SHOP MANUAL NXEDM EXPRESS-SH HCMLU PRINTED 1N ‘ IMPORTANT SAFETY NOTICE Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed. 0N Indicates a possibility oi personal injury or equipment damage if instructions are not followed. NOTE: Gives helpful inlormation. Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all con- ceivable ways in which service, whether or not recommended by Honda might be done or oi the poss- ible hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Any« one using service procedures or tools, whether or not recommended by Honda must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service method or tools selected. (F) HONDA fig NXSOM HIIW T0 USE THIS MAIIIIAL This shop manual describes the technical fea~ tures and servicing procedures for the HONDA NXSOM EXPRESS-SR. Sections 1 through 3 apply to the whole motor- cycle, while sections 4 through 13 describe parts of the motorcycle, grouped according to location. Find the section you want on this page, then tum to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration and all the required specifications, torque values, general information, tools and troubleshooting for the section, The subsequent pages give detailed procedures for the section: If you are not familiar with this motorcycle, read the TECHNICAL FEATURES in section 14. If you don‘t know the source of the trouble, go to section 15, TROUBLESHOOTING 1982 service inlormation is in section 16. ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS IN- CLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT IN. FORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING, HONDA MOTOR C0,, LTD, RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITH- OUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PER- MISSION. HONDA MOTOR C0., LTDT SERVICE PUBLICATIONS OFFICE GENERAL INFORMATION ll LUBRICATION E MAINTENANCE El FUEL SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/CVLINDER/PISTON Ia I“ Z 6 A.c.OENERATOR Z ‘“ DRIVE AND DRIVEN PULLEV/ KICK STARTER/CLUTCH FINAL REDUCTION El cRANKCASE/CRANKSHAFT E. g STEERING/FRONT WHEEL/ a FRONT BRAKE/FRONT FORK E REAR WHEEL/REAR BRAKE/ U REAR SUSPENSION ‘ ELECTRICAL EQUIPMENT IE TECHNICAL FEATURES 1‘ TROUBLESHOOTING IE '32 NX50 ADDENDUM : Dlte oflssue: Sept.,1981 © HONDA MOTOR 60., LTD. HONDA NXSOM GENERAL SAFETY 1—1 SERVICE RULES 1—1 SPECIFICATIONS 1—2 TORQUE VALUES 1—4 LGENERAL INFORMATIBN TOOLS 1—5 MODEL IDENTIFICATION 1—6 CABLE & HARNESS ROUTING 1—7 GENERAL snrm If the engine must be running to do some work. make sure the area is Mll-wntllaled. Never run the engbre in a closed arm. The exhaust contain:- poisonous carbon monoxide gas. Gasoline is extremely flammable and is expluu‘ve under certain conditions 00 no! make nr allow flame: or sunk: in ynur working area. SERVICE RULES The battery electrolyte contains sulfuric add. Prater! yaur eyet‘, skin and rlallring. In case Itfmntart, flush Ihamugllly with water and call a dncmr if your eyes were exposed. The ballery (enemies hydrogen gas which can be hkhly explaxivc. Do not make or allow flame: or sparks near the battery. especially while charglnx in 1. Use geniune HONDA or HONDA-recommended parts and lubricants or their equivalent. Pam that do not meet HONDA‘s design specifications may damage the motorcycle. , Use the special tools designed for this product. 9.)» . Use only metric tools when semeing this motorcycle. Metric holts, nuts, and screws are not interchangeable with English lastenars. The use at incorrect tools and lusrennrs may damage lhe motorcycle. 4. Install new gaskets, Orrings. cutter pins, lock plates. etc. when reassembling. 5. When tightening baits or nurs. begin with largerdiamerer or Inner bolts rust, and llghlen to the specified torque dia- gonally, unless a particular sequence is specified. 6. Clean Darts m cleaning solvent upon disassembly. Lubricare any sliding suriaces before reassembly. 7. Aiter reassembly, check all parts for proper installarion and operation. Date of Issue: Nov” 1980 © HONDA MOTOR (20.. LTD. 1-1 GENERAL INFORMATION HONDA NXSOM SPECIFIBAIIIIIIS Cylinder arranwmant Bore and stroke Displacement Compression ratlo Iransmissinn nil capacity Oil tank capacity Lubrication system IYEM DIMENSIONS Overall length 1,568 mm ( 61.7 in) OveraII width 620 mm I 24.‘ in) Overall height 930 mm ( 38.6 in) Wheelbase 1,095 mm ( 43.1 in) ‘ Ground clearance 110 mm ( 4.3 in) Dry weight 57 kg (1256 lb) FRAME Typl Back bone l F. suspension, travel Telescopic fork, 50 mm (1.97 in) R. suspension, travel Swingarm, 39 mm (1.50 in) Vehicle capacity load 32 kg (180 lb) F. tire size, pressure 2.75lev2PFl , 1.5 Irg/cm2 (21 psi) a. tire size, pressure 17540.2“ . 1.75 kg/cm2 (24 psi) ‘ F. brake Internal expanding ‘ R. brake Internal expanding Fuel capacity 3 (Z (0.79 U.S.gal. 0.66 Impvgal.) Fuel reserve capacity 0.85 ll (0.22 U.S.9al. OAS lmp.ga|-l Caster angle 25°30' ‘ Trail-length 65 mm (2.6 in] Front fork grease 11 g (0.4 01:) ENGINE Type Air cooled 2-stroke Single cylinder (lat 40 x 39.3 mm (1.57 x 1.54 in) 49 cm’ (2.99 min.) 7.3 : I 90 cc (3.0 U.S.oz, 2.5 Imp.oz) I.2 lit. (1.27 U.S.ql, 1.06 lmD.ql.l Forced and wet sump Alr screw initial setting Float level Port timing Intake Open Rand valve controlled Close Reed valve controlled Exhaust Open 57° (BBDC) Close 67' (AEDCI Scavenge Open 47" (BBDCI Close 47° (ABDC) Engine dry weight 16.4 kg (36 lb) Idle speed 1.800 rpm CAHBUNETION Carburetor type Piston valve ldentifiution number PA 13A 1-16 turns out 122 mm (0.48 in) 1-2 Date of Issue: Nov.. 1980 © HONDA MOTOR (20.. LTD. HONDA NstM GENERAL INFORMATION ITEM DRIVE TRAIN Clutch type Automatic dry mnuiiugal clutch Primary reduction V-Belt Gear ratio 2~ 1:1 Final reduction 10244:! ELECTRICAL Ignition Condenser capacitive discharge ignition (CDI) Starting system Starting matar and kick start»: Generator A.C. Generator l2V tam/5,000 rpm Spark plug NGK: BF~5HS (BF-4H5, BP«6HS) ND: W16FP (W14FP-L, WZUFP) Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) Ignition liming "F" mark 15° BTDC Buttery capacity 12V4AH Fuse apacity 7A LlGHTS Headlight Low/High 25/25W Tail/Stoplight 3/27W 3/32 cp SAE No, 1157 Spudamutar light SAW 2 an SAE No.57 High burn indicator 1.7W 1 CD SAE No. 53 Turn signal From/Hear 23/23W 32/32 q) SAE No. 1073 Turn signal indi-tor 3.4W 2 an SAE No. 57 Date of Issue: Nov., 193) © HONDA MOTOR 00., LTD. 1-3 HONDA GENERAL INFORMATION NXSOM ENG I NE lram O‘ty I Thread Dla (mm) Torque N-m (kg-m, h-Ib) Remarks Cylinder head 4 E 8 — 12 [0.8 — 11, 5 — 9) while the englne is cold. Flywheel 1 10 35 — 40 (3.5 — 4.0, 25 — 29) Below 35“c, 95°F) Drive pullIy l 10 35 ~ 40 (3.5 74.0, 25 — 29} Inlet pipe 4 6 8 —1210.8 ~12, 6 — Bl tWhilo the engine ls cold. Clutch outer l 1 1o 35 — 40 13.5 — 4.0, 25 — 29) (Below 35°c_ 95°F) CHASSIS Item O'ty Thread Dia (mm) Torqun N-rn lkgm. ft-lbl Remarks Staering stem nut 1 25 75 — 85 (7.5 — 8.5, 54 - 61) Front axle nut 1 10 40 — 50 [4.0 — 6.0, 29 — 36) S'lHocking nu! Rear axle nut 1 1 14 E0 — 109 (8.0 — 10.0, 53 — 72) Self-locking nut Engine hanger bolt _ _ ‘ _ - (Upper) 1 10 59 — 65 (5.9 6.5, 43 47) Self locking nut , l Efim$W ”'3" ‘ 1o 35 — 45 (3,5 - 4.5, 25 — 33) Sen-locking nut Rear shod: absorber 4 10 30 — 40 (3‘0 — 4.0, 22 — 29) Front/Rear trike am 2 5 4 — 7 (0.4 — 0‘7, 3 — 5) l STANDARD TORQUE VALUES Torque specifications listed above arr: for important fastanavs. Others should be tighlaned to standard torqul values balow. Item Torque N~m (kg-m, lr~lb) Itzm Torque Nm (kg-m, ftslb) 6 mm bolt and nm 6 mm bolt and rm! 8 mm bolt and nut 10 mm bolt and nut 12 mm ball and nut 4— 6(O.4—0.8. 3~ 4) 8—l2 (0.8-1.2. 6— 9! 18—25 (1.8—2.5. 13—18) 30—40 (3.0—4.0. 22—29) 50—60 (5.0—6.0. 36—43) 5 mm smw 6 mm screw 6 mm flange bolt and nut 8 mm flange bolt and nut l0 mm "urge bolt and nut 3— E (0.3—0.5, 3— 4) 7—11 (0.7-1.1, 5— Bl 10—14(1.0—1.4, 7—10] 20—30 (20—30, 14—22l I w-40l3.0—4.U,22—29l Dale of Issue: ch., 1930 O HONDA MOTOR my LTD. GENERAL INFORMATION TUIJLS SPECIAL Tool Name Tool No. Remarks Rel. Page 1 Lock nut wrench 39 mm 079164870001 Driven lace disassembly/nsembly 8-16, 0-21 2 Flywheel holder 079244870000 7-3, 7-4 3 Driven gear holder 079244970000 Drive lace disassemblv/assemblv 8-4, 8-7 Kick driven gear lixing 5,10 4 Flywheel puller 079334550002 Flywheel removal ‘ 7-3 5 Crankcase puller 07935-1 B70000 Crankuse disassembly 10—3 6 Ball race driver 07944—115000] Ball race removal/installation 11-21 7 Mechanical seal driver attachment 079454150200 Final gear oil seal installation 03 8 Bearing outer driver 28x30 mm 079464870100 Driven face hearing/front wheel bearing 8-14, 11-12 9 Cllfld’l spring compressor 079604870000 Driven lace disammbiy/aseernbly 8-16, 8-20 10 Seal and case assembly tool 079654480001 Crankmse assembly/oil seal installation 10-5 11 Assimiblv tool attachment 07965-1 B70100 Crankoaso assembly 10-5 12 Rear shock absorber attachment A 07967-GA70100 Rear shock absorber disassembly/assembly 12-8, 12-9 COMMON Tool Name Tool No. A???“ Tool No. 7 Remarks Ref. Page 1 Float level gauge 074010010000 079 4-7 2 Pin spanner 077020010000 Pin 1 Top head thread nut 11-21, 11-22 or M9361-412- . ‘ Spanner 099788 tightening 3 Lock nut wrench 077160020400 — Stern nut tightening 11-7, 11-8 socket 30x32 mm Commarciallv available 11-22 4 Extension bar & handle 077160020500 — Stem nut tightening 11-7, 11-8 Commercially available ‘ 11-22 5 Universal holder 077250030000 — — Clutch outer holding 3-15, 8-21 6 Bearing outer driver 077460010100 — # Driveshaft bearing 9-3 32x35 mm installation 7 Bearing outer driver 077400010200 7 Final gear bearing/seal 9-3 37x40 mm installation 8 Bearing outer driver 077460010300 Bearing 07945-3330100 Crankshaft bearing 104 42x47 mm driver installation 9 Bearing driver pilot 077400040100 — Front wheel bearing 11-12 10 mm installation 10 Bearingdriver pilot 0774641040200 — -—— Driven lace bearing l 0-14 12 mm installation 1 1 Bearing driver pilot 07746-004030!) # — Driveshalt bearing 9-3 15 mm installation 12 Bearing driver pilot ‘ 077460040400 — - — Final gear buring 9-3 17 mm installation 13 Bearing driver pilot 077460040500 — Crankshaft bearing 10-4 20 mm installation 14 Bearing driver handle 077490010000 Bearing 07949-6110000 Bearing driver pilots 3.14. 9.3. outer A driver are not applicable to "3.4‘ ”42 handle “079496110000" 15 Rear shock 079593290001 Rear shock 079594990000 Rear shod twrber 12—8, 12-9 L compressor oomprassor disassemblv/assembly Date of Issue: Now, 1990 1 _5 © HONDA MOTOR 00.. LTDt @ HONDA GENERAL INFORMATION $3,] NXSOM MIIDEL IDENTIFICATION BEGINNING WITH Engine No. ASIDE-2000001“- Frame No, ARIN-2000001 N VIN JHZABMO-BSOOOOOI “ The frame serial number is stamped on (he steering head The VIN (vehicle identification number) is on she Safaty IeIt side‘ Certificaliun Label on the steering head right side. IDENTIFICATION NUMBER The engine serial number is stamped on the 9M side 01 The carburetor identification number is on the carburulor crankcase. body. 1 -6 Date of Issue: Nov., 1980 © HONDA MOTOR CO” LTD. HONDA NXSOM é GENERAL INFORMATION BIBLE 8. IIAIIIIESS RllllIIIIE OIL PUMP CONTROL CABLE i THROTTLE = ‘ CABLE T” REAR BRAKE CABLE (I I VIEW FROM REAR OIL PUMP CONTROL CABLE THROTTLE CABLE OIL OUTLET LINE OIL INLET LINE OIL INLET LINE FUEL TUBE / BVSTARTER ’ CHAMBER ‘ ,5 AIR CLEANER / ‘ I/THROTTLE CABLE \ \ OIL PUMP CONTROL CABLE OIL OUTLET LINE VACUUM "' TUBE ‘.“,L ,, ' CLAMP fill“ ti“. «7;an CONTR L aox CLAMP ‘l’nfi! ‘11 ~ —‘* AIR VENT u . 5‘. 9 fl?)' 6 TUBE ,, '\ - CLIP 5‘ - -\“ ‘ v f/ T CLAMP . / _ BATTERY 4, ‘ BREATHER \ T L5. ”9-" \7L \ TUBE CAHBU RETOR DRAIN TUBE Data of Issue: Nov., 19% © HONDA MOTOR (20.. LTD. 1-7 GENERAL INFORMATION SILICON RECTIFIER ' ‘ IGNITION eon. WIRE GUARD WIRE HARNE$ STARTING MOTOR COUPLER THROTTLE CABLE WIRE HARNES SPEEDOMETER CABLE FRONT BRAKE CAB LE A.C‘ GENERATOR WIRE 1 .8 Date of Issue: Nov., 1980 o HONDA MOTOR 00., LTD. HONDA NXSOM GENERAL INFORMATION WIFIE BANDS LEFT - ‘ ‘ , 9mm” me ‘ \ communion REAR BRAKE SPEEDOMETE R CABLE W“ "A SPEEDOMETER " *’ CABLE TURN SIGNAL WIRE TAILLIGHT V“) BRACKET I \ REAR BRAKE 1 ‘ , CABLE j? VINVL TUBE Dam of Issue: Nov.. 1980 1 -9 © HONDA MOTOR 00., LTD. LUBRIIIM'IIIN SYSTEM g HONDA “é uxsom 2-0 Dale of Issue: Nov‘, 1980 0 “ONDA MOTOR 00.. LTD. 2. LUBRICATIIIN LUBRICATION SVSTEM 2—0 OIL STRAINER CLEANING 2—5 SERVICE INFORMATION 2—1 OIL PUMP REMOVAL 2—5 TROUBLESHOOTING 2-1 OIL PuMP INSPECTION 2—6 OIL PUMP DIAGRAM 2-2 OIL PUMP INSTALLATION 2—6 FINAL REDUCTION OIL 2—3 OIL PUMP BLEEDING 2—7 OIL TANK 2-3 LUBRICATION POINTS 2—8 SERVICE INFURIMTIIIN GENERAL INSTRUCTIONS The engine must be removed Irom the frame when removing and installing the OH pump. - Use care when removing and installing rhe oil pump not to allow dust and din tn enter me engine and Oil IIne. r Do no‘ unemm w disassemble the oil pump. - Bleed air from the oil pump if there is air In lhl! oil inlei line (from (he oil tank Io the Oil pump) or if the oil line is diswnuecled (Page 2-7). - Bleed air from the oil ouIleI line (irom the oil pump to me carburetor) If The line is disconnected (Page 2-7). SPECIFICATION Specified oil ls HONDA 2-strake injectar oil or equivalent TIIflIIBLESIlUflTINII‘ Excessive smoke and/Dr carbon on spark plug 1. Pump noi Droperly synchroniled (excessive Dill 2T LDW qualiiv engine oil Overheating 1. Oil pump not adjusted properly (inmiiiciam oiling) 2. Low Oualrly ail Seized piston 1. No oil in tank or clogged Oil line 2. Pump not properly adjusted (insufficient oiling) 1 Air in Oil lines 4. Faulty Oil pump 5. Clogged DII strainer Oil not flowing out oi tank 1. Clogged oil tank cap breather hole 2. Clogged oil strainer Dale of Issue: Nov., 1980 2 1 © HONDA MOTOR co“ LTD. ' LUBRICATION OIL PUMP DIAGRAM DELIVERV (CC/MIN) OIL PUMP PERFORMANCE CURVES /— 0.20 0.15 0.10 006 (ENGINE SPEED Isoorpm) 10" 20° 30° 40° 50° 60° CONTROL LEVER ANGLE 2-2 Dale of Issue: Nov., 1980 Q HONDA MOTOR 60., LTD. m HONDA {33/ NXSOM LUBRICATION FINAL REIIIIIITIlIIl flIl OIL LEVEL CHECK Pul lhe motorcycle on its cenler stand on level ground. Slop (he engine and remove the oil level check boll and sealing washer from the final ledunion gear case. A small amount of oil should llow out of the oil level ched< bolt hole. Add the specified all type through the check bolt hols, ll necessary. OIL LEVEL CHECK BOLT HOLE OIL CHANGE Remove [he oil check bolt. Remove the oil drain plug and dram the oil. Make sum lhal the sealing washer on the dram plug is in good condition. Reinstall me drain plug. TORQUE: 10—14 N-m (1.0—1.3 kqm, 7—10lblbl Refill the case up [0 the proper level. OIL CAPACITY: 90 on: (30 US 01., 2.5 Imp. n2.) SPECIFIED 0le 2‘90 gay oil Remslall the all check boll. Slan