69$ HON DA.

SHOP MANUAL

TGSDM Gyro s

 

 

 

IMPORTANT SAFETY NDTICE

Indicate: a strong possibility n/severe personal injury or loss of life i/insmwtimrs are not [ii/lowed.

CAUTION: [ridicules a passibiliry afpersmml injury or equipment damage if Munro/ion: are not followed.
NOTE: Gives helpful information.

Detailed descriptions of standard workshop procedures safety principles and service operations are not included, It is
important to note that this manual contains mme warnings and cautions against some specific service methods which
could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand
that those warnings could not cover al conceivable ways in which service, whether or not recommended by Honda
might be done or oi the possible hazardous consequences of each conceivable way, nor could Honda investigate all such
ways. Anyone using service procedures or tools, whether or not recommended by Honda must sariva himself thorough
LV that neither personal safety nor vehicle salety will be jeopardized by the service method or tools selected.

 

 

 

 

HOW T0 USE THIS MANUAL

Follow the Maintenance Schedule recommendar
tlons to ensure that the vehicle is in peak operat
ing condition and the emission levels are within
the standards set by the US. Environmental
Protection Agency. Performing the first schedule
ed maintenance is very important. It come
pensates for the initial wear that occurs during
the breakrin period.

Sections 1 through 3 apply to the whole motor
scooter, while sections 4 through 15 describe
parts of the motor scooter, grouped according
to location.

Find the section you want on this page, then
turn to the table of contents on page 1 of that
section.

Most section start with an assembly or system
illustration, service information and trouble
shooting for the section. The subsequent pages
give detailed procedures.

If you don’t know what the source of the
trouble is, refer to section 16 Troubleshooting.

All information, illustrations, directions and
specifications included in this publication are
based on the latest product information available
at the lime of approval for prlnllng. Honda Motor
(30., Ltd. reserves the right to make changes at
any time Without notlce and Without incurring
any obligation whatever.

No part of this publication may be reproduced
WlthDul written permission.

HONDA MOTOR CO., LTD.
Service Publications Office

ENGINE

CHASSIS

ELEC-
TRICAL

CIJNTENTS

GENERAL INFORMATION

 

LUBRICATION

MAINTENANCES

FUEL SVSTEM

ENGINE REMOVAL/INSTALLATION
CVLINDER HEAD/CYLINDER/PISTON
ALTERNATOR
CLUTCH/TRANSMISSION
CRANKCASE/CRANKSHAFT

FRAME COVERS

STEERING/FRONT WHEEL/
BRAKE/SUSPENSION

REAR WHEEL/BRAKE

REAR SHOCK ABSORBER/
SWING JOINT UNIT

ELECTRICAL EQUIPMENT
WIRING DIAGRAM

TROUBLESHOOTING

 

Date of Issue: September, 1985
© HONDA MOTOR (30., LTD.

 

 

 

 

 

 

 

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I. GENERAL INFURMATION

 

 

GENERAL SAFETY 1-1 TOROUE VALUES 1-5
SERVICE RULES 1-1 TOOLS 1-6
MODEL IDENTIFICATION 1-2 CABLE Bi HARNESS ROUTING 1~7
SPECIFICATIONS 1-3 NOISE EMISSION CONTROL SYSTEM 1-11

 

 

GENERAL SAFETY

 

 

 

If the engine must be running Ia da same work. make The battery electrolyte contains sulfuric acid. Protect
sure the area is well-ventilated Never run the engine in your eyes. skin and clothing. In case (If contact, flush
a elased area, The exhaust contains parlwnaus carbon thoroughly with water and calla docrar If electrolyte gets
monoxide gas, in your eyes.

-

Gasoline is extremely flammable and is exp/mire under The battery generates hydrogen gas which can be highly
terrain Hindi/inns, Do not smnke 0r allow flame: or explosive. Do rm! smoke or allow flames or sparks near
marks in your working area. the battery. especially while charging it.

 

SERVICE RULES

1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that do not meet HONDA's
design specifications may damage the scooter.

2. Use the special tools designed for this Scooter.

3. Use only metric tools when servlcing this scooter. Metric bolts. nuts. and screws are not interchangeable with English fasten-
ers, The use of incorrect tools and fasteners may damage the scooter.

4. Install new gaskets, O-rlngs, cotter pins, lock plates, etc. when reassembling.

5. When tightening bolts or nuts, begin with larger-diameter or inner bolts first, and tighten to the specified torque diagonally
in 2-3 steps, unless a particular sequence is specified.

6. Clean parts in non-flammable or high flash point solvent upon disassembly. Lubricate any sliding surfaces before assembly.

7. After reassembly, check all parts for Drone! installation and ODElaDOn.

3. Route all electrical wires as shown on page 1-7, Calbe and Harness Routing and always keep them away from sharp edges
and areas where they might be pinched between movmg parts,

 

1-1

 

GENERAL INFORMATION

 

MODEL IDENTIFICATION The vehicle Identification number is on the frame tube in

front of the floor board.

\

  
  

   

VEHICLE IDENTIFICATION NUMBER

The frame senaI number rs stamped on the rig!“ srde 01 the The carburetor rdentrhcatmn number >5 on the carburetor
frame. body,

 

.
FRAME SERIAL NUMBER CARBURETOR IDENTIFICATION NUMBER

The color code label is attached to the IueI tank under the
The engine senaI number Is stamped on the left srde of the seat, When ordering a color ceded part, always specify rts
engme case designated color.

 

r
ENGINE SERIAL NUMBER COLOR CODE LABEL

 

 

1-2

 

GENERAL INFORMATION

 

SPECIFICATIIINS

 

 

 

 

Cylinder arrangement
Bore and stroke
Displacement
Compression ratio
Transmission oil capacity
Oil tank capacity
Lubrication svstem

Port timlng
Intake Open
Close
Exhaust Open
Close
Scavenge Open
Close

Engine dry weight
Idle speed

ITEM SPECIFICATION
DIMENSIONS Overall length 1,710 mm (67.3 in)
Overall width 605 mm (23.8 in)
Overall height 1,010 mm (3951")
Wheel base 1,285 mm (50.6 in)
Ground clearance 70 mm (2.8 in)
Dry weight 64 kg (141.1 lb)
FRAME Tvpe Back bone
Front suspension, travel Telescopic fork, 65 mm (2.6 in]
Rear suspension, travel Unit swing, 60 mm (2.4 in)
Vehicle capacity Ipad 82 kg (150 lb)
Front tire size, pressure 3.00—10—ZPR, 150 kPa (1.50 kg/cm’, 21 psi)
Rear tire size, pressure 4.50—6—‘2PR, 75 kPa (0.75 kg/cmz, 11 psi)
Front brake Internal expanding shoe
Rear brake Internal expanding shoe
Fuel capacity 3.711(10 US gal, 0.81 Imp gal)
Caster angle 27u
Trail 52 mm (2.4 in)
Front fork grease 5 Cr: (0.17 US 01, 0.18 Imp oz)
ENGINE Type Air cooled 24stroke

Single cylinder

41.0x 37.4 mm (1.61 x 1.47 in)

49.3 cm’ (3.0 cu in)

6.9: 1

210 cc (7.1 US 02,7.41mp oz)

1.2 lit. (13 USqt,1.06lmp qt)
Lubricated by the fuel and oil mixture

Reed valve controlled
Reed valve controlled
735° BBDC

73.5“ ABDC

53" BBDC

53" ABDC

12.0 kg (26.5 lb)
1,800 2 100 rpm

 

CARBUHETOR Carburetor type
Identification number

Air screw initial setting

 

Float level

 

 

Piston valve

'85: PA27E
After’BS: PA27F

2-1/4 turns out
122 mm (0.48 in)

 

 

 

1-3

 

GENERAL INFORMATION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ITEM SPECIFICATION
DRIVE TRAIN Clutch type Automatic centrifugal, Wet clutch
Transmission 2-speed automatic
Primary reduction 2.636
Gear ratio 1st: 1.623, 2nd: 1.000
Final reduction 3,925
ELECTRICAL Ignition Condenser capacitive discharge ignition (CDIl
Starting system Starting motor
Alternator 91W/5.0DO rpm
Spark plug NGK ND
Standard BPRSHSA W20FPR~L
For cold climate BPR4HSA W14FFR»L
For extended high speed riding BPHBHSA W24FPR-L
Spark plug gap 0.6~0.7 mm (0024—0028 in)
Ignition timing "F” mark 14.5“ BTDC
Battery capacity 12V SAH
Fuse capacity 10A
LIGHTS Headlight Low/High 12V—25/25W
Tail/stoplight 12V—3/23W 3/32 up
Turn signal 12V—23W 32 an
Speedometer light 12V—3.4W 2 cp
High beam indicator 12V—3.4W 2 cp
Tum signal indicator 12V—3.4W 2 cp

 

 

1-4

 

 

GENERAL INFORMATION

 

TIJRIIIIE VALUES

 

 

 

 

 

 

 

 

 

 

 

E NG IN E
r Thr (1 013. T r ue
Item 0 (y (film) Nm “if“, mm Remarks
Cylinfler head bolt 4 6 5712 (0.8—1.2, 679) TWhile the engine is cold.
Flywheel nut 1 10 35—40 (3.5—4.0, 25729) riBelow 35°C, 95°F)
Crankcase bolt 5 6 8—12 (0.8711, 6—9)
Intake pipe bolt 3 5 8—12 (0.8712, 6—9) TWhile the engine is cold.
(Below 35°C, 95° Fl
Low drive plate nut 1 17 38742 (3.8—4.2, 27731) Left hand threads
Carburetor bolt 2 6 9—1 2 (0.9—1.2, 6—9) IWl’lile the engine is cold.
Ratchet plate bolt 3 6 10—12 (1.0—1.2, 7—9) (Below 35°C, 95°F)
Transmission oil level check bolt 1 12 50—60 (5.0—6.0, 36743)
CHASSIS
ltem O’ty Th’f'zj‘n?'a~ N-m £33 1-le Remarks
Rear axle nut 2 12 65-80 (6.5—8.0. 48—58) Apply oil
Front axle nut 1 10 40—50 (4.0—5.0, 29—36)
Joint shaft pivot bolt 2 10 40—55 (4.0—5.5, 29—40)
Steering stem lock nut 1 25,4 5—13 (0.5—1.3, 16—9)
Steering stern nut 1 25:4 GO—BO (6.0— 0, 43—58)
Speedometer cable set screw 1 4 1.5—2 (015—01, 1.1—1.5)
Brake arm bolt 2 5 4—7 (0.4—0.7, 3—5)
Rear brake cable primary adjuster lock nut 1 7 3.5—5 (03570.5, 2.5—3.6)
Joint case bolt 2 8 24—30 (2.4—3.0, 17—22)
4 6 10—14(1.0— 7—10)
Joint shaft nut 1 12 55—65 (5.57 ,40—48)
Swing lock arm A 'l 5 4—7 (0.470 7 3—5)
Rear shock absorber damper rod lock nut 1 10 30—45 [3.0— 22—32) Apply locking agent
Rear shock absorber mounting bolt 2 10 30—45 (3.0—4.5, 22—32)
Rear brake equalizer cover screw 3 5 2.574 (0.25—0A, 1.8—3)
Front fork bridge bolt 2 10 40—50 (4.0—5.0, 29—36)
Rear wheel disc bolt 3 8 24—30 (2.4—3 0, 17722)
Rear wheel hub bolt 3 10 45—50 (4.5— 32-36) Apply oil
Fuel strainer cup 1 — 375 (0.3— 2.2—3.6)
Engine mounting bolt 3 8 24—30 (2.4—3 17722)
Exhaust pipe, muffler joint nut 4 6 10—14(1.071.4,7—10i

 

 

 

  
 
 

  
 
 

 

 

 

below.

STANDARD TORQUE VALUES

Torque specifications listed above are for important fasteners. Others should be tightened to the standard torque values listed

 

Item

Torque N-m (kgm, ft-lb)

Item

Torque N‘rn (kg~m, ftAlbl

 

5 mm bolt and nut
6 mm bolt and nut
8 mm bolt and nut
10 mm bolt and nut
12 mm bolt and nut

 

 

4.5—6 (OAS—0.6, 374)
8—12(0.B—1.2,679)
18—25 (1.8—2 ,13—18)
30—40 (3.0—4.0, 22729)
50—60 (5.0—6.0, 36—43)

   

5 mm screw

6 mm screw, SH bolt

6 mm flange bolt and nut

8 mm flange bolt and nut
10 mm flange bolt and nut

 

 

3575.0 (0.35—0.52, 2.5—3.6)
7711 (0.7—1.1,5—8)
10714 (1,071.4, 7—10)
24730 (2.4—3.0, 17—22)
35—45 (3574.5, 25—32)

 

 

 

1-5

 

GENERAL INFORMATION

 

 

 

 

 

 

 

 

 

 

TUBLS
SPECIA L
Description Tool Number Alremare Tool Tool Number l Ref. Page
Universal bearing Euler 07631:0010000 Commercially available 92
in u.s,A.
Snap ring pliers 07914—3230001 Commercially avaialble 11-15, 11-16
in U.S.A.
Lock nutwrench 07916—1870101 11-17, 1118
Lock nur wrench 07916—KM10000 11-10
Shaft prorecror 07931 -1 370000 9-2
Crankcase puller 07935-GJ50000 Crankcase puller ‘ 079374300000 9-2
Bearing remover set, 12 mm 07936—1660001 ‘ 8-7
— Bearing remover shaft, 12 mm (079364660100) 8-7
— Remover waight (0774170010201) Remover weigh! 0793673710200 67
Crankcase assembly rool 079654480010 94 9-5
— Collar (07965—1480100) 9-4, 9-5
— snail l07965—GM00300), 9-4, 9-5
Altachmem, 28 x 30 mm 07946—1870100 ‘ 11-10
Rear shock absorber ‘
anachrnenr A 07967—GA70101 13-2, 13-3
Rear shock absorber
anachment B 07967—GA70200 13-2, 13-3
Steering slern driver 07946—4900101 11-17
Ball race remover 07946<GA70000 Not available in U.S.A. 11.17
Hand vacuum pump m7x—041—xxxxx U.S.A. unlv ST—AH—260—MC7 4-5
lU.s.A. only)
Digirai multimeter 0741140020000 KS—AHM—32—003 14-4
lu.s.A. onlyl L
COMMON
Description Tool Number i Alternate Tool Tool Number Refr Page
Floar level gauge 07401—0010000 48
Lock nut wrench, 30 x 32 mm 07716—0020400 Cammercially available 1146, 11-18
in u.s.A.
Extension 07716—0020500 Commercially available 11-16, 11-13
in USA ‘
Universal holder 07725—0030000 l 73, 7-5
Cluxch center holder 07724—0050000 Commermally available SB, 975
in USA. i
Flywheel puller 07733—0010000 Flywheel puller ; 0793340010000 74
Attachment, 24 x 26 mm 07746—0010700 ‘ 7-6
PlloL 10 mm 07746—0040100 76, 11-10
Anachmenr, 32 x 35 mm 0774642010100 ‘ 0-13
Pilot, 15 mm 0774670040300 ‘ 8-13
Anachmenr, 37 x 40 mm 0774670010200 9.4
Pilot, 17 mm 0774670040400 9-4
Attachment, 42 x 47 mm 07746—0010300 9-4.11-17
Pilor, 20 mm 0774670040500 , ‘ 9-4
Driver 0774970010000 , 76. 8-13
Drlver 07746—0020100 7-6
Bearing remover expander 07746—0050100 11-10
Bearing remover collet, 10 mm 0774640050200 11-10
Shock absorber compressor 0795973290001 13-2, 13-3

 

 

 

 

1-6

 

 

CABLE & HARNESS RlJUTING

Note the following when muting cables and Wm? harnesses:

- A loose wire, harness or cable can be a safety hazard.
After clamping, check each Wire to be sure it is secure.

0 Do not squeeze wlres against the weld or end of a clamp.

a Secure Wires and wire harnesses to the frame with their
respective wlre bands at the designated locations. Tighten
the bands so that only the insulated surfaces contact the
Wires or wire harnesses.

I Route harnesses so they are not pulled taut or have ex-
cessive slack,

0 Protect wires and harnesses wlth electrical tape or tubing
if they contact a sharp edge or corners Clean the attaching
surface thoroughly before applying tapes

0 Do not use Wires or harnesses mm a broken insulator,
Repair by wrapping them With protective tape or replace
them,

0 Route wire harnesses to avoid sharp edges or comers.

0 Also avoid the projected ends of bolts and screws.

0 Keep wrre harnesses away from the exhaust pipes and
other hot parts.

0 Be sure grommets are seated in their grooves properly.

0 After clamping, check each harness to be certain that it is
not interfering With any moving or sliding parts.

I Wire harnesses routed along the handlebars should not be
pulled taut, have excesswe slack, be pinched, 0v Interfere
With adjacent or surrounding parts in all steering positions.

0 After routing, check that the Wire harnesses are not twisted
or kinked,

GENERAL INFORMATION

 

1-7

 

GENERAL INFORMATION

 

 

 

 

1-8

GENERAL INFORMATION

 

 

(I) REAR BRAKE CABLE

  
     
  
 

(2) THROTTLE CABLE

(5) PARKING LOCK

CABLE (3) FRONT BRAKE CABLE

(4) SPEEDOMETE R CABLE

(10) CDI UNIT (6) FUEL LINE

(2) THROTTLE (7) OIL
CABLE INLET (5) FUEL LINE
LINE '

’ (a) REAR BRAKE
CABLES

 

(7)0lLINLET (5) PARKING
LINE LOCK CABLE
(5) PARKING (9) ENGINE WIRE (10) LEFT REAR
LOCK CABLE HARNESS BRAKE CABLE

 

1-9

GENERAL INFORMATION

 

(1) THROTTLE CABLE (2) OIL CONTROL CABLE

    
  

(6) SPARK PLUG WIRE

 

(MOIL INLET LINE
(5) REAR BRAKE CABLE

(7) REGULATOR/RECTIFIER

(9) OIL LEVEL SENSOR ‘ A t ‘ (a) BATTERY

 

1-10

 

GENERAL INFORMATION

 

NIJISE EMISSION CIJNTROL SYSTEM (IISA ONLY)

0 The us. Environmental Protection Agency requires manufacturers to certify that Scooter built after January 1, 1983 will
comva with applicable nOIse emission standards for one year or 1,365 miles (3,000 km) alter the time of saIe to the uIti-
mate purchaser, when operated and maintained according to the instructinns provided. Compliance with the terms of the
Distributor's Warranty for the Honda Scooter Noise Emission Control System IS necessary in order to keep the noise
emission control system in effect. (USA only]

TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the
causing thereof: in The removal or rendering inoperative bv anv person, other than for purposes of maintenance, repair,
or replacement, at any device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or, while it is in use: or (2) the use of the vehicle after such device or
element oi design has been removed or rendered inoperative by any person.

AMONG THOSE ACTS PRESUMED T0 CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:

1. Removal of, or puncturing the mulfler, baffles, healder pipes or any other component which conducts exhaust gases,

2, Removal of, or puncturing of any part of the intake system.

3. Lack of proper maintenance.

4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those speci-
fied by the manufacturer.

 

1-11

 

 

LUBRICATION

 

 

 

 

2. LUBRICATIUN

 

 

SERVICE INFORMATION 2-1 OIL STRAINER 2-4
TROUBLESHOOTING 2»1 OIL TANK 241
OIL PUMP 2»2 TRANSMISSION OIL 2-5
OIL LINES/PUMP BLEEDING 2-3 LUBRICATION POINTS 2-6 a

 

 

SERVICE INFORMATION

GENERAL

0 The Oli pump can be servrced without removmg the engine (rpm the frame

0 When lemovmg and rnslallmg me orl pump do not allow dust or dlrt to enter the engine and all on line.

I Do nor attempt ro disassemble the oil pump.

. Bleed the oil pump if there is air in the oil inlet line ”rpm the Oil tank to the oil pump) or i! the oil line has been discons
Hected.

SPECIFICATIONS

Engine oil recommendation Honda 2~stroke Injector Oil or equrvalent
Engine oil tank capacity 1.2 liters (1.27 US at, 1.06 Imp qr)

Transmission oil recommendation Use Honda 4-stroke oil or equivalent.
API Service Classification: SE or SF
Viscosity: SAE row—40
Other viscosities shown in the chart may be
used when the average temperature lfl your
riding area is within the Indicated ranger

Transmrssion orl capacrty 190 cc (6.4 US 02. 6‘7 Imp all after dIalnlng
210 cc (71 US 01, 7.4 Imp 01) after disassemblv

 

TORQUE VALUE
Transmission oil level check bolt 50760 N~m [50:60 kg-ml 367431t-lbl

TROUBLESHDUTING

Excessive engine smoke and/or carbon on spark plug
‘ Pump not properly synchronized (excessive OIIL

‘ Low quality engine orl.
Overheating

‘ Oil pump not adjusted properly (insufhuent oulmglr
‘ Low quality oil.
Seized piston

' No Oil in tank or clogged oil IInE.

Pump not properly adjusted (insufficient oiling).
Air in oil lines,

Faulty orl pump.

Clogged oil strainer.

Oil not flowing out of tank
' Clogged oil tank cap breather hole.
’ Clogged oil strainer.

