK/FRONT WHEEL 4. Frame REAR SHOCK ABSORBER/FUEL TANK J/SEAT . ELECTRICAL . CABLE ROUTING . SPECIFICATIONS 03wa . WIRING DIAGRAM Dam of Issue: 5e19,, 1978 HONDA MOTOR co” LTD. 28' 3 HONDA l . INSPECTION/ADJUSTMENTJ—A—ig— {IDLE ADJUSTMENT) TH ROTTL E STOP SCREW (I) Warm up xhe engine. Turn the throttle slop screw out to obtain the lowest nable idle speed. (2) Turn xhe air screw either in or out to obtain the highest idle speed. Then turn the screw in approximately 1/4 turn. (3‘ Adjust the ihrottle smp screw until the engine runs a‘ the specified idle speed. IDLE SPEED: 1,800 rpm. (FUEL LEVEL) FLOAT GAUG‘ TOOL no.0; » Measure the float level with the float arm just contacting the float valve. Floai level: 10.2 mm (0.402 in) The float level is non-adjustable. Re~ place the carburetor float or float valve if the level is nm correct. Date of Issue Scp.,1978 28' 4 <6 HONDA MOTOR co. LTD, INSPECTION/ADJIJSTMENT (SPAR K PLUG) I To clean, use a plug ' cleaner ar steel wire, _ o 6 I0 7 mm Replace the plug if it « has burm tip and/ — 0028 IIL| 3:92,“ or a blistered in» sulalor Check' gap . deposut 1 electrode erosion Check: gasket for sealing Use only the specified spark plug: BP4HS, BPSHS [NGK] wlaFPL WlsFP [ND] (BATTERY ELECTROLYTE LEVEL CHECK/REPLENlSHMENT) / Use only distilled water in the batterv. Tap waxer will shonen battery servlce Illa‘ — READING SPECIFKI GRAVITY 0F ELECTHDLVTE - *LOWEé LINE | HYDROMETE R 5,; I; NORMALSGA " 3.260 , LEO/20°C (68°F) ELECTROLYTE _ o The battery electrolyte contain: sulfuric acid. Protect your Eyes, skin and clothing, In case of Contact, flush thoroughly with water and call a doctor if electmlvxe gels in your eyes. I The battery generates hydragen gas. Do not smoke or allow flames or sparks neav the ballery, especially while charging it. Dale of lssue' 35.3.. 1978 HONDA MOTOR co.‘ LTD. 28-5 2 ENGINE REMOVAL/ INSTALLATION All service opemions except crankshaft work may be performed with the engine in the frame. :fi‘ REAR SHOCK ABSORBER/ENGINE MOUNTWG BOLT/REAR WHEEL/MAIN STAND IE REAR BRAKE CABLE Adiustmem: Base Manual PagesB - 1 and 8 - 2. i \ 400 — 500kg - cm 300 —~400 kg ~ cm {29 # 38fi»lbs) (22 —— 29ft-lbs) (4‘) REAR FENDER .2. HEAT SHIELD ® MUFFLER Tighten Ian during assemblv‘ Date of Issue: Sep.. 1978 28' 6 F HONDA MOTOR 60,. LTD. ENGINE REMDVAL/INSTALLATIUH Connecx color» lo-color on re- assembly, @ PRIMARY WIRE v? CARE V UHETORIA'R CLEANER Keep fuel valve dosed during , - ,= /- \ disassembly. /,l, O] L TUBE CAUTION Bleed air from oil pump aher assembly. See Base Manual Page 8 , 7 “BLEEDING OIL PUMP.“ , , 7 7; \ / ’5: SPA P V M LUG CAP Hug lube end, D21: of Issue Sap. ms 28 I‘: HONDA MOTOR co” LTD. . 7 3 Frame HANDLEBAR/ FRONT FORK/ gamma/m FRONT WHEEL a .m— 53% ; j FiN SPANN E R (No. 0791604400001 800 -— 900 km-cm . (43 - 6511-1139 I 3‘ TOP CONE RACE —\ STEEL BALLS 126 PCS) g Q During assembly, fighten men back off ‘A (urn, GREASE K é FRONT FORK 454 t 5 FRONT WHEEL D>sassembry and assembly, See Base Manual page 17 ~Z, . / $1 4 (3!" NOTE 300 —400kg , cm (22 — 29fblbs) I BALL RACE DISASSEMELY AND ASSEMBLY, Sea Base Manual PAGE 17 - 3‘ Date of Issue: Sap.‘1978 28' 8 a: HONDAMOTOR co.. LTD 4 Frame REAR SHOCK ABSORBER/ A FUELTANK/ ‘2; REARICARRIER SEAT ‘ 0/, K1" aoo—mow-cm‘v-W 31 \ / \ , ' , %o\) . (22 ~ 29(14st REAR SHOCK ABSORBER 6 g Q N075 200 — 300kg - cm (14 —22fl-|bs) ® GASOLI NE/OI L TANK After assembling, check 0 peration. @ REAR SHOCK ABSORBER COMPRESSOR ”"’ (No. 079593290000) Dal: uflssue: Sap“ 1978 1‘ HONDA MOTOR CO., LTD. 28- 9 “m HONDA REAR SHOCK ABSBRBER' FUEL TANK/SEAT I NASO j (SEAT) ® SEAT (Front) (fiv HINGE SET PLATE pm (2- SEAT When installing, align the cut-out wuh the pin on xhe other side of the seat. 2 8 Date of l§ue‘ Sep., 1973 ' ll] :7 HONDA MOTOR col, LTD. HONDA 5 NASO ELECTRICAL ELECTRICAL ACCESSORIES AND THEIR LOCATIONS 1. IGNITION SVSTEM 2. BATTERV CHARGING SYSTEM 3. LIGHTING SVSTEM AND OTHERS CONTACT BREAKER AC, FLYWHEEL GENERATOR HEADLIGHT IGNITION COIL RECTIFIER STOP/TAILLIGHT CONDENSER BATTERY HORN SPARK PLUG CONDENSE R I BATTERY I IGNITION COIL g—fi HEADLIGHT 1 STOP/TAILLIGHT j I \ RECTIFIER ‘v/ ,___..