the engine and dleck for leaks after driving. DRAIN PLUG OIL TANK REMOVAL \_ Disconnect the all inlet lune al the oil pump and allow the oil to drain into a clean conlalner. / I OIL TANK l OIL Date of Issue: Nov., 1980 2 3 © HONDA MOTOR (20.. LTD. ' LUBRICATION BA1'I'E RY BOX Remove Ihe banarv and battery box. Remove the oil tank. DISASSEMBLY Clean xhe interior at the oil tank zhomugmy. CAP OIL TANK FLOAT GUIDE $17 5% f @ (I@ y OIL LEVEL WINDOW INSTALLATION 6%0 Installation is the reverse of removal. Refill the Iank up to the upper level. OIL LINE Check for leaks. & 2_4 Date of Issue: Nov., 1980 © HONDA MOTOR C0,, LTDV HONDA NXSOM LUBRICATION llll STRlIlIIEll CLEANING \ Disconnect the oil Inlet line at the oil pump and allow \, l the all to drain into a clean container. >\ Loosen the tube clip and disconnect the oil tube $ loin! under the oil tank. / , Remove the oil strainer screen. OIL TANK OIL STRAINERfl SCREEN TUBE CLIP /~ ~\ \/ OIL TUBE/ Clean the oil strainer screen with compressed air, Installation of the DlI strainer is the reverse order of removal. Fill me oil tank with [he recommended all up to the proper level. Bleed air from the oil pump and cull tube (Page 2A7]. NOTE ‘ - Connect the oil tube securely. ' Check lor leaks. IIIL PIIMP REMIIVIll Remove the engine (Page 52). NOTE: Belore removing the oil pump, clean the all pump and crankcase. l AIR GUN Date of Issue: New, 1950 © HONDA MOTOR 00., LTD LUBRICATION Ditoonnecl the oi! outlet line lrom the carburetor. Remove the oil pump amching butts and rcmovc the oil pump, llll PIIMP INSPECIIDN Remove the oil pump and Inspect the lollowing items: - Damaged or weakened O‘nngs - Damage to crankcase mating surlaca - Damage to pump body - Warn pump 92a! CAUTION #_ \ Dmmnmmmm (Ill. PIIMP INSTALLATIUN Install the oil pump onto the crankcase. CAUTION - Lubritalc the pump gear and 0-ring with clean gyms: before innallntlon. - Make sure that the oil pump 1‘: inserted in to the crankcase properly. Tighten the oil pump attaching bolts securely. Reconnect the oil outlet line as shown HON DA J NXSOM OIL OUTLET LINE OIL PUMP CONTROL LEVER O-RING \ SPIGOT‘FIT OIL OUTLET L|NE OIL PUMP 2-6 Data 0! Issue: Nov” 1980 © HONDA MOTOR 00., LTDa LUBRICATION OIL INLET LINE CONTROL CABLE Install the engine and perform the following m- ' , sections and adjustments: ' Control cable adjustment (Page Svel. Oil pump blending (Page 2-7). Oil out|et line bleeding (Page 2-8). - Check for ail leaks. OIL PUMP BLEEDING CAUTDON ~ Air in 1hr m'l symm will block I)! mm’c! oil flow and may result in never engine OIL OUTLET LIN damage. ' Bleed air frum the oil inln‘ line first, Iherl bleed air from the oil omit? line. OIL INLET LINE WHOM ~ Blzed air from the all lines whenever the 0” line: or pump half been removed or them is air in the oil Ir'nu. RECOMMENDED OIL Nu. l Stop the engine. Fill the tank with recommended oll. Place a shop towel around the oil pump, Disconnect the oil inlet line from the oil pump. Fill the oil pump with oil by squirting clean oil through the joint. (About 3 DC) Fi|| the oil line with oil and connect it to the joint of the oil pump. After installation, make sun thore i: no air in the oil inlet line, OIL OUTLET LINE 1, Disconnect the oil outlet Iinl at the carburetor and fares air out of the tube by filling it with oil using an oil squin can. 2. Connect the oil outlet line to the carburetor. 3. Start the engine and allow it to idle with the all control lava: in the fully open position, making sure that there are no air bubbles in the oil from the oil pump. 4. ll there are air bubbles, repeat steps I through 3 until the oil fins 3: fr” of air bubbles. OPEN CONTROL LEVER FULLY Dam of Itsue: Nov., 1980 2 7 © HONDA MOTOR 00., LTD. - HONDA LUBRICATION NXSOM ENGINE LUBRICATION POINTS LUBRICANT REMARKS Pinon/crankxhah HONDA 2-slroke injector oil or equivalent Kick sun" spindle bushing l General purpou grease _ “ Movable drive lam LITHIUM BASED GREASE ITSUBISHI HD-a NIPPON SEKIVU LlPANOX DELUX 3 107159 IDEMITSU COHONEX 3 or equivalem (0.25—0.53 01.) Starter idle gear General purpose grease F RAME NOTE Use general purpose grese for partsK listed. Apply clean eng‘ne ml or grease to cahles and parts not specified. THROTTLE GRIP & STEERING HEAD BEARINGS BRAKE CAM SHAFT FRONT FORK (OIL FELT Grease 119 (0.4 oz.) I for each OIL FELT‘~ \ SPEEDOMETER GEAR/DUST SEAL/ MAIN STAND FINAL REDUCTION WHEEL BEARING/DISTANCE COLLAH/ PIVOT [3w GEAR OIL 9006 3.0 U.S.oz.) BRAKE CAM SHAFT 2‘8 Date of Issue: Nov., 1980 © HONDA. MOTOR 00.. LTD. “we? 3. MAINTENANCE SERVICE INFORMATION 3—1 CARBURETOR ADJUSTMENT 3—5 MAINTENANCE SCHEDULE 3—2 BRAKES 3—7 BATTERY 3—3 SUSPENSION 3—8 AIR CLEANER 3—3 STEERING HEAD BEARINGS 3—8 BVSTARTER ELEMENT 3—4 HEADLIGHT AIM 3—9 SPARK PLUG 3—4 WHEELS/TIRES 3—9 COMPRESSION TEST 3—5 NUTS, BOLTS, FASTENERS 3—9 IGNITION TIMING 3—5 SERVICE INFORMATION SPECIFICATIONS SPARK PLUG NGK BPSHS (EP4HS. BPSHSI ND WIsFP (w14FP-L,w20FPI SPARK PLUG GAP 0.6 V 0.7 mm (0.024 , 0.023 in) COMPRESSION 13.0 kg/cm: (185 pm) IGNITION TIMING 1513D/2,000 rpm BTDC (CONSTANT) THROTTLE FREE PLAV 2 7 6 mm (Ha—114:") IDLE SPEED Laoorpm AIR sanw OPENING 1-3/4turnsout BRAKE LEVER FREE PLAY FRONT 10 715 mm (3/8 A 5/8 in) HEAR 10*15mm(3/875/8in) TIRE SIZE FRONT 2.75—10—2PR REAR 2,75—10—2PR TIRE PRESSURE FRONT 1.5kg/cmH21mi) REAR 1.75 kg/cm‘ (24 psi) Date of lxsue: Nov., 1980 3_ 1 © HONDA MOTOR co., LTD. HONDA MAINTENANCE NXSOM ThiI maintenance sdwdule IS has-d upon mug: riding conditions Machines subjemd lo swan um, or ridden In unusually (“1st areas. vaquira mom frequent servicing I - INSPECT AND CLEAN, ADJUST LUBRICATE, OR REPLACE IF NECESSARY. C : CLEAN H I REPLACE A : ADJUST L ' LUBRICATE FREQUENCY INITIAL REGULAR SEW"; FER'OD SAFETV Perforhm at 8);.” Ind‘uma? mom or rm e n ervu, PRE'RIDE INSPECTION whichever (:ng Iim We, m INSPECTION 1 month 12 months 24 months Page 200 miles 1,000 miles LNG milos ITEM (300 km) (1,500 km) (3,000 km) AIR FILTER ELEMENT (EVERY 6 MONTHS) C 13 CARBU RETOR I I | 3-5, 3—6 'THROTI'LE OPERATION I I | I 3-5 OIL PUMP I I I 2-7 FUEL FILTER SCREEN C C C 4-12 FUEL LINE I I | 4-13 'OIL AND FUEL LEVEL I — DECARBONIZE CYLINDER HEAD, CYLINDER. PISTON C 8-3.3-5 AND MUFFLER TRANSMISSION OIL ‘ R 2-3 'TRANSMISSION CASE FOR I _ LEAKS CLUTCH SHOE WEAR I 8‘18 'TIRES AND PRESSURE l 3-9 WHEEL TRUENESS I I | I‘I-I‘I,12-3 'BRAKE OPERATION AND FREE PLAV ' ' ' I 37 BRA_KE__ LININGS_ _ | I 37 STEERING HEAD BEARINGS I I 38 SUSPENSION OPERATION I I 38 NIITS_ ROI TS (TIGHTEN) I I I I-4 SPARK PLUG R R 3.4 'BA'I'I'ERY FLUID LEVEL | 33 BATTERY FLUID SPECIFIC GRAVITV I I 13-3 ALL LIGHTS AND HORN I 13-3 Items marked ('I are sivas in podium and may be serviwd by the owner. Other mainumanoa items mould be serviced by an authorized Honda daaler, 3- 2 Dale of Issue: Nov” 1980 © HONDA MOTOR 00., LTD. BANE“ UPPER LEVEL Inspect the battery fluid level. When the fluld level nears the lower level mark, refill with distilled water to the upper levell - Check the specific gravrty oi the batterv electro- Ivte In each cell (Page 138). Fleeharge the battery If necessary (Page 13‘4lt NOTE Add only distilled water. Tap water will shorten the service life of the battery. The Imttely electrolyte contains sulfuric 7 acid Prater: your eyes. skin and clorh- ‘ ing. In can of roman. flush thoroughly LOWER LEVEL will! mm and call a doctor If clac- iolyle gets in your eyes. Replace the battery, tr sulfation forms or V ELEMENT sediments accumulate on the bottom AIR ELEANER Remove the screws attaching the air cleaner cover and remove the air cIeaner cover. Remove the alt cleaner element. AIR CLEANER COVER COVER SEAL MAINTENANCE Wash the element In non-Ilammable or high flash poinl solvent, squeeze out and allow to dry. Soak the element in clean motor oil (SAE WIN-30) or gear oil (380—90) and squeeze out the excess. Reinstall the element and frame cover. ”X ‘ &\V/ELEMENT/ WE < 3W WASH SQUEEZE OUT OIL AND D RV Dale of Issue: Nov.. 1980 © HONDA MOTOR C0., LTD. A - SOUEEZE OUT EXCESS OIL 3-3 MAINTENANCE BYSTARTER ELEMENT Remove the carburetor covers Remove the bystaner chamber and ramove the element. Wash the element in non-flammable or high flash point solvent, squeeze out and allow to dry. Soak the element in clean motor oil (SAE row-3m or gear oil ($80—90) and squeeze out the excess Reinstall the element into the bysraner chamber and reinstall the chamber. ELEMENT BVSTARTER CHAMBER Reinstall the carburetor cover. . 0 6—0.7 mm , Dlsconnect the spark plug cap, and remove the - spark plug. (0‘024~0.028 In) Visually inspect the spark plug eleclrodes for wean The center electrode should have square edges and _, DEF R TlON the side alectrode should have a constant thicknssl GAP "’ 0 MA Discard the spark plug il there is apparent wear or if WEAR the insulator is cracked or dripped. If the spark plug FOULING deposits an be removed by sand blasting, the spark DEPOSITS plug can be reusedr Inspect rhe gap with a feeler CRACKS gauge and adjust by bending the side electrode only. DAMAGE SPECIFIED SPARK PLUGS: NGK: BPSHS (BPSHS, BPAHS) * 7 ND: W16FP (WZOFP. W14FPAL) Check the washer for deformation. ? 3-4 Date 01 Issue: Nov.. 1930 © HONDA MOTOR CO” LTD. @ “figfiA \ ___/ MAINTENANCE CUMPRESSIIIN TEST Warm up the engma. Stop the engine and remove the spark plug. Insert a compression gang?” Open the throttle grip fully and operate the kid< starter several times. COMPRESSION : 13.0 Ito/cm? (185 psi) Luwcumpressron can be caused by: . Blowu cylinder head gasket ~ Worn piston rmgs - Worn cvlinder Hg. commession can be caused by: ' Carbon deposits in Combustmn chamber or on pIston head. IflNlllflN TIMING NOTE FThc C.D,l. Imrtion tIming l5 nol adjusrahlm ll the igmuon [ImInq is correct, check the (200.1. um and AC. generator and replace any laultv partst Remove the AC generator can and check the ignition IIming with a twin light. Timing is current Il the Index mark aligns with the “F" mark [withln 3“) 312,000 rpm. IGNITION TIMING: I5“ 23° BTIJC/zooo rpm CARBURETOR ADJUSTMENT THROTTLE CABLE ADJUSTMENT Measure the fllrottle grip free play at the throttle gripflange. FREE PLAY: 2—6 mm (1/8—1/4in) Adjustments can be made by loosenan the lock nut and turmng the throttle grip lree play adjuster. Regime the throttle cable whln the above proc- edure is no longer slimivav Adiusl the oil pump control cable (next page). LOCK NUT ADJUSTER Date of lssue: Nuvv. 1980 (C) HONDA MOTOR CO.‘ LTD. 3-5 MAINTENANCE HONDA NXSOM OIL PUMP CONTROL CABLE ADJUSTMENT NOTE ALIGNING MARK LOCK NUT - Tm oil pump control cable should be CONTROL CABLE ADJUSTING uur adjust-d afar th- thmltla grip (ms plly ldiustmlnl. ' Then in two typo of oil pump control lav-tr. Open the throttlt fully Ind and that the aligning mark on thl oil pump control Imr ls aligned with ind-x mnrk on the pump bodyl Adiust il nae-sun] by loosening the lock nut and turning adjusting nut. Altar adjustmlmt, tight-n lock nut. CAUTION Refarnu tip alignment wirllbr I mm (0.04 in) aliadexmrkan the open w’dzl‘uccepr- able However, the nl'wlingmnk must never be on the cloud ride of the I'ndwr mark. olheerte entitle damage wlfl occur beam ofluufildcnt Wafiork Exussiva while smoke or hard starting: - Pump central lever EXOGSSIVEIV 0pm Siezed plston: - Pump control lever not propirly diushd. IDLE SPEED ADJUSTMENT NOTE The engine mutt bu warm lot accurate adjust-nut. 1. Amen m endne tachometer. 2. Turn the throttle stop screw to chain the spacllled idle speed of 1,800 rpm. When the engine mirset or runs erratic. proceed as Inflows: II) Screw in the air sot-w until it lightly seals. then turn it out 1-54 tumi. (2) Raul flu: ldla speed with the throttle stoo screw. (3) Turn the air screw to find ma hlytest idle Med. (4) Reset the idla spend with the throttle stop scraw. (SI Malta turn that fits engine does nut miss or run arr-tic. If "seesaw, "put stem (2) through (4). INDEX MARK/ Atwe ADJUSTING NUT B-vae LOCK NUT CONTROL CABLE ALIGNING MARK INDEX MARK OTTLE srop scnew 3-6 Data of Issue: Nuvl, 1980 G) HONDA MOTOR (10., LTD. HONDA. NXSOM MAINTENANCE BRAKE (REAR) ‘l - _. BRAKE ADJUSTMENT l ° '5 ""“ \/° ‘5 """ i Measure the from and rear brake lever free plays (3,54 PM) ‘(3/8—5/8 in) at the end of the levers. FREE PLAY: FRONT: 10—15 mm (3/8—5/8 in) REAR: 10—15 mm (3/8—5/3 in) (FRONT) If adjustment Is necessary, turn the brake adjusting ’ nul. RELOCATION OF FRONT BRAKE ARM ON BRAKE CAMSHAFT Do not use this procedure jar rite rear brdse, If the front brake lever tree play is excessive so that the above procedure is no longer effective, relocate the brake arm on the brake camshaft as follows NOTE ADJUSTING NUT Perform this operation ml; on}. Remove the front brake arm. Reinstall the front brake arm on the brake camshaft with its punch MARK mark one pitch In the counterclockwrse direction i from the punch mark on the camshaft. BRAKE SHOE INSPECTION Replace the brake shoes ii the arrow on the brake arm aligns with the reference mark “A" on full application of the front or rear brake (Page 1| — 15, 12 — 5). ARROW PUNCH MARK Date of Issue: Nov., 1980 © HONDA MOTOR C0,, LTDt MAINTENANCE SUSPENSIUN FRONT Check the action at the front forks by compressing them several times. Chedt the entire lurk assembly for signs of damage. Replace any components which cannot be repaired. Tighten all nuts and bolts to the specified torque values (Paw 1 — 4), REAR Place the motorcycle on the center stand. Hold the rear carrier by one hand and move the left crankcase sideways with force to see if the swing arm bushings are worn. Replace it excessively worn, Check the entire suspension assembly. Be sure it is securely mounted and not damaged. Tiwten all nuts and bolts to the specified torque values (Page 1 ~ 4). STEERING HEAD BEARINGS NOTE 1 check that the control cables do not inter- fere with the handlebar rotation. Place the motorcyle on the center stand. Raise an iron! wheel on rm ground by placing a support under the engine. Check that the handlebar rotates freely. It the handlebar moves unevenly, binds, or has vertical movement, adjust the steering head bearing by turning the steering head adjusting nut with a pin spanner (Page II — 22), BUSHINGS HEAD BEARINGS 3-8 Date of Issue: Nov“ 1980 © HONDA MOTOR CO., LTD. HONDA NXSOM MAINTENANCE HEADLIGHT AIM Adjust the headliyn vertical and horizontal beam with the adjusting scram. NOTE Adjust the headlight beam as specified by local laws and regulations. An improperly adjuxled headlight may blind on coming drivers, or it may [all to light the mad/om WP distance. WHEELS/TIRES Check the tire pressures, NOTE fire pressure should be checked when the tires are COLD. , TIRE PRESSURES: Front: 1.5 kg/an‘ (21 psi) Roar: 1.75 kg/au‘ (24 psi) TIRE srzss; Front: z75—1u—2PR nun zrs-ro-zpn Chew the tires fur wear, damage or imbedded obiects. NUTS, BfllTS, FASTENERS Check that all chassis nuts and no! [5 are tightened to correct torque values (Page 'l-4L Check all cotter pins and salety clipst Date of Issue: Nov., 1980 3-9 (5) HONDA MOTOR C0., LTD. FUEL SYSTEM HONDA NXSOM 4-o Hagan 4. FUEL SYSTEM % SERVICE INFORMATION 4—1 FLOAT LEVEL INSPECTION 4—7 TROUBLESHOOTING 4—1 CARBURETOR INSTALLATION 4—7 THROTTLE VALVE DISASSEMBLY 4—2 THROTTLE VALVE INSTALLATION 4—7 CARBURETOR REMOVAL 4—3 REED VALVE 4—9 FLOAT/FLOAT VALVE/JETS 4—5 FUEL TANK 4—10 DISASSEMBLY FUEL AUTO VALVE 4—13 JETS/FLOAT VALVE/FLOAT 4—6 A$EMBLY SERVICE IIIFIIIIIIITlflII GENERAL INSTRUCTIONS - The fuel tank is equipped with an auto luel valve that is turned OFF automatically when the engine is stopped. ~ Use caution when working with gasoline. Always work in a well-ventilated area and away from sparks or tlames. - When disassembling luel system parts, note the locations of the O-rings. Replace them with new ones during assembly. - Bleed air from the oil outlet line whenever it is disconnected. TOOLS Common Float Level Gauge 0740141010000 Hand Vacuum Pump A973X—041 —XXXXX (U.S.AI SPECIFICATIONS Venturi dim 12 mm Identification number PAIBA Float level 12.2 t 1.0 mm (0.4} t 0.04 in) Air screw opening 18/4 turns out Idle speed 1,890 1 I50 rpm Throttle grip tree play 2—6 mm (1/3—1/4 in) Engine cranks but won’t start Lean mixture 1. No fuel in tank 1, Carburetor fuel lets clogged 2. Clogged fuel lube 2. Fuel cap vent clogged 3. Clogged fuel strainer 3. Clogged luel filter 4. Fuel cock diaphragm suck 4. Fuel link klnkad or restricted 5, Too much fuel getting to Cylinder 5. Float valve faulty 6. Classled air cleaner 6. Float level too low 7. Faulty control box 7. Air vent tube clogged Engine idles roughly. stalls or runs poorly Rich mixture 1. Idle speed incorrect 1. Faulty float valve 2- mm "mm“! 