Introduction

This service manual describes the Service procedures for
the SKSOM.

Thie Model Specific Manual includes every service
procedure the: is of a specific nature to this particular
model. Basic service procedures that are common to
other Honde Motorcycles/Motor Scooters/ATVs ere
covered In the Common Service Manual. This Model
Specific Service Manuel should be used together with
the Common Service Manual in order to provide
complete service information on all aspects of this
nectar.

Follow the Maintenance Schedule (Section 3)
recommendations to ensure that the vehicle is in peak
operating condition. Performing the first scheduled
maintenance is very important. It compensates Icr the
initiel wear that occurs during the break»in period.

Semions 1 and 3 apply to The whole scooter. Section 2
illustrates, procedures for removalfinstallation of
components that may be required to perform service
downbed in the following sections.

Whlle Sections 4 through 17 describe parts of the
scooter. grouped according to locations.

Find the section you want On this page, then turn to the
table of contents on the first page ol the section.

Most nations describe the service procedure through
system illustration. Refer to the next page for details on
how to use this manual.

If you don't know the source of the trouble, go to
section 18 YRDUELESHOOTINGt

 

ALL INFORMATION. ILLUSTRATIONS. DIRECTIONS
AND SPECIFICATIONS INCLUDED IN THIS
PUBLICATION ARE BASED ON THE LATEST PRODUCT
INFORMATION AVAILABLE AT THE TIME OF APPROVAL
FOn PRINTING. HONDA MOTOR 90.. LTD. RESERVES
THE RIGHTTO MAKE CHANGES AT ANV TIME WITHOUT
NOTICE AND WITHOUT INCURRING ANV OBLIGATION
WHATEVER. NO PART OF THIS PUBLICATION MAV BE
HEPRODUCED WITHOUT WRfI'I‘EN PERMISSION. THIS
MANUAL IS WRITTEN FOR PERSONS WHO HAVE
ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE 0N
NONDA MOTORCYCLES.

HONDA MOTOR CO., LTD.
SERVICE PUBLICATIONS OFFICE

 

 

 

Contents

General Information .I
Frame/Body Panels/Exhaust System a
Maintenance a

 

Engine and Drive Train

Lubrication System

an

Engina Remova Installation .3
Cylinder Haad/Cyllnder/Pismn a

Kiokstaner/Drive PUIIay/CIutoll/Drivan Pulley

Final Reduction

Crankcase/Crankshafl

 

 

Chassis

 

Rear Wheal/Susponsion/Bmke

 

 

 

Electrical

charging System/Altimeter

Ignition System

:1]
:E
“W

Front Wheal/Suspension/Staaring/Brako III
Em
Em
:IH

Electric Stamr

 

Lights/Meters/Switcllea

Wiring Diagram In

 

 

Troubleshooting I 8

Index

 

 

Data of Issue: Jen. , 1992
© HONDA MO'TOR C0,. LTD.

 

 

Important Safety Notice

Indicates I "rang pas-lolllty to! severe persoml Mury or death ll Instructions are not lollowed.
cw'nou: Indicates a possibility of equipment damage il instructi ns ere not tollowed.
NOTE: Gives helplul information.

Detailed descriptions of standard workshop procedures, safety principles and service operation! 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 maunv to service personnel or could damage a vehicle or render it unsafe. Please understand
that those warnings could not cover all conceivable ways in which sarv e, whether or not recommended by Honda.
might be done or at the poaslbly hazardous consequences of each conceivable way, nor could Honda investigate all
such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy himsel/
IImmug/Ily that neither petsanal safety nor vehicle salety will be jeopardized by the service methods or tools selected

 

 

 

 

 

How to Use This Manual
Fin my Information You Need

' This manual is divided into sections which cover each at
the major components of the motorcycle.
To quickly find the section you are interested in, the first
page of each section is marked with a black tab that lines
up wlth one or the thumb index tabs before this page.
The first page of each section lists the table of content:
within the section.
Read the service information and troubleshooting related
to the section before you begin working.

- An index of the entire book is provided in the last chapter
to directly locate the information you need.

 

 

 

 

Note on the Explanation Method of This Manual

- The removal and installation or parts are for the most part illustrated by large and clear illustrations that should provide the
reader with visual aid in understanding the major point for servicing.

- The system Illustrations are augmented by sellout: whose numbers or letters indicate the order in which the parts should
be removed or installed.

- The sequence of steps represented numerically are dilterentiatad tram the ones represented alphabetically to notify the

reader that they must perform these steps separatelyt

For axarnpie, if the steps prlor and up to camshaft removal are performed with the engine installed, but the subsequent

steps 'ke cylinder head removal require engine removal, the callouts are grouped in numerical and alphabetical orderst

The illustrations may contain symbol marks to indicate necessary service procedures and oracautlons that need to be

taken. Refer to the next page for the meaning of each symbol mark.

- Also in the illustration is a chart that lists Information such as the order in which the part Is removed/installed, the name of

the part, and some extra notes that may he needed.

Step by step instructions are provided to supplement the illustration: when detailed explanation of the procedure is neces-

sary or illustrations alone would not suffice.

- Service procedures required helore or after the procedure described on that particular page, or Inspection/adjustment pro-
cedures required following the installation of parts, are described under the title Requisite Service.

- Standard workshop procedures and knowledge covered in the Common Service Manual are abbreviated in this manual.

Detailed description

 

 

 

 

 
 
 
   
  
  

symbol mark Systlam illustration of the procedure
.mm...“ / “mm“
cvmmnwvmuum . / _“"“‘_-.:.‘:.‘1“:L“ZT ”- im“
\ 9mm r r"..._.___... a... J “3V

 

 

 
 

  

Step
sequence
lnumaraia
or alphabet:

 

 

 

 

 

 

 

 

 

 

 

 

Part name Number of Extra notes or precaution
parts related to the service procedure

 

 

Symbols

The symbols used th(0ughout this manual show specific service procedure). lf supplementary ln'ormallon is required pertain-
ing to (hose symbols, it would be explained specifically in the text without the use of the symbols.

 

a Replace the panlsl with new onelsl move assembly.

 

 

Use special tool

 

Use optional (00L Use the same procedure you use to order pansa

 

Torque specification. 1O N-m (1.0 kg-m, 7.2 ft-lb)
.2)

3
1°
a

 

Use recommended englne oil. unless othelwlse specified.

 

Use molybdenum all solution (mixture 0' the engine oil and molybdenum grease with the rltlo 1 : 1).

 

Use mum-purpose grease (Lithium based mum-purpose grease NLGl v2 at equivalent)

 

Use molybdenum disulfids grease (containing more than 3% molybdenum disuflida, NLGI #2 0!
equivalent)
Example: Molykote” BR-Z plus manufactured by Dow Corning. U.SaA.

Mulls-puma»: M-2 manufactured by Milsublahi on Japan

 

Use molybdenum disulfide paste (containing more than 40% molybdenum dleulfide, NLGI $2 at
equivalent)
Example: Molykote" Gvn Pasta manufamuved by Dow Coming, U.S,Ai

Honda Muly 50 (U.S.A. only)

Rocol ASP manufactured by Rocol Limlted, U.K.

Raoul Paste manufactured by Sumico Luhvicant. Japan

 

Use silicone grease

 

Apply ll locking agent. Use the agent of the middle sverlgth. unless otherwise specified.

 

Apply saalam

 

 

Use brake fluid, DOT 3 or DOT 4‘ Use the recommended brake fluid. unleel otherwise specified.

 

Use Fork or Suspension Fluid.

I-‘Hl l M44

 

 

 

 

 

 

1 . General Information

 

  

General Salary 1-1
Model Identification 1 -2
Spec‘ cations 1-3
Torque VVelues 1-9

 

Tools 1 -1 1
Lubrication & Seal Points 1-12
Cable & Harness Routing 1 ~14

 

 

General Safety

carbon Monoxide

if the engine must be running to do some work, make sure
the area is well ventilated. Never run ihe engine in an
enclosed area.

    
 

- The exhaust contains poisonous carbon monoxide
gas that can cause loss of consciousness and may
lead to death.

 

Brake Dust

Never use an air hose or dry brush to clean brake as~
semblies. Use a vacuum cleaner or alternare method
designed to minimize the halard caused by airborne
asbestos fibers.

- Inhaled asbestos fibers have been 'ound ‘0 cause
respiratory disease and cancer.

 

Run the angina in an open area or with an exhaust
evacuation system in an enclosed area.

also a
Work In a well ventilated area. Keep cigarettes, flames or

sparks away from the work area or where gasoline is
stored.

  

-Gnso he is extremely flammable and it explosive
under cenain conditions. KEEP our 0F REACH
or CHILDREN.

 

Hot Components

- Engine and exhaust system parts become very hot
and remain hot for some time alter the engine is
run. Wear insulaud gloves or wait until the engine
and exhaust system have cooled before handling
these pom.

 

 

 

emery Hydrogen Gas a. Electrolyma

- The battery gives off explosive gases; keep sparks,
flames and cigarettes away. From 0 adequate
ventilation when charging.

- The battery curtains sulfuric acid (electrolyte).
Contact wim skin or eyns may cause severe burns.
Wear protective clothing and a lace mi
4 if electrolyte gets on your skin, flush w water.
— ll electrolyte am in your eyes, flush w'ah water

ior at least 15 minutes and call a physician.

- Electrolyte is poisonous.

— If swallowed, drlnk large quantities of wmr or
milk and follow with mllk er magnesia ar veget-
able oil and call I physician KEEP OUT OF
REACH OF CHILDREN.

 

 

 

 

 

1—1

General Information

Model Identification

 

 

 

 

 

(1) FRAME SERIAL NUMBER
The frame sarial number is stamped on the left side of the
framei

 

 

(2)

 

 

 

 

(2) ENGINE SERIAL NUMBER
The engine sarial number is stamped on the left side of the
transmission cover.

(3) CARBURETOH IDENT’FICATION NUMBER
The carburetor identification number is stamped on the left
side of the carburmor bodyi

 

 

 

 

 

(5)

 

 

(4) COLOR CODE LABEL
The color code label is attached to ‘he luggage box under
the seat. when ordaring a color coded parts. alwavs
specify its designated color.

(5) SAFETY CERTIFICATION LABEL (CM type only)
The safety certification label is attached ‘0 the right side of
the frame.

 

1-2

General lnformetion

 

 

 

 

Specrfications
.— General um“ mm (m
Item Specifications

Dimensions Overall length 1 ,650 (65.0)
Overall width 645 (25.4)
Overall height 990 (39.0)
Wheelbase 1.145 (45”
Seat height 715 (28.1)
Footpeg height 360 (14.2)
Ground clearance 100 (3.9)
Dry weight 66 kg (146.6 lbs)
Curb weighi 71 kg (157.7 lbs)
Maximum weight capacity 91 kg (200 lbs)

Frame Frame type Under bone
From suspension Telescopic
From wheel travel 53.7 (2.11)
Rear suspension Final drive unit/swingarm
Rear wheel travel 607 (2.39)
From damper —
Rear damper —
Front lire size 3.00— 10 42J
Rear tire size 3.00— 10 42J
Tire brand (Bridgastone) Front/Rear ML31/ML32
Tire brand (Dunlap) Front/Hear K378F/K378
Tire brand (lRC) Front/Rear MB48/ME47
Front brake Internal expanding shoe
Rear brake Internal expanding shoe
Caster angle 26' 30’
Trail length 73 (2.9)
Fuel tank capacity 5.0 liters (1.32 Us gel, 1,10 Imp gal)
Fuel tank reserve capacity —
Fork leg oil capacity —

Engine Bore and stroke 39.0 X 41.4 (1.54 x 1.63)

 

 

Displacement

Compression ratio

Port timing intake open
Part timing intake close
Pan timing Exhaust open
Port timing Exhaust close
Port ti ng Scavenge open
Port timing Scavenge close
Firing order

Lubrication system

Oil pump type

Cooling system

Air filtration

Crankshaft type

Egnine weight (dry)

 

 

49.4 om' (3.01 cu in)
7.1

Reed valve controlled
Reed valve controlled
84' BBDC

84' A500

62‘ BE DC

62‘ ABDC

Oil automatically mixed with gasoline
Plunger type

Forced air cooled
Urethane foam
Assembly type

16.1 kg (35.5 lbs)

 

 

 

1-3

General Information

— General (cont'd)

Unit: mm (in)

 

 

 

 

 

 

Ital-n Specifications

Carburetor Carburetor type Piston valve

Venturi dial 14.0 (0.55)
Drive train Clutch system Dry. automatic centrifugal clutch

Primary reduction —

Final reduction 12.115

Gear ratio 1450—0350
Electrical ignition system CDl

Starting system
Charging system
Regulator/rectifier type

 

Electric starter motor/kickstarter

Single phase ahernator, 12 V— 133 W

scn switching regulator, AC regulator built in type/ single
phase, half-wave rectifier

 

 

 

1-4

General Information

Unit: mm (in)

 

— Lubrication
Item

Stnndnrd

Service limit

 

Engine oil tank capacity
Recommended engine all

1.2 liters (1.27 US qt, 1.06 Imp qt)
Use Honda 2»stroke oil or equivalent

 

 

 

— Fuel System
Carburetor identification number
Main jet

Slow jet

Jet needle clip position

Air screw initial opening

Air screw high altitude adjustment
Float level

idle speed

Throttle grip free play

PBSOF

175A

:35

and groove
1—1/4 lums out

 

8.0 (0.31)
1,300 1 100 min-1 (rpm)
2—6 (cos—0.24 in)

HHHIH

 

 

(_ Cylinder Head/Cylinder/Piston
Cylinder compression

Cylinder head werpage
Cy Inder warpage
Cylinder identification mark lucetion

 

Cylinder ID. A mark
N0 mark
out of round
taper
Piston mark direction
Piston O.D. (D) A mark
B mark
No mark
lerl D.D. measurement point (H)

p-m 'nhl LD. d
1 nm 08 H Aornomark

"(dr—
368
JHL

O/Iinder-to-piston clearance

Piston pi O.D.

Piston~to~piston pin clearance

Top ring-to-rirlg groove clearance
Second ringrto-ring groove clearance
Top ring and gap

Secend ring and gap

Top ring mark

Second ring mark

 

U

 

 

 

 

 

 

 

 

981 kFa (10.0 kg/cm’. 142 950/600
min" (rpm)

 

 

Lower surface of the cylinder

39.000—39.005 (15354—15353)
39.005—39010(15355—15358)

 

”EX” mark facing exhaust side
38.955—33360 (1 ,5337-1 .5339)
assess—38.570 (1.5341—1.5342)
38360—38385 (15339-1.5341)
5.5 (0.26) from the beam

12002—12003 (04725—04728)

0.035—0.050 (00014—00020)
11394—12000 (04722—01724)
0002—00“ (0.0001 —O.DOOS)
0.10—0.25 (0004—0010)
0.10—0.25 ((1004—0010)

“N“ mark

"ZT" mark

 

39.05 (1.537)
39.05 (1.537)

0.
0.

10 (0.004)
10 (0.004)

38.90 (1.531)
38.90 (1.531)
38.90 (1.531)

12.03 (0.474)

O.

10 (0.004)

11.98 (0.4717)

0.

03 (0.001)

 

 

 

 

 

General Information

 

 

 

 

 

 

 

Clutch outer I. D.

 

 

 

 

Unit: mm (in)
— Crankshaft . . .
Item Standard Service limit
Connecting rod small and LD. 17.005—17.017 (06695—116700) 17.03 (0.6705)
Connecting rod big end side clearance 0.15—0.55 (0006—0022) 0.60 (0.024)
radial clearance 0:007‘0019 (00003—00007) 0.04 (0.002)
Crankshaft runout at A —— 0.15 (0.006)
at B 0.10 (0.004)
A E
L_
70 40
(2.8) (1 .6)
,— Kickstaner/Balancer
Kickstarter spindle 0.D. —-— ——
bushing I.D. — ——
Kickstarter idle gear I.D. ~ —-—
bushing 0.D. — _
Kickstanar driven gear LD. — ——~
boss 0.D. — —
— Drive Train
Drive belt width 15.5 (0.61) 14.5 (0.57)
Movable drive face bushing 1.0. 20.035—20.085 (01888—07907) 20.60 (0.811)
bosO.D, 20.010—20.025 (01878—07884) 19.97 (0.786)
weight roller 0.D. 15.92—16.08 (0627—0633) 15.40 (0.606)
Clutch lining thickness 4.5 (0.18) 2.0 (008)
Engine brake clutch lining thickness ~—
I.D. — ——
Drive chain slack —-
Driven face spring free length 98.1 (3.86) 92.8 (3.65)
Driven face 0.D. 33365—31985 (13372—43380) 33.94 (1.336)
Movable dr’wen face LD. 34000—34025 (13385—13397) 34.06 (1.341)
Final reduction gear case oil capacity at disassembly 90 ca (3.04 US 0:, 3.16 imp or)
at draining —
107.071071 (4.21—4.22) 107,514.23)

 

 

’— Cooling System

Coolant capacity (Radiator and engine)
(Reserve tank)

Radiator cap relief pressure

Thermostat begin to open

Thermostat fully open

Thermostat valve lift

 

llllll

 

 

HHH

 

 

1-6

 

General Information

Unit: mm (in)

 

—Wh ls 'es
ee /Tir Item

Standard

Servioe limit

 

Cold tire pressure (Front)

(Rear)
From and rear axle runout
Front and rear wheel rim runout (Radial)

(Axial)
Drive chain slack
Drive chain size/link (DID)
(RK)

125 kPe (1.25 kg/cm’, 18 psi)
200 kPa (2.00 kg/cm‘, 29 psi)

 

 

—- From Suspension

Fork spring free length

Fork spring free length A

B

Fork spring direction

Fork rube runout

Recommended fork oil

Fork oil level

Fork oil level (Right)

(L9?!)