—1_ CONTACT BREAKER SPARK PLUG Inspection See Base Manual page . Inspection, 8 4 and 12 3. / page 28 -5. A.C. FLYWHEEL GENERATOR (LIGHTING COIL) Dale of Issue: Sep., I978 28 H i" HONDA MOTOR CO.. LTD. HON DA CABLE ROUTING ““50 ’” 4' WIRE ‘ REAR BRAKE CABLE HARNESS\ / CHOKE CABLE SKEW BRAKE HEAR BRAKE CABLE SPEEDOMETER CABLE THROTTLE CABLE Make sure the cables and harness are not twisted. IGNITION COIL RECTIFIER REAR BRAKE 1—* CHOKE CABLE ‘ me HARNESS j T THROTTLE CABLE ’ [AL WIRE HARNESS \ T / CHOKE CABLE _ ‘ , f / / /——‘ REAR BRAKE \ , A" THHOTT BL ‘ . LE CA E -\ 1 HARNESS CLIP, _ BATT'ERY FUSE ' CLAMP BATTERY BREATHER TUBE I , _ , , / FRONT BRAKE CABLE SPEEDOMETER CA8 LE Allgn the white cable mark with the frame coupler. BATTERY BR EATHER TUBE Date of Issue: Sen, 1978 (i HONDA MOTOR CO“ LTD. 28-12 HONDA 7 NASO SPECIFICATIONS Bore and stroke 40 x 39,3mm (157 X 1755 in) I DIMENSIONS Overall length 1590 mm (625 in) ’ Overall width 600 mm (23.6 in) I Overall height 995 mm (39.0 in) ‘ Wheel base 1,050 mm (41.3 in) Ground clearance 125 mm 1 4.9 In) 2 Dry walgm 51kg I112Ib) : FRAME l Type Back bone I F, suspension Telescopic fork ‘ R . suspension Swing arm F, tire size, pressure 225 — 14 — 4PR 18 psi (1.25kg/cm’) a. rite size, pressure 2.25 — 14 — 4PR 32 psi l2.25l»§2:zauv‘u—szo:§9 .323“. 5:; ES ”9.3%.; x. _ . u .1 4 :33 em: a?” 5% WIRING DIAGRAM E. h i 233; . a: 0 mm menu: 5% '15 28 1’ HONDA MOTOR CO I. LTD. Daze of Issue: Sepq 1978 é HONDA NEED 'BD ADDENDUM FOR EWARD Refer [O Ihe base shop manual for service items not described in (his addendum. Thus addendum contains service procedures and data for ”121930 Honda N050, ALL INFORMATION. ILLUSTRATIONS, DIRECT; TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LA- ‘ TEST PRODUCT INFORMATION AVAILABLE . AT THE TIME OF APPROVAL FOR PRINTING HONDA MOTOR C0,, LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME ' WITHOUT NOTICE AND WITHOUT INCURR- 1 INS ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE RE- PRODUCED WITHOUT WRITTEN PERMIS- HONDA MOTOR C . LTD. Service Publications Office TAB LE OF CONTENTS . LUBRICATION SYSTEM .............. 29V . INSPECTION/ADJUSTMENT ............ 29. , ELECTRICAL ...................... 29‘ I CABLE ROUTING ................... 29V . MAINTENANCE SCHEDULE ........... 29. . SPECIFICATIONS ................... 29, , WIRING DIAGRAM ................. 29. Date of Issue: July,1979 , HONDA MOTOR C0., LTD‘ 29-1 I LUBRICATION SYSTEM Engine lubricating oil is mixed with the fuel In the carburetor. '80 ADDENDUM 1 gnaw \ [mega/ii: \. {EA—é Eu HETETR L QLL JP‘IA EL 29. Dam of Issue: Ju1y,1979 2 :C HONDA MOTOR co‘, LTD. HONDA L 2 NEED ’3!) ADDENDUM INSPECTION/ ADJUSTMENT CONTROL CABLE LUBRICATION Disconnect the throttle] choke and brake conxrol cables at their upper ends. Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant, Dale of Issue, July,1979 29 a HONDA MOTOR (‘0‘, LTD. ‘3 3 ELECTRICAL ELECTRICAL ACCESSORIES AND THEIR LOCATIONS 'DD ADDENDUM 1. IGNITION SYSTEM 2. BATTERY CHARGING SVSTEM 3. LIGHTING SYSTEM CONTACT BREAKER A.CI GENERATOR HEADLIGHT IGNITION COIL RECTIFIER STOPfI'AILLIGHT CONDENSER BATTERY HORN SPARK PLUG FRONT/REAR TURN SIGNAL TURN SIGNAL RELAV foams? "’ ‘7 I (Except Canadian modem ‘. , 7— w v—-— R _._ . , BATTERY ‘ ITIPN COIL v IFRQAAIT TURNSIGEALJ CONDENSER ' 7 j I {only Capagian model) I / EdNTAIiT BREAKER I 1/ Inspection, page 84 EP— LE and 12 I 3' ‘__ 3} Ihgpaction, ‘A.c3 GENERATOR: page 8 =6} IILIGHTINGEOIL); 29 Date of Issue: July 1979 '4 <3 HONDA MOTOR c0., LTD. N350 'an ADDENDUM ELEchcAL TURN SIGNAL E 20 — 40 kg-cm (1,4 — 2.9 ft-lbs) Remove the lens by pulling forward. Install by pressing the lens top‘ CONTlNU ITY TURN SIGNAL SWITCH HEADLIGHT Hl-LOW SWITCH H? GEN ( _ l l l l l l 'GGO Wire calm GfiAv E '3ng ORANGE Wire calur WHlTE 'BLUE YELLOW Dale of Issue: July, 1979 29. I): HONDA MOTOR 00., [ID 5 HONDA / 4 '60 momma NCED CABLE ROUTING / LafiefilgfiN smwyvmfi (UGHTE'LDEE , Em“ TPF‘NE'ENLHW'EE (ORANGE); L, , FRONT TURN SJGNAL wmes USA Model CANADA Modal Date of Issue: July, 1979 29-6 «0 HONDA MOTOR co" LTD. . ‘.r.,“u‘ HONDA. NCSO E ’80 AIIIIEIIIIIIM 5 MAINTENANCE SCHEDULE 'I REGULAR MAINTENANCE SCHEDULE , lNITlAL SERVICE PERIOD This mainlenance schedule is based upon l SAFETY I Periorm at every indicated average riding conditions, Machines PRE-RIDE I INSPECTION month ormileagelntervaI subjected Io severe use, or ridden in INSPECTION _ ,, , whicheveroccursfilst unusually dusty areas, require more ‘ 1mm" 12mm, frequent servicinsr _, I 200 miles 1,000 miles 2 000 miles 300 km 1,500 km 3, 000 km 7 'TIRES AND PRESSURE , I; I CONTACT BREAKER POINTS , I l IGNIT TIMING THROTTLE OPERATION WHEEL TRUENESS AND SPOKES: NUTS BOLTS ITIGHTENI— BRAKE LININGS ’BATTERY FLUID LEVEL- BATTERY FLUID SPECIFIC GEAVTT‘VM SPARK PLUG AIR FILTER ELEMENT CARBURETOR (EVERY 6 MONTHS) C FUEL FILTER SCREEN V SUSPENSION OPERATION CLUTCH SHOEWEAR TRANSMISSION OIL DECARBOIWZE CYLINDERii-IERB AND MUFFLER ’BRAKE ORERATICN AND FREE PLAY 7 ‘OIL AND FUEL LEVEL i‘ALL LIGHTS {“7 C TRANSMISSION CASE FOR LEAKS 1- Inspect and