SHOP MANUAL NNEDMD GHPD ‘C, HONDA MOYCW. CO, LTD 173-! GIGKUOU PRINTED IN MPAN ' 0 A 21508403E IMPORTANT SAFETY NOTICE 7 a Indium a 31mm: pmr‘bility u/mm palatial Injury or [m n] 11/: l/liumrerlmr: m not followed. CAUTION: Indium a postibfllry of personal injury ur zquipmcnl damage if rrrxrmrrr'nnx are not followed. NOTE: Givn hllpiul rnformlticn. Dob-Had «inscription; of standard workshop procedurrr, umy principles and nrviu operations am not included ll is important to not- thlt thir manual contains some wamlngs and cautions against soml spcciiic urviu mathodr which mould cause PERSONAL INJURY to surviu plrsonnol or could dump a vnhltle or rondar it unsaie. Please understand that those waning wuld not cover al conceivable ways in which servine. whllhll or not "comm-nun! by Honda might be done or 0' the possible hazardous comma-nun of such conceivable way. nor could Honda investigate all such ways. Anyonl using urvico procedures or tools. whether or not recommended by Henri. muxt salts/y Irr‘mleflhnmugh- Iy that nsither personal safety nor which utlty will be loomrdlzed by the service method or tools selected. 7‘3 HONDA ../ NNSOMD HOW TI] USE THIS MANUAL Follow the Maintenance Schedule recom mandations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the US. Environmental Protection Agency. Pere forming the first scheduled maintenance is very important. It compensates for the ini- tial wear that occurs during the break-in period. Sections 1 through 3 apply to Ihe whole motor scooter, while sections 4 through 16 describe pans of the motor scooter, grouped according to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The sub- sequent pages give detailed procedures. II you are not familiar with this motor scooter, read Technical Features in section 17. If you don’t know what the source of the trouble is, refer to section 18 Troubleshoot- ing. All information, illustrations, direc» I tions and specifications included in this publication are based on the latest product inIorrnation 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 obliA gation whatever. No part of this publication may be re produced without written permissionj HONDA MOTOR Co., LTD. Service Publications OIfice ENGINE CHASSIS TRICAL ‘é EEC CONTENTS GENERAL INFORMATION n V LUBRICATION n MAINTENANCE fl FUEL SYSTEM ENGINE REMOVAL/INSTALLATION El CYLINDER HEAD/CYLINDER/PISTON Isl ALTERNATOR k II : CLUTCH/FINAL REDUCTION l:l CRANKCASE/CRANKSHAFT n FRAME COVERS II:I STEERING/FRONT WHEEL/ PRAKE/SUSPENSION REAR WHEEL/BRAKE In ‘ REAn’snocx ABSORBER! SWING JOINT UNIT FUEL TANK/OIL TANK I'll ELECTRICAL EQUIPMENT WIRING DIAGRAM IIEI TECHNICAL FEATURES TROUBLESHOOTING Il:l t , Date DI Ime' March, 1984 l‘. HONDA MOTOR CO. LTD ZAutumn]; \ nsg/ NNSOMD Dale 0! |ssue March, 1984 C HONDA MOTOR CO ,lTD K‘ / Nil; HONDA N N 5 0M D I. GENERAL INFORMATION {7 GENERAL SAFETY 1—1 TORQUE VALUES 1—5 SERVICE RULES 1—1 TOOLS 176 MODEL IDENTIFICATION 1—2 CABLE 8i HARNESS ROUTING 1—7 1—3 NOISE EMISSION CONTROL SYSTEM 1—12 SPECIFICATIONS GENERAL SAFETY If Ill: "xiii: rum be running to rlu Jam: war/i. rrralit me Me arm Li h't‘ll-rorll'lnn‘d. Nut-r mi rlrr trig/n In a rlami am. The (XIII-II tunic/n1 pallarrau urban Int-Inuit! gnu. Gasoline 1, rxtnnltly flammable 11ml .3 (xpllnivr Tlrr balmy clurmlyk cur-Iain; sill/uric arid. ho- recr your tyfl. skin and clothing. In use n/urnraa. [rm mamugnly mm: mm and mu a loan! if (learn/yr: gel: in Jul! q-a. Tire [runny 301ml!!! llydrugu K0) Ivllicll can fit imilrr cumin mmliriirru. Do nut Mia/it ar uIIu-r 11mm w ”"1": in yum marking ma. highly uplatiu. be run! "nuke nr allay»v [lam nr rpnrfl: rm" rlre bunny. nperiully whll: clinging II. SERVICE RULES 1 Us: qlnulnl HONDA or HONDA~rdccmmended parts and lubricants or their mulvnlnnu. Puts that do not mcci HONDA's design specifications may dim-g- th- scooter, . Ulc the special tools designed luv this scooter . Use only metric tools when servicmg xhu scootart Metric bolts, nuts. and screws are not interchangeabl- with English Ii’lSlEn an. Thu us: 01 Incurlecl tools and lasteners may damage the scooter. 4, Install new gaskets, O-rings. cotter pins. lock plum, llc. whan reassemblingr 5 When tightoning belt: or nulL begin with larger diametur or inner bolts lint, and tight-n to the specified torque diagonally All 2—3 slaps, unless a particular sequence is specilmd 6. Clean parts in nonrllammabla or high flash point solvent upon disassemhly. Lubricate any sliding iurlacus helm: reassembly, 7, Altar rcauamblv, check all parts lur proper installation and oparation, 8. Roula iIII electrical wires as shown on page 1-7, (>an: and Harness Ruuting and always away tram iharp ldges and areas where they might b» pinched batwun moving parts. um Dlle cl Issue: March. 1934 C HONDA MOTOR CO .LTD HONDA N N 50MB GENERAL INFORMATION MODEL IDENTIFICATION The vehicle ndunlxhcaliou uumhev I) on Ilw Inuue mm m Iron! of m ngm Iron! cover Thu 1mm mm number I: named on [he mm Side VEHICLE IDENTIFICATION NUMBER oI nu.- IHme. The carburetor ldunlmcalmn numhnr m an the carburetor body CARBUHEIUR IDENTIFICATION NUMBER FRAME SERIAL NUMBER The calm code Iabul is anachcu (0 me fuel Iank The engine sevial uumbcv Is smmpcd uu the lelmde under me seat When ordennq a color Cannd part. no me anqma use always specify ns desxqmnad calm. ENGINE SERIAL NUMBER Ddlu uI Issue. March, 19!” 1'2 C HONDA MOTOR CO.,LTD HONDA % NN50MD GENERAL INFORMATION ITEM SVECIFICATIDN DIMENSIONS Over-II length 1540 mm (60.6 in) Overall width 620 mm (24.4 In) Overall height 955 mm (37.6 inl Whnl bla- 1080 mm (‘2.5 in) Ground clearance 95 rum ( 3.7 In) Dry might 58 kg (127.9 lb) FRAME I ‘iype Back bone Front suspension, travel Rur suspension. tr-vel Vehicle unacitv load Front tire size. prossuro Rear tire slze. pressure Front brake Rur brlke Fuel capacity Caster angle Trill Front fork grease ENGI N E Type Cylindlr Inlngomerlt Barr: and stroke Displecement Compression ratio Trnntmlnion oil :lpuity oil tank capacity Lubrication system Port timmg Intake Open Close Exhaust 09¢" Clou Scavenge Open Cl use Englrw dry weight Idle spud CARBURETION Carburetor type ldantlliution numb" Air screw initial toning Float level Bottom link. 65 mm (2.16 ml Unit Swing, 60 mm (2.36 in) 82 kg (180 lb) 2.1540-2Pn. I25 9.11.25 kn/cm’, 13 psil awe-2m, 100 kPa (1.00 kq/cm2.14 pm Internal expanding shoe Internal expanding shoe 3.2 R (0.85 US. 9-1., 0.71 imp. “I“ 24" 55 mm (2.2 in) 5 g (0.18 oul Air cooled 2-strokrr Singll cvlindu 41.0 x 37.4 mm (1.614 x1.4723nl 49 cm’ (3.0 cu. Inl 7.2 : i 150 cc (5.0 U.S. oz. 4.2 Imp. ozl 1.3 In. (IA US. qt, H12 Imp. at) Lubricated by mlxing with fuel and oil field vllvl controlled Rood valve controlled 72° (EBDCI 72“ (ABDC) 57° (BBDCI 57“ (A306) 120 kgl26.51bI 1.800 2 150 rpm Piston valve PA 27C 2 turn out 12.2 mm (0.48 Inl Due 01 lnue: March, 1934 C‘ HONDA MOTOR C0..LTD. GENERAL INFORMATION HONDA NNSOMD r— ITEM SPECIFICATIONS DRIVE TRAIN Clulch typo Amnmnic centrifugal clutch Primary reduction 2,636 Gear rllio 15!: I552. 2nd: 1.000 FII'III rlduction 1928 ELECTRICAL Ignilian Condenser capacitive discharge ignition (CDII Surfing rvnnm Surfing molor Generator Almrmor 12V sow/5pm rpm Spark plug NGK ND Standard BPRGHS W20FPR For cold climate BPFNHS WIAFPR—L For extendcd ‘ my” riding BPRBHS WZAFPR Spark plug gin ore-0,7 mm (01324—0328 in) Ignition limlng "r" mark 15° BTDC Bunny capacity 12V4AH Fun umnérv 7A LIGHTS Hudliql'n Low/High IZV~25I25W Taillnoplighr IZV-E, 27W 3 32 up Turn signal From/Rur iZVvZSW 32 :9 Socedomctcv light 12V- 3W High bum indie-{or I2V 1 7 W Turn iignlI indicator ‘ZV-3 4 W — 1-4 Date 09 Issue: Much, 1984 LC.‘ HONDA MOTOR COHLTD, TIIHDUE VALUES HONDA NNSOMD GEN ERAL INFORMATION ENGINE Imn O'ty Thu-d Dll (mm) Tarquu Nrm (kgm. it-Ibl Remarks Cylindu had 4 6 8—12 (0.8—1.2. 3—9) While the angina is cold. Flywheel 1 10 35—40 (3.5—4.0, 25—29) (Below 35°C. 95'F) C(ank case 5 6 8—12 [0,84 .2, 6—9) Inuk- pin. 4 8 3—12 (0.8-1.2. 6—9) T While the snglne 1: cold. Clutch outer 1 17 38—42 (3.8—4.2. 2741” (Below 35°C. 95"” Cavburetor 2 6 9—12 (0.9—1.2, 7—9) Twhilu lhl angina is cold. taulow 35°C, 95°F) CHASSIS Item Cl'w Thread Di: (mm) Yovquc N-m (kg-m, lt~lbl Remavks Sturmg mm. m bolt 1 10 40—50 (4.0—5.0. 29—38) Staring Item lock nut 1 25.4 60—80 (6.0—5.0. 43—58) 1 Front axln nut 1 10 40-50 (4.0—5.0. 29—36) | EnniM—Juint can 2 8 24—30 (2.4—3.0, 17-22) Rear axln nut l 12 50—70 (5.0—7.0, 33—51) Rear Shock absorber 2 ‘0 3045 (3.0—4.5, 22—32) Heat shock leO'bl' dumplr lock nut 1 ID 30—45 (3.0—4.5, 22421 Front/Rear brake arm 2 5 4—7 (0.4—0.7. 3—5 ) Swing lock Inn A 1 5 4—7 (0.4—0.7, 3—5 ) Jaint shaft 1 12 55-55 (5.5—8.5, 40‘47) Joint shift pivat nut 2 10 40—50 (4.0—5.0, 29—33) Joint we 2 9 24—30 (2.4-3.0. 17—22) 4 6 10—14 (LO—1.4. 7—10) Tarqua unwillutlons “nod above are for Important human, Others should be tightened to me Inward torqm vuluu Ilstad bllaw. STANDARD TO HOUE VA LU ES Ium Torque N~m lkgm. It’lb) ltcm Torque N‘m [kg-m. film _5 "InAbcht and nut 4.5.6 [OAS-0.6. 3—4) 5 mm smw 375103—0534) 6 mm bolt Ind nut 8—l2 (0.3—1.2, 6—9) 6 mm mm 7—11 (OJ—LL 5—8) 8 mm bolt and nut 13—25 (1.8—2.5,13—13) 8 mm "Ing- bolt Ind nut 10—14 [LO—1.4. 7—10) 10 mm bolt and nut 30—40 (3.0—4.0. 22—29) 8 mm flange bolt and nut 20-30 (204.0. 14—22) 12 mm bolt and nut 50—60 (5.0—5.0, 36—431 10 mm flange hall and nut 30—40 (3.0—4.0. 22—29) Date at Issac March, 1984 C HONDA MOTOR C0.,LTD GENERAL INFORMATION TOOLS HONDA NNSOMD SPECIAL Remarks. Newly plov-ded tools. Ducription Tonl Numb-r l Alum-t0 Tool Tool Number Rel. page Rul- shock lbxorblr comprlssnr 07967-GA70m1 ‘ 13- 2, 13 4 attachment Rear shock absorber compressor 079593290001 13—2, 13—4 Belling lament set, 12 mm 079361660001 - Bearing remover shaft 079361060100 E 73 ' Hemmer weiyhl 077410010201 3* 3 079366710200 3—0 Attachment. 28 x 30 mm 079484870100 No! lVllllbll in USA 1 1 14 l — “SO: 1 - PilaL 30 mm 077460040700 1 I — 14 l - 0mg. ‘ 077490010000 11714 0 Can puller 07935-GJ50000 ('Ju pull-r 079374300000 972 s slomng lock nut wrench o791mxooooo I 11-22. 1 1—25 Burinn remover D7936‘K610500 4 USA only 376 Fork seal drlver 07947-1 100001 ‘ ‘ 1 1—24 Spring attachment 07967-1 150100 13—2. 13-4 Snip rinn plius 079144230001 _ 11—19. 11—20 Ball rm remover onus-cum Not available in USA 1 1A23 Hand vacuum pump A037XMI~XXXXX ST—AH-IEO-MC‘I 4—4 1 (USA nnlyl Dlgltnl multlmrttr KS-AHMJZOO? 15,7 ‘ [USA only) COMMON Dmipliun Tool Number Alternate Tool Tool Numhu Rut pug- Flol! llVIl pup 0740103100“) 4—7 Unlvoml holder 077250030000 7 *4, 7 ~ 5 Clutch holder 0772l0050000 Equivalent tool commnrclallv Wllllbl lrl USA 3—9, 3—14 Art-0711mm. 24 x 26 mm 0774643010700 No: avallable In USA 7—5 Attochmant. 32 x 35 mm 077460010100 3— 14 Attachment. 37 x 40 mm 0774647010200 9—5 Attachment. 42 x 47 mm 077460010300 9—5. 11—23 Pilot. 10 mm 0774643340100 7—6, 11—14 Pilot, 15mm 0774Gm40300 7 —8. 8— 14 Pilot, ‘7 mm 077460040400 9—5 Pilot. 20 mm 071480040500 9'5. 1 l723 Drilllr 0774900111300 7—8. 8—14 Drivu 077460020100 9—6, 7*5 Flywhul bullet 07733100111100 Flvwhnl puller 07933001!!!” 7 4 Clutch hold-r 077240050000 mum...“ “,0. mm Baring remover lxplndlr 07746-005010) 3- mlrcilllv available 1 — 1 3 Bearing remover collar. 10 mm 077400050200 i" U,S.A. Pilot. 25 mm 0774600l05130 7—6 Date 01 Issue: March, 1984 3‘ HONDA MOTOR CO ALTO (1 i HONDA his» NNSOMD GENERAL INFORMATION CABLE & HARNESS ROUTING Note the lollowing when routing cables and wire harnesses: D A loose wlrl, harnuu nr cable can he a Inlltv hazard. Alter clamping, check each wire to be sure it I! “curl. 0 Do not squeeze wrres against rhe weld or end of a clamp when a weld-on clamp is used. I Secure wires and wire harness: In the Irami with their respective wire hands at the designated Iocztmns. Tighten the band: so that only the insulated surfaces contact the wires or wire harnesses. 