 

2-1

LUBRICATION

 

fl". PUMP I (1) PUMP SET PLATE (2)0lL CONTROL CABLE
REMOVAL

NOTE

- Clean the oil pump and its surrounding area thraughiy
before removing the pump.

 

 

Remove the followmg parts:
— engine cover lpage 106).
— air cleaner case (page 473).

. . . , 1’ ET
Disconnect the all inlet line at the Oil pump and clamp the end. (3) 01L INLET LINE ‘ (4i OIL 0U...L LIME
Disconnect the Oil outlet line and the Oll pump con‘rol cable. '-
Flemove the bolts attaching the oil pump set plate. \

 

Remove lhe oil pump by pulling it straight up.
Remove the O-ring.

 

'NSPECT‘ON ll) PUMP CONTROL
Remove the 0” pump and check for: / LEVER

— deteriorated O-ring.
7 damage to the crankcase mating surface, (2) GEAR
— damage to the pump body.

— pump control lever operation.
— worn or damaged pump gear.
A oil leaks.

CAUTION
- Dn nur dixnsxemble the oil pump.

 

 

INSTALLATION

Coat a new Oring wrth grease and install it into the oil pump
mounting hole,

Apply molybdenum disulfide grease to the oil pump driven
gear and install the oil pump onto the crankcase.

 

 

2-2

 

 

LUBRICATIDN

 

Install the pump set plate and tightea the bolt.

Connect the inlet and outlet lines to the oil pump.
Connect and adjust the oil control cable (page 3-5).
Bleed air from the oil pump and oil outlet line.

lJIL LlNES/ PUMP BLEEDING

Remove the air cleaner case (page 4-3).

Fill the oil tank With the recommended oil,

Place a shop towel around the oil pump,

Discannect the all inlet line (tom the oil pump.

Fill the oil pump with oil by squirting aboutdcc (0.14 US 01)
of clean engine oil through the oil pump inlet opening.

Fill the oil inlet line with oil and connect it to the oil pump.

Disconnect the oil out|et line from the intake pipe, fill it with
all and reconnect to the intake pipe‘

install the air cleaner case (page 43).
Temporanly install the exhausx muffler

Start the engine and allow it idle.
Bleed ail from the oil pump bv loosening the bleed bolt on the
Oil pump.

mum——

Perform this operation in a well ventilated area,
Dr: no! race the engine while bleeding air from Ille m'l

pump.

 

Remove the exhaust muffler.
Install the engine cover (page 10-5).

 

 

2-3

LUBRICATION

 

OIL STRAINER

Remove the frame rear cover (page 1074),
Disconnect the oil inlet line at the joint and allow the oil to
drain into a c|ean container,

Loosen the tube Cllp and dlsconnecl the oil tube joint under
the oil tank.
Remove the oil strainer.

Clean the OH strainer with compressed air.

Install the oil strainer in the reverse order of removal.
Fill the oil tank with the recommended oilt

Bleed air from the oil pump and ml lines.

IJIL TANK

REMOVAL/INSTALLATION

Remove the body rear cover (page 10-4).

Disconnect the oil inlet line at the jam: and dram and oil into
a clean container.

(3) OIL TUBE JOINT

 

 

 

 

 

 

 

2-4

 

LUBRICATION

Disconnect the wires from the oil level sensor.
Remove the two oil tank mourning bolts and the oil tank
from the frame.

- - - —-...
(1) OIL LEVEL SENSOR WIRES

    

Install the oil tank In the reverse order of removale
Bleed air from oil pump and oil lines (page 273).

 

 

 

 

TRANSMISSION llll.

Place the scooter on the level ground.

Remove the oil level check bolts

Remove the drain bolt and drain oil thoroughly.

Make sure that the sealing washer on the drain bolt is in good
condition and install the drain bolt.

FIII the transmission with (he recommended oil (page 24)
up to the banam edge of the oil level check bolt hole.

OIL CAPACITV:
190 on (6.4 US 01.6.7 Imp 0:) after draining
210 cc (7.1 US oz, 7.4 Imp 01) after disassemblv

Install and tighten the oil level check bolt.
TORQUE: 50—60 N-m (5.0—6.0 kg»m, 36—43 ftAlbl
Check the transmission case lor oil leaks.

(1) on. LEVEL CHECK
BOLT HOLE ~

 

 

 

LUBRICATION

LUBRICATION POINTS

Use general purpose grease when not speleied here.
Apply oll OI grease to indlng suriaces nm shown herev

CONTROL CABLES

Period'lcally, disconnect the throttle and brake cables at me”
upper ends. Tharougth lubrlcate the cables and their pwm
dents with a commercially avallable cable lubricant are light
weightoil.

E
& I3ITHROTTLE GRIP

I2] PARKING CLOCK LEVER
IIITRAN‘SMISSION PIVOT/LINK (“STEERING HEAD BEARINGS

    
   

 

ISI FRONT FORK

16) BRAKE
CAM SHAFT

I8) BRAKE CAM SHAFT/ (7) SPEEDOMETER GEAR/DUST SEAL/
WHEEL BEARINGS WHEEL BEARINGS

 

2-6

 

3. MAINTENANCE

 

 

 

SERVICE INFORMATION 31 WHEELS 3-7
MAINTENANCE SCHEDULE 3.2 BRAKES 3-7

AIR CLEANER 3-4 PARKING LOCK LEVER 3A3
CARBURETOR IDLE SPEED 3-5 STEERING HEAD BEARINGS 3-9
THROTTLE OPERATION 3-5 SUSPENSION 3-9 -
OIL PUMP 3.5 NUTS, BOLTS, FASTENERS 3.10

FUEL FILTER SCREEN 3-6 SPARK PLUG 3-10

FUEL LINE 3-6 LIGHTS AND HORN 3-10

OIL LINE 3-7 IGNITION TIMING 3-11
MUFFLER DECARBONIZATION 3-7 CYLINDER COMPRESSION 3-11

 

 

 

SERVICE INFORMATION

SPECIFICATIONS

 

 

 

 

 

IdIe speed 1,800 x 100 rpm
Throme grip free play 243 mm [1/871/4 in)
Recommended spark plugs NGK ND
WSIandard BPRGHSAfi 7 7 I w30FPR-L 7
For cold Climate I BPFMHSA I WMFPR-L
For extended high speed rldlng I EPRBHSA I w24FPR-L
Spark plug gap 0.6—0.7 mm (0.024—0.028 in)
Tire size Front 3.00—10—2PR
Rear 4.5046A2PR
Tire pressure From 150 kPa (1.5 kg/cmz, 21 psi]
Rear 75 kPa (0'75 kg/cm2,11p5II
From brake lever free play 10—20 mm (3/8—3/4 In)
Rear brake lever free play 10720 mm (3/Bv3/4 In)
Parking Iock Iever free play 10715 mm (a/aAs/s in)
Clender compression 1,100 We (11.0 kg/cm’, 156 psi)

TORQUE VALUE
FUEI cup 3-5 N-m (0,370.5 kg~m,2,273.6f1-lbl

 

3-1

 

MAINTENANCE

 

MAINTENANCE SCHEDULES
’85 :

I — Inspect and clean, adjust, lubricate or replace if necessary

R — Replace
C — Clean

 

“BRIDE INITIAL REGULAR SERVICE PERIOD
This maintenance schedule is based upon INSPECTION SAFETY pergmm at indicated

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

average riding condition. Scooters subiected INSPECTION mileage interval Refer to
to severe use, or ridden in unusually dustv page
areas, require more frequent servicingt 600 miles 1,000 miles 2,000 miles
(1,000 km) (1,500 km) (3,000 km)
AIR CLEANER ELEMENT (EVERY 5 MONTHS) C 3-4
CARBURETOR I I I 3-5
' THROTTLE OPERATION I I I 3-5
OIL PUMP I | 3-5
FUEL FILTER SCREEN C C 3-6
OIL LINE I | 3-6
FU EL LIN E | I |
(EVERY 2 YEARS) R 36
' OILANDFUEL LEVEL l
DECARBONIZE CYLINDER HEAD, C 3_7 63 6-4
CVLINDER,P|STON AND MUFFLER ' '
TRANSMISSION OIL R 2-5
' TRANSMISSION CASE FOR LEAKS I 25
CLUTCH SHOE WEAR l B-6,8-9
TIRE: PRESSURES AND CONDITION I 3-7
WHEEL TRUENESS l | 37
' BRAKE OPERATION AND FREE PLAY I I I | 3~7
BRAKE LININGS | I 3-7
PARKING LOCK LEVER OPERATION ' I 33
AN D F REE P LAY
STEERING HEAD BEARINGS | | 3-9
SUSPENSION OPERATION I | 3-9
NUTS, BOLTSITIGHTEN) | l 340
' SPARK PLUG R R 3~10
ALL LIGHTS AND HORN l 3-10

 

Items marked' are simple to perform and may be serviced by the ownert
Other maintenance items should be serviced by an authorized Honda motor scooter dealer.

 

3-2

 

 

MAINTENANCE

 

After '85 :

Perform the pre~ride inspection a each scheduled maintenance period.
I: Inspect, and Clean, Adjust, Lubricate or Replace if necessary.
C: Clean Ft: Replace A: Adjust L: Lubricate

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WHICHEVER ODOMETER READING [NOTE 3}
FREQUENCY COMES » \
FlRST _\ *5 °§§ fit-4‘} $55
§§ ee“ §§° «3%?
ITEM EVERV i“ We ”er “(3' Referto page
. FUEL LINE 2 VEARS ”R — I I I 3-6
. FUEL STRAINER SCREEN — C C C 3-6
' THROTTLE OPERATION A I I I 3-5, 3-7
“I OILPUMPANDOIL LINE — I I I 35
AIR CLEANER NOTE I — c c c 3.4
SPARK PLUG NOTE 2 EVERV 1,000 mi (1,600 km) R 3-10
“' DECARBONIZING NOTE 2 EVERY 2,000 mi (3,200 km) C 6-2
. CAREURETOR IDLE SPEED I I I I 3-5
TRANSMISSION on. w — - R 2-5
BRAKE SHOE WEAR — I I I 3-7
BRAKE SYSTEM I I I I 3-7
' BRAKE LIGHTSWITCH — I I I 3-9
. PARKING BRAKE OPERATION I _ _ _ 3~8
AND FREE PLAY
’ HEADLIGHT AIM r I I I 340
” CLUTCH SHOE WEAR A — I — 8-61 8‘9
' SUSPENSION — I I I 3.9
I. NUT, BOLT, FASTNER I > I — 3-H)
.. WHEEL — I I I 3-7
'” STEERING HEAD BEARING I — - I 3-9

 

 

 

 

 

 

 

 

 

 

' Should be serviced by an authorized HONDA Dealer, unless the owner has proper tools and service data and is mechanically
unalified.
' ' In the interest of safety, we recommend these items be serviced ON LY by an authorized HONDA Dealer.

NOTES: 1. Service more frequently when riding in dusty areas.
2. HONDA 2 STROKE MOTORCYCLE OIL has been specifically tested In and is recommended for his engine.
The use of other oils may cause excessive carbon build-up in the engine and exhaust system, resulting in loss of
power and possible engine damage.
3. For higher odometer reading, repeat at the frequency interval established here.

 

3-3

 

MAINTENANCE

 

AIR CLEANER

Remove the carburetor cover by removing me anaching screws

NOTE

 

~ To install the carburetor caver, press In the trim clip screw
While holding the (rim clip down an the Covert

 

Remove the air cleaner case cover screw and the cover.

Remove the air cleaner element.

Wash the element in non-flammable or high flash point
solvent, squeeze out and the element and allow to dry.

- Never use gasoline or law flash point solvents for clean-

ing the air cleaner element. A fire or explaxiun could
resullt

 

Soak the element in clean motor oil (SAE 10W-30) and
squeeze out the excess

Reinstall the element, air cleaner case, and carburetor cover.

 

 

 

 

 

 

 

(2)

AND DRV

 

l4]
(”WASH SOUEEZE OUT (3)0IL SQUEEZE

OUT EXCESS
OIL

 

 

3-4

 

 

 

OARBURETOR IDLE SPEED

Remove the carburetor cover (page 34).

Place the scooter on level ground.

Warm up the engine and attach a tachometer.

Turn the throttle stop screw as required to obtain the specilied
Idle speed.

IDLE SPEED: 1,800 r 100 rpm

Install the carburetor cover.

THROTTLE OPERATION

Check for smooth throttle grip operation with full opening
and complete automatic CIOSI'IQ in all steering positions.

Make sure there is no damage or kinking in the throttle cable.
Replace any damaged parts.

Remove the right handlebar switch housing and disconnect
the throttle cable upper end. Thoroughly lubricate the cable
with a commercially available cable lubricant or grease.

Install the throttle cable in the reverse order of removal.
Measure the throttle grip free play at the throttle grip flange.

FREE PLAY: 2—6 mm (1/8—1/4 in)

Adjustment can be made by loosening the lock nut and turn-
ing the adjuster.

Replace the throttle cable if it can not be adjusted using the
above procedure (page 11-6).

Check the oil control cable adjustment.

OIL PUMP
OIL CONTROL CABLE ADJUSTMENT

NOTE

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

 

Remove the engine cover (page 10-5).

Open the throttle grip completely and make sure that the
alignment mark on the oil pump control lever aligns with the
index mark on the pump body,

CAUTION
‘ Over stroke up to 1 mm [0.04 in} is acceptable. However.
the alignment mark should never be short of the index

mark, otherwise engine damage will occur because of in-
sufficient lubrication.

 

 

MAINTENANCE

 

276 mm

—’| r—n/eem inl

,,,(Z‘I‘I;OCK NUT

  

(II DUST COVE'FI
(‘V

 

I3) ADJUSTER

n...‘ ‘t
(ZI ADJUSTING
NUT

. JV -
(3) ALIGNMENT MARK (4) LOCK NUT
m- an's ) -~

 

 

MAINTENANCE

 

Start the engine and open the throttle slightly above idle speed
and make sure that the oil pump control lever starts to move
simultaneouslv as the engine speed incrases.

Adjust it necessary by loosening the lock nut and turning the
adjusting nut.
Tighten the lock nut securely after adjustment.

NOTE

‘ If the pump control level is opened excessively, white
smoke or hard starting Will occur.

- If the pump control lever movement is insufficient. piston
seizure may result.

 

 

FUEL FILTER SCREEN

Turn the luel valve OFF,

Remove the body center cover (page 1074).

Remove the fuel cup, O-ring, filter screen, and drain the
gasoline into a suitable container.

WE

' Gasoline is flammable and is explasive under (er/air: mn-
diliuns. Du no! smoke 0r allrrw flames ar sparks near Ihe
equipmenl while draining fuel.

 

Wash the cup and filter screen in clean non-flammable or high
flash point solvent.

Reinstall the screen, aligning the hole in the screen with the
round boss on the tuel valve body.

Install a new O‘r‘mg into the fuel vaive body.

Reinstall the tuel cup, making sure the O-rlng is in place.
Hand tighten the fuel cup and then torque it to specification.

TORQUE: 3—5 N‘m (0.3—0.5 kg-m, 2.2—3.6 lt-Ih)

CAUYIDN

 

~ Do not nvr'rtiglrren the fuel cup or yull will damage [he
threads.

 

Atter installing, turn the fuel valve 0N and check that (here
are no oil leaks.

FUEL LINE

Remove the frame center cover and engine cover (section 10).
Replace any parts which show signs of deterioration. damage
or leaks.

 

 

 

3-6

 

MAINTENANCE

 

OIL LINE

Remove the engine cover and frame rear cover (section 10).
Replace any oil line parts which shows signs of deterioration,
damage or leaking.

MUFFLER DECARBONIZATIIIN

Remove the muiller (page 105).
Remove carbon depOsits from the inside of the mufller.
Install the muffler (page 105).

WHEELS

Check the tires for cuts, imbedded nails, or other damage.
Check the tire pressures.

NOTE
' Tire pressure should be checked when the tires are cold.

 

 

TIRE PRESSURE: FRONT 150 kPI (1.5 kglcm’, 21 psi)
REAR 75 kPa [0.75 kglcmz, 11 psi)

TIRE SIZE: FRONT 3,00—10—2PR
REAR 4.50—6—2PR

BRAKES

FRONT BRAKE LEVER FREE PLAY

Measure the free play at the end of the lever.
FREE PLAY: 10—20 mm [3/3—3/4 in)

Turn the brake adjusting nut to obtain specified free play.

 

II) OIL lNLET LINE , (2] OIL OUTLET LINE
i

'=_ I .

 

’
I1) FRONT BRAKE LEVER

  

—10~20 mm

‘ "HT—43mm in)

 

 

 

 

 

MAINTENANCE

 

REAR BRAKE LEVER FREE PLAY
Measure the free play a! the end of the lever.

FREE PLAY: 10—20 mm (3/8—3/4 in)

Adjust the tree play by moving both adjustment nuts an
equal amount to allow the specified traveL

After adjustment, make sure that both rear brake arms have
lree play.

NOTE

If the brake arms have no play. the primary rear brake cable
mav be stretched. Replace the primary cable and adjust the
rear brake cable equalizaer (page 11-8).

 

 

BRAKE SHOES

Replace the brake shoes. if with the correct lever free play,
the arrow an the brake arm aligns with the reference mark
(page 11-12, 12-3).

PARKING LUCK LEVER

Measure the free play at the end of the lever.
FREE PLAV: 10—15 mm (3/8—5/3 in)

(1) REAR BRAKE LEVER

    
 

 

10720 mm
(3/573l4 in)

10715mm
(3/8—5/8 in)

 

3-8

 

MAINTENANCE

 

It adjustment is necessary, proceed as follows:

Remove the head plpe cover (page 10-2].

Loosen the lock nut and turn the adjusting nut until Obtalnlng
the specified free play.

Tighten the lock nut securely.

Install the head pipe cover (page 10-2).

STEERING HEAD BEA-RINGS

NOTE

. Make sure the cables do not lnterfere with the movement of
the handlebar.

 

 

Ralse the Iron! wheel 0" the ground and make sure lhal the
handlebar moves lreely. If the handlebar moves unevenly,
binds or has vertical play, adjust the steering head bearings
(page 11-18).

If the handlebar stlll move unevenly, hlnds or has vertical play
after adjustment, inspect the steering head bearings and
replace If necessary [page 11-17l

SUSPENSIDN

F RONT

Check the aCllOn oi the front fork by compressmg it several
times.

Check the entire fork assembly for damage. Replace or repair
any damaged com ponents.

REAR SUSPENSION

Check the shock absorber lor leakage or damage.
Check the suspension operation.
Tighten all bolts and nuts to the specified torque values.

 

 

 

 

MAINTENANCE

 

SPARK PLUG

Disconnect the spark plug cap and clean and dirt from around
the spark plug base.

Remove and discard the spark plug.
Measure the new spark plug gap using a wirertype feeler gauge.

RECOMMENDE D SPAR K P LUGS:

 

 

 

 

 

 

7 NGK 7 ND
Standard BPRgHSA ‘ WZQFPR~L
7 For cold climate BPR4HSA mg4FPR-L
For extended
high speed riding l BPRHHSA W24FPR'L

 

 

SPARK PLUG GAP: 0.6—0.7 mm (0.024—0.028 in)

Install the spark plug by hand, then tighten wlth a spark plug
wrench.
Connect the spark plug cap.

LIGHTS AND HORN

Start the engine and allow it to Idle.
Check all lights and horn tor proper operation.

HEADLIGHT BEAM ADJUSTMENT

Adjust vertically bv loosening the headlight case mounting
bolts and moving the case.
Adjust horizontally by turning the adjusting screw.

  

I 0.6—0.7 mm
=f 10024—0028 in}

  

I (2) CENTER ELECTRODE

.; a m
(I) HEADLK/SHT MOUNTING BOLT

., . ‘
(2] HORIZONTAL ADJUSTING SCREW
_—

 

3-10

 

MAINTENANCE

 

IGNITION TIMING

NOTE

The Capacitive Discharge Ignition lCDIl system is factory
preset and does not require adjustments

Use the procedures below to check the CDI function and
ignition timing.

 

 

Remove the timing hole cap,
Connect a tachometer and timing light.
Start the engine and allow it to idle.

IDLE SPEED: 1,800 i 100 rpm
Timing IS correct if the “F" mark on the flywheel is aligned

with the index mark on the left crankcase at Idle.
If the Ignition tlmlng Is incorrect, reter to page 1477.

CYLINDER COMPRESSION

Warm up the engine.

Stop the engine and remove the spark plug.

Connect a compression gauge to the engine.

Open the throttle completely and operate the starter motor
for several seconds.

NOTE

 

s Be sure compression does not leak at the gauge connection.

 

SERVICE LIMIT: 800 kPa (3‘0 k9/cm2.114 psi)

Low compressron can be Caused by:
‘ Blown cylinder head gasket.
~ Worn piston ring or cylinder.
High compressmn can be caused by:
Carbon deposits in combustion chamber or on piston head.

NUTS, BOLTS, FASTENERS

Tighten all bolts, nuts and fasteners to their specified torque
values (page l-5l at regular lntervals as shown In the Mainte-
nance Schedule.

Check that all cotter pins and safety clips are in place.