dean, adjust, lubricate or replace if necessary Items marked are simple To perform and may be serviced by The owner R—Replace CrCIean Other maintenance items should be serviced by an authorixed Honda dealer, unless the owner has The proper tools, and Is mechanically proficient. Dale of Issue: July, 1979 I HONDA MOTOR C0.. LTD. 29-1 II HONDA ’Bll ADDENDUM N350 SPECIFICATIONS I DIMENSIONS ‘ Overall length 1,580 mm (62.2 in.) Overall width 600 mm (23.5 in.) Overall height 1,000 mm (39.4 in.) Wheel base 1,050 mm (41.3 In.) Ground Clearance 125 mm ( 4.9 in.l Dry weight 47 kg (104 lb.l Flam: ‘_' 7' A 7' ' V “7 Tyne Back bone F. suspension Telescopic fork R. suspension 1 Swing arm F. tire size, pressure I 2.25 — 14 MFR) 1.5kg/cm2 (21 psi.) R. lire size, pressure 225 — l4 (4 PR) 2.0kg/cm’ (28 psi.) F. brake . Imernal expanding shoes R. brake Internal expanding shoes Fuel capacity 2.0 lit. (0.53 U.S. gal. 0.44 Imp. gal.) Fuel reserve capaclty 0.2 lit. (0.053 U.S. gal. 0.044 Imp, gal.) Caster angle 57° Trail length 72mm (2.8 in,) From fork grease Sec (0,18 025) 7 snéins if " 7' N W Type . Air cooled, 2-stroke Cylinder arrangement Singlecyllnder flat Bore and stroke 40 x 39.3mm {1.57 x 1.55 in.) Displacemem 49cc (299 cu in.) Compression ratio :' 6,5 : l Transmissmn oil capacity I 075 Ht. (0.79 U.S. qt, 0.66 Imp. qt); 10W ~ 40 motor oil Oil tank capacity I 0.8 li‘. (0.84 US. at, 0.70 Imp. qt): 2 norke injector oil Lubricanun system I Forced and wet sump Air screw opening . 2-1/8 Intake Open I Read valve cantrolled Close ‘ Reed valve controlled Exhaust Open I 65" BBDC Close I 65" ABDC I Scavenge Open I 47° 3513c Close I 47° ABDC Idle speed I 1,300 mm 29-3 E?:3§3;“;3¥‘5§339 m, K. ., . !I(JQRII)Z§ é N050 '80 ADDENDUM B SPECIFICATIflNS ' DRIVE TRAIN Clutch Primavy reducxion Final reduetion Automatic centrifugal wet type 5 Chain and gear I 14.220 : 1 ELECTR‘CAL Ignition Starting system Generator Spark plug ( ) Optional Spark plug gap Ignition (iming BaYlErV capacity Fuse capachy Headligh! Low/High TaH/slopllght Speedometer light High beam 'mdicator fight Turn signal light (From/Rear) Magneto and bakery Tap s1aner AC generator SV 63 w/6,000 rpm NGK BP4HS (BPSHS, BPZHS) ND W14FP-L(W16FP, W9FP«L) ! NGK BPRAHS (EPRZHS, BPRSHS) 1 ND W14FPR—L (wsFPR—L, WIGFPRD J 0.6 # 0.7mm (0.024 7 04023 in.) 18° BTDC 6V 4AH 10 amp. ev-15/15 w (21/21 CF) av—5‘3/25 w 13/32 on) 6v.1_5w(1CP) 6V4] w (1 CP) SAE No. 51 6V-18/18W(21/21CP) } [U,S.A, mallet] [CANADA model] Dale of lxsue: July,1979 I‘v HONDA MOTOR CO” LTD. 29-9 7 WIRING DIAGRAM ‘flll ADDENBUM 00302 ~ 147 4 9700 USA model 29. Date of Issue: JuJy, 1979 m z: HONDA MOTOR cow LTD. ’Dl] ADDENDUM é HONDA NCED WIRING DIAGRAM Swat:— Ncmoo _w_uoE INTAKE PIPE Date of Issue: November 1980 31 - 4 © Amencan Honda MotorCov, Incv 1980 - Au mm Remwed HONDA N350 - NAED 6 '81 ADDENDUM AUTOMATIC CHOKE OPERATION This how the automatic choke system worksl BELOW 10°C (50°F) With engine lempevature beluw 10°C (50° F), the conlrcl box bimetal valve holds the valve up so air directly (mm The bvsxaner is blocked. When the engine is started, air from the byslaizer lo the carburetor Choke circuit draws and mixes wilh iuel, then flows mmugh (he control box and to the intake pipe This richens the engine's air~fuel mixture. BETWEEN 10° C (50" F) and 46° C [115° F) The bimetal bends and moves ihe control valve as il is heated by xhc engine. The Valve moves 0.05 mm for each one degree centir grade (1 8" F) change in engine lempevalurel As me valve moves, it opens the air passage directly from me bystarteri Tm: air mixes with the carburetur choke circuit mixture and slowly leans it out to kaep lhe engine running stoth. ABOVE 46° 0 (115° F) When the engine {temperature is above 46"!) (115° Fi, a rich mixture is not needed to starx or run the engine. St: the control box bimetal is fully hem and the valve blocks ihe fuel line (0 the intake pipe. BYSTARTER i} SECONDARY AIR FROM EYSTARTER CHAMBE R INTAKE PIPE Date of Issue: November 1980 @ Amman HondaMowl Co., Inc 1980 , All thht Reserved 31-5 HONDA. é NCSD-NAED 3. NA5O TWO-SPEED AUTOMATIC TRANSMISSION The NAEO transmission is a compaor combination or two centrifugal clutches, a ratcheting unevway clutch, and a planetary gearset. The whole unit spins, on a common axis with (he crankshaft. CRAN KSHAFT EEXT‘EEAR DRIVE SPROCKET DRIVEN SPROCKET STARTER PAWLS \ lNG GEAR/ NO, 1 CLUTCH DRUM HATCH“ PLATE N0. 