CONTENTS 1. FEATURES .................................................................. I A. ENGINE ................................................................. l e. FRAME ................................................................... a c. SERIAL NUMBERS ......................................................... 4 2. SPECIAL TOOLS 5 I, Tools Necessary for Disassemblyandkeassembly. 5 3. ENGINE. . . 7 l. Engine Demipnon. 9 Power Tvunsmission Syslem ............................................ 9 3. Engine Removal and Insiallalion ................................................. 9 A. Engine removal ......................................................... 9 9. Engine insVollalion.. .II 4. Engine Ovarhaul l1 5. CylinderHead . . ..12 I A. DISasseany ........................................................... I2 \ 3. Inspection ............................................................. IA 3 C. Reossembly ................................. l7 6. Comma ...... . .17 A, Disassernbly 19 B. Impedion ................................................... ..l9 7. Cylinder ................................................................... l9 3 A. Disassembly ................................. ’ ........................... 19 a. lnspedion . . ..20 C, Reassembly 20 5. Pinon, Piston ring. ..20 A. Disassembly ........................................................... 22 9. Inspection ............................................................ 22 c. Reasserrbly ..... .,24 9. Corn Chain Tensioner. 24 A. Disassembly ..... . ..25 E. Reassembly ............................................................ 26 IO. RighiQunkcase Cover ................................................... ““26 A. DISasseany.. . 2........6 8. Inspection. H '26 CONT ENIS c. Roussenbly .......................................................... 26 n. Clutch. .......... 26 A. Disassembly. W27 3. Inspsdicn ................................ .,27 c. £505:me 29 12. lubrication swan... ...30 ”3| A. 015.15me ....... a. Inspocnon .. 31 c. Racssenbly .31 la, Crankcose ..... .32 H. Czankshaf! ............................................. A. Disassenbly ,. B. Inspeciion . . . C. Reassembly ‘5. Transmission ...... A. Dismsenbly B. Inspection . . . .33 33 ..34 ”35 36 .37 .39 C. Roassanbly .,4l 16. Kid Stone! ...... 41 . A. Disasmbly.. B. Inspeclion ........ C. Rousmbly .. l7. Calbwolor . . Construction of cmfon B. chvions of each conponenv .................... C. Adiusrmenv ................ D. Adiuslmem a! m. high speed E. Adiuslmenl at inlormediols spced F. Adiusflnem cl slow speed. (3. Adjusting Ibo 'uel level . . A. FRAME ............... I. Sharing Handla ....... A. Disassembly. 3, Inspection C. Reossenbly . 2. Front Cushion ....................................... A. Disasserrhly. 8. Inspection .. c, Reassemhly ........... CONIENTS A. Disassenbly .................................................. .. ....... 57 8. Inspection ........................................................ 58 c. Reusserrbly S'eering S'em . A. Dimssenbly 8. lmpecvion c. Roussembiy Fuel Tank .............................................................. A. Disusenbly . . a. Inspoclion . . C. Reasscmbly .. . . From Body ............................................................. 62 A. Dlwssenbly .................................. . ....................... 62 a Inspsction . C. Reassan'bly 560! and Air Cleans . . . . A. Diwssembly ............................................................ 65 B Inspoc'ion ............................................................ 65 C. Reossen'bly ............................................................ 66 Sland. Blake Pedal .. A. Disammly E. lnspoc'ion . C. Reassenbly MufiIor ..... . ............................................................. 69 c. Roossenbly .. . , , . Rear Fork .................................................................. 70 A, Disassembly ............................................................ B. lmpocvion .................. c. Baassembly From Wheel A. Discssemb|y a. Inspecxion ........ c. Reusserrb|y Rear Wheel 4, Discssenhly B. Impoclion ............................................................. 76 C. Eeassenbly .................................... . ........ . .............. 77 5. ELECTRIC SYSI’EM . . . . L Ignition Ciraiii l . .i A. 6. PERIODIC ADJUSTMENT . i. @5703: r" 2, Electrical Power Supply . Al 8. A. B‘ POW? E. :QFWPOF“> Selenium Reciifier Salary Equipmeni .................... Maintenance inspection CONIENIS Ignilion sysiani Ignition coil. Spark advance: Coniaci breaks: Condenser . . Spaik plug . A. C genomic: ..................... Tremble diagnosing lha flywheel generaior Selenium ieclifiei insiclllaiion and handlirg, Checking ihe condiiion oI "to selenium recliner Insl‘ruciiou on use and servicing .. Servicing dining use ..... Bonery charging procedvre . Tmle shooting 01d pmvenlulivo mainlonanco Trouble shooting and coriaciive aclion Headlight ..................... Taillighl, Sioplighi Neutral Lam . . . . Spoodomoier Lamp Spssdamelal 103 103 Engine Adiusimenl . .. loa Lubrication ......................... ill Dim Chain Adiuslmeni. .ll2 pick. Adiuslml l13 {gallium Cleaning . H4 Bimery inspeclion l. .Ii5 Drive Chain Service ............ II6 Securily Impedion‘. ............ li7 comims 10. SUPPLEMENT TO SSSOZKZ—E/lZ—E, <20le and CD70K1 7. TROUBLE SHOOTING . . . . . . 1 I9 1. Main Engine Tvoublo . n9 2. Engine Noise ...... 121 3. Scsering Sysvem ............................ .. 121 4. CIuIch Syslem ....... . 122 5. Gem Change Syslem , 122 6. Suspensions .............................................................. 123 7. Brake System ..... . 123 8. Drive Chain ...... , I23 9. Tightening Torque Slandavd . 124 8. SPECIFICATIONS a. WIRING DIAGRAM ........................................ 125 I. SPECIFICATIONS ........................................................... 125 2. WIRING DIAGRAM ........................................................ 125 9. CD 50/65 SUPPLEMENT ..................................................... 131 Spacial Features .............................................................. 131 Specificovion Table ............................................................ 132 Engine 1. Can Chain Tensions! .............. . . 136 2. CcvnshuIl. . 1 . 137 3. Transmission. . 138 4. Kick Slorlev ........................ . I40 5. Carbureior ................................ . 141 From: FvonI Cushion ........................ 142 Wiring Diogvan ....................... . 143 I45 Air Cleaner Cleaning , . 145 CansIvaIl (SSSOZKZ-E md B2-EI ...................................... .. I46 Cam Chain Tensioner ........................ . 146 Carburetor Serving ........ ‘ 147 147 .150 From Wheel (55502824) . Mechmicul Disc Type From Brd5 pressed sheev s'ce‘. enclosed backbone rype ’ov greaier ”9»de whom the masswe- ness. The appearance 0' lightness Is farther enhanced by the use of me T~bone frame consimc- Hon 2‘ Telescoping from suspeniion The shocks are compiolely aosorbed by the on )ype damper vo assuve high safety fame: and comfortable riding. 3. Swing arm rear cushion The veer when employs a double stage damper spring .0 provide riding comlofl over blender riding condillons. A l. FEAYURES 7, 7 4‘\ 4. Highly emaem silencer and mufiler In oddifion Vo Ihs highly efi‘bciem mquen a silencer has also been incorpomyed imo the aiv cleaner «0 eliminaia the air inlet noise. C. SERIAL NUMBERS The model 5550 miorcycle is [dammed by mm the engine and home numbers. When placing order iov pans or making Inquiries concerning a moicxcycie, always memion me home Serial numbers {who polls are a” conivolled by the (runs number]. The figures below show me loculons of lhe serial number; (y Engm- mm. Q) horn. mm». 2. SPECIAL TOOLS Tools Necessary for Disassembly and Reassembly (I? (3‘ (5) 2 SPECIAL 70015 pm. swede! mldev Clutch mm spannev Umm lock my Mom Varvu wag mxchmg vac! qu guidl mu m: Voc‘ Vain Mm (upper odwxling box winch yaw Voclmg box wronch Caner holder Vo‘v- nal :umu Vow. wid- roam-I 36mm hook :parmav Mum mm. hook Wm lieu: cushion dlsaxs-mbly m: 29m... mm m: Handle box mm Bio/mg ammmmy Ioal Blunng muolhnn my Volvo m: mm ca:- 1001 box ®®@@®@®@@® @®®®®©®©© ENGINE 3. a. ENGINE / | fig‘ 3.2 Engm cum-My down [2) 1. Engine Description U can be srmcd 0c -he We" cl m3 mo'c' cydc \: m We type 0‘ Engre Vaec We my new cngmo con-3mm» : compac‘wss, lg" wmgh' and mgh rower Ou'pu‘ n oddmon m w Lung ed and ens, v3 harm: :urher 'ze cngmc my mavch we ‘rcme 'M! w n; ms'u.ec on (or u mmnce and noasmg nnmmrce The enng on me 5350 '15 been soecra'w ‘eswgnen wn mesa consamnnn r mm An,» rum a'.Cy u used m "e cyhnuc: has} one :ylmccv hgh‘noss una guurl Cm..n' 'ovza‘ng mg may enmncy and gvcctc' mwe' for mm! o dvsploccmem The overhead ccmsnaiv duvcn w a hgwwegn' cram enczosed m m: “gm me ur' mo engmc makes possub‘e me Ngh speed and g'cmev pan-y WW rhough wagh 'educwon : 'rc mom n2: p'ocovmg componcn's To plowdc qua: ope won 0' lug" :pecd, ‘W: chum ‘5 supponed by <1 damper woe New: renmonov to preven' wbvchcn "~c' '5: cssvc 'zdoquc'e \Ubncnnon 'o "”0 teams: o. 'm h r speed and hem» ‘ocded cra’vs‘n" and "3": mm mi: Conrrdugn cm} SC'ec'v - 1- my: ’Jers me pyowcen Jubey a»: unprcvcd srnbmw 2. Power Transmission System The arctgy hon W: :Omuvs'ou 2'" ‘re we mma nonsmmcd 'c 'f'u .ccnncc~«~: '01 a; nksmn ->ch,';'~ n w: ,c . .. n V » vm—-=ncnon mscacum co"o‘w;,'n W, . hcjl-prmury dn.nv goo: wvxmsscn , .- n awam My gay ,, . :‘Umcv Snail—.dee ED'Z‘CH)". . :r-o tear whce‘, {rogvcsme‘y n w; 50). '50 (Fig. 3. 3) 3. Engine Removal and Insvnnunon A. Engine removal “ My Jcmcve Rho ieF' CTN: ”\C’ 8 - 14m— snmcm hex bo‘v‘ and my. cw (Fig. 3. A) o dnve chum rmy my 30 'e'naved w +3 a: VG s msmnnecnng we Chem 0‘ no \01‘ wk as snow». men we drwe cnom may be rammed O\/\L AND m1 ‘Qn fig 3.: ”mt "uv'mx‘ y augnm :,:« (Fig. 3. 5} . c [Hg 3 7) 9 3.5} (n 7.4 1 (Frg 3.0, 3 my 5. Engine insmHuv (FFg 3 12) A. Engine Overhaul w 3 ‘ mm ,- n a: \\ ‘ ‘ - ),/ ‘ / $3212 ,- .. l2 3 Fig. 3.1: Cy'llldm mm oslemnly Fig 3. I4 cylmdel Mud w Cyllndev mod combuslmn (humbly fig. 3. Is Squlfll ma Fig 3. I6 Removlng I)" am. plug 11} all drum piug ENGINE 5‘ Cylinder Head Cylinder hand delign The cylinder head ls consrmcled of an alumni num alloy Cuslmg incovpomung combusllon chum. bev, inlel pow, sxhausl pod, and comes lhs camshaft. valves, valve locker ovmss [Figs 1”, 3. IA) The culn-dviven camshaft ls Iolaled by me liming spvockel on me .lgm Slds 0! me englne The combusllou crumbs, ls mode semLsphevIcol lo: lncveosed cooling and beller combustion efii Clancy. ll also lncovpomlas a squish 0760. (Fig. 3. l4) (Squish area) ms ls an area pvovrded belwasn lhe plsvon and me cyllnder head to funhev compass porn 0! me fuel a" mlxlure av lbs end of lhe cams busnon sucks to meals a turbulence wilhin lha mom fuel rmxlura As me swirling loel mixlure .s dlverled loword lhe spark plug me flame pro- pugallon ls accelololed, allowing me slows: bom- lng (uel mlxlure or lhinner Fuel-air Iolio lhan normal, lo bum smoolhly, lumen decveoslng me Iendency l'ov knock-n9. (Fig. 3. l5) Because lhe use 0' Vhe 0‘ H. C. have decreased the leclpvocol opevaling load 0| lhs valve mecha- msm, high engine speed and good slablllly or high oulpul have been made possible, ln oddlllon, me increased combuslion efficiency has been achieved due lo Unrestriclad localion ol the valves and the poslllonl'ng ol the Spclk plug cl me center of the combustion chamber. A bells: flow of Ihe coollng all over lhs lop of (he cylinder head ls alluded and this in con; imcnon wilh me clummum head has Increased Vhe cooling emclency lo a considevuble degee. A. Diwssembly lll Unscrew lhe engine oil dvoln plug localed on lhe bottom of lhe cvcnkcase and drain me all complelely, The draimng is made much come! when me englne is warm. (Fig. 3. l6) ( 5, CYlINDER HEAD I3 (Fig. 3.17A, B) (3! Both the righl and (an cyhnder head side com: are separated by lemoving the s x I (1 mm bolls (ram (he ngm hand we and lwo 6 mm hex bolls [rem (he (eh side. lFig. 3. Nil (4] Tum (he cronkshah so lha! (he pmon (s m lop dead camer by uligmg the woodrufl key on lhe clankshah and the "0" mark on (he cam swede! m llne wnh the cyllndel OXIS, mmove (he Ihree 5mm knock bolls from the cam \ (2| Next, remove the flywheel and slate! assy. sp'ockev and dangage me spade, 4,0,“ the Fm 1|“ Rmmmg flywhea] and svavot axssmbly camshaft. (Fig. 3.19) G) Flywheel ® 5mm. mmw (5) Remove the 6mm hex and blind nuts llom me cylmde: head cover and (m 05 the cover and men yemove (he 6mm hex cylinder head be" lrom lhe (en hand flange and Sammie (be head (rem me cylinder (6’ Next, draw out bovh the Intel and exhausv locker arm shah; (mm the nigh! side. (le oul me vocker cum and Vhen remove the camshah. (Fig. 3.20) (Nova) Remove the locker cum shah by pUng our using on firm bah (7| Disassembly 0' me cyhnder hood I: made by first lemving both vanes by pressmg down on valve spnng lemme! "(rough (he (upper desling hole and exvmcnng the valve comm m. 3.173 Remowhg mm, msumbly 0 5mm mm, :2, bx (drum was; sci-w and (hen dmwmg (he valves our from me combustion chamber, (Fig. 3.21) n; a.” Removmy n, ( cylmdol ma ms com and {ylup as: head covey ® (.n mm, mm m. cover Cvlmde: ma cover (3) mm cylmde: mm was cum (4) sxl‘l m bah J ENGlNE Fig. 3. I9 Rummy mm xpllxkel (D, '0' mo-lr (z w oodrm Ray Fm, 4.20 Removmg reerer arm and cum shall I; iodnr mm mall l, l? l 1 Fig. 3 1| Removmg valves (2) Cylmdel Mad e 6) Valve llllq! {w s (2) Roda arm Fl’gs 3.22 Checkmg cyllndel head walpcgl (D cylmaer head «:2: Bluing or lad lead a. lnreeelion The cylinder head is exposed lo lhe high pies- sure and lemperclwe :esulling lrom lhe combus- llon oi the luel mixlule; lurlher, when lhe head is unevenly lovquedy ll may develop a crack or become walped and wxll be lhe cause 0' deleclive seallng belween lha cylmder bead and lhe cylmder, result ing m gas leak, on sucklrlg and consequenl drop m compression, The warpoge of me cylmaer hood does no! develop suddenly and ll may be overlooked, merelore, coullon should be exerelsed dullng leas- sembly. smce me uneven loraulng al lhe cyllnder head ls a new common loull To lnspecl lo: uneveness ol me cylmder head, apply a min cool of blulng a: red lead on a surlace-plale and wovk lhe mllng suvlace ol lbs cylmder head on the surface plale; lhe uneveness can be delermined by me nonsler ol lhe blumg on lo me cylindel band (Fig 3. 22) To couecl the uneveness. lap me cylinder head on (he swiace plale wilh a #200 mndpopol, finally mm by uslng a 3:400 sondpcpel and men lnspecl again wl’lh lhe bluing (Fig. 3. 