0 Route harnmes so they are not pulled taut or have excessive sllck. I Protect wrrex and hlrnesses with electrical tape or tubing il they cunt-ct I sharp edge or corner. Clean the attachlng surface thoroughly belore lpnlying tape, 0 Do not use wires or harnesses with a broken rnsulntur, Repair by wr-ppmg then wnh protec- tivr: tape or replace them. 0 Route wire harnesses to Ivord sharp edges or corn-rs. 0 Also avoid the proiacted ends of bolts and XCYIM. 0 Keep wrr- h-rnesset IWIY lrom the exhaust pipes and other hot parts. 0 ac sure grommets arr.- seated in their grooves properly. I After clamplng. check each harness to be certain that it is Ml intarluring with my mailing or sliding parts. 0 Wire harnesses routed along the handlebars should not be pulled taut. have excessive slack. he pinched, or lnterllrn wrth Idjsclnt or sur~ ruunding parts in all steering positions. 0 After muting, check rhnt the win hum-ms ur- not twisted or kinked. X @ @,,_ fig; 0 X o><>< iii Date cl Issue: Much, 1934 c HONDA MOTOR CO ,LTD HONDA GENERAL INFORMATION NNSOMD CLAMP U (TURN SIGNAL/BRAKE LIGHT SWITCHI CLAMP _, PRIMARY REAR (BRAKE LIGHT SWITCH) BRAKE CABLE OIL PUMP FRONT BRAKE CABLE REQEEBRAKE CABLE TNROYYLE CABLE _ FRONT BRAKE CABLE k REAR anAKE CABLE - SPEEDOMEYEFI CABLE REAR BRAKE CABLE ; TNROTTLE CABLE-,/ . SPEEDOMEYEH CAELiz” 3-- ' FRONT BREKE CABLE « I ’i ‘ maorns CABLE JUNCTION .‘ ‘ sacoqunv 5, ' . mamas I "\ 1Q CABLE RN SIGNAL ' " HEADLIGHT DIMMER TU swwcn mes I' / SWITCH ma 5 I IGNIYION SWITCH WIRES‘ PARKING LOCK CABLE Due oI Issue: Match, 1984 1'8 (CI HONDA MOTOR CO..LTD. HONDA NNSOMD GENERAL INFORMATION IA~ P f“ MAIN HARNESS f-x RESISTOR OIL CONTROL CABLE THROTTLE CABLE RESISTOR TRANSMISSION BREATHER TUBE AUTO BVSTARTER OIL OUTLET LINE , STARTEfi ALTERNATOR LEFT HEAR BRAKE CABLE ' MOTOR WIRE Due aI Ime: Much, IBM 1 9 In: HONDA MOTOR COULTD ' 1.-.:. HONDA GENERAL INFORMATION “5 NN50MD FUEL LINE OIL LINE PARKING LOCK CABLE .SECONDARY REAR BRAKE CABLE THROTT .E CABLE OIL PUMP CABLE FUEL LINE \ RESISTOR WIRE FUEL LINE OIL LINE IGNITION COIL SPARK PLUG WIRE DRAIN TUBE RIGHT REAR BRAKE CABLE D!!! a! Imu: Much, 1984 1'10 (C5 HONDA MOTOR CO.,LTD. @5 $3333? GENERAL INFORMATION FUEL UNIT OIL LEVEL INDICATOR SWITCH FUSE REGULATOR] RECTIFIER Dan 01 Ime: Much, 1984 C HONDA MOTOR COHLTD HONDA GENERAL INFORMATION NNSOMD IIDISE EMISSION CONTROL SYSTEM 0 The US. Environmental Protection Agency requires menuhcturen to certify thet Scooter built eherJanuary 1. 1983 will comply with eppliuble noise emission standards Ior one year or 1,865 miles (3,000 km) alter the time or sele to the ulti- mate purchaser. when opereted end rneinteined Incoming to the innructions provided. Compilence with the terms of the Dinributor’s Warranty for the Honda Scooter Noise Emission Control System is MW in order to keep the none emission control system in effect. (USA only) TEMPEHING WITH THE NOISE CONTROL SVSYEM IS PROHIBITED: Federal law prohibits the Inllowinn In: or the causing thereol: (I) The removel or rendering inoperetive by any person‘ other than for purposes of maintenance, repair. or replacement. of any device or element cl design incorporated into any new vehicle for the purpose at noifl control prior to Its ule or delivery to the ultirnete purcherer or. while It is In use: or (2) the use of the vehicle el‘ter such device or element a! design has been removed or rendered inoperetive hy my person. AMONG YHOSE ACTS PRESUMED To CONSTITUTE TAMPERING ARE THE ACYS LISYED BELOW: . Removal of, or puncturing the muffler. baffles. header pipes or any other component which conducts exhaust geses. . Removel at, or puncturing oi env pert at the inrelre tynernt . Lack of proper maintenance. r Replacing eny moving pert: at the vehicle, or peru of the exheuet or inukl tyttem, with peru other than those speci» lied by the marnflecturer. nan- Data at Issue: Mirth, 1984 1'12 13' HONDA MOTOR COVLTD. MEMO Date 41! lssllfl' March, 1934 I, HONDA MOTOR CO ,LYD HONDA NNSOMD LUBRICATION 01L STRAINEH OILTANK OIL PUMP CONTROL CABLE OIL OUTLET LINE Due 0! Issue: March. 1984 2'0 cl NONDA MOTOR C0,,L‘I’D X;/ NNSOMD 2. LUBRICATIUN Q 3 HONDA SERVICE INFORMATION 2—1 TROUBLESHOOTING 2—1 OIL PUMP REMOVAL 2—2 OIL PUMP INSPECTION 2—3 OIL PUMP INSTALLATION 2—3 OIL PUMP BLEEDING 2—4 ‘ LUBRICATION POINTS 2—5 SERVICE INFORMATION GENERAL 0 The oil pump can be serviced wilhoul removing (he engine from rho Irarru. o Whan rnmavmg and Installing rhn oil pump us- car: no! [u allow dusr or dirI la enter the englne and all llne, 0 Do not auempr to disassemble lhe oil pump. 0 Blood alr from me all pump if [hm Ir nlr in thl oil inln Im- “mm the nil rank to the oil pump) or iv the oil line is discon- nacudl O Bled air Irum the all antler line [from rhe oil pump to the carburerorl i! m. Inns in disconnmad (Pugs 2-5ll SPECIFICATIONS Piston/Crankshalr lubricant: Honda Zsrrnke injector all or eaulvnlenr Final reduction lubricant: Honda 4-srroka oll SAE low-40 or Iquiv-Ium TROUBLESHDIITIIIG EIcessivo smoko and/or carbon on spark plug L Pump not properly iynchmmzod Incas-we nil) 2. Low quality ungim: oil Ovarhealing 1, Oil pump not adjusibd properly (inmflicianr ollingl 2‘ Low qulliry oil Sliud pinon r No all In rank or clogged oll line , Pump nor properly ndlunod (insufficient oiling) . Air in oil lines . Faulrv oil pump . Clomod oil slrlirm m5uu— on not flowing am at unit 1, Clam-d oil unk cup Imam-r hall 2‘ Clogged oil strainer Date ol lswe. March. 1984 c HONDA moron co..no 2.1 p HONDA ’ NNSOMD 0". PUMP REMOVAL sou AIR CLEANER CASE NOTE Clean ma ml pump and m surmundlnq am mruugmy chove removing me pump, LUBRICATION \ Remove the follcrwinq pam. - engine cover mm mm Iah mm wheel .m (.1qu (page 378} an cleanel case PUMP SET PLATE BOLT OIL PUMP CONTROL CABLE Dnconnacl mg ml mlel hm! at the oil pump; pinch [he end lo woven! oil "a!" (lowmg oul. Hmonnecl (h: ml ouuu lune and the oil pump Conlrol cable. Remove the bulls anachmg the oil Dump sul plau- OIL PUMP Remuvn um m1 pump by pulling u sualghl up. Remove the Owing from the oil pump um 01 Issue. March, 1984 2-2 c HONDA MOTOR CO..LTD. \ HONDA NNSOMD LUBRICATION OIL PUMP INSPECTION MATING SURFACE O-RING NOTE Belure rzmavmg lhu oil pump, clean the oil Dump and crankcayc. Remove the oil pump and check lor. - Dereriorared O-ring . Damnga to ma crlnkcul mmng surllcu Damage to the pump body Pump conrrol Invar aparancn Worn or damaged pump gear Oil leaks CAUTION t Du mvr Jiwxscmhfe Ihc all pump‘ GEAR CONTROL LEVER OIL PUMP INSTALLATION Coal a new O-nng wilh grlaiu and slide it onto the on pumpl Grease the gear wuh molybdenum disullidc than lnsull me all pump securely on the crankcase, 01L INLEY LINE PUMP CONTROL CABLE Install me set plan: and maching bolts and nqmen murnlv, Reconnect me all Inlet and outlal Ilnn. Connan the all pump canlrol tabla lnmll the remaining 9am ln me reverse order of removal. NOTE Aflav lnflllllllofl, parlorm [he following inspections and adiusxmcnts - Conlrol cabla adjustment (Pag- 3~B) ‘ Oil pump bleeding (Page 214) ' Check lor orl leaks, Dare ol Issure: March, 1934 : norm/x MOTOR co ,LTD 2-3 HON DA LUBRICATION “5%) NNSOMD UH. PUMP BLEEHING CiJTION ‘ Air in the ml IyJIWH wrll block or rusm'cl nil flow and may rcsull In sewn» mgrnr dam-{er - Blt'fll arr [mm [he oil lines \t‘hcrwrw Iht- rul line: or pump [law been rnrmwd or Jim»: nerml or when [Item is air m [111' Inn-x - Blt'etl arr [mm [/19 oil I'nlu Ir'm' first, Ilrt-n from rhr nllmrtlt-I [mu Ramon the spark plug cap Irom thl tpurk plug. Disconnect [ha wum Item the ignition coil. Ramave the air cleaner case. Fill the 0d tank with the recnmmmdod oll Placca shop mm: lrnund lhn oil tube joint oil pump and carburetor Dimannect the oil inlet linn lrom the oil pump, Fill the all pump with oil by squirting about 4 u: 0! clean oil through 0!! jaintl Fill the all im- with all and reconnect it to the oil pump. Aner installation, mlkl turn there is no air in lhl oil Inlet llne‘ Din-.onnect the oil outlet line from lhl pips. Fill the oil linn wtlh oil and recannect it to the carburetor. lnxtall lha an cleaner case. Start the engine Ind lllow It to idle. Bleed air from the tynem by loosening the hleeder bolt at tho pump. -R'rfimn this apertrrr'an In a lull-ventilated rrmr. .00 um nmv (It: engin- unnmuerlly. OIL OUTLET LINE BLEEDER BOLT Dale 0' lune March, 1934 c HONDA MOTOR COHLTD , i .\HONDA 39/} NN5OMD LUBRICATION ‘ LUBHICATIUN POINTS Apply clun engine oil or gvcase (0 cabins 1nd pans not called out, .64 THROTTLE GRIP rfiu PARKING LOCK LEVER '7' PIVOT LINK FINAL REDUCTION [SAE 10W 40, 150cc, 5 O U 5 my \ .551. STEERING HEAD BEARINGS // ’/ FRONT FORK BRAKE CAM SHAFT nun-um. 1 I SPEEDOMETER GEAR/DUST SEAL/ '6' WHEEL BEARING/DISTANCE COLLAR BRAKE CAM SHAFT/ WHEEL BEARING Dale 0! Issue: Much. 1984 L: HONDA MOTOR CO VLTD 2'5 HONDA NNSOMD MEMO Date o! Issut‘ March, 198.4 C. HONDA MOTOR CO .LTD ET HONDA N N 5 0M D 3. MAINTENANCE SERVICE INFORMATION 3—1 COMPRESSION TEST 3-7 MAINTENANCE SCHEDULE 3—2 IGNITION TIMING 3—7 BATTERY 3—3 CARBURETOR ADJUSTMENT 3—8 AIR CLEANER 3—3 BRAKES 3—9 EFLErIEIfiINE/FUEL STRAINER/FUEL 3—4 SUSPENSION 3—12 I STEERING HEAD BEARINGS 3'13 OIL STRAINER 3—5 WHEELS/TIRES 3—13 FINAL REDUCTION OIL 3—6 NUTS, BOLTS, FASTENERS 3—13 SPARK PLUG 3—6 MUFFLER DECARBONIZATION 343 SERVICE INFORMATION SPECIFICATIONS SPARK PLUG W No — Standard ‘ 8PR6H5 W20FPR For cold climate I spams WMFPR~L Forlxtandnd mgmm riding I BPRBHS wzuva SPARK PLUG GAP COMPRESSION IGNITION TIMING THROTTLE FREE PLAY lDLE SPEED AIR SCREW OPENING BRAKE LEVER FREE PLAY FRONT REAR FRONT REAR FRONT REAR PARKING LOCK LEVEH FREE PLAY TIRE SIZE TIRE PRESSURE 0.6—0.7 mm ((1024—0028 in) 120 kg/Imlz (170 psi) 15‘ mun/1800 mm 2—6 mm (1 1571/4 in) LBDO 1150 rpm 2 mm: out 10—20 mm (3/3—3/4 in) ID" 20 mm (3/873l4 In) 2.75—ID—ZPR :mo-a—zpa 125 kPn (L25 kg/cm’, 13 psi) 100 kPa (1.00 kg/cm“. 14 psi) 5—10 mm [H4718 m, Dale oI Ime: March‘ l934 C HONDA MOTOR COULTD MAINTENANCE HONDA NNSOMD MAINTENANCE SCHEDULE I — Inspect Ind ell-n. adjust. Iubtlolll or unloc- i! may R — Rlpllcl C—Clun mmAL REGULAR SERVICE PERIOD PRE‘RIDE SAFETY Perform It nary indinnd This mulnuoanco schedule is based upon INSPECTION INSPECTION momh m mileage lm-rval III-rage riding nondillon. Scooters subjected whichever occur: first Rater m to lulu ml, or Nada" in unulually duny page urns, r-quirl mun Irlqulm mvicing. 1 month 12 months 24 moqu 200 mill: 1,000 mil-l 2,000 mil-I (300 km) [1,500 km) I3.000 km) AIR CLEANER ELEMENT (EVERY 6 MONTHS) C 3-3 CARBURETOR I I I 3 8 'THROTTLE OPERATION I I l l 3-8 OIL PUMP I l I 18 FUEL FILTER SCREEN C C C 34 OIL LINE l l | 3-5 FUEL LINE I l R 34 'OIL AND FUEL LEVEL I l DECARBONIZE CVLINDER HEAD, C 3-13, 6-4. CYLINDER. PISTON AND MUFFLER $5 TRANSMISSION OIL R 36 'TRANSMISSION CASE FOR LEAKS I 3-6 1 CLUTCH SHOE WEAR 7 I 7 W I 8-10 I TIRE: PRESSURES AND CONDITION | 3-13 WHEEL TRUENESS I | | 343 ‘BRAKE OPERATION AND FREE PLAV | l I I | 3-9. 340 BRAKE LININGS I I I 3-1! i PARKING BRAKE OPERATION AND FREE PLAY I 3-11.3-12 STEERING HEAD BEARINGS I ‘N 1 3-12 SUSPENSION OPERATION | I 3‘12 NUTS, BOLTS (TIGHTENI I I 3-13 'SPARK PLUG R R 3-6 'BATTERY FLUID LEVEL I 3-3 _ BAT‘I’EEV FLUID SPECIFIC GRAVITY I 1 I53 ALL LIGHTS AND HORN I hams mrksd ' In simpln to purform And my In llnlIDld by the own-v. Other mlIIIlIIIlnCI hem: should be sewiced by an "mound Hond- molov «:0qu dealer. 3-2 Dale ol lune. Match. 1984 'D HONDA MOTOR CO..LTDV A HONDA NNSOMD BATTERY Raise UH.