 

 

: ' .‘
(I) COMPRESSION GAUGE,
COMMERCIALLY AVAILABLE
‘9'

 

3-11

 

 

 

4-0

4. FUEL SYSTEM

 

 

SERVICE INFORMATION 4-1 CARBURETOR 4—4
TROUBLESHOOTING 4—1 REED VALVE 4~10
FUEL TANK 4-2 AIR SCREW ADJUSTMENT 4-11
AIR CLEANER CASE 4-3

 

 

SERVIOE INFORMATION

GENERAL

0 Use caution when working with gasoline. Always work In a well-ventilated area and away from sparks or flames.

Bleed air lrom the oil outlet line whenever it is disconnected.
Route all tubes and cables properly.

SPECIFICATIONS

 

Venturi dia. 14 mm [0.59 in)

 

Identification number '55: PA27E
Alter ’85: PA27F
12.2 mm (0.48 in)
2 /4 turns out
' Tribe {loo 'DIT1
2—6 m’nTu/arm .nl

firs, 4F7

 

Float level

Air screw ageing

Idle speed i 7
frhrottle grip free play

 

 

 

When disassembling fuel system parts, note the location of the O-rings. Replace them wlth new ones durlng assembly.

 

 

TORQUE VALUES

Carburetor bolt
Fuel strainer cup

TOO LS
Special
Vacu um pum p

Common
Float level gauge

TROUBLESHOOTING

Engine cranks but won't sun
- No fuelin tank.
Too much fuel gettlng to cylinder.
‘ Clogged air cleaner.
' Faulty auto bystarter.

Engine idles roughly, stalls or rum poorly
' Incorrect idle speed.

‘ Rich mixture.

- Lean mixture.

' Clogged air cleaner.

’ Leaking intake pipe.

' Contaminated fuel.

' Faulty ignition system.

~ Low compression.

- Water in fuel strainer cup.

9A12 N-m (0.9—1.2 kg-m, 6—9 ltrlb]
3—5 N-m (0.3—0.5 kg-m, 2273.6 ft lb)

A937X—O41—XXXXX or STiAH7260—MCV lU SA. onlyl

071101 —00 l 0000

Learn mixture

- Clogged carburetor fuel jets.

- Clogged fuel cap vent.
Clogged fuel liner.

- Kinked or restricted luel line.

’ Faulty Iloat valve.

' Float level too low.

- Clogged air vent tube.

Rich mixture

- Faulty float valve.

- Float level too high.

~ Clogged carburetor air jets.

- Disconnected auto bystarter wires.

. Auto bystarter valve set plan? no: set properly.

 

4-1

FUEL SYSTEM

 

FUEL TANK
[ma

~ Gasoline is (ct'rretmelv flammable and is explosive under
curtain wndilinns. Perform this operatiun in a well-remi-
IarPd area and (In no! smoke m allow marks in [he area.

 

 

FUEL FILTER CLEANING

Remove the body center cover (page 1074;,

Turn the fuel valve OFF,

Disconnect the fuel Ilne at [he jomL turn the value CM and
drain the fuel into a clean contamer

Reconnect the fuel line to the iomt.

Dlsconfiec! the fuel lme from the fuel valve.
Loosen the fuel valve lock nut and remove the valve and filter
harm the tank.

Clean the fulter wuh compvessed alr.

Install the filter and a new O~nng onto the valve.

Install the valve onto the tank and tighten the lock nul. Do
not Overrhghlen the lock nut

Connect the fuel lme to the valve.

Fill the tank wlth gasoline.

Turn the valve 0N and make sure that there are not leaks.
lnstall the bodv center cover lpage 104).

FUEL TANK REMOVAL

Remove the body center cover (page 104).

Remuve the seat attachmg nuts and the seat from the fuel
tank.

Elfl FUEL VALVE

\

(llNUTS

(2) SEAT

.
(3) O‘RING
_ -

    

 

 

4-2

Turn the fuel valve OFF and disconnect the fuel line from the
valve.

Disconnect the air vent tube from the tank
Remove the four tank mounting bolts and the tank.

FUEL TANK INSTALLATION
Install the tuel tank in the reverse order of removal.

Make sure that there are no leaks after installation.

FUEL SYSTEM

(1) FUEL TANK MOUNTING BOLTS

 

AIR CLEANER BASE

REMOVAL/INSTALLATION

Remove the engine cover (page 105),

Remove the spark plug wire from the plug and clamp.
Disconnect the wire connectors above the air cleaner case.
Remove the air cleaner case mounting bolt and the case.
Install the air cleaner case in the reverse order of removalv

3»5 N-m
(DB—0.5 kgrm, 2 273.6 ftelbl

 

 

     

FUEL SYSTEM

 

CARBURETOR

THROTTLE VALVE DISASSEMBLY

Remove the carburetor cover.
Remove the carburetor can and pull out the throttle valve.

Disconnect the throttle cable from the throttle valve,

Remove the throttle valve spring, Carburetor cap and sealing
cap from the throttle cable.

Alter '85:
CAUTION:

 

The carbun'wr cap is an integral part of {he [hmrlle cable
assembly. The cap cannot be xeparared from the axsembly
wirhuur damaging the cable.

 

Remove the retainer and let needle from the throttle valve.
Check the jet needle and throttle valve for wear or damage and
replace if necessary,

(2) THROTTLE VALVE -(3) CARBURETOR CAP

SPRING
,. ‘ .‘

  
      

2] THROTTLE VALVE!
-- _

(”SEALING CAP

A

 

 

(3) JET NEEDLE

(4) THROTTLE
VALVE

C’f;i\l1) RETAINER

1 \(2) NEEDLE CLIP

(6
/

 

 

 

4-4

CARBU RETOR REMOVAL

Remove the engine cover (page 105).

Remove the right rear wheel (page1272).

Remove the air cleaner case mounting bolt (page 43] and pull
the air cleaner case away from the carburetor.

Remove the two muffler bracket bolts and the bracket.
Remove the two Intake prpe cover bolts and the covert

Disconnect the auto bystarter wiresv
Remove the carburetor cap Vrom the carburetor.
Turn the fuel va‘ve OFF and disconnect the fuel line from the

carburetor.
Remove the two carburetor mounting bolts and the carburetor

from the intake PIPE.

AUTO BVSTARTER INSPECTION

Stop the engine and allow It to cool Vov at least 10 mlflutel
RESISATNCE: 10 ohms max.

Rep‘ace the auto bystarter if it is out of specmcatmn or if
there is no continuity.

Allow the carburetor to cool for at ‘east 30 mmules and then
pressurize the enrichmg circuit.

If the passage IS blocked, replace the auto bvstarlerv

FUEL SYSTEM

.(21AIR72LEANERE

we:
.76

J ,

 
 

   
 
 
 
  

 

I ~, -
[H3] BOLTS (4) INTAKE PIPE COVER
’-

12) AUTO BYSTARTEH
WIRES

(1) FUEL LINE

(3) CARBURETOR
CAP
'-
U ETOR
I

 

 

 

 

 

 

   

(1) VACUUM/PRESSURE PUMPV
A937X70417XXXXX OR
PRESSURE PUMP
STiAH7260»MC7 (U.S.A. only)

 

 

 

 

4-5

FUEL SYSTEM

 

Connect a 12V battery between the auto bystarter wires and
wait five minutes.
NOTE

- The auto bystarter wires can be connected to the battery
terminals without regard to the porality.

 

 

Pressurize the fuel enriching circuit.

Replace the auto bystarter if there is not restriction to the
pressure applied.

AUTO BYSTARTER REMOVAL

Remove the two auto bystarter set plate screws. set plate and
auto bystarter.

Remove the O-ring from the auto bystarter.

Check the auto bystarter needle and valve for wear or damage.
Replace the auto bvstarter as an assembly, if necessary.

FLOAT CHAMBER DISASSEMBLY

Place a drain pan under the carburetor and loosen the car
buretar drain screw to drain the fuel.

Remove the float chamber screws and chamber from the
carburetor.

 

  

 

 

(1) VACUUM/PRESSURE PUMP
A937X—0417XXXXX 0R
PRESSURE PUMP
ST—AH72607MC7 (U.S.A. only)

 

 

 

(1) BYSTARTER NEEDLE (2) O-RING

    
   

(3) BYSTARTER VALVE

(”SCREWS

(2) FLOAT CHAMBER (3) 28‘6"“ SCREW

 

4-6

FUEL SYSTEM

 

Remove the float pin set screw, float pin, float and Hear valve.
Remove the (Ming.

Inspect the float valve for grooves and nicks and replace as
required.

Turn rhe an screw in until it seals Iighrly and record the
number or rurns. Use this as a reference for reinstallauon.

CAUTION

- Damage Ir) rhe air screw seal will occur if the air screw is
21'ng [med again.” the seal.

 

 

Remove rhe air screw.
Remove the thronle stop screw.
Remove the ma'm je‘ and needle jet.

Blow compressed aw mrough all carburemr body opemngs.

(1) FLOAT (2) FLOAT PW [3) SCREW

  
     

(MO-RING

(5) FLOAT VALVE
— .

Q ' (1) VALVE SEAT

(2) Tlfieor'rLE
STOP scaew I,
- FE": ‘r

. (2) FLOAT VALVEfi

   
 
  
   

m w

(3) AIR SCREW

 

 

 

FUEL SYSTEM

 

F LOAT CHAMBE R ASSEMBLY

Install the needle jet and main iet.

Install the air screw to its original position as recorded during
disassemny,

Install the throttle stop screw.

Install the float valve, float and float pin.
Tighten the float pin set screw securely.
Install a new float chamber Gring.

FLOAT LEVEL INSPECTION

Remove the O‘ring from the carburetor body.

Measure the float level as the float lip just contacts the float
valve.

FLOAT LEVEL: 122 mm (0.48 in)

NOTE

 

- The float is not adjustable; if the level is Incorrect, It must
be replaced.

 

Replace the float if the float level is incorrect.
Reinstall the D-ring into the carburetor body groove.
Check the operation of the float and install the float chamber.

AUTO BYSTAFITER INSTALLATION

Install a new O-ring onto the auto bystarter.

Install the auto bystarter onto the carburetor.

Install the set plate onto the auto bystarter (in the second
groove from the top) and tighten the two screws.

  
   
 
   
   

(3) TH ROTTLE
STOP SCREW

(1) FLOAT

(4) O-RING

IZI MAIN JET

(4i AIR SCREW

(2) FLOAT PIN 13) SCREW

(1) FLOAT LEVEL GAUGE
07401 ~0010000

 

 

4-8

 

FUEL SYSTEM

    
  
 

CARBURETORINSTALLATION [1)FUELLINE ‘ (2ICARBURETOH'6AW

CAUTION

 

D0 not allow any debris into the carburetor,

 

Be sure the O~ring is in place on the carburetors Install the heat
insulator and carburetor mounting bolts

TORQUE: 9—12 N-m (0.9—1.2 kgrm, 7—9 ft—lb)

lnstall the carburetor cap.

$1
(4) AUTO BYSTARTEH
wIRE§

Connect the fuel line and auto hystarter wires.

   
  

“ (is) BOLT!

«,« n... m a
. l1) MUFFLER .(2) INTAKE PIPE
/.v BRACKET 5’.

 

Install the air cleaner case (page 4-3).

Install the Intake pipe cover using the two bolts.
Install the muffler bracket with the two bolts.

 

THROTTLE VALVE ASSEMBLY
Install the iet needle mto the throttle valve and secure it with

6’
the retainer. \11) RETAINER

[2| NEEDLE CLIP

l4lJET NEEDLE ‘ LEAN lst NOTCH
'
STANDARD
2nd NOTCH
‘
THROTT E
(51 VALVE L RICH 3rd—4th—5th
NOTCH

 

 

 

Install the sealing cap, carburetor cap, throttle valve spring and
valve onto the throttle cable.

Slrde the throttle valve into the carburetor body by aligning
rts groove with the throttle stop screw.

 

 

 

FUEL SYSTEM

 

Tighten the carburetor cap.

Perform the following adiustments and operations.
, throttle cable free play adjustment [page 3-5).
7 air screw adjustment (page 4-11).

7 idle speed adjustment (page 3-5].

REED VALVE

REMOVAL

Remove the carburetor (page 4-5I.

Remove the Intake pipe by removing the two belts.

Remove the reed valve.

INSPECTION

Check me reed valve tor damaged or weak reedst

Check the valve seat for cracks, damage or clearance between

the seat and reed. Replace the valve if necessary.

CAUTION

 

 

- Do rm/ disassemble or bend the reed stopper. To do so can
cause loss of power and engine damage, If [he stopper‘ reed

ur valve seat isfaulty, replace them as a unit

 

INSTALLATION

The Installation sequence Is essentially the reverse order of

removal.

After lnstallatl'on, check for secondary leaks.

m

n CA'P'

a

(I) REED VALVES I2) REED STOPPERS

    
 

(3) REED VALVE SEAT

 

4-10

 

AIR SCREW ADJUSTMENT

NOTE

~ The engine must be warm (or accurate air screw adjust-
ment.

 

 

If the engine mlSSES or runs erratically, proceed as follows:
Screw in the alr screw until It llghlly seats, then turn it out as
specified,

AIR SCREW OPENING: 2‘1/4 turns out

CAUTION

- Damage tn the air screw sear will occur if the air screw it
tightened against the seal.

 

 

Reset ldle speed with the throttle stop screw‘
IDLE SPEED: 1,800 £ 100 mm

Make sure that the engine dose nbt miss or run errancally by
lightlv snappmg the throttle.

If necessary, turn the air screw 1/4 turn lmaxvmum) m Ellhel’
direcllon to find the best performance.

If the engine can not be adjusted Within 1/4 turns, reter to
Troubleshooting, POOR PERFORMANCE AT LOW AND
IDLE SPEEDS (page 1673].

FUEL SYSTEM

 

 

4-11

 

ENG |NE REMOVAL/INSTALLATION

 

     
   

65—80 N«m
(6.5~8.0 kg-m, 48—58 fl-Ib)

 
 
    

 
  

1‘ 24—30 N‘m

(2473.0 kg-m,
17—22 h-lb)

 

5—0

5. ENGINE REMOVAL/INSTALLATION

 

SERVICE INFORMATION 5-1 ENGINE INSTALLATION 5-3
ENGINE REMOVAL 5~2

 

SERVICE INFIJRMIITII'JN

GENERAL

0 The engine must be removed to service me crankshaft.

SPECIFICATIONS a

Engine weigh! 12 kg (265 rb)

TORQUE VALUES

Engine mounlmg bolts 24‘30 N-m12v473 0 kg-m,17722 h-IDI
Rear axle nux 65—30 N‘m (6,5410 kg~m, 43758 f! Ib)

 

5-1

ENGINE REMOVAL/INSTALLATION

 

ENGINE REMOVAL

Remove the engine cover (page 105)
Remove the body center cover (page meal.

Place jacks or other supports under the swing iomt and bmh
Sides of the frame.

Remove both rear wheels wrth the hubs (page 1272).
Dlsconnec! the ground cable from the battery negatwe termi-
nal.

Dlsconnect the engine harness connectors from the main
harness.

Make sure that the parking lock lever ls released and disr
connect the parking lock rod bv removmg the nut.

DlsCOnl’leCI the right and left rear brake cables from the brake
arms.

Disconnect the all control cable from the all pump and cable
holder.
Remove the carburetor cap.

Remove the air cleaner case (page 43).

 

‘—
(1) OIL CONTROL
CABLE

 

 

 

5-2

 

ENGINE REMOVAL/INSTALLATION

 

Turn the tee: valve OFF and disconnect the tuei line at the
joint.

Disconnect the all inlet line at (he iomt and drain the oil
Into a clean container.

Remove the three engine mounting nuts and the engine
trem the swing joint

Remove the two dowel pins from the swmg joint,

ENGINE INSTALLATIUN

Installation sequence is essentially the reverse order 01 re-
movalr

TORQUE:
ENGINE MOUNTING BOLTS:
24—30 N-m (21173.0 kg-m, 17—22 ft-Ih)
REAR AXLE NUTS:
65—80 N-rn (6.5—3‘0 kgem, 43—53 ft—lb)

Perform the (allowing inspections and adjustment after
installation:

7 wire and cable routing (page 1»7L

7 throttle grlp 'ree play adjustment (page 35).

7 oil control cable adjustment (page 35).

7 on pump and line bleeding (page 2-3).

7 rear brake adjustment (page 378).

7 parking lock adjustment (page 378).

 

 

CYLINDER HEAD/CYLINDER/PISTON

 

 

 

 

6-0

 

. CYLINDER HEAD/ CYLINDER/ PISTON

 

 

SERVICE INFORMATION
TROUBLESHOOTING
CYLINDER HEAD REMOVAL

 

64 CYLINDER/PISTON REMOVAL 6-3
6-1 PISTON/CYLINDER INSTALLATION 6-6
6-2 CYLINDER HEAD INSTALLATION 6-8

 

 

SERVICE INFORMATION

G E N E R A L
C
Before disassemblv. cIean the engine to prevent din a
Remove all gasker malarial from the mating suriaces
Use cannon when disassembling and assembling the l:
Clean all dlsassembled pans ‘hcroughly before insp
assembly.

SPECIFICATIONS

All cylinder head, cylinder and pis‘on service can be done will! the engine installed in the frame.

rid dust from entering rhe cylinder and crankcase.

of the cylinder head, cylinder and crankcase.

ylinder head, cylinder and piston to avoid damaging them.

action. Coat all sliding surfaces with clean 2-srr0ke injector oil before

 

ITEM

STANDARD mm (in) SERVICE LIMIT mm [ml

 

 

Svlifligr head warnage
g Cyliinder bore 7 7 7 fl 7
Pi on CD (4 mm from bottom of plslon skirt) I
7 piston aearance
*Plslon pin hole |.D,

TPls'mn pin 0.0,
TfirsitainriE-ipisron an clearance
Pisron ring and gap (top, second)

 

  

 

T 71000—41020(1.70157230150)

. 0035:0050 (00013—00019) 0.10 (0.004)
‘ 10002—10005 (03938—03940) 0* 10.025 (0.3947)?
099440.000 (0393543937) 9.920 (0.3929)

7" 0002—0014 (000017010006) 7

70.10 (0.004)
4105011.6161l 7,
4090005102)

40355—40370 (15124—15130)

 

 

0.10—0.25 (0004;001) 7 0.507002)

 

 

 

TORQUE VALUE

Cylinder head bolt 8—12 N«m

TIIflUBLESHDflTING

Communion to low, hard naning or poor performance
ax low spend

‘ Leaking cylinder head gasket.

Loose spark plug.

Worn, stuck or broken pislon rings.

Worn or damaged cylinder and piston.

Fanny reed valve.

Compression too high, overheating or knocking
Excesslve carlmn build-up in cylinder head or on mp
of piston.

(0.8—1.2 kgrm, 679 iHbl

Abnormal noise-piston
Worn cyllnder and piston.
Worn piston pin or Dislon pin hole.
Worn connecllng rod small end bearing.

Abnormal noise
Worn, stuck or broken piston rings.
Worn or damaged cylinder.

 

6-1

CYLINDER HEAD/CYLINDER/PISTON

 

CYLINDER HEAD REMOVAL

Remove the engine cover (page 105),
Remove the norm rear wheel (page 12-2).
Remove the muffler bracket by removing the two bolts.

Remove rhe intake pipe cover by removing the two bolts.

Remove the spark mug cap.

Remove the two nuts attaching the spark plug guard and
the guard,

Remove the cylmder head shroud by removing the bolt.

Remove the four cylinder head bolts and the cylinder head.

NOTE
Loosen the bolts in a crisscross pattern in 2 or 3 steps.

 

 

Remove the cylinder head gasket.

(1) CYLINDER HEKD " (2) NUTS I

Y
(4JSPARK PLUG
GUABD

(3) BOLT (5)PLUG CAP

 

   

TVLINDEEHEAD ‘

.

 
     

(2) BOLTS

 

6-2

CYLINDER HEAD/CVLINDER/PISTON

 

COMBUSTION CHAMBER DECARBONIZING

Remove the carbon deposits from the combustion chamber]
and the piston head.
Clean the head gasket surface.

CAUTION

 

‘ Avoid damaging the combustion chamber wall and gasket
surfaces.

 

CYLINDER HEAD WARPAGE INSPECTION

Check the cylinder head for warpage thh a straight edge and
a feeler gauge along the lines Indicated.

SERVICE LIMIT: 0.10 mm (0.004 in)

CYLINDER/ PISTON REMflVAL m'éon

Remove the cylinder head (page 62).
Remove the Ielt rear wheel (page 12-2).

Remove the exhaust pipe joint nuts, mounting bolt and the
pipe.

Remove the cylinder being caveful not to damage the piston.

CAUTION

- Do not pry between the cylinder and crankcase or strike
the fins,

 

 

Place a shop towel into the crankcase around the connecting
rod.

 

 

 

CYLINDER HEAD/CYLINDER/PISTON

 

Remove the piston pin CIIp wirn needle nose pliers.
Press the piston pin out of the pisron.

NOTE

- Do not damage or scratch the piston.
Do not apply side force to the connecting rod.
- Do not let the clip fall into the crankcase.

 

 

Remove the piston rings.

NOTE

- Spread each piston ring and remove it by lifting it up at a
point just opposite the gap.

 

 

CYLINDER/PISTON INSPECTION

Check the cylinder and piston for wear or damage.
Clean carbon deposits from the exhaust port area.

CAUTION
- Du no! scratch or score the cylinder liner.