Fork oil capacity

Fork oil capacity (Right)
(Left)

Fork air pressure

Sxeering bearing preload

 

Tightly wound coil facing up

 

l||ll||||

129.5 (5.l0)

lllllllllllll

 

 

— Rear Suspension
Shock absorber spring free length
Shock absorber spring free length A

3
Shock absorber spring direction
Damper drilling point

ll||l

|llll

 

 

r Brakes

From brake fluid
brake lever free play
brake disc thickness
brake disc runout
master cylinder I. D.
master piston 0.0.
caliper cylinder l. D.
caliper piston 0. D.
brake drum LD.
brake lining thickness

Rear brake fluid
brake lever free play
brake pedal free play
brake disc thickness
brake disc runour
master cylinder LD.
master piston 0. D.
caliper cylinder LD.
caliper piston O. D.
brake drum LD.
brake lining thickness

 

 

10*20 (0.4—0.3)

||llll

3.74)
.12)

raw
-0
0A

10—20 (0.4—0.8)

lllllll

3.74)
.12)

win
0‘"
-0
OR

|ll||lll

a)
o.

5%
“9

llllllll

 

95.5 (3.76)
1.0 (0.04)

 

 

 

 

1-7

General Information

Unit: mm (in)

 

— Battery/Charging System
Item

standard

Service limit

 

Alternator charging coil resistance (at ZO'C/EB‘F)

lighting coil resistance (at 20768‘F)
Regulator/rectifier regulated voltage (Charging)

(Lighting)
Battery capacity
Battery specific gravity (Fully charged)
(Needs charging)
Battery charging rate (Normal)
(Quick)
Battery voltage (Fully chargedl at 20'/SB‘F)
(Needs charging, at 20’/68‘F)

Auto bystaner resistor resistance (6.7 S? 5 W)

VOA—1,09 (between W and ground)
02—039 (between V and ground)
14‘0—160 V/5,000 min" (rpm)
12.6—13.6 V/5,000 min" (rpm)
12 V 3 Ah

 

 

0A A x 5 h

4 A x 05 h
13.0-13l2V
12.3V
47—53 9

 

HHHHH

 

 

— Ignition System
Spark plug (Standard)

(For cold climate/below 5'C/41'F)
(For extended high speed riding)
Spark plug gap
ignition timing "F" mark
Peak voltage Ignition coil

Exciter Coil
Pulse generator coil

BRSHSA (NGK)

WZOFR-L (NIPPONDENSO)
BR4HSA (NGK)

W14FR'L (NIFPONDENSO)
BRSHSA (NGK)

W24FR-L (NIPPONDENSO)
0.6-0.7 (0024—0023)
17‘ BTDC/1,800 min’I (rpm)
100 V minimum

100 V minimum

0‘7 V minimum

HM HHHHHH

 

 

 

 

Alternator exciter coil resistance (at 20‘C/68'F) 400—800 9
Ignition coil resistance (at ZO‘C/SB'F)
Primary 0.1 —0.4 a
Secondary with plug cap 65—9] kn
Secondary without plug cap 2.7—35 kQ
Pulse generator resistance (at ZO‘C/SS'F) 50—20052
— Lights/Meters/Switches
Fuse 10 A ——
Headlight (high/low beam) U type 12 V 35/35 W ——-—-
CM type 12 V 25/25 W —
Brake/taillight U type 12 V 21/5 W —-——
CM type 12 V 32/3 op —
Front turn signal light U type 12 V 21 W x 2 —
CMtype 12V21cpx2 —
Rear turn signal light u type 12 v 21 w x 2 —
CMtyps 12V32cpx2 —
instrument light 12 v 1.7 w x 2
High beam indicator 12 V 1.7 W ——
Turn signal indicator I2 V 34 W —
Fuel level sensor resistance (at full position)
between G and V/W 25—45 52 .__
between G and Bu/W 400—700 52 —
between Y/W and Bu/W 450—750 9 —
(at empty position)
between G and Y/W 400—700 (2 —
between G and Bu/W 25—45 9 —
between V/W and Bu/W 450—750 9 —

 

 

 

 

 

1-8

Torque Values

General Information

 

 

 

 

 

 

 

 

 

 

 

 

 

— Standard
Torque Torque
“m" TV” N-m (kg-m, fr-lh) Fm‘m" TV” N-m (kg-m. ft-Ibl
5 mm bolt and nut 5 (0.5, 3.5) 5 mm screw 4 (0.4, 2.9)
6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5)
8 mm bolt and nut 22 (2.2, 16) 5 mm flange bolt (8 mm head) 9 (0.9, 6.5)
10 mm bolt and nut 35 (3.5, 25) 6 mm flange bolt (10 mm head) and nut 12 (1.2, 9)
12 mm bolt and nut 55 (5.5, 40) 8 mm flange bolt and nut 27 (2.7, 20)
10 mm flange bolt and nut 40 (4.0. 29)
- Torque specifications listed below are for important fasteners.
Others should be tightened to standard torque values listed above.
— Engine
, Thread Torque
"’m 0 'V dle. (mm) N-rn (kg-m, ft—lb) ””3""
Lubrication system:
Oil pump mounting bolt 1 6 10 (1.0, 7)
Fuel system:
Carburetor mounting bolt 2 5 10 (1 .0, 7)
Left shroud mounting bolt 2 6 1D (l .0, 7)
Intake manifold mounting bolt 4 6 10 (1.0. 7)
Air cleaner case mounting bolt 2 6 12 (1 .2, 9)
Cylinder need/cylinder/piswn:
Cylinder head bolt 4 6 10 (1 .0. 7) tApply ail to the threads and
Spark plug 1 14 14 (1.4. 10) flange surface.
“Mr/drive pulley/clutch/
drlven pulley:
Left crankcase rear cover bolt 5 6 H) (l .0. 7)
Left crankcase front cover bolt 5 6 10 (1 .0. 7)
Drive pulley nut 1 12 60 (5.0, 43) tApply oil to the threads and
Clutch outer nut 1 10 40 (4.0, 29) seating surface.
Movable drive face seal bolt 3 4 4.5 (0.45, 3.3)
Clutch drive plate nut 1 28 55 (5.5, 40)
Final reduction:
Transmission cover bolt 5 6 10 (1 .0, 7)
Transmission oil level check bolt 1 8 13 (1.3, S)
Cnnkcau/crenkehaft:
Crankcase bolt 6 6 1O (1 .0, 7)
Chiming system/eltemetor:
Cooling fan cover bolt 2 6 10 (1.0. 7)
Cooling (an bolt 4 6 B (0.8, 5.8)
Flywheel nut 1 10 4D (4.0, 29)
Stator bolt 2 6 10 (1.0. 7)
Pulse generator bolt 2 6 1O (1 .0, 7)
Electric mner:
Starter motor mounting bolt 2 6 10 (1.0. 7)

 

 

1-9

 

General Information

 

 

bolt

 

 

 

 

 

— Frame
, Thread Torque
"°"‘ 0 " din. 1mm) N-m (kg-m, ft-Ib) ”mm"
Exhaust system:
Exhaust pipe joint nut 2 6 12 (1,2, 9)
Muffler mounting bolt 2 8 27 (2.7, 20)
Exhaust pipe protector bolt 2 6 12 (1.2, 9)
Engin- mount:
Engine mounting bolt 1 10 50 (5.0, 36)
Engine mounting bracket bolt 1 10 60 (6.0. 43)
Front whael/suspansion/
staatlng/brako:
Speedometer cable set screw 1 4 2 (0.2, 1.4)
From axle nut 1 1O 45 (4.5, 33)
Front brake arm bolt 1 5 6 (0.6, 4.3)
Fork pinch bolt 4 8 27 (2.7, 20)
Handlebar pinch bolt 1 10 50 (5.0, 36)
Steering stem lock nut 1 25.4 70 (7.0, 51)
Rear wheal/suspension/brako:
Hear axle nut 1 14 120 (12.0, E7) Apply oil to the threads and
Rear brake arm bolt 1 5 6 (0.6, 4.5) sting surface.
Shock absorber upper mounting 1 10 40 (4.0, 29)
bolt
Shock absorber lower mounting 1 B 27 (2.7, 20)

 

 

1-10

 

General Information

 

 

 

 

 

 

 

Tools
- Refer to ”Bail bearing replacement” in section 1 of the Common Service Manual.
Description Tool Number Application Section
Float level gauge 07401~0010000 Carburetor float level inspection 5
Clutch center holder 07714—0050001 Drive pulley face removal/installation
Universal holder 07725—0030000 Clutch outer removal/installation
Clutch spring compressor D7960— KM10000 j—Clutch/driven pulley disassembly/aasembly 8
Lock nut wrench, 39 x 41 mm O7GMA—K540100
Bearing driver O7945—GC80000 Driven face outer bearing installation
Crankcase assembly collar D7965—GM001OO jiDriveahaft installation
Crankcase assembly shah O7965—GMOO3DO S
Shaft protector 07931 —1870000 Driveshaft removal
Case puller 07835—GKBODOO Crenkcase separation
Case/driven gear puller 07935—KGBOOOO Crankshaft removal
Universal bearing puller 07631—0010000 Crankshaft bearing removal
Shaft protector 07931—1870000 Crankcase saparati n, crankshaft removal 10
Crankcala assembly collar 07965—GM00100 j—Crankshaft installation
Crankcase assembly shaft 07965—1660200
Crankcase assembly collar D7965—GM00100 jfimnkcase ammbly
Crankcase assembly shaft 07965—GM00300
Lock nut wrench A 079l6—KM10000 jsteering stern lock nut removal/installation
Lock nut wrench B 07916—1370100
Ball raoe remover 07946—GA70000 Steering head ball race removal 1 1
Driver 07749—0010000 j—Steering head bail race installation
Attachment, 42 x 47 mm 07746—0010300
Snap ring pliers 07914—323000! Fork disassembly/Assembiy
Universal holder 07725—0030000 Flywheel removal/installation 13

 

Flywheel puller

 

07733—0010000

 

Flywheel removal

 

 

 

1-11

 

General Information

 

 

 

 

 

 

 

Thob
- Refer to ”Bali bearing replacement" in section 1 of the Common Service Manual.
Description Tool Number Application Section
Float level gauge 07401—0010000 Carburetor float level inspection 5
Clutch center holder 07724—0050001 Drive pulley face removal/installation
Universal holder 07725—0030000 Clutch outer removal/installation
Clutch spring compressor 07960— KM I 0000 j£lmchldriven pulley disassembly/assembly 5
Lock nut wrench, 39 x 41 mm O7GMA—KS40100
Bearing driver 07945—GC80000 Driven face outer bearing installation
Crankcase assembly collar 07965—GM00100 j-Driveahaft installation
Crankcase assembly shaft 07965—GM00300 9
Shaft protector 07931 —-1870000 Drivashaft removal
Case puller O7935—GK80000 Crenkcase separation
Case/driven gear puller 07935—KG80000 Crankshaft removal
Universal bearing puller 07631 —0010000 Crankshaft bearing removal
Shaft protector 07931 —1B70000 Crankcase separation, crankshaft removal 10
Crankcase assembly collar 07965—GM00100 j—Cranksnaft installation
Crankcase assembly shaft 07565— 1660200
Crankcase assembly collar O7965—GM00100 j—Crankcase assembly
crankcase assembly shaft 07965—GM00300
Lock nut wrench A 07915—KM10000 :r-Steennq stern lock nut removal/installation
Lock nut wrench E 07916— 1870100
Ball race remover 07946- GA7000O Steering head ball race removal I 1
Driver 07749—0010000 j-Staering head ball race installation
Attachment, 42 x 47 mm 07746—0010300
Snap ring pliers 07914—3230001 Fork disassembly/Assembly
Universal holder 07725—003000!) Flywheel removal/installation 13
Flywheel puller 07733 ~001000O Flywheel removal

 

 

 

 

 

 

1-11

 

General Information

Lubrication & Seal Points

 

—— En ine
9 Location

Material

Remarks

 

Crankcase mating surfaces

Liquid sealant

 

Oil puma O-ring

Oil pump shaft bearing

Cylinder

Piston

Piston pin

Connecting rod small and bearing
Crankshaft oil seals

Crankshaft 12 mm threaded portion

Honda 2-stroke engine oil

 

Crankshaft bearings

Muntipurpose grease

 

Oil pump gear

Molybdenum disulfide grease

 

Driven face

Kickstarter driven gear
Kickstarter spindle bearing
Starter pinion bearing

Lithium based grease
—MITSUBISHI: HD-S
—NIPPON SEKIYU: LIPANOX
DELUX 3
—IDEMITSU: AUTOLEX B

Pack 5.0—5.5 g (0‘18—
0.19 oz) of grease to the
inside

 

Transmission (final reduction) case

Hypoid gear oil [90

90 CI: (3.04 US oz, 3.16 lmp
oz)

 

Transmission (final reducu'on) oil seal
Cylinder head bolts

4-stroke engine oil

 

 

 

Fork dust seal lip

Fork tube bushing sliding surface
Rebound spring

Fork spring tightly wound coils
Front brake cam

Front brake panel anchor pin
Front brake penal oil seal lip
Hear brake cam

Rear brake anchor pin
Steering stem bearings
Steering stem bearing races
Speedometer cable

Seat lock pivot

Center stand pivot
Speedometer gear
Speedometer pinion

r— Frame
Location Material Remarks
Front wheel dust seal lip Multipurpose grease
Fork Peck 1‘5—2 g (ODS—0.07

oz) of grease between the
bottom case and fork tube
(page 1 1 -9l.

 

Inside of the front brake cable boat
Inside of the rear brake cable boot

 

 

Silicone grease

 

 

 

1-12

 

-— Frame

General Information

 

anmion

Material

Remarks

 

Brake cam fell seals
Brake cablss

Engine oil

 

Inside surface of handle grip

Honda Band A or equivalent

 

Air cleaner connecting tube-to—case joint

Samadain [540

 

Air cleaner elemen:
Engine oil tank

 

 

Honda 2-stroka engine oil

 

 

 

 

1-13

General Information

 

Cable & Harness Routing

(2) REAR BRAKE CABLE

  
  
  
  

(1) FRONT BRAKE CABLE

(3) SPEEDOMETEFI CABLE

(7) THROTTLE CABLE
(4) CLAMP

(6) IGNITION SWITCH

(5) RESISTOR

(8) RESlSTOR

(10) FRONT BRAKE CABLE

 

1-14

General Information

(2) THROTTLE CABLE

  

(1) ALTERNATOR/STARTER MOTOR
WIRE HARNESS

  
 
  

(3) OIL INLET TUBE

(6) REAR BRAKE CABLE (4) CARBUREVDR DRAIN TUBE

 
 

(5) OIL PUMP CONTROL CABLE

(7) CDI UNIT

      

(a) BATTERY

(9) FUEL LEVEL SENSOR WIRE

(10) MAIN WIHE HARNESS

 

1-15

General Information

(1) TAILLIGHT/TURN SIGNAL LIGHT WIRE

_¢%/\

 

 

 

 

(2) CLAMP

 

1-16

 

2. Frame/Body Panels/Exhaust System

 

 

Service Information 2—1 Fuel Tank Removal/Installation 2-8
Troubleshooting 2-1 Muffler Removal/Installation 2-9 ‘
Frame Cover Removal/Installation 2-2

Service Information

 

  
 
 

. Gasoline is extremely flammable and explosive under certain conditions.

 

. Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.

 

. Work in a well ventilated area Smoking or allowing flames or sparks in the working area or where gasoline is stored can
cause a fire or explosion.

- This section covers removal and installation of the frame covers, fuel tank and exhaust system.
Frame cover installation is in the reverse order of removal, unless noted othewvise.

- When removing the cover, be careful not to damage any tab or groove of a cover.

~ Always inspect the exhaust system for leaks after installation.

Troubleshooting

Excessive exhaust noise
- Broken exhaust system
- Exhaust gas leak

Poor performance
- Deformed exhaust system
- Exhaust gas leak
- Clogged muffler

 

2-1

Side Cover

Remove the trim clip and two screws.

®Releaee the front who of the cover from the front fender
while sliding the cover rearward.

@Push the cover rearward and release the four from labs
outward.

®Push the cover rearward and release the three tabs from
the frame body cover downward.