- seal lnsnecl {he bane-w lhnd Tevel When the Child level neivi [ha Inwur level mmk, vclill wuh din-lied wam 1|)th uppcv Ieve< lune. ~ Check me specmc grav-ly n! ma nauery «lacun- |yw m each cul| (Page 15 3L Recharge the banery H necmsary (Page 154). NOTE And only distilled walur Tap water leH shuuun Nu: semce hlc 0! (In: balmy m Immy (Irrrmlyu runmun .mll'uri: .m‘u. Pmm yaw (m. Tun ml cluthinu. In cm: u/ mnnn'l. [huh tawny/nu with water and call u duclur if drum/yu- grls in yum gym. AIH CLEANER Remove this angina cover, Remove {he screw all-Idling the air cleaner case cover and remove the air cleaner case cover Remove me an cleaner alemenl MAINTENANCE UPPER LEVEL LOWER LEVEL AIR CLEANER CASE COVER AIR CLEANER ELEMENT Dau- or Issue, Mum 1934 c HONDA momn co rm 3-3 HONDA NNSOMD MAINTENANCE Wash 1h: llamanl In non-flammable or high flash point solvenl. squeeze out and the alamum lllnw Ia drV Nun "fun gum/II" nr Ian~ rim pain! salmm Iur (Inning III! air cleaner element. A fire a: exp/mini: mu mun. Soak \he elamem In clean motor oil (SAE lOW~301 or gear all (#8090) and squeeze out thu uxcnx. WASH soUEézs our 01L soueezs R . eunmll my: element and an clnnlv can covnr AND DRY OUT EXCESS Ol L FUEL LINE/FUEL FILTEB/ Funsmmm FUEL UN; FlIEI. STRAIHEH Keep awT/mm mum nr marks. Wipe up spilled yamlinr at mice. ‘ Rumovu the ham Ildl cnvers. check the Inc! line 'or delavionuon. damage. or leakage. Tum [he fuel valve w OFF. Remuve the Ne! lxr-Inar cup, Oring and luel strainer. Clun ma fuel walnar cup and strainer. Heir-ml! {he lull manner. o-ring and cup. TDROUE’ 3—6 N-m [0.3~0.5 kg-ml 3—4 (1-!!!) FUEL FILTER Tum me luel valve to OFF and disconnect m- final line I! [ha fual WINE. Lumen [he lock nut and remove the fine! valve (mm lha fuel unk. Remove and clean the fuel filler. LOCK NUT FUEL VALVE Dale ul Issue. March, l984 3'4 l‘. HONDA MOTOR CO..LTD (’2? HONDA NNSOMD MAINTENANCE , ~Dmln Illa gasoline law a raft mnminm 1mm fin gamllu. ‘ -Afier inmlling Ml full filler, duel; fur Ital. IJIL STHAINER Remove the both side omens (Section 10). Ducannoct rho oil inlu line at xh: on pump and allow the oil In dv-in mm a clan ccnuiner, Looun lhl tub. :le under thu oil tank and dilcon. mm the inlet line 'ch1! the oil |ube ioinl. annvl (ho oil nrnimr. Clean m: sva-nar with camprnsed ail. Installmion of the oil strainer is the reverse order of removal Fill me all mnk w-m (hr.- recommended oil no to (he Draper level Bleed air from me oil pump and llnu than 2-4). NOTE Connecl me oil line securely and check lor leaks OIL LINE LOCK NUT TUBE CLIF‘ AIR NOZZLE Dale ul Issuer Much, 1934 C HONDA MOTOR CO ,LTD 3-5 MAINTENANCE HONDA NNSOMD FINAL REDUCTION OIL OIL LEVEL INSPECTION NOTE Place the scaom upngm on lurm. level gro ncl no check the oil level. Sun lhe engine and lel :1 Kill) 001 a Iaw minum Sxan me angina, vemovn the fill level check hull and check (hill the ml Ian] I! at me bottom edge of the on llwel check boll hole. OIL CHANGE Remove We all Invnl check boll. Remove (he drain boll m allow ma oil ID dram thoroughly. Check (In: sealing washar's condmun II It’s in good maps. relnslall i\ wilh \he mam bolt. Or mm" a new senling wuher wxzh the drain bolt and lighlcn the bolt. TORQUE 842 Mm [0.8—1.2 kg-m. 6—9 h-lb) Flll [he Iinil llductiOl‘I use up lo (he propel level will! me vecommended all. OIL CAPACITY: 150 a: (5.0 US 01,. 4.2 Imp. oz.) SPECIFIED OIL: HONDA A-STHOKE OIL SAE 10W 40 cu uquivallm SPARK PLUG Dl$€0nncct the spark plug Cap and clean and an Item mound me spark plug base. flnmova arm :15er me Spark plug Measure Um new spark plug gap usmg a wwe lypc feels: gauge RECOMMENDED SPA R K PLUGS: ,. fi.,._ \ NGK l ND Smudavd ‘ ePKGT-ls w2m=pn Fulculdcllnlfllh‘ l BPRAHS L WIQFPFLL Fol exlandad F highmmmmg BPREHS I W24 PR fil SPARK PLUG GAP: 0.6~0.7 mm (002441028 m) OIL LEVEL CHECK eon “ OIL LEVEL CHECK BOLT DRAIN BOLT SIDE ELECTRODE ‘ 0.6417 mm + (0.025 , 01328 In) CENTER ELECTRODE 3-6 Dau- nl Issur‘ March, 1984 l‘. HONDA MOTOR CO .LTD 1'1 \HONDA 1953;! NNSOMD MAINTENANCE COMPRESSION TEST COMPRESSION GAUGE, COMMERCIAL AVAILABLE Warm un ma Ingll’ll‘ Slop Ihe englne and remove xhe spark plug. Insen n compmsmn gauge Open the mmulc grip Iully and cmnk the engine by nperannq [ha surur. COMPRESSION: 12.0 kg/cmz—GOO rpm (170 uni—600 1'me Law compression can be caused by: - Leakmg cylinder head gasket Worn pismn rings - Worn cylinder ngh compression can be caused by' - Cavbon depoilli m we combustion chambar m on (up of Ihe pmon IGNITION TIMING TIMING LIGHT NOTE ' The CDI I! not adlusub the lgnlllul’l nming Is not correct, check the CDI um! and alumnlor and MDIICI any IauIKy pans. ' Use the Honda Servxce Tester (07308- 0070000 by O7308-0010m0) lo check the Ignlliofl umlng. INDEX MARK Ramon [ha I.“ mm wheel and mu mam: cam. Remova the timing Impactnan rubber plug from the cylinder head shroud‘ Chuck the ignmon nmmg with I ummg Iigm. The timing Is correct iI the index malk aligns with the “F" mark “1,300 rpm. IGNITION TIMING: 15° BTW/1.800 rpm wilhln 13‘ (1.300 mm. find "F" MARK [Jan-DI Issue' Mavch. 1984 {j HONDA MOTOR co ITO 3-7 MAINTENANCE CARBUHETOB ADJUSTMENT THROTTLE CABLE Meuurl ml thruule grip hue play a! me xhronle grip flange. FREE PLAV: 2—6 mm ("84/4 in) Adluslmcnls can be made by looiamng Ihl lock nu‘ and lurnlnq "15 mm"): gnp 'ree pIay adjuster. Henlana ma mmulu uabh: wmm this procedure Is no longer aflocuve Anjuit the oil pump control cable OIL PUMP CONTROL CABLE NOTE The oil pump conuol cable mould he adjunld aher xhronle grin m. pl-y udiuslmenl‘ Remove the hm rear wheel. Remove the cllp. Ind "mow the air duct. 3-8 ADJUSTER AIR DUCT ("m HONDA \Fi's/ NNSOMD 2—6 mm 11/8—1/4 m) LOCK NUT Dale M Issue: March‘ 1984 I: HONDA moron C0,,LTD / t HONDA ‘¢§s.~./ NNsoMD MAINTENANCE Loosen the oil pump control cable lock nut and open the lhrutlII grln lully. Check that the aligning mark an the oil pump canlrol liner is Iltgned mm the index mark on the pump body. Adjust ii nlcnsnry by turning the adjusting nut, CAUTION Its/prena- Ilp all/113mm"! wirltirt 1 mm (0.04 in) of Mir: illllk'x mark an Illr‘ nymr tide Ix am-pmhlt. [loam-er. rho aligning mark nnm tit-m br- all My clmml .trdr' rrfrlrr lllrlt',\‘ mark, orherwlsr trig/nu damugc will nmrr IJt‘mmt' 01' [run ficizn! Iuhnrmmn Excessive white smoke or hard starting: Pump control lever excessively open Setmtl position- - Pump corttral liver not properly adjusted IDLE SPEED ADJUSTMENT NOTE In: engine must be warm iur accurate adjust- anL Remove the left rear wheel Attech I" engine tlchnmulor. Turn the throttle step screw to obtain the specified Idle speed ol 1.800 t 150 rpm, when the engine mines or rum erntlc, F'DCIld n lullaws: ill Screw In the air screw untll rr lightly seen, then turn ll Out 2 turns. (2) Reset the idle speed wlth the throttle storl screw (3) Turn the air screw in ar out to line the hrghest idle speed (4p Reset lhu rula speed wilh the thruttle stop screw. (Si Make sure that the engine don not mm or run erratic. ll necessary. repeat steps (2) through (4). BRAKES FRONT BRAKE ADJUSTMENT Measure the lrcnt brake lever iree play at [be end of the lever. FREE PLAV: 10—20 mm (3/8-3/4 in) ADJUSTING NUT Inpum Ind-l Mull ALIGNING MARK LOCK NUT AIR SCREW FRONT BRAKE LEVER Date 00 Issue: March, 1984 I1 HONDA MOTOR CO ‘LTD MAINTENANCE l1 adjustment is necessary, turn the brake adjuumg "UL REAR BRAKE ADJUSTMENT Mamie the rear brlkl Invu 1m: DIIV ll th- and o! the lever. FREE PLAY: 10—20 mm (3/8—3/4 in] If adjustment :5 naceixary, mm the brake idjuillng nuls equally on bum sides. l0v20 mm (3/8-3“ ml ADJUSTING NUT HEAR BRAKE LEVER ADJUSTING NUTS 3-10 Dale of Issue March, 1984 C HONDA MOYOR CO ,LTD (3f: HONDA $5.» NNSOMD MAINTENANCE Aim adjunmenl. make sure that hath brake arms have no plly. NOTE If me rear brake lever has excessive play even when both brikn mm hm m ally, the primary brake cable may be “ruched. Re- pI-c- mu prrm-ry Ind "century brake cables and adjust as necessary (See section 12). BRAKE SHOE INSPECTION Rnplaca [he brake shoes it lhe arrow on the brake arm a|igm wirh rm.- reference mark "A" on run appliunnn or m 1mm nr rnr bukl (Pm "—17. 12—4)‘ PARKING LOCK LEVER Manure (ha Ming/parking lock Imr free play M the end of the lever. FREE PLAY: 5—10 mm (1/4—3/3 in) -:FRONT) ARROW MARK FREE PLAY (REAR: FREE PLAY ARROW DA"! 0' Issul.r March, 1984 C‘ HONDA MOTOR CO ,LTD 3-11 MAINTENANCE ll adiustment is necessary, proceed u tollows. Remove the leg shiuld. (Pug- 10—4) Loosen the lack nut and remove the parking lock :xhlo lrom the cable holder Turn the ed; ting nut In or out to obtain the corroct tree play. Return“ the cable in the cable holder end recheck the Tree play. Tighten the lock nut securely. Inst-II the Ilg mteld. NOTE When the puking lever cannot be locked t rs an indication that the cabll lt broke or cable removal and replacement see section ll. SUSPENSION FRONT Check the action at the front lorkx by compressing them rev-rel times. Check the entire lork assembly for slgnt of damage. Rnpleco my components which cannot be rap-trod, Tish!!!” all nuts and boltt to the tpocifiad torque vllun (PM! 16). STEERING HEAD BEARINGS Plece the scooter on ltrm. level ground. Raise the Trent wheel a" (ho around by piecing I support under the tram!» Check lhdl the handlebar rat-tat freely, II the handlebar move: unevenly. binds. or has vertical movement. odiuSt the steering head by removmg xhu lug shtnld. laounlng the steering stem lock nut and turning the top cone rum NOTE ~ Screw m the top cone race untll it is snug tight. then back it out Ila turn. - Check thet the hennleher rotates freely and has no vertical movement. Rellglllell the stuenng stern lnck nut securely ( a HONDA \f. NNSOMD ADJUSTMENT NUT A A A LOCK NUT / r TOP CONE RACE 3-12 Due cl luuu: March, 1984 VG HONDA MOTOR CO ,LTD ( HONDA flab NNSOMD MAINTENANCE WHEELS/ TIRES Chack me ure prsuuru. NOTE Tim pressures should be checked when the tires are cold nae Pnessuas: From: 125 kg/un’ nu ma) Run 1.00 kg/cm’ (14 mi) Check Ihe lives (or wean damage or imbedded mail; or mhsr lhnrp ohlecu TIRE SIZES: From: 2.75-10-2PH RI.“ 100-829" NOTE - Dn nox inlaichinqe me from and tear mus as they differ in shape from each olhor. - Roux- lhl rial urns to equalize me wean l; NUTS. BOLTS. FASTENERS Duck may I" chums nuts and balls are lighlencd lo 1h: couec| (ovum: values (page 1A5) Cluck ull cum: puns Ind safely clips. MUFFLER DECAHBONIZATIUN Remove the mufflar (page 6-2). Ramon ma urban 1mm lhi mumeI. Reinsull (he mufllm. One a! lme: Much 1984 C‘ HONDA MOTOR COMLTD 3-13 HONDA. NN5OMD FUEL SYSTEM Itch, 1984 alto! hwc; M LD HONDA MOYOR «5an 4-0 4. FUEL SYSTEM SERVICE INFORMATION TROUBLESHOOTING THROTTLE VALVE DISASSEMBLY CARBURETOR REMOVAL AUTO BYSTARTER FLOAT/FLOAT VALVE/JETS DISASSEMBLV FLOAT/ FLOAT VALVE INSPECTION 4—1 4—1 4—2 4—3 4—4 4-5 JETS/FLOAT VALVE/F LOAT ASSEMBLY FLOAT LEVEL INSPECTION 4—7 4—7 AUTO BVSTAFITEFI INSTALLATION 4—8 CARBURETOR INSTALLATION 4—8 THROTTLE VALVE INSTALLATION 4—8 REED VALVE 4—9 SERVICE INFORMATION GENERAL 0 Use caution when working with gasoline. Always work in a well-ventilated are: and away lrom sparks or llama: 0 When disassembling luel system parts, not: the locatlons ol the O~rings. Replacl them with new one: durlng assembly. 0 Bleed air from the oil outlet line whenever it is disconnected. 