 

 

Inspect the cylinder bore for wear at three levels in the X and
Y directions. Use the largest measurement to determine the
amount of cylinder wear,

SERVICE LIMIT: 41.050 mm (1.6161 in)

    

 

 

(1IPISTONPIN

   

I2] PISTON PIN CLIP /

 

‘.

 

I2) SECOND (1) TOP RING
RING

  
 

(3)
EXPANDER

 

 

 

 

6-4

CYLINDER HEAD/CYLINDER/PISTON

 

CAUTION

The cylinder is ideniified with either a ”A "or no mark in
the [Marian shown. When the cylinder is repheed, um
11 new cylinder wiih [he same mark a: the old one.

 

 

Measure (he piston CD, at a point 4 mm Irom the bottom of
the skin.

SERVICE LIMIT: 40.900 mm (1.6102 in)

Calculare [he msmn-toevl‘mder clearance.
SERVICE LIMIT: 0.10 mm (0.004 in)

Measure rhe piston pin hole LD.
SERVICE LIMIT: 10.025 mm (0.3947 in)

Measure (he piston pm O.D.
SERVICE LIMIT: 9,930 mm (0.3929 in)

CaIculate the pismn‘to-pismn pin clearance
SERVICE LIMIT: 0030 mm (0.0012 in)

PISTON RING INSPECTION

Set each piston ring squarer imo (he cvlinder 30 mm (14/4
in) from me bonom using the pismn and measure me and gap
wixh a feeler gauge,

SERVICE LIMIT: 0.50 mm (0.0197 in)

 

 

 

CYLINDER HEAD/CYLINDER/PISTON

 

CONNECTING ROD INSPECTION

Install the bearing and piston pin in the connecting rod small
end and check for excessive play,

PISTON/ CYLINDER INSTALLATIUN

Clean the piston ring grooves,

Lubricate the piston rings and piston ring groove: with clean
ertroke oil.

Install the piston rings on the piston, with the marks lacing up.

NOTE

. Aiter installation, check that the rings move freely in the
ring grooves

' The lop ring is a keystone ring and is not interchangeable
with the square second ring.

 

 

Check the in of each ring in the ring groove by pressing the
ring into the groove to make sure that it Is Ilush WIlh the
piston at several points around the ring.

A ring that will not compress means that the ring groove is
dirty and should be cleaned or that the wrong ring is in the
groove.

Coat the needle bearing and piston pin with 2-stmke oil.
Install the needle hearing at the connecting rod, and install the
piston with the "EX" mark facing the exhaust side.

Install new piston pin clips.

 

 

(1| PISTON

(2) TOP RING

  

I4) SECOND RING
(3) EXPANDER

 

 

   
 

 

IilTOP RING

(2) SECOND \D
RING

I3) EXPANDER

 

l1) PISTON PIN "V

 

(2) PlSTpN’PIN CLIP [3) "EX” MAEK‘l

 

6-6

 

 

CYLINDER HEAD/CYLINDER/PISTON

 

Remove all gasket matellal from the cylinder and crankcase
mating surfaces.

Install a new cylinder gasket onto the cylinder.

Be sure the ring and gaps are aligned with (he pismn ring
locating pins in the ring grooves.

CAUTION

 

- Be sure the ring: do nu! rotate in the their gronvex over the
locating pins I!) prevent ring breakage mid piston and
cylinder damage.

 

Lubricate the pismn and cylinder with erxroke oil. compress
the rings and slide the cylinder onlo the pismn.

CAUYION

 

 

- A void damaging [he Sliding surface of the pislon,

 

  

(1) CYLINDER GA$K_ET

an.

 

.‘l-lalll fis‘TON RING LoéAT'ING PINS W
F,

  

 

6-7

CYLINDER HEAD/CYLINDER/PISTON

 

Install the following.

7 cylinder head.

7 exhaust pipe using the mcunting bolt and two joint nuts.
7 left rear wheel (page 12-3).

7 engine cover (page 105).

CYLINDER HEAD INSTALLATION

Install a new cylinder head gasket.

Install the cylinder head.
Install and tighten the four cylinder head bolts m a crisscross
pattern, in 2 to 3 steps.

TORQUE: 8712 Nm (0.8—1.2 kgsm, 6—91Hb)

Install the Iollowing:

— cylinder head shroud Wlth the bolt.

— spark nlug guard and tighten the two nuts.
— spark plug and cap.

Install the (allowing:

— intake pipe cover using the two bolts.
— muffler bracket with the two bolts.
— right rear wheel (page 123).

7 engine cover (page 105).

Perform the Iollawing inspections:
— compression test (page 3-11).

— check for abnormal engine noise.
7 check for cylinder air leaks.

   

I4lJ0lNT NUT

lSPARK PLUG
GUARD (5l PLUG CAP

  
 

  

‘
(2) INTAKE
PIPE COVER

  

 

6-8

 

EMO

 

 

ALTERNATOR

 

(1) LEFT~HAND THREADS

 

 

7-0

7. ALTERNATOR

 

 

_ SERVICE INFORMATION 7-1 ALTERNATOR INSTALLATION 7-5
LEFT CRANKCASE REMOVAL 7-2 LEFT CRANKCASE COVER ASSEMBLY 7-6
LEFT CRANKCASE COVER LEFT CRANKCASE COVER
DISASSEMBLY 7-2 INSTALLATION 7-7
ALTERNATOR REMOVAL 7-3

 

 

 

l SERVICE INFORMATION

GENERAL

0 Do not remove the pulse generator Irom me stator base.
0 See Chapter 14 for alternator mspecuom

 

TORQUE VALUE

Flywheel nux 35—40 N-m (35—4,!) kgrm. 25—29 Il-Ib)
TOO LS

Common

FIywheel puller 07733—0010000 0! 07933370010000
Universal holder 07725—0030000

Dnver 07749—0010000

Attachment, 24 x 26 mm 07746—0010700

PIIot, 10 mm 07746—0040100

Diiver 07746—0020100

 

 

 

ALTERNATOR

 

lEFT CRANKCASE REMOVAL (HAIRINTAKE 0627‘

.._, ‘ ,’

Remove (he followmg:

7 engme cover (page 10-5).

-— rear wheels (page 1272).

- cylinder head shroud (page 62) and exhaust pipe (page Gil).
— left rear brake cable fvom the brake arm.

7 air intake duct.

Remove me left crankcase cover bolts and [he cover

LEFT CRANKCASE CflVER DISASSEMBLY

For ease ol dlsassemblvl temporari‘y reinstal! (he lefl crank»
case cover onto the rear wheel and remove the final shah
nut and bearing cap,
NOTE:

The run has \eflrhand threads

 

Remove the snap ring,

 

 

7-2

 

Heat the crankcase cover around the bearing.

CAUTION

Wear glavex ta prolec! yuur hand: when handling the
heated cover.

Thread the nut onto me final drive shah just enough to cover
the end 0' the shaft, and carefully drive the shah and bearing
out of the crankcase cover using a plastic hammer.

Remove the inner beating.

ALTERNATOR REMOVAL

Remove (he following:

— lelt crankcase cover (page 72).
— cooling fan bolls and (he {an
7 two dowel pins‘

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

 

ALTERNATOR

r" ,
,1 l2) UNIVERSAL HOLDER
_ 971254030000

 

7-3

ALTERNATOR

 

Remove the flywheel With the puller.

Disconnect the auto bystarter, resistor and ignition coil wtre
connectors.

Disconnect the wire from the starter motor.

Disconnect the ground wire ov removing the starter motor
mounting bolt.

Remove the body center cover (page 104).
Disconnect the engine harness connectors.

Remove the stator mounllng bolts and the stator.

NOTE

~ Do not try to remove the pulse generator from the stator
base.
- Be carefui not to damage the stator coils.

 

     

(I) FLVWHEEL FULLER

 

0773370010000 or 0793370010000

.7—
-(1) EOLTSQ

 

 

 

g

 

7-4

ALTERNATOR

 

ALTERNATOR INSTALLATIIJN

Install the stator onto the crankcase aligning its wire grummet
with the groove m the crankcase.
Tighten the two stator mounting bolts.

       
    

‘moifi~
. . ‘1’

M

r

l

t Connect the engine wvre harness connectors to the main
harness.

Connect the ground wire USII’Ig the starter motor mounting
belt.
Connect the starter wire to the starter motor.

NOTE
Route the wires properly (page 17).

 

 

lnstall (he woodruff key in the keyway in \he crankshaft.

NOTE
Clean the tapered hole in theflywheel of any burrs and dirt.

 

 

Install the flywheel onto the crankshah aligning its keywav
With the woodruff key on the crankshaft.

Hold the flywheel with the universal halder and tighten the
flywheel nut.

TORQUE: 35—40 N‘m (3.5—4.0 kgm, 25—29 ft-lbl

(1) UNIVERSAL HOLDERV’
0772570030300

 

 

7-5

 

ALTERNATOR

 

Ins‘all me cooling fan onto xhe flywheel usmg the lwo bans.

LEFT CRANKCASE COVER ASSEMBLY

Drive a new inner bearing into the left crankcase cover.

Inna” the final shafL
Drive a new outer bearing over the fina| shalt.

Install the snap ring in the groove in the leh crankcase cover.

. ._.

_- (”BOLTS‘

  
  

' > ’3 ‘—1' 1
a (21 COOLING FAN
. a.

4 (-3. :
Wu) DRIVER 07749—0010000

 

. ,. gm“

(2) ATTACHMENT, 24 x 26 mm 07746—0010700
PILOT, 10 mm 07746—004010!)

(1) FINAL SHAFT

 

(2) DRIVER
(27743-2020100

 

 

 

7-6

 

 

ALTERNATOR

 

Temporarily install the left crankcase cover onto the rear
wheel.
Install the bearing cap and tighten the final shaft nut.

NOTE:
The final shah nu! has left-hand threads.

 

 

LEFT CRANKCASE COVER INSTALLATION

Install the two dowel pInS onto the crankcase.

Install the left crankcase cover onto the crankcase and tighten
the covet bolts.

Install the following
— air lntake duct.
— left rear brake cable.
~ exhaust plpe and cylinder head shround (page S-BL
7 rear wheels (Page 12- 3)
engine cover (page 10- 5).
Adjust the rear brake (page 3- B).

“FF/AW R EADS)

 

(2) LEFT REAR BRAKE CABLE

 

7-7

CLUTCH/TRANSMISSION

 

(SD—6,0 kg~m,
36—43 (1-1!”

 

 

8-0

8. CLUTCH/ TRANSMISSION

 

SERVICE INFORMATION
TROUBLESHOOTING

RIGHT CRANKCASE COVER
REMOVAL

RIGHT CRANKCASE COVER

8-1
8-2

8-3

DISASSEMBLV

REMOVAL

 

LOW CLUTCH/DRIVE PLATE

PARKING ARM REMOVAL
OIL PUMP GEAR REMOVAL

8-4

8-8
8-9

8-10

STARTER PINION REMOVAL

STARTER PINION INSTALLATION
OIL PUMP GEAR INSTALLATION

PARKING ARM INSTALLATION
LOW CLUTCH/DRIVE PLATE

8-10
8-11
8-11
8-12

INSTALLATION

8-13

RIGHT CRANKCASE COVER

ASSEMBLY

RIGHT CRANKCASE COVER

INSTALLATION

 

SERVICE INFORMATIUN

GENERAL

0 All clutch/transmlssmn semce can be done w1th the engme installed.

SPECIFICATIONS

 

 

 

 

 

 

Specified oil

ITEM 77 if 7 STANDARD mm (1n) 7' SERVICETLVIMIT mm (inlfi
Low clutch Clutch outer ID I 110.00-110.2014331—43391 110.5 (435)

Sun gear plate 1.0 23004303 (0906—0907) 23.1 (0.91)

Clutch linlng thlckness l 1.5 (0.06) 1.0 (0.04)

Clmch spring Iree mm 30.5 (1.52) 39511.56)
Second clutch Clutch limng lhlckness ‘ 1.5 (0.06) 1.01004)

Clutch spring free lenglh 19.510771 20.5 (0.81)

Cltuch outer 1.0. 76.00—76.10 (2392—1996) 76.2 (3.001

Second drive plan 10. 22.934233109034305) 22.80 (0 093)

 

 

 

Honda 4-stroke ml
SAE 1DW‘40 or equivalent

 

Transmission oil capacity

TORQUE VALUES

011 level check bolt
Low drive plaxe nut
Ratchet guide plate huh

TOOLS
Special
Bearing remover m, 12 mm

Commun
Clutch center holder

 

190 cc (6.4 US 01,6.7 Imp oz) after draining
210 cc (7.1 US 02, 7.4 Imp 02) after disassembly

50—60 N‘m (5.0—6.0 kgrm, 36—43 ft-lbl
38742 N-m (3.3—4.2 kgm, 27—31 It‘lbl
10—12 N-m (1.071.? kg-m, 7—9 ft-lb)

07936—1660001 —|:

Remover weight

0772470050000 or commercially avallable in U.S.A.

Driver

Attachmem, 32 x 35 mm

Pilot, 15 mm

Bearing vemovev, 12 mm 0793671660100
0774170010201 or
07936—3710200

07 74 9—0010000

0774670010100

07746—0040300

 

8-1

CLUTCH/TRANSMISSION

TROUBLESHOOTING

Engine mm, but scooter won't move
~ Worn clutch Hm'ng.

Worn clutch Dutch

Damaged C‘lflchd

Damaged a. seized gear.

Abnuvmal noise
wdm or sewzed gear.
Worn bearing.

on leaks
~ oulevenoohigh.
wdm or damaged dd seal

 

8-2

 

CLUTCH/TRANSMISSION

 

RIGHT BRANKCASE COVER REMDVAL

Drain the transmission oil (page 2-5).

Remove the engine cover (page 10-5).

Place jacks or supports under the engine and right and left
sides of the frame.

Remove the right rear wheel (page 121).

Remove the two muffler bracket mounting bolts and the
bracket.

Remove the intake pipe cover by removing the two boltst

Disonnect the right rear brake cable from the brake arm and
right crankcase saver.

Release the parking lock iever.
Remove the right crankcase cover bolts and the cover.

Remove the dowel pins and gasket.

(1) M'uF‘FLéKéT :
. ,

:

(2] BOLTS

(1) RIGHT CRANKCASE COVEh
—,

 

    

 

8-3

 

CLUTCH/TRANSMISSION

 

RIGHT CRANKCASE COVER DISASSEMBLY (n‘NEeoLe BEm§§(ZJfiAP 3m

0

Remove the snap ring and needle bearing from the final shaft.

 

Remove the snap ring, washer and second clutch assembty. , ~ (1) WASHER! Var/v
a ~

Remove the prrmary drive gear and thrust washer.

 

Bend down the lock washer tabs and remove the three bohs,
plain washers, lock washers and ratchet plate.

  

a . A.;V " 9
(2) BOLEZPL‘AIB AflD LOCK WASHERS

 

8-4

 

CLUTCH/TRANSMISSION

 

Remove the thrust washer and primary driven gear.
Remove ‘he final drive gear shaft and thrust washer.

Remove the final driven gear and shah.

Remove the snap ring and bearing irom me ngm crankcase
cover,

Remove the oil seal‘

    

(11THnus‘TWASHER (21-PfilMARY DRIVEN
,4 GEAR

   
    

(3) FINAL only; GEAREHAFT

(1) FINAL D‘HIVEN‘GEAB.

  

'I' /

.r
(2) FIN_AL SflAFT'~ /

(HSNAP FUNG

 

8-5

CLUTCH/TRANSMISSION

RIGHT CRANKCASE COVER INSPECTION
Check the bearing bores In the right crankcase cover for wear
or damage,

GEAR/GEARSHAFT INSPECTION
Check each gear and shaft for wear or damageI
RepIace if necessary

SECOND CLUTCH INSPECTION
Measure the clutch liningxhickness.
SERVICE LIMIT: 10 mm (004 in)

 

(I) PRIMARY DRIVE GEAR

 

(2) FINAL DRIVE GEAR

(2) FINAL DRIVEN

III PRIMARY DRIVEN GEAR
GEAR

  
  
 

(3) FINAL SHAFT

 

 

8-6

 

Remove the E-clips, washers, clutch shoes and springs.
Check the clutch shoe springs for damage.
Measure the cluch shoe spring free lengrh.

SERVICE LIMIT: 20.5 mm (0.81 in)

LOW CLUTCH OUTER INSPECTION

Check the clutch ou‘er for wear or damage.
Measure the ID, 0f the dutch outer.

SERVICE LIMIT: 110.50 mm (4.35 in)

Check the needle bearings Ior wear or damage and replace
if necessary.

Remove the needle bearings using the speicaI tools.

Press new needle bearings into the low clurch outer as shown.

CLUTCH/TRANSMISSION

 

 

<—(1) FREE LENGTH

 

 

 

 

(2) REMOVER WEIGHT

07741—0010201 0R 07936-371020!)

 

 

E]

 

 

 

3.1—3.6
(0.1270T4min) .1

 

 

 

 

 

 

 

 

fr

(1571.0 mm
(0.02#D.04 in)

 

 

 

8-7

 

CLUTC H/TRANSMISSION

Check the ratchet pawls and springs for wear or damage.
Measure the sun gear plate I.D.

SERVICE LIMIT: 23.1 mm (0.91 in)

('l) RATCHET PAWL

 

Measure the OD, of the second drive plate.
SERVICE LIMIT: 22.80 mm (0398 in)

 

Check me pranelaw gear fol wear or damage and replace
.4 necessary,

 

[OW CLUTCH/ DRIVE PLATE REMOVAL

Remove the nght crankcase cover (page 831‘
Hold the drive plate with a holder and remove the nut.

  

, .,.—___—,_‘___: , -‘«<- -
(1) CLUTCH CENTER HOLDER 07724-0050000
. 0R COMMERCIALLY AVALLABLEflESA.
' .

   

    
  
 
  

NOTE
The nut has left-hand threads.

Remove the low clutch/dnve plater

 
 

(2) NUT

(3) LOW éLUTCH/ -
(LEFT-HAND THREADS)

DRIVE PLATE \

8-8

 

CLUTCH/TRANSMISSION

 

LOW CLUTCH INSPECTION

Measure the clutch Iming thickness.
SERVICE LIMIT: 1.0 mm (0.04 in)

Inspect the clutch springs for wear or damage.
Remove the E-clips, washers, and clutch shoes.

Measure each clutch shoe spring free length.
SERVICE LIMIT: 39.5 mm (1.56 in)

Replace any worn ar damaged parts.

SECOND CLUTCH OUTER INSPECTION

Check the second clutch outer Ior wear or damage.
Measure the ID,

SERVICE LIMIT: 76.2 mm (300 in)

PARKINE ARM REMOVAL

Remove the right crankcase cover (page 8-3)‘
Unhook the spring and remove the parking arm assembly and
arm shaft.

Remove the left rear wheel (page 112)
Remove the nut and parking arm from the left end of the
parking shaft.

Remove the parking shaft from the crankcase.

(1) CLUTCH SPRING

(2) WASHER

(3) E-CLIP

 

 

 

 

CLUTCH/TRANSMISSION

 

PARKING ARM/SHAFT INSPECTION
Inspecx (he parking arm] shafts and spring for wear or damage.

OIL PUMP GEAR REMOVAL

Remove the following:
A clutch (page 84!).
— oil pump drIve gear.

— parking arm assembly (page 8-9).
— hoIder plate bolt and the pIaxe.
— oil pump dviven gear.

STARTER PlNIflN REMflVAL

Remove the following:
7 clumh (Page 378).
7 starter pinion.

(2) PARKING ARM
ASSEMBLY

U) PARKING SHAFT

 

(3] SPRING [HARM SHAFT

 

(HouLPu—MP ' I'm—Hanan PLATE
‘ DRIVEN GEAR guy 'I -~
. ~ '

I” ‘.

    
    
   

> ’ (HSTA’ TER Pl

I A

  

 

8-10

 

CLUTCH/TRANSMISSION

 

STARTER PINION INSPECTION

Check that the starter pinion rotates only In one direcIIont

Also check that the gear returns freely.

STARTER PINlllN INSTALLATIIIN

Install the starter pinion onto the crankcase,

OIL PUMP GEAR INSTALLATION

Apply grease to the oil pump drive gear and journal.
Install the oil pump driven gear into the crankcase.

Install the gear holder plate with the bolt.
Install the parking arm assembly (page 812),

 

  

(1) STARTER PINIOI‘

*GlI'

   
 

*0,
(I) OIL PUMP DRIVEN GEAR

a ’ (7)73‘EAR Hd'LDTR PLATEU
' ' » . " “m 1"

       

(2) PA‘RKING ARM
ASSEMBLY >

 

CLUTCH/TRANSMISSION

Install the all pump drlve gear omo me crankshaft. /
I’

PARKINE ARM INSTALLATION

Install the patklng shah mm the crankcase.

(1) OIL PUMP DRIVE GEAR
‘ .-

     

Install me am onto me Ieh end oi lhe parklng shaft and
ughxen the nut.
Install the Izh rear wheel (page 12-3).

Install the parking arm assembly and shaft. I

 

I \
(H PARKING ARM ASSEMBLY

 

8-12

 

CLUTCH/TRANSMISSION

 

LOW CLUTCH/ DRIVE PLATE INSTALLATION

Install the low clutch/drive plate onto the crankshaft
Hold the drive plate with a holder and tighten the nut

TORQUE: 3842 N-m (33—42 km“, 27—31 h-Ib)

NOTE
' The nut has left-hand threads.