®Release me two rear tabs while pulling down the rear of
the cover.

NOTE
Attach the rear of the front fender with the side cover front
screw.

 

Frame] Body Panels/Exhaust System

 

 

 

 

Frame Body Cover

Remove the Iuggage box (page 2-4)‘

Disconnect the turn signal light and taillight wire connectors,
Remove the three bolts and the rear carrier assembly.

Remove the side cove“.

Remove the center cover (page 2-4).

Remove the two tipping screws and two trim clips.

®Release the from tabs upward‘

®Remove the frame body cover rearward.

@Remove the two tapping screws and the body cover ne.

®Pull the left frame body never back to release the two tabs
and separate the left and right frame body COVBVS‘

 

(2) SIDE COVER

(I) SCREWS (3) TRIM CLIP

 

 

(1) BOLT (2) HEAR CARRIER ASSEMBLY

 

(3) WIRE CONNECI'ORS

 

 

     
 

 

(”TAB

(2) TAPPING
SCREW (3) BODV

COVER

(7) FRAME
BODY
COVER

(6) TAPPING SCREW (5) TAB

(4) TRIM CLIP

 

 

 

2-3

Side Cover

Remove the trim clip and two screws.

®Re|euse the front tabs of the cover from the front fender
while sliding the cover rearward.

®Push the cover rearward and release the four front tabs
outward.

@Push the cover rearward and release the three tabs from
the frame body cover downward.

@Helease the two rear tabs while pulling down the rear of
the cover.

N OTE

Fra me/ Body Panels/ Exhaust System

 

 

Attach the rear of the front fender with the side cover from
screw.

 

 

 

Frame Body Cover

Remove the luggage box (page 2—4).
Disconnect the turn signal light and taillight wire connectors.
Remove the three bolts and the rear carrier assembly.

Remove the side covers,

Remove the center cover (page 2—4).

Remove the two tapping screws and two trim clipst

®Release the front tabs upward.

®Hemove the frame body cover rearward.

®Remove the two tapping screws and the body cover lid.

©Pull the left frame body cover back to release the two tabs
and separate the left and right frame body covers.

 

(2) SlDE COVER

(1) SCREWS (3) TRIM CUP

 

 

(1) BOLT (2) REAR CARRIER ASSEMBLY

 

(3) WIRE CONNECTORS

 

 

(”TAB

(2) TAPFING
SCREW

      
 

(3) BODY
COVER
LID

(7) FRAME
BODY

 

(6) TAPPING SCREW

(5) TAB

(4) TRIM cue

 

 

 

2-3

Freme/ Body Penels/ Exhaust System

Luggage Box
NOTE

 

 

| - The luggage box can be removed together with the seat.

 

Open the seat.

Remove the two screws and the battery cover.
Open the body cover lid.

Remove the oil tank cap and seal rubber‘
Remove the five bolt and the luggage box,

NOTE

 

. After removing the luggage box, install the seal rubber
and oil tank can to prevent dirt and dust from entering

 

 

the oil wnkt

 

Center Cover

Remove the luggage box.
Sllde the center cover upward to release the two tabs from
the frame body cover and remove the center cover.

Open the fuel tank lid.
Remove the two screws and the fuel tank lid.

(2) BATTERY COVER
(3) BOLTS

    
  
  

(1) SCREWS

(4) OlL TANK
CAP

RUBBER

(6) BODY COVER LID
(7) LUGGAGE BOX

 

 

 

(1) FUEL TANK LlD
(2) CENTER COVER

  
 
 

(3) SCREW

  
   

l4) TABS

 

 

2-4

 

Seat

Open the seat.
Remove the two nuts and the seam

Floor Board
Remove the frame body cover (page 24).

Remove the four bolts.
Raise the rear of the floor board slightly, pull the floor board
rearward to release the tabs and remove it‘

Front Cover

Remove the four tapping screwst

Remove the two trim clips.

Remove the three screws.

Release the tabs while pushing both sides of the cover
inward and the remove cover.

N OTE

Frame/ Body Panels/ Exhaust System

 

(1) SEAT

 

 

 

  
 

(3) TAB

 

 

 

- When installing, make sure that the tabs are aligned with

 

the slots properly before tightening the screwst

 

 

 

(2) FRONT COVER
(1) SCREW

 

l4) TRIM CLIPS (3) TAPPING SCREW

 

 

 

Frame/ Body Panels/Exhaust System

Frame Cover Removal/Installation

Frame Cover Locations

 

®Side cover ®Rear Fender
®Center cover ®Front cover
®Frarne body cover ®ant inner caver
®Floor board ‘ @Handla from cover
®Batlery cover ®Handle rear cover

©Luggage box

Frame Cover Removal Chart
- This chart shows removal order of frame covers by means of arrowr

.Front cover ®side cover ©Banery covar

©Luggaga box

@Handle rear cover
®Handle front cover

       
   
   

 
 

 

   

 

®Center cover

®Frame body cover
©Floor board

      
 

 

 

®Rear fender

 

®Front inner cover

 

2-2

Freme/ Body Panels/ Exhaust System

Front Inner Cover

Remove the floor board (page 2-5).
Remove the front cover (page 2-5)‘

Remove the four tapping screws attaching the inner cover to
the front fender.

Remove the screw attaching the inner cover to the frame,
Pull the upper portion of the cover back out of the frame.
Slide the cover upward along the frame and remove it.

Remove the six tapping screws and separate the upper and
lower inner covers.

NOTE
- when installing, align the bosses of the inner cover with
the holes in the frame properlyt

 

 

 

 

Rear Fender

Remove the oil tank (page 4-4).
Remove the ignition coil (page 14-6).

Remove the CDI unit, starter relay switch and fuse holder
from the rear fender.
Remove the rear fender from the frame.

 

(3) UPPER FRONT INNER COVER

 
  
   
 
  

(2) TAPPING SCREW

(4) SCREW
(1) TAPPING SCREW

(6) LOWER FRONT
INNER COVER

(5) FRAME

 

 

 

(I) STARTER RELAY SWITCH

   
 

(2) CDI UNIT

/

(4) FUSE HOLDER

(3) REAR FENDER

 

 

2-6

 

Handle Rear Cover

Remove the rearview mirrors.

Remove the two tapping screws and the screw.

Release the three hooks by pushing down the cover and
sliding it rearward.

Remove the cover from the handlebar.

NOTE
F When installing, be careful not to pinch the wires.

 

Disconnect the speedcrneter cable from the speedometer.
Disconnect the five connectors from the handlebar
switchesr

Remove the three screws and the cover from the instrument
case.

NOTE

- It is not necessary to remove the handle rear cover from
the instrument case to remove the handle from cover.

 

 

 

 

Handle Front Cover
Remove the handle rear cover from the handlebar.

Remove the two tapping screws and the screw.
Disconnect the headlight connector.

Disconnect the turn signal light wire connectors and remove
the handle front cover.

Frame/Body Panels/Exhaust System

 

(1) REAR VlEW MIRROR

 

   

(5) SCREW
\

l4) TAPPING SCREW (3) HANDLE REAR COVER

 

 

(1) HANDLE REAR COVER
(2) SCREW

  

(5) CONNECTOR
(3) SPEEDOMETER CABLE

(4) INSTRUMENT CASE

 

 

 

(1) TAFPING SCREW
(2) HEADLIGHT CONNECTOR

(3) HANDLE FRONT

 

(5) TURN SIGNAL WIRE

l4) SCREW

 

 

 

2-7

Frame/ Body Panels/ Exhaust System‘

Fuel Tank Removal/Installation

 

(3)
(3) (5)

(4) ——->

(S)

 

 

 

 

 

- Game In is extremely flammable and is explosive under certain condition. KEEP OUT OF REACH OF CHILDREN.

- Work in e well ventilated area. Smoking or allowing flames or sparks in ihe work area or where gasoline is stored can
cause a fire or explosion,

Requisite Service

- Front inner cover removal/installation (page 2—6)

 

Procedure Q'ty

 

 

Remarks

Removal Order Installation is in the reverse order of removal.

Fuel tank
H) Fuel unit wire connector 1
(2D Fuel line 1 NOTE

- Plug or clamp the fuel line to preveni gasoline from
flowing out

(3) Fuel tank mounting bolt 4
(4) Floor plate 1
(5) Fuel tank 1

Fuel level sensor
(6) Retainer ‘l
(7) Fuel level sensor 1
(8) Seal rubber l

 

 

 

 

 

 

 

Muffler Removal/Installation

Frame/ Body Panels/Exhausr Sys‘em

 

 

(3)

 

 

 

- Serious bums may resul! if the exhausi system is not allowed to coal before componenu Ire removed or serviced.

 

Hequisite Service

- Center cover removal/installation (page 2-4)

 

 

 

 

 

 

Procedure Q'ty Remarks
Removal Order Installation is in the reverse order of removalr
(1) Muffler mounting bol! 2
(2) Exhaust pipe joinr nut 2 Loosen.
(3) Muffler 1
(4) Exhaust pipe gasker 1

 

 

 

 

 

3. Maintenance

 

Service Information 3-1 Oil Pump and Oil Line 3-6
Service Access Guide 3-2 Headlight Aim 3-6
Maimenanca Schedule 3—4

 

 

 

Service Information

- Refer (a Common Service Manual far service procedures of items not included in this manual.
- Refer a: Specificatiuns (section 1) for maintenance service data.

 

M eintenance

Service Access Guide

- The following shows the locations of the parts that must be removed for the maintenance items listed below. Refer to the
Common Service Manual for items not included in this manual.

- Refer to section 2 (frame/Body PaneIs/Exheust System). for the parts that must be removed for service
For example: FUEL UNE (Damage. leakage) —— Maintenance pert

     
 
  
      
  
 

- Fioor board —— The part that must be removed for service.
(2) SPARK PLUG (Wear, damage, color) (3’ THROTTLE GRIP (Operation, free play)
——__,

  
   

(4) FRONT BRAKE LEVER

(1) TIRE (Wear, damage, pressme) (Operation, free play)

(5) HEADLIGHT ADJUSTlNG SCREW
(Aim: page 3—6)

 

§

(5) STEERING HEAD BEARING
(Damage)

(7) WHEEL
(Damage, runcut)

    
 
 
   
 
   

(11) WHEEL (Damage, runout)

(8) SUSPENSION

(Loose, weer. damage)
(10) CYLINDER HEAD (Decarbonizing)

(9) TIRE (Wear. damage, pressure)

 

Maintenance

(3) OIL PUMP AND OIL LINE

(2) FUEL LINE (Damage, leakage, deterioration) (Adiustmnt: page 3-6)
FUEL FILTER (Clogging) damage, leakage, deterioration)
- Floor board - Frame body cover

 

(4) SUSPENSION
(Loose, wear, damage)

(1) REAR BRAKE LEVER
(Operation, free play)

 
 
  
 
 
  
 
  

(5) AIR CLEANER (Contamination.
clogging, cleaning)

 

 

(6) REAR BRAKE
(Brake shoe wear)

 

I9) FRONT BRAKE

(Brake shoe wear) (7) CLUTCH (Clutch shoe wear)

(8) THRO'I'ILE STOP SCREW
(Idle speed adjustment)

 

 

3—3

M nintenenca

Maintenance Schedule

Perform the Pre<ride inspection in the Owner's Manual at each scheduled maintenance period.

I : Inspect and clean, adiust, lubricate or replace if necessary.

C: Clean R: Replace A: Adjust L: Lubricale

The following terns require some mechanical knowledge. Certain items (particularly those marked a and a a i may require
more technical information and tools. Consult your authorized Honda dealer.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

U type
Frequency Whichever Odometer Reading (Note 1)

20;“ ¢ x 1,000 km 1 4 a 12 Here, m

x1,ooo mi 0.5 2.6 5 7.5 page

Items Note Months 6 12 1B

' Fuel Line I I I Note a
' Throme Operation I I I Note 3

-- Oil Pump and Oil Line I I I 3-6
Air Cleaner Note 2 C C C Nate 3
Spark Plug Every 1,300 km (1 ,000 mi) R Note 3
" Decerbonlzing Every 3,000 km (2,000 ml) 0 Note 3
’ Carburetor Idle Speed I I I l Note 3
Brake Shoe Wear I I I Note 3
Brake System I I I I Note 3
‘ Brake Light Switch 1 I I Note 3

' - Headlight Aim 1 I I 3-6
" Clutch Shoe Wear I Note 3
' Suspension I I I Note 3
' Nuts, Bolts, Fasteners l I Note 3
” Wheels/Tires I I I Nate 3
" Steering Heed Braarings I 1 Note 3

 

 

 

 

 

 

 

 

 

 

e Should be serviced by your authorized Honda dealer, unless the owner has proper toels and service data and is
mechanically qualified.
* it In the interest of safety, we recommend these items be serviced only by your authorized Honda dealer.
Notes: l . At higher odometer reading, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Refer to Common Service Manual,

 

3—4

Maintenance

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CM type
Frequency Whichever Odometer Reading (Note 1)

2:3“ I) x 1,000 mi ole 2.5 5 7‘5 Refer m

X 1,000 km 1 4 8 12 page

Items Nate Months 6 12 18

’ Fuel Line I I I Note 4
' Throttle Operation I I I Note 4

“ Oil Pump and 011 Line I I I 3-6
Air Cleaner Note 2 C C C Note 4
Spark Plug Note 3 Every 1,000 ml (1,600 km) R Note 4
“ Decerhonizing Note 3 Every 24000 mi (3,200 km) C Note 4
‘ Carburetor Idle Speed I I I I Note 4
Brake Shoe Wear I 1 I Note 4
Brake System I I I I Note 4
‘ Brake Light Switch 1 I I Note 4

' Headlight Aim 1 I I 3»6
" Clutch Shoe Wear I Note 4
‘ Suspension I I I Note 4
‘ Nuts, Bolts, Fasteners I I Note 4
" Wheels/Tires I I I Note 4
" Steering Head Brearings I I Note 4

 

 

 

 

 

 

 

 

 

 

t Should be serviced by your authorized Honda dealer, unless the owner has proper tools and eerviee date and is

mechanically qualified.

:- nln the interest of safety, we recommend these items be serviced only by your authorized Honda dealer.

Notes:

1. A: higher odometer reading, repeat at the frequency interval established here.
2‘ Service more frequently when riding in unusually wet or dusty areas
3

. HONDA 2 STROKE MOTORCYCLE 01L has been specifically tested in and is recommended for this engine. The
use of other oils may cause excessive carbon build—up in the engine and exhaust system, resulting In less of
power and possible engine damage

4. Refer to Common Servioe Manual.

 

Maintenance

Oil Pump and Oil Line

Oil Pump Control Cable Adjustment

NOTE

 

 

- The oil pump control cable should be adjusted after the
throttle grip free play adjustment.

 

 

 

Remove the center cover (page 24).

Open the throttle fully and check that the aligning mark on
the oil pump control lever is aligned with the index mark on
the oil pump body.

Adjust by loosening the oil pump control cable lock nut and
turning the adjusting nut.

CAUTION
- An adjustment within 1 mm (0.04- in) of the Index
mark on the open side is acceptable. However. the
a gning mark must never be on the closed side at the
index mark, otherwise engine damage will occur
because of insufficient lubrication.

 

 

 

(1) CONTROL LEVER (2) OIL PUMP aoov

   

(3) ALIGNING
MARK AND
INDEX MARK

K T
(5) LOC NU (4) ADJUSTING NUT

 

 

 

Headlight Aim

 

- An improperly adjusted headlight may blind
on-oomlng drivats, or it may fail to light the road tor a
safe distance.

 

 

Place the scooter on firm, level ground and suppott it with
the center stand.

Start the engine and allow it to idle.

Make sure that the headlight and taillight are on.

Check the operation of the headlight dimmer (Lo~Hi) switoh‘
Adjust the headlight beam by turning the horizontal
adjusting screws,

CAUTION

- Adjust the headlight beam as specified by local laws
and regulations.

 

 

 

 

 

 

ll) ADJUSTING SCREWS

 

 

3-6

 

 

 

4. Lubrication System

 

Service Information 4-1 Oil Pump Removal/Installation 4—3
Troubleshooting 4-1 Oil Tank Removal/Installation 4-4
Lubrication System Diagram 4-2

 

Service Information

CAUTION

 

- Ail in oil system will block a! "strict oil flow and may result in severe engine damage.

I from the all lines whenever the oil Ilnes or pump have been removed or there is air in the oil lines
- Blood air from the ail inlet line first, then bleed air from the oil outlet line.

 

 

 

 

- The oil pump servicing can be performed with the engine installed.

- When removing and installing the oil pump,be careful not to let any foreign materiel enter the engine.
- Do not attempt to disassemble the oil pump.

. Fill the oil outlet line with oil whenever the oil outlet line is disconnected.
~ Refer to section 2 of the Common Service Manual for oil strainer screen cleaning.
- When disconnecting the oil inlet tube, clamp or plug the tube to prevent oil from flowing out.