0 Route all tubes and tables properly, SPECIFICATIONS fl jemrl dia. Flo-t luv-I Alr mew opening Idle speed 14 mm (0.59 in) luefimmiou number PA27C ' 12.2mml0.481n) i 2 turns out 1860 2 150 rpm A Throttle grip free play 2—6 mm ”/34“ in) TOOLS Smlal Vlcuum Pump Common Float Level Gauge TROUBLESHOOTING Engine armlu but won‘t Inn 1. No Iuel in tank 2‘ Too much fuel gettlng to cvllnder 3. Cloned air cleaner 4. Faulty auto bvstarter Englm lulu roughly, tall: or run: poorly t ldll spud immune! . Rlch mlxture . Lun mixture Clogged air cleaner . Intake pipe leaking . Fuel contaminated . Faulty ignition system . Low compression . Water in luel strainer cun mmwcrmpwnJ-n 074010010000 Loan mixture ummbun» Rlch mlxture art-uro— . Faulty "out vulv- . Float level too I . Curburetnr arr jet! clogged . Disconnected auto bystarler wires . Auto hvltnrtsr valve set plate not set properly A837X-0l'l-XXXXX or ST-AH-260—MC7 (USA. onlv) . Carburetor final int: clogged . Fuel cap vent cloned . Clogged fuel Iilter . Fuel line kinknd ur restricted . Float valve laulty t Flai! level too low . Alr vent tube clogged Date ol Issue. March, ISM C HONDA MOTOR CO .LTD FU E L SVSTEM THROTTLE VALVE DISASSEMBLY Remove Ihe engine cover. Fir-move rm» arr mm: and IN charmer case Remove me carbulewl ton and pull oul [he throttle vdlve. Disconncu me rhromu cams 0mm 01: mmrrla vulva Remover mu mrnnlu valve ipnng, Cdvburelor up and scaling up from me rhronlc cable. THROTTLE CABLE THROTTLE VALVE CARHUHFTOH CAP SEALING CAP THROTTLE VALVE SPRING Darn n! Issue. Mirch, 1984 C HONDA MOTOR CO ‘LTD a ,HONDA $3, NNSOMD FU EL SYSTEM Pry of? who ruramar nnd umove me in needle JET NEEDLE/THROTTLE VALVE INSPECTION Chuck the jar nuadln and rhronle valve for wear or damage. Replace them if they are worn or damaged, CAHBUHETIJH REMOVAL Turn the fuel valvn OFF Remove (ha Engine cover. stconnect me wires lrom ma rgnmon cull. Remove rho spark plug cap from ll“: spark plug, and remove lhu air cleaner case, Discannccr the aura hvnnnar wrres and connectors. Ramon xh' lhroule valve Irom the carburetor body by loosening the carburetor lop, Drscnnnecr ma Iusl II": Item the caruuretor, and remove the carburetor by unscrewing rho anaching bolrs. ‘ RETAINER NEEDLE CLIP SECOND NOTCH (STD) JET NEEDLE THROTTLE VALVE AUTO BYSTARTER WIRES BOLT AIR CLEANER CASE FUEL LINE CARBURETOR YOP Due ol lune, March‘ 1984 C HONDA MOTOR CO. LTD FUEL SYSTEM HONDA @ NNSOMD AUTO BYSTAHTER INSPECTION Measure the reslstnnce between tn: 1qu hymn-r wurni Rlplm thl Iutu bvmrter with a new on! if it is out at specification or if there is no continuity RESISTANCE: 10 ohm: max. L-t th- urburuor sit my 30 munitm. Conth a wessuw pump to the enriching circuit. Apply prmuro tn the circuit. ll tha pang- il block-d. rial-cl the lute hvstarter wit I new one. Connact n 12V hlmrv latwun ml Auto hysteria: wires and wait five mlnutos. NOTE TM nutn hymn-r wins an bu connected to the battery terminals without regard to the ponlltv. Connect a unsure pump to th- tunl unridiing circuit Ind apply pram" to it. Replace the auto hynlrtcr with I nm on- it thin in no rntriction to flu 9"sz applied. _ \«= i" \ , it, \ 7 x VAcufiF/fiessuaa {UMP Eamouxxxxx on passsun: pump ST»AH-260~MC7 (USA only) PRESSU RE PUMP ST‘AH-QBOMC7(U.S.A.on|y) VACUUM/PRESSURE PUMP A937X-041-XXXXX OR 4-4 Date 0‘ Inns: March. 1934 ti HONDA MOTOR COHLTD (A HONDA $9 NNSOMD FUEL svsrm REMOVAL Remove the two screws attaching the auto bvslaner ho‘dlh Ind ramovu Ihe lulu bysllnlr hum the carburetor body. AUTO BYSTARTEFI HOLDER FLOAT/ FLOAT VALVE/ JETS DISASSEMBLY Place a drain pan under the carbureror and loosun thn carhumor dram screw ro drain the {ML Remove me floar chamber (rum lhl clrbumor bodv Remove the carburuor flout Ind "on valve by removing (h: anaching screw‘ FLOAT VALVE SCREW FLOAT/FLOAT VALVE INSPECTION VALVESW Chnck rm vulva sail [or wear or damagc‘ Check me lloar lor deformarion or fue| mside the float SEAT CONTACYING FACE Dan: 0! Issuer March 1984 c HONDA-MOYOR co .Lru 4-5 HONDA N N 5 OM D FUEL SYSTEM L THROTTLE STOP SCREW Tum [he an screw In Ind rucord the number of mrns um" il seals lightly. so can be mlumvd m m original palmon during relunmblv. Remove the .16: and throttle slop screws. CAUTION Du uul farm the 11'!th again" Iherr mm m prawn danmgr In (In- men, AIR SCREW Remove m. mum Ind Mama jets. NOTE Do not ant-mm l0 romave the “skid. n n u Blow open all [us and body openings with com- messed arr. Duo 0! Issue‘ March. 1994 4-6 ‘cx HONDA MOTOR CO..LTD ”R HONDA $5/ NNSOMD FUE L SVSTEM JETS/ FLOAT VALVE/FLOAT ASSEMBLY Instill the throttle stop screw. main and needle iets. Inn-II the air screw. Turn it in until it lightly mats and back it out the number 0' turns recorded before it was removedt ll the number 0' turn: wu not rlcnrdnd, turn It out 2 must Perform elr {crew adluxtment after the carburetor it "installed (page 3-9). Imlnll the float valve, "oil and float pin, Tighten the lloat screw securely. NOTE |nsta|| the "on! valve and float pin first, then Install the float. FLDAT lEVEL INSPECTlflH Manure thl "out level n my main jet parallel with the float pint FLOAT LEVEL: 12.2 1 L0 mm (0.48 1 0.04 in) Replace the float it ll |S out of the (penned level rlnge. Check the oporltion ot lhl flait Ind install the “on! chambert Date 07 Issue: March, 1984 C HONDA M070“ CO LTD THROTTLE STOP SCREW l AIR SCREW F LOAT VALVE FLOAT PIN SCREW FLOAT LEVEL GAUGE 074010010000 (3 "-\ HONDA FUEL SYSTEM ¥§; / NNSOMD AUTO BYSTARTEH AUTO EYSTARYER NEEDLE SCREWS INSTALLATION BeIDre Installing the bysunal on thl carhuvator, check the valve and nmdle. Replace the byslartm H the valve or needle show signs DI waar or damage, Position the auto bystarter on the carburetor body and install w-th the set plate and scram AUTO BVSTARTEFI VALVE SET PLATE CABBUIIETOII INSTALLATION CAUTION Do ”or allow flung" pallit‘ln m mm the L hurrmr NOTE Check that the fuul and oil tubes are not pmcned The Installation sequence Is ossentmlly the Inverse order OI removal Perform the (allow-n9 oparutton und adjustments: Throttln cable adjustment - Oil oullfll tube bleeding Idle speed adjustment THROTTLE VALVE INSTALLATION Install the int needle into the throttle vilv: Ind secure wnh tha ratamer Assemble the lhtotlle tabla. carburelct cap lubblr seal and throttle valve spring. \ RETAINER NFEDLE CLIP lEAN JET NEEDLE 2 ,1 NOTCH 1‘ STANDARD ‘ 3rd NOTCH I» RICH THROTT LE VALVE 4 ” 5m NOTCH DilE OI Inue, Mirth, 1954 4.8 c MONDA moron co ,LTD (’3 HONDA ‘ NNSOMD FUELSYSTEM GROOVE Gourmet (he lhrunla cable (a ma Ihruule valve. Slide ‘h: rhroula valve lnlo the carburexor body. NOTE Align the gram: n the vulva pin on the carburetor bod . CARBURETOR TOP hgman mu carburelm lupA Inslun me .121 cleaner case and an duct. Adilm lhronle tabla Imn play (page 318), BED VALVE REMOVAL Remove the carburetor {page 4-3) Remove [ha Intake pipe by removing [he lluee bolls INTAKE PIPE Dan- of Issue: March. 1984 L‘ HONDA MU'IOR CO LTD 4-9 FU EL SYSTEM annvu mu rm vllvn. INSPECTION Chuck lhl Ind vilvl for dlmamd or weak weds. Check the valve seat for cracks, damage or ulurance bnwun 1h. llll Ind and. Rlpllci m- vllvl if necessary. CAUYIOI! 7 [In no! dmmzmblt ur haul the reed Iluppn. Tu :10 so can Pall!“ Ion of power and mgln: danmge. I] III! slappn. reed or 1'11le .mn LI faulty. u‘plaa' [hem as a unit, INSTALLATION The imtallaxion unuanm is essentlallv mu r-v-m order or rlmovll. Am: inslnHaxion. check lor secondary leaks REED REED VALVE SEA] REED STOPPEH 4-10 Dale 0! Issue: Mavch, 1934 c HONDA MOYon co .LYD f3 HONDA \fifé/ NNSOMD 5. ENGINE HEMUVAL/INSTALLATIUN SERVICE INFOFIMiATION 7 5—1 ENGINE REMOVAL 5—2 ENGINE INSTALLATION 5—4 SERVICE INFORMATION GENERAL The engine must be removed Io service (he crankshaft, SPECIFICATIONS Engine weight I? kg (26.5 lb) TORQUE VALUES Engine mountmg bolls. 24—30 N m (2.4—3.0 kg-m, 17—22 [I In) Rear ax|e nu!‘ 50770 N‘rn (5,077.0 kg~rnI 367751 h~lb| Date 09 lswu. March, 1934 c HONDA moron co .LTD 5-1 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Rumnve the ma! skin and engine covi‘r [Section ‘0) Remnvn [hp ugh! and 10" how Su‘le cove! (Scttlon 10‘ Rmse me my whacli by placmg suppun blocks unnar ma englm.’ and l'u: vighl and left frames ran; Rumuvc me rear wheels (Page 12-?) DISCOnnnCY m! ham-w ground cable from the balmy nuguuve lermmul Ramnva the Icrew remlmnq Im- harness coupler box (0 lhu hmnev ancnnnncx [he ahemaxor. 51mm. and auto by signer couplers and connectors. Chuck mm m pamng loch lever :5 nrnwan dawn m mu RELEASE Dosmon msmnnm mp palklnu mt! by mmovung [hp rod mu Duconnacl the nth Ind Ieh mar hvike came; K \HONDA “vb! NNSOMD COUPLER BOX PARKING HOD REAR BRAKE CABLE Dam o! Issuer March‘ I984 C‘ HONDA MOTOR CO ‘LTD ENGINE REMOVAL/INSTALLATION MUF F LE R AIR CLEANE R CASE SEPARAYOR PROTECTOR Remove the air ducL ' I Remove the mumer nrorector and muffler [Page 6-2‘, Remove the air cleaner case (Page 2-2). Rumova tho aparuror (Page 6-2) 4‘ A AIR DUCT MUFFLER CARBURETOR CAP OIL PUMP CONTROL CABLE Tum the lual valve OFF and disconnect the fuel line a! the carburetor. Disconnect the oil lines Iran the oil pump and allow the all ten drain Into a clean eonninar, Disconnect the on pump control cum. (ram the oil pump. Remove the carburetor can Unscrew the three engine mounting bolts, and removo the englne from the frame. Date or Issuat March, 1984 t: HONDA MOTOR CO .LTD 5'3 ENGINE REMOVAL/INSTALLATION Remove the Mo dowel pins (mm m: xwmg joint ENGINE INSTALLATION Installation nquanca Ii uwnllllly (hl rlvnm ordlr cl removal. TOROU ES: Engine mounting bolts: 24—30 N‘m (2.4—3.0 kIM, 17—22 lb“) Ru: whul nun: 50—70 N-m (54,—7.0 RM. 3541 I511) Parlour: [he (allowing inspections and adiusimnms Ihnr imullllinn. - Wive and cable routing (Page 1-7). Thronla Ind ail puma control cable Idiunmnms (mg. 3-8). Oil pump Needing (Page 2-4). Rlnr hvlkl ndjuumnm (Page 3-10). Panung lock Idpslmem [Page 341) Dan M Issue: Much, 1984 C HONDA MOTOR COHLTD \HONDA NNSOMD MEMO om u'lssuc anch,19m F. HONDA MOTOR CO .LTD n2? HONDA CYLINDER HEAD/CYLINDER/PISTON “ho NNSOMD (330N131; VIA NNSOMD 6. CYLINDER HEAO/CYLINOER/I’ISTON SERVICE INFORMATION TROUBLESHOOTING CYLINDER HEAD CYLINDER/PISTON SERVICE INFORMATION GENERAL assembly. SPECIFICATIONS 6—1 6—1 6—2 6—4 All cylinder head, cylinder and piston su'viDI out be don! wnh (I‘ll angina ll‘lfllIIOd in the frame. Below dlsuumlbly. clean the onglna to prevent dirt Ind dust (rum entering the cylinder and crankcase. Remove all pskut mat-rill from the muting surface: of the cylinder head. cylinder and crankcase. Use cautlon when disassembling and assembling the cylinder head, cylindlv and piston to avoid dam-gmg mam. Clun all disassembled Dam thoroughly belora Inspection. Coat all sliding surfaces with clean Zotroke injector oil beIora ITEM STANDARD mm (In) Cylinder head wntpagc Cylindnr born Pismn 0.0. (4 mm Iron: bottom of piston skirt) Cylmdar-toplston cleavance Piston pin hol- 1.0. Piston pin 0.0. Piston~lo-piston pin clear-rice Pinon ring and all1 (top. lacuna) Connecting rod small end I.D. 41000—41020 (13142—10150) 40955—40370 (13124—15130) 11035—0050 (00013—00019) 10002—10008 (03938-03940) 9394—10000 (03935—03937) 0902—0014 (00001—00006) 0.10—0.25 (0004—001) 14.005—14.015(0.5514-0 5518) 0.10 (0.004) 41.050 (1.6161) SERVICE LIMIT mm (in) ‘I 40.900 (1.6102) 0.10 (0.004) 10.025 (0.3947) 9.980 (0.3929) 0.030 (0.0012) 0.50 (0.02) 14.025 (0.552) TORQUE VALUE Cylinder head bolt 8—12 N-m (0.8—1.2 k9~m, 6—9 (1-!!!) TROUBLESHOOTING Comprouion too low. hard starting or poor parlonnnncl It low loud 1. Loading cvlindor hold gain! 2. Loose spark plug 3. Worn, think or bvokan pinton rings 4. Worn or demon-d cylindor and piston 5. Faulty reed valve Companion too high, ovlrhauting or knocking 1. Excesslvo carbon bulld‘up In cylinder head or on top o) pinon Abnounal moist-piston 1. Worn cyllndar and piston 2. Worn pmon pin or pmon pin hole 3. Worn connecting nod small and bearing Abwmfl nuiu 1. Worn, stuck or broken piston rings 2. Worn or damaged cylinder Date 0! Issue: March. 