2. Float level too high 3. Lean mixture 3. Carburetor air jets classed 4. Clogged air cllaner 5_ Inlet pipe leaking 6. Fuel contaminated Date of Issue: Nov., 1980 4_ 1 © HONDA MOTOR 00., LTD. FUEL SYSTEM THRUTTLE VALVE DISASSEMBLY Remove the carburetor cover. NOTEV ,, _ ' Remove the rear shock absurher to facrlrrate operation, CARBUHETOR CAP Remove rhn carburetor cap and pull out the throttle . valvet THROTI'LE CABLE Dlscorrnect the lhfollle cable from the throttle valve. Remove the throttle valve sprung, carburetor cap and mrortle velvet 4-2 Date of Issue: Mom, 198!) o HONDA moron 00., LTD‘ HONDA NX50M FUEL SYSTEM Pry off the needle mainer and remove the jet needle. ? JET NEEDLE/TH BOTTLE VALVE NEEDLE RETAINER INSPECTION Check me is! needle and mmnle valve for wear or CUP damage. SECOND NOTCH (STD) JET NEEDLE TH ROTTLE VALVE EIRBHRETDR REMOVAL Remavu ma A.C, generator and stanar wires {mm the clamp. Remove me oil pump attaching bolts and turn me oil pump and lines to point toward you. Remove the tubes from the carburemr. NOTE It is no( necessary to plnch the tubes as the fuel valve :5 automallcallv closed. v -. . BYSTARTER TUBE OIL OUTLET LINE Data 0! Issue: Nov., 1980 4_3 C) HONDA MOTOR C0.. LTD. FUEL SVSTEM Remove Ihe bolls anaching the mar lander. Separate the bystaner chamber from the air cleaner case. Remove me air cleaner case attaching bolts. Remove me carburamr anaching nuts Remove the air cleaner case and carburetor as an assembly. REAR FENDER BVSTARTER CHAMBER Date of Issue: Nov.. 1980 6 HONDA MOTOR (20., LTD HONDA NxsoM FUEL SYSTEM FLIIAT / FLIJIIT VALVE / IETS DISASSEMBLY Place a drain pan under the carburetor and loosen me carburetor drain screw to allow fuel to drain in the drain pan. Remove the "on chamber from the carburetor body. anova the carburetor floal andfloal valvn by remov-ng the attaching screw. FLOAT/FLOAT VALVE INSPECTION Check the valve seat lor wear or damage. Ched< ‘he floa! (or deformation or fuel insid! the float. F LOAT CHAMBER DRAIN SCREW VALVE SEAT FLOAT Data of Issue: Nov., 1980 © HONDA MOTOR (20., LTD; FUEL SYSTEM HONDA NXSOM Remove the air screw, "cord the number of rota- tions until it seats lightly, so il can be rotumad to the original position. CAUTION Do not force the screw agnlnsl it: 3m! to pram! danugel Blow open all jam and body openings with com. pressed aiv. JETS / FLllAT VALVE / FLOAT ASSEMBLY Install the air screw and throttle stop screw. AIR SCREW OPENING: 1-Xtumlout Install the float valve, float and float pin. Tighten the float screw securely, THROTTLE STOP SCREW A”? GUN THROTTLE STOP SCREW AIR SCREW 4-6 Date 0! lssue: Nam, 1930 O HONDA MOTOR 00.. LTDT HONDA. NXSOM FUEL SYSTEM FUIAT lEVEl INSPECTlflN Measure the lloat level at the main jet parallel with the float pm. FLOAT LEVEL: 17.2 21.0 mm (0.4820.04 In) Replace the float il il is out 01 the spedlled level range, Check operation of the float and install the lloat chamber. FLOAT LEVE L GAUGE BARBURETDR INSTALLATIIJN WHOM Do nat allow foreign particles to enter the carburetor. lnsm” the carbuwtol with the air cleaner case. CAUTION Do not falgzl Io inxmll the an'ng, 1 Connect the tubes and line to the carburetor. LINE THRflTTLE VALVE lNSTAlUlIIflN \NEEDLE CLIP Install the jet needle on the throttle valve and secure with the needle clip. RETAINER LEAN JF’ NEEDLE m NOTCH (STD) 2nd NOTCH THROTTLE VALVE mg” 344+51h NOTCH Date of Issue: Nov” 1980 4_7 © HONDA MOTOR 60., LTDl HONDA FUEL SYSTEM NXSOM Assemble the runner sual, carburetor cap and throt- tle valve spring. RUBBER SEAL CARBU RETOH CAP VALVE SPRING TH OTTLE VALVE Connect the throttle cable to the throttle valva‘ ' Slide the throttle valve into the carburetor body. NOTE Align the groove in the valve with the thrnnle stop screw on the carburetor body. Tiyuen the carburetor cap. Perform the following adjustmenu and operation: - Throttle cable lree play adiustment (Page 3-5) - Oil pump control cable adiuslmem (Page 36) - Oil pump and line bleeding (Page 2~7l Idle speed adjustment (Page 3-6) Gnoov? 4-8 Dale of Issue: Nov” 1930 © HONDA moron cot, LTD, HONDA NXSOM FUEL SYSTEM REE” VALVE > . REED VALVE INSULATER REED VALVE REMOVAL Remove Ihe carburetor (Page 4-3). Remove the inlet pipe. Remove the reed valve, insulator and gasket, GASKET INLET PIPE REED VALVE INSPECTION Check the lead valve for damaged or weak reeds. Check the valve seat for cracks, damage or clearance between (he seat and reedl Replace mo valve iI necessary. CAUTION Do not disassemble or bend the reed nmer To do so can cause loss oI power a engln! damage. If the stopper, reed or Lvalve seat is faulty, [enlaoe them as a unit. REED VALVE SEAT BYSTARTE R TUBE REED VALVE INSTALLATION The installation sequence is essentially the ravens of removal. Connect the byslarter lube to inlet pipe (Page 178). After installation, check Ior leaks. Dam oI Issue: Nov., 1980 4 9 © HONDA MOTOR (30., LTD. ' mm mm a j, FUEL SYSTEM fllEl. TANK Date 0' Issue: Nam, 1930 9 HONDA MOTOR 00., LTD. 4-10 HONDA NXSOM FUEL SYSTEM FUEL TANK REMOVAL Keep gasoline away from flanm or sparks. Wipe up splfled gasoline at once. Disconnect the right and left turn signaI wire connectors. Remove the rear carrier. Remove the nuts attaching the tank brackal and remove me bracket. Disconnect the stop and tailight wire mnnectovs, Remove the taillight brackat by removing the attaching nuts. Disconnect the fuel tube and vacuum tube at the fuel valve. Remove the fuel tank, FUEL TANK INSTALLATION The insta|lalion it the reverse 0' removal. FUEL TANK BRACKET REAR CARRIER TAI LLIGHT BRACKET FUEL TANK L§ Date oflssue: NDV-.19m © HONDA MOTOR CO.. LTD. FUEL SYSTEM FUEL STRAINER CLEANING —‘ Keep am from flame: or marks. Wipcup spilled aniline at ante. Disconnect me fuel tube and vacuum tube at the fuel valve. Remave the fuel tank, Drain the genuine into a safe container bbeledfnrwflnt. Remove the luck nut and remove the fuel valve. Remove the fuel snainer. Clam the strainer with compressed all. ggég'ffi W /LOCK NUT FUEL VALVE” lnsull the fuel valve. NOTE - Alter assembling, check for leaks. - Do not overtimlan the lock nut. 4. 1 2 Dan 0! Issue: Mom, 19:30 © HONDA MOTOR 00., LTD. HONDA NXSOM FUEL SYSTEM FUEL All") VALVE FUEL mm | NSPECTI ON Q2 WARNING K p my Wipe up spilled gnu/In: at mm. FUEL VALVE 1. Remove the fuel tube from the carburetor and vACUUM TUBE FUEL TUBE allow remaining fuel to drain (about 5 — 10cc). The fuel valve is normal if there is no furlher HAND VACUUM PUMP flcm of fuel from the tube. If there is fuel flow, A973X-041— perform the following: XXXXX (USA) Clean the vacuum tube. ' Remove the fuel valve and clean it by apply» ing low pressure air from the top. FUEL Z Disconnect the vacuum tube from the infer pipe and apply vacuum through the tube. Fuel should flow out of the fuel tube when negative , pressure is applied. Perform the following if INLET PIPE there is no fuel flow: éAReu RETOR - Clean vawum tube. - clean fuel nrnlner with compressed air (Page 4-12). ' Remove fuel valve and apply low pressure air to top nf fuel valve to free seized diaphragm Date of Issue: Nov..1980 D HONDA MOTOR (20.. LTD, 4' 1 3 J3 HONDA ‘ NXSOM ENGINE REMOVAL/INSTALLATION 5.0 Date of Issue: Nov.,1980 o HONDA MOTOR co., LTD. (Q “m7“ SERVICE INFORMATION ENGINE REMOVAL ENGINE INSTALLATION SERVICE INFIJIIIMTIIIII GENERAL INSTRUCTIONS Pans requmng engine removal 90¢ Servicmg: O Crankshaft I OH Dump SPECIFICATIONS Engine weigh! 164 kg [36 lb) 5. ENGINE REMflVAL/ INSTALLATIIJN 5—1 5—2 5—4 Date of Issue: Nov” 1980 © HONDA MOTOR CO.. LTD. 5-1 "I J HONDA ENGINE REMOVAL/INSTALLATION NXSOM ENGINE REMIIVM. FRAME cogn Hamova [he frame cover, righr and Ian side covers, mt] righr and lelr steps. Remove the spark plug cap, LEFT sulfa COVER Remove the rear brake adjusling nut. Remove me rear shock absorber attaching bull and nut. REAR BRAKE ADJUSTING NUT Remove me carburetor cap and pull the throttle COUPLERS O'L PUMP CONTROL CABLE valve out. Disoonnecl the throttle cable from the ' throttle vulva and ramove me relurn spring. car- bumor cap and rubber seal. Disconnect me oil pump comrul cable. Disconnect the slarxer and AC generator wire couplers. 5-2 Date a! Issue: New, 1980 © HONDA MOTOR co., LTD, HONDA NXSOM ENGINE REMOVAL/INSTALLATION Disconnect the fuel tube, vacuum tube and oil liner CAU‘HON Plug the end of the oil line In prevent oi! fiom flowing out oflhe tube, Unscrew the rum and rcmme the engine mounring bolt. Ramove rhe engine. Remove the following pans when the crankcase is to be separated. - Mulller - Air cleaner case Carburetor Inlet pipe/Reed valve Oil pump Rear lender Rear wheel Canter stand A.C, generamr/Stamr motor Drive pulley Cvlindar haad/CvlinderlPismn VACUUM TUBE ENGINE MOUNTING BOLT Dare ol Issue: Nov” 1980 © HONDA MOTOR C0,. LTDr ENGINE REMOVAL/INSTALLATION ENGINE INSTALLMIIJN Installation sequence is essentially the reverse oi removaL Torque m. angina hangar boils m m specified torque-A TORQUE: UPPER BOLT: 59 — 65 N-m (5.9 — 6.5 kg-m, 43 — 47 fl-lb] LOWER BOLT: 35 — 45 N-m (3.5 —4.5 kgom. 25 —~ 33 Mb) Pariorm the following inspecxions and adiusrmems almr installation: - Wire and cable routing (Page 1‘6, 1-8) - Carburetor adjusimeni (Page 35) ' Rear brake adiustment (Page 3-7) - Oil pump bleedlng/priming (Page 2-7) 5-4 Dale 0' Issue: Nov.‘ 1980 © HONDA MOTOR C0.. LTD. CYLINDER HEAD/CYLINDER/PISTON 6-0 Date of Issue: Nuv‘, 1990 o HONDA uo-ron oo.‘ LTDK HONDA CYLINDER HEAD / BYLINDER/ nxsom B. PlSTll N SERVICE INFORM/“107M 5—1 TROUBLESHOOTING 6—1 CYLINDER HEAD 6-2 CYLINDER/PISTON 6—3 SERVICE INFURMHIHN GENERAL INSTRUCTIONS - All cylinder head, cylinder and nislon maintenance and inspection can be accomplished wilh the engine installed. ' Before disassemblv, clean the engine to prevent dirt and dust from entering the cylinder and crankcase. Remove all gasket material from the mating suriaces of the cylinder head, cylinder and crankcase. SPECIFICATIONS ?‘ SERVICE LIMIT mm (in) ITEM _ STANDARD mm (in) Cylinder head warpage - ‘ 0,10 10.004) Cylinder born 40000—4001 5 (15748—15754) 40.050 (1.5763) Piston 0.0, ‘13th 'sfi'firmm °' 39950—39330 (15728-157321 39.900 (1.5709) Cvlinderslo-oiston clearance 0040—0055 (DDD‘lfi—ODOZZI 0.100 (0.0039) Plston pin hole LD. mom—10.008 (03933—03540) 10.030 (0.3549) Piston pin OD. 9394—10000 (03935—03937) 9.970 (0.3925) Piston-to-pistnn pin clearance 0.002—01112 (03001—03005) 0.040 (0.0016) Piston ring and gap (top, second) 0.15—0.35 (0006—11014) 0.60 (0.024) Connecting rod fmall and LD. 14005—1 4.01 7 (0.55l4—D.5519) 14.030 (0.5524) TRUIIBLESHUBTINE Compression too low, hard starting or poor Ahnovmal noise-piston performance at low speed Blown cylinder head gasket Loose spark plug Warn, stuck or broken piston rings Worn or damaged cylinder and piston Faulty reed valve 9‘.“ri Compression too high overheating or knocking 1. Excessive carbon buildup in cylinder head or on piston top 1. Worn cylinder and piston 2. Worn nis‘on pin or piston pin hole 3. Worn connecting rod small and bearing Abn l. 2. orrnal noise Worn. stuck or broken piston rings Worn or damaged cylinder Dale of Issue: Not, 1980 © HONDA MOTOR (20.. LTD. CYLINDER HEAD/CYLINDER/PISTON CYLINDER HEM] CYLINDER HEAD REMOVAL Remove the frame cover, rig“ and lei! side covers and right and left steps. Remove the step cross bar by removing the mach my belt. Remove the spark p|ug Cap‘ - STEP CROSS BAR Remove me bolls attaching me choke control box and remove the control box. Remove lhe (our cylinder head bolts, and the cylinder head. CYLINDER HEAD 6- 2 Dale of lisue: Nov.. 1980 © HONDA MOTOR CO‘. LTD. HONDA. NXSOM CYLINDER CYLINDER HEAD INSPECTION Check Ihe cylinder head for warpam with a straiyn edge and a lzeler gang: in ms directions shown. SERVICE LIMIT: 0.10 mm (0.004ln) HEAD/CVLINDER/PISTON CYLINDER HEAD DECARBONIZING Remove the carbon depasixs 1mm the combustion chamber. Clean the head mskzt surface of any gasket mate- rial. CAUTION - Avoid damaging the mmbum'on chamber wall and guskel mrface: - Remove carbon deposits from Mt pislon ‘ head. CYLINDER / PISTON CYLINDER REMOVAL Remove the exhaust muffler by remnvmg the anaching bolls and nuxs. EXHAUST MUFFLER Due 0! Issue: Nov., 1980 6 3 © HONDA MOTOR (30.. LTD. - HON DA. NXSOM CYLINDER HEAD/CVLINDER/PISTON CYLINDER Remove the cylinder. - . CANNON Do not pry between the cylinder and crank- case or strike Ihe flux ——1 PIS 0N PIST Pl PISTON REMOVAL ,/ ‘ 0N N PISTON pm cup Hemovu the piston pin dip using a pair of pliers. Press the piston am out of the piston. NOTE - Do not damage or scratch the piston. * Do not apply sldl fame to the connecting rod. A Do not let the slain Ian into the crank- case. PISTON RING/EXPANDER REMOVAL Remove the piston ring. SECOND RING TOP RING NOTE Spread uach pls ring and mauve by liking it up :1 a point just opposite the mp. Remove the expander. 