1 CLUTCH SHOE DRIVE PLATE 3.04.5 kgrm (22—25 ft-lb) RING GEAR PLANET CARRIER SUN GEAR PLANETCARRIER PIN The gearser has three main compunents: I The sun gear (in (he center), PLANET GEARS 0 The rlng gear (around the outside). I The planet gears/planet carrier assembly. Planetary gears are simple, compact, durable and extremely versatile. A single gearset can perfarm a number of different torque multiplication tasks; holding different parts of the gearset stationary, or lacking different parts together can change the be- havior of the twin 31 Date of lssue: November 1980 ‘ 6 © Amermn Honda Molar Co., Inc. 1980 , An Rights Reserved N650 - NASO m ADDENDUM A OMATIC TRANSMISSION HOW THE TRANSFVHSSlON WORKS IN 18'? G (pew u u; we M'Fl-‘H wncrnm-m» lmvmvnnw.l_ "no H mm .,-. m H mm. Mum u’llwp/dle' mm sulldlw lo me claukshall, l5 allowed .e- mm lreely xnslde rs‘ mu {0 .. . he ‘40. 1 CM shoes on the drlve plate move outwald e: U E . ‘ ‘Gll1l’flfl’llnll gear, lorcing no rotate a engine speed m (Um \l m» u: re ’10 m the npposlle direcllon o! lllu mug TH? 51/179843! we: , which ls firmly spmm to thaw. coveved rawva-vmre, bolted vs the clankc n al'ld prr‘ l; has mm splmgrloadec ratchet mom These engage wlm the rubber m the sun (will from rotallng backwards, Tnu VAN; 1m [ ,wzary w! mm the we lcuumloll mm, w m we sun geav mollomass. The planel earner rotaKE: :mh red eed meet em multlpl‘lev torque, amimd the 51m gush TM» dxl've 5pm: 0/, splmcrl m ma planermn’er, awn; me rear wheel \hmugh a chain and separam gear palr in the rear of we :l‘limfaw HOW THE TRANSMISSION WORKS IN 2ND GEAR m mars ewe Wm chinMAm ow.” l l mew. lawn» mm m u ,l mum ground speed of 20- 25 kph l12~ 13 mph) th.‘ »‘ - s the insmu ‘ace of the nave pr .churm, vlgldly attached to the nianet came: lane output shafl), Thls locka the ring gem and the planel emler togeihm, mm m» m mumhmfi of a plaru m lengmc weed, (an mm near mu: Belioi' :(lmlly locks we we WlUl mm, The lll’ll; gem and plane: earner are now mm mer' e: plate stopped ltl Now it is W: U1 the Puwul la transml‘wd to {he H mm tlallamlssiun uni? leekevl me drw: swam, splmod to me pla earner, sens directly w m engme ratatlon, r wheel a! wax m in 9-1.“, 0316 of Issulz' lx ember 1980 g; , nel‘canHonnaMoero, Em. WEEDVAHFNJIH) 31—7 HONDA. NCSD - NAED 4. INSPECTION/ADJUSTMENT IGNITION TIMING Ignnion timing is mum If me index mark signs with me “F” mark I: a“) at 2,000 rpm. Use :he HONDA GENUINE SERVICE TES- TER (073080070000) to check the ignition timing, The Ignition timing is not adjustable. If the ignition timing is incorrect, check the CD! mm or AC generaior and replace any IauIlv parts. BYSTARTER ELEMENT CLEANING ALIGN MARKS BYSTARTE R CHAMBER ELEMENT ,r' Remove the element from the bystarter chamber, Wash the eIement in nonrflammabIe or high stn poim solvent, squeeze cm the solvent \horoughlv, and alIow In div, Soak the element in gear ail (SAE 5080) and squeeze out excess, {7 \ Insiall xhe element. “1“ i WASH IN SOUEEZE OUY GEAR OIL SQUEEZE OUT SOLVENT SOLVENT (SAE 80—90) EXCESS OIL 31 Dam of Issue: November 1980 ' 8 © American Honda Mom (10., inc. 195mm: Rights Reserved HONDA N650 - NABD ‘81 ADDENDUM é lNSPECTlON/ADJUSTM ENT THROTTLE GRIP FREE PLAY 2—6 mm LOCK NOT ADJUSTER ‘ , \ OIL PUMP CABLE D Excessive exhaust smoking can be caused by incorrect oil pump cable adjustment, ' Admit the oil pump cable aftet adjustlng throttle grip free play. Close the throttle giip. Check that the oil pump body projection and control lever Dointet align If not, adjust: Loosen the adiustur lock nut and mm the adjusting nut as required‘ Tighten the lack nut. IDLE SPEED TH BOTTLE STOP SCR EW Adjust throttle grip free play as follows: Puli the adjuster cover off. Loosen the lock nut and turn the adjuster to obtain 2—6 mm (1/8—1/4 in) of free play at the grip flange. Adiust the oil pump cable. ADJUSTING NUT OTE The engine must be warm for accurate idle speed adjustmenti Attach a tachometer. Turn the throttle stop screw to obtaln an idle speed of L800 rpm. If the engine misses or runs erratic when the throttle grip is operated, do the following; Screw (ha air screw in until it lightly seats, then turn it Uutl full turn. Reset the idle speed with the throttle smp screw, Turn the air screw in or out to obtain the highest idle speed‘ Reset the idle speed with the throttle stop screw. Make sure that the engine does not miss or run rough. It necessary, repeat steps 2 through a. Date of Issue: November 1980 e, American Honda Meter Co” 1ch 1980 , All Rights Reserved 31-9 INSPECTION/ADJUSTMENT ‘81 ADDENDUM HONDA N850 - NAED OIL PUMP BLEEDING/PR'MING OTE Bleed the oil Dump inletlme when it has been removed from the ml pump or if i‘ contalns aiv Bubblei Flll Khe ail tank thl" two’stroke injector ml, SAE 30W. Place a shop towel under the bleed screw. Bleed