1984 C HONDA MOTOR CO..LTD / .1 HONDA CYLINDER HEAD/CYLINDER/PISTON $95” NNSOMD CYLINDER HEAD MUFFLER PROTECTOR NUTS A MUFFLE R/SEPARATOR REMOVAL Remove the Iwo bolts and a nut attaching ma mquar prommmn and remove xhc mqucv urolw (av Ramon 1hr Iwo nuxs auachlng my engine cover blackcl, and remnve [he angme cover bracket. ENGINE COVER BRACKET BOL‘IS MUFFLER MOUNT BOLTS MUFFLER Remove xhe two bolls and mu uxhausl plpfl 1mm nuts and Iamnva thu mufllar‘ Afi ~11 of"- EXHAUST PIPE JOINT NUTS SEPARATOR Remove the separator by remnvmg [he (hm: attach mg nun. Due 0| Issue. MiVChl 1934 6'2 (. HONDA MOTOR C0..LTD. HONDA . _/ NNSOMD CYLINDER HEAD/CYLINDER/PISTON CYLINDER HEAD REMOVAL Rumovl m. Inllowmgv - right rear wheel. muffler and "DIVIIOI {Page 52). ' spark plug. - shroud 8 by ramming l muunnng bun. ~ shroud A by removing a mounting boll. Remove the {our cylinder head amching bolts and vlmovl the cvllndur hold. Ramon the cylinder gsket. NOTE m panern in 2-3 Slaps. CYLINDER HEAD INSPECTION Chock ma Cvllndof hand for wurmgn wnh a mmght edge and a Ioelev gauge in [he diveclions shown, SERVICE LIMIT: 0.10 mm (0.004 in) 5H ROU D A SHROUD B ' I 0m 09 Issua: March, 1984 C HONDA MOTOR CO .LTD CVLINDER HEAD/CYLINDEH/PISTON \ HONDA 5513/ NNSOMD CYLINDER HEAD DECARBONIZING Remove lh: carbon demils Irum [ha combustion chamber. Clay; uh: hnd nuke! surf-ca nI lny glskut mnnn-I. CAUTION wlmid damaging III! tombuxrlou chamber mall and make! :wfncm -Rcmuvc turban deposit: frum Ilu.‘ pislun lrmd. CYLINDEH/ PISTON CYLINDER REMOVAL Remnve (he cylinder and cylinder gasket. being carelul nor [0 damage me oinon. CAUTION Du uul pry berm-arr I’M‘ qvllndcl and crank raw or mike (hr fim. PISTON REMOVAL Flue a shop towel Into the crankcasa around the pismrL Ramon Ihl piston pm clip uling I pair of floodli- nose pliers. Press rhe piston pm out of the piston CAUTION - Du nu! damage ur :marrh Ilrz pixrun, ' Do In)! apply side force In Ihc wnncrrlng rod - Du rlul Iv! zinc clip [all mm [In- mukmm PISTON CYLINDER PISTON PIN CLIP 6-4 Date a! Issue. March, 1984 ‘L' HONDA MOTOR CO .LTD (fl HONDA mg/ NNSOMD -' PISTON RING/EXPANDER REMOVAL Remove the piston rings, NOTE Spread each piston tiny and rumove by Ilftlng , It up at a point inn opposite tha gupt f Remove Ihe expandel. CYLINDER/PISTON INSPECTION Check the cvlindav and piston Iov wear or damage Clean carbon deposits «am [he exhaull port Ira CAUTION , , LB“ m)! Scmlt'h or mm' Ihc 'Iiudtr liner , Inspect the cylinder bore Iur wear at three |evelx m " X and Y dlI’DCIIDI'IL Use lhu largest measumnant tu dommma tha amuunt of cylinder wurt SERVICE LIMIT: 41.050 mm H.616 inI CYLINDER HEAD/CYLINDERIPISTON TOP RING SECOND RING ‘ Date 0! Issue: March, I984 C HONDA MOTOR CO LTD CYLINDER HEAD/CYLINDER/PISTON CAUTION Some qvlindrrs urL' marked willl an "A "on the rmnkmsc marlng mrfitrc. when Ilum’ ryh‘rr . this an repIm-rd, [hr Irplurrmrlll mus! be an "A " type. Measun thu putan 00‘ at a point 4 mm (0.16 in) irom the bottom 0! th- skirt. SERVICE LIMIT: 40.90 mm (1.610 In) Calculate the niston~tocvllnder clurunee‘ SERVICE LIMIT: 0.10 mm (0.004 in) Mt-asum the pislnn pm hols LDV SERVICE LIMIT: 10.025 mm (0.3907 in) Measure the piston pin 0.0. SERVICE LIMIT: 9.980 mm (0.3829 In) (‘Alcullte lhe ninvtu~plsmn clearance. SERVICE LIMIT: 0.03 mm [0.001 in) HONDA ‘5 NNSOMD MARK A or NO MARK PISTON PIN HOLE |.D. PISTON PIN 0.0. 6-6 Dlte at lnuu: Much, 1934 c: HONDA MOTOR C0..LTD Q25, 133,3? PISTON RING INSPECTION Measure uch pman ring end gen with a Ianlar giUgI. SERVICE LIMITS: Top/Second: 0.50 mm (0320 in) CONNECTING ROD INSPECTION Instill the bearing and plsron pin in tho connnmma rod small and and chuck Ior Ixccssive play. Manure th- annealing rod small and LD. SERVICE LIMIT: 14.025 mm (0.5522 in] PlSTON/CVLINDEFI INSTALLATION CIean me gaskex surIacos ol the cylinder and crank an. Insull rho expander in the second 7an groove. Align (h: ring ends with "1- lac-ling pin: In rhu ring groovasr Install the top and second rings In their respeclIve ring um with (In muting Ming up. NOTE The non ring I: a kevgtone rlng and is not invading-bl: with flu mum unond ring. Chick [III lit 09 non rlng in the ring groove by passing lhl rim into (In moon to nuke surl am It Is flush wlrh the piston at several poinls around rh- ring. A ring thar will rm comm: mum mu (he ring groov- is dirty and should be cltanrd ar "m m- wrong ring is in rhe groove. CYLINDER HEAD/CYLINDER/PISTON PISTON RING I’ E XPANDE H PISTON TOP RING SECOND RING Du: oI Issue: Much, 1984 C‘ HONDA MOTOR CO .LTD CYLINDER HEAD/CYLINDER/PISTON NOTE Do not rnplace one ring without replactng the ’ I ‘ Olhw. YOPHING SECOND RING EXPANDER / “m PISTON RING MARKINGS' . J IT: TOP \ ZT' SECOND RING PINS He sure the ring and gum an aligned with the piston ling pins m the rlng groavcst CAUTION Ba nm- I/u.‘ mg; :1” nut mime m I/ll'l'l groom over 1/12 Inmu’ng plus to pn-wnl ”NR hrrakagr and plum: and L'ylimlrr tblnage‘ PISTON PIN Din the piston pin and bearing in clun 21traka oil. lmnll the hearing m the connecting rod. and install the piston with [I’ll pilton "Ex" mark facing the exhaust side‘ Install new piston pin clipst “EX" MARK Dan! M Issun: Mirth, 1984 6'8 ‘C HONDA MOTOR CO ,LTD m HONDA 3&2/ NNSOMD Remove the shop towel (mm the crinkcan. Install a new cylinder gasket on the crankcase. Lubricate the piston and cylinder with 2 make all and Install tho cylmdcr nvat tha plston whlle corn‘ " pressing the piston tings. CYLINDER HEAD INSTALLATION Install the cvltndur mm on the cyllnder With a new cylinder head gasket. Install and tighten the tour cylmder head bolts. TORQUE: 4—12 N-m (0.8—1.2 kg-mt 6—9 ft-lb) "‘ NOTE r— Tlghton tho boln m a crmcrnfi pamrn m l 2 3 steps. lllfild” the spark plug and xhroud: A and B Inna” all removed parts in the rEVEIiI on!" of the removal, Purtmm tha lollawlng lnSDeCIIDHS Complession test (Page 3-7). Check cor abnormal engine nolsc, Check (or cyllnder llr lulu, CYLINDER HEAD/CYLINDER/PISTON GASKE I SHROUD B SPARK PLUG CAP Date ul Issue. March, mm C HONDA MOTOR CO .LTD HONDA ALTERNATOR % NNSOMD LEFT HAND YH READ 35-40 N~m (3.5 ~41: mm, * » ,7 2549 mm Du. a! Inua: Much, 1984 7.0 m HONDA MOTOR conuov / A HONDA i‘éé/ NNSOMD 7. ALTERNATOR SERVICE INFORMATION 7—‘I LEFT CRANKCASE REMOVAL 7—2 LEFT CRANKCASE COVER DISASSEMBLY 7—2 ALTERNATOR REMOVAL 7A3 ALTERNATOR INSTALLATION 775 LEFT CRANKCASE COVER ASSEMBLY 7—6 LEFT CRANKCASE COVER INSTALLATION 7—7 G E N E R A L 0 Do not vumovl the pulse generator from the stator base. 0 See Chapter I5 (or all-mater Inspection. TO ROU E VALU E Flvwheel nul 35—40 N-m (345—4.!) kq‘m, 25—29 h-lh) TOOLS Common Flywheel PuIIar 07733—0010000 or 07933 , 0010000 Univ-ml Home: 07725—0030000 Oviver 07749-0010000 Altlchmbnl 24 x 26 mm 07746—0010700 ar PiIoL 25 mm 00774G»0040600 IL) 5 A only) Film. [0 mm 07746—004010) Drivur 0774643020100 Date m Issue: March, I934 ‘C HONDA MOTOR CO [LTD 7-1 ALTE RNATOR {V a? HONDA Q; NNSOMD LEFT CHANKCASE REMOVAL Humuve «he anglnu cavnr, ma In“ my whnal, and the air ducl Remove th‘ mufller. separator, and shmuds (Pane 6‘2) Discunuecl [he left veal brake cable Remove the me halls and ma Ian crankcase cover. LEFT CBANKCASE CDVEH DISASSEMBLY Install \hu Icll cmnkcase covey on [he may wheal; Icmove the run and hunnq can NOTE [ Yhe nul has lehAhund “Heads Prv on m.- circlip. LEFT CRANKCASE COVER BEARING CAP CIRCLIP Dau- of Issue: March, 1934 C HONDA MOTOR CO .LYD Heal the case around the beating CAUTION Mm gluwx lu pram-1 mm 1mm]: why]: (mm/ling the hmwd (use. Thread the nu! onto mu final drive shah just enough to cover the end of (he shah, and :arefullv drivo (he shah and buying out of m. crlnknlla cover uling a mastic hammer. Remuve |he innm bearing. ALTERNATOR REMOVAL leove me la“ crankcase cover (Page 7-2), Remove m.- cooling Ian, ALTERNATOR F|NAL DRIVE SHAFT \ , INNER HEARING Dale of Issue: March, 1984 C HONDA MOTOR (20 [TD 7-3 ALTERNATOR NNSOMD Install the unwursal hnldlv on ma flywhnui, Ind remove me flywheel flange nuL Remnv» the flywheel, NOTE En Cilc'ul no! lo mnpllca me waodnm kav, Roman the loft body m1: cover Unscrew [he screw anachmg (h: couplu box, Ind disconnect the alternator. aulo bystaner and ignition coil couplers and wnu. Disconnect me cabtes hum [he slam" mulur. UNIVERSAL HOLDEN 07725 0030000 A FLYWHEEL FLANGE NUT FLYWHEEL FULLER 07933» 0010000 or D7733<0010000 COUPLER BOX A - . \ STARTER MOTOR WIRE 7-4 Dan: a! [sum March, 1984 C HONDA MOTOR CO .LYD HONDA NNSOMD Remove the ma halls attaching the stator to the crankcaut Ind remove the stator. NOTE - Do nol remove the pulse genaralor from th- Stator hlil. - Avoid damagrng the stator coils Inspect the alternator (Sectron 15! ALTERNATOR INSTALLATION Install the slum in the crankcase alrgmng the cable grommet wuh the aroma In the crankcase Install and trghtcn the two stator bolts. Connect the alternator. auto bystarter and Ignltmn coil couplers and cnnnocmn. Connect thn starter cables tn the starter motar NOTE Route and sacum the cahlus Ind wlres prayer Iv (Page I 7). Install the wnodrufl key m the crankshaft kevway, NOTE Clean the inside and liner hole DI the "VA wheel 0! any burrs and foreign particles Install the flywheel on tho.y crankshalt. Hold the llvwhtcl with lhl universal holdur and torque the nut, TORQUE: 35—40 N‘Il‘ (3.5—4.0 kwm, 25—29 ll-lh) Inmll the Ian and trghten the two In" bolls. Dau- ol lsstrP' Murclt‘ l984 t; HONDA MUIOR CO ,LTD ALTERNATOR CABLE GHOMMET STATOR UNIVERSAL HOLDER U7725~003WOD ALTERNATOR (g2 HONDA $9 NNSOMD LEFI' CHAHKCASE COVER ASSEMBLY Pack Ill cwltlu of the inmv buring with amuse. and drive it imn the h" crankcase cavlr. TOOLS: Dvluv 0771941010000 "In, 10 mm "7146—0040100 Annulmm. 2‘ x 26 mm (”146—00107“) OI Orin! «1149—0010000 Ind Pllot, 25 mm 00116-00508!!!) (U.S.A. only) Pack all cavixes ol the out" buring with gum and arm it one the final drive shaft TOOL: Drivlr 07746 43020100 lnnall me final drive shah. Inmll the circlip. INNER BEARING FINAL DRWE SHAFT CIRCLIP 7-6 Date 0! Issue; March, 1954 ,‘c‘ HONDA MOTOR C0..LTD. (TA HONDA $9) NNSOMD Instill the bearing cup. Insml the mm wheel on the Inn crankcase com and ughmn the mu, NOTE fi 7 7 The nul has It“ hand lhriads. ‘— , [EFT CHANKCASE COVER INSTALLATION Install (ha two doweI pm; on me crankcase‘ Insnll me let! crankcasc nnver on the crankcase and nqhtrn the {we anaching bolls. Reinsull all removed mm m the vevmsc ovdm Ev removal ALTERNATOR NUT (LEFT HAND THREADS) . -~.~‘. LEFT CRANKCASE COVER Dale of 159m? Mavch, 1934 I2 HONDA MOTOR CO ,LTD 7-7 CLUTCH/FINAL REDUCTION HONDA NN5OMD 8-0 M N \ (3.8—4.2 kgrm, 27—3! h‘lbl 2v \/ Dale 0' Issue: March, 1984 C) HONDA MOTOR CO..LTD HONDA NNSOMD 8. CLUTOH/ FINAL REDUCTION SERVICE INFORMATION TROUBLESHOOTING RIGHT CRANKCASE COVER REMOVAL RIGHT CRANKCASE COVER DISASSEMBLY LOW CLUTCH/DRIVE PLATE R EMOVAL PARKING ARM REMOVAL SERVICE INFORMATION GENERAL 0 All clutch/“nil veduclion service can be don: wilh m: mama install-d. SPECIFICATIONS 8—1 OIL PUMP GEAR/STARTER PINION 8—12 B 2 REMOVAL OIL PUMP GEAR/STARTER PINION 8-13 3—3 INSTALLATION 8—4 LOW CLUTCH/DRIVE PLATE INSTALLATION 3—14 RIGHT CRANKCASE COVER ASSEMBLY 8—14 8-9 RIGHT CRANKCASE COVER INSTALLATION 8—16 8—10 \ ITEM STANDARD mm (m) SERVICE LIMIT mm (In) Clutch out-r I.D, 11000—11020 (4.3314339) 1105 44,35) Law much Sun year plan: LD. 23.00—23.03 (0906—0907) 23,1 (0,91) Clutch mm mmknm 1 5 (0,06) ‘ 1.0 (0.04) Clutch swing 1m: leng‘h 43.1 (L7) «,1 11,736) Clu|ch she: Ihickness 1.5 [0.06) 10 (0,04) Cluxch spying cm Ilng‘lh 19.3 (0‘78) 203 (073) 5mm“ “W" Clulch outer I.D. 760046.10 (299272.996) 76.20 (3.0) Second am plate I o 22.93—22.98 10903—0 905) 2230 (0.898) Spnclhgd ml Honda A-nroke oll SAE 10w-4o or Iquilenm OII gummy 150 cc (5.1 oz) TOROUE VALUES Oil drain bull Clulch TOO LS Common Clutch holder Driver Anachmem. 32 x 35 mm Film, 15 mm 590cm Bearing remover set. 12 mm Beavinn removal, l5 mm 8—I2 N-m (0.8-1.2 kgm, 6—9 h-Ib) 38~42 Nvm (1874.2 kw". 