6.4 Dale 0' Issue: Nam, 1980 © HONDA MOTOR 00., LTD. HONDA NXSOM CYLINDER HEAD/CYLINDER/PISTON CYLINDER/PISTON INSPECTION Check the cylinder and piston Ior wear or damaget Clean carbon deposits from the exhaust port area. Inspect the cylinder bore for wear at three levels in X and Y dimctions. Take the minimum leagure measured to determine the cylinder wear. Avoid the port area. SERVICE LIMIT: 40.05 mm (1.5758 in) CAUTION —/ The cylindar has at A or B mark on the cranked." mating fate as shown When the cylinder is to be rephcd with a new one. we a cylinder having the mint mark as the IM—_ Measure me piston 0.0. at a point 4 mm from me botlom of the skin SERVICE LIMIT: 39.900 mm (1.5709 in) Calculate the piston-toeylinder clearance. SERVICE LIMIT: 0.100 mm (0.0039 In) MARK A OR B Data of Issue: Nov., 1980 © HONDA MOTOR Cot, LTD. CYLINDER HEAD/CYLINDER/PISTON Measure me piston pin hole 1,0» SERVICE LIMIT: 10.030 mm (0.3949 in) Measure Ihe piston pin O.D. SERVICE LIMIT: 9.970 mm (0.3925 in) PISTON RING INSPECTION Measure each piston ring and gap. SERVICE LIMITS: TOP/SECOND: 0.60 mm (0.02‘ in) NOTE Sex each piston ring squarely into the cy- linder at a point 31 mm (Main) from the bottom using me piston and measure the end gap, CONNECTING HOD INSPECTION Insta|l the hearing and piston DI" in lhe connecting rod small and and check for excessive play. Measure the connecxing rod small and LD. SERVICE LIMIT: “.030 mm (0552‘ in) HONDA NXSOM PISTON PIN HOLE LD. PISTON PIN O.D. Dam of Issue: Now, 1980 © HONDA MOTOR OOH LTD. HONDA NXSOM CYLINDER HEAD/CYLINDER/PISTON PISTON/CYLINDER INSTALLATION Clean the gasket surfaces GI the cylinder and crankcase. Install the expander in the second ring groove. Align xhe ring ends with “18 locating pins in the ring grooves. Install the (up and second rings in their respective ring grooves with the markings Iacing up. CAUTION ‘ , S The rop ring is a keystone ring and is no! inmchmueable wnh the square second ”'Ll Ched< the Ii! 01 each ring in its groove by pressing the ring into me groove to make sure that it is flush with the Dislon at several points around the ring. A ring thai will nut compress means that the ring groove is dirty and it should be cleamd, cgumou Do mu replace one I the other. PISTON TOP RING SECOND RING EXPANDER TOP RING SECOND RING \5 ‘ — EXPANDER \P PISTON RING MARKINGS: 1T: TOP 2T: SECOND Date of Issue: Nov., 193) © HONDA MOTOR CO., LTD. HONDA CYLINDER HEAD/CYLINDER/PISTON 'E NXSOM RING PINS Be sure the ring and gaps are aligned with the nistvn ring pins in the ring grooves. Inn-ll the needle bearing in tho connecting rod, install th: piston with the piston pin. cwnou _, ‘ Install the piston with (In: "EX” Mk facing the “him“ side. ’ Dip the piston pin in clean engine ail pgfqn Installation. Install new piston pin clips, NOTE Do not let the clip fall intgme crankcase. ”EX" MARK Flaca the cvllnder gasket on the crankcase. Lubricate the pistan and cylinder with 2-Serke oil and install the cylinder over the piston while compressing the piston rings. CAUTION Be sure the rings do not rotate in [hell grooves over the locating pins to prevent ring breakagu and piston and cylinder damage. 6-8 Dale 0! Issue: Nov.,19m © HONDA MOTOR CO” LTD. HONDA. NXSOM CYLINDER HEAD/CYLINDER/PISTON CYLINDER HEAD INSTALLATION lnsull the cylinder head on (he cylmder using a new cylinder hand gaskeL Install and tighten the four cylinder head bolts. TORQUE: 9—12 N-m (0.9—1.2 kglm, 7—9 fl-lb). Install the choke control box. CAUTION Befone installing the mnrml box. clean 7):: cylinder head mating surface fhoroudlly. lnsmll me muffler, Insxall the step cross bar, frame cover, rig“ and left sxeps and side covers. Perfnrm the following inspecuons: - Compvession test (Page 3-5) - Check for abnormal engine noise. - Check lor cylinder air leaks. CONTROL BOX Dale of Issue: Nov., 1980 © HONDA MOTOR CO” LTD. A. c. GENERATOR Kg, NXSOM (15—40 kg-m. 25-29 fI-lb) 7-0 Date of Issue: Nov., 1980 © HONDA MOTOR 00., LYD. @“fi’x‘m‘ 'I.A.C. GENERATOR l SERVICE INFORMATION 7—1 A.c. GENERATOR REMOVAL 7—2 A.c. GENERATOR INSTALLATION 7—4 SERVICE INFURMHIBN GENERAL INSTRUCTIONS - All A.C. gmralor maintenance can be made with lhs angina lnslalled. ~ Do not remove the pulse generator from the stator basel ~ See Chamer 13 (or A.C. generatar inspfictiofl‘ TOOLS Special Flywheel Hulda! 079244 870000 Flywheel Puller 07933—155000? Dale 0' Issue: Nov., 1980 7. 1 © HONDA MOTOR CO.‘ LTD. HON DA A. c. GENERATOR 6%/ NXSOM M). flENERATflR REMUVAL 6 coupqus Remove {he carburetor cover‘ Drsconnect the A1; generator and starter couplers. Remove the bolts auachmg the generator cover and remove the cover. Rsmuve the rear fender attaching Don. GENERATOR COVER REAR FENDER Unclamp the wuss "cm the sraner mutur body. p’ Pull the rear fender away arr! remove the starter. Remove the staner motor cable. Check the starter motor (Page 13-10) STARTER MOTOR 7- 2 Date of Issue: Nov.. 1930 © HONDA MOTOR (20., LTD‘ HONDA NXSOM A. c. GENERATOR Install the flywheel holder‘ Remove the flywheel 10 mm flange nut. FLYWHEEL HOLDERV 07924—187000!) FLYWHEEL FULLER 07933-155000? Remuve the flywheel. - . ‘ NOTE Keep the woodrufl key in a part rack to prevent it from being scatters Remove the MD bolts attaching the stator t0 the ganemor cover. Remove the stator. NOTE 7 f - Do not remove the puke generator from ‘ the slaw! base. ‘ Avoud datnfllng the stator cmlst inspect the Act generalor (Page 13-6, 13-81 PULSE GENERATOR Date 0| Issue: Nov., 193) 7 3 (c) HONDA MOTOR co.. LTD. ' HONDA A. c. GENERATOR NXSOM LC. BENERHflR INSTALLATIIJN Install the 5‘2")! in the mnerator cover, GENERATOR COVER Insull ‘he woodru" key in the crankshalt keyway. NOTE Clean the taper hole In the flywheel 0! any burrs and dirt. Ins‘all lhe flywheel onto thn crankshaft. Torque (he flywheel 10 mm flange nut. TORQUE: 35PM) N-m (3.5—4.0 kg-m, 26—29 lt—Ibl Attach the starler motor table and Install the starter motor. Clamp the wires to the Stine! molar body. STARTER MOTOR 7.4 Date ol Issue: Nov., 1980 © HONDA MOTOR C11. LTD. HONDA NXSOM A. c. GENERATOR $53; Install the generalov covey. Secure the wires wi‘h the wire clamps. Inslall the rear fender boll, COUPLERS Connect the A1; generator and siarlel mole! couolers and secure the wires with the wire clamp. Check the Ignition timfing (Page 35). INDEX MARK Dale of Issue: Nov.. 19K) 7 5 © HONDA MOTOR 00., LTD. - DRIVE AND DRIVEN PULLEY/ HONDA KICK STARTER/CLUTCH (gig, NXSOM TORQUE: 35—40 N-m (3.5—4.0 kg-m, 25—29 lblb) TORQUE: 354D Nrm (3.5—4.0 kg-m, 25‘29 h-Ib) 8-0 Dane 09 Issue: Nov., 1980 © HONDA MOYOR 00., LTD. HONDA 8 DRIVE AND DRIVEN PllllEY/ Nxsom . KIIIII STARTER ELIITIIH SERVICE INFORMATION 3—1 TROUBLESHOOTING 8—1 DRIVE PULLEY 3.2 KICK STARTER 3.3 CLUTCH/DRIVEN PULLEV 8—14 GENERAL INSTRUCTION - Keep oily substances all the drive belt and pulley. TOOLS Special Common Lock Nut Wrendi (39 mm) 07916—1870001 Universal Holder 07725—0030000 Driven Gear Holder 07924—1970000 Clutch Spring Compressnr 0796071870000 SPECIFICATIONS ITEM STANDARD mm (in) I SERVICE LIMIT mm (in) Drive belt width . 14.0 (0.55) I ran (0.5m Movable drive face bushing LD. 25035—25095 (09856-09560) . 25.130 (09894) Drive lace has 0.0. 24395—25025 (09841—03852) 24.939 (0.9327) Weight roller 00. 15.92—16.08 (0627—01533) 15.40 (0.606) Kick slaner spindle 0.0. 13357—11984 (05495-05506) 13.900 (0.5472) Kick starter spindle bushing 1.0. (MB) Mme—14.051 (05518—05532) 14.100 (0.5551) Kick slarlel spindle bushing on. (AIM 17.965» 18.000 (07073—07087) 17.900 (0.7047) Kick starter idle gear shaft 0,0. 9365—9387 (03923—039321 9.900 (0.3898) Kick starter idle gear shalt bushing LD. 10013-10035 (0.3942—0395“ 10.100 (0.3976) Clutch outer |.D. 1070—1072 (4.21—4.22) 107.5 (4.23) Clutch shoe Ihickness 4.0 4.1 (0157—0161) 2.0 (0.08) Driven lace spring free length 93.4 (3.68) 38.0 (3.46) Driven lace O.D. 33850—33875 (13366—13376) 33.930 (1.3358) Mavable driven lace LD. 34000734025 (13386—13396) 34.060 (1.3409) TllllllIlLESIIllllTlIlli Engine starts, but motorcycle won 't move 1-"?wa Worn drIve bell Broken ramp plain Worn or damaged clutch lining Broken torque spring Damaged driven pulley shalt splines Engine stalls or mutorcycle starts suddenly 1. Broken clutch weight spring 2. Damaged clutch lining Pour perlormanoe at high speed or lack of power Worn drive bell Weak torque spring Worn weight roller Faulty driven lace Worn or seized driven pulley bearing P‘PP’N,‘ Clutch noise or smell 1. Oil or grease on drive belt or pulley 2. Worn drive belt 3. Weak torque spring 4. Worn or seized driven pulley bearing Date of lgue: Not. 1980 © HONDA MOTOR 00.. LTD. \ HONDA DRIVE AND DRIVEN PULLEY (if; 1 KICK STARTER/CLUTCH / $§/ NXSOM DRIVE PULLEY LEFT CRANKCASE COVER REMOVAL Remove the kick starter pedal. - Remove xhe boll attaching me Is“ case cover. Remove the left case covev‘ Remova ma kick slarlav spindle bushing A Irom (he I case coverI Chad the kick starter spindle bushing A for dam- age, Muasuve the bushing ID, SERVICE LIMIT: MJDOmm (05551 in) BUSHING A 8-2 Date of Issue: Nov” 1930 <0 HONDA mama col. m). HONDA. DRIVE AND DRIVEN PULLEY/ NXSOM KICK STARTER/CLUTCH DRIVE BELT REMOVAL DRIVE BELT Expand the movable driven lace enough to remove " V the drive belt. Remove lhe driva belt. CAUYION Do nar bend [he drive belt 2 . I / MOVABLE DRIVEN FACE DRIVE BELT INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wean Measure the drive hell's width. SERVICE LIMIT: 13.0 mm «151 in) KICK STARTER IDLE SHAFT KlCK STARTER SPINDLE MOVABLE DRIVE FACE REMOVAL/ Q ' DISASSEMBLY Ramove \he kick slarter spindle wilh installing the kick arm. Remove the kick starter idle aha“ (Pam 3-9), KICK ARM Dale of Issue: Nov.. 198) 8 3 9 HONDA MOTOR Col, LTD. - HONDA NXSOM DRIVEN GEAFI HOLDER 10mm NUT _ 0792471970000 DRIVE AND DRIVEN PULLEY/ KICK STARTER/CLUTCH White holding me cvankshah, remove me 10 mm nut. Remove the movable drive face assembly. MOVABLE DRIVE FACE ASSEMBYL FACE SEAL MOVABLE DRIVE FACE DISASSEMBLY Remove the three boll: anachmg (he movable drive face seal‘ Remove the seal. RAMP PLATE Remove the ramp pla‘e. 8-4 Date of Issue: Nov., 19% 9 HONDA MOTOR C0.. LTD. HONDA / NXSOM DRIVE AND DRIVEN PULLEY/ KICK STARTER/CLUTCH Remove the weight rollers. MOVABLE DRIVE FACE INSPECTION Check each wIlel for wear or damage. Measure each roller 0.0. SERVICE LIMIT: 15.10 mm “16“ in) Measuve the movabIe dnve face bushing ID. SERVICE LIMIT: 25130 mm (0.9394 In) WEIGHT ROLLER OI TAKE MEASUREMENTS AT WORN AREA Date of Issue: Nov” 1980 © HONDA MOTOR C0,, LTDI HONDA DRIVE AND DRIVEN PULLEY/ NXSOM KICK STARTER/ CLUTCH Inspect the drive face boss for war or damage. Measure the 0.0. at the drlve face cnnucling face. SERVICE LIMIT: 24.960 mmIfl.9827In) MOVABLE DRIVE FACE ASSEMBLY Lubricale the inside M the drive Iace wim grease, lherl install Iha welmt fDllEfS‘ N975 , lApplv 10 — 159 (035 — 0.53 01,) OI grease , to the inside DI the drive lace evenly. SPECIFIED GREASE: LITHIUM BASED GREASE MITSUBISHI HD»3 (NIPPON SEKIYU LIPANOX DELUXE 3 IDEMITSU CORDNEX Bar equivalem lns‘all the ramu plate and movable face seal. Torqua the seal attaching be": to the Speclfied torque. TORQUE: 2.5—4.0 N~m (0.25—0.40 kn-m, 2—3 ft-Ib) NOTE Make sur: that ‘he O-Iing is no! disposi- uoned. / ' MOVABLE FACE SEAL I 8-6 DaIe of Issue: Nov., 1980 © HONDA MOTOR (20., LTD. DRIVE AND DRIVEN PULLEY/ KICK STARTER/CLUTCH MOVABLE DRIVE FACE ASSY DRIVE FACE 30$ Install the drive lace boss in he movable drive Iaces s.“ " ' , ' Install Ihe assembly on me crankshalts ' OW Clean the hole in the movable drive fact. drive fin'e ban and the cranluhafl. lnswll ma drive lace and tighten with (he 10 mm I'IUL TORQUE: 35—40 N-m (3.5—4.0 kg—m, 25—29 ft-Ih) CAUTION __——_ Do not gt! oil or grease on the drivebelt or pulleys. DRIVE FACE on: EN GEAR HOLDER 079244070000 Install the kick sxarter ldle shah and the lek slarlav spindle (Page 843i, Install me drive bell over the pulleyss CAUTION Dd not bend [he drive belt. Install the Iah case cover. Install xhe kick starter pedal and Ieh side cover. Dan of Igue: News, 198) 8'7 © HONDA MOTOR CO” LTD. DRIVE AND DRIVEN PULLEY/ KICK STARTER/CLUTCH KIBK STARIER g ‘ HONDA ,_/ NXSOM 8.8 One of Issue: Nov., 1980 o HONDA MOTOR co., LTD. 2 “$3133 DRIVE AND DRIVEN PULLEY/ KICK STARTER/CLUTCH KICK STARTER REMOVAL MOVABLE DRIVE FACE ASSEMB Remove the Ielicase cover and drive bell. " ‘ STOPPER Disengage me pawl on 1h: back of the kick starter spindle gear from the idle shah by roaring the spindle counterclockwise wlm kick arm. Remove me kick starter spindle‘ IDLE ‘SHA KICK STARTER IDLE SHAFT Remove the kick starter Idle shah. Dale of Issue: Nov., 1980 8_9 © HONDA MOTOR (10.. LTD, DRIVE AND DRIVEN PULLEY/ KICK STARTER/CLUTCH Remove 1he movable drive face assembly (Page 3—4]. Remove the kick starter driven gear using a cum- mercial gear pallet, CAUTION _ Hold the driven gear Wllh fingers m prevent tommg out dumg upzrunon. KICK STARTER DISASSEMBLY Disassemble the kick starter spindle. Disassemble the kick staner MIG shah. GEAR FULLER AND SHAFT PROYECTOR HONDA NX50M KICK STARTER DRIVEN GEAR DRIVEN GEAR HOLDER 079244970000 SPRING COLLAR KICK STARTER SPINDLE " STARTER IDLE GEAR @: E STARTER |DLE SHAFT I WQQ 8-10 Date ai Issuz: Nov" 1980 © HONDA MOTOR 00., LYD. HONDA NXSOM KICK STARTER INSPECTION Inipecl the kick Stfll‘el spindle lav wear or damage. Measure the spindle O.D. SERVICE LIMIT: 13.900 mm (0.5472 in) Inspect the kick starter spindle bushing B for wear or damage: Manure [he bushing |.D. SERVICE LIMIT: 14.100 mm (0.5551 in) Measure (ha bushing 0.0: SERVICE LIMIT: 17.9001"!!! (0.7M7in) Inspect the idle gear and bushing 1m wear or damage. Measure xhe bushing |.D. SERVICE LIMIT: 10.100 mm (0.3976 in) Measure the bushing 0.D. SERVICE LIMIT: 13.900 mm (0.5472 in) Measure the idle gear CD, at the bearing surlacss: SERVICE LIMIT: 9.900 mm (0.3898 in) DRIVE AND DRIVEN PULLEY/ KICK STARTER/CLUTCH Data 0' Issue: Nov" 1900 O HONDA MOTOR 00., LTD. 8-11 DRIVE AND DRIVEN PULLEY/ KICK STARTER/CLUTCH KICK STARTER ASSEMBLY Align the punch mark on the idle gear and idle shaft and assemble Ihem. NOTE The marked surfaces should be flush with each other. Inserl the short end a! the spring in the hole of the kick starter spindle, Install the spling collar with me gvoova In the collar aligned with me spring. Install the thrust washer on the spindle. 