23) lll Cylmder bead combusllorl chamber ll landmd volw Halghl l ”30:0 05 l ID‘55210.002lnl (emery 15:0 2 x lplug mxlallodl m an l22tuml l2l Cylindel head goskel lhickness. Slandard value—u l.0~1.l l0.039~0.0431nl Serviceable limil—uReplocs ll under 0.5 l0,032inl lsl Cyllnder head lorque 90~l20kgcm l6,5~9.0ll. lbs) Hl Volvo seal conlocc surlace Apply 0 mm cooling ol bluing or red leod evenly on me enme surloce ol me valve lace, hold me valve firmly agamsl lho valve seal whlls Iolullng lhs valve. Inspecl lhe valve seal (or a uniform and a conllnuoos widlh ol blulng. Slandard value~>1~l3 l0 040~0.051 in] s. CVLlNDER HEAD IS The valve seal is (owned wllll llwee lypes of caller: 60", 45" and 30° cullels, The localion and Illa width of lhe valve seal conlacl area IS made wull lbe 60° and lbs 30" callers wlnle me 45‘ cullel is used lav me lacing al "16 valve canlacl area (Fig. 3. 24) Finally, me valve lopplng operollon ls pen lama. Place a liberal amounl oi lopplng compound on me valve lace and lap lhe valves Opplylng a sllgnl pvessuve wh'lle loyallng lo the liglll and lell. using a suallon cup lapping lool fig, 3,1: Rapo'vifla wuvpei :vlindor ma Wash ofl lne compound lhovoughly and inspecl ® Cvlndev land ® Sand Paw lbe sealing wilh lle bluing lsl lnspecllon of valve co'llacl alea 6‘, A, Vulvn Fm wmxl mu Assemble lne valve mla lbe cyllnder bead “K '3» JD-Smlmoin) as shown In Fig. 3. 26 so mal lhe valves are ' ‘\ (“Min-n95 well sealed, and lhen rlIl llle combuslion cham- // g '°"' b“) be. wlln all, ln‘lacl a blasl of all lnlo lhe cvllnanleae .: inlel and axhausl polls and ll any bubbles “3m: 2" appear. il is an mdicclllon lhal lhe valve seals ale nal complelelv sealed. (Fig. 3. 26) —l- Valve slem lo guide clealclnce, Inlel Slandard vulne—>0,0|0~0.030 (0.0004~0.00l2inl rig, 3.24 Valve 1001 contact men Servlceabla llmu—hkepluce ll over 0.06 (0.0023 In! —2— Valve stem lo guide clealonce, Exhausl Slondcrd value—-0.030~0,050 l0 0012~0.00203nl Selvlceabla llmll—vReploce ll ever 0.08 Valve ‘uldu lo be mnalv localed an l0.0032inl ~37 lnlel and exhallsl valve glllae llem Slandmd value ‘ Selvlcuuble 1mm 0mm. ala I0nlm 10.39“ Nanossmm n, __ ng. 3‘25 Rawovkmg valve seal +0055 moo @ Valve xtul will! (2) Cylindu hlod lnlellalana. m a.oto~u oes l0 ooz~o.uoze.nln‘ lnsiaa ale 5 5 mm (0.21“ l alac. ll am 70.0l5|0.0006lnl . —o.025lo.oumlnl 5'53”““97‘” Fig. 3.16 luspccmlg valve "chug 16 3. Fl’g. 1.77 Measufing bend in vulva xlem (l) Dlu‘gauge (i) Vblod ENGINE _4, We! valve llem I Slundmd Va . ovuull longlh “amasomfl Head lhiclmau 0.5 (o 020 m) 10! "Locum Slam dvfl 5.5mm l0.1|7lu| . Sonicaehll llmil keplcco N was: 55.5 I} 530ml Replace il Ma. 5.“ [0.2llinl Rep‘ou ll mm. 0.2 lo.ooslnl —5- Exhausl valve lllm [ Slando'd Hull). Sank-abl- lmlll mm” ""9" ‘ 653mm12.573lnl Replau l7 undll 6A.? mm12.557 ml 70 055 «1002mm 47.055 10.0026ln0 o 7 «mum in! [0.00Un‘ mud mam; sum an: 5.5 mm (0.2I7in) I Replace H mm 5.4mmfl72I3ln) name:- It under 0.0 ID.OIMA) A67 QAIer vulva spring ll". ‘ Slnnduld ma.- Fvee 'W‘” 76! ll llOlnl I102) 4lg/l9,7m [52.031IIOID/ 0.7m nl lm/llu mm ulna/0150:“ m Paul S'lvlrauhll lmlu Raglan I' and» 25.9 [1.060an leplaco .1 am 2° lnxlullld ‘ 7.710.55kg/2k9mm lunglh a ludllls 9: .1! lbwnial -7— Inner valve spvlng Fig. 1.25 anv. opem’lnq mechcmsm ® Rode: mm (s) Pmon ® Comma“ @ Cam min (:3) Val" ® Clcnkshah (3 Cum xplmku llcnl ‘ Slorlduld value rm mam ‘ 255 um inl 5a. a l ll.o:n.5la/l7.2m pun-re ‘zm 24] I mm 578 ml 7ll! ‘ l°3u’ lnsmlled ‘ a 7:0.I5kg/22Jmnl lengm and . [m lla,llzo.3alb/a,3v.nl p 24 3 m 950 In) I-plx- 4 cm 2‘ -8~ Rockel mm (Fig. 3. 28) l IUmm lOJVJmI Shall bow I +0.0” IUDDOéinl ‘ —0l700001n) um ‘ Slandmd vulm Selvlcaable 1mm Shaw w. I Roplcc- 2! am lac. wear l 0.3 lD.0|2inl Ruplael ll om 10.1 (0.398m1 l l —9- Rocket arm shalt ' I lt-m ' Slandotd value Sctviceublo ltmlt Oulxldn din ‘ lcmm «1.394 ml 77 77 room roooosm :9' ”Hum" i 70.022 l00009m| * ' ‘0' "" Clearance l not3~o 037 1 Replace .l uvut l l0.0005~0.00l5mt l 0| manual c. Reassembly llt Perform the reassembly operatlorr m the re- verse order at disossembly described in s Section 4. l. A. figs 3‘29 installing the cylinder me (COMM) (D Cylinder me (9 Cylinder C ock I Do not target to install the two hollow ® “W ° knock pins and "0" rings, cyltr‘det head and Cylinder head cover gaskets. \ [2) Lubriccte the valve stem, rocket amt shall, ‘ © and camshatt with engine oil before assemblf» , irtg into the cyllnder head. (Fig, 3‘ 29) _ 2 (3t Tigrrerr the nuts on the cylindel head cover . evenly and torque dtagoflully to 90~120kg- cm l6.5~9.0 ft. lbs). [4| When installing the corn sprocket and cam chain, position both the cronkshalt key and the "0" mark on the cam sprocket so that they om ollgisd in the same direction and on the rig, 3.3M Component parts at extieerr valve ussy r . ll) Elba-Ill valve l5; lrmr vulvl wring piston centerlrne. (Fig. 3. l9) @ Wm“. hm @ Vow. wing (51 Fig, 3. 30 shows component parts of the (a) Volvo me (D Vein collot cylinder head assembly (I) Own valv- we 6. Camshaft ' in a tour stroke cycle engine, the camshalt i makes one revolution for every two revolutions ' of the crankshalt. The power to drive the cam- shaft is through the cam chain drrverr by the ‘ ' ‘ crankshalt sprocket which provides the owner ‘ cronkshu'nocomshah ratio. The lubricating oil is pressure led into the right side of the camshaft and is forced out of the holes in the corn lo lubricate the cam sulloces, r rocket arms and the slippers The camshaft is rifle 3,30: Carport-"I earls ct mllt vulva nssv made of special cast steel with the com and the ® tut-t valve (4) lm: vulva swim (z) quire-r me (it velv. spttr'tg tllulnlt @ Outet valve Spring :5) Valve :atllt beating area being precisionly ground alter heal treatment. The camshaft is supported at both ends by the bearings in the cylinder head and the cam sprocket is installed on the left end of the camshaft with 6mm bolts and is driven at one hall ctmksl'tctit speed by the timing sprocket press .‘ Titled to the Crankshaft and (Fig. 3‘ 3|, 3. 32) ll 3. ENGINE Fig. 3. 3t Canisnoir Fig. 1.32 Commit cemtmetlorl‘ Fig. 3.33 Cunt comet. me staidatd tappel clearmae measured cold is 0.05m [0.002 in) tor both the inlet md exhaust valves This is the clealaics measuied when the rocker arm is against the heel ol the cam lobe; in order to obtain this condition. the crankshaft must be rotated so that the "T" timing mark on the flywheel is aligned with the timing mark an the left crankcase. otherwise, the rocker arm may be on the tilting slope of the cam. (Fig. 3. 33) The ’oponing and closing at the valve IS deteb mined by the piston stroke and' is timed to the crenkshott rotation, During the inlet cycle, the inlet valve is opened at the beginning and closed at lite and o! the inlet cycle. [hiring the extant cycle. the same opening and closing sequence takes place with the exhaust valve. The open angle between the opening and closing is we pressed in terms oi algilal rotation since it is the game as the omit-shell mgulor ratatian. When point "a" in the Fla, 3. 33 passes be- yond the rocker arm, the vertical movement at the valve increases and at a certain point where the cam lobe comes to a peak. the movement of the valve slows down and comes to a halt at point "b" on the cam The inlet valve opens at H)" below topdeod center of the piston movement and closesol 35° alter bottom dead center, permitting on open duration of 225°. Ihe exhcusl valve opens at 30° below bottom dead center ad close: l0“ altar top dead center. This allows 220° at eximt valve open dura- tion This sequence IS shown In Fig. 3. 34 and is called the valve timing diagram 7. CVLINDER l7 A. Dimsnmbly Ill Refer to section 4.] A, Cylinder head disr (TDC) assembly. Bl Inlpedion lien Siendud value Serviceuble l-mll l ‘ lelt and am 29m (LHOlnl my“, ,r “1., ‘ 0.in |0.0020rnl 2, a m u 135 W 0.07: (0.0030mt ' ' Right end die r r. i shutr rerreui Replac- il wdlv 0.05 “7.0020ln) cern helghr 5.345 lo.2los lnl if???) ggffi',’ ‘ letiendnighi 29m (I.H0mt . end bowling +0.02l tonnage.) '59:)?“ ("sfxf' dlu —0 (0.0000 In! ' ' 7. Cyllnder .05 The cylinder is made at aluminum alloy and “fun“, the cylinder sleeve made 0' special oust iron m telial. The cylinder wall is subiocl lo heavy WW Va". "m “mm wear due '0 in “We '0 "'9 high weed ® inlet yelve eeern © lrm mak- reciprocating action at elevated temperdlure. © inlet valve elem © Corner-uteri rarel- Dist heal the inlet air, lereiga mailers in ihe 8 Ex: :3: 3:: g 33:79:?” lubricant, presence at metallic dust, all hasten the wear lo the engine components. therefore, particular attention should be given lo their peri. odic servicing. To provide a perlect seal, a gasket is installed between the cylinder and ltie A cylinder hood. (Flg. 3.37) g A. Dleeuembly :1; ill Relieved the cylinder heed in accordance 3 will. the procure described in seciien ii A, (2) Remove Iha 6m cylinder inslollm'lon H. 5. nuts. (3) Remove the cam chain glide roller pin and F“. 5.15 semen new . remove the com chain guide roller J r 20 3. Fig. 3. 37 Cyltrdct t> rra. 3.38 Remamg (ytrdzr Fig. 3.3? Measurrtg Cylinder rnrae diameter 0‘ Dial gauge @ Cylinder gauge r3. Cylinder ENGlNE a. inspection (I) Cylinder bore, (Fig. 3.39) Standard value—>39mm H.535 int +0015 (0.0006 inl +0005 «10002 int Serviceatsle limit—h Repair by rehoning if over 391 H.545inl l2) Cylindei overslza Standard overstze 0.25 (0.0] ml t:ll Cylindel barrel Slondotd value—>6255 t2.47inl rt 0 [0.000an —O.l (0.004 irti C. Reassembly lll Nate sure that the cylinder gasket endths- two hollow dowel pins are in place l2t Alter comp‘etmg the cylinder installation, Fix the corn chain gUlde roller In place wrth the cam chain gum gurde teller pin. 8. Piston, Piston ring The piston is mode of material corresponding to JIS ACBB ulUmanm casting. This material is light and, tierelora, suitable lor high speed; in addition. it possess good heat conducting propetty to dissipate heat rapidly. Furthermore, the coefi‘ciertt ol heat expansion is small, thus minimt. zing the watpoge at elevated temperature and permitting a small piston-locyllndet clearance desigt. The shape or the piston is arr elliptical rapar. the head at the piston, compared lo lhe skirt. is exposed to higher lempetature and since the expansion ls greater, it is. tapered smaller toward the top, The tapering ot the piston also tends to lessen the piston slap when the throttle is lighlly snapped without the engine being loaded. The piston in the model 5550 employs a three step taper. The piston pin boss area is made tttrctrer, thereby resulting in greater expansion at high temperature. For this reason. the diameter at the piston skirt is rrtode smaller in the direc- tion of the piston pin so that at the high operat. Ing temperature. the piston will expand into a true circular shape. The slrirt is constantly pro vided with nexrbility to assure that no delarma- tion will result even from extended continuous riding. a. piston VISION RING 2i The piston pin is ofiset lrrtrrt [0.039inl trout the piston centerline in the direction ol the inlet side. so that when the piston approaches the top deed center of the compression stroke, the side load from the cy|lnder moves trout the right sise to the lett. With a "0" ofiseL the point will move to oligt with the topdeadcenter of the compression stroke. (Fig. :l. 40) As shown in Fig 3‘ Al, the point 0' maximum combustion pressure occurs alter the top dead center, therefore, the purpose ol the other is to move the point toward the point of weeker pres sure which is betore top dead center, and by so doing, escapes the powerlul pressure movement and makes it possible to eliminate piston slap rlstort rIrta The top and the second ring wvesas a seal lor the combustion chumben the oil ring scrapes the excess oil lrotrt the cylinder wall to control the cylinder watt lubrication. Further. they trans. ter rhe high temperature at the piston to the cylinder wall where it is dissipated out througt the cylinder cooling nrrs. For this reason. a spe cial alloy 0! cost iron is used to provide strength. wear resistml heat resistance, and good heat conducting properties and is also given purlratiz trig treatment or lerrox coating Yhe top ring espectally rs plated on the outer surlcce with herd chrome and tnished by wet honing. To prevent mtter, the thickness at the rings are mode narrower and the width increased inertia is made smaller to increase the pressure agath the cylinder wall. Furlherl the top and the second rings are mode at a sligtl lupsr where it contocts the cylindal wall so that the little required for wear-in IS lessened. (Fig. 3‘ 42, 43) Fig, 3.40 Piston ' Vlmlm cm Wt. ton 4: [DC of collar": fig. 3." Cytlhder oflnl ® n... 3.12 Plslon ring ® toe compression "W (9 Second companion titre (a) on rlhg 22 a. ENGINE A. Disassembly m Remove lhe pisvon pin cup and pushouv the pmon pin. (Fig. 3.44) (Cauoion) Exercxse care so vhm me clip Is no! dropped In (he crankcasev :2) When lemoving me pislon nngs, use a pisoon nng removal vool 0! open the pislon ring by splecding upon Iha ends of vhe ring and cure- turly rm lhe ring out wrlhou! Iwisling. r... 3.13 Piucmnn inchng and on Krapmc luncvion Li) top ”"9 a) on Mug 3. inspection (3) mm m, g; o" scraping . . . (3) on ”W m {5} WW “mm m Inspecv me piston lop, (ace and skm, pm Fig. 3.13 Eomcvinq pum- pm :l-p @ mum @ Pmun pin cup ”Manama u, m Fig. 3.45 Mano mind.” mum-m. damn":- q) Puma @ Cylind-l bore for any damages or sclclches. l2) Piston clearance (Fig. 3,45) Standard valuevoODl (0.000400 Sevviceable hmil—hEepluce il over 0.12 (0.0047 in) :31 Pm" pzn bove (Fig. 3.45) Slundcvd value 13(+0.5120 in) +0.008 (0 0003 in! +0002 (0.0001 in] Selvlcecble “mu—hkeploce a over 0.12 (0.0047 in] (41 Piston pin oversize Slandard oversize—>025 “10099 in) (5| Pislofl ring side cleavance (Fig. 3.47A.). Slandavd value (10p, Second] 0.015~0.045 l0.0006~0,00l67nl Svordctd value (on ring) 001—4145 (0. ooo4~0 001 a in) (6| Pislon ring. compvession V I2 ’0 0“ Fur thclnau La (0.07! m! PepVou IV ndav 10.1 moan.» L6 «0 06 RM; clmlnu 0 3H: 52x9 RapVocl « undar «m. m 75~L3um 0.20; n 4 m II-m smmm yum. §9vwzwbln mm wmn [0.0573 m: Rnpluu a under B P‘SYON. PISYON RING 2: (7) OH n‘ng Hem ‘ Svundmd mm Selwcaatfla mm! w‘dm ‘ 25 ‘0 WWW ‘ 4mm mooamm Rem“: .0 My 40 025 (0 com m7 7 ‘2 ’0 9953 "" mamas ‘ \ n+0] ‘ Region; 4| undev we my mum \ v s (0.05”; Ran cramg ‘ n ¢5~u 75kg \ mm, a We" «may u o~x 55w 0 3n kg m 5mm bug and gap ‘ u I~D.35 m noa~oou w ‘ 36:00ch 0‘2'0 "T" \ (B) Oversize pisvon ring Smndard ovemzeaolé ‘0 01 m1 (9) szvon nng and gap (Fig. 3. 