Troubleshooting

Excessive smoke and/or cat-hon on spark plug
- Faulty oil pump (too much oil flow)
t Low quality engine oil

Overheating or seized piston

- No oil in tank or clogged oil line

. Air in oil lines or oil pump

- Faulty on pump (too little oil flow)
- Clogged oil strainer

- Clogged oil tank cap breather hole

 

Lubrication System

Lubrication System Diagram

 

(6) OIL PUMP

(1) OIL TANK

(5) OIL PUMP CONTROL CABLE

 

4-2

Lubrication System

 

Oil Pump Removal/Installation

 

NUT

 

 

NOTE

 

- It is not necessary to loosen the oil pump adjusting nut. It the nut is loosened, perform the oil pump control cable
adjustment (page 3-6) after installing the oil pump.

. After installing the oil pump, perform the oil pump/oil line bleeding refering to page 4—11 of the Common Service
Manualt

 

Requisite Service

- Frame body cover removalfinstellation (page 2»3)

 

 

 

 

 

Procedure Q'ry Remarks
Removal Order Installation is in the reverse order of removal,
(1) Oil inlet tube 1 NOTE
‘ Before disconnecting. clamp or plug the tube to prevnt oil
from flowing out.
(2) on outlet tube 1
(3) Starter motor mounting bolt 1
(4) Oil pump mounting bolt/harness clamp 1/1 NOTE
- Be careful not to lose the nut at the oil pump side,
(5) Clamp 1 Remove from oil pump control cable.
(6) Oil pump control cable 1
(7) Oil pump 1
(8) Oil pump mounting collar 1
(9) O—n'ng 1

 

 

 

 

Lubrication System

Oil Tank Removal/Installation

 

 

 

(4) (2)

(7)

 

NOTE

-' After installing the oil tank, perform the oil pump/oil line bleeding relering to page 4»! 1 of the Common Service Manual.

Requisite Service

~ Battery removal/installation (page 13-4)
- Rear combination dummy removal/installation (page 16-4)

- Ignition coil removal/installation (page 14-6)

 

 

 

 

 

 

Procedure Q’ty Remarks
Removal Order Installation is in the reverse order of removal.
(1) Rear fender mounting bolt 1
(2) Oil tank mounting bolt 1
(3) Oil level switch connector 2
(4) Oil tank 1 Slide the rear fender down and remove the tank.
(5) Oil inlet tube 1 NOTE
. Disconnect the tube at the oil pump and drain the oil into
the clean container.
(6) Oil strainer
(7) Oil level switch

 

 

4-4

 

 

 

5. Fuel System

 

Service Information 5-1 Carburetor Disassemny/Assembly 5-5
Troubleshooting 5-2 Reed Valve Removal/Installation 5-6
Carburetor Removal/Installation 5-3

Air cleaner Case Removal/Installation 5-7

Throttle Valve Disassembly/Assemhly 5-4 Fuel Pump Removal/Installation 5-8

 

Service Information

 

 

- Galol e is extremely flammable and is explosive under certain conditioner

- Work in a well ventilated area. Smoking or allowing flame: or sparks in the work area or where gasoline is stored
can cause a fire or explosion.

 

- Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind.
reuniting in loss of vehicle control.

 

 

- When disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly.

. Before disassembling the carburetor, place a suitable container under the carburetor drain screw, loosen the screw and
drain the carburetor,

- After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with piece of tape to
prevent any foreign material from dropping into the engine.

NOTE

 

. If vehicle is to be stored for more than one month, drain the float chamber. Fuel left in the float chamber may cause
clogged jets resulting in hard starting or poor driveability.

 

 

 

 

Fuel System

Troubleshooting

Engine won't start
- No fuel to carburetor
—No fuel in fuel tank
—Fusl filter clogged
—Fuel line clogged
—Float valve stuck
—FIoat level misadjusted
—Fual tenk breather hole clogged
—Fuel pump malfunction
- Too much fuel getting to the engine
—Air cleaner clogged
- Flooded carburetor
‘ Intake air leak
. Fuel contaminated/deteriorated
. Bystaner circuit clogged

Lean mixture

- Fuel jets clogged

- Float valve faulty

- Float level too low

- Fuel line restricted

- Carburetor air vent tuba clogged
- Intake air leak

- Fuel pump malfunction

- Throttle valve operation faulty

Rid’t mimre

- Bystaner valve in ON position

- Float valve faulty

- Float level too high

- Air iets clogged

- Air cleaner element contaminated
. Flooded carburetor

Engine stalls, hard to sun. rough i
- Fuel line restricted

~ Ignition malfunction

- Fuel mixture too lean/rich

- Fuel contaminated/deteriorated
- Intake air leak

- Idle speed misadjusted

- Fuel pump malfunction

- Air screw misadiusted

- Bystarter circuit clogged

- Float level misadiusted

- Fuel tank breather hole clogged

 

Afterbum when engine braking is used
- Leen mixture in slow circuit

Beckfiring or misfiring durlng acceleration
- Ignition system faulty
- Fuel mixture too lean

Poor performance (driveebility) and poor fuel economy
- Fuel system clogged
- Ignition malfunction

 

5-2

Fuel System

Carburetor Removal/Installation

 

 

 

DRAIN TUBE HOLE IN THE SHROUD

 

 

W

 

(6)
cm (1.0, 7)

Requisite Service

 

 

 

 

- Center cover removal/installation (page 2—4) . Air cleaner case removal/installation (page 57)
Procedure Q‘ty Remarks
Removal Order Installation is in the reverse order of removal.
(I) Carburetor top/throttle valve 1 Disassembly/assemblv (page 5-4)
(2) Drain tube 1 Disconnect from the carburetor‘
NOTE

- When installing, insert the other end of the tube into the
hole in the shroud.

(3) Fuel line 1

(4) Oil outlet tube

NOTE

- Bleed air from the tube when installing.
(5) Auto bystaner wire connector
(6) Carburetor mounting bolt

(7) D-ring

(8) Insulator

(9) O»ring

(10) Carburetor

add—INA

 

 

 

 

Disassembly/assembly (page 5-5)

 

 

5—3

 

Fuel System

Throttle Valve Disassembly/Assembly

 

(6)

 

(7)

(5)

(2)

 

 

(3)/©
V /

(1)

 

 

 

CAUTION

 

assembly without causing damage to the cable.

-The :Irburetor top is an integral pert of the throttle cable assembly. The top cannot be separated from the

 

Requisite Service
- Carburetor top/throttle valve removal/installation (page 53)

 

 

 

 

 

 

Procedure Q’ty Remarks
Diussembly Older Assembly is in the reverse order of disassembly.
(1) Throttle cable 1
(2) Throttle valve spring 1
(3) Carburetor top gasket 1
(4) Retainer 1
(5) Jet needle 1
(6) Needle clip 1 Remove from the jet needle.
Standard position: 3rd groove
(7) Thronla valve 1

 

 

 

Carburetor Disassembly/Assembly

Fuel System

 

 

(2)

 

(l5)

(5)

(9)

 

 

- Requisite Service

- Carburetor removal/installation (page 5—3)

 

Procedure

G'ty

Remarks

 

Disassembly Order
Auto bvmrtsr

(1) Auto bystarter cover
(2) Screw

(3) Auto bystaner set plate
(4) Auto bystaner

dde

Assembly isvin the reverse order of disassembly.

 

Float chamber
(5) Screw

(6) Float chamber
(7) O-ring

(3) Float pin

(9) Float/float valve

\dHAN

 

carburetor body
(10) Main jet

(11) Main jet holder
(12) Needle jet holder
(13) Slow jet

(14) Air screw

(15) Throttle stop screw

 

 

(16) Spring/O-ring

 

1/1

NOTE

- After installing the carburetor. adjust the idle speed.

 

 

 

 

5-5

Fuel System

 

Reed Valve Removal/Installation

 

    

<2) 310(140, 7) 43’

10(1.0. 7)
(1)

(7)
9!

 

CAUTION

 

- Do not disassemble or bond lhe reed flapper. To do so can cause log of power and engine damage. If the stopper.
read or valve seat is faulty, replace them as a unit

 

Raquisile Service

 

 

 

- Luggage box removal/installalion (page 2-4) Carburetor removal/installation (page 5-3)
Procedure O‘ty Remarks
Removal Order Installation is in xhe reverse order of removal.
(1) Left shroud mounting bolt 2
(2) Left shroud 1
(3) Intake manifold mounting bolt/clamp 4/1
(4) Intake manifold 1
(5) Gasket 1
(8) Reed valve 1
(7) Gasket 1

 

 

 

 

 

 

Fuel System

Air Cleaner Case Removal/Installation

 

(B)

(2)

(4)

 

 

 

 

 

 

 

 

Procedure Q'ty Remarks
Removal Order lnstallaflen is in the reverse order of removalr
(1) Tapping screw 5
(2) Air cleaner case cover 1
(3) Air cleaner element 1
(4) Connecting lube band screw 1 Loosenr
(5) Breather rubs 1 Disconnect from the air cleaner case.
(6) Air cleaner case mounting bolt/nut 2/1 NOTE
- Do not lose the rim.
(7) Air cleaner case 1

 

 

 

5-7

Fuel Sys‘em

Fuel Pump Removal/Installation

 

(2)

(5)

 

 

 

NOTE

 

. Do not enempt to disassemble the fuel pump
- After installing the fuel pump, bleed air from lhe fuel lines and pump,

 

Hequisits Service
- Floor board removal/insullafion (page 2-5)

 

Procedure O'ly Remarks

 

filmwal Order
( l ) Bolt 2
(2) Fuel pump

Installation is in the reverse order of removal‘

Inspecfion (page 5-9)

—Air bleeding (page 6—9)
(3) Fuel line (discharge side)

(4) Fuel line (suction side)
(5) Vacuum tube

‘LLJ

NOTE

- When installing, do not connect the vacuum tube to the

fuel suction pipe of the pump
(5) Fuel filter 1

 

 

 

 

 

 

 

Fuel Pump Inspection

NOTE
- Before inspecting the pump discharge volumev warm up
the engine and check that the idle speed is within the
specification.

 

 

 

 

Start the engine and allow it to idle.

Disconnect the fuel line from the carburetor, allow the fuel
to flow out cf the fuel line for more than 5 seconds, then let
the fuel flow into the graduated beaker for 10 seconds. Stop
the engine and connect the fuel line.

There should be 20 cc (0.70 US oz, 0.67 Imp oz) in the
beaker.

If the fuel pump discharge volume is less than specified
volume, check the fuel lines. vacuum tube and fuel filter for
clogging or damage, If they are OK, replace the fuel pump.

Air Bleeding

After replacing the fuel pump, bleed the air from the pump
and fuel lines as follows:

Disconnect the fuel line from the carburetor and feed the
gasoline from the other container through the suitable fuel
tube,

Start the engine and allow it to idle to operate the fuel pump
until the fuel flows out of the fuel line.

Stop the engine and connect the fuel line to the carburetor.

Fuel System

 

 

(1) FUEL LINE

    

l2) BEAKER

 

 

 

l‘ll FUEL LINE

   
 

(ZI GASOLINE
CONTAINER

 

 

 

 

 

6. Engine Removal/Installation

Service Information 6-1 Engine Removal/Installation 6-2

 

 

 

 

Service Information

- The following components require engine removal for service:
— Drivesheft and final gear shaft bearings (section 9)
, Crankcase (section 10)
— Crankshaft (section 10)

- After installing the engine, perform the following adjustments:
— Throttle cable
— Oil pump control cable (page 3—6)
— Rear brake cahle

 

6-1

Engine Removal/Installation

 

Engine Removal/Installation

 

 

 

 

 

 

6-2

Requisite Service

- Frame body cover removal/installation (page 2-3)

Engine Removal/Installation

- Carburetor top/throttle valve removal/installation (page 5-3)

 

 

 

Procedure Q'ty Remarks
Removal Ordnr Installation is in the reverse order of removal,
(1) Alternator/starter motor wire connector 2
(2) Auto bystarter wire cennectar 1
(3) Oil inlet tube 1 NOTE
- Before disconnecting, clamp or plug the tube to prevent
all from flowing out.
(4) Fuel line 1
15) Carburetor top 1
(6) Fuel pump vacuum tube 1
(7) Spark plug cap 1
(8) Oil pump control cable 1 Disconnect from pump and remove from cable stay.
(9) Hear brake cable 1 Remove from the rear brake arm, crankcase and clamp.
(10) Rear shock absorber upper mounting bolt 1
(1 1) Engine mounting bolt/nut 1/1
(12) Engine 1 NOTE
- Support the frame securely.
(13) Engine mounting bracket bolt/nut 1/1
(14) Engine mounting bracket 1

 

 

 

 

 

 

6-3

 

7. Cylinder Head/Cylinder/Piston

send“ '"fwma‘h" 7-1 Cylinder Head. Cylinder and Piston
Troubleshooting 74 Removal/installation 7.2

 

 

 

 

Service Information

- Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before
inspection.
- Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike the

cylinder too hard during disassembiy, even with a rubber or plastic mallet, to prevent the possibility of damage to the
cylinder fins.

- Take care not to damage the cylinder wall and piston.

Troubleshooting

Compression too low, hard starting or poor performance at low speed
~ Cylinder head
— Leaking or damaged cylinder head gasket
— Warped or cracked cylinder head
- Loose spark plug
- Worn, stuck or broken piston rings
, Worn or damaged cylinder and piston
. Leaking crankcase primary compression
— Blown crankcase gasket
— Damaged crankshaft oil seal

Compression too high, overheating or knocking
~ Excessive carbon build-up on piston or combustion chamber

Abnormal noise

- Worn cylinder, piston, piston ring

- Worn piston pin or piston pin hole

- Worn connecting rod small end bearing

 

7-1

Cylinder Head/Cylindar/Piston

Cylinder Head, Cylinder and Piston Removal/Installation

 

 

 

 

 

 

 

7-2

Requisite Service

- Muffler removal/installation (page 2-9)
- Fan cover removal/installation (page 13-8)
- Left shroud removal/installation (page 5-6)

Cylinder Head/Cylinder/ Piston

 

 

 

 

 

Procedure Q’ty Remarks

Removal Order Installation is in the reverse order of removal.

Cylinder head
(1 ) Spark plug 1
(2) Cylinder head bolt 4 Loosen the belts in a crisscross pattern in 2 or 3 steps.
(3) Cylinder head 1
(4) Cylinder head gasket 1

Cylinder
(5) Cylinder I CAUTION

- Do not pry between the cylinder and crankcase or strike
the fins.
(5) Cylinder gasket 1 NOTE
- Clean the gasket surfaces of the cylinder and crankcase
being careful not to damage them.

Piston
(7) on pin clip 2
(8) Piston pin 1
(9) Piston 1
(10) Piston ring 2
(1 1) Expander 1 Install the expander behind the second ring,
(12) Connecting rod small and bearing 1

 

 

 

 

 

 

7-3

 

 

8. Kickstarter/Drive Pulley/Clutch/Driven Pulley

 

Service Information 8A1 Drive Pulley and {Hutch/Driven Pulley
Troubleshooting 8-1 Removal/Installation . 8-5
Left Crankcase Cover Removal/ X25222: Drive Face Drsassambly/ 8-7
installation 8-2 y. .

Kickstarter Removal/Installation 8-3 gggg/Sywn Pulley Disassembly/ 8-8

 

 

 

Service Information

NOTE
1 - Do not apply grease to the movable drive Cece and weight rollers.

 

 

- Avoid getting grease and oil on the V-belt and pulley drive faces in order to prevent belt slippage.
~ Never operate the starter motor with the left crankcase front cover removed.

Troubleshooting

Englne starts but scooter won't move
- Worn drive belt

- Damaged ramp plate

~ Worn or damaged clutch lining

- Broken driven face spring

Engine stalls or scooter weeps
- Broken clutch shoe spring

Poor performance at high speed or lack of power
- Worn drive belt

- Weak driven race spring

- Worn weigh: rollers

~ Contaminated pulley faces

 

8-1

Kickflarter/Drive Pulley/Clmch/Driven Pulley

Left Crankcase Cover Removal/Installation

 

(6)

g

(5)

  
   

 

 

 

 

 

 

 

Procedure Q'ty Remark:
Removal Older Installation is in the reverse order of removall
(1) 6 mm special bolt 5
(2) Left crankcase rear cover 1 Push down the kickstarter pedal and remove the cover.
(3) Rubber gasket 1 NOTE
- Replace wkh a new one if damaged.
(4) 6 mm bolt 5 NOTE
- when installing, do not forget to insmll the cable clamps
in position.
(5) Lefl crankcase front cover 1
(6) Gasket 1
(7) Dowel pin 2

 

 

 

Kickstarter Removal/Installation

Kickstaner/ Drive Pulley/Clumh/ Driven Pulley

 

 

 

Roquisita Service
- Left crankcase cover removal/installation (page 3-2)

 

 

 

 

 

Procedure Q'ty Remarks

Removal Order Installation is in the reverse order of removal.