8-12 HONDA NXSOM SPRING COLLAR THRUST WASHER PUNCH MARKS SPRING KICK STARTER SPINDLE Dale of Issue: Nov.,19w 6 HONDA MOTOR 60., LTD. HONDA NXSOM DRIVE AND DRIVEN PULLEY/ KICK STARTER/CLUTCH KICK STARTER INSTALLATION Clean the taper on the crankshalt and install the driven gear. Install the drive lace assembly (Page 8‘7lr Install the kick staner idle shaft aligning the friction spring with the groove in the left case as shown. Point the arrow mark on the starter idle gear toward the crankshalt, pressing the starter idle gear against the left case by turning the idle gear shaft counter» clockwise NOTE Apply grease to the spring groove and spline of the idler gear. Turn the idle gear shalt until more is no clearance between the idle gear and idle shah gear. Hook the long and ol the spindle return spring on the move on the kick starter idle shaft. Install the kidt starter spindle; turning the idle gear to align the punch marks as shown. Install the Ielr case cover, left side cover and kick starter pedal‘ NQIE FRICTION SPRING ”ARROW 6 is KICK DRIVEN GEAR KICK STARTER IDLE SHAFT PUNCH MARKS RETURN SPRING m PUNCH MAR KS Align the punch marks on the kick staner pedal and the kid: starter spindle when installing the kick starter pedal. Date 0! Issue: Nov., 1930 © HONDA MOTOR (20‘, LTD. DRIVE AND DRIVEN PULLEV/ @' 83:23:1‘ KICK STARTER/CLUTCH \,/ lIlllTCH / DRIVEN PllllEY / W TORQUE: 35—40 N-m (as—4.0 kgrm, @@ a g 2549 Mb) , Q) .. TORQUE: 35—40 N-m (3.5—4‘0 kgm, 25—29 ft-lh) 8.1 4 Date of Issue: Nov., 1930 © HONDA moron co., no. HONDA NXSOM CLUTCH REMOVAL Remove the left case cover. Remove the ID mm nut holding the clutch oular. Remove the clmch outer. Wilhdraw me movable driven 1302 from the drive shaft wuh me drIve beh while expanding the movable dnven Iaoe‘ DRIVE AND DRIVEN PULLEY/ KICK STARTER/CLUTCH UNIVERSAL HOLDER Date of Issue: Nam, 1980 © HONDA MOTOR 00.. LTD. DRIVE AND DRIVEN PULLEY/ KICK STARTER/CLUTCH DRIVEN FACE DISASSEMBLY Remove the 28 mm nul using the spacnal tools. CAUYION I Do not m’ertighren the clutch spring m prawn LOCK NUT WRENCH [39mm) 28mm NUT' 079164570001 DRIVE PLATE \ 1 CLUTCH SPRING CLUTCI I WEIGI IT / 28 mm NUT 8.1 6 Date 0' Issue: Nov" 1980 © HONDA MOTOR 00., LTD. HONDA NXSOM DRIVE AND DRIVEN PULLEY/ KICK STARTER/CLUTCH “1% Remove the seal collan SEAL CO LLAR GUIDE ROLLER PIN Withdraw (he finds roller pin and guide roller. GUIDE ROLLER MOVABLE DRIVEN FACE DISTANCE COLLAR SEAL COLLAR GUIDE ROLLER PIN" GUIDE ROLLER Date of Issue: Nov., 1980 © HONDA MOTOR 00., LTD. 8'1 7 DRIVE AND DRIVEN PULLEY/ KICK STARTER/CLUTCH CLUTCH/DRIVEN FACE INSPECTION Impact the clutch outer (or wear or damage. Measure the clutch outer I.D. SERVICE LIMIT: 107.5 mm (4.23 in) Inspect the clutch shoes Io: wear or damaga. Measure the Ihiekness of each shoe. SERVICE LIMIT: 2.0 mm (0.079 in] Measuve the driven face spring Iraq length. SERVICE LIMIT: 88.0 mm (3.48 in) CLUTCH SHOE CLUTCH WEIGHT HONDA NXSOM 8-18 Date 0' Issue: Now, 1980 © HONDA MOTOR 00., LTD. HONDA NXSOM lnspecx rhe driven lac: assembly lor wear or damage Measure the drivun lacs 0.D. SERVICE LIMI'I: 33.930 mm (13358 in) lnspecl the movable driven face for wear or damage. Measure the movable driven hoe I.D. SERVICE LIMIT: 34.060 mm [1.3409 in) Check the oil seal for mar, damage or other faults. check the drive shah collar O-rlng and replace il worn or damaged. DRIVE AND DRIVEN PULLEY/ KICK STARTER/CLUTCH DRIVE SHAFT COLLAR \ \ Dale of Issue: Nov" 1980 © HONDA MOTOR C0,. LTD. 8-19 DRIVE AND DRIVEN PULLEV/ KICK STARTER/CLUTCH DRIVEN FACE ASSEMBLY Install the movable driven face, guide roller, guide rollar pin, oil seals and O-rings. NOTE Apply 4‘ 4.59 (0.14 — 0.16 oz.) of grease to the areas shown. Slide the distance collar Into the movable driven lam. CAUTION V? Immll the dimmcc coflar with rhe oil ho]: ml the drive sha/i‘ collar side. DRIVEN PULLEY ASSEMBLY Positian the driven face assembly, spring and drive plate assembly on the clutch saring compressor. Compress the spring by turning the handle while aligning lhe flat faces oi the driven face and drive platel GUIDE ROLLER PIN HONDA. ‘ _/ NXSOM GUIDE ROLLER SEAL COLLAR CLUTCH SPRING COMFR ESSO Fl 0796071870000 8-20 Dale of Issue: Nov.. 1980 © HONDA MOTOR CO., LTD, HON DA DRIVE AND DRIVEN PULLEV/ NXSOM KICK STARTER/CLUTCH CLUTCH SPRING COMPRESSOR D7960~1870000 lmtall and tighten the 28 mm special nut. TORQUE: 35—40 N—m (3.5—4.0 kg—m. 26—29 h-lh) 1/ LOCK NUT WRENCH 39 mm) 07916—1870m1 CLUTCH/DRIVEN PULLEY INSTALLATION Place the drive belt on the driven face. Install the driven face on the drive shaft while spreading the movable ngen face. Install the clutch outer and tighten the nut. TORQUE: 35—40 N-m (3.5—4.0 kg-m, 25—29 lt-lh) Install the left case cover. Install the kick startur pedal. UNIVERSAL HOLDER Dale of Issue: Nov., l980 © HONDA MOTOR (30., LTD. FINAL REDUCTION HONDA NXSOM 9-0 Date of Issue: Nov., 1980 © HONDA MOTOR 00., LTD. HONDA NXSOM 9. FINAL REDUCTIUN SERVICE INFORMATION TROUBLESHOOTING FINAL REDUCTION DISASSEMBLY FINAL REDUCTION INSPECTION FINAL REDUCTION INSTALLATION 9—1 9—1 9—2 9—3 9—4 SERVICE IIIFIJIIMIITIIIII GENERAL INSTRUCTIONS Specified oil Oil quantity TOOLS Special Mechanical seal driver attachment Common Bearing Outer Driver & x 36 mm Bearing Outer Driver 37 x 40 mm Bearing Outer Driver 42 x 47 mm Baarlng Driver Film 15 mm Bearing Driver Film 17 mm Omar Handle A TIIIIIIBLESHIIIITIIIE Engine srarls, bm motorcycle won‘r move 1. Damaged transmission 2. Seized or burn: xransmission Abnormal noise 1‘ Worn, seized or chipped gears 2. Worn bearing 3, lnsulflcien! oil #90 gear oil 900: (3.0 US 31., 7.5 Imp. oz.) 079454150200 07 746-00 1 0 l 00 07746-00I02w 07 74500 1 0300 07746-00403“) 077460040403 07749-001000!) Oil leaks 1‘ on level [00 high 2. Worn or damnged ail seal Dale of Issue: Nov., 1930 © HONDA MOTOR co‘, LTD. FINAL REDUCTION FINAL REIJIJCTIIIN DISASSEMBLY Remove the driven pulley (Page 845]. Dram oil from the transmission case (Page 23). Remove the rear wheel (Page 12-2]. Remove the bolts attaching the transmission cover and remove the cover. flemove the final gear and countershalt. FINAL GEAR TRANSMISSION COVER Remove the drive shaft from the transmission caver. y. DR IVE SHAFT 9- 2 Date of Issuct Now, 1980 © HONDA MOTOR mt. LTD. HONDA NXSOM Check the transmission cover hearing play by routing the hearing by hand. Replace the bearing with a new one if is is noisy or has excssive play (Page 95). Inspect the oil seal for wear or damage. Replace (he oil seal with a new on. if worn or damaged. TOOLS: Bearing Outer Driver 32 x 35 mm Driver File: 15 mm Ourer Handle A Check the left case bearing play by rotating the bearing by hand Replace the bearing with a new one if it is noisy or has excessive play. Check the 01' seal for wear or damage and replace with a new one if necessary. TOOLS: Common Bearing Outer Driva 37 x 40 mm Drive Pilot 17 mm Outer Handle A Spea’al Medlanical Seal Driver Armchmenr 079454150200 FINAL REDUCTIUII INSPECTIIIN Inspect the drive shaftand gear for wear or damage. FINAL REDUCTION Date of Issue: Nov” 1930 Q HONDA MOTOR 00‘, LTD. FINAL REDUCTION Check the oountershaft and gear for wear 07 damage‘ Check the final gear for wear, damage or signs 07 wizure. FINAL REDUCTION INSTALLATION Clean the cover mating surface a! the final reduc- uon case 0! any gasket maxerial. 9.4 Date 00 Issue: Nov.. 1980 © HONDA MOTOR 00., LTD. ‘ HONDA NXSOM FINAL REDUCTION TRANSMI$ION COVER ASSEMBLY TRANSMISSION COVER Slide me drive shaft through me bearing from the inside. DRIVE SHAFY _ COUNTERSHAFT Install the munmuhan and firm gear. - s ‘ Install the breather tube, ‘m FINAL GEAR BREATHER TUBE WASHERS WAVE WASHER mm" the lvansmission cover using a new gasket. lnslall me rear wheel (Page 12-3). SEAL WASHER Date of Issue: Nov” 19w (9 HONDA MOTOR 60., LTD. m HONDA FINAL REDUCTION 339/ NX50M MOVABLE DRIVEN FACE A§YA Install the (“Well face and the clutch outer (Pay: , > ' - . 8211. « _ 9 Pour (he specdied amount of OH through the Iillcr opening. SPECIFIED OIL: #90 par oil QUANTITY: 90 0: (3.0 U.S. 01., 2.5 Imp. on Slarl the engine and check for leaks. 9-6 Date of Issue: Nov“ 1980 © HONDA MOTOR C0., LTD. HONDA NXSOM CRANKCASE/CRANKSHAFT Dale of Issue: Nov., 1980 © HONDA MOTOR 00., LTD. 1 0-0 cRINKcISE II]. CRANKSHAF SERVICE INFORMATION 10.1 CRANKSHAFT INSPECTION 10~3 TROUBLESHOOTING 10—1 CRANKCASE ASSEMBLY 10—5 CRANKCASE SEPARATION 10.2 CRANKSHAFT REMOVAL 10.3 SERVIBE INFIIRMATIIIII GENERAL INSTRUCTIONS ' The following pans must be removed before separating the crankcase: crankcase: Engme Page 5-2 — Mounting bracket ~ Center stand Oil pump Page 25 Reed valve Page 4-9 chk staner dnven gear Page 8-9 A.C, generator Page 7-2 Cylinder head, cvllndev Page 6-2 In addiIion to the above, remove the following parn when Ihe |91l crankcase halve musI be rcplaoad: Rear wheel Page 12-2 Final reduction Page 92 T00 LS Special Crankcase Fuller 079354870000 Seal And Case Assembling Tool 079654480001 Assambling Tool Attachment 079651870100 Common Bearing Outer driver 42 x 47 mm 077430010300 Bearing driver pilot 20 mm 077460040500 Bearing drivcv handle outer A 07749-001000!) SPECIFICATIONS 7 STANDARD mm (In) SERVICE LIMIT mm (inI CONNEOTING RO‘D BIO’END’SIDE — 0.60 (0.0241 CLEARANCE CONNECTING ROD BIG END RADIAL —-—- 0.05 (DDOZI CLEARANCE CRANKSHAFT RUNOUT A — 0715 (00061 B — 010 (0.004) TROUBLESHOOTINE Abnormal engine noise 1. Worn main journal bearing 2. Worn crankpin hearing 3. Worn (ransmissron bearing Date of Issue: Nov., 1933 - © HONDA MOTOR (20., LTD 10 1 CRANKCASE/CRANKSHAFT CRINKEASE SEPARATIIJN Pavlorm the following operations: Engine removal (Page 5—2I Oil pump remuval (Page 2-5I Reed valve removal [Page 4-9) Rear wheel removnl (Page 122! Remove the engine mnunting bracket. Remove the canker sland hrackel. Remove me cylinder head, cylinder and piston (Page 6-2). Remove the A.C. gemrilul (Page 7-2). Remove the kick starter driven gear (Page 8-9), - Remove m2 llnal Ieduuion assemhlv (P29! 9'2)l Remove ma crankcase machmg bolts. 1 0-2 Date of Issue: Nov.,1980 e HONDA MOTOR co., LTD. HONDA NXSOM CRANKCASE/CRANKSHAFT CASE FULLER 07935-1370” Much "I smdal tool on ‘he right crankcau a: ,. " shown Separate the ermkcm halves, IIIIAIIIISIIAFT REIMIVAI Attach the special tool on the left crmkcase as shown; Ramon ma crankshaft from the left crankcase. CRAIIIISHAFT IIISPEETIIIII Measure the conneuing Iod big and side clearance with a Iaaler gauge. SERVICE LIMIT: 0.60 mmll).024in) Dam of Issue: Nam, 1930 _ O HONDA MOTOR C0.. LTD. 10 3 CRANKCASE/CRANKSHAFT Measure the connecnng rod big and radial clearance ax two points in the X and Y directions. SERVICE LIMIT: 0.05 mmIOJJOZin) Set an: crankshak on a stand or V-blocks and read runout using a dial mugs. I The actual mnoul is V: of TIR (TOTAL INDICA- I TOR READING). SERVICE LIMITS: A: 0.15 mm (0.006 in) B: 0.10m!“ (0104 in) Spin the crankshaft hearing by hand and check for play. The bearing must be "placed if it is noisy or has excessive play. PLAY PLAY HADIAL AXIAL 1 0.4 Date 0' Issue: Nov., 1930 o HONDA moron 00.. LTD. CRAIKCISE ASSEMBLY Wash the crankshaft in solvent and blow dry with compressed air. Check for cracks or ether faults. Remove all gasket material from the crankcase mating surfaces. Dress any roud'rnes or irregulalities with an oil stone. Apply dean engine oil to all moving and sliding surfaces. Install the crankshaft into the left crankcase. NOTE Lubritzte the crankmah main and humai bearings with Honda Estroke iniector oil or equivalent. Instzrll a new gasket and the dowel pin to the crank- ase matinu surface. Assemble the erankmse halves. Assemble the removed parts in the reverse order of removal (Page 10-2), ORAN KcASE/CRANKSHAFT ASSEMBLING TOOL ATTACHMENT 07965-187010!) SEAL AND CASE ASSEMBLING TOOL 079551480111 ‘ . Dam of Issue: Nov., 19m © HONDA MOTOR (20.. LTD. 10-5 HONDA EEEEEE NG/FRONT WHEEL/FRONT BRAKE/FRONT FORK NXSOM 11-0 HONDA H STEERING/PRINT WHEEl/ NXSOM FRUNT BRAKE/FRlllll FURK SERVICE INFORMATION 11—1 TROUBLESHOOTING 11-2 SPEEDOMETER 11—3 HEADLIGHT 11—4 HEADLIGHT CASE/FRONT CARRIER 11—5 STEERING HANDLEBAR 11_5 FRONT WHEEL 11—10 FRONT BRAKE 11~14 FRONT FORK 11—16 STEERING STEM "—19 SERVIIIE luromllllnll GENERAL INFORMATION ’ Brake dust may contain asbestos which can be harmful (0 your health, ' Do not use compresyed air to clean brake drums nr brake panels, ‘ Use a vacuum with a sealed dust collector. Wear a proteaive face mask and rhoroughly wash your hands when finished TOOLS Special Ball Race Driver 079444150001 1 1 Bearing Diner Driver 28 x 30 mm 079464870100 Common Pin Spanner 07702-001000!) nr M9361—412—099'IBB (USA Dnlv) Lock Nut Wrench Soda" 30 x 32 mm 077160020400 — Commarciallv available Extension Bar & Handle 077160020500 , Commercially nvailabla Bearing Driver Pilot 10 mm 077460040100 Bearing Driwr Handle Outer A 077490010000 SPECIFICATIONS 7 ITEM [ STANLZARD ‘1 SERVICE LIMlT . Axle shaft runout 0.2 mm (0.008 in) Him runoul Radial -— 2.0 mm (0.08 in) Axial 2.0 mm (0.08 in) Brake drum |.D. 79.5 mm (3.13 in) 80.5 mm (3.17 in) Fork snrinniree length 94.5 mm (3.7231) 92.0 mm (362 in) Fork lube runomi r 0.2 mm (0.008 in) , 1 gate oi Issue: Nov.. 1930 1 1 _ 1 HONDA MOTOR C0., LTD. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT FORK TROUBLESHOOTING Hard Steering 1. Steering sum not too tight 2. Damaged steering stem bearings 3. Damaged steering bail and cone races 4. Insufficient tire pressure Steers to One Side or Does Nat Trad< Straight 1‘ Bent iront forks 2t Bent front axle 3. Bent spoke plate HONDA NXSOM Front Wheel Wobbling . Bent rim Axle not tightened properly , Bent spoke plate . Excessive wheel bearing play t Faulty or unevenly worn tire Ulbugo- Soft Suspension 1. Wtak lurk swings Front Suspension Noise 1. Slider binding 2. Loose iron! fork fasteners 3. Lack oi lubrication 11-2 Data oi Issue: Now. 1980 © HONDA MOTOR C0.. LTD. HONDA NXSOM STEERING/FHONT WHEEL/FRONT BRAKE/FRONT FORK i SPEEDBMETER ‘ 3mg PA L REAR seven 1 REMOVAL Remove the speedometer cable from the brake panel by removing the set screw. Remove the speedometer with the rear cover by removrng the attaching bolt. Remove the rear cover from the speedometer by bending the retaining springs. Disconnect the speedometer cable lrom the speed- ometer by removing the cable nut. Remove Ihe speedometer lamp sockets and remove the speedometer. CAUTION Do no! 1:! the rpeedomem upside down. because internal lubricant may get on the tear. INSTALLATION Install and tighten the speedometer retaining spring attaching screw: Connect the speedometer cable [0 the speedometer. Install the rear cover, NOTE Make sure that the headliylt case engages , the rear cover properly. Carelully prexs the speedometer into position unlil the retaining springs engage the rear cover. Dam of Issue: New, 198) 1 1 _3 © HONDA MOTOR CO” LTD. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT FORK HEADLIGHT REPLACEMENT Remove the headlight by vemoving the attaching screws and collars. LOCK SCREW LOCK PIN Disconnect the headlight connectors. » ' ‘ : Remove the lock pin and lock screw. Remove the headllyn beam adjusting screw. Replace the headlight wilh a new one. insult the headlight in the headlight case. Adiust the headlight vertical 3nd horizontal aim with the adjusting screws. 1 1 -4 Date cl Issue: Mon, 1930 © HONDA MOTOR 00.. LTD. ’ HONDA NXSOM HEAlllIGHT EASE / FRllllT CARRIER HEADLIGHT CASE REMOVAL/INSTALLATION Remove the from basket by removing the mo attaching screws and a bolt Remove the speedometer and the rear cover (Page 11-3). Remove the right and left front turn signal mounu. Remove the iron! basket mounung hracket by removing the can nut. Remove the [we halts attaching the lront basket mounting bracket and headlight case. Remove the bracket and headlight case. Installation of the headlight case is essEntiallv the reverse order oi removal. NOTE - Check that all wires and cables are routed properly. r - Check the front carrier ior proper instal- Iatinn before installing the headlight case. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT FORK FRONT BASKET SPEEDOMETER MOUNTING BRACKETS TURN SIGNAL MOUNTS 'FRONT CARRIER Date 0' Issue: Nov‘, 1980 © HONDA MOTOR (30., LTD. 11-5 STEERING/FRONT WHEEL/FRONT BRAKE/FRONT FORK STEERING HANDLEBAR HANDLEBAR REMOVAL Remove the speedometer (Fag! 113). Remove Ihe haadlight casa (Page IT‘S). Remove the from carrier by removing the two flange mm and flange bolts. FRONT CARR ER WIRE BANDS Ramove (he wire bands aluching the right and left handlebar switch wires to the handlebar. Remuve the Mn screws auacfiing rhe lighting swirch housing Remove the switch housing. Remove the two screws anachmg the throttle yip hOUSlflg. Remove the lhroitle grip housing, NOTE Loosen the rear screw first to ease removal. 1 1 .6 Dam of Issue: Now, 1930 © HONDA MOTOR 00., no. HONDA @ NXSOM STEERING/FRONT WHEEL/FRONT BRAKE/FRONT FORK EXTENSION BAR 8t HANDLE (Commercially available) Disconnect the combination switch coupler. \ » fl ‘ 1 Remove the steering stem nut and remove the ' handlebar. ‘ V. ‘ ;. o ‘ LOCK NUT WRENCH SOCKET 30x32mm (Commercially available) ‘ _ _ . LOCK PIN COMBINATION SWITCH Remove the combination SWIICII by remuvmg the two attaching screws. HANDLEBAR INSTALLATION Install the combination switch on the handlebar. NOTE Applv locking agent to the screw threads. (Tm-It the steering lack pin for operation With Ill! cambinnfion :wr‘rch Izzy. Install the handlebar on ths steering stem. Align the tab 0' the handlebar with the groove in the steering stflm. GROOVE / Date 07 Issue: Nov., 1930 1 1 -7 © HONDA moron co” LTD. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT FORK Install and uwxen thu nearing stem nut to the specified lornue. TORQUE: 75—85 N-m (7.5—8.5 kq-m. 54—61 h—lb) Lubrrcale the mrome grip area 01 lhc handlebar with grease. Alim the punch mark on me handlebar with the wlit in the mronle grip housing, - Tighten the furward screw first, then l tighten the rear screw‘ ‘ . After lightening the screws, check tho! the throttle grin Imam freely Install xhe hghnng switch housing on the handlebar with the punch mark an the handlebar aligned wixh (he spli‘ in the switch housing, NOTE Tighten the forward screw first, Ihen lighten the rear screw to the Jame torque ‘ ti<)nw131L / Nxsmu LOCK NUT WRENCH SOCKET 30x 3 mm EXTENSION BAR &HANDLE (Commercially available) PUNCH MARK 11-8 Date of Issue: Now, 1980 © HONDA MOTOR 00.. LTD. HONDA Connect each coupler and attach the rigut and loft handlebar switch wnres to me handlebar with the wire bands where shown (Fag re). Install the front Daniel. Install [he headliwt case and mm tum signal mounts (Page 11-5). Install the rear cover and speedometer (Pug: 113). Install the from basket. Install the headlight NXSOM STEERING/FRONT WHEEL/FRONT BRAKE/FRONT FORK WIRE BANDS FRONT CARRIER HEADLIGHT CASE SPEEDOMETER TURN SIGNAL MOUNTS FRONT BASKET HEADLIGHT Date of Issue: Nov” 1980 © HONDA MOTOR 00., LTD, 11-9 STEERING/FRONT WH EEL/FRONT BRAKE/FRONT FORK FIIIJIII WHEEL FRONT WHEEL REMOVAL Disconnect lha speedomemr cable Irom the bvalw panel. Remove the brake cable Item the brake am‘ Home" the axle nut. Pull out the axle and remove m from wheel. AXLE SHAFT INSPECTION Set the axle in V blocks and measure the runout. Thu actunl mum: is 1/2 of TIR (TOTAL INDI~ CATCH READINGL SERVICE LIMIT: 0.2 mm [0.008 in) SPEEDOMER CABLE . l 11-10 Dale 0' Inna: Nov., 1980 Q HONDA MOTOR 00.. LTD. HONDA WHEEL BEARING INSPECTION Oleck the wheel bearing play by placing the wheel in a truing stand and spinning the whesl by hand. Replace the bearing if there are noisy or have excessive plav‘ WHEEL RIM INSPECTION Check the run runuut by placing the wheel in a lruing stand. Then spin the wheel by hand and read the mnout using a dial indicitov. SERVICE LIMITS: Radial: 10 mm (0.08 in) Axill: 2.0 mm [0.08 in) FRONT WHEEL DISASSEMBLY Remove the dust seals, wheel bearing; and distance collar from the wheel hub, NXSOM STEERING/FRONT WHEEL/FRONT BRAKE/FRONT FORK PLAY b.— AXIAL PLAY RADIAL DISTANCE COLITAR Data of Issue: Nov.. 1950 (Z) HONDA MOTOR CO.. LTD. 11-11 HONDA NXSOM STEERING/FRONT WHEEL/FRONT BRAKE/FRONT FORK FRONT BRAKE DRUM INSPECTION Remove the brake panel from "I! from wheel. Inspect the brake drum I.D. SERVICE LIMIT: ”.5 mm(3.11lnl FRONT WHEEL ASSEMBLY Pack all bearing cawiliei with gram. Drive in the righ! bearing Install the distance collar. Drive in the left bearing NOTE - Drive the bearing sQUarer. ' Install the bearing with the sealed and facing ouL M Contaminated brake lining: mince stup- pinc power. ‘ Keep grease 01711:: (Inlay and firm drum. 0 TER DRIVER 23x30 mm 079451870100 DRIVER HANDLE OUTER A DRIVER PILOT 10mm AXLE COLLAR Apply guise In the inside of the dun seaL Install the dust seal and axle oollav . _ D mu ll 1 N ..19eo 1 1 1 2 ©3H°°N05119M°$gn C07. LTD. HONDA Nxsm STEERING/FRONT WHEEL/FRONT BRAKE/FRONT FORK FRONT WHEEL INSTALLATION Install xhe brake panel into the wheal hub. Position lhe from wheel between xha from lorks and insert the axla waft mrougl the wheel hub lvom the rigm side. NOTE Be sure to fit the longu: of lhe rig“ fork leg into me groove in the backing plat. Install and Hyman the axle nut to the specified lorque. TORQUE: 40-50 N-m (4.0-5.0 kg-m, 29—38 ft-lh) AXLE NUT ' SPEEDOM ETER CABLE Connccl [he speedometer cable. Connect the brake cable. Adjust the front brake lever lree play (Page 3-6). BRAKE CABLE 11-13 Dam of Issue: Nov., 1930 C) HONDA MOTOR (20., LTD. 4:23 HONDA STEERING /FRONT WHEEL/FRONT BRAKE/FRONT FORK % NXSOM FRflNT BRAKE TORQUE: 10—14 N-m / (Lo—1.4 kg-m, 7—10'(-lbl % 1 1 . 1 4 Dam of Issue: Nov., 1930 © HONDA MOTOR co.. Lm HONDA NXSOM BRAKE LINING INSPECTION Measuyn the tank: lining thickness, SERVICE LIMIT: 20 mm (01min) - Cnnmnu‘nated brake l'nl'ny mint-z stop pinspnmr. - Keep mas: off the (filings. - Brake dust may contain 0:06:10: which an be harmful to your health. BRAKE CAM ASSEMBLY Apply iilimn great: to the anchor contacting area of each shoe. Apply silicon grease to the brake shoe contacting ana oi the brake cam. Install ma brake cam. A mid (9111qu on lhz inside nf the brake drum. Clean the lurid: uf the brake panel thamughly. Install th: wear indicator plate on the brake cam shah. NOTE Align the wide tooth on the plate with the wide groov: on the camshaft. Install the brake arm on tho brake mmshafl. NOTE Align the punch mark on the brake arm with the punch mark on the cam shaft. Install and tighten tha brute arm bolt to the ucilied torque. TORQUE: 10—14 N-m (1.0—1.4 Ito-m, 7—10 Mb) STEERING/FRONT WHEEL/FRONT BRAKE/FRONT FORK BRAKE CAM PUNCH MARKS One of Issue: Nov., 1930 © HONDA MOTOR CO., LTD. ?) HONDA STEERING/FRONT WHEEL/FRONT BRAKE/FRONT FORK gy NXSOM FRONT FIJRK Date 1| : N .,1980 1 1 '1 6 © HSNDsjallemogn 00.. LTD- STEERING/FRONT WHEEL/FRONT BRAKE/FRONT FORK FRONT FORK REMOVAL Remove the from wheel (Page 11-10), Remove the from fender anaching bolts and the from fender. CIRCLIP Slide U19 dust seal down and remuvc [he 35 mm internal circlip. DUST SEAL Remove me lo-k lube. FORK TUBE D In H : N ., ‘980 ©aHgNDsimMogsR 00., LYD. 1 1 '1 7 STEERING/FRONT WHEEL/FRONT BRAKE/FRONT FORK FRONT FORK DISASSEMBLY/ INSPECTION Check the fork tube for runout. Check each pm for abnormal wear or damage. NOTE —_‘% Replam the Iron! fork rubs IV 5 bank. FRONT SPRING INSPECTION Measure the fork spring free length, SERVICE LIMIT: 92.0 mm (3.52 in) FRONT FORK A$EMBLY NOTE Before assembly. apply grease to the sliding surlaues of the fork tube (119 0.4 01.). Assembly of the from fork is the reverse order of disasembly. HONDA NXSOM FORK SPRING 11-18 Dam of Issua: Nov., 1980 © HONDA MOTOR 00., LTD. f: HONDA ® NXSOM STEERING/FRONT WHEEL/FRONT BRAKE/FRONT FORK STEERING SIEM Date a! Issue: Nov., 1980 _ © HONDA MOTOR (30., LTD. 1 1 1 9 STEERING/FRONT WHEEL/FRONT BRAKE/FRONT FORK STEEHlNG STEM REMOVAL Remove the headlight case and hunt carrizr (Page 1 1-5). anava the handlebar (Page ”-6). Remove me from forks (Page 1H7), Remove [he steering head (op thread nuL Remove the nearing 5mm. NOTE l Do not allow the sleefialls [0 fall PIN SPANNER (M9361412—099788U3Amnlv) BALL RACE DlSASSEMBLY/ASSEMBLY Use the special tool "BALL RACE DRIVER" to remove the ball races‘ To lnstall the ball races, use the special lools “BALL RACE DRIVER". CAUTION W i - Do not allow the ball races to all when Installing - Drive in the race: until they bottom. T0 REMOV E TO INSTALL BALL RACE DRIVER 8E 079444150001 & STEEFllNG STEM INSTALLATION Lubricate the ball laces, steel balls and cone races with grease. lnsull the steering slam. FRONT FOR OP THREAD J NUT 0» come M RACE HTEEL BALL (26) TOP BALL RACE @«acnom BALL an \\STaEEL EBALL (26) OTTOM CONE @@ .359 RACE ?@ 11-20 Dale of Issue: Nov., 1980 © HONDA MOTOR CO.. LTD. HONDA Install and tighten the head top thread nut to the specified torqua‘ NOTE W , ‘ Screw in the head top thread nut until snug against the top cone race, then back it out l/B turn. - Check that the steering stem rotates 1 freely without vertical play. Place the handlebar over the steeringstemt Install the steering stem nut and tighten m the specified lquue. TORQUE: 75-86 Mm (7.5—8.5 Ito-m, 54—61 ft‘Ib) NOTE Check that the steering stem rotates freely without vertical plav. ‘ Install the front lender. front wheel and headlight case. NX50M STEERING/FRONT WHEEL/FRONT BRAKE/FRONT FORK PIN SPANNER (M9361—412—099788 U.S.A.on|v| EXTENSION BAR Bi HANDLE LOCK NUT WRENCH SOCKET 30x3me Date of Issue: Nov.' 1980 © HONDA MOTOR (20., LTDt 11-21 HONDA NXSOM REAR WHEEL/REAR BRAKE/REAR SUSPENSION TORQUE: 33—40 N~m TORQUE: (”—40 N-m (3.0—4.0 kg-m, 22—29 'I-Ib) (3.0—4.0 kg—m, 22—29 ft-lb) TORQUE: 30—100 N-m (8.0—10‘0 kg-m, 58—72 fl-Ib) 1 2-0 Dan 0' Issue: Nov., 1980 © HONDA MOTOR (20.. LTD. HONDA @ NXSOM 12. REAR WHEEL REAR BRAKE/ REAR SIISPE SIIIII SERVICE INFORMATION TROUBLESHOOTING REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER 12—1 12—1 12—2 12—4 12—8 SERVICE INFRRIAATIIIII GENERAL INFORMATION Brake dust may contain asbestos which cm be harmful to vour health. Do not use compressed air to clean brake drums or brake panels. Use a vacuum with a saaIed dust collector. Wear a protective Iaoe mask and thoroughly wash your hands when finished. TOO LS Special Rear Shock Absorber Compressor 07959-329001“ or 07959—3290000 Rear Shock Absorbar Comprassor Attachmem D7967-GA7DIW SPECIFICATIONS A ITEM STANDARD mm (in) SERVICE LIMIT mm (in) A7 7, A ,, , A 7, Rear wheel rim runout 2.0 (0.08) Rear brake drum I.D. 95.0 (3,74) 955 (3.76) Rear brake lining thicknou 5.0 (0.2m 2,0 (0,03) Rear shodr absorber spring free 160.4 (6.31] 157.2(619) length IRUUBLESHIIUIIIIR Rear wheel wobhling I. Distorted rim 2. Faulty tire 3. Axle not tigxtaned properly Soft suspension 1. Weak shock absorber wrinn Suspension noise 1. Cushion use interferring with cushion spring 2, Damaged cushion stopper rubber Poor brake performano! . Brake not adjusted properly . Contaminated brake shoes . Worn brake shoes Worn brake shoes at cam contacting area . Worn brine cam . Worn brake drum . sluggish or elongated brake wire Nmmyuna Brake squeaks 1. Worn braka shoes 2. Foreign matter on lining 3. Rough brake drum shoe contacting lace Data of Issue: Nov.. 1980 © HONDA MOTOR (30.. LTD. 12-1 (/9, HONDA REAR WHEEL/REAR BRAKE/REAR SUSPENSION \Q‘ég/ NX50M REAR WHEEL CARBURETOR COVER REAR WHEEL REMOVAL ,7 3‘ Remove the cavburelor cover. Remove the axhausl pipe auaching nuts, Remove the muffler auachmg bolts and remove the mufller. EXHAUST MUFFLER Remove me rear Vendev blanket bolls and remove HEAR FENDER the lender. " X Remove me rear axle nul. A LE NUT Remove the rear wheel. 1 2-2 Dale of Issue: Nov.,1930 © HONDA MOTOR (30., LTD. HONDA NXSOM REAR WHEEL RIM RUNOUT INSPECTION chad: the rim Ior runoul using a dial gauge as shown. SERVICE LIMITS: R d‘nl: 7.0 mm (0.08 In) Ann-l. 2.0 mm (018m) REAR BRAKE DRUM INSPECTION Musura the mar buka drum LDV SERVICE LIMIT: 95.5 mmllfiin) REAR WHEEL INSTALLATION Install me rear wheel and torque the lea nut. TORQUE: 80—100 N—m [RD—10.0 Inn-m. 58—72 h~|h) Install the rear fender, exhaust mufller and car- burelor Coven REAR WHEEL/REAR BRAKE/HEAR SUSPENSION Dam of Issue: NovI, 1980 6 HONDA MOTOR (XL, LTD. REAR WHEEL/REAR BRAKE/REAR SUSPENSION REAR BRAKE @ /%%\’ TORQUE: 4—7 N-m (0.4—0.7 k9-m,3—51Hb) " 1 2-4 Date of Isms: Nov., 1980 ® HONDA MOTOR 00., LTD. ' ' NXSOM REAR WHEEL/REAR BRAKE/REAR SUSPENSION Remme the rear wheel (Page 12-2). REAR BRAKE LINING THICKNESS INSPECTION Measure the brak: lining thickness. SERVICE LIMIT: 20 mm I0.