 

 

RIGHT CRANKCASE CBVER ASSEMBLY

Install a new oil seal onto the right crankcase cover.

Drive a new bearing into the right crankcase caver.

Install the snap ring.

    

 

(1) CLUTCH CENTER HOLDER 07724 06. 0000 _ORW
COMMERCIALLY AVAILABLE IN U S A

 

.4 r A I'w
(2) ATTACHMENT, 32 x 35 mm 07746—0010100
PILOT, 15 mm 0774670040300

 

 

CLUTCH/TRANSMISSION

 

Install the final shaft and final driven gear onto the Vlght
crankcase cover.

Install the thrust washer and hnal drive gear shah.
Install the prlmarv dnven gear and thrust washer onto the
dnve gear shalt.

NOTE ,
Face the dishead end of the thrust washer in.

 

 

Install the ratchet plate using new lock washers, the clam
washers and bolts, Tlghten the bulls In the sequence shown.

TORQUE: 10—12 Nem(1,0——1.2 kg-m, 7—9 h-lb)

Bend the lock washer tabs up against the bolt heads.
Make sure that the prlrnary driven gear rotates smoothly.

Install the sun gear plate, thrust washev and prIrnarv drtve gear
onto the secnnd drlve plates
Install the thrust washer onto the iinal shaft.

2
\e

(‘} “(2) FINAL SHAET‘ v

(1) FINAL BETVE’ tzfiHRUST WASHER
GEAR SHAFT J

9:
(2) TEEUET WASHER

   
  

 

 

8-14

 

CLUTCH/TRANSMISSION

 

THRUST wAgHea’ filENAPfiNGS "l ‘

Install the following:
- second clutch assembly omo the final shatt.
— thrust washer and a new snap ring.

— need|e bearing and a new snap ring,

Apply grease to the needle bearing.

RIGHT BRANKBASE COVER INSTALLATIBN

Install the two dowel pins and a new gasket.
Apply grease to the crankshaft borer

Install the rlghr crankcase cover and tighten the belts in a
crisscross pattern in 2 to 3 steps

 

Connect the right rear brake cable [0 the brake arm.

(1) RIGHT REAR BRAKE CABLE

 

 

CLUTCH/TRANSMISSION

Install the intake plpe cover with the two boltsl

2) BOLTS

 

Inslall me muffler blacks! using me [W0 bolts,

Fill the transmission with the recommended oil (page 2-5).
Install the right rear wheel (page 12-3).

Install lhe engine cover (page 10-5).

Adjust the rear brake (page 38).

Adjust the parking lock (page 3-8).

1) Mu‘FF‘LER BRACKET
‘ A. ' an, ‘\ ‘
‘ Ml;

“7"“)

          

 

8-16

 

MEMO

 

AAAAAAAAAAAAAAAAAAAA

 

 

 

9-0

9. ORANKOASE/ORANKSHAFT

 

 

SERVICE INFORMATION
TROUBLESHOOTING
CRANKCASE SEPARATION
CRANKSHAFT REMOVAL

 

9-1 CRANKSHAFT INSPECTION 9-3
9-1 CRANKSHAFT INSTALLATION 9-4
9-2 CRAN KCASE ASSEMBLY 9-5
9-2

 

SERVICE INFORMATION

GENERAL

I This section covers crankcase separation to service the crankshaft.
o The Ioilowing parts must be removed before separating the crankcase

Engine

Carburetor

on pump

Reed valve

Starter motor

Alternator

Cylinder head and cylinder
Clutch

SPECIFICATIONS

If 7 ITEM,

Section 5
Section 4
Section 2
Section 4
Section 14
Section 7
Section 6
Section 8

STANDARD mm (in)

SERVICE LIMIT mm (in)

 

 

Connecting rad big end side clearance
Connecting rod big and radial clearance
Cran kshait runaut

 

 

0V5 [0'02l
004 (0.002]
0.15 (0.006l

 

TOO LS

Special

Crankshaft assembly tool
Universal bearing puller
Shaft protector
crankcase puller

Common

Driver

Attachment, 42 x 47 mm
Pilot, 20 mm
Attachment, 37 x 40 mm
Pilot, 17 mm

Clutch center holder

TROUBLESHOOTING

Abnormal engine noise
Worn main journal bearing.
Worn crank pin bearing.
Worn transmission bearing.

07965—1480010 Collar
07631 —0010000 Shaft
07931 —1 870000

07965—1430100
0796570M00300

07935—GJ50000 [Not available In USA) or 07937—4300000

07749—0010000
07746—0010300
0774641040500
07746—0010200
07746—0040400
07724—0050000

 

9-1

 

 

CRANKCASE/CRANKSHAFT

 

BRANKCASE SEPARATION

Remove the breamar mbe from the crankcase.
Remove the crankcase assembly bolts.

Remove the nghx cvankcase from the left crankcase.

NOTE

 

Use me crankcase puIIer If dvfficulty is encountered m
separating the crankcases.

BRANKSHAFT REMIJVAL

Dru/e om the crankshan irom the lefx crankcase USIng a plasxic
hammen

Remove the left crankshaft bearing from the crankshaft.

NOTE
Dc mm reuse {he old bearing

 

 

 

.(1) CRANKCASE FULLER WEISS—(3.150000

(NOT AVAILABLE IN U.S.A.] OR

01937—430000!)
, 1

    

 

(1) UNIVERSAL BEARING PU‘LLFR 07631—0010000
OR COMMERCIALLY AVAILABLE IN U .A.

 

(2) §flAFT PROTECTOR 0793171870000

 

9-2

Remove the Dil seals from the both crankcase;

CRANKSHAFT INSPECTION

Measure the connecting rod big and side clearance thh a feeler
gauge.

SERVICE LIMIT: 0.5 mm (0.02 in)

Measure the connecting rod big end radoal clearance at [We
poims in the x and Y directions.

SERVICE LIMIT: 0.04 mm (0.002 in)

Set the crankshaft on a stand or V-blocks and read runouk
using a dral gauge.

SERVICE LIMIT: 0.15 mm (0.006 in)

CRANKCASE/CRANKSHAFT

(HOILSEALS Qgé"
:g/

    

(2) LEFT CRAN KCASE \(3I _FIIGHT CRANKCASEJ"

 

 

    

58 mm
(2.3 in)

 

9-3

CRANKCASE/CRANKSHAFT

 

 

Spin the crankshaft bearing by hand and check for play. The

bearing must be replaced if it is noisy or has excessrve play. m ”U“ PLAY 0’ RAD'AL PLAY

—~~— i
T

 

 

 

 

 

 

 

 

 

CRANKSHAFT INSTALLATIDN

Wash the crankcase and crankshaft in solvent and blow dry
with compressed air. Check lor cracks an other faults.

NOTE

Apply clean Zstroke injector oil to all moving and sliding
faces oi the crankcase.

Remove all gasket material from the crankcase mating sur~
laces. Dress any roughness 0r irregularities with an Oil
stone,

 

Drive a new journal hearing into the right and left crankcase
halves

TOOLS:

LEFT CRANKCASE

l1] DRIVER 07749g0010000

(2] ATTACHMENT, 37 x 40 mm 07746—0010200
PILOT, 17 mm 07746—0040400

RIGHT CRANKCASE

l1) DRIVER 07749—001000!)

(2) ATTACHMENT] 42 x 47 mm 07746~0010300
PILOT, 20 mm 07746-0040500

Install a new oil seal onto the left crankcase.
Install the crankshalt into the left crankcase.

NOTE

If assembly is difficult, use the crankcase assembly tool as
shown.

Do not use a press or drive the crankshaft into the case.
Lubricate the journal bearing and connecting rod big end
with Honda 2-stroke oil or equivalent

 

 

 

(1lCRANKCASE ASSEMBLY TOOL
0796571480019 ,

 

9-4

CRANKCASE/CRANKSHAFT

 

lnslall the on seal We the left crankcase usmg the specual tool
as shawns

CRANKCASE ASSEMBLY

Install the two dowel pins and a new gasket,

Assembly the crankcase halves.

NpTE
To draw ll’le crankshalt mm the right crankcase, tempo-
rarlly Install the oil pump drive gear and clutch, and thread
the low drwe plate nut onto the crankshalt (the nut has
lellrhand threads].

 

 

Install and tighten the five crankcase attaching bolts In a CrlSS'
cross pattern.

Alter assembling, check that the crankshaft rotates lreely
without bmdingt

Install the crankcase breather tube

Remstall all removed parts and mount the engme in the frames

(1) CRANKCAS’EVA$EMBLV TOOL 0796571480010
. , t

   
  
  
  
  

4-5 mm (Zl OIL SEA

(0.18 m)
L

5 a;

 

 

(1) C‘Lu'TCH CENTER HOLDER 0%‘724—0050000
0R COMMERCIALLV AVAILABLE IN U.S.At 6
_ . V ‘

 
         

km BREATHER TUBE
"fig,” .3 3

 

9-5

FRAME COVERS

 

 

 

 

10-0

10. FRAME COVERS

 

 

SERVICE INFORMATION 10-1 BODY CENTER COVER
FRONT COVER/HEAD PIPE COVERS/ REAR COVER
FLOOR BOARD 10-2 ENGINE COVER

 

10-4
10-4
105

 

 

SERVICE INFORMATIIJN

GENERAL

0 AIign [he Iabs on the covers properly wuh me gvooves when InstaIIing,
. Take Care that the eres are not cough! when InstallIng the Covers,

 

10-1

 

FRAME COVERS

FRONT CUVER/ HEAD PIPE COVERS/
FLOUR BOARD

REMOVAL

Remove the heaeiighr (page 1475) and disconnect the OII Ievei
warning light wires in the headlight case.

Remove the two bolts attaching the from and head pipe covers
and remove the from caver.

Turn the ignitlon switch OFF, release the Datklng lock lever
and remove we head pipe upper cover.

Raise the parking lock lever up and remove the head pipe
lower cover,

Remove the floor board by removmg the two boils.

INSTALLATION
Align the tabs on the “our board With the groove in the Center

plate.
Tighten the two floov board bolts.

Aiign me tabs on the head pipe iovver cover vvirh the groove In
the floor board and install the cover.

'1 i a.
m HEAD PIPE L‘JPPfiI COVER « (2D FRON‘T COVER

 

(2) TABS AND GROOKES

 

10-2

FRAME COVERS

 

A|ign the holes in the head pipe lower cnver with me bosses on
the frame as shown.

Release the parking lock lever and install the head pipe upper
cover, then raise the parking lock leverl

Align the hole in the head pipe upper cover with the bosses on
the frame as shown,

Inslall lhe from cover aligning iks holes with the bosses.

Install and lighten rhe two bolrs.
Connecr the oil level warning ligm wires to the wire harness
and Install me headllght.

(2) HOLE AND 8055

 

 

 

FRAME COVERS

 

BODY CENTER COVER

R EM OVA L

Turn the fuel valve OFFL

Remove the screw attaching the fuel valve knob and the knob
Remove the center plate by removing the two bolts.

Remove the two screws and two bolts attaching the body
center cover to the frame and the cover.

INSTALLATION

lnstall the body center cover In the reverse order of removal.

REAR COVER

REMOVAL

Raise the seat and remove the document compartment.

Remove the four rear CarrlEV attaching bolts, earner, four
collars and rear cowlv

12) REAR COWL

   

(I) FUEL VALVE KNOB

 

\l

(3) BOLT OLLARS

 

104

 

FRAME COVERS

 

Disconnect the tail/brake Iight coupler.
Remove the rear cover by removing the two nuts and bolts.

INSTALLATION

InstalI the rear cover In the reverse order of removal.

ENGINE COVER

REMOVAL

Remove the two muffler mounting nuts.

 

- Remove Ihe muffler when it is moi.

 

Remove the two muffler joint nuts and me mufller (mm the
exhaus‘ pIpE.

Remove the four engrne cover heirs and remove the cover.

INSTALLATION
Install the engine cover in the reverse order of removal.

NOTE

5 Make sure that the exhaust mumer 30am gaskex is in good

condition before installing the muffler.

 

      

(ZENGINE CQVER

(3) TAIL/BRAKE

LIGHT COUPLER

 

 

10-5

STEERING/FRONT WHEEL/BRAKE/SUSPENSION

  

 

8.0 kw», 43—58 ft-lb)

60—80 N-m

(6.0—

            

(0.5—1.3 kg-m,

3.6—9 h-lb)

(4.0—5.0 kgrm, 29—36 h-lbl
5—13 N-m

40—50 N-m

(4.0—5.0 kg—m, 29—36 be)

40—50 N-m

4—7 N‘m
(0.4—0.7 kg-m,
3—5 hvlb)

 

11-0

 

ll. STEERING/ FRONT WHEEL/ BRAKE/ SUSPENSION

 

 

SERVICE INFORMATION
TROUBLESHOOTING
HANDLEBAR

PARKING LOCK
THROTTLE CABLE

 

11-1 REAR BRAKE CABLE 11-7
11~Z FRONTWHEEL 11-9
113 FRONT BRAKE 11—11
1175 FRONT SUSPENSION 11-14
11-6 STEERING 11-16

 

 

SERVICE INFORMATION

GENERAL

I Brake dus‘ contains asbestos which can be harmful ‘0 your health.
I Do not use compressed air (0 clean brake drums or brake panels. Use a vacuum wilh a sealed collector. Wear a protective
face mask and lhroughly wash your hands when finished.

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

ITEM STANDARD mm (in) SERVICE LIMIT mm (in)
Axle shah runuul — 0.2 (MW
Flym runout Radlal — 2.0 (0.08)
‘ Axlal 7 2.0 (0.08)
From fork spring flee length 121.8 (4.80) 117.0 (4.61)
From brake drum ID 80.01115) 80.5 (3.17)
From brake lining thickness 3.5 (0.14) 1.5 (0.0m

 

TORQUE VALUES
Handlebav lower holder nut
Brake adjusler boll lock nut
From axle nul

From brake arm bolt
Sreeringslem lock nu!

Fork budge ban

Sleerlng 5mm nux

TOO LS

Special

Lock nu! wrench

Lock Hm wrench

Snap rmg pliers
Anachmem, 28 x 30 mm
Ball race remover
Steering skem driver

Common

Extension

Lock nut wrench, 30 x 32 mm
Attachment, 42 x 47 mm
Pilot, 10 mm

Bearing remover shah

Bearing remover head, 10 mm
D(iver

40750 N-m (4.0—5.0 kgrm, 29736 beI
3.5—5 Nvm (03570.5 kg m, 2.5—3.6 ftrlbl
40-50 N-m (4.07.5.0 kg-m,29—361(~Ib)
4-7 N'm (0.4707 kg-m, 3—5 frlhl

5—13 N»m (0.5—1.3 kg-m, 3.679 (Hm
40750 N-m (4.0—5.0 kg-m, 29736l1-lb)
60780 N-m (6.0—8.0 kg-m. 43758 ltslb)

0791671870101

079167KM10000

0791473230001

0794671870100

D7946—GA70000 (N01 avallable m U.S.A.l
07946—4300101

07716—0020500
07716—0020400
07746—0010300
07746—0040100
07746—0050100
0774670050200
0774970010000

:— or commercially available m U.S,A,

 

11-1

 

STEERING/FRONT WHEEL/BRAKE/SUSPENSION

TROUBLESHOOTING

Hard steering

Steering [Op cone race/nut too tight.
Damaged steering bails and races.
Insuiflment tire pressure.

Steers to one side or does not track straight
‘ Bent front iark.
‘ Bend front axle or spoke plate.

Parking lever not locked
‘ Cable not adjusted properly.
Damaged or elongated cable.
Damaged engine Side parking return spring.

Parking lever dues not return or is stm

‘ Insufiiment cable play.

Damaged parking lever spring.

‘ Cable E-ring disengaged from swmg lock lever.
Swing mechanism is locked, but parking lock lever is not
engaged

‘ Improperly adiusied cable.

Swmgtovarklng lock rod disconnected.

Parking lock arm pawl damaged or chipped.

Parking dlsc teeth damaged or chipped.

Parking lock lever is engaged, but swing lock is not
applied

Cable not adjusted properiv.
Swing lock pawl damaged.
Swing lock pawl linkage damaged.

Pnrking lever returned with ignition switch in LOCK

Deformed or damaged lever stopper.
TWlstEd or damaged parking lever shaft.
Worn or damaged parking lever shah-to-sropper faces.

Front wheel wohbiing

Bent rlm.

Axle not tightened properly.
Bent spoke plate.

Excessive wheel bearing play.
Faulty or unevenly worn tire

Sufi suspension

Weak fork springs.

From suspension noise

Slider blndlng.
Loose front iork fasteners.

 

11-2

 

 

STEERING/FRONT WHEEL/BRAKE/SUSPENSION

HANDLEBAR (1) WIRE BANDS'?

REMOVAL
Remove the handlebar switch wire bandst

 

Remove the two left handlebar switch housing screws and
remove the left handlebar switch housing with the rear bvake
lever bracket.

 

Remove the two right handlebar switch housing screws and
remove the right handlebar switch housing with the ham
brake lever bracket.

Disconnect the throttle cable from the throttle grip and slide
it of! the handlebar.

    

(2) THROTfLEfi-JRIP

 

11-3

STEERING/FRONT WHEEL/BRAKE/SUSPENSION

 

Remove the tour handlebar holder attaching bolts and the
handlebar.

INSTALLATION

Install the handlebar onto the lower holder, then install the
upper holders with their punch marks facing the forward.

Align the punch mark on the handlebar with the top edge or
the lower holder.

Tighten the upper holder bolts.

NOTE
‘ Tighten the forward bolts first, then the rear bolts.

 

Apply Honda Band A, Honda Hand Grip Cement (U.S,A.
only) or an equivalent to the inside surface at the grips and to
the clean surface of the left handlebar and throttle pipe.
Wait 3—5 minutes and install the grips. Rotate the grips for
even application of the adhesive.

NOTE:

 

- Allow the adhesive to dry tor an hour before using.

 

Slide the throttle grip onto the handlebar.

Connect the throttle cable to the throttle grip and apply
grease to the cable end.

Install the right handlebar switch housing, aligning the punch
mark on the handlebar With the switch housing matting
surface.

Tighten the forward screw first, then tighten the rear screw.

 

(1) PUNCH MARK

 

    

 

11

h

 

STEERING/FRONT WHEEL/BRAKE/SUSPENSION

 

Install the left handlebar swrtcn nausrng, aligning the punch
mark on the handlebar with the much housing manmg
surface.

Tighten the forward SWItch housing screw lirst, then, tighten
["2 rear screw.

Install the handlebar swutch wire bands.

Adjust the throttle grip tree play (page 3-5) and brake lever
free play (page 3-7)

PARKING LUCK

LEVER REMOVAL/INSTALLATION

Remove the head pipe covers and floor board (page 10-2].

Support the scooter by placing the floor jack or other adjust-
able support under the frame.

Move the parking lever down and loosen the lock, adjusting
nuts, and disconnect the parking cable.
Remove the two nuts and parkmg lever.

Install the parking lever in the reverse order of removal and
adjust the parking lever free play [page 3-8).

CABLE R EPLACEMENT

Remove the floor board, engine and body center covers
(section 10].

Support the scooter by placing the floor jack or other adjust-
able support under the frame.

Loosen the lock, adjusting nuts and disconnect the parking
cable from the cable guide and parking lever,

    

(1] PUNCH MARK

‘9

/ J
(2) ADJUSTING WT ‘ (3) NUTS

./,

TIN‘G N
_.

 

 

STEERING/FRONT WHEEL/BRAKE/SUSPENSION

 

Remove the cotter pin and washer, and disconnect the parking
cable from the swlng lock arms

Replace the parking cable With a new one it required and
install in the reverse order or removal.

NOTE

‘ Route the wire and cable securely as shown on page 1-7.
‘ Use a new cotter pin when reinstallan the cable.

 

 

THROTTLE CABLE

PRIMARY CABLE REPLACEMENT

Remove the two right handlebar switch housing screws and
separate the switch housing,

Disconnect the throttle cable from the throttle grip.

Remove the engine cover 03399105).
Pull the cable junction box out] remove the screw and open
the cover.

Remove the [Omt plate and disconnect the primary cable from
the junction box.

Replace the primary cable with a new one if required and
install the cable in the reverse order of removal.
NOTE

' Route and clamp the wires and cables securely as shown on
page 1-7.

 

 

Adiust the throttle grip free play (page 3-5).

(2) PARKING CABLE (4; CQEEPIN

 

(ll THROTTLE (is?

  

 

 

11-6

I

 

STEERING/FRONT WHEEL/BRAKE/SUSPENSION

 

SECONDARY CABLE REPLACEMENT

Remove the engine cover (page 1075) and disconnect the
primary cable from the junction box (page 116).

Disconnect the throttle cable from the carburetor top (page
44)

Disconnect the oil control cable from the oil control lever
(page 22).

Remove the secondary cable lrom the junction box.

Replace the cables With new ones if required and install in the
reverse order of removal,

NOTE

Route and clamp the cables securely as shown on page 1-1

 

 

Adjust the throttle grip free play and all control cable (page
3-5).

REAR BRAKE BABLE

PRIMARY CABLE REPLACEMENT

Remove the brake lever pivot bolt, nut and brake lever and dis-
connect the brake cable from the lever.

Remove the body center cover (page 10-4).