(1) Kickstaner driven gear 1 Rmove while turning the kickstener pedal.
Installation (page 8—4)

(2) Thrust washer 1
(3) Bolt 1
(4) Kickstaner pedal 1
(5) Snap ring 1
(6) Washer 1
(7) Copper washer 1
(8) Kicksuaner spindle 1 Uhook the return spring and first and remove.
(9) Kickstarter return spring 1 }~lnspectin (page 8-4)
(10) Spindle bushing 1

 

 

 

8-3

Kickstarter/Drive Pulley/Clutch/Driven Pulley

Kickstarter Inspection

Check the kicksumer spindle for wear or damage.
Check the kickstartar return spring for weakness or damage,
Check the spindle bushing for wear, scratches nr scoring.

Check the kickstaner driven gear for wear or damage.
Check rhe friction spring for weakness or damage.

Check the spindle and driven gear hearings for wear 0r
damage.

Kickstaner Driven Gear lnstallafion
Align the friction spring with the boss on the crankcase front
cover and install the driven gear while turning the kicksmner

pedal.
Engage the spindle gear and driven gear while returning the

kickslaner pedal.

 

(I) RETURN SPRING

 

(3) KICKSTARTER
SPINDLE (2) SPINDLE BUSHING

 

 

(1) FRICTION SPRING

 

(2) DRIVEN GEAR

 

 

(1) SPINDLE BEARING

 

(2] DRIVEN GEAR BEARING

 

 

 

(1) DRIVEN GEAR (z) FRICTION SPRING

(3) BOSS

 

 

 

8—4

 

Kickstzmer/Drive Pulley/clutch/Driven Pulley

Drive Pulley and Clutch/driven Pulley Removal/Installation

 

(6)

(4)

(3)

(2)

   
 

(10)

 

8
c 40 (4.0, 29)

 

Requisite Service

- Left crankcase cover removal/installation (page 5-2)

 

 

Procedure O'ty Remarks
Removal Order Installation is in the reverse order of removal.
(1) Nut
(2) Washer

(3) Drive pulley face

(4) Starter pinion

(5) Drive belt

(5) Movable drive face

(7) Movable drve face boss
(8) Clulch outer nut

(9) Clutch outer

(10) Clutch/driven pulley

Removal/installation (page 8-6)

Disessemny/assembly (page 8-7)

Ramovelfinstallation (page 8-6)

 

 

 

 

 

Disessembly/assembly (page 8-8)

 

 

8-5

Kickstarler/ Drive Pulley/clutch/ Driven Pulley

Drive Pulley Face Removal/Installation

Hold the drive pulley face with the clutch center holder and
remove the nul.

Remove the washer and drive pul|ey face from the
crankshaft

Clutch center holder 07724—0050001
Installation is in the reverse order of removal.

NOTE
~ Nign the splines of ‘he drive pulley face and crankshaft
properly.

 

 

 

 

Clutch Outer Nut Removal/Installation

Hold the clutch outer with the universal holder and remove
the clutch outer nur.

Universal holder 07725 ~ 0030000

Installation is in the reverse order of removal.

 

(1) DRIVE PULLEY FACE (2) NUT

 

 

 

 

(3) UNIVERSAL HOLDER

 

 

 

Kickslamer/ Drive Pulley/Clu‘ch/ Driven Pulley

Movable Drive Face Disassembly/Assembly

 

 

 

 

 

 

 

(4) (5)
(6)

Requisite Service

~ Movable drive face removal/installation (page 8-5)

Procedure Q'ty Remarks
Disammhly Order Assembly is in the reverse order of disassembly.

11 ) Bolt 3

(2) Face seal 1

(3) Ramp plate 1

(4) Slide piece 3

(5) Weigh: roller 6 NOTE

(6) Movable drive face 1 - Do not apply grease to the movable drive face and weight

 

 

rollers.

 

 

 

Kicksrarter/Drive Pulley/Clutch/Driven Pulley

Clutch/ Driven Pulley Disassembly/Assembly

 

  

 

  

 

 

 

 

 

 

 

 

 

LONG SHORT
(WHITE PAINT) “” ‘°’ ‘9’ m

Requisite Service

- Clutch/driven puley removal/installation (page 8-5)

Procedure Q‘ty Remarks
Disassemblv Order

(1) 23 mm special nut 1

(2) Clutch assembly 1

(a) Snap ring 3

(b) Washer 3

(0) Clutch shoe 3

(d) Clutch shoe spring 3

(e) Dampr rubber 3

(f) Clutch drive plate 1

(3) Spring collar 1

(4) Driven face spring 1

(5) Seal collar 1 NOTE

- When removing, be careful not to damage or deform.

(6) Guide pin 2

l7) Movable driven face 1

(8) O-ring 2

(9) Oil seal 2

(10) Inner bearing 1

(1 I) Snap ring 1

(12) Outer hearing 1

(13) Driven face 1

 

 

 

Kickstarter/ Drive Pulley/Clutch/Driven Pulley

 

 

 

 

 

 

 

 

Procedure O'ty Remarks
Assembly Order
(13) Driven face 1 NOTE
- Pack 5.0—5.5 g (Oils—0.19 oz) of specified grease to
the inside when installing, '
(12) Outer bearing 1 Drive in with the sealed side facing down.
(1 1) Snap ring 1
(10) Inner bearing 1 Press in with the sealed side facing up
(9) Oil seal 2
(8) O-ring 2
(7) Movable driven face 1
(6) Guide pin 2
(5) Seal collar 1
(4) Driven face spring 1
(3) Spring collar 1
(f) C|utch drive plate 1
(e) Damper rubber 3
(e) Cluch shoe 3
(b) Washer 3
(a) Snap ring 3
(d) Clutch shoe spring 3 NOTE
- Note the installation direction.
(2) Clutch assembly 1
(1) 25 mm special nut 1

 

 

28 mm Special Nut Removal/Installation

Align the holes in the clutch spring compressor with the
bosses on the clutch drive plate and install the compressor
on the clutch/driven pulley)

Clutch spring compressor 07960— KM‘I 0000

Hold the clutch spring compressor in a visa.
Remove the 28 mm Special nut with the socket wrench.

 

Socket wrench 07GMA— K8401 00

Installation is in the reverse order of removal.

 

(2) CLUTCH SPRING

(n CLUTCH/DRIVEN COMPRESSOR

PU LLEY

    
  

 

 

(1) SOCKET WRENCH

(Z) CLUTCH SPRING
COMPRESSOR

 

 

 

 

8—9

 

9. Final Reduction

Service Information 9-1 Final Reduction Disassembly/Assembly 9-2
Troubleshooting 9-1

 

 

 

 

Service Information

- The final reduction servicing can be performed with the engine installed in the frame. However, it is necessary to remove
the engine from the frame and remove the rear brake from the left crankcase to prevent the crankcase from damage when
the hearings in the left crankcase are to be replaced.

- When installing the driveshaft, be sure to use the special tool; position the special tool against the bearing inner race and
pull the driveshaft into the bearing.

Troubleshooting

Engine starts but name: won't move
- Damaged transmission
- Seized transmission

Abnormal noise
‘ Worn. seized or chipped gears
- Worn or damaged bearings

Oil Ialka

- Oil level too high

- Worn or damaged oil seal
' - Cracked crankcase

 

9-1

Final Reduction

 

Final Reduction Disassembly/Assembly

 

 

(1)clo(1.0,7)

 

Requisite Service

- Rear wheel removal/installation (page 12-2)
- Air c|eaner case removal/installation (page 5—7)

- Cluxch/driven pulley removal/installation (page 3-5)

 

 

 

 

 

 

Procedure O'ty Remarks
Disanlmhly Order Assembly is in the reverse order of disassembly,

(1) 6 mm bolt 5

(2) Transmisson cover 1

(3) Gasket 1

(4) Dowel pin 2

(5) Final gear shaft I

(6) Thrus! washer 1

(7i Countershsh/genr 1/ 1

18) Thrust washer 1

(9) Driveshafi 1 Replacement (page 9—3)

 

 

 

Driveshaft Replacement
Press the driveshah out of the transmission cover.

 

 

NOTE

| - Be careful not to damage the cover mating surface. |
_

Shah [Imam 07931 - 1 870000

Remove the driveshah oil seal and bearing from the
transmission cover.

Drive a new bearing into the transmission cover with the
marking facing outi

Driver 07749 — 001 0000
Attachment. 37 x 40 mm 07748—001020!)
Pilot, 1 7 mm 07746 —0040400

Pull the drivsshah into the bearing in the transmission cover.

Crankcaso assembly collar 07965— GMOO1 00
Crank-also assembly shaft 07965— GM00300

Install a new driveshafl oil seal,

Final Reddction

 

  
 
  

(1) SHAFT
PROTECTOR

(3) TRANSMISSION COVER

(2) DRIVESHAFT

 

 

(1) OIL SEAL (2) BEARING

  

 

 

  
  

(1) DRIVER

(2) PIEOT. 17 mm

 

 

 

 

(2) CRANKCASE ASSEMBLY SHAFI'

 

 

 

9-3

 

10. Crankcase/ Crankshaft

Service Information 1 0-1 Crenkcese Separation/Assembly 1 0-2
Troubleshooting 1 0-1

 

 

 

 

Service Information

A This section covers the crankcase separation to service the crankshaft.

- The following parts must be removed before separating the crankcase:

— oil pump (page 4-3)

- Carburetor (page 5—3)

- Reed valve (page 5-5)

- Engine (section 6)

— Cylinder haad, cylinder, piston (page 7-2)

— Drive pulley (page 8-5)

— Alternator (page 134)

— Starter motor (page 15-4)

In addition to the parts listed above, remove the following parts when the left crankcase half must be removed:

a Driven pulley (page 8-5)

— Final reduction (page 9~2l

— Rear brake (page 12-3)

- The crankcase separation/assembly and the crankshaft removal/installation require special tools.

- when assembling the crankcases, be sure to use the special tools; position the special tool against the bearing inner race
and pull the crankshaft into the bearing in the crankcase. Therefore, if the bearings stay on the crankshaft after removing
tha crankshaft, remove them and drive new bearings into the crankcases. Also, be sure to install new oil sealst

Troubleshooting

Excessive noise

. Worn connecting rod big and bearing

- Worn connecting rod small and bearing
- Worn crankshah main journal bearing

 

10-1

Crankcase/Crankshaft

Crankcase Separation/Assembly

 

 

10(1.0, 7)

 

Requisite Service

- Refer to page 104 for the parts that must be removed before separating the crankcase.

 

Procedure

Q'tY

Remarks

 

Separation Order
(1) Crankcase bolt
(2) Right crankcase
(3) Dowel pin

(4) Crankshah

(5) Rig)“ oil seal

(6) Left oil seal

(7) Right bearing

(8) Left bearing

Separation (page 1045)

 

_._...__.N_.q,

l |

Removal (page 10-3)

 

A'sembly Order
(7) Right bearing

(3) Left bearing

(4) Crankshaft

(6) Left oil seal

(3) Dowel pin

(2) Right crankcase
(5) Right oil seal

(1) Crankcase be!

 

 

 

 

 

‘nstallation (page 104)

Assembly (page 10-5)

 

 

 

10-2

 

Crankcase Separation

Screw the case puller shaft onto the crankshaft and.
Attach the case puller by threading the bolts into the bolt
holes of the stator.

Separate the crankcase by turning the case puller shaft
clockwise.

Case puller
snan protector

07935 — G KBOOOO
07931 — 1 870000

Crankshaft Removal

Attach the case/driven gear puller on the left crankcase as
shown, and remove the crankshaft by turning the puller
shaft clockwise.

 

case/drivan gear puller 07935—KGBODOO
Shaft protector 07331 — 1870000

NOTE

| - Do not remove the crankshaft by tapping it. j

 

Remove the right and left oil seals from the crankcases.
Remove the right and left hearings from the crankcases.

When the bearing stays on the cranbhaft, remove it with
the universal bearing puller.

Universal bearing puller
shah protector

07631 —0010000
07931 — 1 870000
NOTE

~ Replace the crankshaft bearings and oil seals with new
ones when the crankcase is separated.

 

 

 

 

Crankshaft Installation

Wash the crankcase in solvent and blow dry with
compressed air.
Check the crankcaees for cranks or other faults.

Apply clean 2-stroke engine oil to all moving and sliding
surfaces.

Remove all gasket material from the crankcase mating
surfaces.
Dress any roughness or irregularities with an oil stone.

Crankcaee/Crankshaft

 

(l l CASE FULLER

  

11) SHAFT
PROTECTOR

 

(4) LEFT CRANKCASE

 

 

(1) CHANKSHAFT (2) CASE/DRIVEN GEAR FULLER

  
 

(3) SHAFT
PROTECTOR

(4) LEFT CHANKCASE

 

 

 

(1) SHAFT PROTECTOR

 

(2) UNIVERSAL BEARING FULLER

 

 

 

1 0—3

Crankcasa/Crankshalt

Drive a new cranlshaft bearing into the right crankcase.

Driver 07749 - 001 0000
Attachment. 52 x 55 mm 07746—001044”
Pilot, 20 mm 07746—0040500

Drive a new crankshaft bearing into the left crankcase.

Driver 07749—0010000
Attachment. 52 x 55 mm 07746—001040!)
Pilot, 20 mm 07746 —0040500

Pisition the assembly collar against the crankshaft bearing.
Thread the assembly shaft onto the crenkshafi.

Hold the assembly shaft and turn the nut counterclockwise
to draw the crankshaft into the bearing inner race in the left
crankcase.

crankcase assembly collar 07965—GM00‘IOO
Crankclsa assembly shaft D7965 — 1 630200
CAUTIO N

 

. Be careful not to In the connecting rod press eyeing
the crankcase mating surface while drawing the
crankahait.

 

 

 

Install a new left crankcase oil seal until it is 1.0 1 0,5 mm
(0.04 1 0.02 in) below the surface of the left crankcase as
shown.

 

   
  

(1) DRIVER

(2) ATTACHMENT,
52 x 55 mm

 

 

  
   

l1) DRIVER

(3) ATTACHMENT, ‘ \\
52 X 55 mm (2) PILOT, 20 mm

 

 

(1) CRANKCASE ASSEMBLY COLLAR
(2) CONNECTING ROD

   

(3) CRANKCASE ASSEMBLY SHAFT

 

 

 

(1) OIL SEAL

(6.

 

 

 

 

 

 

 

l2) LEFI' CRANKCASE

 

 

1 0-4

 

Crankcase Assembly

Apply liquid sealant to the crankcase mating surfaces and
install the dowel pine

Install the right crankcase over the left crankcase.

Place the crankcase assembly collar against the bearing
inner race in the right crankcase. Thread the assembly shaft
onto the crankshaft.

Hold the assembly shaft and turn the nut counterclockwise
to draw the crankcase halves together.

Crankcnu assembly collar
Crankcaso assembly shaft

07965-6 M001 00
0796543 M00300

Install a new right crankcase oil seal using the crankcase
aesmblv collar and shaft until it is 5.0 1 0.5 mm (0.20 1 O.
02 in) below the surface of the right crankcase as shown.

Crankcasa assembly collar
Crankcau assembly shaft

07955—GM00100
O7965-GM00300

Crankcase/ Crankshaft

 

(1) CRANKCASE ASSEMBLV

  

 

 

 

SHAFT [0.

 

  

(2) OIL SEAL
(3) CRANKCASE ASSEMBLY COLLAR

 

 

 

10-5

 

11 . Front Wheel/Suspension/Steering/ Brake

 

 

 

 

 

Service Information 1 1-1 Throttle Housing Removal/Installation 11-5
Troubleshooting 1 1 -1 Handlebar Removal/Installation 1 1 -6
From Wheel Removal/Installation 1 1—2 Steering Stem Removal/Installation 1 1-7
From Wheel Disassembly/Assembly 1 1 -3 Fork Disassembly/Assembly 1 1-9
Front Brake Panel Disessembly/
Assembly 1 1 A
Service Information

- In asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry
brush to clean brake assemblies. Use a vewurn cleaner or alternate method to minimize the hazard caused by
eirbome asbestos fillers.

. A mnemineted brake drum or lining reduces stopping power. Discard contaminated linings and clean a
contaminated drum with a high quality brake decreasing agent.

 

 

- Always check the brake operation before riding the scooterr

Troubleshooting

Herd steering

- Steering top cone race too tight

- Worn or damaged steering stem bearings

- Worn or damaged steering stem bearing races
- Insufficient tire pressure

Steers to one side or does not track straight
- Bent fork

- Bent front axle

- Faulty steering stern bearings

- Bent frame

~ Worn or damaged wheel bearings

From wheel wnbhling

- Bent rim

- Worn front wheel bearings
- Faulty tire

Wheel turns hard
. Misadjusted brake
- Faulty wheel bearings

Soft suspension
‘ Weak fork springs

Front suspension noise
. Fork spring binding
- Loose fork fasteners

Poor brake performance

- Improperly adjusted brake

. Worn brake linings

- Worn brake drum

- Worn brake cam

v improperly installed brake linings

. Brake cable sticking/needs lubrication

- Contaminated brake linings

- Contaminated brake drum

- Worn brake shoes at cam contact areas

- Improper engagement between brake arm and cam
serrations

Brake lever hard or slow to rewum

- Worn/broken return spring

- Improperly adjusted brake

- Sticking brake drum due to contamination
- Worn brake shoes at cam contact areas

- Brake cable sticking/needs lubrication

« Worn brake cam

- improperly installed brake linings

Brake squeeks

- Worn brake linings

- Worn brake drum

~ Contaminated brake linings
- Contaminated brake drum

 

11-1

Front Wheel /Suspension/Steering / Brake

Front Wheel Removal/Installation

 

 

 

 

 

NOTE

 

L After installing the front wheel, adjust the front brake.