the oil pump inlet lme hy loosening the bleed screw. Allow oil to run out until the oil line is free of air bubbles, Khan tighten the “x. screw. OIL PUMP INLET LINE OIL PUMP OUTLET LINE OPEN CONTROL LEVER FULLY OIL TANK OIL PUMP INLET LlNE‘—’ OlL PUMP OUTLET LINE ‘\ {ix OILP'U‘MP , \ l] SHOP TOWEL BLEED SCREW Prime (he oil pump outlet line as follows: Start the engine and let it idle Hold the oil pump control lever full open by hand and check for air bubbles in me oil line In the carburemr. Hold the pump open unlil all air bubbles are gnne. 31-10 Date of |ssue: November 1980 m) American Hanna Moxor C0,, In: 1950- A11 Righls Reserves f Y HONDA mesa-NAao 5. CYLINDER HEAD/ CYL|NDER/PISTON CONTROL BOX FUEL LINES ROUTING Do nox disassemble the control box asszmblv. mean the cvfinder and control box mating surfaces before assembly. 0.8—12 kg—m (5.878] ft-lb} CVLINDER REPLACEMENT Repiace the cylinder with one that has the same A or E Ieuer code at the cxhausk part. AorB Date of Issue: November 1980 31 (a American Honda Mueru., Inc. 1980- An Rightsfieservad ' 1 1 HONDA 6 Mesa - NAso ‘ Oil pump removal can be performed With me engme in the frame, ' Bleed the 0H pump/lines after oil pump installation (page 3140). 6. OIL PUMP CARBURETOR OIL PUMP 1 Daxe of Issue: November 1980 3 ‘ 12 3 American Honda Moxor Cm, Inc. 1930 - Au Righvs Reserved HONDA NCED - NAED 7. A.C. GENERATOR ® FLYWHEEL (x) ROTOR 3033 Remove any metal filings from me flywheel before installation Do not damage thu generator windings when remnving the roxor boss. 3.0A3.5 kg-m (22v25h-1b) / ®GENEHATOR COVER (D STATOR Install the stator assembly, routing the wires through the case‘ Dam of Issue' Novembet 1980 31 g) American Honda MowrCo‘ |na1980AAl|fiighls Regen/er: ‘ 13 HONDA NGEO - NAEO 8. KICK STARTER DISASSEMBLY/ASSEMBLV KICK STARTER SPINDLE Remove the engine outer cover. STARTER DRIVE CHAIN STARTER DRIVEN SPROCKET IDLE SHAFT / ' IKICK STARTE R SPRING \ I Remove the kick starter componenu from the )uter coverr KICK STARTER SPINDLE \ KICK STARTER IDLE SHAFT STARTER D H IVEN SPROCKET STARTER STARTER , OIL SEAL SFROCKET DRIVE CHAIN HOLDER 31 Daxe of Issue: November 1980 '14 © American Honda Motor (20., Inc, 1930 - An Righu Reserved rt HONDA NDEO- NAED ‘81 ADDENDUM KICK STARTER . , KICK STARTER IDLE SHAFT STARTER SPROCKET Install the luck starter Splnd‘e Inlu the outer SPINDLE HOLDER nover, whlh: [Josllilminy the kick alarm; spring mm placev Install the kick starter pedal onto the spindle. Install the ouler cover assembly with a new gasket Fill the case with (he recommended type and quantity of oil. TYPE: Above 5° C (41° F), SAE 10W40 Below 5" C (41“ F), SAE SSW—30 STARTER DRIVEN Quantity: After draining, 400 ca (14 oz) 3? ROCKET Aher dnussembly, 600 cc (20 ozI 9. CLUTCH V ASS LY DRIVE SPROCKET - Remove the engine left outer cover and clutch D‘SASSEMBL / EMB DRIVEN SPROCKET nut. Remove the clutch using the clutch puller, P/N 0793571470001, (page 31-21), 30—35 kg-m (22—25 tt-Ibsl SUN GEAR PLATE ‘ SECOND CLUTCH DRIVE PLATE Assembly Is the leverse of removal. Be sure to push the chive sprocket onto the crankshalt securely. D339 of ISSUE: November 1930 1 .c; American Honda Mow: m, Inc. 1930 ‘ Aie filgms Reserved 3 - 15 m HONDA C R C NCED - NABD “'\ ELECTRICAL ACCESSORY LOCATIONS 1. IGNITION SYSTEM 2_ BATTERY/CHARGING SYSTEM 3. LIGHTING SYSTEM AND HORN IGNITION COIL A. C. GENERATOR HEADLIGHT A. C. GENERATOR RECTIFIER STOP/TAILLIGHT CDI UNIT BATTERY HORN SPARK PLUG TURN SIGNAL PULSE COIL IGNITION SWITCH FRONT STOPLIGHT SWITCH RECTIFIER STOP/TAIL LIGHT BATTERY HEADLIGHT '“ IGNITION SWITCH TURN SIGNAL SPARK PLUG PULSE CO'L AC. GENERATOR Dam of Issue: November 1980 31 ‘ 16 © Amman Honda Mom: Co” Inc, I980 ~ All Highs Reserved HONDA r‘ NCEO- NASD ‘81 ADDENDUM ELECTRICAL CHARGING CIRCUIT SILICONE RECTIFIER WHITE VELLOW TEATTEHY va 4A SFEEDOMETER LIGH Ac, GENERATOR « 6" "5W INDICATOR TAIL LIGHT LIGHT 6V 1/7; (W 5;” HEAD» LIGHT 6V 15W PERFORMANCE TEST Warm up the engine beIore taking readings. Use a fully charged bauerv Io check (he charging system outpuL BATTE RV SPECIFIC GRAVITY: 1260-1280 (20“ 0) Connect a voltmeter and an ammeter as shown. Raise the engine speed gradualIv obsevving the meter readings, Charging Starts 4,000 rpm 6,000 mm 2,000 rpm max, (7.0V) 0,7A mIm (8.5V) 2.nA max, (8.7V) Check Ihe battery, A.C. generator and resistor when {he readings do noI match r- the given specifications. Date 0! Issue: November 1980 a American Honda Mam C0,, Inc. 1983 - AII High“ Resvrved 31-17 ELECTRICAL '81 ADDENDUM NCED - NAEO HONDA é A. C. GENERATOR INSPECTION Unplug the siator connector and measure ihe resistances between the Ieads with an ohm~ MEIEIZ Sex me ohmmeter w the RXi scale. (XI 52) Whlle and engine ground 0,1 — 1.0K} Yelluw and engine ground 0,3 — 15:2 Blue/Yellow and engine ground 10 — 1009 Black/Red and engine ground 50 7 3009 Replace the stalbr coil and flywheeI as a 55!. Do not replace cine without replacing the other. RECTIFIER INSPECTION BLUE/YELLOW Check the rectifier with an ohmmeiev, revers my me um leads once. There should be continuity In one direction and nocontinuily in the other direciiun. Repiace the rectifier if mere is continuiiy in both direntions or if there is no cominuity in barn direciiuns. 