Remove the equalizer box cover and disconnect the primary
brake cable from the equalizer plate.

Replace the brake cable With a new one if required and install
in the reverse order of removal,

NOTE
Route and clamp the cable securely as shown on page 1-7.

 

 

Adjust the rear brake lever free play,

SECONDARY CABLE REPLACEMENT

Remove both rear wheels with the wheel hub attached (page
12-2).

Remove the rear brake cables from the brake arms.

(1 SECONDARY?ABLES

 

(2) BRAKE ARM

 

11-7

STEERING/FRONT WHEEL/BRAKE/SUSPENSION

 

Remove the body center cover (page 104).
Remove the equalizer box cover and disconnect the secondary
cables from the equalizer plate.

Replace the secondary cable WIlh new ones if required and
install in the reverse order 0' removal.

NOTE

 

- Route and clamp tne’cables securely as shown on page 177.

 

REAR BRAKE ADJUSTMENT
NOTE

Adjust the rear brake when the cables have been replaced
or the rear brake can not be adjusted with the adiusters.

 

 

Remove the body center cover (page 10-4) and the equalizer
box cover.

Loosen the lock nut and turn the primary cable adjusting bolt
in.

Turn the rear brake adiusters until the brake shoes lust touch
the brake drum.

Make sure that the clearance between the cable flange and the
cable stopper is zero then turn the primary cable adjusting
bolt counterchCkWIse untll the brake lever free play is zero,
then turn ll 2 more times counterclockwrse.

Tighten the lock nut.
TORQUE: 35—5 Nsm (0.35—0.23 kg-m, 2.5—3.6 ftvlh)

Loosen both rear brake adjusters equally so that the rear
brake lever free play is 10—20 mm (3/8—3/4 in).

Apply rear brake and make sure that the clearance between
the secondary cable llange and cable stopper is equal.

If they are not equal, adjust them by turning the rear brake
adjustert

Install the equalizer box cover and body center cover.

(1) SECONDARY CABL

 

 

(2) CABLE STOPPERS

 

11

I
oo

 

FRONT WHEEL

R E MOVA L
Disconnect the front brake cable and speedometer cable.

Raise the front wheel of! the ground by placing a floor jack
my other adiustable support under the frame.

Remove the axle nut and pull out the front GXIE.

Remove the front wheel.

INSPECTION

O AXLE SHAFT

Set the axle shaft in V blocks and measure the runout.
The actual runout is 1/2 of the total indicator reading.

SERVICE LIMIT: 0.2 mm (0.01 in)

0 WHEEL RIM

Place the wheel in a lrulng stand.

Spin the wheel by hand and measure the rim runout using a
dial lndlcator.

SERVICE LIMIT: RADIAL: 2.0 mm (0.08 in)
AXIAL: 2.0 mm (0.08 in)

0 BEARING INSPECTION

Turn the inner race of each bearing with your finger. The
bearings should turn smoothly and quietly. Alsa check that
the hearing outer race fits tightly in the hub,

Remove and discard the bearings if the races do nor turn
smoothly, quietly] or if they fit loosely in the hub.

NOTE:
- Replace hub hearings in pairs,

 

 

For replacement of bearings, see page 11-10.

STEERING/FRONT WHEEL/BRAKE/SUSPENSION

l1) Sheena/large

   
      

~. V \V ‘ Ape .
)BRA‘KE CABLE” L (3) AXLE NUT

 

 

 

 

 

 

 

 

 

 

11-9

 

STEERING/FRONT WHEEL/BRAKE/SUSPENSION

 

DISASSEMB LY
Remove the side collar and all seal.

lnsen a bearmg remover head Into the bearing,
From the opposite slde Install the bearing remover shall and
drive the bearing out of The wheel,

Remove IrIe distance collar and drIve out the other bearing.

ASSEMB LY

Pack grease Into Ihe bearing cavities,

Drive In Ihe right bearing into me wheel securely with iIs
sealed side lasing out until ll seals.

Install lhe disiance collar and drive In Ihe lelI bearIng wiIh Iis
sealed side lacing out until It seals.

NOTE
Do not allow me bearings to tilt while driving (barn in.

 

 

k (2) (ML SEAL

 

 

CAUTION

 

- Once Ihe bearings are remmred. the bearing mus! be re»
placed will: rmv mm.

Install a new oil seal on The wheel.
Install the side Collarv

 

k (2) OlL SEAL

III BEARING REMOVER fiAE‘T 07746—0050100
(EQUIVALENT COMMERCIALLY AVAILABLE
IN u.s.A.I

67"}
(I

(2) BEARING REMOVER READ, 10 mm
07746—0050200 [EQUIVALENT
COMMERCIALLY AVAILABLE IN U.S.A.l

W11) DRIVER

07749—0010000
A

 
   

(2) ATTACHMENT, 28 x 30 mm 07946—187010!)
‘PILOT, 10 mm 07146—904010!)

\W

  

lllSIDE COLLAR w \

  
  

(IISIDECOLLAR ‘ ' \

 

 

11-10

STEERING/FRONT WHEEL/BRAKE/SUSPENSION

 

INSTALLATION (“GROOVE
Position the front wheel between the fork legs, aligning the
brake panel groove with the stopper on the lork.

Insert the axle shaft through the wheel hub from the right
side.

(2) STOPPER

 

l
l
I Install and tighten [he axle nut.
TORQUE: 40—50 N-m (4.0—5.0 kg-m, 29—36 R-lb)

      
 

I
(1) AXLE NUT

C k | d . ‘IA
onnect the front bra e ch 2 an speedometer cable (1) SPEEBOMETER CABLE >

Adjust the front brake tree play.

KE CABLE,

FRONT BRAKE

Remove the from wheel [page 1179) and brake panel lrom the
front wheel.

 

INSPECTION \_
. BRAKE DRUM ,..- \

Measure the brake drum |.D.
SERVICE LIMIT: 80.5 mm (3.17 in) \ \W

 

 

 

STEERING/FRONT WHEEL/BRAKE/SUSPENSION

 

- BRAKE LINING
Measure me brake lining thickness.

SERVICE LIMIT: 1.5 mm (0.06 in)

M
' Contaminated brake Iiningx Iedace stopping power.
Keep grease off the linings.
‘ Brake dusl contains asbeslos whirl! can be harmful layout
healrh. Do not use compressed air to clean brake pans‘ Us?
a vacuum will: a sealed dust calla-Ion
Wear a urolecn‘ve [are mask and wash your hands when
finished.

 

DISASSEMBLY

Remove the brake shoe spring and brake shoes.

Remove the brake arm bolt] brake arm, wear indicator plate,
return spring and brake cam.

Remove the oil seal and speedometer drive gear,

 

(I) SHOE SPRING

(2) BRAKE SHOES

 

(1)0IL SEAL

 

(3) SPEEDOMETER
DRIVE GEAR

(2) BRAKE CAM

- \
(4) BRAKE ARM

 

11-12

 

STEERING/FRONT WHEEL/BRAKE/SUSPENSION

 

ASSEMBLY

  
 
    
 

4—7 N-m
(GA—0.7 kg-m.
375mm

Lubricale me speedomexer drive gear with grease and install
the drive gear in the brake panel‘ ’61

4

(1) SPEEDOMETER DRIVEGEAR

Insxall the oil seal. (1) O|L SEAL (2) BRAKE cam”
«r

Apply grease to the brake cam and anchor pin, and insen the
brake cam in the brake panel.

' Conlaminated brake linings reduce slapping power.
- Keep grease tiff the brake linings.
Wipe any excess grease off [he brake mm‘

 

 

11-13

STEERING/FRONT WHEEL/BRAKE/SUSPENSION

 

Apply oil lo 1""? fell seal and xnszall to me make panel.

Install the brake arm return spring.

Inslall xhe wear indicator plate allgl’lil’lg the wide moth on the
plan? wnh [he wide gronve m the brake cam.

lnslall me brake alrn aligning lhE punch mark on the brake
arm with (he lndex line on the brake cam.

Install and ngmen the bvake arm boll,
TORQUE: 4—7 N‘m (0.4—0.7 kg-m, 3—5 flalh)

lnslall the brake shoes and shoe spring‘

' Conmrnlnaled bmlz: linings reduce slapping power,
Keep grease off the brake linings,

 

Place the brake panel in the from Meele

Install the front wheel (page 11-11) and adjusl the lront brake
"as My (page 17).

FRUNT SUSPENSION

REMOVAL

Remove the "on: wheel (page 11‘8).
Remove lhe Iron! fender by removing the four bolts.

 

(”WEAR INDICATOR PLATE (2] ALIGN

(a) FELT‘SEAL

(4) RETURN SPRING

  
   

(1) INDEX MARK

  
 

Xi
(2) PlJNCII‘LAARK

(1) SHOE SPRING .,

      
 

(3) BRAKE ARM

(2) RRAKE SHOES

(1) FRONT FENDER

 

11-14

STEERING/FRONT WHEEL/BRAKE/SUSPENSION

 

Slide the barn down the fork leg.

Remove the snap ring, from shock rod, stopper rubber and
lrom shock spring from (he fork plpe‘

IN SPE CT | O N
Inspect for wear or damage and replace 1! necessary.

Measure the spring free length.
SERVICE LIMIT: 117.0 mm (4.61 in)

 

INSTALLATION
Apply grease 10 the front shock sliding surIaces.

(1'1 BOOT (2) SNAP RING

   

(3] SNAP RING PLIERS 0791441230001
(EQUIVALENT COMMERCIALLY
AVAILeBLE IN L_J.SVA.I

(1) FRONT SHOCK ROD

(2) SPRING (3) STOPPER RUBBER

WMNVWWWVI

 

 

11-15

 

STEERING/FRONT WHEEL/BRAKE/SUSPENSION

 

 

 

 

Install the spring, stopper rubber and from shock rod in the 1—H) SNAP RING PLIERS 0791443230001
fork pipe and secure with the snap ring. (EQUIVALENT COMMERCIALLY
AVAILABLE IN U.SVA.l
NOTE
Install the snap ring With its radiused edge facing up and be ‘ '
certain the snap ring is sealer! firmly in the groove, f 4 .
o I
Slide the boot up onto the fork pipet
‘(Zl S_NAP RING (3) 390T

Install the front fender using the four bolts.
Install the front wheel (page 11~11).

STEERING

REMOVAL

Remove the following:

— lront wheel (page 119).

— right and left lront suspensian (page 1144),

— front cover and head pipe covers (page 10-2),

7 handlebar (page 11-3),

# headlight (page 14»15)4

A speedometer cable and grommet from the head pipe.

 

   

 
 

Disconnect the horn wire cennectorl and remove the horn and (1) EXTENSION 077‘540020500

frontlurnsienal- (EQUIVALENT COMMERCIALLV
AVAILABLE IN U.S.A.)

Remove the steering stem nut. ‘ (V. . , . J

   

Remove the two bolts attaching the fork bridge.

(EQUIVALENT COMMERCIALLY AVAILABLE
IN USA.)

 

 

11-16

STEERING/FRONT WHEEL/BRAKE/SUSPENSION

 

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

Hold the front fork and remove the top cone race and front
fork.
NOTE

The steel balls are loose in the races, and can be easl|v
dropped or lost.

 

 

BALL RACE INSPECTION

Inspect the top and bottom ball races for wear or damge, and
replace if necessary.

BALL RACE REPLACEMENT

Drive both ball races out oi the steering head using a ball race
remover or a suitable punch.

Drive the top and bottom ball races into the steering head
using an attachment and driver.

NOTE
Do not tilt or damage the races while driving them in.

 

 

BOTTOM CONE RACE INSPECTION

Inspect the bottom cone race for wear or damage and replace
ii necessary.

BOTTOM CONE RACE REPLACEMENT

Remove the bottom cone race using a chisel and discard it.
Place a new bottom cone race on the stern.

Drive the new cone race on using steering stern driver 07946;
4300101.

(1) LOCK NUT WRENCH
0791671870101

\

(2) LOCK NUT WRENCH
27.9l5-.K_M1099L _

 

 
      

k
(1) BALL RACE REMOVER 0794676A70000
(NOT AVAILABLE IN US.

   

(19%“ "(1)DRIVERO7749»001DOOD
\‘

(2) A‘I'I'ACHMENTT42 x 47 mm
0774670010300

(1) BOTTOM CONE RACE

 

 

STEERING/FRONT WHEEL/BHAKE/SUSPENSION

 

INSTALLATION

Apply enough grease onto both races to retain the steel balls
and lnstall 26 balls onto each race.

Apply grease to the bottom cone races and install the fork into
the head pipe being careful not to drop the steel balls.

Apply grease to the top cone race and screw in the race until
snug against the top ball race, then back it out 1/8 turn.

Turn the steering stem lock-to-lock 475 times to seat the
bearings and check that the steering stem rotates smoothly
and that there is no vertical play.

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

TORQUE15—13 N-m (0.5—1.3 kg-m, 3.6—9 ft-Ih)

Install the fork bridge and (ork bridge mouting bolts.

Tighten the fork bridge mounting bolts.
TORQUE: 40—50 N~m (4.0—5.0 kg-m, 29—36 71-11))

Install and tighten the steering stem nut.
TORQUE: 60~BO Nam (GD—ED kg-m, 43—581t-Ib)

Insert the speedometer cable into the steering stern and
install the cable grommet.

Install the following:

~ handlebar (page 114).

A horn, horn. wrres and front turn signal stav.
- headlight (page 14-16).

— front cover and head pipe covers (page 10-2).
7 front suspension (page 11-15).

7 front wheel (page 11-11).

 

 

(1) TOP CONE RACE ‘ (2) FRONT FORK
\ ‘,

 

(I) LOCK NUT WRENCH
t 979164870101

  

(2) LOCK NUT WRENCH
0791s—KM1_0000

(2) FORK BRIDGE
MOUNTING BOLTS

 

». x
(1) LOCK NUT WRENCH, 30 x 32 mm

s,
077164020400 (EQUIVALENT ‘ d“
COMMERCIAILLvaflLABLEQl U.S.'A:) 1!!

1(1) GROMMET

(2) SPEEDOMETEBCABLE

 

11-18

 

 

MEMO

 

REAR WHEEL/BRAKE

 

  
  
 

477 Nm
(0.4—0.7 kg-m, 3—5 flJb)

(2.4730 kg~m, 17—22 ft-lb)
45—50 N«m
(4.5—5‘0 kg-m,
32—36 ft~|b)

65%!0 N-m
(6.5—8.0 kg~m, 4875B fl-Ib)

 

12-0

 

12. REAR WHEEL/ BRAKE

 

 

SERVICE INFORMATION 12-1 REAR WHEEL 12-2
TROUBLESHOOTING 12»1 REAR BRAKE 12~4

 

 

 

SERVICE INFORMATION

GENERAL

I Brake dust contains asbestos which can be harmful to your health.
I Do not use compressed air to clean blake drums or brake panels Use a vacuum with a sealed duct collector.
Wear a protective face mask and thoroughly wash your hands when finished.

SPECIFICATIONS

 

 

 

 

 

 

ITEM EANDARDmm (m) SERVICE LIMIT mm lml
Rear wheel rim runout 7 2.0 (0.08)
Rear brake drum |.D. 80.0—80.2 (3.154.151 50.5 (3.17]
Rear brake lining thickness 3.5 (0.14) 1,510.06)
TORQUE VALUES
Rear axle nu! 65—80 N»m (6.54.0 kg-m, 43753 me) Apply on
Rear wheel hub bolt 45—50 N-m (4.5—5.0 kgrm, 32736 mu) Apply on
Rear wheel rim boIt 24—30 N-m (2.4—3.0 kg-m, 17—22 mm
Rear brake arm bolt 4—7 N-m (0.4—0.7 kg-m, 3—5 me)

 

TROUBLESHOOTING

Rem wheel wobbling
Bent rlm.
Faulty or unevenly wom tires.
Axle nut lmproperly tlghtened.

Poor brake performance
- Brake not adjusted properly.
Contaminated brake shoes.
Worn brake shoes.
Worn brake shoes at cam contacting area.
Worn brake came
Warn brake drum.
Improper engagement between brake arm and camshaft
serratlons.

 

12-1

REAR WHEEL/BRAKE

 

REAR WHEEL

REMOVAL

Support the scooter by pIacing the floor jack or mher adjust-
able suppurt under the swing joint.

ApuIy rear brake.

Without the wheel hub anached
Remove the three rear wheel hub bolts and remove the rear
wheeI

With Xhe wheel huh attached
Remove the wheel cap and rear axle nut, [hen remove the rear
wheel wi‘h the wheel hub.

INSPECTION

Remove the tear wheel with the wheel hub.

Check the wheel rIm runout using a dial lndICaIOr as shown,

SERVICE LIMIT: RADIAL: 20 mm (0.08 in)
AXIAL: 20 mm (0.08 in)

Measure the rear brake drum ID‘
SERVICE LIMIT: 80.5 mm (3,17 in)

:(1) B’ofis

 

 

 

 

 

12-2

 

REAR WHEEL/BRAKE

 

REAR BRAKE DRUM REPLACEMENT

Remove the three rear wheel hub bolts and remove the wheel
hub from the wheeL

(”WI-ism HUB eons

Install a new wheel hub onto the rear wheel and tighten the
rear wheel hub bolts.

NOTE
Apply oil to the bull's threaded portion.

 

 

TORQUE: 45—50 N-m (45—5,!) kg-ml 32—36 (t-lh)

DISASSEMBLY/ASSEMBLY

Remove the rear wheel rIm bolts and separate the wheel vim.

 

ASSEMB LY
Install the rear wheel and tighten the wheel nrn bolts.

TORQUE: 24—30 N~m (14—3.!) kym, 17—22 lt—lb)

24—30 N-m

(2.4—10 If), 17—22 h-lbl @

45750 N-m
[4‘5A5.0 kg-m,
32~36 It-lbl

   

65~30 N-m
(6.578.!) kg~m,
48—58 it-lbl

INSTALLATION

Without the wheel hut: attachld
Install the rear wheel, apnly DII to the belt's threaded portion
and tighten.

TORQUE: 45—50 N-m (AS—5,0 kgwn, 32—36 mu)

(2) AXLE Nu‘r

With the wheel hub attached
Install the rear wheel.

Apply oil to the axle nut threaded portion and [Ightem

NOTE
Install the washer under the right axle nut,

 

 

 

TOROU E: 65—30 N>m (6.5—8t0 kgm, 43—58 ft-Ib)

 

12-3

REAR WHEEL/BRAKE

REAR BRAKE

INSPECTION

Remove xhe reav wheels With me wheel hub anached (page
122).

Measure the brake lining thicknessv
SERVICE LIMIT: 1.5 mm (0.06 in)

 

- Keep grease off the brake fillings. Wipe off any exun
greasa

 

Replace the shoes 37 they are worn beyond the service limit.

DISASSEMBLY

Remove me rear brake came from me bvake arm.
Remove the brake shoes, shoe spring, brake avm spring.

Remove the brake arm bolx, brake arm, wear IndlCalOl plaxel
felt sea‘ and brake cam.

 

r-fii 4—7 N-m

   

(0470.7 kgm, 375 ft-lb)

 

 

12-4

 

Apply grease to the brake cam and anchor pin.
Install the brake cam.

Apply oil to the ten seal and Install it over the brake cam.

Install the weav Indlcalor plate ahgnlng the WldE tooth ol the
plate With the wide groove on the brake came

Install the brake arm onto the brake cam, aligning the mde

tooth of the brake arm with the wide groove ol the bvake
Cam and tlghten the brake arm bolt.

TORQUE: 4—7 N-m (0.4—0.7 kwm, 3—5 ftvlb)

Install the brake arm springt

Install the brake shoes and shoe springv
Connect the brake cables.

Install the rear wheel (page 1273) and dajust the rear brakes
(page 3-5).

‘6 ,

t

(1) BRAKE CAM

REAR WHEEL/BRAKE

    

HIE‘Efiufil-‘tm‘ V

 

 

REAR SHOCK ABSORBER/SWING JOINT UNIT

 

Mme!
10714 N‘
E / (1.0—1.4 am, 7710 Mb)
E
‘3 ' “fie @
2440 N-m

(244.0 kg-m ¥\__ ‘ ®
17—22 mm ‘

  

/" 1 O ‘
55-65mm
(5.54.5 kg-m,

® ® 40—48 h-lb)
30—45 N~m m

(ac—4.5 kg-m,

22—32 ftvlb)
r fi
90 ®

'I’ \

 

I 30—45 N-m *-
@ % (an—4,5 kg-m.
4/ 22—32 Mb)

  
 

(3 30—45 N»m
9 (3.0—4.5 kg~m4

N 2242mm
@

 

40—55 N~m / ‘ L
(4.0—5‘5 kg~m, V , $
29—40 ma) I’m

‘0’ (3

 

13-0

 

13. REAR SHOCK ABSORBER/SWING JOINT UNIT

 

 

SERVICE INFORMATION 13-1 REAR SHOCK ABSORBER 13»2
TROUBLESHOOTING 13—1 SWING JOINT UNIT 13-4

 

 

SERVICE INFORMATION

GENERAL

I The compression rubbers are made of natural rubber and erI derriorate if they come m comact wrm ml or grease.