 

Requisite Service

When removing the front lender:

 

 

- Front inner cover (page 2—6) - Side cover removal/installation (page 2—!)
Procedure O'ty Remarks
Removal Order Installation is in the reverse order of removal.

(1) Speedometer cable set screw
(2) Speedometer cable

(3) Front brake adjusting nut
(4) Front brake cable

(5) Brake arm joint

(6) From axle nut

(7) Front axle

(3) Front wheel

(9) Side collar

(10) Front brake panel

(1 1) Front fender

Disassembly/Assembly (page 1 1-3)

Disassemly/assembly (page l 14)

 

 

 

 

 

 

 

11-2

Front Wheel Disassembly/Assembly

Front Wheel/Suspansinn/Steering/Brlke

 

l4)

 

I FRONT

  

(2) (1)

 

Requisite Service

- Front wheel removal/installation (page 11—2)

 

Procadu re

O'ty

Remarks

 

Dlsassembly Ordet

(1 ) Dust seal

(2) Right wheel bearing (62000)
(3) Distance collar

(4) Left wheel bearing (62001))

 

 

 

 

Assembly is in the reverse order of disammbly.

 

 

 

11-3

Front Wheel / Suspension/Steering / Brake

Front Brake Panel Disassembly/Assembly

 

E c 6 (0,6. 43) (3)
(4) (4)
A; Q?

   

 

 

 

(6)
(9) (B)

Requisite Service

- Front wheel removal/insulation (page I 1-2)

Procedure O‘ly Remarks
Diaasusmbly Ordar Assembly is in the reverse order of disassembly.

(1) Brake shoe/shoe spring 2/2

(2) Eraka arm bolt/nu! 1/1

(3) Brake arm 1 when installing, align the punch mark on the arm with the

index mark on the brake caml
(4) Wear indicator

(5) Return spring

(6) Brake cam

(7) Felt seal

(3) Bus: seal

(9) Speedometer drive gear
(10) Brake panel

 

 

 

 

 

 

 

11-4

Front Wheel/Suspension/Steering/ Brake

Throttle Housing Removal/ Installation

 

(9)

 

(4)

 

Requisite Service

- Handle cover removal/installation (page 2»7)

 

Procedure

O‘tv

Remarks

 

Removal Order

Front bfake lever

(1) Nut

(2) Front brake lever pivot screw
(3) Front brake lever

(4) Front brake cable

Installation is in the reverse order of removal,

 

Throttle housing
(5) Bolt
(5) Upper throttle housing

(7) Lower throttle housing

(8) Throttle cable
(9) Throttle grip

 

 

 

 

when installing, hook the slot in the upper housing to the

tab of the lower housingr

When installing. align the bass on the housing with the hole

in the handlebar.

 

 

11-5

 

Front Wheel /Suspension/Sreering/ Brake

Handlebar Removal/Installation

 

(10)

 

 

  

 

Requisite Service
~ Thronle housing removal/installarion (page 1 1-5)

 

 

 

 

 

 

 

 

Procedure O’ty Remarks
Removal Order Installation is in the reverse order of removal.
Hear brake lever
(1) Nut 1
(2) Rear brake lever pivot screw 1
(3) Rear brake lever 1
(4) Rear brake cable 1
Rear brake lever bracket
(5) Bolt 1
(6) Lever bracket band 1 when installing, hook the slot in the band to (he tab of the
lever tracker.
(7) Rear brake lever bracket 1 Whn installing, align the bass on the bracket with the hole
in the handlebar.
(8) Nut I
(9) Handlebar pinch bolt 1
(10) Washer 2
(11) Handlebar 1 When installing, align the boss of file handlebar wirh the
groove in the steering stemr
(12) Handle grip 1

 

 

11-6

 

Steering Stem Removal/Installation

Front Wheel/Suspension/Stearing/Brake

 

c 27 (2.7. 20) (41

(9)

l8)

(7)

    
 

(5)

(page 1-11)

 

Requisite Service

- From wheel removal/installation (page 11-2)

- Handlebar removal/installation (page 1 1-6)

 

Procedure

G'ty

Remarks

 

(1)

Removal Order
Stealing stem
Steering stem lock nut

Installation is in the reverse order of removal.

1 j—lnstallation (page 1 1—8)

 

 

 

 

 

 

 

(2) Top cone race 1
(3) Steering stem 1

Steering stern bearings/races
(4) Steering stem bearing 2
(5) Bottom cone race 1
(6) Ball race 2

Front inner fender
(7) Attaching bolt 2
(8) Front inner fender 1

Fork
(9) Fork pinch bolt 4 NOTE

- The upper pinch bolts are (he locating bolts.

(10) Fork 2 Disassembly/Assemblv (page 1 1-9)

 

 

 

11-7

From Wheel / Suspension/Stearing/ Brake

Top Cone Race/Stem Lock Nu: Installation
hate" the mp cone race and hand-tighten it.

Rotate the sxeering 519m lock»to-Iock several times to seat
the bearing;

Make sure mat the steering stem rotates smoothly without
venicel play.

Hold the top cone race and tighten the steering stem lock
nut.

Torque: 70 Mr" (7.0 kg<m, 61 h-Ib)

Lock nut wrench A 07918— KM1000O
Lock nut wrench B 07916—1870100

 

 

(1) LOCK NUT WRENCH A

(2] LOCK NUT WRENCH B

 

 

118

 

Front Wheal/Suepension/Steering/Erake

Fork Disassembly/Assembly

 

(9)

          

 

 

 

 

 

 

 

 

 

 

 

 

 

 

‘ (9) a 1-5—2 9
\ ( ) (005—007 02)
(3) (2) 5
(4, ‘ ’
\ (5) (page 1.11) l
/ (6)
,6. i
Requisite Service
- Fark removal/installation (page 11-7)
Procedure O'tv Remarks

Disassemhly Order Assembly is in the reverse order of disassemblyt
(1) Fork tube cap 1
(2) Dust seal 1
(3) Snap ring 1 NOTE

- ~ After instaHation, pack 1.5—2 9 (005—007 02) of

grease between the bottom case and fork tube as shown.

(4) Bushing 1
(5) Rebound spring 1
(6) Fork tube 1
(7) Fork spring 1
(8) Stopper rubber 1
(9) Bottom case ‘

 

 

 

 

11-9

 

12. Rear Wheel/Suspension/Brake

Service Information 12.1 Rear Brake Disassemny/Assembly 12-3
Troubleshooting 1 2-1

Rear Wheel Removal/Installation 12-2

 

Shock Absorber Removal/Installation 12-4

 

Service Information

lnh bestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry
brush to clean brake assemblies. Use a vacuum cleaner or alternate method to minimize the hazard caused by
airborne asbestos fibers.

-A contaminated brake drum or lining reduces stopplng power. Discard contaminated linings and clean a
contaminated drum with a high quality brake degreesing agent.

   

 

 

 

- Always check the brake operation before riding the scooter.

Troubleshooting

Rear wheel wobbllng Poor brake pertarmanoe

- Bent rim - Improperly adjusted brake
- Axle nut not tightened properly - Worn brake linings
- Faulty tire

- Worn brake drum
- Worn brake cam

- Improperly installed brake linings
Wheel turns hard - Brake cable sticking/needs lubrication
- Misadiusted brake - Contaminated brake linings
- Faulty wheel bearings - Contaminated brake drum

- Worn brake shoes at cam contact areas
Soft suspension - Improper engagement between brake arm and cam
- Weak shock absorber spring serrations
- Oil leakage from damper unit

- Insufficient tire pressure

Brake lever hard or slow to retum
- Worn/broken return spring
- lrproperly adjusted brake
~ Sticking brake drum due to contamination
Rear suspension noise - Worn brake shoes at cam contact areas
. Shock absorber spring binding . Brake cable sticking/needs lubrication
- Worn brake cam
- Improperly installed brake linings

Hard suspension
- Bent damper rod

Brake squeaks

- Worn brake linings

- Worn brake drum

- Contaminated brake linings
- Contaminated brake drum

 

12-1

Rear Wheel/ Suspension/ Brake

Rear Wheel Removal/Installation

 

 

(2)

 

Requisite Service
- Muffler removal/installation (page 2»9)

 

Procedure

Q'ty

Remarks

 

l1)
(2)
(3)

 

 

Removal Order
Rear axte nut
Washer

Rear wheel

 

 

Installation is in the reversa order of removal.

 

 

1 2-2

 

Rear Wheel/Suspension/Brake

Rear Brake Disassembly/Assembly

 

 

 

 

 

NOTE

 

[ - After insramng the rear wheel, adjust the rear brake.

Requisite Service

- Rear wheel removal/installation (page 12-2)

 

Procedure O'ty Remarks

 

(1)
(2)
(3)
(4)
(5)
(6)
(7)

(8)
(5)
(10)

 

 

Disassamhly Order Assembly is in the reverse order of disassembly.
Rear brake adjusting nut 1
Rear brake cable 1
Brake arm joint 1
Brake shoe/shoe spring 2/2
Return spring 1
Brake arm bolt 1
Brake arm 1 When installing, align the punch mark with the wide groove
in rhe brake cam.

Wear indicator 1
Felt seal 1
Brake earn 1

 

 

 

 

 

1 2-3

Rear Wheel/Suspension/Brake

Shock Absorber Removal/Installation

 

 

(2)

40 (4‘0, 29)

(3)

27 (2.71 20)

   

 

NOTE

{ ~ Do not anemm xo disassemble the shock absorber. Replace it as an assembly.

Requisita Service

- Frame body cover removal/installation (page 24)

 

Procedure

O'ry

Remarks

 

(U
(2)
(3)

 

 

Removal Order
Lower mouming bolt
Upper mounting bolt
Shock absorber

 

 

Installation is in the reverse order of removal.

 

 

1 2-4

 

 

 

13. Charging System/Alternator

 

Service Information 13-1 Lighting Voltage Inspection 13-6
System Location 1 3-2 Regulator/ Rectifier Inspection 1 3-6
Troubleshooting 1 3-3 Alternator Removal/Installation 1 3-8
Battery Removal/Installation 1 3‘4 Alternator Inspection 1 3-9
Charging System Inspection 13.5 Resistor Inspection 1 3-9

 

 

 

Service Information

 

 

~ The battery gives off explosive gases; keep sparks. flames, and cigarettes away, Provide adequate ventilation
when charging or using the battery In an enclosed space.

- The battery contains sulfuric acid (electrolyte). Contact with akin or eyes may cause severe buns. Wear protective
clothing and a face shield,
— It electrolyte gets on your skin, flush with water.
— If electrolyte gets in your eyes, flush with water [or at least 1 5 minutes and call a physician immediately.

- Electroryu is po‘sonous. If swallowed, drink large quantities of water or milk and follow with milk of magnesia
or vegetable oil and call a physician.

- KEEP OUT OF REACH OF CHILDREN.

 

 

- Always turn off the ignition switch before disconnecting any electrical component.

CAUTION

- some electtical components may be damaged if terminals or connectors are connected or disconnected while the
ignition switch is ON and current is present.

 

 

 

- For extended storage, remove the battery, give it a full charge, and store it in a cool, dry place.
- For battery remaining in a stored scooter, disconnect the negative battery cable from the battery terminal.

NOTE
| - The maintenance free battery must be replaced when it reaches the end of its service life.

 

 

CAUTIO N

- The battery caps should not be removed. Attempting to remove the sealing caps from the cells may damage the
battery.

 

 

 

 

- Battery can be damaged if overcharged or undercharged, or if left to discharge for long periods. These same conditions
contribute to shortening the “life span” of the battery. Even under morrnal use, the performance of battery deteriorates
after 2-3 years.

- Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventually
die out, For this reason, the charging system is often suspected to be the problem. Battery overcharge often results from
problems in the battery itself, which may appear to be an overcharge symptom. If one of the battery cells is shorted and
battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions,
the electrolyte level goes down quickly,

- Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery
is frequently under heavy load.

. The battery will self-discharge when the scooter is not in use, For this reason, charge the battery every two weeks to
Prevent sulfation from forming.

- Filling a new battery with electrolyte will produce some voltage, but ' order to achieve its maximum performance, always
charge the battery, Also, the battery life is lengthened when it is in ~charged.

- When checking the charging system, always follow the steps in the troubleshooting flow chart (page 134).

- For battery testing/charging, refer to section 22 of the Common Service Manual.

- For charging system location. see page 13-2.

 

 

 

13-1

Charging System/Alternator

System Location

(1 ) BA‘I'I'ERY

 

(4) ALTERNATOR

 

l I (8) FUSE [10M ‘
1 G __

 

 

 

 

 

 

 

 

Y W G R
L l I l
(5) ALTERNATOR (7) REGULATOR/
RECTIFIER
(5) BATTERY
Y + O
(6) AUTO (10)
BVSTARTER DIMMER
SWITCH
‘i’
Bu W Y Y

 

 

 

@569 E) E)

(13) RESISTOR Hi La

 

 

 

 

 

 

 

 

(12) HEADLIGHT (1|) INSTRUMENT _
LIGHT

 

13-2

 

Charging System/Altemetor
Troubleshooting

Battery Overcharglng
- Faulty regulator/rectifier
r Broken regulator/rectifier ground wire or faulty cnnection.

Battery underoharqing

NOTE

 

. In order to obtain accurate test readings for charging system, the battery must be fully charged and in good condition
See Common Service Manual section 22 for check the battery condition.

 

 

 

Measure the battery current leakage ampere

 

 

 

 

 

 

 

“160"“?ct Check the regulator/rectifier unit inspection
(Leak test) (page 13-5) (page 13-7)
| |
Incorrect Correct
- shorted wire harness
- Faulty ignition switch
Correct

- Faulty regulator/rectifier

Correct
Inspect the regulated voltage (page 13 ) Check the battery u ng a Honda Battery Tester

Incorrect

 

 

 

Correct
- Electric system overloading
. Faulty battery
Not Charging

Check the voltages of the regulator/rectifier Ab _ . _ ,

battery charging line and ground line (page $ '°P°" ”mum“ W" harness

1345) - Poorly connected connectors

l
Normal

 

Check the alternator (charging coil) resistance at

 

 

 

 

 

 

 

 

 

 

Abnormal Check the charging coil at alternator (page
the regulator/rectifier connector (page 13-6) 13-9)
l
Abnormal Norrnal
- Poorly connected alternator
connector
Normal

- Faulty alternator
Check the regulator/rectifier unit inspection Abnormal . .
(page 1&7) ———— - Faulty regulator/rechfler

 

 

 

1 3-3

charging System/Altamira»

Battery Removal/Installation

 

 

 

Requisite Service
- Luggage box removal/installation (page 2—4)

 

Procedure

O'IY

Remarks

 

(1)

(2)

(3)
(4)

 

 

Removal Order
Battery negative 9 wire terminal

Battery positive ® wire terminal

Battery holder
Battery

 

 

Installation is in the reverse order of removal.

CAUTION

- With the ignition switch OFF. rarmwe the negative 9
terminal first, then the positive 9 terminal.

CAUTION

«when installing, install the posiivs ® terminal first.
then the negative 6 terminal.

 

 

1 3-4

 

Charging System/Alternator

 

Charging System Inspection

Leak Test

Remove the battery cover (page 2-4),

Tum the ignition switch off and disconnect the ground 6)
wire from the battery.

Connect the ammeter ® probe to the ground wire and the
ammeter 9 probe to the battery 9 terminal.

 

With the ignition switch off, check for current leakage.

 

NOTE

- When measuring current using a tester, set it to a high
range, and then bring the range down to an appropriate
level. Current flow larger than the range selected may
blow out the fuse in the tester.

~ While measuring current, do not turn the ignition on. A
sudden surge of current may blow out the fuse in the
tester.

 

 

 

 

 

 

Specified Current Leakage: 1 mA max.

It current leakage exceeds the specified value, a shorted
circuit is likely.

Locate the short by disconnecting connections one by one
and measuring the current.

Regulated Voltage/Ampere inspection
NOTE
- Before performing this test, be sure that the battery is

fully charged and that the voltage between its terminals
is greater than 13.0 V.

 

 

 

 

Start the engine and warm it up to operating temperature,
then turn the ignition switch OFF.

 

- It the engine must be running to do some work, make
sure the area is well-ventilated. Never run the engine
in an enclosed area.

- The exhaust contains poisonous carbon monoxide gas
that may cause loss of consciousness and lead to
death .

 

 

 

Remove the battery cover (page 2-4)
Connect the tachometer,

 

    

Connect a multitester betwen the battery terminals.