31-18 Date of issue: November 1980 © American Honda Momr (30., Inc. 1980 . AI! Rights Reserved g’ HONDA NCED - NABO '31 ADDENDUM ELECTRICAL IGNITION CIRCUIT/INSPECTION 'GNITIDN SWITCH ON OFF _ r"'—' ' A. c (:ENERATOR ‘- IGNITION COIL /’ CONDENSER “7-- BLACK/RED I ‘ Aer I . D , Excmzn COIL BLUE/VELLOW I jSCR ) SPARK PLUG GATE PULSE \‘ COIL I cmcun’ I I GREEN 1 CDI umr PHlMARY SECONDARY WINDlNG WINDING lGNlTlON COlL Check the primary and secondary windings for contmm‘ty between me leads wixh an ohm- mew, RESISTANCES Primary 0.2 — 0.39 Secondary 3.4 v 4,2k n PRHWARY SECONDARY WINDING WINDlNG 6mm MlNIMUM SECONDARY PRIMARY ELECTRODE ELECTRODE SPARK Perform a spark test with a service (esxer according to the (ester manufacturer's Instruc» lions. SERVICE LlMI . Dam of Issue: November 1980 @ Amaxican Honda Motor Co‘. Inc. “330- An 5.9m; Rewrved 31-19 ELECTRICAL '81 ADDENDUM HONDA. ; N650 - NAED CD! UNIT Measure the teststances between the CDI unit terminals wtth an ahmmeter Replace the CDI unit with a new one if the readings do not fall withm the hmtts shown in the table. - The GUI is a transisznrizcd unit, I A high quality ohmmemr is recommended for accurate test resulu. . The test chart is for a positive ground tester, so you may have to reverse yout tester leads to ubtatn the specification given. Measuring units: SANWA [SP-10D tvpe] : Xk n KOWA KTH~5H type] ‘ X10051 T r ”We "“ @ sw EXT PC E IGN SW 00 co co co EXT 0’1 __ 10 00 a, Needle swings, then retums PC 05 — 200 05 v 50 1 — 50 30 E (12 — 30 0‘1 - ID no no IGN no 00 no 00 31-20 Date of Issue: November 1980 © American Honda Motor 00., Incr teso - mt Rtgms Reserved HONDA / N950 . NASO ‘81 ADDENDUM 1 1 . TOOLS f Rel . 0 Na, Tool pans No. DESCrIDttDn Remarks G 07935 — 1870000 Case puller R'lght crankcase disassembly G: 07933 » 1470000 Case puller Len crankcase disassemblv G} 07965 — 1480001 on seal assembling tool Crankcase,crankshaf1 and all seal assembly 6) 07935 A 1470001 Clutch puller Clutch drive plate removal /“ Dale of Issue: November 1980 © American Honda Motor Co.. Inc. 1980 ~ All Flam; fimrvad 31-21 HONDA NCED - NAED 12. CABLE AND WIRE HARNESS ROUTING FRONT BRAKE REAR BRAKE . “ CABLE ~ CABLE ,, ITI/BATTERV THROTTLE CABLE * ‘ SPEEDOMETER I», CABLE "/ FUSE OIL PUMP THROTTLE Ef‘QEEBRAKE CABLE CABLE me HARNESS REAR BRAKE ,; CABLE I Afign the white cable mark with the frame coupler. Tia-s ‘ 5‘ F \ _ ‘ ' WIRE HARNESS’/& ‘ M" SPEEDOMETER CABLE FRONT BRAKE CABLE Date of Issue: November 1980 31 ' 22 a; American Honda MmurCa_, |nc,1980- All mgrns Reserved CABLE AND HARNESS '81 ADDENDUM ROUTING ' N050 TURN S|GNAL o RELAY CDI UNIT IGNlTION C0|L THROTTLE CABLE REAR BRAKE CABLE FRONT BRAKE CABLE BATTERY 204.0 kg-m TURN SIGNAL (1,4—2.9n.lb) Remove me turn signal lens screws and lens. When installing the turn signal lens, do not overtighten the lens screws to avoid cracking, Date of Issue: November 1980 [a American Honda Mover Ca,lnc,1QBo-AI|Righls fiesewen 31 “ 23 HONDA % ncau - NAso 13. MAINTENANCE SCHEDULE REGULAR SERVICE MAINTENANCE SCHEDULE INITIAL , - This maintenance scheduIe is based upon SAFETY giggig'gftnfiijggflgfiv‘jf‘ average rIding conditionsi Machines sub‘ FRE-RIDE INSPECTION whichever comes fim ’ jected to severe use, 01 rIdden in unusually INSPECTION I dustv areas, require more frequent 1 month 12 months 24 months servicing. 200 miles 1,000 miles 2mg miles 300 km 1,500 km 3,000 km ITIRES AND PRESSURE I ‘THROTTLE OPERATION I I I WHEEL TRUENESS AND SPOKES I I NUTS, BOLTS ITIGHTENI I I BRAKE LININGS I ‘BATTERY FLUID LEVEL I BATTERY FLUID SPECIFIC GRAVITY I SPARK PLUG R AIR FILTER ELEMENT (EVERY BMONTHS) CARBURETOR I I FUEL FILTER SCREEN C C SUSPENSION OPERATION I CLUTCH SHOE WEAR I TRANSMISSION OIL R DECARBONIZE CYLINDER HEAD AND MUFFLER ”BRAKE OPERATION AND FREE PLAY | | I 'DIL AND FUEL LEVEL | ’ALL LIGHTS I "TRANSMISSION CASE FOR LEAKS | OIL PUMP ADJUSTMENT I BYCHAMBER ELEMENT I n I-Inspecl and clean, adjust, lubricate or replace if necessary RrRaplace GCIean “ These items are simple in check and service and may be done by the owner, omer mainmnance items shnuld be sen/Iced by an authoriled Honda dealer, unless me owner has the proper tools, and is mechanic-any proficient. 