SPECIFICATION

 

F 7 ITEM 7 7' STANDARD mmIinI I ESERVICE LIMITmmIInI
L Rear shock absorber sprring Iree length 103.6(4.08] I 100513.96)

 

 

 

 

TORQUE VALUES
Hear shock absorber:

 

mounnng bolr 30745 N»m (3.0—4 5 kg~m, 22—32 fr-lb)
bower joim lock nur 30—45 N-m (3.0—4.5 kg-m, 22*32 Ilsib) Apply locking agent
Swing iomr:
jolm shah pivot bolr 40755 N»m (4.0—5.5 kg-m, 29‘40 frlb)
shaft nut 55—65 Nrm (5.5765 kgAm, 40748 fr-lb)
unir case be“; 8 mm 24—30 N-m (2,4#3.D kg-m,I7—221Hh)
6mm 10v14 N-m(‘I.0—‘|.4 kg~m,7710I(-lb)
Swing Iuck arm A bolt 4—7 N~m (0.4417 kg m, 3751!“)!
T00 LS
Special
Rear shock abnsrber anachmenl A 07967-6A70101
Rear shock absorber attachment B D7967—GA70200
Common
Hear shock absorber compressor 0795973290001

TROUBLESHOOTING

Refer to page 165 (or parking/swing lock Iroubleshooung.

Soft suspension
Weak shock absorber sprmg.
Damper or! leaking.

Hard suspension
Benr damper unrr.

Suspension noise
Shock absorber spring bindmg.
Damaged smpper rubber.

 

13-1

 

REAR SHOCK ABSORBER/SWING JOINT UNIT

 

REAR SHOCK ABSORBER

REMOVAL

Remove the body center cover (page 1074).

Support the scooler by placing a floor jack or other adjustable
support under the frame,

Remove the rear shock absorber upper and lower mountrng
bolts and the shock absorber,

D ISASSEMB LY
InstaH the shock absorber compressor as shown and compress
the shock absorber.

Loosen the damper lock nut, and remove the lower joint and
lock nut.

Disassemble the rear shock absorber.

NOTE
- Do not damage the damper slrdung surface.

 

INSPECTION
Measure the rear shock absorber spring free length.

SERVICE LIMIT: 100.5 mm (31,96 in)

Inspect the damper ror damage and repIace If necessary.

  
   

 
 
  

(1) UPPER MOUNTING BOLT.

‘ ,.
(2) REAR SHOCK ~ . 0"

L

(1) REAR SHOCK ABSORBER
ATTACHMENT B
D7967—GA70200

  
  
   
 

ATTACHMENT A
_07967#GA70101

xa>\

    

(3) REAR SHOCK ABSORBER
COMPRESSOR
07959—3290001

(2) 'LOWER JOINT

Aasggagajgsl LOWER MOU TING BOLT

(2) REAR SHOCK ABSORBER

  
   

 

13-2

   

 

REAR SHOCK ABSORBER/SWING JOINT UNIT

ASSEMBLY

3045 N-m
(3D~4,5 kg~m, 22-32 fplb)

    

(1) Apply a locking agent —>

.: 30—45 N-m

\

   

(3.0745 kg~m,
22—32 flrlbl (@
3045 N-m
(3.0—4.5 kgrm.
22412 ll lbl
Install the shock absorber spring wim the closely wound coil (1} REAR SHOCK ABSORBER

ATTACHMENT B
07967—GA70200
(2) HEAR SHOCK ABSORBER
ATTACHMENT A
\D7967—GA70101

\

loward the top.

  
 
 
 

Compress the shock absorber wixh the compressor and attach- \-
ments as shown.

   

(3) REAR SHOCK ABSORBER
COMPRESSOR
07959—3290001 “"

Extend she damper rod fully and apply a locking agem to the

V1) DAMPER LOCK NUT
threaded ponion of the damper rod. * _

  

Install the lock nut and lower joint and righsen the lock nuL
TORQUE: 30—45 N-m (304.5 kg-m, 22—32 h—lb)

/

(2) LOWER JOINT

 

13-3

REAR SHOCK ABSORBER/SWING JOINT UNIT

 

INSTALLATION

Install the rear shock absorber In the reverse order oi removal
and tighten both mountlng bolts.

TORQUE: 30—45 MM (3045 kg—m, 22—32 ft—lb)

After Installing the rear shock abosrber, check for operation.

SWING JOINT UNIT

REMOVAL

Remove the engine (section 5).
Release the cables from the cable clamps.

Turn the fuel valve OFF and disconnect the fuel line from the
tu be joint.

Disconnect the oil inlet line from the tube joint,

Remove the cotter pin, plain washer and disconnect the park»
my cable.

Remove the rear shock absorber lower mounting bolt

   

(1) CLAMPS

\*

7(1) LOWE R MD

_
l2) FUEL LINE

LR r
UNT|N§3 BOLT

       
     

Ll

 

 

13-4

 

 

REAR SHOCK ABSORBER/SWING JOINT UNIT

 

Remove the swing joint shaft lower pivot bolt and swing joint
unit.

Remove the upper pivot bolt and remove the swing joint link
from the frame.

INSPECTION
Inspect the swlng joint link rubber bushings and stopper
rubbers for wear or damage.

Check the joint link for cracks or damage.

DISASSEMBLY

Remove the bolt and swmg lock arm A.

NOTE

 

Align the splits before removing the arm,

 

Remove the seven case bolts.

(1lsw1NG JOINNW
.

(3) SWING JOINT LINK

(H STOPPER RUBBEHS

(2) PIVOT BOLTS

 

 

 

REAR SHOCK ABSORBER/SWING JOINT UNIT

 

Remove me swing joint upper Case.

Remove the swing 101m shaft from the lower case.

Remove xhe compression rubbers from the upper case.

NOTE

 

The compression rubbers are made of natural rubber and
wul deterioratel if they come in Contact wnh oil or grease,

 

Remove rhe coner pm, nut and washer,

(Z) NUT

I» 1‘” UPP RCASE

 

(3] COTTER PIN

 

13-6

 

REAR SHOCK ABSORBER/SWING JOINT UNIT

 

Remove the bearing, washer, compression Cam, washer, swing
lock pxarer spacer, bearing and seal from the shaft in the order
hsted.

Remove rhe circIip and washer, then remove rhe swing Iock
arm from upper case

INSPECTION

Check each compression rubber Ior cracks or deterioralions

Check she swing lock plate teeth for wear or damage.

Inspecr me swing lock pawl, shah and bearing area for wear or
damage.

(2) BEARING I4) WASHERS I5] BEARING

      
   

I3) LOCK (7D COMPRESSION
(I) SEAL (6) SPACER PLATE CAM

I1) SWING LOCK ARM
r w , x

r h

 
 

o,

mcmcup (MW/ASHER

(1) COMPRESSION RUBBERS

 

 

REAR SHOCK ABSORBER/SWING JOINT UNIT

 

ASSE M B LY
Install (he seal and bearing.

NOTE

 

' Install the bearing with the retaining groove facing far»

ward.

Instaii the spacer, swmg lock plate, washer, compression cam,
washer and bearing in the order listed.

NOTE

 

 

- Align the swing lock plate and cam teeth with the shaft
teeth.
Noie the direction of the swing lock plate.

 

lnsiali the washer and nur onto (he swmg Joint shall and
tighten the nut.

TORQUE: 55-65 N-m (5.5—8.5 kgvm, 40—48914!”
Insert a new couer pin.

NOTE

. Spread the ends of [he coner pin so they will nor interlere
will the swing joint upper and lower cases.

 

 

Apply grease to all sliding surfaces. men instalI (he swing lock
arm, spring, shall and collar to the upner case and secure wrrh
(he Washer and circIip.

NOTE

- Install xhe sprlng as shown,

 

 

 

I2) BEARING

(3) GROOVE

I1] SPACER

(2) SWING LOCK
PLATE

(3) WASHER

  

Id) COMPRESSION

CAM (5) WASHER (6l BEARING
—. ,
[1) NUT I2] WASHER

 

(3) COTTER PIN

(”SWING £00K _

i2l SHAFT?
ARM 1

[3) SPRING

[4) WASHER AND
CIRCLIP

(5) coELAR

 

13-8

 

 

REAR SHOCK ABSORBER/SWING JOINT UNIT

 

Install the compression rubbers ‘m the upper case.

NOTE

Keep grease or oil 0" the compression rubbers.

 

 

Set the bearing retalnlng rings in the groove of the shaft
bearing.

Install the swing shaft assembly in the lower case.

Install the two dowel pms onto the lower case.

Apply sealing agent to the case mating surfaces and install
the upper case onto the lower case.

Install the two 8 mm bolts and live 6 mm SH bolts and tlghten
them.
TOROUES:

8 mm: 24—30 N-m (14—10 kgem, 17—22 h-Ib)

6 mm: 10-14 N-m (1.0—1.4 kg~m, 7—10 ft-lh)

NOTE

   

 

~ Do not forget to install the clamps as shown.

 

 

(2) LOWER CASE

    

(2) 67m" BOLTS

(ll UPPER CASE
arr ~ ~‘

)5“.

(3H1 mm BOLTS

 

13-9

 

REAR SHOCK ABSORBER/SWING JOINT UNIT

 

install swing lock arm A on the shaft aligning the punch mark
on the arm with slit in the shaft.

Make sure that the swing lock shaft protrudes above the park
ing lock arm face by 1.5 mm (0.06 in) or less.

Tighmn the arm bolt.
TORQUE: 4—7 Nrm (0.4—0.7 kgm, 3—5 ftvib)

INSTALLATION

Loosely install the swing joint link with its pivot bolt and nut.
Loosely install the swmg joint unit to the swing joint link with
its plvm bolt and nut.

Install the rear shock absorber to the swing joint unit and
tighten the rear shock absorber lower mounting bolt.

TORQUE: 30—45 N~m (3.0—4.5 kg-m, 22—32 lt-lb]

Tighten the joint shaft link pivot bolts.
TDROUE: 40—55 N-m (4.0—55 kg-m, 29—40 (Mb)

Connect the Darklng cable to swing lock arm A wlth washer
and a new cotter pin.

Connect the fuel and oil inlet lines and secure With the cable
clamps.

NOTE
Route the cables properly as shown on page 1.7.

 

 

Install the engine (section 5].

  

1.5 mm" (1) BOLT
(0.06 in)

 

‘\
l1) LOWER
MOUNTING BOLT ‘

(”CLAMPS

  

   

(2) ALIGN
, i‘

 

“ '\
l2) FUEL LINE

 

13-10

        

 

14. ELECTRICAL EQUIPMENT

 

 

 

SERVICE INFORMATION
TROUBLESHOOTING
BATTERY

CHARGING SYSTEM
IGNITION SYSTEM
STARTING SYSTEM

14-1
14-3
144
14-5
14-7
14-9

INSTRUMENTS
IGNITION SWITCH

OIL LEVEL SENSOR/INDICATOR

HANDLEBAR SWITCH

BULBS
HORN

14-12
14-13
14-13
14-14
14-15
14—17

 

 

SERVICE INFURMATIUN

GENERAL

0
o

Siow charge the battery whenever possrble, qutck charge is an emergency procedure only.

Remove the battery from the scooter Ior charging.” the battery must be charged on the scooter,disconnect both battery

cables

The battery on this scooter is a sealed type. Do not try to remove the filler hole caps even during charging. Do not use a

nonrsealed battery as a replacement.

All Charging system components can be checked on the scooter.

W

- 00 not smoke, and keep flames away [rum a charging ballery. The gas pmduced by a battery will explode [fa flame 0!

spark is broughl near,

 

CAUTION

 

Fur balmy charging. du "(11 exceed the charging current and time specified rm the battery caller. Use rlfcxccssil'c current

or charging time may damage the bar/emu

 

Ignition timing can not be adjusted since the CDI (Capacitive Discharge Ignition] unit is factory present.

For spark plug inspection, refer to page 3-9.

For alternator and pulse generator removal. refer to section 7.
Some wires have driferent colored bands around them near the connector. These are connected to other wires which cor

respond With the band color,

All plastic plugs have locking tabs that must be released belore disconnecting] and must be aligned when reconnecting.
The Iollowing color codes used are indicated throughout this section and on the witing diagram.

Bl = Black G = Gteen
Br = Brown Gr = Grey
Bu : Blue Lb : Light Blue

L9
0
p

= Light Green
= Orange
: Pink

R
W
Y

1 Red
1 White
: Yellow

To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually
be made without removing the part from the scootert Simply disconnect the Wires and connect a continuity tester or volt

ohmmeter to the terminals or connections.

A continuity tester is useful when checking to find out whether or not there is an electrical connection between the two
points. An ohmmeter is needed to measure the resistance at a circuit, such as when there is a specific coil resistance We
valved, or when checking for high resistance caused by corroded connectlons.

 

14-1

 

ELECTRICAL EQUIPMENT

 

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ITEM STANDARD mm (in) SERVICE LIMIT mm (in)
Battery Capacity 12V73AH
VolKage 13.0—1342V
Charging current 0.4A
l Charging time 5 hours
Alternator capacity 91W/5,000 rpm
Chargmg call resistance Yellow-Green 0.1—1.0 SI
White~Green 0.1 —1 .5 S2
Spark plug mm,“ | ( 3:130? Sting}: ) Fogszgznggzjngign
NGK BPRSHSA BPRAHSA BPRBHSA
ND WZOFPR-L W14FPR~L W24FPR-L
Spark plug gap 0.6—0.7 (0.024—D,028)
Ignition coil resistance Primary 0.2—0.3 51
Secondary 3.4—4.2 kfl
Ignition timing 14° BTDC
Pulse generator resrstance 10—100 9
Exciter coil resistance 100—400 (I
TOO L
Special
Digital multimeter 07411-0020000 or KS—AHM—32—003 (U.S.A. only]

 

14-2

 

 

ELECTRICAL EQUIPMENT

 

TROUBLESHOOTING

CHARGING SYSTEM

No current

‘ neaii battery.
- Battery sulfatiun.
— Internally shorted battery.
- Charging system failure.

' Disconnected battery cable.

' Fuse burned out.

' Faulty ignition switch.

Low current

- Weak battery.

~ Loose battery connection.
~ Charging system iailure.

' Faulty regulator/rectifier.

IGNITION SYSTEM
No spark at plug

- Poorly connected, broken or shorted Wire.

— Between pulse generator and cm unit.
— Between CDI unit and ignition coil.

— Between CDI unit and ignition switch.
— Between ignition coil and spark plug.
Faulty:

— Ignition switch,

, ignition coil.

7 CDI urilt.

— Pulse generator.

— Spark plug.

STARTING SYSTEM
Starter won‘t turn

~ Burned out fuse.

~ Weak battery.

' Poorly connected. broken or shorted wire.

' Faulty:
— Ignition switch.
— Starter switch.
— Rear brake light switch.
— Starter relay.
7 Starter motor.

Intermittent current
- Loose:
— Battery cable.
— Charging system connection.
, Connection or short circuit in lighting system.
- Ignition system connection.

Charging system failure

' Loose, broken or shorted WIVE or connection.
- Faulty regulator/rectifier.

- Faulty alternator.

Engine starts but runs poorly
' Ignition primary Circuit.
— Faulty ignition coil.
— Loose or bare wire.
— Poor connection at ignition switch,
- ignition secondary circuit.
— Faulty ignition coil.
7 Faulty spark plug.
— Faulty spark plug wire,
7 Poorly insulated plug cap.
~ improper ignition timing.
— Faulty pulse generator.
— Stator not installed properly.
— Faulty CDI unit.

Lack of power

' Weak battery.

~ Loose or bare Wire.

- Faulty starter or starter gear.

Starter routes, but engine does not start
~ Faulty starter pinion.
- Low battery.

 

14-3

ELECTRICAL EQUIPMENT

 

BATTERY

REMOVAL/INSTALLATION

Open the seat and remove the rear compartment.

Remove the battery holder bolt.

Dlsconnect the battery negative cable tirsty. Lhen positive
cable.

Remove the battery.

Install the battery ln the reverse order of removal.

VO LTAGE

Remove the seal, rear compartment and remove the battery
positive terminal cover.

Measure the battery voltage uslng a digital multrmeter 074117
0020000 at KsiAHM—32~003 (USA. only).

VOLTAGE: Fully charged 13.0—13.2V
Under charged Balow 12,3V

CHARGING

Remove the battery cable: and the battery.

Connect the charger positive l+l cable to the battery positive
it) terminal,

Connect the charger negative (rl cable to the battery "Egallve
l—l termrnal

Charging current: 0.4A (standard)
Charging time: 5 hours (standard)

[mm——

- Keep flames and marks away fmrrr a charging battery.
T um prmw (NV/OFF at the charger, not at the battery
terminals.

 

‘l‘ll BATTERY

 

 

 

 

CAUTION

an‘i'k 'harging :hould rrnly he dime m an emergmr
charging i: preferred.

‘ l'hr battery charging, do not exceed the charging current
and time specified ml the haul/(r. L'xr'rrg excessire current
at extending the charging time may damage the battery.

 

Slow

 

After installing the cables, coat the terminals wrth clean
grease.

 

14-4

 

 

ELECTRICAL EQUIPMENT

 

CHARGING SYSTEM

[Bl AUTO BYSTARTER

 

 

 

 

 

 

(1) INSTRUMENT Br Br , Y G
LIGHT G
12v, 3.4w FI
Bu 5

 

 

 

 

 

 

 

 

(2) HEADLIGHT
12V, 25/25W

 

(4) REGULATOR/
RECTIFIER

 

 

(3) DIMMER
SWITCH

   

 

 

— (5| FUSE 10A

ALTE R NATO R
0 PERFORMANCE TEST
Warm up the englne before taking readings.

Raise the seat.
NOTE

Use a fully charged 12V battery to check the Eharglng
system output.

 

 

Stop the engine and open the fuse holder.
Disconnect one end of the Iuse at the terminal, and connect
an ammeter between the fuse and [Ermlfial as shown.

NOTE

—omo—|||I|i|r—_L

(6) BATTERY

(9)
RESISTOR
5W, 3.50

(7| ALTERNATOR

 

 

 

Do not allow the fuse holder lead lredl and tester probes
to touch any metal parts.

 

Connect a voltmeter between the positve («fl and negative l—l
termlnals of the battery.

Start the engine, gradually increase engine speed and read the
ammeter and voltmeter. The readings should be DA min. and
14~15V.

If the readings do not meet the specifications, check the wires
for a loose connectlon and repair if necessary. H the wires are
lll good condition, replace the regulator/rectifier wrtn a new
one and retest.

O RESISTANCE TEST

NOTE

- ThlS test can be made thhoul removlng the stator ftom the
engine.

 

 

Remove the body center cover (page 10-4).

Disconnect the alternator and auto bystarter wire connectors.
Measure the resistance between the stator yellow wire terminal
and ground] and the whlte wrre terminal and ground.

RESISTANCE: W and ground: 0.1—1.5 ohm
Y and ground: 0.1—1.0 ohm

For alternator replacement, refer to page 773.

 

 

 

 

 

[1) STATOR WIRE

 

14-5

 

ELECTRICAL EQUIPMENT

RESISTOR INSPECTION

Disconnect the green wire connector from the auto bystarter.

Measure the resistance between the auto bystarter green wrre
and grounds

RESISTANCE: 3.5 ohm

REGULATOR/RECTIFIER INSPECTION

Remove the rear cowl (page 1074).

Remove the bolt, disconnect the Coupler and remove the
regulator/rectifier.

Measure the resistance between each terminals With an ohmr
meter. Replace the regulator/rectifier II the readings do not
fall Withln the limits shown in the chart below

NOTE

For accurate testing, it is necessary to use a spemIied tester.
Use of an improper tester or measurements in an improper
range may give Inaccurate readings,

Use Sanwa Electric Tester 0730870020000, Kowa Electric
Tester TH75H or Digital multimeter, KSvAHM—32—003
(U.S.A. onlyl.

 

Flanges: Sanwa Electric Taster: R x kil
Kowa Electric Taster: R x 10052

 

 

 

 

 

 

 

 

 

\m PROBE A L a E
(ii PROBE\

A w 0.57100 m
7 L so \ f A 57100

B m as m

E no 5400 w

 

 

 

(ll RESISTOR

 

 

 

14-6

ELECTRICAL EQUIPMENT

 

IGNITION SYSTEM

III IGNITION SWITCH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

——o/z>——E
I3I ENGINE STOP
SWITCH G
I2) EXCITER COIL :1 I
Bl/W —=—
G
[M PULSE
GENERATOR I5) CDI UNIT
SPARK PLUG

For spark plug inspection, refere to page 3-10V

IGNITION COIL INSPECTION

Remove the engine cover (page 10-5).

Disconnect the ignition Coil wires and remove the spark plug
cap from the spark plug.

Measure the resislance between the ignition coil primary wire

terminals.
RESISTANCE: 0.2—0.3 ohm

Measure the resistance between the ignition coil primary
terminal (7) and spark plug cant

RESISTANCE: 8.2—9.3 k ohms

  

(6) IGNITIN con. lei
3'” 81' Black
G: Green
Y' Yellow
Bu Bule
H: Red
_ lVlSPARK PLUG —: w: wme

 

 

ELECTRICAL EQUIPMENT

 

Remove the spark plug cap from the spark plug wire and
measure the reslsrance between the lgnlIan corl primary wire
termlnal (—l and spark plug wrre,

RESISTANCE: 3.4—4.2 k ohms

EXCITER COIL INSEPCTION

NOTE
Thls test can be performed wrth the stator Installed m the
ungme

Remove the body center cover (page 10m.
Dlsconnecl [he excrter corl ere connector (BI/RI and measure
the resistance of the excite! corl,

RESISTANCE: 100—400 ohms
Refer to page 7 3 for exclter coll replacement,

PULSE GENERATOR

Drsconnect the nulse generator wrre connector lBu/V] and
measure the resistance between the connector and ground.