 

(1) FUSE

 

 

 

_ TER M INALS
Dlg tel Multitemr 0741 1 —0020000
Open the fuse holder and remove the fuse. Q)
Connect the ammeter between the fuse terminals as shown. (2) FUSE ’7

 

 

 

 

13-5

Charging System/Alternator

CAUTION

 

- Be careiul not to short eny tester probes.

- Although the current could be measured when the
ammeoar is connected between the battery positive
tarminel and the positive cable, a sudden surge of
current to the starter motor could damage the
ammater.

- Always tum the ignition of! when conducting the test‘
Diecennecting the ammeter or wires when current is
flowing may damage the ammeter.

 

 

 

Stan the engine and increase the engine speed gradually.

Regulated voltage: 14.0-15.0 V/5,ooo min" (rpm)
Charging current: 0—0.5 A/5.ooo mirr- (rpm)

Lighting Voltage Inspection

CAUTION

~ Failure to measure the lighting voltage may lead to
electrical damage of lighting components.

 

 

 

 

Remove the handle front cover (page 2-7),
Connect the tachometert

Start the engine and turn the headlight dimmer switch to
"Hi" position.

with the headlight connector connected, connect the
ammeter @ probe to the blue wire terminal, and 9 probe to
the green wire terminal.

NOTE
~ Select the AC range on the multitester.

 

 

Gradually increase the engine speed and read the lighting
regulated voltage.

Regulated voltage: 123—133 V/5,000 min“ (rpm)
Regulator/ Rectifier

Wire Harness Inspection

NOTE
- If the engine has been running, after stopping the
engine, wait for 10 minutes or more and perform the
inspection.

 

 

 

 

Disconnect the regulator/rectifier connector and check the
connector for loose or corroded terminalst

 

 

(1) HEADLIGHT

 

(2) HEADLIGHT CONNECTOR

 

 

1 3-6

 

Charging System/Alternator

 

Measure the following between connector terminals of the
wire hameas aide.

 

 

 

 

 

Item Terminals Specification
Battery chrging Red (+) and Battery voltage
line ground should be measured
Ground line Green and Continuity
ground
Charging line White and 04— ‘l .0 (1
ground (20‘C/68‘F)
Lighting line Yellow and 0.2~0.B 9‘
ground (ZO‘C/GB'F)

 

 

 

 

 

1- Disconnect the auto bystartar connector, taillight yellow
connector and SF connector located at the steering head
and measure.

Unit Inspection

 

 

 

 

 

(‘ll HARNESS SIDE CONNECTOR

 

(2) REGULATOR/RECTIFIER

 

 

 

 

 

 

 

 

 

 

Provided the circuit on the wire harness side are normal and L
there are no loose connections at the connector, inspect the
regulator/rectifier unit by measuring the resistance between
the terminals.
Unit: kg
6») Probe
6 Probe A L B E
A 00 3 — 50 a: E
L on a: 5 — 1 00
B so no no
E on 5 7 1 00 a:
NOTE

 

- You'll get false readings if the probes touch your fingers.
- Use the specified multitesters. Using other equipment
may not allow you to obtain the correct results.
This is due to the characteristic of semiconductors,
which have different resistance values depending on the
applied voltage.

Specific Multimeter:

—0741 1 -0020000 (KOWA Digital type)
-07308 ~0020001 (SANWA Analogue type)
—TH — 5H (KOWA Analogue type)
- Select the following range:

SANWA: kQ

KOWA: x1 00

~An old battery stored in the multltester could cause
inaccurate readingst Check the battery it the multitester
registers incorrectly.

- When using the KOWA multitester, remember that all
readings should be multiplied by 100.

 

 

 

Rapiece the regulator/rectifier unit if the resistance value
between the terminals is abnormal.

 

13—7

Charging System/Altamator

Alternator Removal/Installation

 

(12)

10 (1.0. 7)
(3)

10 (1.0. 7)

   

(9)

    

(5)

 

Requisile Service
- Frame body cover removal/installation (page 23)

 

Procedure

Q
2

Remarks

 

Removal Order

(1) Spark plug cap

(2) Ban

(3) Fan cover

(4) Bolt

(5) Cooling fan

(6) Flywheel nut

(7) Flywheel

(S) Woodruff key

(S) Altemakor wire connector
(10) Starter motor connector
(1 1) Samar motor lower mounting bolt
(12) Pulse generator bolt

(13) Pulse generator

(14) Stator bolt

(1 5) Stator

(1 6) Grommet

 

 

 

d‘ndNA-N_Adfl¢AN_

 

Installation is in the reverse order of removalr

Removavinstallation (page 13-9)

Remove the starter motor ground wire.

 

 

1 3-8

 

Flywhel Nut Removal/installation

Hold the flywheel with the universal holder and remove the
flywheel nut.

Universal holder 01725—0030000

Install the nut in the reverse order of removal.

Alternator Inspection

NOTE

Charging System/Altemetor

 

(1) FLYWHEEL NUT

 

(2) UNIVERSAL HOLDER

 

 

 

-Thie inspection can be performed with the stator
installed.

 

 

 

Remove the frame body cover [page 2-5).

Disconnect the alternator 6P connector.

Measure the charging coil resistance between the white wire
terminal and ground,

Standard: 0.4—1.0 Q (20’C/SB‘F)

Measure the lighting coil resistance between the yellow wire
terminal and ground.

Standard: 0.2—0.8 £1 (ZO'C/BS’F)

Resistor Inspection

Remove the front cover (page 2-5).
Disconnect the resistor wire connector and measure the
resistance between the wire terminal and body grounds

Standard: 4.7—5.3 Q (ZO‘C/GS‘Fl

 

(1) ATERNATOR 6P CONNECTOR

 

 

 

(1) RESISTOR WIRE

   

(3) GROUND (2) RESISTOR

 

 

 

139

 

14. Ignition System

 

Service Information 1 4‘1 Ignition Coil 1 4-6
System Location 14-2 Alternator Inspection 14-7
Troubleshooting 1 4-3 Ignition Timing 1 4-7
Ignition System Inspection 1 4-4

 

Service Information

A n

 

m.

- If the engine must be running to do some work. make sure the area is well-ventilated. Never run the engine in an
enclosed area.

- The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.

 

 

 

 

~ When checking the ignition system. always follow the steps in the troubleshooting flow chart (page 14—3).

- The CDI ignition system uses an electrically contro|led ignition timing system. No adjustment can be made to the ignition
timing.

. The CDI unit may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive
voltage may damage the unit. Always turn off the ignition switch before servicing‘

- A laulty ignition system is often related to poorly connected connectors. Check those connections before proceeding.

- Make sure the battery is adequately charged. A weak battery may be unable to turn the starter motor quickly enough, or
adequate ignition current may not be supplied.

. Use a spark plug of the correct heat range. Using a spark plug with an incorrect heat range can damage the engine. Refer
to section 23 of the Common Service Manual.

- For ignition switch inspection, check for continuity on the continuity chart of the Wiring Diagram (section 17).

 

14-1

Ignition System

System Location

(1) CDI UNIT

 
    
  
   

(2) SPARK PLUG

(3) IGNITION SWITCH

(4) PULSE GENERATOR

(GI IGNITION COIL
(5) ALTERNATOR

Bl/H
Bl/lW Sui/Y Bll/V
(10) cm UNIT x

(9) IGNITION SWITCH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(11) IGNITION COIL
(7) PULSE GENERATOR

(3) ALTERNATOR (12) SPARK PLUG

 

1 4-2

Ignition System

 

Troubleshooting

- Before troubleshooting. check that no spark jumps at the spark plug using a known good spark plug (to ensure that the
plug does not cause the problem).
Moreover, check for proper spark plug gap and loose spark plug wire as well as for leakage of the ignition coil secondary
current caused by moisture.

No spark at plug

 

 

Unusual condition Probable cause (Check in numerical order)
Ignition coil Low peak voltage (DThe multitester impedance is too lowt
primary ®Cranking speed is too low.
volmge . Battery is undercharged or operating force of the

kickstarter is weak.

©Ths sampling timing of the tester and measured pulse

were not synchronized. (System is normal if measured
‘ voltage is over the standard voltage at least once).

®Pooriy connected connectors or an open circuit in
ignition system.

@Faulty exciter coil. (Measure the peak voltage.)

®Faulty ignition coil.

®Faulty CD! unit (in case when above No. ®—© are
normal).

No peak voltage. ®lncorrect peak voltage adaptor connections.

®Faulty ignition switch.

®Loose or poorly connected-OBI unit connector.

®Open circuit or poor connection in ground wire of the
CDI unit.

®Feulty peak voltage adaptor.

®Fau|tv exciter coil. (Measure the peak voltage.)

@Faulty pulse generator. (Measure the peak voltage)

.Faulty CDi unit (in case when above No. (D—® are

 

 

 

normal).
Peak voltage is normal, but no spark jumps at ®Faulty spark plug or leaking ignition coil secondary
plug. current.
®Faulty ignition coil.
Exciter coil Low peak voltage. @Tha multitester impedance is too low.

®Cranking speed is too low.
- Battery is undercharged or operating force of the
kickstarter is weak.
©The sampling timing of the tester and measured pulse
were not synchronized. (System is normal if measured
voltage is over the standard voltage at least once).
©Faulty exciter coil (in case when above No. ®—® are

 

 

normal).
No peak voltage. (DFeulty peak voltage adaptor.
®Faulty exciter coilt
Pulse Low peak voltage. (DThe multitester impedance is too low.
generator ®Cranking speed is too low.

- Battery is undercharged or operating force of the
kickstarter is weak.

@The sampling timing of the tester and measured pulse
were not synchronized. (System is normal if measured
voltage is over the standard voltage at least once).

@Faulty pulse generator (in case when above No. ®—®
are normal).

No peak voltage. ®Faulty peak voltage adaptor.

®Faulty pulse generator.

 

 

 

 

 

 

 

1 4—3

Ignition System

 

Ignition System Inspection

NOTE

- If no spark jumps at the plug. check all connections for
loose or poor contact before measuring peak voltage,

- The reading differs depending on the multitester input
impedance, Therefore, use only Honda genuine digital
muln'tester or commercially available multitesters with
the input impedance higher than 10 M o/DCV.

- If using lmrie diagnostic tester (model 625), follow the
munufacturer's instructions.

 

 

 

 

Connect the peak voltage adaptor to the digital multitester.

 
 

lmr diagnostic tester (model 625) made in Australia or
P. voltage adaptor 07HGJ —oozo1oo with
Digit-I multimeter 0741 1 —0020000

Ignition Coil Primary Peek Voltage
NOTE
- Check all system connections before inspection. Poor

connected connectors can cause incorrect readings.
- Check that the cylinder comprmion is normal and the

 

 

(1) DIGITAL MULTITESTER

 

 

 

 

 

spark plug is installed correctly into the cylinder head.

 

Place the scooter on its center stand.

Remove the frame body cover (page 2-3).

Remove the spark plug cap from the plug, install a known
good spark plug to the plug cap and ground it to the engine
as shown.

Connect the peak voltage adaptor @ probe to the ignition
coil primary (black/yellow) wire terminal and the 6 probe to
the body ground.

Turn the ignition switch 0N.

Crank the engine with the kicksterter or starter motor and
read the ignition coil primary peak voltage.

Connection:
Black/yellow wire terminal (43— Body ground 9
Peak voltage: 100 V minimum

 

- To avoid possible electrical shock during voltage
measurements, do not much test probe metal parts.

 

if the peak voltage is abnormal, check an open circuit or
poorly connected connectors in black/yellow wire.

If no deform are found in the harness. refer to the
troubleshooting chart (page 14.3).

 

(1) KNOWN GOOD SPARK PLUG

 

 

 

 

(1) IGNITION COIL (2) @ PROBE

     

        
     

 

" f IE.“ _'
(3)6PROBE [EJJ

 

 

1 4-4

 

Exciter Coil Peak Voltage
NOTE

. Install the spark plug into the cylinder head and measure
the peak voltage under normal cylinder compression,

 

 

 

 

Remove the frame body cover (page 2—3).

Remove the CDI unit from the rear fender and disconnect 6P
connector from the CDI unit.

Connect the peak voltage adaptor © probe to the exciter coil
[black/red) wire terminal and the 6) probe to the ground
(green) wire terminal,

Crank the engine with the kickstarter or starter motor and
read the exciter coil peak voltage.

Connection:
Black/red wire terminal (1)—Green wire terminal 9
Peak voltage: 100 V mi

 

 

- To avoid possible electrical shock during voltage
measurements, do not touch teat probe metal parts.

 

 

If the peak voltage measured at the cm unit connector is
abnormal. disconnect the alternator wire connector and
connect the adaptor probes to the exciter coil terminal and
engine ground,

In the same manner as at the CDI unit connector, measure
the peak voltage and compare it to the voltage measured at
the CDI unit connector.

- if the peak voltage measured at the CDI unit is abnormal
and the one measured at the exciter coil is normal, the wire
harness has an open circuit or loose connections.

- if both peak voltages measured are abnormal, check each
item in the tro bleshooting chart. If all items are normal,
the exciter coi s faulty.

 

Pulse Generator Peak Voltage
NOTE

lgn on System

 

(1) CDI UNIT CONNECTOR (Z) CDI UNlT

 

 

 

 

 

 

 

 

 

 

 

 

(4) e PROBE

 

 

 

(1) EXCITER COIL (BLACK/RED)
WIRE TERMINAL

    

 

 

 

 

(3) E) PROBE

 

 

~ Install the spark plug into the cylinder head and measure
the peak voltage under normal cylinder compression.

 

 

 

Remove the frame body cover (page 2-3)

Remove the CDI unit from the rear fender and disconnect 6P
connector irom the CDI unit.

Connect the peak voltage adaptor (+3 probe to the pulse
generator (blue/yellow) wire terminal and the 9 probe to the
ground (green) wire terminal.

Crank the engine with the kickstaner or starter motor and
read the pulse generator peak voltage.

Connectio :
Blue/ye ow wire terminal ®— Green wire terminal 9
Peak voltage: 0.7 V minimum

 

 

(1) CDI UNIT CONNECTOR (2) cm UNlT

 

 

(4) 9 PROBE

 

 

 

Ignition System

 

  

-To avoid possible electrical shock during voltage
measurements, do not touch test probe metal parts.

   

 

 

If the peak voltage measured at the CDI unit connector is
abnormal, disconnect the alternator wire 6? connector and
connect the adaptor probes to the pulse generator terminal
and engine ground,

In the same manner as at the CDI unit connector, measure
the peak voltage and compare it to the voltage measured at
the CDI unit connector,

- If the peak voltage measured at the CD1 unit is abnormal
and the one measured at the pulse generator is normal, the
wire harness has an open circuit or loose connections.

- it both peak voltages measured are abnormal, check each
item in the troubleshooting chart. If all items are normal,
the pulse generator is faulty.

Ignition Coil

ROMOVBI

Remove the frame body cover (page 2—3).

Remove the spark plug cap from the spark plug.
Remove the mounting bolt and the ignition coill
Disconnect the ignin‘on coil primary wires from the coil.

Continuity Test

Measure the primary coil resistance between the primary
wire terminals.

Standard: 0.1—0.452 (ZO'C/BS'F)

Measure the secondary coil resistance between the spark
plug cap and primary wire a terminal.

Standard (with plug cap): 3.5—5.7 kn (ZO‘C/BS'C)
Remove the spark plug cap from the spark plug wire.
Measure the secondary coil resistance between the spark
plug wire and primary wire 9 terminal.

Standard (without plug cap): 2.7—15 k9 (20'0/68'F)

Install the removed parts in the reverse order of removal.

 

(1) ALTERNATOR 6P CONNECTOR
/

 
  
 

 

(3) ® PROBE

 

12) e PROBE

 

 

l1) BOLT

 

 

 

 

 

 

 

 

14-6

 

Ignition System

 

Alternator Inspection

NOTE

- This inspection can be performed with the alternator
installed into the engine.

 

 

 

 

Remove the frame body cover (page 23).

Exciter Coil

Disconnect the alternator black/red wire connector.
Measure the exciter coil resistance between the black/red
wire terminal and engine ground.

Standard: 400— 800 Q (ZO‘C/GB'F)

Pulse Generator

Disconnect the alternator wire 6? connector.
Measure the pulse generator resistance between the blue/
yellow wire terminal and engine ground.

Standard: 50‘ 200 9 (ZO‘C/GB'Fl

Ignition Timing

NOTE
- The CDI ignition timing is not adjustable. If the timing is
not correct, check the CD! unit. exciter coil and pulse
generator, and replace any faulty parts.

 

 

 

 

Remove the cooling fan cover (page 13-8).
Warm up the engine and connect the timing light and
tachometer.

NOTE

 

 

(1) BLACK/RED WIRE CONNECTOR

    

‘
r . a
K);
(2) GP CONNECTOR

 

 

 

 

 

 

- Follow the timing light and tachometer manufacturer's

 

 

 

instructions before operating,

 

 

Start the engine and check the ignition timing.