47 a) Svondard vows—>0 l~0.3 l0 004~0 012w (IO) szvon pm Hem ‘ swam mm. ‘ Sew-cenb‘u Wm! 0mm am ‘ 13mm m 512w + u no 000 m» u 002, re 0002 .n) hpza“ ‘I may 1293 msmm Henghl JO 7 u 21 w 0 o 2 <0 005m) - n 10 000w (In Plslon pm vo pmou clearance (Fi 1A8) SVandatd vu\Ue—>0.002~O.DI A (0 00006~D 00055 m) Semceame llmvl—hileptuce l' ovet 0.05 (0.0020 m! l l / ”+0003 \ , A7 +0002 [ I +0000: (°‘5'7+o.oom'" ‘ fig. 3.45 Pxxlon pm hole dramnlev Fig. 3J7A Mnnwnng defiance heku-n vmg gvoovc and pm Hug a) Monday ® rum gangs (2) mm. Fig. 3.475 G) Fallorguuga ® Cylindnr (5) Pinon Hug 7A 3. ENGtNE a ooz~o.ol4 (o 00008~ODOO5E Fig. 3.13 Fig 3.49 Pinon nit; G) valor-ring ® rig. 3.50 turn th. ting atom to in. piston and that tn. contact condition l . . .. Fig. 3.5! Arrow mark er. ptsten head (D Arrow mark c. Reassernlsly i. Assemble Piston ring (Caution) Make sure that the rings are not inslailed in the invetiad position. The top side 0! the ring is marked with a "T" odiocent lo the ting gap. (Fig. 3.49) When installing new tings, roll the ring ototmd the circumference of the ting groove- to check the clearance belora making the .in- sleltattan. (Fig, 3.50) 2. installing the pision a. Make the piston installation so that the arrow marked on top 0! the piston Is painted toward the exhcmst part. b. The piston pin is a sliding fir and should only requtre a slight pressure with the finger to make the pISIOfl pin in the piston pin bore and the connecting rod small end. c. Always use a new piston pin clip. 3 Install the corn chain roller lo the cylinder. 4. Install the cylinder 1:. The ring gaps of the three rtngs should be spaced 120” apart. 9. Cum chain tensioner An all dampet type at a cum chain dampev is employed to suppress the vibration of the cam chain, thereby. making it posslble ta control the com chain (at high speed operation and also pvevanilng chem noise Betore the englns starts. the chain tensioner spttng compartment rs flooded with the oit which enters from the art damper strainer Alter the engine starts, the air remaining above ' the statling oil level in the tensioner spring com- porlmeni, posses irom the hole A in the guide to hole a due ta the reciprocating motion at the“ tensiotter spring guide and enters the crankcase. When the engine starts, the oil level rises above the oil hole E. ln addition to the air in the tensioner spring compartment being eiected lrom hole A to B. the oil is sent into the tension spring compart- ment from hole B to A. in this way the tem sioner spting compartment is constantly and com- pletely flooded with oil, performing the iunction of a damper. Therefore, it is necessary to check the orifice of the tensioner spring guide and the operation at the tensioner spring, (Fig. 3. 45) 9. Com CNMN TENS‘ONER 25 ‘ Fin. 3,52 Cam mm mmu dun-ail dingmm (.3 Cam mm mum-m mm (s) hallo-m “why (2) Cam chum mm. mm (9 m...“ xoulinw m Q) mum: puma Mud q) le yum ® A. Diwsxemhly ll) Remove flywheel and mold assembiy as described in section 4.1 A. 12) Remove me Nmm seulmg boll located on Ike honom of the Ieh crankcase, (Fig. 3. 53) {3) Disassemble the damper, (Fig. 3. 54) Fig. 153 Rumovlng Hmm mo‘mfi boll (D Hmm wanna mu wivh“. 4}; u a, ENGINE rig 3.54 “WM Canteen-m pulls at tgnsto'tav (D Yenxt'ottnr push rod need ® tension-r push rod Q) Yer-Stone: spttng (r) Nmm stating wash: (51 “mm xeuling bait Fig. J. 55 a, :tanlcuu (:0le air puma- @ it, crankcase con/It it: rim-1.56 crutch (9 Clutch assembly 8. Reammbty Assemble the com chain tensioner on the la" crankcase. (Fig. 3.54) (Note) Alter assembly, check the tensioner tar oper» ation. IO. The right crankcase cover Is mode at special heat resistant aluminum alloy. The lubricating oil under pressure flows in the direction at the cytinder head and the rigtt crankcase cover to lubricate the crankshatt and component parts (Fig. 3.55) we Right Ccrankcase Cover A, Disassembly ttt Dram the on. (Fig, 3‘ l6) [2) Remove the ktck starlet arm. (3) Unscrew eight rrgttt crankcase covet attach- ing 6mm cross screws. 3. Inspection (It Check the mating surtace for any scratches or damages C. Reauembly [H Reussernble in the reverse order of discs- sembly. (Caution) o, Exercise caution not to damage the fight ¢.. , crankcase cover”gasket nor to install it misaligned. 1]. Clutch The [uncltou at the clutch is to temporarily disengage the transmitting o! the rotary motion between the engine and the transmission during the gear change and than after the gear change, permit a smooth power transition. The condition at the clutch will have a varying eflect on the direct transmission at the engine rotary outpuL A new clvlch lifter desigt is Incorpotated in this rnodet ta provrde a smoother operation. (Fig. 3‘ 56. 57) Ctuvcn A. Dimmmbly (1) Remove the rig" amkcuse cover. l2l Unscrew lou 5X|0mm cross s‘crew md remove the clutch owe! covev. [3| Unlock the Hm lock wosher and loosen lhe Hmm lock not mm 0 Spain! tool. The clutch assy. am he removed as a mm. (Fig. 3.55) (41 The clulch is easily disassemble by Ike use oi me special tool (clutch ussenbly moi). (Flg. 3.59) When disassomblying lhe clutch outer, lhe access to the drive plats (drive plate spring seclion) must be has in order to compress Ibo m. any. plate. a. Inspeeolon [ll Quack lhe gleam bafween the clutch cemar guide and the primary an». gear. (rug, 3. 60) Slmdad value 0,050~0l09l l0.0020~0.0036 in) Serviedble limit “place il Oval 0, l5l0. 006! (2) Check cleatanoe between clutch MIG! 915d: and lid" crankshaft. (Fly. 3. 60) Sunderd value 0,004~0‘040 (0.00016~0.00l6 in! § / ~ ... § Fig. 3.5“ Clam. ulumbly and oil pomp. dlogvum Drlv- plum Malay any. 300v Clmdn w mm Clultfi Mellon dllc mum m n» Chm plan. no boll boating Claw. mm mm Clurm on!" Clmcn Mm m plul. ® ® ® ® ® © ® © ® ® za 3‘ ENGINE Chm. dumpev xming aura. cum com pom: m Gulch cum" was (2‘) Pr‘mmy am. 9007 ® mum m ving (U Clulrh plur- © Clwch mum. dis: (6 Dnvl plai- (1) C‘ulch 391mg ® Clul:h we: @ 69 ri.. 3.55 anovmg (ma. ® cm». away spat-nu (2) 14mm lock n... mm». ® cum @®®@r“© Fig. 3.5” Commm pom cl cram. chm own com 600! mu mm on mymn guld. on gum. mung 0.: guid- Cluvch 1m. (31 Clulch cenler glide nun Slandurd vol»! mid. am Ilmn (0.670?!“ +0006 “1.0002 lnl ~nV0I2 [0.00m rm Some-obi. lmm mayo:- yl om ”J (a 574m) Qfludt dva 2| m (03274“) Rnnloc- ll wdu 70,05 (0.00m: :79» “1mm, Vow 10,003 My ‘ ‘ nag». 25.1 "mm.” ”In“ H M" +0 (+0.000ml 2:9 mm m ~0.I «Loam: - - Rummy I Eupluc. .I ave! ‘ D.03nox.fll00l2ml 0'15 mm”, (4) Primoxy drive 9w (Fig, 3.57) um \ Slendavd valu- lnxndu 21mm 10,830w diam-my ‘ Hum «1,0008 in) ‘ 41000 mvouuoln) [maul an. ‘ laws 40 545w mm moss 70.021 maooaa m) momKS yum , 0 on (0.001621!!! S-wictobh Hmu Ruplaca VI over 21.!5 “1633 my Reprace ‘l mdev I195 (0.517 in] Thickness of ciInch iriclion disc. Slandord value—>15 (0.13801! Servioeoble limit->Repiaoe ii under 3.| [Dil22inl (5i (6] Clutch piule (Fig. 3.6” Imn Widm ul claw ‘ Smd vol». I Suviuabll mil . CLUTCH 29 +0 ’5 —o.l (0.530 :O 382:2) hole“ ii ind-r IsJ mun ml rnlcmu I.6:D.05 (006310.002 ml hpluc. il md'r Ls (0.05%.: (7) C'indl outer claw width Slaldard value—hi6.0:g'1~16.3:g’l + 0.0m (0'63 — 0.000 ~0lé42 +0004. —o.ooo '") Serviceduie limit—.165 (0.65 in) (5] drive plain or clutch plate. Standard value—>0.3~0.5 (0.0] 2~0.02 in) Angula play between lha clinch outer and [9) Clutch spring lmn I Srondord vain Sorvizoobla Iimil rm llnglh lulu. ll undo: 1M Iwulnr ”J (0.7mm Spring Vern 13.210.8kg/IZJM ml“. ll ind-r I29.0:I.75hb 6.5lg/I2.Blnm (0.504 inl ”Lam/0.504 inl c. Reassambly (ll Parlorm ma reassembly in me reversaordor oi disossembw. Into lbs Clll'dl ouler. assemble Fig» 3.50 (D cum osxombly loo! (9 cum assembly Fin. 1w CI-mam bolwun mm quid. and R. crunkshoil ® anury dllv- gm ® a. crank shun @ Clulch new we. clinch spray. drivo plate, iriclion disc. clurch plole. ' V ' Compress lhe drive plule and insiull the Sc! ring. refer to section 7. A, clutch disassembiy. Inslall clulch danper spring. Assemble "to clutch osserrbly on the rid" amkshail logeiilor wilh rho drive gear, clurch cemar glide and lien Did-lien wilh rho lock Torque 350~450kgan (23.|~33.Hl.lbsl ' (2! (3! E; o 55 :2: Fig. 3,6! Cluldl plulo ~ ENGINE Installing clutch unembiy tum locking warn-r Fig. 3.44 on pump theory et ermine (Caution) Alter proper torquing al the nut, do not target to lock the not by bending up the washer tab. If the tab does not coincide with the side at the null Over-torque the nut until one at the tab coincides with the side ol the nut. (Fig 3. 62) (4) install the clutch outer cover assy. [5) install the rigtt crmkcose cover. l6l Install clutch cover. 1 2. Lubrication System The oil from the cratkcase oher being drawn into the oil strainer is diverted lor lubrication into the (allowing two routes, Ill Right crankcase—upossageway in the right ctmkcose cover—>centrilugal fillet—Ho lubri- cate the cratlrshalt and associated pats (2) Right crankcase [upper pert oi the oil pump) athottdt the cylinder stud bolt Iright lower side)» into the rocker arm side cover—.spruyed from the tour oil holes in the camsholt-uto lubricate the respective sections ol the cylinder heod—rinto the oil return hole at the lower end of the exhaust valve and returns to the amkcoset The oil that passes through the camshaft lubricates the cam chain and returns to the crmkcose, In this wuyt the lubrication of the engine is performed by the two oil routes and the oil spray in the crankcase. (Fig. 3t 63) This pump consists of at inner and m outer rotor. The pumping action is produced by the dlfierence in the shape and number of the teeth between the inner end the outer rotors. (Fla. 3. 64) l2.|.UBRICATION svstEM 3| Al Dixuuembly (ll Remove the clulch assembly as a complete unit, refev to sectlon. 7. A. l2l Remove three bolts and detach Ihe oil pump (tom the crmkcase as a mm. (Fig. .165) (31 Disassemble lhe on pump by removing the three 5mm cross screws. 3. Inspection In on pump cuter veto! housing clearmoe. (Fig. 3. 66) Standard value—>0.|~0.l5 [0.004~0.006 in] I?) Rotor to totov cleavmce Stmdord value—t0.02~0.07 (0‘005~0.028 in) [3] Rover Np cloamce (Fla. 3.67) Slandad vulue—eDJSrnux @006 int Servtceable limit->Reploce i! ovet 0‘2 (0,008in1 C. Reanemhly (It Fit the inner voter to the cute: 10k)! and then install the pump assembly to the right :rmkcuse. (2) Install the clutch assembly and the tag“ ctmkcosn COVOL "I. 3.65 Dlmsmmymg m. oil pump on pump body gush! on Mp mm em on pump body Owl" IOIO' tum tote. on Mp mm mm on mm mm 5mm spam mum on pump dun anon @@@@@®©®® o.oz~ 0.07 (moms—momma) _ c. o.t ~ 0,1 5 (moon—omen.) , d :gmll in ) (0M9 Fig. 3.“ on pump gm elwm. Fifi. 3‘67 on w backlash 32 3. ENGINE I 3. Crunkcuse The crankcase an tntegal part of the ttmsmissiou, is at aluminum alloy die casting composed at tight and la" halves. A bteclhet compottmem and a weather passage is mean» rated in the Uppet seclio't 0! both ctunkcase i halves to dissipate the pressute built up I" the ctmkcoss. (Fig. 3. eat Breather The inletiov oi the crankcase is cotmmully undo: Fig. 3.65 R and \ :rartknse . . . . G) “h ”Mm“ ® mm mm” varying pIBSSUi’e, built up by the tectptocattng piston. in addition, the crankcase is Filled with gases from the blow-by ol the piston and the gases ptoduced by the heat of the crankcase. Fot this reason, the decomposition of the oil v is hastened. In addition, together with the rise in the crankcase tntemcl ptessttte, the possibility oi oil leaks at the case patting am is increased. The hteathet IS destgmt and Incotpomtad In the case to exhaust the gases to the outside and also to maintain a constant pteswa within the ctmkoase. (Fig. 3.69) 1:! Gas _ Oil rig. 3.69 Bvoolhet lunctional “gem (D Ctunkcuo gash! (9 oil ® It mince;- @ i acnkcuu @ Ftam R. cvunlcuso com ® To 1. mittens. com ‘ V\\\ czmxsun 33 1 l4. Crunkshafl me high sllenglh carbon sleel ctunkshah lo~ gelhm wllh connechng rod convene lhe reclwocm lung motion of me plslon lo the lowly movie" and, m oddllion, performs lhe luncllon o! lhe flywheel by ubsovblng lhe nucluallng lorque. The pressurlzsd Cll from lhe pump posses llom llle nghl crankcase )hlough lhe ughl crankcase covel, me me crankshall by lhe way of lhe cemnfugol filler and lubrlccle lhe large and of lhe comecling lodand clutch camel gll-de. (Fig. “H 3,70 0mm“ 3.70) A. Disassembly lll Remove the cylinder head, cylinder. flywheel. slolov assy. Reie: lo seclion 5 A ‘ [2! Remove the nghl crankcase cover and lhon the cluvch assembly as a mll. Refer lo sec lion l0.A. [31 Remove me 17mm cllclip and pull 05 me « primary drlven gear Disassemble me all pump 1 assembly. (Al Remove me gee: shlh assembly and men gm,” remove vhe shill drum stoppel plele allochlng . (y Gem 3th xplndle scvew, (Flee 3.7l, 72, 73) (z, 0" mm mm” (5| Remove the kick slaler spindle La) SM“ em mapper (6| Remove elglu 6mm cross scvews and lhe G) ”‘5 W“ “"W K I . righl clankcase can be disassembled, also pen (5) “ "“"°' ”M“ milling lhe plslon lo be sepamled hom lhe loll crankcase. we 3.72 Removmg gem mm xplndls Q) Gaol shxh wlndls 31 a. ENGINE I. Ympenion (I) Support the cronkshalt on V blocks at both bearings and measure the amoum of wheat (Fig. 3.74) Item I SIlndmd vu’ue Setvizaubte It'll?! 3 'mr bearing oots Replace il ova: g web xid to 1100.5 ml 0.05 “100th int E Vargtrrtmrrrrg 0.0ts Repiarl it ever 3 ‘ web std! ] taonoerrrr nus [0.0020lnl . i . Fig. 5.72 Removing shrlrdtum "09901 pram (21 The clealunce in the bearing is measured ® SN“ drum Mower him. by supporting the crankshaft orr centers and moving the bearing in the axial and vertical directions. (Fig. 3. 75) turn ‘ Stmtdurd valu- Servtcnoblo iirrrrt Axial ouc¢~0.u:t.s chloc- II aver chow»:- tn.oonz~o.oot in) 0.! (0,001 lttl Chaotic. ‘ normal It: am ooio~u.025 xrpirx- it am i to.0004~o.oui ml 0.05 "1002 inI r When the clearance in the axial direction becomes excessive. the crankshalt will move Fin. 3.74 Checking cranium" aiignmr "0'" side '0 side when engine I: tummy and a) Dial gouge produce undesirable noises as we“ as causing @ “WWW" uneven wear to the cylinder. piston and the tirrirng gear. It will also shorten the irte of the clutch. If the clearance ts too small, it will cause a 1190er in the power oulpui and shorten the Me 0' the crmkshah. (3) Clank pin Illm Standard valve SON-enable ttmrt Oulltdo an: 23.1mm m‘nw‘ Rem“ V, W" +0.00? (0.0W3Inl 23 045 m 905 W 70.002 "1.0001 in) ' ‘ MI 0.002~0.ua7 rig. 3.75 Mnomtlng axial clwancu (0 uaz~a 003‘ W ® Center (9 Dralwug. ® Ctunhhuli (E Center [4] Left crankshaft sprocket root diameter. (Fig. 3. 76) Standatd value->25.24i0.025 l0.994i0.001 in) Serviceabla limit—>Reploce if undet 25.19 [0.991 in) [st Right crankshaft spline play. Standard value—>D.010~0.040 (0.0DO4~0.0020 in) u. Servicaabls limit—>Repluce if over 0.08 [0.0032inl (6) Maximum crankshafl assemny mm S'mdard value—Humour a! web ouiar surface 005 TIR (0.002 in) Serviceabla limi'—>Replocc if over 0.2 [0.008inl (7] Connecting vod smell and I. D, [Fig 3. 77) +0043 Slandclvd value—ulSmm+0~o]6 (0.512141002. ) +0.00] ‘" Serviceobla limiV-hReploca if ovev 13.1 (0.52m! (8| Connecving rod smcll end to pislon pin cxsar- once Skndald va!ue—>0.0l6~0.043 (0.00] ~0.002 inl Serviceabla limiV—>Replace it over 0.08 (0.003201! (9] Connecting rod ml! and deflection. Standard value—>15 (0.06001) Servicecble “mu—.Repluce if over 3.0 [0.120 in) I10) Comecnng rod large end lllm smdmd vulun Scnluabll lmm End p‘uy 0,I0~0.35 I-plan II on. Y0.00(~0.DH [III 0.6 IQDZI in! naming u~0.0lz luplac- [l mu cleamncc m~0.0005in> 0.05 “1.00200 (l H Connecling rod aligmenl mm Sim-dad mm Serviuoblo Inmil Pamflllvm mum n av 0.I0 mom...) win huh-x. I om D.Is 10,006 inl C. Reassembly ‘ (ll Make cencin "10! the crankcase gaskel and the N40 knock pin is in piece below assem— blying me right crankcase. (Fig. 3.78) [2) Assemble in ma revewe order of disassembly. Refer to seclion 13. A. CRANKSHAFI 35 2521:0015 (0wn+0mvin) Fig. 3.7:. Timing mom: new we! comw Ruiprooumg monkl Gymfi‘ m =% wk". m=1ee< mu =cm el yvmy + N113 u ‘ +0010 + 0.001. (msnflwm ) m. 1.77 Conn-ulna rod 3.7a Asumblylng R cvankcox- ® Raankcau ® Cmnkmh ® Luankcaw w :6 3. ENGINE '5. Transmission The Iror|smussuon receives the reunion which has been "unshared ham me crankshaft no m min shah, and mag. a selles of gears, changes u .0 ma desired speed and succeedingly nonsmi's il to me sprockev mounted on lha counter shah. The Honda 5550 Is equipped wilh a 5 speed nonsmssyon Io gwe n a We sponing feature. (Fig. 3. 