RESISTANCE: 10—100 ohms

Refer to page 7-3 for pulse generator replacement.

 

cm UNIT INSPECTION A

Remove the body center cover (page 104). -~

 

m”.

Dlsconneet the CDI unit coupler and remove the CDI unit
from its mounting rubber.

 

 

14-8

 

ELECTRICAL EQUIPMENT

 

Measure the resistance between the terminals.

Replace the CDI unit if the readings are not within the speci'ir
catiuns in the table below.

NOTE

- For accurate testing, It is necessary to use a specified tester.
Use of an improper tester nr measurements in an improper
range may give false readings.

' Use a Sanwa Electical Tester 07308—002000!) or Kowa
Electric Tester TH~5H, or Digital muitimeter KS—AHM—
003 (USA. only).

- In the table, "Needle swings then returns" indicates that
there Is a charging current aupIied m a condenser. The
needle wIII then remaIn at "an" unless the condenser is
discharged,

IGN

EXT SW

 

 

 

Use the ka1 range for Sanwa tester.
Use the x1009 range for Kowa tester.

STARTING SYSTEM

(1) STARTER SWITCH
R

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I+)PHOBEI I I |
s. SW EXT PC I e . IGN
APROBE“ I
sw on m m m
7 A._ 7.", e "A _
EXT 0‘ ‘0 “Mandy
, \ an m swmgsl en
\ . :eiurns"
Pc ‘07 m IOrZOD IrIOO N
Y .
I
E IrIOD 01720 ‘ m \ I w
IGN we =0 w 9° r \
7 7 e e e . I, ,_
(2) MAIN
FUSE 10A (3) IGNITION SWITCH
_ [4) BATTERY
E (5) FRONT O (5) REAR
L BRAKE -——1 w—«I BRAKE
I SWITCH 9 SWITCH
G/Y

 

 

 

 

 

 

(9) BRAKE LIGHT

 

14-9

 

ELECTRICAL EOU|PMENT

 

STARTE R RELAY INSPECTION
Remove the body center cover (page 104).

Remnve the starter relay attaching bolt, disconnect the wire
coupler and remove the starter relay.

Connect an ohmmeter or continuity tester between the A and
E terminals of the starter relay.

Connect the 12V battery positive wire to the starter relay C
terminal and battery negative wire to the starter relay D
terminal using jumper wires.

Check for continuity between the starter relav A and B
terminals

Replace the starter relay with a new one if there is no con»
tinulty.

STARTER MOTOR REMOVAL

Remove the iollowrnq:

» engine cover (page 10 5).
7 left rear wheel (page 12-2).
7 air ducL

, insulator plate.

NOTE

 

- Before removing the starter motor, disconnect the negative
cable from the battery

 

 

 

 

 

 

 

 

 

 

 

 

14-10

 

ELECTRICAL EQUIPMENT

 

Remove the two starter motor mounting bolts and the starter
motor.

Disconnect the starter motor wire connector Irom the motor.

Remove the caring from the starter motor.

STARTER MOTOR INSPECTION
Connect the battery positive wire to the starter motor wire
terminal and battery negative wire to the motor body and
check its operation.
NOTE

Be careful to observe polarity.

 

The motor should turn clockwise (View from shaft side),

NOTE

 

(2) small/Toma

My!

 

 

Do not try to disassemble the starter motor.

 

INSTALLATION

Apply grease to a new O-ring and install onto the starter
motor.

Connect the starter motor wure to the motor terminal.

Install the starter motor and tighten the two mounting bolts.

NOTE

 

I2) STARTER MOTOR
TERMINAL

     
   
 

[3) BATTERY

 

 

   
   

 

Tighten the ground wire together with the lower mounting
bolt.

 

Install the removed parts in the reverse order of removal.

(HO-RING

(2) CONN ECTOR

 

 

 

ELECTRICAL EQUIPMENT

 

INSTRUMENTS

REMOVAL
Remove the headlight (page 1445).

Disconnect the instrument wire connectors.

Remove the handlebar holder lower bolts and dlsconnect the
speedometer cable.

Remove the instruments.

Remove the two nuts and speedometer bracket.

INDICATOR LIGHT BULB REPLACEMENT

Remove the lndicator light lens.
slide back the rubber and turn the socket to remove the bulb.

Replace the bulb with a new one if necessary.

5 \ a ..
(”WIRE CONNECTORS“

 

   
  

l2) BULB

 

         

(3) RUBBER

 

14-12

 

 

ELECTRICAL EQUIPMENT

 

IGNITION SWITCH

INSPECTION
Remove the floor board (page 10-2),

Disconnect the ignition switch coupler.
Check for continuity between the terminals.

Continuity shcuid exist between color coded Wires indicated
by interconnecting circles on the chart below.

 

 

 

 

 

 

 

 

 

 

 

 

Tavminal BAT1 BATZ IG E

ON 0740

OFF 07%

LOCK O——O

COLOR CODE R BI BI/W G
R EMOVA I.

Remove the floor board (page 10-2lt

Disconnect the ignition switch coupler.

Remove the two screws attaching the ignition switch and
remove the ignition switch.

OIL LEVEL SENSIIR/ INDICATOR

OIL LEVEL SENSOR

Disconnect the oil Ievel sensor wire connectors and pull out
the sensor.

Check for continuity between the sensor terminals with the
Heat in upper and lower positions.

Continuity should exist with the float in the lower position
and should no exist with the float in the upner position.

    

I'll IGNITION SWITCH

I .
IZI IGNITION SWITCH.
COUPLER ‘_

 

 

 

ELECTRICAL EQUIPMENT

 

OIL LEVEL INDICATOR INSPECTION

NOTE

Before pertorming the rollowing test, operate the turn
signals to determine that the battery Circuit is normal.

 

 

Connect the oil level sensor wires and turn the ignition swltch
ON.

Raise and lower the float lo make sure that the oil level
Indicator blinks on and off.

NOTE

 

 

If the indicator falls to go on and out as the float is moved
up and down] check Ior a loose connection and repeat the
above procedure

HANDLEBAR SWITCH

Remove the headlight (page 14-15I and disconnect the handle
bar switch wire couplers and connectors.

 

Continuity should exist between color coded wires indicated
by interconnecting circles on each chart.

ENGINE STOP SWITCH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Terminal STOP E
OFF O-——O
ON
OFF O—‘O
Coloricode BI/W G
STARTER SWITCH
Terminal ST E
FREE
PUSH O———C
Color cnda V/R G
DIMMER SWITCH
Terminal
H|
(N)
La
Color code Br
TU RN SIGNAL SWITCH
Terminal W
R
N
L
Color code
H O R N SWITCH
Terminal Ho BATZ
FREE
PUSH O——O
Color code Lg Bl

 

 

 

 

 

 

 

   

 

 

(2) STARTER SWITCH

(1) DIMMER SWITCH (2) TU-F‘IN SIGNAL
SWITCH

(3i HORN SWITCH

 

14-14

 

 

ELECTRICAL EQUIPMENT

 

BRAKE LIGHT SWITCH

Remove the headlight and disconnect the brake light switch
wire connectois.

Check for continuity between the switch terminals.

The switch is normal it there is continuity between the termir
nals when the brake lever 15 pulled on.

Replace the switch if it is faulty.

BULBS

HEADLIGHT

Remove the two screws and headlight from the headlight case,

Disconnect the headlight wire connectovs and remove the
headlight from the headlight case.

Remove the screws and headllght nm from the headlight.

 

   
   

 

BRAKE LIGHT SWITCH

(ll HEADLIGHT

l I

(1) HEADLIGHT CASE

(2D HEADLIGHT

(”SCREWS (3) HEADLIGHT

(2) HEADLIGHT HIM

 

14-15

 

ELECTRICAL EQUIPMENT

Remove the two bolts and headlight case.
Install the headlight in the reverse order of remnval.

NOTE

Align the alignment marks on the headllght Case and the
bracket.

TAIL/BRAKE L|GHT
Remove the two screws and remove the tail/brake light lens

Replace the hulb WIth a new one and install the lens and
screws.

TURN SIGNAL LIGHT
Remove the screw and turn signal hght lens.

 

(2) SCREW

14-16

ELECTRICAL EQUIPMENT

 

Replace me bulb with a new one and insrall the lens and
screw.

Discannect the horn wirh connectors.

The horn is normal i1 ix sounds when a 12V battery is con-

nected across the horn wire rerminals,
Repkace the horn if necessary.

 

(1) EULB

 

 

(2)12VBATTERY 'IMIIIM

     

 

 

 

14-17

 

MEMO

 

15. WIRING DIAGRAM

 

SEIQEUINOMGO

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

omo: . ,3 o o .. : oé‘ o o‘
[ 90 :2 0.0 0 0‘0 .2. 90
one 0,0 __ 00 90‘
u my“ w 5 3 i .x «1.1 m 9 Lin. 1 .5
x. : E
a E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

15-1

 

 

MEMO

 

IO. TROUBLESHOOTING

 

 

ENGINE DOES NOT START OR IS

HARD TO START
ENGINE LACKS POWER

16-1
16-2

POOR PERFORMANCE AT LOW AND

IDLE SPEEDS

POOR PERFORMANCE AT HIGH
SPEED

 

16-3

16-3

CLUTCH AND TRANSMISSION 16-4

POOR HANDLING
SWING LOCK

OIL INDICATOR
STARTER MOTOR

16-4
16-5
16-6
16-7

 

 

ENGINE DOES NOT START OR IS HARD TO START

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

FUEL TO CAREUHETDR

2‘ Try spark test

SPARK JUMPS

3‘ Test cylinder compression

NORMAL COMPRESSION

4. Start by iollowmg normal
starting procedure

ENGINE DOES NOT FIRE

 

5. Remove spark plug

DRY

CARBURETOR

Probable Cause

No FUELTO ——’(I) No fuel in the tank

(2)
(3)
(4)

(5)
(6)

WEAK OR NO SPARK4>III

LOW COMPR ESSION

ENGINE FIRES BUT
SOON STOPS

l2)
(3)
(4)
(5)
l6)
(7)

.>(l)
(2)
(3)
(4)

(5)
(6)

>(1)
(2)
(3)
(4)

WET PLUG —>(l)

(2)
(3)
(4)
(5)

Clogged fuel line to the
carburetor, vacuum tube up to
the inlet pipe, or fuel pipe,
Clogged float valve

Clogged fuel tank can breather
hole

Clogged fuel stfalner

Clogged fuel filter

Faulty spark plug
Fouled spark plug
Faulty 601 unit

Faulty alternator

Broken or shorted spark plug wue

Broken or snorted Ignition coil
Faulty ignition switch

Stuck plston rings

Faulty or deteriorated reed valve
Worn cylinder and oiston rings
Faulty cylinder or Cylinder head
casting

Compression leak into crankcase
Leaking cylinder head gasket

Faulty auto hystarter
Air leaking past intake plpe
Improper ignition timing

 

Carburetor air screw out of adjust»

ment

Carburetor overflooded

Faultv auto bystarter

Throttle valve open excesswely
Water in fuel line

Deteriorated fuel in float chamber

 

16

1

 

TROUBLESHOOTING

 

ENGINE LACKS POWER

1. Lightly accelerate engine

ENGINE SPEED INCREASES

2. Check ignition liming
CORRECT

3. Test cylinder compression bv
operatlng the starter

NORMAL

4. Check carburetor for clogging

NOT CLOGGED

5. Remove spark plug
NOT FOU LE D O R
DISCOLORED

6‘ Check if engine overheats

NOT OVERHEATED

 

7. Try rapid acceleration or run at
high speed

ENGINE DOES NOT KNOCK

Probable Causes

ENGINE SPEED DOES NOT 4>I1I
INCREASE SUFFICIENTLV I2)
I3)

(4)

INCORRECT ‘>(1I
(2)

T00 LOW ————>I1)
(2)
I3)
(4)

CLOGGED w

FOULED OR DISCOLORED —>(1)

(2

OVERHEATED fi’”)
(2)
(3)
(4)

(5

ENGINE KNOCKS ‘—>I1)

(2)
(3)
(4)
(5]

Clogged air cleaner

Restricted fuel Iluw

Clogged fuel tank can breather
hole

Clogged muffler

Faulty CDI unit
Faulty alternator

Worn cylinder or piston rings
Blown cylinder head gasket

Flaws in cylinder or cylinder head
Faulty or deteriorated reed valve

Carburetor no! serviced
frequently enuugh

Plug not replaced frequently
enough

Use of plug with improper heat
range

Worn cylinder or piston
FueI~air mixture too lean

Use 0! improper grade of fuel
Excessive carbon build-up in
combustion chamber
Ignirion timing too advanced

Excessive carbon build-up in
combustion chamber

Use at improper grade of iuel
Clutch slipping

Fuel~air mixture too lean
Ignition timing too early

 

16-2

 

TROUBLESHOOTING

 

PDDR PERFORMANCE AT LOW AND IDLE SPEEDS

1‘ Check ignition timing
CORRECT
l

l

2. Check carburetor air screw for
proper adjustment

CORRECT
V
3. Check if air is leaking past intake
pipe

NOT LEAKING

4. Try spark (es!

GOOD SPARK

PDDR PERFORMANCE AT HIGH

1. Check ignition timing
COR RECT
2. Disconnect fuel tube at
fuel valve
FUEL FLOWS FREELY
3. Remave carburetor and check
for clogged jets

NOT CLOGGED

Probable Cause

INCORRECT —_—> ('I]

(2)

INCORRECT

all)

(2

LEAKING —> (1)
l2)
(3)
(4)

WEAK OR INTERMITTED ——> (1)
SPARK
(2)
(3)
(4)
(5)

(6

SPEED

Faulty CDI unit
Faulty alternator

Fuelrair mixture too rich
(Screw out to correct)
Fue|~air mixture too lean
(Screw in to correct)

Deteriorated insulator gasket
Loose carburetor

Deteriorated intake pipe gasket
Deterioraled insulator O-nng

Faulty, carbon or wet fouled
spark plug

Faulty CDI unlt

Faulty alternator

Faulty ignition coil

Broken or shorted high tension
wire

Faulty ignition switch

Probable Cause

INCORRECT —-—> ll)

(2)

FUEL FLOW RESTRICTED —>(1)
(2)
(3)

CLOGGED ——>

Faulty CDI unit
Faulty alternator

No iuel in iuel tank

Clogged iuei tube of fuel filter
Clogged iuel tank cap breather
hole

Clean

 

16-3

 

TROUBLESHOOTING

 

CLUTCH AND TRANSMISSION

Probable Cause

1. If engine starts but scooter does not move —> (I)

(2)

(3)
(4)

2. If scooter creeps or engine starts but stalls *7 , , ~—>
(rear wheels rotate at idle]

POUR HANDLING

Separated clutch linings

Loose clutch drive plate nut or
damaged splines

Damaged transmission

Seized transmission

Broken shoe spring

LOSS OF CONTROL * Check tire pressure Probable Cause

 

i. If steering is heavy (1)

i (2)

2t lfeitherwheeliswobbling 7 , ———>(1)
(2)

(3)

3. H the scooter pulls to one side ——a (1)

Steering head adjuster too tight
Damaged steering cones or steel
balls

Excessive wheel bearing play
Bent rim

Loose axle nut

Bent front fork

(2) Twisted ioint shaft bracket,
cracked or damaged mount rubber
POOR FRONT/REAR SUSPENSION PERFORMANCE Probable Cause
1. if suspension is too soft ——> (1) Weak spring
I2) Excessive load

(3)
2. ll suspension is too hard ..__..— —> (I)
3. If suspension is noisy (1)

l2)
l3)

 

Leaky damper seal
Bent fork or shock rod
Slider binding

Damaged shock stopper rubber
Loose fasteners

POOR BRAKE PERFORMANCE Probable Cause

1. If wear indicator arrow aligns with index mark on brake panel —> (1)
(2)
(3)
(4)

2, If either brake is squealing ——> (1)
(2)
(3)

3. If brake performance is poor ———> (1)
(2)

(3)
l4)

Worn brake shoes

Worn brake cam

Worn cam contacting face of shoe
Worn brake drum

Worn brake shoes

Foreign matter on brake lining
Rough shoe contact face of brake
drum

Misadjusted or stretched brake
cable

Brake shoes partially Contacting
brake drum

Mud or Water in brake drum
Brake linings fouled with grease or
oil

 

16-4

 

TROUBLESHOOTING

 

SWING LUCK

Probable Cause

1‘ If parking lever does not lock ——————> (1)
(2i
(3)

2‘ If parking lever does not release or is sluggish ———> (1]
(2)
(3)

3. If parking brake is not locked wrth swing mechanism locked —————> (1)
(2)

(3]
(4)

4. If parking lever can be returned with ignition switch in -————> (1)
LOCK position.
(2l

(3)

Improperly adjusted cable
Broken or stretched cable
Damaged parking return spring
on swing case side

Excessive cable play

Damaged return spring

Cable clip coming off swing lock
lever

Cable not adjusted properly
Broken or disconnected rod bet-
ween swing lock and parking lock
Damaged parking lock arm pawl
Damaged parking gear teeth

D‘eformed or damaged stopper
Dlate

Twisted or damaged parking lever
shaft

Worn iriction suriace between
parking lever shaft and stopper
plate

 

16-5

TROUBLESHOOTING

[Ill INDICATOR

INDICATOR DOES NOT LIGHT WHEN IGNITION SWITCH IS TURNED ON OR WITHOUT OIL

IN THE TANK

1. Check battery circuit by operating

turn signals

SIGNALS OPERATING CORRECTLY

(607120 flashes/min)

2‘ Remove instruments and connect
black wire to battery positive

terminal and green wire to
negative terminal

LED LIT

l

3. Check for Iaose,disconnected or
improperly connected terminal

CORRECT

4. Remove oil level sensor and
Check operation
Float up: Indicator off
Float down: indicator on

CORRECT

Probable Cause

SIGNALS DIM, REMAIN ‘>l1l
ON OR DO NOT OPERATE (2)
(3)
(4)
(5)

LED DOES NOT LIGHT —'—‘>(1l
(Z)

INCORRECT ——>(Il
(2)
l3)

INCORRECT —>(1)
(2)

Blown fuse

Weak or deal battery

Faulty ignition switch
Disconnected wire connector
Broken Wire harness

Loose connector

Faulty LED or LED drive circuit

Lease or disconnected terminal

Broken wire harness
Incorrect connection

Stuck float
Internal fault

INDICATOR LAMP REMAINS ON WITH SUFFICIENT OIL IN OIL TANK IIGNITION SWITCH ON)

I. Check for loose, disconnected or
improperly connected terminals

CORRECT

l

2. Disconnect the green/
red Wire at instruments

LED GOES OFF

3. Remove oil level sensor and
check operatlon
Float up: Indicator on
Float down: Indicator on

CORRECT

4. Check for delormed tank or

foreign matter In tank

Probable Cause

 

INCORRECT —>(1l
(2)

(3)

LED REMAINS ON —>lll

INCORRECT *4“)

(2)

Loose or disconnected terminal

Broken Wire harness
Incorrect connection

Faulty LED drive circuit

Jammed or stuck float
Broken or shorted oul level
sensor

 

16-6

STARTER MOTOR

STARTER MOTOR DOES NOT TURN

1. Check operation of brake light
by operating brakes

WENT ON

2. Check battery circuit by operating
turn signals

SIGNALS OPERATE PROPERLY
(607120 (lashes/mini

3. Check starter relay (or operation
by depressing starter button

NORMAL

4. Test starter by connecting it to
battery

TURNS

TROUBLESHOOTING

Probable Cause

DID NOT GO ON I» (‘II
(2)
(3)
(4)
(5)

SIGNALS DIM, REMAINED —>
ON OR DID NOT OPERATE

ABNORMAL 7 , ,—,(1)
(2i
(3]

DID NOT TURN ——>(1i
(2)
(3)
(4)

STARTER MOTOR TURNS SLUGGISHLY OR FAILS TO CRANK ENGINE
Probable Cause

1‘ Check battery circuit by operating
turn signals

SIGNALS OPERATED PORPERLY

2. Connect starter motor sub wires
across battery terminals

SIGNALS DIM, REMAIN ——‘>
ON OR DID NOT OPERATE AT ALL

TURNED PROPERLY _—> (I)
(2)

OPERATES NORMALLY :——>(1)

STARTER WONT' STOP

1. Turn Ignition switch OFF

(2)

Blown (use

Weak or dead battery

Faulty brake light switch
Disconnected terminal

Broken or shorted ignition switch

Dead battery

Poorly contacted starter switch
Broken or shorted starter relay
Loose connector or terminal

Worn brushes

Broken or shorted rotor windings
Broken starter motor wire

Loose terminal

Dead battery

Loose connector/terminal
Poorly contacted starter relay

Broken or shorted starter motor
windings
Faulty starter pinion

Probable Cause

, —.

STOPPED

 

DOES NOT STOP

Pinion stuck out

Starter relay shorted or stuck
closed

 

16-7

 

 

MEMO

 

HONDA MOTOR Cf).LTD. TOR

 

 

   

 

 

 

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