27—31 hrlb) 0772443050000 or Equivaltm comm-Icially Ilelnhln In USA. 077494010000 07146—001010] 07746—004031” Bearing (cmovuv, 12 mm 07936 , IGGOIOO 07936 466000! E Removar wuigm Remove: weighl O7936—KCIOSOO (U.S.A. unlv) 07741 —0010201 07936—37 IOZOO (USA. only) Dale 0! (sue. March, 1984 ‘C HONDA MOTOR CO..LTD. a HONDA NNSOMD TROUBLESHOOTING Engine itarls, but scooter won't move I. Warn dutch Ilmng 2. Worn clutch ouier 3 Damaged cluxch 4. Damaged or sailed gear Abnormll nolu L Wm" or seized gear 2, Worn bearing Oil leaks 1. on um um mgh 2, Worn or damaged oil seal 8-2 Duo 01 lnue: March, 1984 C HONDA MOTOR C0.,LTD (j 1HONDA §w NNSOMD CLUTCH/FINAL REDUCTION RIGHT CHANKCASE COVER REMOVAL Remove m- angma uuvlr‘ Remove :hn muffler and separalov (Page 6-2). Drain ail "am [hi “all reduction may use {Pam 3 6|. Remove the right rear brake cable. Suouon mo motolcvclc by nlacmg support: 01 blocks under Me engme and name. lower the park-rug lock mm Remove me ugm bolls attaching me right cvankcase cover to me crankcase and remove {ha cover. Ramove me two dowel nuns and me glikel. RIGHT REAR BRAKE CABLE HIGH] CHANKCASE COVER DOWEL PINS Dan: 01 Issue: March. 1984 L HONDA MOTOR CO ‘LTD CLUTCH/FINAL REDUCTION RIGHT CHANKCASE COVER DISASSEMBLY Pry of! th- circlip and remove [he needle bearing and washer. Remove [he circlip and wuhar and take out the mend clutch and low clulch outer n in Immbiv. Remove the pnmarv dnv: gem and llllusl washen 8-4 NEEDLE BEARING CIRCLW WASHE R PRIMARY DRIVE GEAR THHUSI WASHER Dav: oi |ssuuv March, 1984 C HONDA MOTOR CO .LTD CLUTCH/FINAL REDUCTION ( HONDA \ ( 33y NNSOMD K‘\ Straighten the tabs 0! the lock washers and remove the lhru bum alt-china xhu mclm plnn, Harm" the menu plots. 3 A Remove the washer and primary driven gear Hlmovu (ha (in-l dli" an! and thrust wash-r. /‘- fl-mova (he final driven gut Ind final drwa shah. RATCHET PLATE THRUST WASHER 53 FINAL SHAFT LOCK WASHERS AND BOLTS Daxe 0' Issue: Mavch. 1984 O HONDA MOTOR C0.,LTD CLUTCH/FINAL REDUCTION Remove the snap ring and ramovo [In bearing wnh mm (nah: Baring anu. 15 mm Wm—KCINOO (U.S.A. MIVI Rumour mint 07339—87102“) Remove the ail seal. GEAR/GEAR SHAFT INSPECTION Inspect ma gums and gear smlls (or signs of wulr or dim-g0. HONDA NNSOMD SNAP RING BEARING OIL SEAL FINAL SHAFT I FINAL DRIVEN GEAR Om a! Isms: Mlmh, 1984 I‘D HONDA MOTOR C0..LTD. CLUTCH/FINAL REDUCTION FINAL DRIVE GEAR Insnccr [he Iinal drive and primary driven gears lur Slgns or wur m dlmnqq. I PRIMARY DRIVEN GEAR lnsoccu the right crankcase cover for wear or dam- age lo m. hearing bum. SECOND CLUTCH INSPECTION Measure the dumb lining thicknaxs. SERVICE LIMIT: 1.0 mm (0.06 in) Check cam clutch mo- Sprlnu Iur war or damage, To rupllce the springs, remove me E-cllps, washers and clutch shoes. Dale oI Issue March 1984 C HONDA MOTOR CO ‘LTD 8'7 CLUTCH/FINAL REDUCTION Manlula m clutch spring In: Inngm. SERVICE LIMIT: 20.3 mm (0.30m) LOW CLUTCH OUTER INSPECTION Check the clutch oumv Iov wear or damage. and measum the ID SERVICE LIMIT: "0.50 mm (4.35 in) Inspccl {he nudlu having for wur or durum Ind replace ll necessary. SPECIAL TOOLS: Bearing amour int, 12 mm 07936466001 0' Burma nmmu, 12 mm 0133—1860100 Roman! waist“ 07936-37!on (U.S.A. only) Dvive lhe inner needle hearing In so that It is 2! mm (012 in) below tho and of (ha rotor cIulEh ouurl 3mm(0l121nI lnspecl me menu pawl; for mu m dumagn. Ruplacn Ihen il "my bind or have broken swings. Measure me sun gear DIM: I.D. SERVICE LIMIT: 23.10 mm I031 in) C HONDA ® NN5OMD FREE LENGTH RATCHET PAWLS 8-8 Due of Issue: Malnh, 1984 C HONDA MOTOR CO.,LTD (A HONDA *ik‘é/ NNSOMD Manure mg second dnve plate I.D. SERVICE LIMIT: 22.80 mm (0.893 In) Inspect each planetary gear lov wear or damage flaplaca Il necassarv. LIJW CLUTCH/DRIVE PLATE REMOVAL Remove me right crankcase cover (Page 5.3). Hold an drivl plul wnh tho clulch hold-r Ind remove the clutch lock nuL NOT E The clutch lock nm hzs Ian-hand threads. Rernove the low clutch/drlvo plate. Dale 0' Issuev Murch‘ 1984 C HONDA MOTOR CO .LTD CLUTCH/FINAL REDUCTION CLUTCH HOLDER 077247 0050000 av Equivalent cammerclallv mum. in U.S.A. LOCK NUT (LEFY HAND THREADSI LOW CLUTCH] DRIVE PLATE CLUTCH/FINAL REDUCTION LOW CLUTCH INSPECTION Measuvc me cIulch linIng lhicknass. SERVICE LIMIT: 1.0 mm (0.04M) Inspacl the ciulch swings Ior wear or damage II replacement is necessary. remove lha E-chps, washers, and clulch man. Measure each clulch shag Ipnng Irn Ilnglh. SERVICE LIMIT: 44.1 mm (1.74 In) SECOND CLUTCH OUTER INSPECTION Check the second clutch outer Ior wear or damage Measure the I D SERVICE LIMIY: 76.20 mm [3‘0 In] PARKING ABM REMOVAL Ramon the right crankcase wvnr (Page 8'3). RIIIISI lhl wring hook Irom 01- um Ind rlmovl the parklng mm and arm shah, Q \HONDA ‘8“; 9/ NN50MD E CLIP/WASHER CLUTCH SPRING ARM SHAFT SPRING PARKING ARM AND SHAFT 8-10 Date of lss'uI: Maren, 1934 c HONDA momn co ,LTD HONDA NN50MD CLUTCH/FINAL REDUCTION Remove xhe nut from me left end of the parking xhafl. Remove the pavkiuq shafl‘ PARKING ARM/SHAFT INSPECTION Inspect (he parking arm, sham and sprung [or weal or dnmaga. PARKING SHAFT ARM SHAFT PARKING ARM PARKING SHAFT Dale of Issue‘ Mi'Ch, 1934 C HONDA MOTOR CO LID CLUTCH/FINAL REDUCTION {j 5 f;\/ HONDA fi‘é-v/ NNSOMD OIL PUMP GEAR/STARTER PIIIIOII REMOVAL Remove (he low clutch/drive plan: (Page 8-9). Ramovn ma ml pump dnu gur. Remove “1“ parking arm assembly (Page 840) Human ml your hold-r by vamovmg lhu nuchmg bulL Ramon ma nil pump driven gem and ma mrm pinion, STARTER FINION INSPECTION Check Ihal ma Slafler mmon mums only In one direcliun. Alsu chuck mm (In: gear velums freely. OIL PUMP DRIVE GEAR STARTER PINIDN HOLDER PLATE PARKING ARM ASSV STARTER PINION ‘3 8-12 Dan- M lssus' March‘ l984 C HONDA MOTOR CO .LTD (“A HONDA ~3® NNSOMD OIL PUMP GEAR/STARTER PIIIIIIII INSTALLATION Install the mmr DlnIDn. Grease the all pump drlvun gnr math and mating sud-us Ind insu" the gear. Install (ha drlvnn guy holder plate and nghlan lhu bolt. Install the narklng um assembly in the neverae order of rammal. I Install (In: oil pump dnva 9m. CLUTCH/FINAL REDUCTION STARTER PINION OIL PUMP DRIVEN GEAR GEAR HOLDER PLATE Dale of Inue. March, 1984 l'. HONDA MOTOR CO ,LTD CLUTCH/FINAL REDUCTION ( flHONDA ‘359/ NNSOMD LUW CLUTCH/DRIVE PLATE INSTALLATII'JII Ins‘all the low clutch/drive plan: on ma crankihuh. Hold the drive plate with ma :quch holder and tighten me luck nut. TORQUE: 38—41 N-m (3.3—4.2 kn—m, 27—31 h-Ib) NOTE The lock nul his Im hnnd thruds. EIGHT CHANKCASE COVER ASSEMBLY Install I new oil 5.1!. Drive {he beating in and install [he may ring‘ TOOLS: Oliver 07749-001 0000 Film, 15 mm 07746—004030!) Almhm'nk, 32 x 35 mm 07746—001 0100 CLUTCH HOLDER 07724 0050000 0! equivaIenl commercially I lablu m U.S.A. SNAP RING 8-14 Dew u! Issue. March, mm C HONDA MOTOR CO .LTD F ‘HONDA fig/ NNSOMD CLUTCH/FINAL REDUCTION FINAL DRIVEN GEAR Insull the Inn-l dnva mm and Iinal driven gear. FINAL DRIVE SHAFT PRIMARY DRIVEN GEAR Insull rhc fin-l um: um rhrough ma thrun washer. Insull me primary driven gear and thrusr washer It shown. NOTE 7 r lnslall the thrust washer w h lhu tacing toward (he our de (crankcase). Inn-ll rho ratchet plus using rhroe bolts and now luck washers. Band~up rhc labs of the lock washers. NOTE ~ hghmn rm bolu In the uquenu shown. - Aim insralling the ratchet pIaIe. check “1!! the primary drlvan gear rotates freely Data of lswu: March. 1984 c HONDA moron 00.4.10 8.15 CLUTCH/FINAL REDUCTION Insta” Ihe sun gear glam and primary drive quay I" Ihe Iuw clmch cum. Sllde [he Ihrun washer DMD the final shaft. Install the low clutch outar Install the thrust washer and civclip. Install (ha needle bearing. washer and CIICIID. NOTE ' Ula nuw cuclim‘ ~ Pack me needle heaving with molybdenum disullidu gram. HIGHT CHAIIKCASE COVER INSTALLATION Install the two dowel pins and a new gasket on the crankcase cover mating surllcl. PRIMARY DRIVE GEAR WASHER CIRCLIP NEEDLE BEARING 6 MOLVBDENUM CIRCLIP WASHER DISULFIDE GREASE DOWEL PINS GASKET 6 MOLYBDENUM DISULFIDE GREASE 8-16 Dale uI Issue. March‘ 1934 C HONDA MOTOR CO..LTD HONDA NNSOMD CLUTCH/FINAL REDUCTION Imun me ngm cunkcase cover and hghtcn mu e-gm buns Insluil [he ugh! Duke Cablev Install vhe separator and mumer Install [he enqma cover, FHI [he Inna! rcducnon case wilh (he recommended ml Wage 3-5) Adlusl llluvuav bvakea (Page 3 10’. Check me pavklng lock lever Ree play M the and 01 me lava-r (Pug! 3711), BRAKE CABLE Dale ul Issuc. March, 1384 . C HONDA MOTOR CO .LTD 8'17 CRANKCASE/CRANKSHA FT Dun 0| lune. Match, 1984 9'0 fix HONDA MOTOR CO..LTD (Te gonna 9%». NNSOMD 9. CHANKCASE/CBANKSHAFT SERVICE INFORMATION GENERAL SERVICE INFORMATION TROUBLESHOOTING CRANKCASE SEPARATION CRANKSHAFT REMOVAL ‘ CRANKSHAFT INSPECTION I CRANKSHA FT ASSEMBLY CRANKCASE ASSEMBLY u ThIs Mcuon covm crankcasa ieparillon lo sevvlca mu crankshah. 0 The la|luwmq pans must be removed bciure separating the crankcase. Engine Curbuumv Oil pump Reed valva . Sum" mom! Alternator Cylinder hand and cvhndav Clulch SPECIFICATIONS ITEM ' Connncnng rod big and side cleavancc Ounnecxing rod big end radial clearance Branksha" runout TORQUE VALUES Llnk “app" boll Engine mourning bah TOOLS Special Crankcase Puuor Common Drlvev Amalmlnt. 42 x 47 mm Film. 20 mm Attachment. 37 x 40 mm Film, 17 mm TROUBLESHOOTING Aboomul mlnu noun 1. Worn main [cum-I baring 2. Wom mnkpin bearing 3. Wom final reductian bearIng Socnon 5 Seclion 6 Section 2 Sccunn 5 Section 15 Section 7 Section 6 Section 8 mm (in) 20730 N-m (2.0—3.0 mm. 14—22 It‘lb) 35—40 N-m (3.5—4.0 kg m. 25- 29 ft-Ibl 9—1 9—1 9—2 9—2 9—3 9—4 9—5 SERVICE LIMIT mm Inn! | 0.50 [0.02) 0.04 “10016) 0.15 (0.006) 07935—GJ50w0 (Na! available in USA). or 079374300000 07749—001 00W 07746—001 0300 07746413405!!! 07 746-001 0200 0774643040400 Dllc oI Issue: Match, 1984 C HONDA MOTOR CO.,LTD CRANKCASE/CRANKSHAFT CHANKCASE SEPARATION Remove the crankcase attaching bolls. Somme 1h: nght crankcase half lrom the lull crankcase hull. SPECIAL TOOL Cnnkuu pull" 01935-650000 (No! avallahh in U.S.A.) or 07937—430000!) NOTE Us! “In Ipecul tool "CRANKCASE FULLER" it difficullv is uncounurvd in “naming (m crlnknlu hllvas. CHANKSHAFT REMOVAL Remove the crankshah from me left crankum. CRANKSHAFT 9-2 Dale 0! Issue: March. ‘98.! C; HONDA MOTOR CO LTD F‘~ Q NNSOMD CRANKCASE/CRANKSHAFY Remove Ihu ail seals Imm Ihe light and Ian crank case halves. CBANKSHAFT INSPECTION Manure thn connecting rod big and side clearance mm a leelev gaugcl SERVICE LIMIT: 0.5 mm I032 in) Measure the connecting [Dd big and radial clearance a two nolnts in the X and Y dlflfiIOl’li. SERVICE LIMIT: 0.040 mm (0.0016 In) OIL SEALS LE FT CRANKCASE RIGHT CRANKCASE Date 0' Issue: Mulch, 1984 C HONDA MOTOR COULTD HONDA NN50MD CRANKCASE/CRANKSHAFT 501 lbs crankshah on a stand or Vblocks and read runout uling I dill giugn. SERVICE LIMIT: 0.15 mm (0.005 In) Spln Iha cranium“ hearing by hand and check Ior play‘ The baring must but IIFIIDId if it Ii noisy ar has exceulve play‘ PLAY RADIAL CHANKSHAFT ASSEMBLY Wuh xho crankcase and crankshah In solvent and blow dry wixh compmud nir. Chock for crucks or other hulls. NOTE - Apply clean Invoke Inloctor all to all moving Ind sliding Incl: of flu mnkuu. ' Remove all oaskul nut-rill from lhu crink- cau mung suflam. Dress any voughm or irnnullrilius with In all nanl. Dale of lisua: March, 1984 9-4 © HONDA MOTOR C0..LTD, ( i HONDA $9 NNSOMD CRANKCASE/CRANKSHAFT Drive a new ionrnal bearing inm ma rigm and Ian crankcase hllves‘ Pm: me crankshan Ima the Inf! crankcaw. NOTE Lubvicate the ioumal bearing and connecling rod big and with Honda anoke oil or equiva~ lent. CRANKCASE ASSEMBLY Install and downl pm! mm the crankcnn malmg :uvlnce. D \RIGHT) 0774970010000 STARTER MOTOR INSTALLATION NOTE: Below ”mall-nu lhu slam-r, lcsl us operaunn by connocnng the sinner coupler to the wire "alums. If Install mu starter motor In the nurse order n! removal. D II M h. 1584 15-12 ‘C H323; :UOGTORMCCO {LTD (”g HONDA {$2, NNSOMD SWITCHES/ HORN Remove the hamligm, handlebar cuvur and lag smald, and disconnect the cauplnrs and connaclon. Check me cominuily of each swixnh. Cominuiw should exis‘ between calm coder wiles intimated by inlurcannucled “rd!!! on each chm. IGNITION SWITCH cons coma RED BLACK “firm? DAT! an: 10 on o——o 565$”, 7 7 7 7 7T1); ELECTRICAL EQUIPMENT Date 0! Issue: Mum. 1984 C HONDA MOTOR CO .LTD. 15-13 / f; HONDA ELECTRICAL EQUIPMENT K; NNSOMD To remove mu ignition switch. remova [ha handle- bar upper cover Wm: H 3! and unscrew me two at lachmg scrnws SCR EWS ENGINE STOPiszTCH ENGINE STOP swncu CODE BALCKI COLOR WHIIE IG E GHEEN OFF , RUN O 7 —0 OFF DIMMER SWITCH cone coma Ram/Vii VELUE HL H7 .7 ”' °——9,, 1N) o__oi Lo 0— i TURN SiGNAL SWITCH DIMMER swrrcH 1 con: coma eaev uam‘ BLUE paANGe W H L '7 o———o N C —O HORN BUTTQN PODS COLON LIGHT BLUE GHEEEN Ho E (Hg—1 HOHN BUTTON TURN SIGNAL SWITCH Dal- II a: M ch,1934 15-14 m “0,331 3%Toa'éo..Lm Cg: HONDA “Rs. NNSOMD ELECTRICAL EQUIPMENT STARTER BUTTON CODE COLOR YELLOW/RED GREE _’ 51 s ' FfiEE pus", 7 o——w *1— FRONT/REAR BRAKE LIGHT The much is novmal it "we is continuiw when the brake lever u pulled in. HORN The hum Is comm i! it sounds when a12V baunrv A! cannecled (o the xerminalt STARTER BUTTON Dale ollswe: March. 