79A, 3. 7?B Conslmc'IOfl daiall) rig. 3.7VA Immune» :ocmmcnon dulml a) Gun ml: drum g: Cowl-r mm ® Mam shah Fig. 3,79I Goa: shvll macho/him Q) Gm emu. pedal (D smug”... stopper pm. @ Gear shin spinal. © <3“. mm (or! @ sum em Hows! erm- © em. nun ill Disassemble lhe lransmissiori by relerrmg lo section H. A (cronkshafl dismyemblyl The shcfl. counler shall, gear shill drum can all be dis- assembled as a complele mil. The gear shril drum assembly IS disassembled by rrrsl unlocking lhe shill glide pin lack washer and rernarlng the guide pin lo allow lhe gear shill lork lo be disassembled. (Fig. 3. 80) Low gear: l2l lransmission gear, irammlss‘lan I5 1 A. Disemmbly l r l lal l r l l l l The power lram ihe crankshall is ironsmllled } re rhe driven gear which is spline engaged lo lhe lrarlsrnissiori main shall and rum: in ’ lhe some direcrion as lhe shall. E The power lrom lhe lranslnlssion main shelf! is lionsm'lssion main " lransmilled lo lhe low gear on rhe Ironsmlssion comrer shall. The low gear nol being can- i necled lo lhe calmer shall, rolclles heely on the shall. However, when lhe comler shall lop gear which is spline slide rrlled lo lhe counler.shah is moved loward lhe low gear by lhe shill fork and engages wilh lhe dowel hole, lhe lap gear rolales wilh lhe law gear as an in~ legral unil and lransmils lhe driving force lo lhe drive sprockel ollached lo lhe lell end ol rile comlershali. (Fig. 3.82) YRmSMISSION fry. 2. m. 3. cu ©®©® u (D @Q@@®®®©® ® ® Gear Shirl drum assembly Gear ml. lork sum [an pin leelzrrg waxhar Shin lork guide pin Gear shill am Numbar 0! can: leelh Main shell tlow pearl l2 reem ~ lSecmd gnarl I7 ~ ~ l'hlrd war) zu ~ ~ lFo-rrlh plan 22 ,, n in» over) 24 r Corrrllll men llow marl as lull. ~ lSazoM gear: 3a ~ ~ [thrd gnarl 27 ~ a (leh geerl 25 ~ ~ lrep gnarl 2: a Main shah Comer mall an 3 ENGINE It Second gear- The main shaft third and fourth gears which are spline slide fitted to the main shaft are moved with the shift fork toward the main shaft second gear and engages with it through a dog: further, the power transmitted from the driven gear to the transmtssion main shaft ts further transmitted to the main shaft fourth gear ‘ and tn turn to the main shaft second gear. .3 The power next is transmitted to the counter , . shaft through the spiined counter shaft second Fte- 3-53 Second gear and henceforth to drive the sprocket. (Fig. 3.63) Third gear: The power from the transmission main shaft is transmitted to the counter shaft third gear through the main shaft third gear. The counter shaft third gear rotates freely. Counter shaft lop gear which ts spline stide fitted is moved toward the lhtrd gear and when engaged with it through a dog, the third gear revolves with the cotmlersl'tah as a unit to drive the drive splockef. (Fig. 3.34) Fourth gear, The spline slide titted main shaft fourth gear transmits the power from the driven gear to the counter shaft fourth gear. The counter- shait fourth gear rotates freely on the counter shaft and when the spline stide fitted counter shaft second gear is moved toward the fourth gear and engages through a dog. the fourth gear rotates with the counter shaft as a unit to drive the sprocket at the end of the counter shah. (Fig. 3.35) Top gear: The transmission top gear rotates freely on the transmission tnain shaft. The main shaft third gear is moved by the shift fork to engage with the do gon the top gear which then ftans~ mits the power to the drive sprocket through the counter shaft top gear. (Fig. 3.86) Fig. 3. 84 htird Fig 3.95 Fuutlh Hg. 3.“ tap Is. YRANSMISSION 39 Neutral; '—" Without any gears being locked, the main shah transmits power from the low gear to the chants! shah low gear Further, the min 1 shaft third and fourth gear transmits power to r the counter shalt third and fourth gears. How- i ever, the counter shaft gears rotate treeiy on , the shalt and consequently deliver no power ! to the drive sprocket. (Fig. 3.87) ‘ 8, Inspection ' § in Main shaft and second gear clearance rt... mar Nculral (Fig. 3. as) Standard value—ro,o22~o.051 '5‘ ”a 1 r0.ooo9~o.oozo in: fig § : Servicaable Iimir—rkopiece it over 0.1 ‘7? 7' i‘ [0,004tnr 5% g [2: Main shaft and top gear ciearerrce °s’ e- (qu. 3, as) , Standard value->0.022~0.05l . to.ooo9~o.oozo in) ‘ Serviceable itmtt—tkeproce it over 0.] «1.00m; ‘31 L‘" 5“)"ka “Wing “’90 ”d "“i” 9‘0" Mg. LII C'Oovanco bflwun maln shall and lop, more 14mm section. (Fig. 3.59) m. Standard verve-+0.016~0.052 ® Naiv- shah to: em l0.0006~0.0020in) g mggggfl‘grm ’ Serviceable Iimil-bReploce ti over 0.1 f ‘ (0.004 in) r N) Main shah o. D. ”lbw: s'mld “wan—0.006 tam.ootra.rt 41017 _ _ , - (0.670 —0.ooozt in) —o.oooe7m Servicacble limiiwkeploce if under 16.94 (0.667 in) ® Fig. 3.39 craararre. baby-on rneir. nah and |. cranlcun (D L crank can ‘. ® Maln than 4:“ ' 10 :. ENGINE +3.02: ~00“ 10 0009— 0002.») I5) Comb! shafi aid mild and but!!! gear clearance (Fig. 3. 90) Slandard value—t0,022~D.051 I0.0009~0. 0020 in] Sevvicaoble Iimiv—>Reploce if over 0.] (0.004 in) (6| Coumer shah and low gear cleavance (Fig. 3.90) Siandold value—h0.022~D.05I (0.0009~U.0020 in) Sewiceable limit—bkepluce il oval 0.] Fin. 3.90 Clmvanca bulwun cowl-r shah and low, third. (own gem Cwmer mu \ow m. CM... mall Mud m. Covmu inch 1mm. ular 'Ionxmuxmn «3mm: mu Fig. 3.9: 6) Emmy :llalunu mm.» l cranlcmu and cow-m mu" 0 crunkou 6) la 5 Imus! wash-I Cour-m mm H wmmumzsi-J Fig. 3.91 q @ C‘autonce tum“ gear mu dun: and gun :qu York 0w mlv 1m (3ch SN" drum (0.0!“ in) (7) Counvev shall. and R. crankcase (Flg. 3.91) Svmdard value—>0,0l7~0.062 (0.0007~0.0024 in] Sewiceabla limit—bkeplace it over 0.1 (QDIN in) (8! Counter shah O. D. —0.006 svmdaid value—vl7_o‘o|7 —0.00024in) (°“7°— 0.00067 in Servicoabla limit-DEBphce if under 16.94 [0.667 in) [9) Shin drum and shin kuk Ium Slandovd val»: Suvlcuoblc Ilmli 0115m- dio 31m (l 3355i!“ ' llplofii I, MO! —0.02 0.00070». 4.032100013an 33.9: ”.3355 w 5 Shanda-.1 um msnsm v - Rlplacc ii um. — 0.01 610.0006 In g 403 410.0013... 12535015091 "I! dem 4.5 mm in) +0.! 10.004000 5.3.73: B'V'I l°"' —0 01.000000 ‘ ' " Hon diu a‘mumaum . ”plot. ” uvlf a +0.025l0.0010m| . 3 —0 [0.000001 Mowoaamiu E Tip 0rd mzom Rop‘ou n undu lhicllnlu (0.l92910.00!6ln) 4.50 IOJBIImI IIDY Clocrmcs belween shill fovk L D. and gear shill drum. Smxdavd value—>0.02~O.D$7 l0,0005~0.0023 in) Serviceabla limil—>Reploce if over 0.]35 (0.0053 in) Upon completing the nrausmissim reassembly and the insiallcrion of me right and lefl crank- mse, inspect to 055019 mm me nonsmission specular: wopevly, A truismission which Vurns Mavy will cause mlfmclion or will heat up. [6. c. Reassembly tlt Perform the reassembly in the reverse order at disussembly. (Note) Check to make sure that the l3,5mm thrust washer is installed hetare reassembly. (Fig. 3. 93) 16s Kick Starter As the kick starter is depressed, the kick starter spindle rotates and the ratchet, due to it being held against the ratchet spindle in the direction of rotation, moves in the direction of the arrow by following the spiral groove cut in the spindle and causes the kick starter pinion to mesh with the counter shalt low gear. The main shalt being engaged to the clutch center. transmits the kick starter torque to the engine crankshctt and turns over the engine. When the engine starts, the rotating speed at the pinion exceeds that at the spindle and theretore the pinion is held. As the spindle returns to the original position by the action of the kick starter spring. the ratchet disengage: from the pinion and returns to the position for the next kick cycle. (Fig. 3.94) A, Disassamhty (ll Remove the clutch mil i2t Remove flywheel and stator assembly tat Remove the primary driven gear Ml Remove the gear shitt spindle i5t Remove the lrsrnm ctrcIip iron. the kick spin. die and disassemble the kick spring retainer and the kick starter spring. (6| Separate the right and iett crankcase halves and then hit out the spindle iron the tail crank» case. a, inspection iii Check tar wear ot the ratchet and pinion teeth, replace it wear is excessive c. Reassembiy [H Assemble in the reverse Gide! of disassem- bly. (Fig. 3.95) KiCK sun": u tum mun washer I crankcase COMIC? shalt 13.5mm Ilium wuxMr rig. 3.94 ©9698 Kick “any! construction Kict start-r ratchet Kick starter spindl- Kick start-r pinion Kick Han-t rataot twine 13;?“ Conpomrrt Dori: ot kick stertar Kick start-r splhdll Kick rtarter ptrrien Washer temm circitp Kick starter ratchet spring Kick “all! ruichni 22.5mm circlrip a. ENGINE (Nate) Alter lhe kick starter spring has been in- stalled, check the kick starter return lor smooth operation. (Fig. 3.96) Fig. we @ Kick rrerier spindle i7. Carburetor A. Construction a! carburetor I. The air taken in from the air cleaner enters the inlet side III of the carburetor asa main air (law, passes Under the throttle valve (6) and then leave the carburetot through passage [8) to be taken into the engine This tlow al air creates a negative pressure around the needle iel (4t and causes the teat in the float chamber (2) to be drawn up through the main iet [101, the needle is! holder (3) where it is mixed with the air that is taken in at air let (5) and enters through the air bleegwholes l9) lacatea around lhe needle iel holder lét, and is then discharged between the needle iet (4i and jet needle I7l.located directly below the throttle valve (6). The discharged fuel is mixed with the main air flow and alomixed belae being taken into the eng'ln:/ In addition, to regulate the luel xture at small .-x throttle opening, the air taken in from carburetor inlet [it passes by the opening l12I oi the air screw (ill. where it is regulated by the air screw Illl, enters the slow iet list by the way of the bleed hole, and lhen is mixed with ”‘9 fuel discharged From the hole loculed under the three ttle valve to produce a rich fuel mixture. This discharged fuel mixture is mixed with the main inlet air (law and laksn into the engine. The fuel mixture adiustrnent oi the slow iet system is made by regulating the air screw Illl. Turning the air screw clockwise will produce fig. :4. 97 Carbine“)! a rich mixture, Turning the air screw counters clockwise will produce a thin mixiute.(Figi3.97, 3. 9B) l7. allusion 4a @ -\ 9 \\\\ \\\\ t i 'H Fig. 3.” Crossimrionel vluw el mew-tar 2. Float Chambev The carburelov produces luel mixture which is suited to the throttle opening md engine speed. However, for that pulpose, it is necessary to keep luel level constatt in the caburetoc This Is perfumed by the float chamber, The fuel iron the fuel tank passes through the passage "0, between valve seat (15] md the vulva llél. aid El then enters the float chamber l2t. The "out @ @fl (9 e a” tl7l becomes buoyant as luel enters. raises the Float valve llél lunged at the lloat am end which seats the float valve into the valve seat to Fi a.” cm“ stop the (low 0! the fuel. when fuel in the float chamber is consumed and the luel level drops, the float H7), is lowered along with the fuel level. Clearance between the-valve (l6) md the valve seat ”5), allows luel to enter the (loot chamber. By repeating lhis, the level is always maintained constant. A spring is fitted into the section of the valve (l6Lwhich contacts the float arm llB), md pmvents the valve lrom oscillating. When the vehicle is on a grade or when dirt “ is lodged between the valve and seat. gasoline will over [low and eats! the cylinder. There- toro, tor pveventing the tuel to rise above a certain level. an overflow line is installed. (Flu. 3.98) ENGINE ,; HI. 3.100 Main in Fig. 3. I02 Needle .: a. cut: When an engine is cold or the temperature is low during starting, a rich luel mixture is torn- potarily required. This can be had by the use of the choke. When the choke lever is pulled up, thn choke (20) is lully closed. The opening [’23l is normally closed by the reliel valve [2“, however, during starting when the throttle ts opened approximately 1/4 and the kick starter operated, the negative pressure created in the cylinder will cause the reliet valve (21) to open by the proper amount [dotted section 2M and permit air to pass through the carburetor; this flow at air draws the luel out at the needle iet (Al to provide at ciretuel mixture ideal lot stating. Alter the engine starts, the intake nego» rive pressure increases, and causes the reliel valve an to open correspondingly wider to assure a suitable mixture. Thus, the opening at the reliet valve i2lt changes according to the opening at the throttle valve (6|, section l25l. (Fig. 3.99) a. Funulom of each component 1. Main Jet Its main purpose is to obtain a proper tuel mixture ratio by controlling the how at luel when the throttle ts tully opened (operating at the maximum speedl. However, the fuel ratio is influenced down to around one halt throttle opening. (Fig. 3.100) 2. Air iet To prevent the mixed gas from becoming rich at high speed, and lean at low speed, air is led to the needle is! holder, The lunction ol the air |et is to control the amount of air. At a constmt throttle opening, the larger the air let. the smaller will be the dilletence in tuel flow between high and low speeds. and a consequent reduction in luel now. (Fig. 3.10” a. Needle iet ’ The needle iet controls the tuel which had b3pnetered by the main ietl between the In termediats and lull throttle. The control is per- lanned by varying the clearance between the needle jet and let needle described in the tollowing section. Hole in tha needle iet is made with high degree at precision to assure accurate tuel control. (Fig. 3.l02) CARMHOR 45 4. Jet needle The iet needle, in conimction with the above mentioned needle iet. controls the fuel mixture ratio at intermediate throttle opening trnoinly between 1/4 and um. The long tapered jet needle is fitted in the center hole of the throttle valve with the tapered and inserted into the needle iet. The vertical movement of the throttle valve correspondingly moves the tapered iet needle within the needle ist, varying the clearance between the needle and the iet, aid in this way. the proper tuel mixture is obtained in reference to the position of the throttle valve, There are live cllp groove positiom an the hood oi the iet