“ inI Keep was: off the brake linings, Wipe 015’ the excess grease. BRAKE CAM INSTALLATION Apply grease to the cam contacting area of each shoe. Apply grease to the braka cam Install the brake cam. _ BRAKE ARM Install the oil ielt and the war indicator platet NOTE # - Align the wide groove on the cam with the wide tooth on the indicator plate. Install the plate with the arrowmark facing the brake shoes. Install the brake arm. NOTE Align the mark on the brake arm with the punch mark on the brake cam. Tighten the brake 3"“ bolt to the specified torque. ' ‘ ‘ V TORQUE: 4—7 N-m (0.4—0.7 km, 3—5It-Ilsl PUNCH MARK Data 0! Issue: Nov” 1980 © HONDA MOTOR 60,. LTD. 1 2'5 HONDA NXSOM REAR WHEEL/REAR BRAKE/REAR SUSPENSION Install the spring guide and brake arm spring 'SPH'NG GUIDE BRAKE ARM SPRING UNDER BOLT lnsnrl Ih: rear brake cable in the grams in the [all uankcase, and much the brake cable holder, Install the bake arm cover md [he bake ioml on the bake arm, and install file brake adjust". lnslall me rear wheel (Page 12-3). Adjust the rear brake. BRAKE SHOE BRAKE SHOE SPRING 1 2.6 Date of Issue: Not. 1930 © HONDA MOTOR col. LTD. NXSOM REAR VVHEEL/REAR BRAKE/REAR SUSPENSION TORQUE: 15—20 N-m (1.5—2.0 kgm, 11—14't-lb) é?) TORQUE: 30-40 Nvm ,\ / (ac—4,0 ”mm—29 mm TOHOUE: 30—40 Nvm (3.0—4.0 kQ-m, 22—29 Vl-lb) Din of lung: Nov., 1980 _ O HONDA MOTOR 00., LTD. 1 2 7 REAR WHEEL/REAR BRAKE/REAR SUSPENSION REAR SHflCK ABSURBER REAR SHOCK ABSORBER REMOVAL Remove the rear shock absorber upper and lower Hulk Remove [he rear shock absorber. REAR SHOCK ABSORBER ATTACHMENT A D7967-GA70100 REAR SHOCK ABSORBER DISASSEMBLY Compress the shock and remove the upper joint. UPPER JOINT REAR SHOCK ABSORBER COMPRE$OR PPER JOINT LOCK NUT STOP RUBBER 1 2-8 Date of Issue: Nov.. 1980 © HONDA MOTOR COA, LTD. HONDA NXSOM REAR SHOCK ABSORBER SPRING FREE LENGTH Measure the spring free length SERVICE LIMIT: 157.2 mm (6.19m) REAR SHOCK ABSORBER ASSEMBLY NOTE - Inshll the spring with [he tiguly wound ‘ coils laclng up. I - Apply locklng agcm (0 me lock nut threads and (Maul: the lock nut. TORQUE: 15—20 N—m (1.5-2.0 k9m,11—14 fl-lh) REAR SHOCK ABSORBER INSTALLATION Install the rear shock absorber, Tiwten the upper and lower nuvs to the specified mruue. TORQUE: 30—40 N-m (3.0—4.0 kg—m, 22—29 ”413) Check (In operation a! Ihe shock absorbev by pressing dawn on me end of [he Irame several times REAR WHEEL/REAR BRAKE/REAR SUSPENSION REAR SHOCK ABSORBER ATTACHMENT A O7967»GA70100 REAR SHOCK ABSORBER COMPRESSOR LOCK NUT Dam of Issue: Nov” 1980 © HONDA MOTOR CD‘, LTD, 12-9 ELECTRICAL I 3. EIIUIPMENT SERVICE INFORMATION 13— 1 IGNITION SYSTEM 13— 7 TROUBLESHOOTING 13— 2 STARTING svsTEM 13—10 BATTERY 13— 3 SWITCHES/HORN 13—13 CHARGING SYSTEM 13— 5 WIRING DIAGRAM 13—15 SERVICE INIBIIMITIIJII GENERAL INSTRUCTIONS ‘ Do not quIck charge the battery. Quick charging may damage the battery. . Remove the battery from the motorcycle for charging Remove the cell ups before charging the battery. - Do not smoke or have Ilames near a charging battery. The gas produced by a battery is very flammable and can explode. ~ Ignition timing cannot be adjusted since the C.D.|. unit is non-adjustable. - If the timing is incorrect, inspect the C.D.l. unit and A.C. generator and replace any Iaultv pans. SPECIFICATIONS CHARGING SYSTEM ITEM SPECIFICATION Battery Capacity 12V4AH Specific gravity 1170—1290 at We l68°Fl Charging rate 0.4 ampere: maximum A.C. generator Charging rpm 23(1) rpm mam. 12.6V Capacitv 0.7A min/4,000 rpm (15.1w 1.2—1.3A (6,000 rpm Il5.5V) ITEM SPECIFICATION I Spark plug NGK: BPSHS (BPSHS, BPdHSI ND: W167? (MZDFF, W14FP-L) Spark plug 98? 0.6 0.7 mm (0.024 ~ 0028 in) Ignition coil 3-point spark test 6 mm (‘4 in) min. Ignition timing ‘5" 13" BTDC Date of Issue: Nov.. mm 1 3- 1 © HONDA MOTOR C0,. LTD. ELECTRICAL EQUIPMENT TRIIIIBIESIIDIITIIIE CHARGING SYSTEM No power 1. Dead battery — Low fluid level — Battery sullation r Internally shorted battery — Charging system lailure 2. Disconnected battery cable 3. Fuse burned out 4‘ Faulty ignition switch Low power 1. Weak battery 2. Loose battery connection 3. Charging system failure IGNITION SYSTEM No spark at plug 1. Faulty spark plug 2. Poorly connected, broken or shorted wire — Between A.C generator and C.D.I. unit — Between C.D.l. unit and igli 'on coil — Between C.D.I. unit and ignition switch — Between Ignition coil and spark plug . Faulty ignition switch . Faulty ignition ooil , Faulty C.D.lt unit . Faulty A. . generator Gama-u STARTING SYSTEM Starter won't run I. Fuse burned out i Weak battery . Faulty ignition switch Faulty starter switch . Faulty front or rear Stop switch . Faulty starter relay . Poorly connected, broken or shorted wire i Faulty starter motor mwmupun HONDA NXSOM Intermittent power I. Loose battery cable 2. Loose charging system connection 3. Loose connecton or short circuit in “fitting system Charging system Iailure 1. Loose, broken or shorted wire or connection 2. Faulty silicon rectiler 3. Faulty A.C. generator Engine starts but runs poorly I. Ignition primary circuit 7 Faulty ignition ooil — Loose or have wire or connector — Poorly contacted ignition switch 2. Ignition secondary circuit — Faulty ignition coil — Faulty spark plug — Faulty higi tension wire — Poorly insulated plug cap 3. Improper ignition timing ‘— Faultv A.C. generator — Stator not installed properly — Faulty C.Dtlt unit Lack ol power 1. Weak battery 2 Loose or bare wire or connection 3. Foreigr matter stuck in starter or starter gear Engine does not aankatarter rotates 1. Faulty Hater pinion 2. Reverse rotation of starter 13-2 Date of Issue: Nov" 1980 © HONDA MOTOR 00., LTD. HONDA r11t5<>nn BATTERY REMOVAL Remove the plate by removing the bolt. Remove the battery cover, Disconnect the negative cabiei Dismnnect the positive cable. Remove the battery, NOT E Installation cf the bauery is the reverse of removal. I——4 SPECIFIC GRAVITY TEST Test each cell by drawing electrolyte into a hydra} meter, SPECIFIC GRAVITY (20“C, 68“Fl Fully charged iUthrchargedi NOTE - The battery must be charged ii me specific gravity falls below 1.230. . The specific gravity varies with the tem- perature as shown. (Specific gravity changes by 0.007 for every 10°C). Replace the battery I! sulfation has I formed, or ii the space below tha on“ plates is fiIIed with sediment. - The battery contain: sulfuric acid. ' Avoid contact with skin. :ya. a! clothing, Antidote: Flruh with win and get i prmnpl medical amnrlon. BATTERV COVER ELECTRICAL EQUIPMENT BO LT NEGATIVE CAB LE HYDRDM ETE R \ gaff ‘ \ ELECTROLYTE \ \ ELECTROLYTE TEMP VS SPECIFIC GRAVITY L350 E 7.230 2 n: o o I 250 E 0 III g I Vzan ELECTROLYTE TEMPE RATURE 0 I0 20 :u w r. 32 so 53 35 Im 'F Data 00 Issue: Nov., 1980 C) HONDA MOTOR CD., LTD. 13-3 ELECTRICAL EQUIPMENT BATTERY CHARGING Connect the charger positive (0) cable to the banery positive M terminal. Connect the charger negative (—) cable to flu: bamry negative (—I terminai. Charging current: 0.4 ampere: maximum - qure charging a battery, remove all caps to prevent battery as: damager - Keep flames and spark: any from a charging battery In pmwnt Igniting the hydrogen gas produced by the banana - Tum power ON/OFF at (It: charger‘ not at the baflery terminal: to prevent sparks new the balmy cells. - Discontinue charging If the eleurolyte temperature exceeds 45 "C I I I 79F}, L.— CAUTION Quirk charging should anly be done in an emergency, slaw charging is prefared. Chiming hours: (L15 hours Charging: Charge m: battery a! 0AA umil specific gravilv is 1270—1290 (20°C, 63°F). CAUTION Check mulling of the breathe! tube as shown an the barrery can! u label. HONDA NXSOM —. SPECIFIC GRAVITY 2 4 G 8 I0 12 SPECIFIC GRAVITY VS CHARGING TIME 14 15 16 —+ CHARGING TIME C A U I l I] II an m Put! AIVINIIE our mm m mm on unm "mm with mow strum III nnm nnmm war unm 1 3-4 Dame of Issue: Now, 1980 9 HONDA MOTOR 00., LTDI HONDA NX5OM ELECTRICAL EQUIPMENT CHARGING SYSTEM CHARGING CIRCUIT MI- GENERATOR SILICON RECTIFIER WHITE R FUSE DI ED RED YELLOW COMBINATION SWITCH _-_ EATI'ER‘I LIGHTING SWITCH BLACK BROWN — BROWN GREEN HEADLIGHT TAILLIGHT SPEEDOMETER LIGHT PERFORMANCE TEST Warm up the engme before taking readingsA NOTE Use a Tully charged battery Io check the charging svskam output. Connect an ammeler and vohmncr as shown‘ Sun the engine and take readings. TECHNICAL DATA CHARGING RPM I (INITIAL) 4,000 rpm 6.000 rpm 2,3)0 rpm max. (12.8w 0.7A min. (15.1V) 1.2—1L8A (15.5w Date of Issue: Nov., 1930 © HONDA MOTOR 00., LTD. 1 3'5 ELECTRICAL EQUIPMENT A.C. GENERATOR INSPECTION NOTE cessary m remove the stator ro ‘ make ”“5 rest. , Disconnect the stator coupler‘ Check the resistances between the terminals with an ohmmeter: VellowEnuiM ground 0.3—1.5“ WhiuAEngina ground 0.5—1.5!1 NOTE Measure the resistances In the X151 range. AC. generator removalfirrstallatiun Page 7-2 NOTE Replnce rhe smor eoul and flywheel as a SSL SILICON RECTIFIER INSPECTION Check fur conrinuilv between the terminals wirh an ohmmeterl The rectifier is normal il mere is Continullv only in lha drremrun shown. 13-6 Dare 0' Issue: Nov.. 1980 © HONDA MOTOR 00., LTD. ELECTRICAL EQUIPMENT IEIIITIIIII SYSIEII IGNITION CIRCUIT ON \ELACK/WHITE C.D.I. UNIT IGNITION COIL AC G EN ERATOR IG CONDENSERj T Egl :5 % ‘ GATE \ PULSER COIL CIRCUIT ‘\ SPARK PLUG For spark plug gap inspection and adiustmentIFage 34L 5)an >| HVdS I 1 sea ‘ { l | I o :n m Q | i i G) Jul 711 "'1 ZLLLL ill—‘9 (— IGNITION COIL Remove the frame coverr Remove the ignition coil. Disconnect the plug cap from the high tension wire while rotating the plug cap. \ . IGNITION COIL onnrinuitv test PRIMARY con. SECONDARY COIL NOTE This rest can be performed without remov- lug the coils fram the lrame. Measure me resistances of the primary and second- ary coils. RESISTANCES: Primary coil: 0.2—0.3!) Second-w coil: 3.4—4.2!) NOTE §—_—___—__ To determine if the $9 ition coil will lunc- i lion properly after 3 minutes of operation perform the performance test, described on the nlxl pagl. Dale of Issue: Nov.. 19% 0 HONDA MOTOR CO" LTD, 1 3'7 ELECTRICAL EQUIPMENT Performance test Parlorm [he 3poim spark test with a service lesteL SERVICE LIMIT: 6 mm (1/4 in) L—w—w — 1Follow me [ester manufacturer‘s Instruc- tron: 7 A.C. GENERATOR INSPECTION NOTE I! is no! necessary to remove the scalar [0 make IhlS testr Disconnect the smor cnupler. Measure the resisxances between the terminal: 50—3005! 10—1009 Black/Red — Engine ground BIue/VelInw — Engine ground NOTE Take reécfings In the x19 range. ‘ A.C. generator removalfinstallanan Page 7.2 CAUTION—7 7, !_ Replace the stator and jlvwheel as a set, if SECONDARY 252%, MORE THAN 6mm PRIMARY ELECTRODE fi'k rirlmr out nme rcplaccmcm. BLACKRED BLUEJ’YELLOW 13-8 Date of Issue: Nov” 1980 © HONDA MOTOR 00., LTDr HONDA NXSOM ELECTRICAL EQUIPMENT C,D.I. UNIT Remove the frame cover. Disconnect the coupler. Remove the 01). l. unit. Inspection Measure the resislances between me terminals. Replace the C.D.L unll with a new one ii the I“ readings do not 'all wimin me limits shown in the "u able. NOTE 0 The C.D.l. unn is fully liaflsistor‘led‘ For accurale lesling, ir Is necessary to use a specified tuner. Use of an improper lesicr or measurements in improper range may give false landings, 0 Use SANWA ELECTRIC TESTER Tvpe SP~1UD [PIN 07308-002000!” I In the able, “Needle swings (hen returns" indicates that there IS achargmg curreni applied to a condenser. The needle will then remain at "0°" unless the eggdenser is discharged NOTE Take readings in xkn range. __ a , UNIT: K9. \xfirnoae i \, SW ‘ EXT PC F IGN :VPROBE i 7 sw -, \ w a. a, w 'h‘ ‘ EXT 01— 10 \ m .. "Needle s'wings ' " but returns" PC on E 7 on IGN ” , , Data of Issue: Nova, 1980 © HONDA MOTOR C0,. LTD. 1 3'9 ELECTRICAL EQUIPMENT SATIIIIIIII SYSTEM STARTING CIRCUIT STARTER SWITCH RED RED/WHITE STARTER RELAY INSPECTION Connect a 12V battery acres: the Grmn/Vellnw (4-) and Yellow/Red I—I terminals. Check Iur continuity between the Red and Red] White terminals WII’I’I an ohmmetert The relav ls normal :1 mere :5 continuity. STARTER MOTOR REMOVAL Perfnrm this operation while Ill: engine and exhaust muffler are COLD. Remove the carburetor covert Disconnect the starter motor couplar. Remove the rear fender attaching bolt, Remove the A.C. generator cover. Remove the starter motor. GREEN/YELLOW HONDA NXSOM IGNITION SWITCH FRONT BRAKELIGHT SWITCH \REAR BRAKELIGHT SWITCH STOP LAMP STARTE R MOTOR 13-10 Date of Issue: New. 1933 © HONDA MOTOR (30.. LTD. HONDA NXSOM STATER MOTOR DISASSEMBLY Disconnect the sure: cables. CAUTION - The blush spring: will pop our when removing the bunk holder plate. ‘ Record til: number and location of [he commutator (hum Misha: BR USH INSPECTION Measure d1: length of eadi brush SERVICE LIMIT: 4.0 mm (0.16 in) COMMUTATOR INSPECTION Check the commutator for diycoloration and olhur visual Iauits. Blackened, adjacem segments are an indication of .1 shorted circuit. CAUTION Do not use sandpaper to clean the cam- muramr. Check for continuity between segments, and cum- mumor and shaflr The commutator is normal i' there is continuity between lhe sewanls. There should be no can tinuity between the commutator and shah. ELECTRICAL EQUIPMENT ®Qi ROTOR \/ THRUST WASHE RS Date of Issue: Nov., 1980 © HONDA MOTOR ‘30., LTD. HONDA NXSOM ELECTRICAL EQUIPMENT COMMUTATO R STARTER MOTOR ASSEMBLY Install the brush spring and brushes in the holder plate. Install the commutator and thrust washers while extending the brushes outwardt CAUTION Note the number and location of the thrust washers. BRUSH HOLDER PLATE Insert the commutator into the starter bow. Lubricate the starter pinion with clean glean. Install the pinion and start" Dov-r. Attach the starter wires, lnstall the terminal cover. STARTER MOTOR INSTALLATION NOTE Before installing the shirt", test (or opera- tion by connecting the stanor coupler to the wire harness Install the starter motor in the reverse order or removale Secure the wires with the clamps. D le II : N ..19&) 1 3'1 2 Qangunjxmmo%n 00., LTDA HONDA NXSOM SWITCHES / IIIIIIII Check COnIII'IuIlY of each sztch. Continuity should exist between color coded wires Indlcated by Interconnected circles on each chart. COMBINATION SWITCH RED BLACK BLACK I GHEENI [WHITE‘ ~o 00 OFF GO w my TURN SIGNAL SWITCH LIGHT GREY BLUE ORAN HEADLIGHT DIMMER SWITCH LL BLUE WHITE HORN SWITCH LIGHT GREEN GREEN FREE PUSH O——O HORN Connect the ham to a full merged 12V battery and check it the horn munds propevly. HORN SWITCH ELECTRICAL EQUIPMENT COUPLER TURN SIGNAL ‘SWITCH Data DI Issue: Nov., 1980 © HONDA MOTOR (20., LTD. 13-13 ELECTRICAL EQUIPMENT FRONT/REAR STOPLIGHT SWITCH 1 GREEN/ BLACK YELLOW YFREE PULL O——O ENGINE STOP SWITCH BLACK [WHITE OFF O——O RUN OFF 00 STARTER SWITCH GREEN YELLOW IRED GREEN FREE PUSH O——O—1 1‘ STARTER SWITCH 1 3- 1 4 Date of Issue: Nov., 1930 © HONDA MOTOR 00.. LTD. WIRING DIAGRAM “WV wan SGML um Arm-h BEAM \NJICAYO'! man IN 7!: -MN SIGNAL mmuvofl LK'rY (Mu Tsvamtse um uvxw mm: my» ‘ mom 5m: um swo , . . mu a. mum: / Msrm swan mm)» swan .