31 Date at Issue. November 1980 ‘ 24 g Amencan Hanna MDtDr C0,. Inc 1930 A AII Rrgms Reserved /_ é HON DA NCEO - NAED NOTE: Specifications fol the NCSD are the same as for the NASO except as nnted. 14. SPECIFICATIONS NA 50 N650 DIMENSIONS Overall lengxh Overall width Overali height Wheel base Ground ciearnnce 1,660mm (65.4 in) 600mm (23.5 in) 995mm (39.2in) 1,050 mm (41.3 inI 125mm (4.9M) 1,580 mm (62.2in) 1,000 mm (39.4 In) Dry weight 52.5 kg (1361b) 46.5 kg (1025 lb) FRAME Type Back bane F. suspension R. suspension F. (ire size, pressure R. tire size, pvessure F. brake R. brake Fuei capacity FueI reserve capacltv Telescopic fol‘k Swing arm 2.25 — 14 7 4rwi1.25kg/cm2 (13 psi) 2.25 -14 7 41:11 2.25lqi/cm2 132 psi) InlemaI expanding shoes Internal expanding shoes 2.5 Iii (0.65 U 3 gal) 0.5m (0.13 L) 3 gal) 15 kg/cm2 (21 psi) 2.0 kg/cm2 (28 psi) 2.0 [it (0.53 U S 93!) 0.2 Ii! (0.05 U S gal) Caster angle 23" 30’ 23° Trail length 76 mm (3.01M 72 mm (2.3 In) From fork grease 5 cc 10.18 025) ENGINE Type Air Conled, 2-stroke Cylinder arrangement Single~cvlinder flat Eon: and stroke 40 x 39.3 mm (1.57 x 1.55 inI Dispiacement 496C (3.0 cu in) Compression raiio 7.3:) Transmission oil capacity 0.55 Iil. (0.59 U S qt); SAE 10W~40 motor oil 01) tank capacity, NASD 0.9 (it (0.95 U 5 qt); 2-stroke injemov cliI SAE 30W N550 0.8 III. I084 U 5 qt]; 2-stroke injector oil SAE 30W Lubrication system Air screw OpenIng Intake Open Close Exhaust Open Close Scovcngc Open Close Idie speed Forced i turn om Heed valve controlled Heed va|ve controlled 65° EBDC 55“ AEDC 47“ BEDC 47“ ABDC 1,300 rpm Daxe of Issue' November 1980 @- American Honda Mme: 1:0,, Inc. 1980 - All Highs Reserved 31-25 HONDA é '31 ADDENDUM N650 - NAED NA50 | N050 DRIVE CHAIN Ciuich Automafic centrifugal we! type Primary reduc‘ion Chain and gear Gear ram: | 11182:} 1.0%:‘1 II 1 000:1 Not applicahie Final reducn‘on 14.220:1 ELECTRICAL Ignition Capacinve Discharge Ignition Starling system Kick SKarter Generator AC. gene'alor 6V, (SSW/5.000 rpm Spark pxug () :oplional NGK:BP4HS. (BPSHS). ND:W14FP7L (W16FPI Spark piug gap 0.6 — 0.7 mm (0.024 - 0.028 in} Ignition timing 18" BTDC Baxtery capacity 6V AAH Fuse capaciw 10 amp Headlight Low/High 6V-15/15W Tail/stopligm Turn signal Speedometer iigm High beam indicator Tum signal indicator sv-ss/zsw 13/32 CF) 6v-17/17w (21/21 CF) 6V-1.5W(1CF) 6V-‘I.7W (1 cm SAE No. 51 6V-117W (1 CF) SAE No.51 31-26 Date of Issue: November 1980 © Amsncan Honda Mutov Co, Inc. 1980 - AH Rights Reserved 15. WIRING DIAGRAMS HONDA NCSO . NAED » oouclmi‘ Names :1 :55 ii .5; rs 5m 5:: 265.2“ 0 , @5345 O 333:. 3.3 :5 5mm M £53: KO 46m $3 «9 N. .3: 5:; $25! =83 :3: :5.“ 5:: '81 NA50 Ma P: 5 § 2 Ema :2. 3. 3.: a: 1. gym: 85 £32“ 553 :52 $56 $5» :sESu 5:: .95 5.23 :53 35mm 5.2 5:5;2555: Jl _ A iii. .35 in: .55 a O is. IL . ‘ E .V . x GIDAI .191 THAI, 1.5;. :33: > E 53:: xi 5: ;, TDAI : E KEHBSKM x? s. , a 3:09, .153 g» n 932 «3 E $5.5 2:22 :5,» EB 55 k 5:5 m S . 5:5 :85 .95 “2355 _ f /‘ 31-27 Dam of Issue: November 1980 © American Honda Mumr 8a., Ma 1980- An Rigms Reserved HONDA NEED - NAED '81 ADDENDUM WIRDNG DIAGRAMS » n33 En”. Sir 2:82! 3.9: “48:9: 38: , A. was" 2% 2:2 5:3: 9:9 v.5 2:... 22:: 2:2 .32 a, my; ”mafia i. ll. 2:9,. 8‘ @fl ,2, z» 3 1% u w h : v 35:; a! 22.; 55:2 msfizs , 5...». m an”: 5.2 .r . J .. ( x I R011, 4 w .2 . , $325.. 1.: |_ ibflv; _ _ . . J ..\.wHT _ lIEUIw . "F pfiwmvé , ‘ ‘ _ , 5 E , _, aficflwmy :? 5.. 8.2.2 29. :. xinwmv _ TEA E _ g Q. g a; {man .IUII kw. 55.5.: 2; _=. r—Jlr . . rLUiLlfiKL ”\flI. « n W _1é.1Hr,T§ mac fiamnwrwmg _ . . _ (WT lfiwmmr , ‘IVfiUL H r :33 .3: was. 2:3... “ a , x 91. AYLAME. L 11nd: Mammy . VHT ._ ‘ r R: :1 32: r ,_ fiva 38;: é E. m D . , .. .,. a n. ‘ x ,_ w! ( E: 2 if _ O. E a 9. @m3 9:. aria .2. 9 9.. Es 28:93.32. rhx Mu A x. (9. 2:, 5 E: ms. :22 gei§§zflg :5. H uxmmr :v” a: a 9.5 w 323.! E: u 3. $29 8.3!: i: we? 02;; . . . r x r r . , ‘81 NCSO nzezm man 32:52 .i ‘ z. . . .: 9.00 w... ‘ $00 oomoN \ 3o \ 38 Date of Issue: November 1980 @ Ameticnn HondaMmorCo., Inc. 1980 - An Rigms Reservzd 31-28 é HONDA. N650 32. ‘82 ADDENDUM FOREWORD This addendum contalns service procedures and data for the 1982 Honda NCEO. Refer to the base shop manual for servrce items not described in this addendum. ALL INFORMATION, ILLUSTRATIONS, DIREC~ TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PROD- UCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. N0 PART OF THIS PUBLICATION MAY BE RE- PRODUCED WITHOUT WRITTEN PERMISSION. HONDA MOTOR CO., LTD. Service Pubhcations Office TABLE OF CONTENTS ‘I. FRONT FORK/FRONT WHEEL ....... 