needle. The luel mixture becomes richer as the clip is moved from the first groove (tap) toward the filth groove (Fig. 3.103) 5. Throttle valve The throttle valve regulates the amount of air taken into the engine, this essentially controls the engine speed as well as the power output, in addition. the throttle valve performs other impor» tant control lunctions. The skirt at the throttle valve is cut at an angle on the inlet side : the size at this cutaway is designated by the cutaway nunber which is described in succeeding section F, 2. By chatging the valve with a difierenl size cutaway, the negative pressure in the victntity oi the needle tel is charged, afiscting the lust flow and con- sequently changing the tuel mixture ratio. This change is efiecttve in the slow speed range between idling and U4 throttle opening and has no efiect above l/2 throttle opening, 6. Slow iet The slow iet meters the flow at the tuel at idling and in the slow speed range, and corsets the fuel to be atomized by mixing it with the air taken in from the air bleed holes, (Fig. 354) 7. Air screw The art screw regulates the amount of air entering the slow iet system. The air which passes by the air screw mixes with the lite! trotn the slow iet and is discharged in the proper mixture. prodtcing a spray to asstst vaporization. (D Fashioning etip Q) iet needl- 3. ENGINE Fig. not Ma... in ® Muln [at C. Adiustment in order for the carturetor to produce the maximum perlormonoe at the engine‘s capability it must be Odllls’ad so that a proper luel mixture is available over the complete speed range from idling to the mxtlmm speed and lurther, be able to maintain thls condition. This carburetor has been designed and mmlactured to satisiy these conditm by the precision mamlocture ol the components and specially in the use at superior quality wear resistant materials. Tile iel needle, needle iet. throttle valve and the float valve being susceptible to wow, have been made at mterials possessing good wearing durocteristics, precisionly mtactured and Wicca treated to give extended satislactary service without change to pertorrrtance. The odiusttmnts ore ocmutaly made and per- tnrmmce checked by both the mtectmer and lactory patsomei to assure that the setting at the vaious puts me precise. Therefore, when making any odlustments. performing engine repair or replacing warn puts. give particula attention to the iollatwitg points, ® Make sure that the eruine is adiusted in accombnoa with the specifications. © Check to see that there we no air leaks at the carburetor mounting flange. © When the controlling carpanents become worn, replace with new parts. D. Adinstment at high weed The control of the fuel mixture between l/2 throttle and lull throttle opening is the tunctiorl of the main iet. (Fig. “04) The determination at the [net mixture ratio is made by the laltawing method. I. At full throttle it the engine speed increases when the choke is slifiltly closed. it is an inflection at lean mixture. Prayesslvely rep lace the main jet and note the pertarnlance. [main iets are matured in seq-lame of 5). l7. CAR-mack 47 2. If the engine speed drops when the choke is slightly closed, it indicates that the main jet is either at the proper size or that it may be too large, in which case. perlorm the lallewing check to make the determination. lol ll the main iet had been at a proper Size, the engine speed will drop when the main iet is replaced with one of a smaller size and the speed will increase it the choke is slightly closed. in such case. the original iet was of the proper , size and therelere should be retretelled. fin» 3-‘05 1" W”- W"- W'" (bl li the main iet had been too large, replace 3 iuofzzd'v'um the main iet in sequence with that al a smaller size until the condition in (at above is found and then reinstall the proper size iet. E. Adiultment at intermediate speed The luel mixture adjustment in the intermediate speed range between US and 1/2 throttle opening is made by relocating the iet needle pestioning clip and replacing the throttle valve with that al a difietent size cutaway. However, changing the throttle valve will also efiect the operating con— dition below the speed range ol i/B tlvoltle opening, therelore, it is very diflicult to adiust for intermediate speed by replacement at the throttle valve only. It is recomvended that the adiustment tor the intermediate speed be made by the iet needle and stay within the range of acceptable accelerating performance since this would make a tuel consumption much Iowan (Fig. 105) I, Jet needle to) Block smoke emitted lrorn the exhaust gas at intermediate speed is an indication ol too rich ct fuel mixture. which is corrected by odiusting the let needle to a lower position. [bl Flat spot [similar to engine missingl during acceleration or at intermediate speed indicates that the fuel mixture is too teart and is oonected by adiusting the iet needle to a higher position. 2, Throttle Valve lcutawayl The throttle valve is numbered so that the larger the stormed number size. the leaner the fuel mixhrre will be When dtanging the throttle Valve, it tmst be considered that slow speed will be afiected as well 3 the intermediate speed. 46 a. ENGINE Fifi. 3.!06 throttle valve. arr screw (D ® thotll- valve Alr xctnw Fig. 3. IN Measurement a! test tent in lh. noer chamber @ @ rloet am Float (ml standard mrloco Ft Adiustment at slow speed The adjustment of the luel mixture between 1/8 throttle opening and idling is made by the air screw and the cutaway of throttle valve. (Fig. moo) ’ I. Air screw The luel mixture adiustment at idling speed is made by the air screw. Turning the screw in the clockwise dlrectlon will produce a rich mixture; o lean mixture can be had by turning the screw in the counterclockwise direction. However, the idle screw ls not only to odiust the idling since attention should also be given to the transition period from idling to throttle opening, in other words. the tool mixture to provide the smooth operation at the point where throttle is opened slightly beyond the idle speed. 2. Cutaway ol the throttle valve There may be times when the air screw will not be able to provide proper luel mixture in the vicintity oi 1/3 throttle opening. Under such a condition, the throttle valve is to be replaced. When the mixture is too rich. change the throttle valve lor one with a larger reunber. ed size cutaway and in case al too lea: a mixture, use one with at smaller numbered cut- away and then readiust the air screw. G. Adiuning the fuel level Since it is difficult to measure the actual height ol the luel level, the measurement at the height of the float valve is made which will correspond to the height ol the luel. Float measuring method (at Tap the float lightly lrorn Ielt ta right with the finger and locate the position where the tip ol the float valve iust barely comes in conlocl with or a cloaonce of 0.lmm [0.004 in! exist between the float arm. (bl in this position, the distance between the base of the float and the carburetor body @ should rrteustlre 21.0 mm [0.827 inl. ll odlustrnent required, carefully bend the float arm by the proper amount.(Fig.3. 107) t7. CMWIEVOR 49 (CAUYION) A spring is incorpomted in the base of the float valve, therelore, i! the float arm is pres- sea against the valve] the spring will be com- pressed into the valve and true indication wilt not be obtained. Cereiul observation must b: made to accurately detect the point at contact between the float arm and the float vatve. 55 50 carburetor setting table Modot curb‘ttalov type 55 so tooo-tsz—Doot sum walk 5: so A 1mm. born 15¢ mow mt thlun born 3 Main int :50 E Alt m : too Main ait blud A». 0.59“ mom lttl IV A5: ‘ ~ A5: D sfi < 2 t 5 . A5. a 523x 2 ,‘ é ~ Aai 0.5:tx 2 i g «m a Act It d1. mill—3 nag. Cut-awcy tmrorit. “.5 volvll Slow m :35 Slow all bleed in. 0,9,5“ <0 0355 w ~ ; AB: 0 9¢x 2 ~ t ~ 1 AB: 0 9a x 2 ~ > Alt Icy-w I 1 l/B ' yum flul mas (0 ans ml mt tmt 2t 0:0,5 (actual tit-I height» tun: .ntw mt 4. FRAME 1‘ Steering Handle The handle IS held In place by lhe handle pipe upper and lhe Iowa: holders, and mourned lo mo imk (op blidge plate. The complete assembly m lum ls moomed on Me from cushlon mm from ioykbolls. (Fig. 4,!) A. Dimmmbly (I) The Iron! bmks cable IS dlscomecved cl lhe broke arm by holding me arm m we broklng altitude and loosening the cable odlusllng nut. (Fig. 4‘ 2) l2) The clulch cable is dlscoflnecled at me clulch lever. (Fig. A. 3) sl Fig. 5.2 Removing hon! mks =nble (17 From bunk- mm @ from tuck- mm (2: Adwsllng nul ngv 4.3 Rumovinw :lulch cahl- ® Clulch :ahla ® Cum ”lam. arm 52 4 FRAME (3| Disconnecv vhe Ihrome cable by unscrewing Ihe curburevor cup and drawing out me Ihronla valve hem which !he cable and can be dis- connecred (Fig 4.4) Fig. 4.; Removmg Wonk- mm. (D 1mm: cable (a) Cable 2nd {2) 1mm. valve w Remove lhe 6x25 screws and detach «he hocdhghl case and men drscomecr me lamp mil lrom the wwre homes a: the conneclovx [Fig‘ 4‘ 5) Fig. 4.5 Drszonnachng Macmm‘ \eud an Elatmcal lead: [5) loosen me (out a x 28 hex bells and remove 1h: handle pvpe upper holder and than Ismove lhe sleenng bandie plpe and lbs connecling wwes and cables as a complete mm. (Fig. 4.6] Fig. 4.5 Rumevmg hand‘c m. (9 Hum. ha. (2) From mu tabla Q) cum mu, (6! Disconnect the brake and clulch cables heat the handle lever by first removing the levers lrom the handle at the pivot screw, ( 4. 7) (71 To remove lbs throttle cable. unscrew the two 5 x 2:5 screws and disassemble the dlm'nel switch assembly followed by lemovlng llte throttle grip ptpe. Unhook the ttvottle cable end from the throttle cable hinge, (Fig. 4.8) l8) Remove the lork top bridge plate by unscrew» mg the two ltont fork bolts and the steering stem nut. (Fig. 4.9) l9l Unscrew the two l0mm handle pipe mder holder attaching nuts to remove the handle cushion upper and lower tubberl and the handle cushion seat from the too bridge plate. a. inspection tlt Inspect the cables and housings al the Witch tle cable, clutch cable and txcke cable lot any damages such as troyed. broken, or kinked wires or broken cable houstng and also tor any lalsa blndlng condtion Apply grease to the cable belote assemblying into the housing. I?) Check to make sure that the throttle grip pipe operates smoothly. l3t Check tor the proper movement ol the handle lever. l4) lnspecl the handle pipe lot twist, bends. dents, or other damages. (5) Check the respective switches lot proper operation and inspect the lead wires lat Seculr ity at the lermlnals and the condition of the wire covering. Ci Reossembly tit Assemb‘e the handle plpe under holder. the upper and under cushion rubber, and the cushion seat to the top bridge plcle with the lOmm mounting nuts (2) Mount the top bridge plate to the lronl lork with the two lront fork bolts and the steering stem nut.and Ilglhten to the proper lorqoe. Standard lightening torque Flatt! tort bolt IOO~45019 ctr. [25 9~34 7 ILIbl Slaettng stern nu! wo~7uutrg.crrr u: {~50}: tr. lhl SYEERING HANDlE 53 fig. 1.7 Remaving tandl. lava: 6) Handle lever © Cabta and Fig. 4.3 Removing thtollln cable (I) throttle cael. (2: Vhtollle cable hingl (a) own: cable rhrorrt. holder (3) Handle bot lub- Fig. 4.9 Removing tort lap bridge plale 6, 77mm star. nut Lhandle box wrench @ Slaelmg slam nut (3} Front lotk bolls © tort top bridal! 5, r fRAME (31 Apply grease to the throttle cable hinge, in. ternal suttace of the throttle grip pipe which comes in contact with the hinge, and the in- ternal surloce at the throttle grip pipe belare assemblying the parts to the handle pipe. [41 Connect the clutch and the front brake cables to the respective handle levers and make sure that they are operating pvope'lyl (5] Route the cables through the proper passages and clamp the handle pipe between the upper and lower holders and tighten with the tour 6 x 28 hex bolls. Fig.1.I0 lhsrarlrrrg ltitaltla gltp (it Throttle gllp (it thrertle cahle htngt; (Note) I3“ ”We came Position the handle pipe so that knurled sec. u Oulet thrertle cable halrler . . . . tron at the pipe ts centrally located tn the holders. Torque ta 85~95 kg—cm l6.2~é,9lt-lbsl tel Connect the lower end ol the brake cable on the trout brake arm and odtust the cable ta the ptopet ploy, lo~20rhrrr (0t4~0t5ml (Fig A. III l7) Slide lhe lhrotlle cable through the carbu- retor cap and fit the cable end to the throttle valve Insert the valve into the carburetor body and screw on the carburetor cap lollawed by adrustrng the throttle cable to the proper rig, Alll Front wheat bralc :ot’a lclnilallud play. IL Flott bl t rm in W, mg; jaw“ M [St Connect the clutch cable to the clutch lever (a; trert brute cable and oditrst the cable to the proper play. The clutch cable adiustrrtent is made at the adruster Incorporated tn the cable houstng. (Fig. 4. l2) l9t Connect the headlight lamp to the wire har. ness connectors and alter poslllonl'tg into the headlight case. install the headlight assembly wrlh 6x25 screw. (Note) After complellng the installation, swtng the handle lull to the tlghl and left to make sure that there is sufficient slack in the wires, that wues are no! being pulled, or that the wires rte 4.12 Aarvsrrng clutch are not binding or pinched. (1 Clutch cable (2, loclr taut L32 Adtuxter 2. Front Cushion Conslruciion The from cushion and he V90! cushion cunnoi be lhoughl as being lndependenl when considar- mg lhem hem me lunciioncl sicmdponi This shock absorbing Chumcteristlc prcvldes suieiy is me Sleerlng and slubllliy io ihe riding, The Ironi fork in pcr'lculcl, absorb: and dampen: ihe vevr iicol shock of lhe from wheel and In uddilion, ii suppovls lhs dynamic load ol me lion: wheel and Conllols and sleevs lhe from wheel. The honi cushion spring ulillzes a lwo siege spllng. The bollom case conlains 105:: I6 43 cuirl] 0' oil, lhe slroke is 100~57.3mml3.94 ~2.26inl (Figl 4.13) A. Disanembly lll Remove lhe handle lop bridge plale us desr cribod in section Al A [2| Unscrew me speadomelev cable coupling ml! and disconnecl lhs cable hom lhe spam molar mm and unscrew ihe lwo 8x22 hex balls to remove me neodllgm assembly l3i Sec ihe engine up on a block lo YGISG me honl wheel of? lhe ngnd and lhen loom me from uxlo nui lollowed by pulllng oul me axle. The wheel will crop away 'IOM lho lork and may be removed Ml Unscrew me two 6x l2 hex bolls on bolh sides ullochlng the lendei lo ihe lroni cushions. (Fig. 4. l4) (5) Pull ofl bolh me righl and left “on! 007i Upper covevs (Fig. A. 15) from CUSHlON a e o@@@e@@®' hem hem hem hon. hour hm hm hem 55 .le ”WW? ' Componam poll: ei [mm (‘13th lm bollom w:- lovk .ie paclmg lovlz covet mi lei upper elm. :uxhlon xpving :ushlnn Xplmg wide lovll plpe lovl bonen pip. Fig. 4. u quleu hon! mm: 6) BXIme h.