-m m ._ 57 s g n: : z m , n n o -n n 0 [IF I? T l ’ ' ' n— a G u m: am or I a s— ‘ su—DD—am 1 ,— ‘/\ "Y 2%,“. '6 “ w I p w H2513» 5 s—DD—s« E a w s r. 5— _ am- 3 6 I Vin—DEI—VJR V—DCI—V a—DCJ—Gr LB —LE u———— a ‘3 w B o:gE> l ' ° “ 1 & Lafi— w—DEI—W warm 3 _ “EC L5 —3 B L mow rum swam um snucm EC ‘mzwam! u L5 _ v L ‘ | _ Aw SID" Ltd" 5091 0 $ 0 00 O — — ~c n u n . .a m arm smcu cammvv am sue u: E w L >01. mm slam - DMIER - wow 5mm cnurw l v R w Lr Dam of Issue: Nov., 193] © HONDA MOTOR (20., LTD‘ '0 E ruRn samL- mMMER- mm - umrsmcn swam: 5mm cmvmul'v [MGIM 5m: 51mm comm ST E I6 E m: W O- IIHC lawman 00L SHARK mm H “J TUSE NJ FL _ fl BAFTEWV 12v m1 l_mJ ii mi Mn WAL LIGNY m QIWHMHIJ R : :wuw 1mm: 6 a Law. nu. ma smp Liam 1m 31ml! 1M m—D; 3—l _ CDHMIV [a “25.;71: W ALTH'MVOD Dom Y Vehw End 3 Blur m, a Gav L-y' Gm m LIN a“ w o ow- Emu P on. 003 l— ? Alwyn»: v am I swam ask.” my swam MOVDR L REA: Mn slam um mumml 02—187—6700 13-15 , HONDA 7, NXSOM i4.TECHN|CAL FEATURES C.D.I. (Capacifive Discharge Ignition) AUTOMATE CHOKE V-MATIC DRIVE AUTO FUEL VALVE 14—1 14—3 14—5 14—8 (LBJ. (Capacitive Discharge Ignition) . IGNITION COIL PULSER COIL AC. GENERATOR SPAR K PLUG ADVANTAGES I. The C.D.I. gives a sworn; spark at high rpm and reslfls spark plug louling allow rpm. 2. The C.D.I. does not require adjustment, it ha; no wearing pans. 3. The NXSOM Ignrxion system works on AC. voltage. Dan-3 of Issue: Nov., 1980 © HONDA MOTOR (30., LTD. HONDA NXSOM TECHNICAL FEATURES IGNITION SWITCH A.C. GENERATOR \_ IGNITION COIL i i i j J, i i GATE son ‘ PLUG Cl ncuur‘ » r i i I l PRIMARV COIL SECONDARY COIL OPERATION AC. voltage is induced when the rotor magnets pass the exciter coil. The positive hall of the A.C wave passes through the C,D.I. unit diode D to charge the condenser c. The condenser cannot discharge through the magneto bemuse the diode aliows current to pass in one direction only. Alternating Durrenl induced in the pulse coil is used to open and close the 6.0.1. unit electronic switch (SCH) through the gate direuit (the SCR and gate cirwit are more complex than shown]. The magneto charges the condenser with the SCR open. The condenser is grounded thraugh the SCH when the SCH closes The condenser then discharges through the ignition coil primary windings, causing a rapid magnetic field build up. High voltage is induced in the coil’s secondary windings which firms through the spark plug 1 4- 2 Date of Issue: Nov., 1980 0 HONDA MOTOR (30., LTD. HONDA NX5°M TECHNICAL FEATURES AUTOMATIC CHOKE An automatic choke richens the full mixture for cold engine starting. The choke svslum has a bystarter chamber and a oonlrol box. ’ EYSTARTER / /, ./ CHAMBER CONTROL BDX’/" BYSTARTER CHAMBER The bystaner chamber is like an air cleaner box except it supplies air to the carburetor choka circui| and direcrly to rhe comrol box. CONT RO L BOX The control box has three control lines connected to il: (1) an air line 'rom [he bystarrer. (2) a fuel line from the carburetor choke circuit, and (3) a fuel line ‘0 rhe inrake pipe, The flow of air and fuel throng: them line: i: controlled by a bimeral and valve inside the control box. BIMETAL SECONDARY A'R AIR CLEANER ‘— lBYSTAfiTEH CHAMBER) RICH MIXTURE CARBURETOR <— (CHOKE Cl Rcum CONTROLLED MIXTURE _> IN LET PIPE Date 01 Issue: Novr. 1980 © HONDA MOYOR CO., LTD. 14-3 YECHNICAL FEATURES OPERATION This is how the mtomatic choke system works. BELOW 1o“c (50°Fl With engine temperature below 10°C (50°F) the control box birnerzl holds the valve so that air directly from the bystarter il blocked. When the engine is started. air "cm the bystaner [D the carburetor choke circuit draws and mixes with fuel, than flows through the control box and to the intake pipe. This richens the engine's air-luel mix- ture. BETWEEN io°c (50°F) and 46°C (115°F) The blmetal bends and moves the control valve as it is heated by the engine. The valve moves 0.5 mm for each one degree centigrade (1,8" F) change in engine temperature. As the valve moves, it opens the air passage directly from the bystarter. This air mixes with the carburetor choke cirmit mixture and leans it out to keep the engine running smoothly. ABOVE 46°C {115°F) When the engine temperature is above 46°C (115°Fl, a rich mixture is not needed to start or mn the englne. So the control box bimemal is fully bent and the valve blocks the ins! line to the intake ptpe. (N HONDA fie) uxsom BYSTARTEH CARBURETOR INTAKE PIPE SECON DARY AIR FROM BYSTARTE R CHAMBER 14-4 Date of Issue: Nov., 1930 0 HONDA MOTOR C0,, LTD. HONDA NXSOM I-IMTIC IIlIIVE HONDA V»MATIC provides various drive ratios between the engine and rear wheel according to the engine speed and load. It accomplishes this by two sets 0' pulleys, drive and driven, and by the use of a drive belt between the pulleys. The drive pulley is attached to the engine crankshaft. The driven pulley is attached to the shaft and also incorporates a centrifugal clutch. In the V-Metic Drive, there is a final gear reduction between the driven pulley and rear wheel, providing an additional increase in torque. TECHNICAL FEATURES DRIVE SHAFT CLUTCH DRIVE BELT OUTER CRAN KSHAFT DRIVEN FULLEV DRIVE PULLEY DRIVE PULLEY DRIVEN PULLEY DRIVE PULLEY DRIVEN PULLEY When the engine is running at low speed, the As the speed of the engine incmxm, or load on unit can increase or multiply. torques so that the rear wheel decreases centrifugal form on more torque Is delivered than at him speed the weight rollers throws the rollers radially through a greater drive ratiee outward. When the rollers are Ierced outward, they press in the movable face of the drive REDUCTION RATIO: 2 : 1 pulley closer to the drive lace which will result in a reduced drive ratio between the driven and drive pullevs. REDUCTION RATIO: 1 2 1 Date of Issue: Nov, 1980 © HONDA MOTOR 00., LTD. 14-5 HONDA NXSOM TECHNICAL FEATURES DRIVE PULLEY WEIGHT ROLLER RAMP PLATE MOVABLE DRIVE FACE DRIVE FACE The drive pulley consists M a lixed and a mmable laces The movable face is capable ol sliding axially on me boss ol the fixed face. The ramp plate‘ which pushes in the weight rollers against the drive lane, is anached to the boss of the drive lane with a nut DRIVE BELT MOVABLE FACE AS SPEED INCREASES RAMP PLATE ’ DRIVE FACE —’ IE WEIGHT ROLLER v As the speed of engine increases, cantriluual force on the weight roIIEls is also increased. This pushes the movable drive law inward, The unil then acts with a reduced drive min by allowing the (“We belt to run on a pulley of greaterdia- "Eur. 1 4-6 Dale of Issue; News, 1980 © HONDA MOTOR co., LTD. HONDA NXSOM TECHNICAL FEATURES DRIVEN PULLEY BALL BEARING NEEDLE BEARING CLUTCH WEIGHT I RIVE SHAFT /GU|DE HOLLER DRIVEN FACE DRI EN FACE SPRING GUIDE PIN AND ROLLER The driven pulley and clutch weights are attached over the drive shah. The clutch outer is attached to the drive shaft with a nut. The force 0! the driven face spring is always exerted on the rnavdnle face to push it against the driven face, Therefore, when engine speed is increased, the driven pulley turns and the clutdr connects automatically The effec- tive diameter of the drive pulley is increased. The movable face is forced outward by means of the belt until an equilitr final is reached between the torque tension of the belt and Force oi the spring. When this oewrs, the drive ratio decreases and less torque is delivered lo the final reduction. Date of Issue: Nov., I980 © HONDA MOTOR CO” LTD 14-7 TEC H NICAL FEATURES AIITll FIIEL VALVE The valve consists oi a valve body, spring, diaphragm and check valve, When ma engine is stationary, the diaphragm closes the fuel pas- sage lrom lhe fuel lank to the carburuor by means of the spring. As the engine starts, vaulum is applied to the spring side of [he diaphragm and opens the fuel passage. Then fuel starts to flow from the fuel tank to the carburetor. When the engine is stopped. Vlcuum is no longer applied. A leak hole near the check valve allows atmospheric pressure to equalize pressure on the spring side. This allows the spring to close the valve, shutting off fuel to the carburetor. HONDA NXSOM FUEL STRAlNER FUEL TANK LOCK NUT x GASKET A. VALVE aonv . CARBURETOR = SPRlNG : ' DIAPHRAGM CHECK VALVE LEAK HOLE FUEL INLET PIPE VACUUM 1 MANIFOLD 14-8 Date oi issue: Nov., 19m 6) HONDA MOTOR (20.. LTDV “Ego? I5. TRUIIBLESHIIUTING ENGINE WILL NOT START OR IS HARD TO START 15—1 ENGINE LACKS POWER 15—2 POOR PERFORMANCE AT IDLE AND LOW SPEED 15—2 POOR HIGH SPEED PERFORMANCE 15—3 STEERS TO ONE SIDE OR DOES NOT TRACK STRAIGHT 15—3 ‘ ENGINE WILL NOT START OR IS HARD Tl] START Probable Cause 1, Check if fuel reaches FUEL DOES NOT REACH carburetor by lousening CARBURETOR 7 #(1) Empty fuel tank drain screw (drain fuel into (2) Clogged fuel line betwezn Iuel tank cuntainerl and carburetor. or vamum pipe between fuel tank and inlet pipe FUEL REACHES (3) Clogged Iuel valve CARBURETOR (4) Clogged Iuel tank cap breather hole I 2. Remova spalk plug and WEAK OR NO SPARK —'(Il Faulty plug test spark (2) Fouled plug (3) Broken or shorted high tension wire GOOD SPARK (4) Open or shorted ignition coll ‘ (5) Faulty Ignition switch (6) Faultv C.D.l. unit (7) Faulty A.C. generator 3. Test cylinder compression LOW COMPRESSION—oil) Stuck piston rings (2) Faulty reed valve NORMAL COMPRESSION I3) Worn cvllnder and piston rings (4) Blown cylindel head gasket (5) Flaw in cylinder and cylinder head [6) Leaky crankcase 4‘ Startengine ENGINE FIRES, BUT DOES NOT START —~( I) Faulty choke control box ENGINE FIRES [2) Air leaking lhruugh intake pipe [3) Incorrect ignition timing 5‘ Remov‘e and lnspect spark WET PLUG i 7 7 «(1i Flooded carburetor plug (2) Faulty choke control max (3) Throttle valve excessively open Date of Issue: Nnv., 1980 1 5- 1 © HONDA MOTOR COI, LTDt TROUBLESHOOTING ENGINE [Mills PIIWEII 1. Rev upgradually ENGINE SPEED INCREASES 2. Check Ignition timing CORRECT TIMING 3. Test cylinder compression NORMAL COMPR ESSION 4. Check carburetor Iar clogging CAHBURETOR NOT CLOGGED 5. Remove spark plug PLUG NOT FOULED OR DISCOLORED 6. Check if engine overheats ENGINE DOES NOT OVERHEAT 7t Rapidly accelerafl! or run at high speeds ENGINE DOES NOT KNOCK ENGINE SPEED DOES NOT INCREASE (ll (2| (3] l4) INCORRECT TIMING—n 4-H) (2) LOSS OF COMPRESSION -III (2) {III (M CARBURETOR CLOGGED -(Il PLUG FOULED OH DISCOLOFIED all) l2) ENGINE OVERHEATS (I l2) (3) (4) (5i (II (II (3) (4) ENGINE KNOCKS - I5 PDDII PEIIFDIIIMIIEE AI IDlE AND [W SPEED , Check ignition timing CORRECT TIMING 2. Check carburetor air screw adjustment CORRECTLV ADJUSTED l 3. Check lor air leaks NO AIR LEAKS 4, Remove spark plug and test spark GOOD SPARK 15-2 INCORRECT TIMING 7 7 all) INCORRECTLY ADJUSTEDi 7 -(1) (2) AIR LEAKS an) (2) (3) l4) WEAK on INTERMITTENT SPARKi -11) (2) (3] (4| (5) l8) HONDA NXSOM Probable Cause Clogged air cleaner Clogged luel line Clogged fuel tank can breather hole Clogged mumer Faulty C.D.It unit Faulty AtC. generator Worn cylinder and piston rings Blown cylinder head gasket Flaws in head or cylinder Faulty reed valve Carburetor jets clogged Fouled plug Incorrect heat range plug Excessive carbon in combustion chamber Incorrect or poor quality Iuel Slipping clutch Slipping drive belt Mixture loo lean Worn piston or cylinder Mixture too lean Incorrect or poor quality Iuel Excessive carbon in combustion chamber Ignition timing too early Probable Cause Incorrect timing [Iaulty C.D.l, unit or A.C. generatorl Mixture too rich (turn out screw) Mixture too lean (turn in screw) Faulty carburetor gasket Carburetor not securely tightened Faulty intake pipe gasket Faulty carburetor Ovring Faulty or fouled plug Faulty C.Drl. unit Faulty A.C. generator Broken or shorted high tensmn cord Open or shorted ignition coil Faulty ignition switch Date of Issue: Now, l980 © HONDA MOTOR 00.. LTD. TROUBLESHOOTING PllflH HIGH SPEEI] PEIIFIIRIIAIICE 1‘ meckignirion timing INCORRECT TIMING Probable Cause (1) Faulty C.DVI, unit (2| Faulty A.C.generaror CORRECT TIMING 2. DiscomIect Iuel tube at fuel RESTRICTED FUEL FLOW 7t!) Empw iuel rank auto valve and check for (2) Clogged fuel rube or fuel filler clogging (3) Clogged fuel tank cap breather hole (4) Clogged fuel valve UNRESTRICTED FUEL FLOW 3. Check carburetor ier for CLOGGED 7 441) Clogged jet clognms NOT CLOGG ED STEERS TII IIHE SIDE [JR DflES HUT TRACK STRAIGHT 7mm tivevressure Probable Cause (From and rear lire pressures currecrl 1. HARD‘STEERING 7 77 7(1) Steering sum nut too tight (2) Damaged steerrng srem bearings 1 2. FRONT OFI REAR WHEEL WOBBLING— 7(1) Worn or loose wheel bearings l (2) Ben! rim (3) Loose axle . 3. STEEFlS TO ONE SIDE 7 777 7 7(1) Benllron! forks Date 0! Issue: Now. 1980 © HONDA MOTOR C0,, LTD‘ 1 5'3 3 HON DA V NXSOM 16. '82 ADDENDUM INTRODUCTION CONTENTS This addendum contains informaIian Io! the 1982 NX50I 1 MODEL IDENTIFICATION ................... 16~2 ReIer to the base shop manual for service procedures and 2- SPECIFICATIONS IIIIIIIIIIIIIIIIIIIIIIIIII 1&2 data not Included have. 3. MAINTENANCE SCHEDULE .................. 16-2 _— 4. CLUTCH DRIVEN PULLEY ................... I6-3 ALL INFORMATION. ILLUSTRATIONS, 5' FINAL REDUCTION IIIIIIIIIIIIIIIIIIIIIII 1&4 DIRECTIONS AND SPECIFICATIONS IN» CLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT IN~ FORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITH- ‘ OUT NOTICE AND WITHOUT INCURRING ‘ ANY OBLIGATION WHATEVER NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERr MISSION. HONDA MOTOR CO‘, LTD. SERVICE PUBLICATIONS OFFICE Date of Issue: Sept, 1981 © HONDA MOTOR CO., LTD. 16-1 '82 ADDENDUM 1. MODEL IDENTIFICATION The Iollowmg models are covered by thus addandum: Eeqinnlng with Frame Nol ABDdO‘CS1 00001 — VIN No. JHZABOAO'CS1000OI — 2, SPECIFICATIONS HONDA NXSOM Only specllmanuns Ihal are new are Ilsled below. Reler la page 1-2 In! other spaclhcatlons. ldenuhcatlon Number PA 135 CARBURETOR A" Sevew Inmal Semng 1% Turns Out For cold climala For extended ELECTH'CAL SW" ”I“ 5mm” balow 5=c (41°F) mgh spud riding BPR-SHS BPR-4HS BPR-BHS (NGK) INGK] INGKI WI SFPH W1 ‘FPR-L WZOFPR (ND) (ND) (ND) 3. MAINTENANCE SCHEDULE Only the fuel screen maintananca schedule has been changed for 1932. ReIer la page 3-2 let all mher maintenance schedule Rams. \ FREQUENCY ITEM \_ FUEL FILTER SCREEN INITIAL REGULAR SERVICE PERIOD SAFETY Perlorm ll every Inducaled INSPECTION month at mileage inlervaL whichever occurs first Re." to 1 monlh 12 months 24 months Page 200 miles 1.000 miles 2,000 miles 000ka (1,500 km) (3.000 km) Clean 1 Clean 4-12 16-2 Date a! Inna: 59pm, 1981 © HONDA MOTOR C0,, LTD. HONDA % NXSOM '32 ADDENDUM CLUTCH DRIVEN PU llEY The clumh driven pulley assembly [or 1982 is shown below, The clutch driven pulley ouler nut (mqus has been changed. 0 "‘8 , oak; (3 31°25 @@ (3‘5 — 40 Ryan. 25 — 29 fl-Ib) a /, ,; \ (o TORQUE , 35 — 40 N-m (3.5 — 4.0 kg-m. 0 25 —- 29 ft-lh) .% Dam of Issua: Sepl., 1981 © HONDA MOTOR (30., LTD. 1 6-3 HONDA NXSOM ’82 ADDENDUM FINAL REDUCTION The final reduclion assembly has been changed beginning with the 1982 made! and is shown bolow. / TORQUE 1o— 14 N m (Lo—1,4 kg-m 7—10 ft-Ih) 1 6-4 Dam of Issue: Sept.,1981 © HONDA MOTOR (10., LTD. HONDA NXSOM '82 ADDENDUM FINAL REDUCTION INSPECTlON Inspecl the nave shaft and gear for wear or damage‘ Check the counterihah ll'ld gear tor wear or damage. Check me llnnl gear (or wear in damaga‘ Dau of Issue: Sepl., 1981 O HONDA MOTOR CO.. LTD. 16-5