The ignition timing is correct if the 'F" mark on the flywheel
aligns with the index mark of the crankcase at 1,800 min’|
(torn).

ignition timing: 17‘BTDC at 1.800 min" (rpm)

 

14-7

 

15. Electric Starter

 

Service Information
System Location
Troubleshooting

1 5-1
1 5-2
1 5-3

Starter Motor Removal/installation 15-4
Starter Motor Disassembly/Assemblv 1 5-5

 

Service Information

 

- Always mm the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing

 

Ierlous injury.

 

 

- A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
- If the current is kept flowing through the starter motor to turn it while the engine is net cranking over, the starter motor

may be damaged.

 

15-1

Electric Starter

 

System Location (4) STARTER squcn

   
    

(1) STARTER RELAY SWITCH
(2) BATTERY

(5) STARTER MOTOR

(6’ FUSE “ON (SI/IGNITION SWITCH

R/w , /
(10) REAR BRAKE I 3
LIGHT SWITCH \
(a) STARTER MOTOR «7) STARTER

\T'a\-
SWITCH FOT')‘

i a
If:
T: Ml

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

G
" .0 0—] u 1) BATI'ERV
i (13) STARTER

RELAV
SWITCH (12) FRONT BRAKE

LIGHT SWITCH

 

 

Y/H G/Y

 

15-2

Troubleshooting

Starter motor will not tum
- Check for blown fuse before checking.

 

VVlth the ignition switch ON and the brake lever
sqeezed. push the starter switch and check for a
"click" sound from the starter relay switch.

 

Clicks

Electric Starter

 

 

 

 

No click

 

Disconnect the starter relay switch connector
and check the ground circuit for continuity.

 

Continuity

 

 

Connect the starter relay switch connectori
With the ignition switch 0N and brake lever
squeezed, measure the starter relay voltage at
the starter relay switch (between the green/
yellow wire terminal and body ground).

 

 

 

Battery voltage

. r Normal

Abnormal

 

Starter motor turns slowly

- Weak battery

- Poorly connected battery wire terminals
- Peony connected starter motor wire

- Faulty starter motor

Starter motor tune. but engine does not turn
- Faulty starter pinion

No continuity

No voltage

Starter motor and engine turn, but engine does not start

- Faulty ignition system
~ Engine problem

— Low compression

— Fouled spark plug

 

Connect the starter motor terminal to the battery
positive terminal directly (do not use thin wire
because of a large current flowsli

 

Starter Starter
motor motor does
turns not turn

- Faulty starter motor

Loose or disconnected starter rnotor wire
Faulty starter relay switch

~ Faulty starter switch
Lease or poor contact of connectors
Open circuit in wire harness

Faulty ignition switch

Faulty brake light switch

Loose or poor contact of connectors
Open circuit in wire harness

- Loose or poor contact of the staner relay
switch connector

_—__—————» - Faulty starter relay switch

 

15—3

 

Electric Starter

 

Starter Motor Removal/Installation

 

  
 

GROUND WIRE (3)

 

Requisite Service

- Frame body cover removal/installation (page 2-3)

 

 

Procedure Q'ty Remarks
Removal Order Installation is in the reverse order of removal.
(1) Oil pump mounting bolt 1
(2) Starter motor mounting bolt 2 when installing, do not forget to install the ground wire
with the lower mounting bolt.
(3) Oil pump control cable stay 1 NOTE

- Do not loosen the oil pump cantrol cable lock nut and
adjusn'ng nut. ll they are loosened, perform the oil pump
control cable adjustment (page 3—6)

(4) Starter motor 1 Disassembly/assernbly (page 15-5)
(5) Starter motor wire connectar 1
(6) O-ring 1

 

 

 

 

 

 

 

1 5-4

Electric Starter

Starter Motor Disassembly/Assembly

 

 

 

(5)

 

 

 

 

 

 

(Z)
6
t ’ 9!
Requ its Service
- Starter motor removal/installation (page 15-4)
Procedure Q'xy Remarks
Disassembly Order Assembly is in (he reverse order of disassembly,
(1) Motor case screw 2
(2) Molar case 1 NOTE
- When installing, make sure that there are no metal particle
inside ‘ha case‘
(3) Armamre 1
(4) Brush holder 2
(5) Spring 2
(6) O-ring 1
(7) ant bracket 1

 

 

 

 

 

 

 

15-5

 

1 6. Lights/Meters/Switches

 

 

Service Information 1 6-1 Ignition Switch Replacement 16—2

Fuel Level Sensor Inspection 16-2 Bulb Replacement 16-2

Oil Level Switch Inspection 16-2 Reer Combination Dummy Removel/
Installation 1 6—4

 

 

Service Information

- A continuity test can be made with the switches installed on the scooter. Refer to the continuity chart of the wiring
diagram (section 17) for switch continuity,

- Check the battery condition before performing any inspection that requires proper battery voltage.

- Refer to page 25~2 of the Common Service Manual for oil level indicator inspection.

- Refer to page 25-7 of the Common Service Manual for fuel gauge inspection

 

16-1

Lightn/Meters/Switches

Fuel Level Sensor Inspection

Remove the fuel level sensor (page 2-8),

Move the float with your hand and measure the resistances
between the terminals with the float at the FULL (upper) and
EMPTY (lower) positions.

 

 

 

 

Wire color of terminal FULL EMPTY
Green and yellow/white 25 — 45 n 400— 700 9
Green and blue/white 400— 700 {z 25 — 45 Q
Yellow/white and blue/white 450— 750 (2 450—- 750 Q

 

 

 

 

 

   

<———(1) FLOAT

 

Oil Level Switch inspection

Remove the oil level switch (page 44),
Check for continuity between the terminals.

There should be continuity with the float at upper position
and no continuity with the float at lower position.

Ignition Switch Replacement

Remove the front cover (page 2-5).

Disconnect the ignition switch wire connector.
Remove the two screws and the ignition switch.

Install the ignition switch in the reverse order of removal.

Bulb Replacement

Headlight
NOTE

‘If the headlight bulb has been blown, replace the
headlight unit,

 

 

 

 

Remove the handle front cover (page 2-7)i

Remove the four screws and the headlight with the bracket
Irom the handle front cover.

Remove the two adjusting screws, attaching screw and the
headlight from the bracket.

Install a new headlight in the reverse order of removal.

After installing, adjust the headlight arm (page 3.6).

 

 

(1 ) FLOAT

 

 

 

 

7a (1) SCREWS
/

   

I3) IGNITION
SWITCH

 

 

 

 

(1) HEADLIGHT

  

 

 

1 6-2

 

Front Turn Signal Light
Remove the handle front cover (page 2-7)t

Remove the bulb socket from the turn signal light by turning
it counterclockwise.
Pull the bulb out of the socket.

Install a new bulb and removed pans in the reverse order of
removal.

Instrument/Indicator light
Remove the handle rear cover (page 2-7).

Remove the bulb socket from the instrument case.
Pull the bulb out of the socket.

Install a new bulb and removed parts in the reVBrse order of
removal.

Taillight

Remove the two screws, taillight lens and packing.

Turn the bulb counterclockwise while pushing it in, and
remove it.

Install a new bulb and removed parts in the reverse order of
removal,

Rear Turn Signal Light

Remove the screw, turn signal light lens and packing.
Turn the bulb counterclockwise while pushing it in, and
remove it.

Install a new bulb and removed parts in the reverse order of
removal.

NOTE
- Align the lug on the lens with the slot in the light case
properly.

 

 

 

 

Lights/Meters/Switches

 

(l) TURN SIGNAL LIGHT

 

 

l3) BULB

 

 

 

 

 

l4) LENS

 

 

 

l1) BULB

l2) LENS

 
 
  

l3) SCREW

 

(4) PACKING

 

 

1 6-3

Lighis/Meters/Switches

Rear Combination Dummy
Removal/Installation

Remove the frame body cover (page 2-2)r

Remove the two bolts and xha rear combination dummy.
Remove the taillight/turn signal light wires and wire clamp
from the rear combination dummy.

Install in the reverse order of removal.

NOTE
Facing the taillight/rum signal light wires properly.

 

 

(1) CLAMP

(2) REAR COMBINATION DUMMY

 

(4) WIRES

 

 

1 6-4

 

TC.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

  

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RES...

 

18. Troubleshooting

 

Engine Does Not Start or is Hard to Start 18-1

Engine Lacks Power

 

Poor Performance at Low and Idle Speeds 18-3

18-2 Poor Performance at High Speed 1B-3

 

Engine Does Not Start or is Hard to Start

1 . Check if fuel is getting to
carburetor by loosening drain
screw

GETTING TO CAHBUHETOR

2. Try spark test

SPARK

3. Test cylinder compression

NORMAL COMPRESSION

4. Start by following normal
starting procedure

ENGINE DOES NOT FIRE
l
5. Remove spark plug

DRY

NOT GETTING T0——————
CARE U RETOR

No fuel in fuel tank

Clogged fuel tube to carburetor
Clogged fuel filter

Clogged float valve

Clogged fuel tank can breather
hole

- Faulty fuel pump

WEAK OR NO SPARK—> .

Faulty spark plug

Fouled spark plug

Fauty CDI unit

Fauty alternator

Broken or shorted spark plug wire

- Broken or shorted ignition coil

LOW COMPRESSION

 

Faulty ignition switch

Stuck piston rings

- Faulty or deteriorated reed valve

ENGINE FIRES BUT_-—>
SOON STOPS

Worn cylinder and piston rings
Compression leak past crankcase
Leaking cylinder head gasket

Faulty auto bystaner
Air leaking past intake pipe

- Improper ignition timing
- Misadjusted idle speed

WET PLUG——-—~> ‘

Carburetor flooded
Faulty auto bystener

- Throttle valve excessively open
- Clogged air cleaner element

 

18-1

 

Troubleshooting

Engine Lacks Power

L Lightly accelerate engine

ENGINE SPEED INCREASES

Check ignition timing

CORRECT

3. Test cylinder compression

NORMAL

4. Check carburetor for clogging

NOT CLOGGED

5. Remove spark plug

NOT FOULED 0R DISCOLORED

6. Check if engine overheats

NOT OVERHEATED

7. Try rapid acceleration or run at high
speed

ENGINE DOES NOT KNOCK

Probable cause

ENGINE SPEED DOES NOT~——>- Clogged air cleaner element
INCREASE SUFFICIENTLY - Restricted fuel flow
- Clogged fuel tank can breather hole
- Clogged muffler

INCORRECT———>- Faulty CDI unit
- Faulty alternator

TOO Low—w‘» Worn cylinder or piston rings
. Blown cylinder head gasket
- Compression leak past crankcase
- Faulty or deteriorated reed valve

CLOGGED————>Carbur’etor not serviced frequently

FOULED 0R DISCOLOREH-

OVERHEATED——>-

ENGINE KNOCKS———>-

enough

Plug not serviced frequently enough
Use of plug with improper heat range

Worn cylinder or piston
Fuel-air mixture 100 lean

Use of improper grade of fuel
Excessive carbon build-up in
combustion chamber

Ignition timing too advanced

Excessive carbon buildup in
combustion chamber

Use of improper grade of fuel
Ignition timing too advance
Fuel-air mixture too lean

 

18-2

Poor Performance at Low and ldle Speeds

1‘ Check ignition timing

CORRECT

2, Check carburetor eir screw for proper
adjustment

CORRECT

3. Check if air is leaking pest intake pipe

NOT LEAKING

l

4, Try spark test

GOOD SPARK

54 Check auto bystener

NORMAL

Troubleshooting

Probable cause

INCORRECT

 

INCORRECT

 

LEAKING—~.—————p.

WEAK OR lNTERMITTENT
SPARK

 

ABNORMAL

Poor Performance at High Speed

1‘ check ignition timing

CORRECT

2. Disconnect fuel tube at carburetor

FU El. FLOWS FREELY

l

3. Remove carburetor and check for
clooged jet

NOT CLOGGED

4. Check auto bystaner

NORMAL

 

Faulty CDI unit
Faulty alternator

Fuel air mixture too rich
(Screw out to correct)
Fuel air mixture too lean
(Screw in to correct)

Loose carburetor
Deteriorated intake pipe gasket
Deterioreted insulator O»ring

Faulty. carbon or wet fouled spark plug
Faulty CDl unit

Faulty alternator

Faulty ignition coil

Broken or shorted spark plug wire
Faulty ignition switch

Faulty auto bystener

Probable cause

INCORRECT

 

FUEL FLOW RESTRICTED——.

CLOGGED—w

ABNORMAL#———>.

Faulty CDI unit
Faulty alternator

No fuel in fuel tank

Clogged fuel tube or fuel filter
Clogged fuel tank can breather hole
Faulty fuel pump

Clean

Faulty auto bystaner

 

18-3

 

Air Cleaner Case Removal/Installation
Alternator Inspection
Removal/Installs on .
Battery Removal/Installation .
Bulb Replacement ..
Cable 3. Harness Routing.
Carburetor Disassemny/Assembly .
Removal/Installation
Charging System Inspection ..
Clutch/Driven Pulley Disassemny/Assembly .
Crankcase Separation/Assembly .......
Cylinder Head, Cylinder and Piston
Removal/Installation
Drive Pulley and Clutch/D ven Pulley
Removal/Installation
Engine Does Not Start or IS Hard to Start
Engine Lacks Power...
Engine Removal/Installation
Final Reduction Disassembly/Assemblv
Fork Disassemny/Assembly .....
Frame Cover Removal/Installation
Front Brake Panel Disassemny/Assembly
Front Wheel Disassembly/Assembly
Removal/Installation
Fuel Level Sensor Inspection.
Fuel Pump Removal/Installation
Fuel Tank Removal/Installation t
General Safety
Handlebar Remov
Headlight Aim
Ignition Coil
Ignition Switch Replacement.
Ignition System Inspection
Ignition Tlming .......
Kickstarter Removal/Installation
Left Crankcase Cover Removal/Installer n,
Lighting Voltage Inspection.
Lubrication & Seal Points.
' Lubrication System Diagram
Maintenance Schedule
Model Identification
Movable Drive Face Disassembly/Assembly
Muffler Removal/Installation
oil Level Switch Insoectro
Oil Pump Removal/Installation .
Oil Pump and Oil Line ..
Oil Tank Removal/Installation
Poor Performance at High Spe
Poor Performance at Low and Idle Speeds.
Rear Brake Disassemny/Aasembly .......
Rear Combination Dummy Removal/
Installation .
Rear Wheel Remova / nsta ation .
Rear Valve Removal/Installation
Regulator/Rectifier inspection
Resistor Inspection .
Service Access Guide .

  
 
 
  
  
 
 
 
 

 

 

 

 

  
 
   
  
 
 
 
  
  

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Index

Service Information
Charging System/Alternate
Crankcaee/Crankshaft
Cylinder Head/Cylinder/Piston
Electric Starter .
Engine Removal/ nsta atlo
Final Reduction
Frame/Body Panels/Exhaust System
Front Wheel/Suspension/Steering/
Brake . .
Fuel System
Ignition System
Kickstarter/Drive Pulley/Clutch/
Driven Pulley
Lights/Meters/Sw
Lubrication System
Maintenance .. ..
Rear Wheel/Suspension/Erake
Shock Absorber Removal/Installation
Specifications...
Starter Motor Disassembly/Assembiv.
Removal/Installation
Steering Stem Removal/Installation
System Location Charging System/Alternator
Electric Starten
ignition System.
Throttle Housing Removal/Installation
Throttle Valve Disassembly/Assembly
Tools
Torque Values
Troubleshooting
Charging System/Alternate
crankcase/Crankshaft ..
Cylinder Head/Cylinder/Piston
Electric Starter .
Final Reduction
Frame/Body Panels/Exhaust System
Front Wheel/Suspension/Steering/
Brake ..
Fuel System
Ignition System
Kickmrter/Drive Fulley/Clutch/
Driven Pulley
Lubrication System .
Rear Wheel/Suspension/Brake.
Wiring Diagram

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(130]

To prlnt chapters, click on the printer icon and fill
in the page range.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1. General Information 5 - 20

2. Frame/Body panels/Exhaust 21 - 29

3. Malnlenance 30 - 35

4. Lubrication system 36 - 39

5. Fuol system 40 - 48

6. Engine removalllnstallatlon 49 - 51

7. Cylinder head/Cylinder] 52 - 54
Plston

8. KickslanerIDrlve Pulley S5 - 63
Clutch/Driven Pulley

9. Final reduction 64 - 66

1o. CrankcaselCrankshafl 61 - 11

11. FrontwheellSuspenslon 72 - 80
IS‘eerlng/Brake

12. Rear wheel/Suspension B1 - 84
[Steering/Brake

1 3. Charging system/Alternator 85 - 93

14. Ignition system 94 - 100

1 5. Electric starter 101 - 105

1 6. Lights/MeterslSwltches 1 06 - 1 09

17. Wiring diagrams 110

18. Troubleshooting 111 - 113

 

 

 

Index

 

1

 

Note: Make sure to select ‘1 Shrink to fit in the
primer dlalog box when printing wiring diagmms.