“ boll Fig. A. ls Removing was: com (D Eleni [elk upper (our 5!: Fig, A. l6 Removing irorn Vovk (i) val iori axxembly Flu. ¢. I7 Dvaimna oil (D 6X6mln m boll fig. 4.1M Meoxunnq xprrrrg‘ianrron (D Spring m... ® SWW (6) Remove ihe iwo 8x32 hex bolts aimching Ihe Iron: cushion Io lhs from fork bonom bridge and draw out ihe Iron! cushion Iowavd the bonom. (Fig. 4. l6) (Note) Piece 0 mark on the from cushion beiore disuss'mib’y, ihrs Will iaciiriare msiallrng me cushions back io Ihe origimi posinon. [7) Before disassembiying lhe from cushion, drain me orl wiihin lhe lroni iork pipe by iemoving ihe drain boll oi the honour of lhe cushion. (Fig. 4‘17) The irony cushion spiing and me spring guide can be removed by disassembiying ihe from York rib, ironv lovk nb packing and the hon! iork unde: cover. (8) By removing ihe bollom case cover and Ma 35 mm rrrierrral crrclrp, me ironi iork pislon can be removed hem the hon! (ark case. a. impeuiorr ll] Measure Ihs lion! cushion spring. (4, 18A] Slandmd vuim ‘ Scrvrclahlo iirnrrs unwise...” i 439.6 "3/1.?! mi 5U.7lg/IDL2mm Iiii Slbll i 'n! Rlplacl .1 War I6! mm i7 iiirii Evplacl .1 over ‘0 My.» 19L3mm i7.ssrrri Viv-nus 1 Pao' [2| From lork pislon dimension Ouisrde drameier 70.040 Slandard value—>29mm _ >073 70mm. ("H —o,uoso'") (3) From io:k boilom case made diameter - Slandcrd value—>29 mm faggg (w taggiarni (4i Froni fork pision lo bonom cuss ciaarance. (Fig. 4. I3 B) Svmdurd value —» 0.04~0.'| 06 mm (0.0016~0.004 in} [5) From cushion dampening force in lag/0.5 m/sec (22 ibs/i 9‘7 in/seci a. REA! CUSHION 57 0.01— 0. I06 (000! b~0.00425n) Fig. LII! Ci.erurru.=erripon-hi pails el irorri iori C. Reassembly ill Clean all the pans thorougily before assembly at Perform the assembly in ihe reverse order oi disassembly. 3. Rear Cushion The rear cushion connects the lrame wilh lhe rear fork and absorbs the shock from ihe tear wheel The coil spring having two orHereni pilches is "2- 4- W Comm-"l w” 0' m" Milo" . . ® Roar cushion upper loclirig rm housed wtihiri the metal lower case and ihe mgr @ m. mm" “09W Wm stength hlzex plastic, upper case absorbs ilte (,3 swing We. ioed of the heavy cargo cairied on the luggage 3 5mm can > _ aoiierri mic! rock, The hydiuulic damper which dampen: the © WW W mm mm recoilng extension loree contains 17 cc ll, 04 ® Umr m. cu. ml 0! 3360 white spindle Oll. (Fig. 4. I9) © 24...... wan-t ® loci comm spring Rear cushion slicks: $3.6mm (262ml A. Disassembly ill The van! cushion can be removed as an assembly by unscrewing ihe upper and lower blind nuts. (2) The rear cushion is disassembled by using the rear cushion dmssembly root, (Fig. 4‘ 20) Fig, 1,20 Eamon/w rear :vxhlon Q) Rout cushloti dixuss-mbly reei ® Rear cushion assembly rig. 4.2| Mamet operation at the Spring 61 Rent :ttxhton Hg. 4.22 Sineting mm mnenet diogtum H... 4.2: Remuvtng stmng head is; intend (t; 36mm hook spanner @ srunng me top thread 5. Inspection 11: Rent cushtoh dampening torcs 25: 3kg/O.5 m/sec 6516.6 lbs/19.7in/sec) (21 Rear coshion spttng i Item 5mm vtceubh )tm tau tengrn ‘ mm mm $15)") 5 mg rennei In mm/tékg new 01 Icplcca ‘ i75m/35.Zibl ‘tl \mdut Homm' ”>2 mat/65 kg mug in . m/ua ml is sum/254 rm ”T ti nvnt It Venus: ‘ x 1’30' \ C, Rec-assembly (Note) Atrar completing the reassembly of the cush~ 10", compress the cushion by hand to make sure that there are no binding. (Fig. 4.2” 4. Steering Stem Construction The steering stem supports both the right and Ielt front cushions and serves as the pivot ’01 the home heed pipe. included are the cone races on whtch the bolls rotate to prowde easy steering A port 0' the handle )ock ‘ts also but" into the tort bottom bridge. (Fig. A. 22) A. Dixcssembly l1) Disassemble the iork top budge in accord- ance with section 4. I A. l2] Disassemble this Iron! cushion in accordance with section 4. 2A. (3| Loosen the steering head top thread thh the 36mm spanner and remove the steering stern untl horn the bottom. iFig. 4.23) (Caution) When removing the steering stem, exercise care so that the sleet balls do not drop out. (Fig. 4.24) 5. Inspection (ll lnspecr lhe 2| steel balls (or damages and wear (Fig. 4. 25) [2) lrispecl me sleeving lop and honour cone race bealing surface lor damages and wears. l3) lnspecl S'Bsrlng head dusr seal for wear and damage. (41 Check the sleev'ing srem for rwisi and bends. c. Reassembly ii) Clean vlie steel balls and alior mixing wnh grease, lay inro me cone race lnsevl me sreering stem In (ram me borrom side, insloll lhe lop cone race over lhe sieering stem and ihen screw on and lighlen lhe steering head lop thread. (Note) ll lye sreering head roe rhread is iarqued loo iigm, excessive load will be imposed on lhe bulls and WI" cause the handle lo mm hard. Alrei Iarqurng, make Sure mar vhs handle moves lreely lrom rrgrl lo leli and when lhe handlers checked for loosenoss In "as vemcal, lore and all. and SlderSE direction, vhere should be no slack. (2) Assemble me lop bridge, lrani cushion, the from wheel and me steering handle (2i Connocl all We conlrol cables and make lhe proper odiuslmenl 5. Fuel Tank Connrudion The Fuel leak is lnsvalled on Ilia lrame body above me engine Ir is held in piece wilh lvel lank hem and rear cushions, and me Iuel rank spacer lo rsoiave any vrbralion from rlre frame The lonk copocl'y is 7.0 In (12.3 Imp. an 145 user), sufi‘rciem :0 allow long irips wilhoul Ie~ rueiing Furlher, me fuel rank is equipped wilh e knee grip pad 90 provide safer riding and a better coordinaled body comrel. (Fig. 4, 26) FUEL iANK 59 m. «24 Remavmg fleeing me Q Sisaling Hum Fig, 4.25 Sreei balls in piece in rm (0 5i... sari (P, lmm~2mm l0 BAND DB ml Fig 4.25 Flu! lank unambly (y m: Iank so Fm. 4,29 (U (27 ha. 4.27 {i 1; Removmg m mu 5m 6x13 hex non Romovmg mm hm wank Sea) New um Fm rm Ccvu (am. A FRAME A. Dismsembly (I) Remove me )wo 6X13 hex seav mounv'mg bolts and shde of? Vhe sea! (Fig‘ 4‘ 27~28l [2) Se! me flue} cock vo We “5" posuion no luvn off me fuel flow, unach a hose clip to me cock Side of Ihe rue! level mbe and remove me Lem :ube and also lhe mew vube hom lhe (ue‘ cock, 43y Pull Vhe we! mnk away (mm m; tank may cushon by ccvc‘tu vmsmg me back ol the me! wank. (4! To remove We luel tank cover, “'5' remove the two scmws munching ma emblem to me cover and Men Unscrew the 6x10 hex bou cuochmg (he covey lo (he (uel tank. The fuel lonk cover can now be vemoved by shdmg the cove: lotword. (Fig, 4. 2v) t5t The iuet cock is iemeved hem the tank by first unsaewmg the strains. bowl, removing the "O" ring. the strains: screen and then the 6X16 Cross screw. (Fig. 4.30) is, Inipeciion llt Inspect the tank tar fuel leak. at Check to see that the iuel filler cap vcnt hole is not clogged. (Fig. 4. 3|) (3: inspect the fuel tank ltoni and rear cushions and spacers tot defamation and damages. i4) Inspect the iuel cock body, packing and screen tot damage at defamation. i5t inspect the lust tubes to. aging and damage. c. Reassembly lll install the luei cock assembly to the tank. (Fig, 4. 32) [2] lnsluli the tank cover. (Note) The teat oi the tank cover is hooked to the backs! on the tank body and held in place with the 6X IO hex bolt undet the emblem. thetelore the bolt should be at the specified size and, lype to obtain the tummy fit 0! the side cover to the tank. A bolt the! is too long may pmclute the tank when tightened and cause ct fuel leak. (3) Install the from and rear cushion lo the frame body, attach the spacers lo the tuel tank and install the fuel tank to the frame from the '80! and sliding lorwatd so that it fils’on the tank tear cushion. (Note) When installing the tank, make sure that the wires are pvopetly routed and that the tank does not become scratched or matted. t4) install bath the fuel tubes. l5l Mount the seat and install the two -5x 13 hex bolts. 5 run TANK Fig. LJO ksmaying tuei (och assembly (D Fuel tank (3 Fuel sock axxembly @ ® Ne :t TJmnd‘o saw any." Fig. L3! Full tank cap cross Section 433222 r... as: Component pun} oi luel cost assembly (i), met (on body (2) 5m” 3 '0' W q; ciass mm (5) © Washet Bowl e2 6. Frame Body The lrome is the backbone ol lhe motorcycle and mounts the engine, and it comes tn contact thh the robe surloce lhtough the rear cushions. Funhet H is the very important loctor m deler- mtmrtg the rrtoiorcycte slyltng The mosl important 'Unc'lofl ol the lrome l5 provudtrlg the necessary strength to the entire molovcycle. It supports the engine, the ridev, cargo and through the ttres end cushlon. must rrg 4.1: rm. My wulhsland the shocks produced by lravelltng over » tough road. Further, lrom the stondpotnt of steer- tng, high 69969 at rigidity is required. On the other hand, lightness ts desued tor riding pet- lovrnance. The T-borte design ultltzed in thrs home provtdes htgt strength at e mtnlmum weight and also givesc pleosmg stytmg, ( , A. 33) A. Disouembly llt Remove the engine by telerrmg to section 3. A, (Z Remove the Sleerlng handle by lefemng to seclton 4.1.A. Fig. 4.34 Removing combination xwtlch (I) Combmaltovt swtlch :3: Remove the from cushion by referring sec- {2) Main xwrlch hoo'l Spanner “on to 4.2. A. (4) Remove the lront wheel by referring Secllorl to LILA. (5) Remove lhe Iuel tank by reterrmg lo sectietr‘ 4.5. A. (6) Remove the rear wheel by referring to sec» hon 4. )2. A. l7] Remove the rear cushion by referring to see tton 4.3. A. ,_ (8] Remove the rear lork and lender by reler- ring to section 4. 10. A. l9t Remove the air cleaner by relerring to sec- Eemovihg selenium tlcllfiet ”m 4' 7' A' @ Selerttum tecllfial (10! Remove the main stand by relerring to sec- @ Flume body tion 4.8. A. (I ll Remove the Comblmllon swrtch lrom the left center 0! the home with the mum switch hook spannen (Fig. 4.34) «3.9V e FRAME now .43 112p Remove ma Saiemum recnficr (Fig, 4.35), A c igmnon con (Flg. 4.36), wve harness, 1 mp swuch assembly (Fig. 4.37), from me home body. n; 4.25 Removing Igmnon (ad { A C \gmlion can (2) Am um: um a m. 4.17 Elmovmg mp xwuch assembly m Slop mm nxxemh‘y 12» mm lacy 1 (13: Romova Ihs sveev balls and dyive om lhe ' bull vucas horn Insxde vhe svaenng head pipe wnh a wooden or fiber duh. (Fig. 4. as) 459 fig, 4,33 Romovmg be“ vac. @ Ham: Hammer (2,- Sch duh Q} nan. mm m u A FRAME B‘ Inspecllon ll) Inspccl me (fleas around lho home la 5(2va volion, buckling around we head pp: and 0"“)! damages I21 lnspccl me angle 0' We head pipe and lay dmomon l3) lnspea me top and honor“ pull races lo. gall‘mg. wear and damage (Nave) The m between me bal! races and We head plpe ls *0 005~+K1003 mm I70V0003~ 7w A. :9 lwallmg hall lace 0 00m lnl. however, we .pces can be lemoved S If“: 7W" by lnserllng 0 wooden 04 fiber mm mm me 1; .ol m (y Frame head pupa read plpc and lapping gemly, When dnving cu! lhc ball luce‘ make sure lhal lhey are drlven om amlmmly (Fig. 4‘ 39) (Ill lnspecl me home 101 buckles. damages and who condmon oi me palm C. Reonembly Ill Mlx me sleel bolls .n grease and lay lhe 21 balls imo lhe lap and me bollom ball laces l2l lnslqll lhe respecllva elecnlcol eqmpmenl ln lhe levers. order or dlsassombly. Fig. LIOA Double seal «WV-piers 7 $90? and Aif Cleaner (D Dcubln my commu- The double sea! I: lnslalled on the ham W:lh lwo 8mm bolls. he an alarm elemenl .5 con» lalned wumn lhe (lame undel me see). Seal ls padded mm loam rubber sponge and covered wwh good gods alllflclcl lealhev. The seal is naked cl me 7801 lo plevenl me body hom slld. mg durlng accelerollon ov sudden slam. (Fig. 4. 40 A, 440 s) mg 1.409 Ail dummy .lmm Q7 A” (Ina/lav .lmm .,A._____.., . 7. SEN AND AIR CLEANER A; A, Disassembly {11 Remove ms Iwo 8X ‘3 sea! onocnng was and shde me sea! ofl lo me rear (Fig. 4. 27) (21 The rubbev strap )0 hold Vhe an dean?! elemenl m p‘clce >5 \ocaved under vhe sea: Remove mas strap and unscrew me érrm hex Ml attaching the on cleaner e‘enem anj :e’ move me on deans: covet (Fig. 4.4), 42) 43) The air cleaner elemem can be dlscssew‘blei aim Sepomhng the doom! mm mm and m: sflcncev. (41 The consnucnon of rho sflencav .s as shown m Fig. 4.43. s, Inspecvicn [I] \nspecv lhe lecvhs: covering oi Ihe sec! [04 may or olher damages (2] \nspect lhe hmge and rubber io. dumgo uni buckhng. l3! Inspec' Me alr cleaner '01 damage and dean. hness. m. «u Av downer (n An c‘aonal covey (2; mm mp fig 1.12 Ar: mam mm. Q) A” dunner a‘omenl cover ® A" dunner mum Fig. 4, u Nance: Q) some, g; v.9. @ Flue {up C. Reatsembly (ll Connect We Silencer to )he cliv cleaner inlet and install an cleaner inlet pipe band A to ptsvem Separation, (Fig. 4,44) m Fix the air cleaner COVBV on the air cleanei with the 6mm nut and attach the rubber strap. (3t Reinstoii the sect 8. Stand, Brake Pedal The mom stand is constructed of pipe, bent IL) in; LIA ‘mlqllmg m. an". eiamanl the pYOpeI shape to: ngidity Feet we welded ‘W “WW elmw' plates to pmwde a game: ground contoci 0190 ® S“"“°’ to pievem the sland [tom sinking into the ground Under the weigit of the motovcycte The btakes we the most imponant sataty item on me maimcycte Rec: mike is opeiaied by the ugttt loci wuh the pedal pivoted on the mom stand pivot pipe which actuate: the tear bloke film tnmgti Iha interconnechng bvuka m. The siep be: is unoched to the bottom of the engine with tow a x 22mm hex bolts. (Fig. 4. 45) Fin. A. ‘5 6) Sup bill (a Main mind (9 Mam “and pivot bot: ® Bvuko pedal (9 km brak- lad r-ueuw— ‘ a S‘MND. BRAKE PEDM A7 A, Disassembly uo" m Remove the mFfler. IO [21 Unscrew the [our 8x22 hex bolts and 1e move me slap but l3} Rome me mototcycle and phase a mock unde' vhe englfls and remove ihe bvoke peda‘ spung, mom srund spnng and me syop swifich spnng (Fig. 4. 46] w {man We 3mm cone! pm horn the mom . stand pwol pipe and remove me broke pedo‘. ‘0 (Fig. 4.47) 5‘: ‘1 1 L5. The main stand can be removed by pulling PM! «a: Remwng varrg: w . , 7 Slap swv: spun; J oul me mom svand pwo' plpe. [Fa 4.48) (2/ em“ ”‘0‘ “My d ' a; Mom Hand ””9 by, 4.47 Removwg Dru".- pcdu‘ n, Mum 5mm! my hon r2. mt. mam Fm. 4.43 Nan “and pure! Lo" (I New mud pm Lo! ‘2 mm m M 63 t. ERAME m. 4.»; Mam slond m p-pe cyan mm B. Inspection (I) Inspect the main slond spying free Isngvh 80mm (3.14m). (2) Mam stand pupa Inside diameler Siandcrd value—t 16,9:3'2 0.66570-Dooom [3) Inspect svand, slep buy and Dvoke pedm [or bends +0.0079.) C‘ Reasxembly 111 Clean )he pans vhoroughly and apply grease befove assemblying. {7) N49 the main stand Io me home and slide m vhe mam slond pwo! hon lanowed by )he IHSVOHDHQ" o‘ xhe brake pedal and lock in place my). Ihe 3mm comer pin. (do my [0196! lo lnS‘G“ vhe 17x22 washer under me toner pmy. 131 lnsfiall yhe l2mm hex nu! on me main stand 9W0) boh OppOSIIB ma cone: pin end‘ fly, «so Mama: cum sezhon ngth lor v, l4t Hook the btoke pedal Spttng to the uncle. IED! engtne bolt and hook the stop smlch spttng to the stop swuch assembly. let tt the bloke rod had been temovea, telnstall the make rod and lock wuh a Lamm cottet pm Hook the main slcnd Spftng to the matn stand. [él tnstail the step bat to the bottom al the Engtne wtth tout 8X22 hex halts, t7l tnstall the muffler (Bl Ftnatly, petlotnt the btake odlustment, [Nate] Attet lnslalling the cotter ptnS, make sure that the ends are both spteod upon to prevent the cottet pln ltom wotktng loose and refldelr tng the make to become tnopetattve 9. Mufiler The atesent mater t: a completely welded single untt consltuction which cannot be taken apart The exhaust Yrom the engtne enters the muffler and altet passtng through a sane: at pas- sages whats the notse ls reduced. tt ls exhausted through the dlfluset whete the noise ls lurlhet teduced. A, Dixuuembly llt The mumet can be removed by Ioasentng the two 6mm nuts (tom the exhaust flange at the cyllndsr head, the teat tort pivat bolt nut and than the lower bracket bolt (Fig. A452) at Remove the dlnuset plpe ey Unscrewtng the émem hex bolt at tha and at the muffler. (Fig. 4. 