32-2 2. FUEL TANK/SEAT/REAR CARRIER. , . 32-3 3. ELECTRICAL ...................... 324 4. CABLE AND WIRE HARNESS ROUTING ......................... 32-5 5. MAINTENANCE SCHEDULE ... ..... 32-8 6. SPECIFICATIONS .................. 32-9 7. WIRING DIAGRAM ................ 3240 Date 0' Issue: September. 1981 © American Handa anr C0,. Inn, 1931 » AII Riqu Reserved 32-1 HONDA '32 ADDENDUM NCSD I. FRONT FORK/FRONT WHEEL NOTE: The front axle nut torque has been increased Refer to page17-1 for steering Stem tighlemng procedures. b.0490 kg-m (43—65 ft-Ihs) STEEL BALLS (26 pcs) 4.0—5.0 kg—m (29—35 ft-lh’ .® FRONT FORK FRONT WHEEL 3 2 2 Date of Issue: September, 1981 - © Arnevfican Honda Mnmr Co., Inc. 198‘ > All Righli Rewved ’82 ADDENDUM 2. FUEL TANK/SEAT/REAR BARRER REAR CARRIER SEAT F EL U OIL TANK TANK FILTER SCREEN FUEL cuP 0.3—0.5 kg—cm (2—4 mm) 32-3 Dam of Issue: September, 1981 c American Honda Maw 05.. Inc. \991- All Right: Hesmed m HONDA. '82 ADDENDUM NCEO 3. ELECTRICAL COMPONENT LOCATIONS I. IGNITION SVSTEM 2‘ BATTERVICHARGING SYSTEM 3. LIGHTING SYSTEM AND HORN IGNITION COIL A.C. GENERATOR HEADLIGHT AVC. GENERATOR RECTIFIER STOP/TAIL LIGHT C.D.|. UNIT BATTERY HORN SPARK PLUG TURN SIGNAL PULSE COIL MAIN SWITCH ENGINE STOP SWITCH ENGINE STOP SWITCH f’ I MAIN / . 4 SWITCH STOP/TAIL TU RN SIGNAL BATYE RV PERFORMANCE TEST Check the battery, AC. generator and resistor when the readings do not much xhe specifications beIow. Chalging starts 4mm rpm 6,000 rpm 1,600 rpm max (7.0 v) 1,3 A min, (8.5 v» 2.5 A max (8.7 v) Date of Issue: September, 1981 3 2 " 4 © American Honda Moxor Co” Inc. ‘93? - All Righls Rush/Ed HONDA. N850 ‘82 ADDENDUM 4. CABLE AND WIRE HARNESS ROUTING THROTTLE/OIL PUMP CABLE 3/ fl COIL SPEEDOMETERK CABLE FRONT BRAKE CABLE A.C.G. WIRE CONNECTOR SILICON RECTIFIER WI'EHARNESS \ , \ 3%. Dale of Issue: September] 198I © Amnricln Honda Mowr 00., Inc. 1951 . AII Right! fiaserved 3 2 ' 5 '82 ADDENDUM . I REAR BRAKE ’r CABLE THROTTLE/ OIL PUMP “ CABLE CLIP l I I REAR BRAKE WIRE HARNESS CABLE , , . REAR TURN SIGNALS w 3 2 6 Dale of Issue: September, 1981 ' © American Hands Mom! (20., Inc. 1981 » Au Righn Roserved HONDA. N550 ‘82 ADDENDUM FUEL LINE ROUTING THROTTLE CABLE ‘ ’ — , w / *’ CARBURETOH REAR BRAKE CA LE BREATHER TUBE I r BYSTARTER CHAMBER OIL LINE FUEL LINES Dale of Issue: Septemhex,1981 3 2 7 (:3 American Honda Moxor Cm, Incv IQEI - Au RAths stcrved ' '32 ADDENDUM 5. MAINTENANCE SCHEDULE The fuel filter screen maintenance schedule has been changed, Refer to page 31-24 for all other maintenance schedule items. REGULAR SERVICE MAINTENANCE SCHEDULE INITIAL Perfoim at every indicated This maintenance schedule is based upon SAFETY month or mileage interval, average riding conditions. Machines subv INSPECTION whichever comes first iected to severe use, or ridden m unusually dusty areas, require more frequent 1 month 12 months 24 months servicing. 200 miles 1,000 miles 2,000 miles 300 km 1,500 km 3,000 km FUEL FILTER SCREEN C C 32-8 Date of issue: September, 1981 © American Hand: Momr Ca., Inc. 1931 A All Right: Reserved "\ é HONDA K NCSD '32 ADDENDUM Only specifications (hat are new or different for 1982 are listed below. Refer to page 3125 for other Specifications. ‘ DIMENSIONS Overall length 1,615 mm (63.6In1 Overall width 610 mm ( 24 in} Overall height 1.005 mm (39.5111) ' Wheel base 1,057 mm (41.6 lnl Ground clearance 127 mm ( S in) Dry weight 50kg (1101b) FRAME Fuel capacflv 4.55 liters (1.13 U.S.gal.1.0lmp.gal.l Fuel reserve capacity 0.75 liters (0.19 U.S. ga|.0.161mp. gal.) Caster angle 25° Trail length 80 mm (3.15 in) Front fork grease 11 cc (0.36 oz.) ENGINE Transmisslon oil capacitv 0.65 liters (0.68 US. qt., 0.57 Imp. qt]; low-40 motor oil Oil tank capacity 1.2 liters (1.26 U.S. qt, 1.05 Imp. ("1:2 stroke injector oil Air screw opening 1 1/2 turns out /_. "” DRIVE TRAIN Gear ratio | 1.432t’l || 1.00011 ELECTRlCAL AC. generator 6 V. 76 w/5,000 rpm NGK ND Spark plug Standard EPRAHS W14FPR-L For cold Climate BPRZHS WQFPR-L For extended ridlng BPRSHS W16FPR Spark pluggan 0.6—0.7 mm (0132441028 inl I" - ‘ Date of lssue: September, 1981 © American Honda Mom Ca, Inc. 1931 - Au Highxs Rum/ed 32—9 HONDA NGSD ’82 ADDENDUM 7. WIRING DIAGRAM '82 N050 003024 GAG 4 6700 5 ‘4 . Date of Issue: September, 1981 3 2 ‘1 0 © American Honda Mom: (19., in; 1581 -An Righzs Rasema m m um .u, ‘.