1934 C HONDA MOTOR C0.,LTD 15-15 [RHONDA ELECTRICAL EQUIPMENT {55/ NNSOMD FUEL LEVEL SENSOR FuFL LEVEL sswson INSPECTION Remove ma luel Iavul sensuv hum me fuel my «page 147 3) NOTE' Do now bznd [he llaal arm GREEN BLUE/WHITE Manure the Insuslanals hevwnen [ha rnrmlnals wuh "II: "0." ll [he UPPER (FULL) and LOWER (EMPTY) positions. ,1 UPPER 1 1‘ ummwnm» Yollnw“ “ 2 1 Gwen whquvwn UPPERIFULU ‘ 3:: 5660 H v v ‘ a: T; 7 V ‘ " V ‘LOW: 1EM1I7 756:: 33 LOWER YELLOW/WHITE FUEL GAUGE INSPECTION Connect xha wuss and turn the lgnmon swnch 0N NOTE: Balm? perlmmmg ma (allowing m1, apatite the [um sugnals l0 dclmminc that the bancw circml is normal Check the gauge needle lor corms! indicalion hv movmq (hi! "on up and down. , fl Neudle posmon Float at UPPER position "FULL" LFIOJI Jl LOWER position “EMPTY“ D l- Ilssuc. March, 1984 15-16 L NSJSA MOTOR CO ,LTD <3; HONDA i NNSOMD ELECTRlCAL EQUIPMENT OIL LEVEL SENSOR 7 ’ INSPECTION Discunnecl the wives and remove the wnsor. anar Inn "on lullv until M will no longer 90. Measure the resistances bemoan the mrmlnals as shown. Resistance Grn-n/ Rid Glélln ; 0 ohm Willi the llnm raised lullv, mum's mo ruin-ne- balwun 1h. mmmalm Ruimnm Grcc/Rcd l Green «in o w {m 09mm the mm signals to see mu m: battery cir~ suit is normal. then perform th- lallowing inspec- NO". Connect the win: and mm m: Ignition twitch 0N. Raise and lower the float to Malta tun flu! "in oil law-I indicnor blink: on Ind v". we: , Slould the lndlcamr fail to go on and cut as rh- llolx is moved up and down, check far I loose connecrlon and rape" llu Ibuve nm~ cedure‘ HEADLIGHT/FRONT TURN SIGNAL HEADLIGHT ADJUSTMENT Adiuu th- nudl‘mhl burn vunieally by turning the adiusling screws on tha lower slde of the rim. Turn the adlustlng Icnws clockwiu to dim "II burn down. CAUTION: A r Ihl lieadlkhl beam as we ed by lam! lows and ugululinm. ADJUSTING SCREWS Dne cl Imus: March, l984 C‘ HONDA MOTOR CO.,LTD. HONDA NNSOMD ELECTRICAL EQUIPMENT FRONT TURN SIGNAL BULB REPLACEMENT Rzmave [he screw and lum slunal lens. SCREW Discard the bluwn bulb Ind lnilfl" a new mm TAILllGHT/REAH TUHN SIGNAL BU LB REPLACEMENT Unscrew the two screws and roman the rear wrn ugnal and (um signal lenses. Dalu cl Isiue: Mavch, 1984 15-18 C HONDA MOTOR CO ,LTD ELECTRICAL EQUIPMENT Replace me Lrulb wnh uvw mm. TAILLIGHT/REAR TURN SIGNAL COUPLER REMOVAL/INSTALLATION Remove bum sldu cum (Pug;- H 4). Rpmnv» m- two nnlu and lallllqhumm signa! mummy. D f | M , 9 KESNSSXLJSS £0830 15-19 MEMO HONDA NNSOMD Dan 01 Issue Match, 1994 c HONDA MOTOR co LTD Sun: | (~11 5m sumo. [_ ”on ma mu smo- v u- 1:.- 41% u. ‘ v- — a I run rm». S‘WL ’ '—F--¢ DG wmnmmK u-A D-L mum smo- mm um um menu- , " vm n. m ummu wt _ wt» cm , mu SWIM. mu m \: v: .- y‘ -n mama Vim‘m '\ “' ._ ~e. .‘ u a I.“ 009 DO .1 MUN WW L rum mm mm urn-mm) M n 5 5‘5 um 54m “,0" ma 51w W: “no. v7 KIND- WIW ‘ 0mm ww- swmu «am me my mum mm mm. smcu mun 5m ‘ mwmd: v g .5 . k m M 0—0 w 00 - 00 - 0+ as: ‘ .u. ‘ . . Q,( Inna-[ma mun onO—O ‘O._.O HO— um I" E M It _ LI 1 D m V Dale 0! Issue: March. 1984 C HONDA MOTOR CO .LTD I. WIRING DIAGRAM :J 13} [354 7 .* 4;;3: ‘01-? T;u 076 OOSOZ—GKO— 6700 16-1 Q; fifififif,‘ I7. TECHNICAL FEATURES SWING JOINT 17—1 REAR BRAKE EQUALIZER 17—9 SWING JOINT PARKING LOCK 17—3 ENGINE 17—10 SWING JOINT LOCK 17—7 DIFF-LESS MECHANISM 17—10 K PARKING LOCK MECHANISM 17-8 SWING JOINT I” G E N E RAL I The "Gyro" has a Ironl Irlml suction and a swing jaim Ior \hc rear frame Section. The Mlng loin! has a pivol IhaI allows rm: from and rur oI mu secular Io more independenrly of each orhar. Thu duign Iels III: from Irame section lean lrom siduo- side thle Ihc rear section can remain Ilnt, nor bring I: angered by cenIriIugal Iorce durIng rurns‘ trauma nI ma :wmg jam vaor. II (ha rwnng iuinr Ind its pivul were not used, the outside rear wheel would bl IIhad during normal Iums by (he mm; M cmlr-Iugal Iorce, CENTRIFUGAL FORCE IF) ON TURN UPRIGHT LOCATION or CENTEFI or \ LOCATION GRAVITY @ OF CENTER\ CENTRIFUGAL FORCE IF) OF GRAVITY‘ W GRAV'T“ ' GRAVITY (WI VECTOR PRODUCT III /‘ TURNNING kn DIRECTION {A TREAD INIDTH TREAD WIETH CONDITION WITHOUT SWING JOINT CONDITION WITH SWING JOINT CONSTRUCTION The swing lnlnr I: In lsilmhlv at upper and lower case-s. ball bearings. a communion cam, a Shlhl Ind I pair ol cumpression rubbers around the cam. This is the basis cl rha "Gyro's" urIIqua nuring sysum. A}? UPPER CASE COMPRESSION RUBBERS ,- BALL BEARING SWING JOINT SHAFT COMPRESSION CAM LOWER CASE BALL BEARING Duo OI que: March. 1984 C HONDA MOTOR CO .LTD 17-1 HONDA NNSOMD 0n: Ind ol the leng loin! ls attached rigidly lu lhe angina and (In mhnr and o! the swlng Joint ls nmchod la lhn Irom Ir-ma mlion and In (In: mar shack Ibwrhu‘ TECHNICAL FEATURES REAR SHOCK ABSORBER SWING UNIT SWING JOINT SHAFT SWING ANGIE Dunng oorrmlng 1h: swing ioinl will mavu lidlwlvl Io axon prossure on the luv wheels by allow-n9 them to movaa small amount in Ihl dirm-on 0' 1h: turn. This amino is called lh- Ming |n|m angle and keeps a balance between [he Iron! and rur wheels Inr smooth cornering, (5H “ 'swmcmme‘c- “ Dateol Issue: March, I984 17.2 0 HONDA MOTOR C0,.LTD HONDA Qk: NNSOMD TECHNICAL FEATURES OPERATION When Ihe scooter comers so that the swing; ioim is routed. the compression rubbers are compressad bv [ha am, Thu oom- prmlon rubb-n than try lo rawm to "Mr onginal lhlpl. Th: mull-r fincompnslion. lhl Sfllllllf Ih' reaction. rvsulling in (he desired nearing under all riding condilions, paniculaily a: very slow speed, or when braking or stopping RETURN RETURN SWING JIJIIIT/PABKIIIG LOCK G EN E HA L This system locks me swlng ioim shah and rur whnsl driv- shift to kuv nu scouts" upright and hem rolling down gradu‘ PARKING LOCK SWING LOCK PLATE SWING JOINT SHAFT SWING LOCK LEVER PARKING BRAKE CABLE COMPRESSION RUEBE R Dale 0' Issues: March, I984 'C‘ HONDA MOTOR CO..LTD. 17-3 TECHNICAL FEATURES Q}: ‘ifififi? LOCK LEVER The plrklng lock Ilvnr u Ineched la a brackex with two mount bolls a! Ihe center ol the Hearing handlebar, Pulling this lever causes the swing and parking locks. To r-luu the loclu, press down on the lever. IGNITION SWIYCH PARKING LINK U‘ PARKING LOCK LEVER PARKING BRAKE CABLE LOCK LEVE R OPERATION A: the lever u pullad up, a roller relates the link LEVER mm and pull! up parking cable. ROLLER LINK ARM when m. lever I: pulled up Iunhoi m that the roller CABLE reaches the position shown, me much" Iorcl (P‘) of the Inn iusl works on (he lever pivm through the "all." (SII Date ol Issue: March, 1984 17-4 :m HONDA moron co..L‘rn. /‘ HONDA % NNSOMD TECHNICAL FEATURES As the lever reaches poinl B. it is aulomalicallv head in position by Force P'. IGNITION SWITCH LOCK The Ignmon lelch um I lock pm lhil works wilh m: ignilion key, Scion Ihl ignition swilch can be luvned lo [he “lock” position with the key. the lock lever must be pulled up. Likawwa, in: parking look luv-v mull bl puihed down before [he ignilion switch can be turned to (he "on" position STOPPE R PLATE LOCK PIN IGNITION SWITCH STOPPE R PLATE LOCK PIN LOCK LEVER Dale of Issue: Much, 1934 ‘C‘ HONDA MOTOR CO ,LTD 17-5 Qééf HONDA TECHNICAL FEATURES , ‘ NNSOMD HANDLEBAR LOCK Pulling up the swing joinl/pnrking lock lava! |ockl (ha hundlahar. A: m- lock laver is raised, the link arm mmu, Dressing dawn an m. handlebar lock rod until il runs against the stopper, illnhllv cnmpvunng [he spnna. LlNK ARM HANDLEBAR LOCK ROD LOCK PIN LOCK PIN STOPFE R PLATE When the handlebar II mrnnd nghl or Ian corn- vlelely lhe luck pin is moved hue of [he “upper and pressed down by spring tension to lock the handler hlr‘ SPfllNG STOPPER PLAT E LOCK PIN Dan: 0! Issue: March, 1984 17-6 ,3 HONDA MOTOR CO ,LTD HONDA NNSOMD TECHNICAL FEATURES /‘ SWING JIIIIIT LOCK CONSTRUCTION Thu swing lock system has I mcnn ml. 3 chain link and a lock Huh. "I: Ming lock plate has six lunlh Ind is located at the hunt a! m- :wmg xhnfi‘ The ratchet pawl, chnin Ilnk Ind lock arm shah are martini-d in tha Ming join: case, f‘ RATCHET PAWL LOCK ARM SHAFT /— RETAINING SPRING RETURN SPRING SWING LOCK PLATE CHAIN LINK JOINT SHAFT ,— OPERATION Whln lhl incur/parking lock lever is yaised. the luck I"?! mow-mum (lrrow) is transmitted "110th a chain link In (in ruchu pawl. causing it in Inglgl am 0! (ha six teeth on the sector. The swing xii-n is shun “cur-Iy Iockod. Thu Ruining wring forcos the naive! pawl inla ennui-mm with an “(nor when the name moves side [0 side, if th- mow men! a! (he swing/parking luck mar fails to lock the shah. RATCHET PAWL IN SPRING RETAIN G CHAIN LINK LOCK ARM LOCKING PLATE RETAINING 395le RETURN SPRING PARKING CABLE Dun a! Issue: March, 1984 c HONDA momn couun 17.7 HONDA TECHNICAL FEATURES NN50MD PAIIKIIIG LOCK MECHANISM CONSTRUCTION Thzs consuls 07 me parking lock wit. puking luck lrmx A Ind B, puking Incl: drwl mm. and puking Iock rod 5; shown. "1- plrkIng lock gut in Int-grind with the drivn shaft parking lock arm A and B are insullad an m- num use emu. PARKING LOCK GEAR PARKING LOCK ROD PARKING LOCK DRIVE SHAFT PARKING LOCK ARM A OPE RATION As lI‘Il swung jolnllurkmg lock lever is raised. a (one lrom xhc lock rod. xhrough [he shall and spring moves parking luck urn B cuunmclockwise. Furlong Inck lrm A mun movu into onwmom with one of the moth on ma parking lock your. A: a bat-Jr up future. me spring will also proper W a! the Inn when [he 1-! whoab m mums lboul In mm (ovumrok- clnulllmg) in cm rho mm is ran-mg on top of any gear tooth, PARKING LOCK GEAR PARKING LOCK ARM B PARKING LOCK ROD PARKING LOCK ARM A PARKING LOCK LEVER mu oi Issue. March, 1984 17-8 C‘ HONDA MOTOR C0..LTD HONDA NNSOMD TECHNICAL FEATURES REAR BRAKE EQUALIZEH CONSTRUCTION A rent brake :qulluar i: bnwaen lhl from brake levar and (ha rear brakes. PRIMARY BRAKE CABLES OPE RATION A nivoung link avm mainlains an equal distribution of baking force from me handlebar brake lever to me mu whnll. LINK ARM To REAR BRAKE PRIMARY BRAKE CABLE SECONDARY BRAKE CABLES TO BRAKE LEVER Dale of Issue: Much. 1984 C HONDA MOTOR CO .LTD 17.9 @: HONDA TECHNICAL FEATURES NNSOMD ENGINE FINAL DRIVEN GEAR CLUTCH /“‘* PRIMARY DRlVE GEAR > Low CLUTCH OUTER POWER new: ‘I H Cunkshah 7 7 1. Clutch l f ‘l 4150~M50rum l 6050*6550mm ON ON SECOND CLUTCH omen Law clutch cular Slmnd clutch cum Prlmlrv driv- gar ‘ ' ' ‘ J ‘ ' I ' i _ Primary drlvan gur P l [ 1 \ CRANKSHAFT Final drlve gear J t CLUYCH Final drlven m: l RIGHT ‘ ‘ Rinhl linnl shun @3135 l , PfiIMARY DR'VEN GEAR Right vurwhul FINAL DRIVE GEAR DIFFLESS MECHANISM RIGHT REAR WHEEL The scooter dou nox have a amen-nun! Instead, [he drlve side rear wheel has a roe-la. The loein ensures pavallel rolling 0! m- mr who-Is, subiliu: mering, Ind prwmu ma uduhpping‘ To oqualiu urn wan, n Ix ldVlllhll to route rear mes at regulav intervals. um 01 Isa": Much, 1934 17-10 rc) HONDA Moron coanv HONDA N N 5 0M D 18. TROUBLESHORTING L ENGINE DOES NOT START OR IS HARD TO START ENGINE LACKS POWER POOR PERFORMANCE AT LOW AND IDLE SPEEDS POOR PERFORMANCE AT HIGH SPEED CLUTCH AND TRANSMISSION POOR HANDLING SWING LOCK OIL INDICATOR FUEL GAUGE STARTER MOTOR ENGINE DOES NOT START OR IS HARD TO START , Check il luel is getting to carburetor by Ioosanmg dram screw GETTING TO CARBURETOR . Try spark lest SPAR K JUMPS . Test cylinder compassion NORMAL COMPRESSION . Start by Icllowrng normal mmng procedure ENGINE DOES NOT FIRE . Remove spark plug DRY 13;1 1sv2 18—3 18—3 1sv4 13—4 18—5 13—5 13—7 18-8 Probable Cause NOT GETTING T0——.lll CARBURETOR IZl (3| (4) (5) (6) WEAK OR NO SPARK——>lll (2) (3| (4) (5) (El l7l LOW COMPRESSION———’lll (2) (3) Ml I5) (5) ENGINE FIRES BUT———’I1l SOON STOPS I2) (3) l4) WET PLUG————>(ll (2) l3) [4) (5) Not quI \n Iuel tank Clogged Iuel line to carburator. vacuum tum up In rnlat pipe, or Incl pipe Clogged "oat valve Cloggad fuel tank up breather hole Clogged Iuel strainer Clogged Iuel Iiltcr Faulty spark plug Fouled spark plug Faulty CDI umt Flully illemilol Broken or should tp-rk plug wrr: Braken or shorted rgnrtrcn Coll Faulty ign‘mnn swrtch Stuck wston rungs Faulty or duerioratcd reed valve Worn cylinder and prston nngs Faulty cylrndar or cylinder head mung Compression Isak put crankcase Leakrng cylinder I‘M gasket Faulty auto bystaner Arr leaklng put InIikB pipe Improp-r ignilion timing Carburetor air scraw out of adiustmant Carburetor overlloodnd Faulty luto bystarter Thraule valve excesswely npcn Water In luel llnl Fuul deteriorated In Heat charm I!!! Date of lawn: March. 1984 O HONDA MOTOR COWLTD. 18-1 YROUBLESHOOTING HONDA NNSOMD ENGINE LACKS PflWEH I. Lightly localerate engine ENGINE SPEED lNCREASES 2. Check ignition timing CORRECT 3. Test cylindnr onmprmion by operating the slivlar NORMAL 4. Duck carburetot lor clogging NOT CLOGGED 5, Remove spark plug NOT FOULED OR DISCOLORED Bi Cnack ll engine overheats NOT OVE RHEATED 7. Yrv rapid acceleration or run at high speed ENGINE DOES N07 KNOCK Pruhlbll (‘Jme ENGINE SPEED DOES NOT‘H‘I) INCREASE SUFFICIENTLV (2) I3) (4) INCORRECT—u“) (2) Too LOW ———‘>III (2) (3) I4) CLOGGED g FOULED OR DISCOLORED—bll) (2) OVERHEATED El” (2) l3) (4) l5 ENGINE KNOCKSgfll l2) l3) l4) (5) Clogged air cleaner Rmrictld tuel flow Clogged luvl link up hruthnr hull Clomd mulflnr Faulty CDl unit Fnulty alternator Worn cylinder or piswn rings Blnwn cyllndlr nud gasket Flaw: in cylinder Dr cylinder hlld Faulty or deleriarltod rand valve Carburelur not urviced Irv quently enough Plug not enough Uta or plug with Impraper heat range Iarvlce Irequenlly Worn cylinder or piston Fuel-air mIXXUIB too loan Use 0! improper grade at 1qu Excaniv- carbon buildup in combustiun chimblr Ignition timing too advanced Exmsive carbon build-up in cumbustion chumbar Use of improper grade of luul Clutch slinging Fucl~arr mixture (00 lean ignition timing too aarlv 18-2 Dale oHssoa: March, 1984 Q HONDA M070)! C0..LTD ‘ HONDA \:§§‘§,/ NNSOMD TROUBLESHOOTING POOH PEHFflHMAllCE AT LOW AND IDLE SPEEDS 1. Check igmtion liming CORRECT 7 Check carburetor air wrew lov proper adjustment CORRECT 3. Check if an is laakmq put tntaku pipe NOT LEAKING 4 Try spark test GOOD SPARK Probable (hula INCORRECT—5(1) Faulty CDI unit (2) INCORRECTqblll (2 LEAKING——-l1l (2) l3) (4) WEAK OR lNTERMlTTED—‘(ll SPARK POOH PERFORMANCE AT HIGH SPEED INCORRECT—H“) 1 Check ignition timing CORRECT 2 Duconnact lual tube It (ucl valve FUEL FLOWS FREELY 3 Remove carburetor and check tor clogged iau NOT CLOGGED (2l (le (4) (5) (6 (2) FUEL FLOW RESTRICTED—H1! CLOGGE D — (2| (3) Flultv Iltlmltor Full-ll! mixture too rich (Screw out to conect) Fual-air mixlum too lean (chan on to contact) Duerioratod insulator gasket Lnnse urhuramr Deteriuvatcd Intake pipe gasket Datanaratm insulator O-ring Faulty, carbon or wut loulod spavk plug Faulty CDI unlt Fiully lllemitm Faulty ignition coll Hmkan or Inonod high mutton will: Faultv ignlllon switch Faulty CDI unlt Faulty alternalol No (uel in luel tank Clogged luel tuba or luel litter Clogged lucl tank cap bleathet hole Clean Bit! 0’ Issue: Match, 1984 l'. HONDA MOTOR CO..LTD 18-3 TROUBLESHOOTING / HONDA figs-:2 NNSOMD CLUTCH AIII] TRANSMISSION Probable Cause I. II anglnl II": In.“ scomar does "OI still ——'—‘—'—’I“ 12] (3) [4| 2, II scooter creeps or engine mm but flaHS—> (rear wheels rolara at Idll) Pflflfl HANDLINE LOSS OF CONTROL I. lfnnrmguhuvy m c ‘ (2! Check lire pressure 2. II «mm wheel is wobbllng————>I1l [2| [3’ 3 II m- xcoour polls to cm iide ——>(Il (2D POOR FRONT/REAR SUSPENSION PERFORMANCE 1. II suxpnnslon ls ton Ioh (ll (2) 13) 2 II mpansmn Ii mo hard ' I) 3, II xuspanslon Is noisy (I) I?) (3) POOR BRAKE PERFORMANCE ‘l, lfwelr mdlcalnr arrow aligns wllh lmlex mark on brake panel—DH) (2) (3) (4) 2. II mhnr brake IS squlalinu ————>m (2) (3) 3. II brake performance is poor———>II) l2 (3) (4’ 59mm": clutch lining: Loose clutch drive plan: nut or damaged Spllnm Damaged transmission Seized lransmlssmn Broken shoe spring Probahla Cause Slcorlng head adiusler too tight Damaged unrmg canal or nnl balls Excasma wheel bearing play Bern rim Loose axle nuv Ben! Ironr Iork Twrstnd jainl shall buckel. cracked or damaged mourn vuhhu Prohahla Cause Weak spring Excasslve load Leakv damper seal Ben! fork or shock rod sum" hlnqu Damaged shock stopper rubber Loose 4351mm Prnhahle Causn Worn brake shoes Worn hraka cam Worn cum cunlacllllu Ian.- 01 shoe Worn brake drum Worn brake shnu Foreign miller on make lining Rough shoe contam lace nl bflkl drum Mrndimrad or snatched brake cable Brakl shun pamally contacting brake drum Mud or will! In brake drum Brake linings (ouled with grease or an Dale 0' Issue: March, 1984 C: HONDA MOTOR CO ,LTD C - HONDA i» NNSOMD TROUBLESHOOTING SWING LOCK Probable Cause Ii) 12) [3) I H parking lever ix ml locked 2, ll parking lever does no! release or I: sluggish—fl!) (2) (3) 3 ll parking brake is nor locked with Ming mechanism locked —’Hl (2i (3) " m 4. Il parlurrg lever can be reiurrred wilh rgnilron swiich ln—DU) LOCK position. (2) (Si Imuroplrlv Idluned cable Broken or matched cable Damaged plrklnn mum spring on swing case side Excesiive cabh nliy Damaged return spring Cable :llp comma a" wing lack lever Cable nDl Idxusled properly Broken or disconnected rod harwun mlng lack mu plrklng luck Damaged parking lock arm pawl Darn-god puking gear Ieulh Deformed or damaged “opp-r Blit- Twisted or damaged parking lever Ihnh Wurri lriclion surlacc between parking rem man and mapper Dlale Dara arr-m: March, 1934 c HONDA MOTOR CO..LTD 18-5 TROUBLESHOOTING DIL INDICATOR HONDA NNSOMD Qt, INDICATOR DOES NOT LIGHT WHEN IGNITION SWITCH IS TURNED ON OR NO OIL IN TANK Probable Cause IV Check battery circuit by operating rum lignals SIGNALS OPERATING CORRECTLY (60—120 flashes/mm) 2 Remove tmtrumontl anrt connect black wlrc to battery positive terminal and green wire to negatrvu lurmlni) LED LIT 3. Check for loose. disconnect or Improperly cannaCIad termtnal CORRECT 4' Remove all level sensor and check ODI'iIIOH FloaI up. Indicator 0" Float down: indicator on CORRECT SIGNALS DIM, REMAIN—DH) ON OR DO NOT OPERATE I2) 13) [4) l5) LED DOES NOT LIGHT—fin) l2) INCORRECT—_DI1) l2) l3) INCORRECT—all) l2) Blown Iusl Weak or deal battcvv Faulty )gnltlon Iwrtch Disconnected wire connector Broken wire harness Loose connection Flulty LED 0! LED drive EII'CUII Loose or disconnected terminal Broken wlre harness Incorrect connection Stuck Iloat Intern-l tlult INDICATOR LAMP REMAINS ON WITH SUFFICIENT OIL IN OIL TANK (IGNITION SWITCH 0N) Wnblhll Cum: INCORRECT ———’ll) Loose or disconnected termlnal l2) Broken wire harness 1 Check Ior loose. rtitconnocted or improperly connected terminals CORRECT 2. Disconnect the green! red wrrn ll rnstrumantx LED GOES OFF 3. Remove all IIVII tumor and check operation: Float up: Indicator of! Flo-t down: Indicator on CORRECT 4. Check Ior delarmed tank or Iorergn matter In tank III) Incorrect connection LED REMAINS ON———>ll) Faulty LED drive circuit INCORRECT—>I1I Jlmnud or stuck float (2) Broken or sensor shorted indicator Date oI Issue: erch, 1934 lcl HONDA MOTOR CO.,LTD ‘ noun ‘3, NNEOMD TROUBLESHOOTING FllEL GAUGE POINTER DOES NOT REGISTER CORRECTLY (IGNITION SWITCH 0N) Pratt-bl: (Inns: 1. Chuck battery cucurt by operating lurn slgnals SIGNALS OPERATED PROPERLY 2‘ Remove Iuel level sensor and check lor operation by movrng llnat Flual up. Painter a! FULL Float down‘ Pointer at EMPTV POINTER DOES NOT MOVE 3‘ Short lhb oven tank unit tannin-It an wtu hlrness side POINTER NOT MOVED 4‘ Check lnr loom, disconnected or Incorrectly cannoctad tannin-Ir SIGNALS DIM. REMAINED—HII ON OR DID NOT OPERATE l2) (3) l0) (5) POINTER MOVED——————> POINTER MOVED— INCORRECT ———>(I| l2) I3) Blown fuse Walk or dead hattarv Faulty ignition switch Disconnlctld llrminll Broken wire harness Faulty llual Broken or shorted balancing coil CDII Disconnected terminal lncorrecrly connected tannin-Ir Shanna or broken balancing call/lead POINTER FLUCTUATES OR SWINGS VIOLENTLV (IGNITION SWITCH 0N) Probable Cause 1. Check bllllry :Irmm by uperating turn signals SIGNALS OPERATED PROPERLY 2. Remove unk unit and check for operation by moving lIn-t POINTER MOVED 3. Mon flout up Ind down rapidly (up and-down stroke/sec) POINTER MOVED 4. Checked each connector CORRECT SIGNALS DIM. REMAIN IT) ON OR DID NOT OPERATE (2) (III (4) I5) POINTER DOES NOT MOVE—> POINTER DOES NOT MOVE—p INCORRECT—HI) l2) Blown Iun Weak or dead battery Brokan or shun-d Ignition switch Luau nr discunnecled terminal Broken wire harness Loose or poor connecllon‘in fucl level ”mot Lack of dumper oil in meter Loose or dIsconnocud tannin-l Short“! or broken balancing coil/lead Date 0! Issue: March. 1984 C‘ HONDA MOTOR CO ,LTD 18-7)] <7 HONDA TROUBLESHOOTING fig NNSOMD STARTER MOTOR v ¢ "i STARTER MOTOR DOES NOT TURN I onblbla Cause ‘ I. Check operatIon a! brake slop liqlu DID NOT GO IBM—‘91” Blown lam - by oparnnng huku (2) Weak 0' dead banerv Ax (3) Faully stoplight switch ' ’ WENT ON M) DISCunnIcIld urmmal (SI Brokcnm shorted ignIIionswitch . 2‘ CHECK hllury clrcuu by operating SIGNALS DIM. REMAINED————> Dead hungry ’ tum signaIs ON OR DID NOT OPERATE SIGNALS OPERATE PROPE R LY (SCI-I 20 flashes/mini 3‘ Chuck slim" rnlny Ior sperm-on ABNORMAL—#III Poorly camaclcd Starla! switch by denmssing 51mm human (2) Broknn or nhonad lunar ralav (3) Loam conncclm or terminal NORMAL 4. Ten starlet by connecling il lo DID NOT TURN——>III Warn mums: bunny (2) Bmkeu m shaded mmr wind "'9‘ TURNS (3) Evoke" slim" molar win ; (4) Loose (ermlnai , fl. . STARTER MOTOR TURNS SLUGGISHLY 0R FAILS TO CRANK ENGINE I Probable Came I. Chock battery cucun by operanng SIGNALS DIM, REMAIN ———> Dead battery luvn xignili ON OR DID NOT OPERATED AT ALL SIGNALS OPERATED PROPE RLV 2. Conn-cl mmr molar nub wires TURNED PROPERLY ———>(l) Loose connactor/termiml acvoss balmy wminals (2) Poorly contacted 5mm veIav OPERATES NORMALLY -———>(1) Brokun or snarled suite momv windings ‘\ (2) Flully lunar pmlon STARTER WONT' STOP Probable Came ’ 1. Tum lgnimn Much OFF STOPPED ———> Pinion stuck out , DOES NOT STOP * Starter relay snarled or stuck closed '\ One of luuu: March, 1984 X: HONDA MOTOR C0.,LTD. .uv: .