52) 3. Inspection (ll lnspect the mumer lat buckles and damages. Cl Reauembly tll Temporarily tnslclll the mumet and the exhaust |ortl collar to the cyllndel exhaust flange. l2t Install the teat fcxk plvol bolt nut and the lownt btucket hex boll, and then tlghlen the exhaust pipe [Oln' nut. MUFFLER 69 rte. 1.5! Mum.” Q) Exhautt mutttu (2) Mum-t bvockel rte. 4.52 ttmevtag muMnt a) 6mm hex boll, ttange ® lzmn. hex belt, Ila! tett plvet (a) town lstacm bolt. rte. 4.53 Ramovl’tg atttumt plpa fi Exhauxt tnufimt ( A x a tax bolt i} clause: the. 7o Fig. 4.51 n; Rear [anew (1) Few bmka 10¢ch Myth ‘5; Rear [ark pivoi eon mum. (2, m, mx 3‘; when me Hi ' 7‘ IO. Rear Fork K.l‘—NK,',.7.I-'I. . :er-rfl'", The real fork is a swing arm desigt which plvols a! the teat fork pivot boh and tronsmrtts the load to the home through the rear cushions. The rear fork pit/01ml! ts located approxmteiy at me center oi the engine sprocket. theretore, the change in the tension of the chain is not oflected dunng ihe swing of lhe rear iork. [Figi 4‘54) Fig,1.55 Removing may rm A- ”hummuy m Rear lorL m Remove the teat wheel by relemng re sec» (2: 12mm hex nu! Mon 4 12. A. (2) Remove the rear cushion by referring 10 sec Hort 4,3. A. (3) Tl‘e drive chain case can be separated Into the Uppel and rower sections by removing the (our 6X10 hex bolts. (4) Disconnect the drive chain by removing the faint chp. Remove the axle nm, dmw out the real 'ork pivot bolt and the rear iork can be disassembled (Fig. 4.55) ‘ m (51 The raw brake «aqua link can be removed by exfmclmg the 2.0mm cone: pm and me 8mm cusyfe nuv. (Fig. 4.56) s. Inspecfion m \nspec: lhe year fork pivof rubber bushing. (Fig. 4.57) \ Srandcrd vu‘usx \ Samzeahln mm was mummy ,2 1:32,“ [ +ovoa79 ‘(0 "770.0000 "M Imam-m m o.os~o I I0 002~n.uot .m (2) Rear fork pivof ban outside diamefe' 12mm 10.47:") 13] Check ‘0' damaged dvive chain case packing. Replace if necessary. [4) Check fhe pivor rubber bushmg fa damage, Loss of elasnvify due to aglng a: vhe scam. ing fooseness, yepVacs f' necessovy. [5) Check fhe lacy fork fov fwisf 0v defomanon, Replace if beyond lmm [0.04m (6) Chuck fhe war broke lorque Imk k): bend Replace if necessary. c. Reauembly [1) mm" me fear lender vogefhe: wyvh Ihe mu» Iighf to the frame, and conned Ibo we: a' ma conneclor (2| Face m me rear fork pwof vubbev bushing We the ram 'Olk [3) Inslull me veer btoke lovque mk logevhev wifh me Spring, 5mm flu! washer. casHe um and cofler pm (4) Assemb‘e vhe reav fork to me home mm ma rear fak axle, followed by msxaumg me axle um and fmqumg (5) Inslafl the tear cushion. l6) Insfall fhe rear wheel. (7| \nslall the dive chain case. (B) Adjusr the rear bvokes offer on me insyulluA lion have been complered REAR FORK 7| Fig. 4.56 Eemovmg may blah 10'un Imk 6) Ram 10le (i, he: bmlo Vowqw lmlk @ am. came Am (9 20mm coffov pm he. 4. 57 Necxwmg pwo' may buthg a; flea' um (21 my Incl-,1): mm mm, cahpov 72 Fig. 4.59 Component pom cl hon: whnal ll ham whlll only (7) (2, has; all cl (37 at AOOI boll homing (9) a) item axle dtstcnco (allay ® (5} Flam wheel Mb (5) Roll mung @ swamtnn gent on not amt. Shoe :ti Erma mm at. hem btnly mm .ts Ftonl bmle at!!! slllmg nul angle moo xymtq as) Brake null wmhet Fronl bvcle panet (L7, 6x22 m boll All. M! II. Front Wheel lnslctll two sets of ball bearings into lhe brake drum. Assemble the bake poneh speedomtet gear tnto the Olumanm hub. Install the front wheel and axle nut Dunng broking. the panel is pvevemed 5mm tototmg wnh the wheel by the bake panel stoo- pet betng connected to the (vent lork. The wuter and dust is prevenled from enleving the wheel hub by the lncorpOtalion ol the labyrinth in the hub and btctka patel. (Fig. A. 58) At Diwuembly lll Place a suppon block under the engine. (2) Remove the from btoke odiusling nut and disengage the brake cable from the trout brake orm. l3l Disconnect the speedometer cable lrom the . 1:“ an .n. - from bloke panel. l4) Remove the horn wheel axle nul and dIOW om me oxlev lsl The wheel will lep o“ lhe from fork (61 Sepalme llle bloke panel llom llle hub, [Er move me speedometer gem and dlsassemble me bloke mm Ilom llle panel, (Fig 4.59) (7) The bloke shoes are held m place by spllngs. melslole. splecd lhe shoes aparl lo disassemble llom lhe bluke panel (Fig. 4.60) l5l Dlsassemble lha brake com Ilom me from bloke panel [9) Remove lhe oil seal (31455871 from lhe lronl brake panel. llO] Remove lhe side collar and "ls oil seal ($121357) From the Iron: wheel hub (Ill Remove lhe ball bearing l: 600M and llle axle dlslance collal from the from hub. ll?) Remove me lire horn lhe llm wllh lhe me love! and pull om me lube, 8. Inspection lll Check me llm lol bolh velllcal and side lunr om. (Fig. 4.61) ”am l Slandard value; ‘ Sumeubl. llmm 5m “mew Rwaw ll Ml l a ‘ l0.D?B~DD10-nl ‘ lo moml mm “maul 2.9m l m. lo l as max lo.02l1ml l ,0 mu m \ lZl Check lhn Iron! axle la wear and bend llam Slandord valvu 1 Serwcacbla mm Dlumule: " , a 005 ‘0 4 o 050 ‘ 3 42mm, l /o 3?” 00020 m) o 05 max «1 0020 ml Bend Eep'uce ll on. o 2 la cos ml (3| Check me wOl boll beanrlg lov uxlol and ladlal play null ‘ Slandavd valve: [ Selvlcouhle lmm fled-a! play . Replace ll avg! 005 luoozoml 0] “wow, Replace ll am 0.05 lo DDQEnl Axlul my l FRONY WHEEL Fig. A, 57 {D (2) imam: xpe'dmalev gaal Speedomewl gear Flofll blah poll-l Fig. 4. on Q7 (2) (a) Fig. 1.6] ® ® Eumovmg blan- shoe Blah moo slate cam Blule shoe spllng meng wheel m ml Dl'ul new. Wheel he La! (i Q, Menu/ting Yvonl qnlu meet Ciu‘ gauge Iron cute v e ocl . i meetmg met tut: mime riaxm hum/net Beutmg teat MI Check brake shoe spt'tng. mm “ Standard va‘ues ‘ Setviceuble mm Frzte iength 25 7 [I 124 ml ‘ [51 Check lhe btcke shoes, hem t Slandmd valve: I Setvxclcbla itrmu Ouistda “mew toz u 02w ‘ timg thtzlnexx ‘ no [0 tsamt \ (6) Check the thickness at the trout broke cam Standard vaiue—té mm (0.236 in) Servicectble limits—hkeploca at exeessiveiy wom. deformed 0. damaged. l7) Check the spokes (ct tightness. Retaque any spokes lound loose, 7~21k9- cm ID.5~Y.5 ft ibsl (8| inspect the tube to: tacks by inflating, sub. merge in Waite! and check [or bubbles. (9) Inspect the tire both on the inside and on the outside for damages and tmbedded nails. C, Reassembly ll) Peitomi the ossembty 'tn the teverse Oidcv o! disassembty. (2) install the um bond so that it completeiy Covers the spoke nipple l3) Own a” the aid geese lrom the whee! hub and beating, and vepock with new grease insteii the distance coilur and dViVS in the 96001 beating [Fig 4.63) (4) Apply geese to the shaft ot the bake com and assemble into Vhe broke panel. Assemble both bvake shoes and 'tnstuli the brake sptings. (51 Assembte the speedometer gear into the front bake panel. Install the distance collar and the brake panel on the hub, toliowed by inr setting the axle through the hub and tetque wiih the axis mu. [6) instoii the speedometer cable to the from broke panet. l7] Assemble the from bmke aim to the bake cum shcth connect the brake cobis to the bake aim and odiust the play at the brake ievat wnh the adjuster nut. (Note) Attet instaiiing the brake aim, do not forget to tighten the rocking nut. mus l2 2m wum Am w m (MIA udwmr 6mm flu! wash-I 6mm sprlng “my 6mm hu mu m. who-I m. calla: man on ml 4:013 bull mm»: @@@@G@@® [2. Rear Wheel Flu. 4.64 Component 90va ul "a. whul 50mm (Itelip HMI drivfll wuxlu ha: wmu damper :uvov Rm win-I dump‘v Rm whul hvb Dlsmm (alloy 630: R boll mom-g Bvuh Shot smug ©®®©©©®® The war wheel is conslwclsd similov to the from wheel with ball bearings, casl aluminum wheel hub and brake panel. The rear brake panel is assembled on lhe righl side which includes the bloke shoes and brake Cum. On lhe lefl side ol the hub are inslalled lhe final dlIveu spvockel ald lhe wheel dampec cover held in place by staking and set wilh the cilclip. the', lo pvevenl enny of wave: and dusr mlo lhe hub] labyvinlh are incorpomled in bolh the hub and bake panel. (Fig. 4. c4) ®®®§fl®®®© Rem blah cam ami- shoe in: bid“ penal law b! pungl xlda collar Dnvo mm new" aw wmol am ,- 6x22 hu boll Rear bran nun 7e Fiw, 4.65 Removt‘ng tmt htala tod 6) Pen: broke arm 6‘ Rear brute rod (5 state tortt at". fig, 4.66 Eemovmg rear wheel damper mm 0) 50mm mttp (2‘, rtrtat artwt Splklnl (3) Rear wheel demvel com rte, 1.67 Rear wheel damper CDVGY (D rm. We: damper mm (2) mt wt..,r A. Disassembly ll) Remove the left crankcase cover, disconnect the drtve chem l2) Unscrew the 6 x 10mm hex bolls and remove the churn case. l3l Remove the muffler (Fig. A, 52) (41 Remove the rear brake torque link bolt and separate the torque Irrtk from the bvoke panel. l5] Unscrew the rear brake cdtusttng ml! and dlsconnect the rear brake rod horn the brake arm. (Figr 4‘65) (6) Unscrew the rear axle nut and draw out the axle to remove the chem odtuslor and the 5th collar together (7) Remove the root wheel. lat Pemove lhe 50mm circltp and then remove the final dltven sprocket and damper Covet together as a unit (Fig, 4,66) (97 Remove me wheel damper and the 23 26376 orl seal and then remove the 3630]}? ball beattrtg and rear axle dtslance collar. (lot The brake shoes etc assembled on me brake panel wrth the btuko sprrrtgs, therelors, spread the shoes apart to dtsassemble the brake shoes. Remove the brake cam tram the brake panel (Fig, 4, 60) (I l) Remove the trre and tube ltom the rim wtlh the tire tool. a, Inspeuion ttt Check the rim tor both vetl'tcal and side tunou! (Fig. 4.6” tt.rtr Slendutd value; ‘ Sarttceabt. ttrrrtts Std: Iultov' t o7~l,0 Replocl tt ever to 023~o om trtt t D to 040 trrt t t“ — Vettru‘rl whom 05mm: m 020”" l Tagtessaottwavat (21 Check the rear axle lar wear and bend. \ Hem Standard value: l Servicvable ltmtlx V "l V 7707087 Dtamnlul 127 0 on; ea noose lanaiwon tr.) 1 Roplacl '! ovu 005max (0002 ml 0.2 ”1008.", Bend (31 Check the wear 0! the sprocket. Root dtcmetet Standard value» 155.56i0406mm lttcct lOVO ‘lnd ma ’11‘ tel l2 (Al Check the ball bearing [0! axtal and radial play. Hem [ Slandatd values ‘ Setvrceehle ltmllx Rad-fl’ WV ‘ oos tomzmm l leviacl t' Dvet l at l0 on..." Axlui play ‘Rsniaco it over 1 ans IDJJDtht! l5) Check btuke shoe sptlng. Item ‘ Standard tat Flee length l 28.; ll'l24m' ‘ (6] Check the bmke shoes. llem Standard value: Sewiuabl. llmm Omstde diamelat I02 0 ”,02 inl llrtlttg mm.“ 4.0l0,155ml l l7) Check the thickness of the rear brake corn. Standard value—témm [0.236Inl Setvlcecbls limit->Replacs it excessively wotn. detomtsd on damaged (Bl Check the spokes tor tightness. Retotque any spoke Iound lease {9) inspect the tube (or leak by inflating, sub- merge m water and check tor bubbles. (Ill Inspect the tire both on the inside and on the outside for damages and imbedded nails. c. Raauembly [ll Install the rim band so that it completely covers the spoke nipples. l2t Assemble the tube and tire on the llm by lflnclmg the tube slightly so that ll holds the shape, place inside the tire md liven lnstail the tlte on the rim. (Ceutien) a. Alter the tire has been installed on the rim, innate to approxrmately 1/3 normal pres- sure and then lightly tap the tire all the way around with a mullet to correct any portion at the tube which may be pinched. (Fig, 4. 69) b. The tube valve stem must be pointed radi- cally inward toward the axle, otherwise, air leak may develop REAl WHEEI Fig. 1.63 O) r.“ A." G) (2) ltulalllng we ttep tn. tlap 'npptnfl uh. lite ell elem mth a hammer Plaxltc hammer Roar wheol 77 7a rial 4.70 lmqumg ball beulmg a) Plum hummer (gl Bearmg locl m. 4.7I lnslcllmg may bmla penal (1*, Ram bwlte pawl Q) Racy whaev hub m, 4.72 mm. chum adiuxle: ® Dnve mm adluslar @ 6mm hex nu! (3) Pack lhe rear hub with grease and assemble lhe dlslance collar, and then drlve ln vhs 630T R bull becung, 26376 oil seal and veer whee‘ dampel. (Fig. 4. 70) Ml Assemble lhs bmke cowl lo lhe brake panel, hook me [make shoe spungs lo me shoes and lhen assemble il lo lhe broke panel (Fig. 4. 7|) (5) Assemble me btoke panel lo lhe wheel hub lnslull me lea: wheel lo lhe rear lcxk by as semblymg me chum cdwslor, brake panel side collar, Insert vhe axle mrough me real loll: and wheel hub [61 Assemble lhe chem over Dom spmckals and lom the ends wuh me lolm cllp lollcwed by Ddlusllng lhe anSlOfl and lorqmng me axle nul. (Fig A. 72) (Cannon) a, The chum loin! Cllp ml Io lnslcllod so when me openmg lS cpposne no lhe dlfficllon oi rolcvlon b. The chum lenslon mus! be nude so me? lhe Iighl and lell chum adiusvers are m Ills some locallon valulwe lo lhe may lork Thls can be checked by Ihe allgnmefll marks on borh Ma udluslals and lhe lovk l7] lnsloll the rear bmke lovque Ilnk lo the law bvaks panel. [8) Connecl lbs brake vod lo the ram bmke arm and make vhs odluslmsnl wwh lhe adlusv. ing nul on we end of lhe [Dd so lhcl Me play 0' lbs and ol me bvake pedal Is 2~3cm (0‘80 ~l.2ml. [9) Install the WW. no; Inllole me was lo lhe moper aessuve. nble 1| R tee nat. ml 71) db. is 335 ind :rld :ty 4t. 5. ELECTRIC SYSTEM All models use essentially the sum: basic type electncel system with a vcltylng degree of aillermas The elecluca' Oqupmen‘ and Walt installation depend upon the wmng Circuitry. On the $350, the ignition system ts compuscd al a spectal A. c. generolor with the use al an ignition coil and contact bracket to provide easy sterling. The chaging and supply at the eleclricol system is provided by the combnetion ol bollery and Selenium tectlnet to take cote oi the anchuige load such as the hem, lum signal lights and the neutiel lamp. The lunctian of the elaclticul system can be classified as follows; (It Ignition system [ignition coil. condenser. contact bteaks! and Spolk plugl l2t Generating system (A. C. generolovl l3! Rectiiytng system (selenium rectifier) (4) Ballely (5| Various loads (lights and homt I. Ignition Circuit A. tgaitian system In a gasoline engine. some means of ignition is necessary to twte the comessed fuel-air mixtute at the pioper lime to cause an explosion of the fuel oi! mixture. In the 5550. this is accomplished by the hi9. volloge elecltical spait. Q \_.. H am 0 n :————‘ \ —_._ 7* Male. electrizul (Emporium Igntliovl system components lgmllon coil ® Slalcn mm, (a) Span plug so 5. EiECmC SYSTEM Fit 5" (Emu-cum 0| VQNHOTI €Dil iron can Primary can Sacmdary cotl Secondary winding fishbord (on Socondcly winding uppov Insulolov plai- in..=i.en mid-e cm. Piimmy coil ieinnnat Slcoodnry coil lotmtnnl High ionxion (otd mm cabl- ngh 7.7mm had @©®®@©©@®® Fin. 5.5 lgntitatu can! omlultnn ® ignition con ® A. c. unnatuiov © Bunny 5. lgnilion coil (Fig. 5.3) The igiitian coil is made up a! a ptimury coit which comings oi approximalely 200 to 300 turns at 0,6 mm (024 int enameted copper wire wound over a steel cons, and a secondary coil 0! 10,000 10 20,000 iutns of 0.075 mm [.003 mi enameled copper wire. Coil is cooled with dieleciric matenal and molded in a synthetic cmpoundl and with two exposed terminals. (Fig. 5. 4) Its functions are shown in Fine 5. 5. C. Spark advance: Igiihon timing IS outamaticoiiy advanced with the increase in engine RPM The device which perlorms this 'Unchofl IS the automatic spark advancei. Ii ul‘tlizes the centrifugal force a! a Iomllng mss lo aciuate a cum which cannols the opening oi the beaks: paints, (Fig, 5. 6) The spark odvancen as shown in Fig, 5.7, is held in a fixed posixion, at 0" advance, by a spring. As lhe engine speed incteases, the revol» Vlng weights on ihe advance! moves auiwaid by the cautniugal facei overriding the force 0! ihe spiing to move the mm In the direction to cause an eaiiy tg‘iiliofl. The dotted hne shows the governov wetgils In ihe Iull advancsd position. The spark odvancet stuns to become active at ihe engine speed 01 25001150 RPM and is My advanced )0 15° a. ¢,ooo:§°° RPM. l IGNlTION ClRCUIl al D. Contact breaker ‘0“ a conical breaker is a device whlch perrorrns a no " very rrnparlanr lunclion al inrermprrng rhe prlmoly re . crrcml of lhe rgmrron call or 0! Ihe magnela on 1 corl. ll r5 composed ol the beaker arm, slur 33 :. rrmery and movable palms, primary rerrrnnal. rm 1 spring and oil lelr, all of which are married on .lc j; me base plays. The breaker arm is a larrned ,5_ I sheel melal piece with a bakellle cam follower ; anacned lo one end. Ir rnusI opelule vary ’ lrghrly and, lurlher, in order Io Mlnlrmze Ihe ; rnerria, lhe arm mus! be lighl In wergnr. ‘; Tna poinl requires a slrang Spflng Iension Io rrn i prevenr chollering during lhe collapse al me ch r. prrrrarv cichll, however on me 'arher hand, me Ienslm musr no! be excessively slrong so as lo cause wear of the flichon areas which would Icsull rn change Ia me ignirron liming, The proper breaker pom! rensrorr Is eso~ 5509 ll.4~l 9 lbsl To prevenr wear re "re Irrcrrarr areas, apply a small amounr ol grease flmfl a rri lo Ihe lell lubricaling wrck, remove Ihe breaker ,ry ' arrrr and grease me plvol shall. (Fig. 5.5) f 5 7 5m “mm ,0 i Necessary lequllemenls ior breaker palms ' ’ 4. ® Must be wear resrslance U Q) Good eleclrrcal conduclor g) Hrgh melllng Ismperalure e (7:) ngh resisrance Io oxidation d Q5) Nor eflecled by orI or waler Possess suilable boldness nxpec'ion , Make sure rhal the palms are free of all Io prevenr Ihe lollowmg candrllons. a. Pain! becomes black and resulls in ex- cessive erosion. I I Fig. 5.5 Conracr breaker a. ll Ielr unclsaned lor a long Iirne, a bar. dened oil insulalion film wrll farm on me pain: surface and cause laully rgnilron. 2. Breaker arrn wirlr excesswely wom plvol hole should be replaced. 3, Make sure lhal Ilre rnsulalran aI Ihe conlacl breaker Ierminal IS free oi orl. molswre or drrl. ’ 4. Filled 01 drrly poims should be cleaned wim a poinl Irle ar sandpaper. Excessively pllled pom! surlcrces should be Iemoved and hem surfaces dressed so Ihal the palms are making parallel comacL (Fig, 5. 9) @ Dilslons ® Cormxl hreallu 82 Fig. 5. lo 6) hi, 5.“ Condenser (Zena-ml Spark plug 5. ELECTRIC.,SYSTEM E. Condenser The purpose 0’ lhe condenser is lo prevenl unwanled sparking across llle poinls, however, ll me condenser capaclly l5 loo large, lhe lgnll‘lorl spark will deleriarale, normal value is 03 M, Al lhe lnslance of pom) openlng, lhe condense: WI” have several hundred valls applied momenr lanly, lllerelore, .l musl have suFTlcierll chOClly la wilhsland lbis surge. (Fig. 5. m) Aller performlng a leak lesl on lhe meggar, a simple capocfly lesl of lhe condenser can be made by removing me lelmlnals llom lha megger whlle sllll ln operallon and use a wire la shell across the lermlnals, II mere is a good strong spark. me condenser can be assumed la be m good candllian Aclually. lhe capaclly ol lhe con denser wrll nol change. A use of a servlcs lesler wlll plovlde an accurala measurement ol me cupoclly and Iasislunce values. F. Spark plug Spark plug perlomrs one cl [he masl imporr larll lunclians m me engine lgnrllou syslem The hlgh volluge mocked by lhe magneto or me rgnll-oll coll ls renewed by lhe spark plug and produces me high vollage spark lo lump across from llle cenler eleclrode of lhe spark plug lo me slde eleclrode The spark lgnlles me compressed luel mixlure m We combusllon chamber and causes an exploslon which operales me engine. Even under venous adversa condillons, dxoblllly and reliabilr lly ls .eaurrea. (Fig, 5. ll) revenl Jill, if inition 'tfi tenser )msn. acity gel, in be :gger ,nort ‘rong pod con VlCe i of nor. l. IGNITION CIRCUIT l. Spark Plug The operulion of the engine can be determined by the condition ol the spark plug. Firing area at the insulator colored while gray or light gray indicates good condition and is performing satisloctorily. 2, Heat Range of the Spark Plug The firing area of the spark plug insulator is exposed to carbon and oil while the engine is operating and lo prevent its buildup, plugs are designed to burn all any deposits by the heat of combustion. In order to lmctiotl as above. the surface at the insulator fling area must be minloined at approximately 500~870"C [932 ~l600°Fl range. This temperature is referred to as the sellcleaning temperature The temperature of the plug will vary to a considerable degree with the type engine and design, riding condition and type tual. in order for the plugs to Ittnction properly under the diflerent milieu; it is necessary for the plugs to properly dissipale the beat cl co-n- buslionu The rate at heat dissipaliotl at the plug is determined by the heat range of the plug, A plug which readily dissipates the heat and which is difficult lo oval-heal is relerred to as a “Cold Type". A plug which retains the heat and which will burn readily is referred to us 0 "Hal Type'fl On engine operating at high temperature, a plug that is difficult to overheat, in other words, the cold type plug is used and lor engine operating at low lsmperolure a hot type plug is used (Fiat 5‘ 12, 5. l3) s: Fin. 5.” Conilrltcllotl ul spark plug Como! rlnstroae Will packing Galkot M-lul peeling Soul 909 Yormlnal lrlwlulcr (corrugateat Filler powdu Cam-til Wnllchlng surlaca than Main body Side aloctrode Reach lthuad l-ngl’ll @®©®®@®®@©@®® “01 w . Rtpull roe. conlocl lII llwmg xwltct. Rlploco ‘ l. Charging call I Own mil Molding unplm ”my M. Sclmlun l Pmlutod mom-i R-plac‘ Va rucllfiv l mom win. poet cmnlcilon melt ““M'W N. erlnq l. [on 0! ningnoilxm llpchl 0. low: 2. on... coll winding Rnplan Inlpefllon Proudure (I) Hard xlaning First condicl the spark porlorme lesl in suction 4 (it and check to see that tho condition ol the spark plug is sotisiaclory; periortn the slarling operation and il a good spark is produced ul lhe plug gap, it indicates thul the ignition coil, role! and breaker are all in salisloclory COfldiltOn. The [unit can be assumed lo be In the liming. When no spark is prodiced. dleck the tracker, igniliovl coil and flywheel A. C. generally. l2l Whenever there IS my malfunction of the lamps or the battery system, list, check lor poor wiring connection 01 grounding. Next, start lhe sngine and measure the voltage at the 00le tetmlnals. If the outpul voltage IS norml, check lbs battery and lbs lighling syslem for trouble. 5. ELECTRIC SYSTEM lq 2 Ed 2 l Half wave @ rectification Full wave rectification Fig. 5.20 mrrnrr hum-on (D Runner (2* Allemaiing cull-m air Drrurnmm 6) ® W413 g 'A V70 @ “3 <4) Fla, 5.” Sal-mum mull-a! a) iniuiaia. (2 Silunllml walrr (a. Ellfllflda g Nltlel nloled sl-el or aluminum ball Ls, Normal air-cher- cum-M liaw 3. Selenium Reclifler A reclifier is on equipmenl which converts ihe A. C. [ollernalingl currenr re a D. C. (direcrl currenr and is necessary for use wilh an A. C. generolor or on A. C. generoiirig coil. This is beoouse barrery quuiles D. C. volloge lor charg— ing. Recril‘icalion IS a process of causing ihe cyclic reversing currerrr lo flow in only one direciian. As shown in lhe figure rr pennirs lhe cuneni ro now in one direclion bul blocks rho currenr from flowing in ihe opposile direciion, ihus is known as a hall wave rocriricoiion. There is aiolher lype which changes me reverse flow of currenl so lhol 1! also flows in rho some diracrion. ihis lype is known as lull wave recrificaiion (Fig, 5. 20) Recliners ore ol many lypes in conslruciion, malarial and shape, however, principally lhe theory 0! aperarion is me same, i.e., lhe cwranl ls reodily permiriod io now in one direcriorr bur vesmcled lrom flowing in rho opposile direciion, The selenium recrll‘ier is mode wirh rho plare oi ailher aluminum or nickle plaled sreei sheer cooled or vacuum ploied wirh o highly mined selenium and a rare elemenr. This plale is lieai neared under a conlrolied pressure followed by spray cooring m area which will be used as a rerrninai. In which case, a special eleclrolyric ocrion is sel up oi rho layer belween lhe sale nium waler aid lbs spmyed auoy rerrninoi. As shown in rho figure, lhe curreni will readily now in rho normal direcrion aid only a negligible ornooni flows in lhe opposire direclion. When rhis unir is placed in lhe primary AC. circuil, llie currenl will flow in only rho specified dllecllon. (Fig, 5. 2r) as SELENIUM RECTIFIER u A. Selenium rectifier installation and hand- rls the “"9 _ ~/® __ _ fined, (I) Do not bendl cut or scratch the selenium :— "-- 1| A.C. waters. (Fist. 5‘ 22) I I rms is (21 The recliner locking not should not be Ioo- . .@ : O : 3mg ' sened or the wafers rotated. (Fig. 5. 23) \\ ‘l Any mavemenl will cause the electrode \ L _____ ; Cyclic alloy to peel, afiecting the rectification lunction — \ lam. further, it will desltoy the moistureproofng / ® 3," ,0 aid lheteby, shorten the lite o! selenium rec- ® from tiller. mow" > l3l Take odeqaote caution not to permit roin, (D Mam” Wm, Home, salt water, water or battery electrolyte to ® MM“ mm“ we”, get on the selenium rectifier as it will couse 8 Eel-env- emit “on, lhe current flow in the reverse direction to "‘ :ation increase Further, if the selenium wafer il (D exposed to moisture (or my length of time, Mon, oxide will be ploduce on the mince, resulting _ / m m a shorted condition and the lollo wing we". trouble will occur. w W o. Loose or disconnected lead at the battery “on. terminal. olole b. Loose ot disconnected terminals on lhe (2) new lead between the ballety md the @ side lied ol the selenium reclirtet. mm c. Running without o battery. . . j b It the engine should be ”Med W59, me r... em Solanjum "Clint! mslullulloh Y above common or it my. condition should (9 Selenium recllfiel is o G) locking mu We develop while the engine is being operated, Am a high voltage will be ptochlcad due lo the As absence of any load on Ihe coil. and this ,‘ow ‘ high voltage will cause a large omowt ol Able entrant to now though the rectifier in the reverse direction resulting in the eventual . damage to the selenium recliner. ' c' melam- l‘led ' 0. Always maintain all eleclticul comedians in the circuit in a good condition b. Under no circumstances should the engine be slorteo without the bottery camectedl 9o 5. ElECTlIC SVSYEM B. Checking the condition of the selenium rectifier ill Use service tester KSM—S—D type manutoc- tuted by Jonm Electric Co. at Test procedure l at Set the selector switch to "Resistancex 100". Use 6 V as a power source. Short across the (9 and (9 leads oi the tester md regulate the odiuster knob so that the tester indicator needle is pointing to "0" on the "ResistoncexlOO" scale. ® Resistant ‘ _ _ + A o, 12v WW Hwy (3) Inspectth the selenium rectifier + Normal direction tit-autumnal a. Disconnect the lead wire from the rectifier tevminul. V n Fig. 5.24 Menxuma in ttt. le dtlicltofl b. Measuring in the normal direction Con bed the (9 side of the tester "X" termi- nals Utd the white lead of the selenium rectifier with test teedr connect the G) side 0! the tester "X" terminals and the red lead at the rectifier and then measure the resistance. The selenium rectifier is in good condition in the normal direction it it measures less than ISO. (Fig. 5.24) rig, 5,25 Mlasuttw in the nm a. chm 5- MBGSU'i'tQ i" "9 We!” direclim PB!- ® luluun! term the measurement in lhe some manner + hm" "‘°°""'""’" as for the normal directtori measurement but with the tester "x" terminals connected in reverse, the e comected to the white lead at the selenium rectifier and rte (9 side to the red lead at the rectifiari The , selenium rectifier is in good condion in the 1‘, reverse direction it it mecstnas over 15000 t (Fig. 5. 25) Ml Checking the condition 0' the selenium rectl- .‘ fie! as described above, the low resistance in the normal direction and e high resistance in ‘ the reverse direction indicates a good condition at the selenium rectifieri (Note) The service tester will give a condition indication of the selenium rectifier, however, since the true churoctetlstics will vary with the applied voltage arid wave term, an elec» trtcul test should be pertorrricd by a specialist tn accordmce with the Specification 552 '.""“‘L‘" 4i BAYTERY 9| \ < _ 4. Battery A. Conxfruflion The battery stores the electricity ptoduced by the gettemtor lor use as a source of power for the solely items such as the lights and boms. At presenl, all batteries used for small type vehicles Ole of a lead slowlge lype inclosed in a plastic case. The construction and the name of the , component pans are shown in Fig. 5.17. (Fig 5. 27) » , A . » , , Fin. 5,26 Boll-1y a. Rating Type 843—6 Voltage ev Capacity 2AHHD hour miei Normal charging Iclle 0‘“ Specific gavity oi I.260~l.280 electrolyte at 20°C (65°Fl C. lmlruflion on use and xervlcina t, Chock specmc glovily Before Using the balletyl check the capacity and it the specific graVlly fl the elscltolyle is m. 5.17 Cmmm Dr Mum i below LZZD at 20“C [68 Ft (less thai 75% G) Fill" (Up capacity], the battery should be rectntged. (2) Ballety ceei. c , . (Caution) 8 cl.” ‘ The telulion between the battery capacity (9 Vcnl pip. ‘ end the specific glavlly (lasidual capacityt is © 9 °'°"'°d° 9‘“ 5‘; shown in Fig. 5.25. when the specific grcl ‘ vity is LIB? at 20°C (68°F) (less than 50% copacityl the lesidxil capacity is small and il 7» loop contimed to be used in such a condition, it 8 {$23 will eventually lead to trouble as well as § 1% Shoflefling the battery life, thelefote, the batter E H33 should be Ischaged as soon as possible. § fig, (”9' 5'23) '5 ‘1‘” lo 70 $0 to so be 70 so 90 too :lmncut capact’y (”/c) acnawt