CONTENTS SECTION Data chart 1 Maintenance information 2 Inspection, adjustment 3 (Engine) Oil lubrication channel .......................................... 4 Engine attachment/ removal 5 Cylinder head, valve 6 Cylinder, piston 7 Clutch 8 Oil pump 9 AC generator, cam chain tensioning 10 Crank shaft, transmission 11 Carburetor 12 (Frame) Steering, front wheel, front suspension .................................... 13 Rear wheel, rear suspension 14 Electrical devices 15 Addendum Pertaining to Monkey Z50Jf—7 ........................ 16 Addendum Pertaining to MonkeyZSOJm (Monkey Baha) Addendum Pertaining to MonkeyZSOJn . Addendum Pertaining to ZSORp ................................. 19 Addendum Pertaining to Monkey ZSOJn (Monkey Baha) 20 Addendum Pertaining to Monkey Z50Jp .. 21 Addendum Pertaining to Monkey Z50Jp (Monkey Baha) 22 Addendum Pertaining to ZSOJw . 23 Addendum Pertaining to Z50Jw-6 (Gorilla) ........ 24 Addendum Pertaining to ZSOJy 25 Addendum Pertaining to 250J2 26 Addendum Pertaining to 250J4 27 FOREWORD This service manual explains the maintenance requirements for the Honda Monkey Z5OJZ-1 and Honda Gorilla ZSOJz-3. Maintenance details pertaining to the ZSOJz—7 that have been altered from the ZSOJz-3 and can only be found in chapter 16. Any maintenance details for the ZSOJm (Monkey Baha) which differ from the ZSOJz-1 and ZSOJf—7, as well as any standard parts that have been altered will only be listed as they come up in the course of explaining ZSOJz—1 and ZSOJf—7. Block diagrams have been used to make the explanations in this service manual easier to follow. Be aware that there may be certain areas on your vehicle that will differ from what is stated here. June 2007 Honda Co. Ltd 1. SPECIFICATIONS SPECIFICATIONS HON DA HONDA Mode1 Monkey GLmHa ATT cIeaneT lype Urethane Imam Iype ZSOJ l 25mm :1 Lengm 1 340m 1 365m 9 Fue1 1ank eapaeny 5t 1 9t WTdm 0 600m 0 s25rn % n Mpde1 RA11 Hergm 0 845m 0 875m 5 w anome ppre mameier 13mm Wheerase 0 895m 5 g Vemun d1arne1er 11mm (eqmvalem) Engme rnpde1 1504 E a ATT vaIve Iype ManuaHy opera1ed p151L7n type Engme capacn 49ch Type Magnelu: 1gnmon Fuel type Unleaded Fue10n1 E Ignmdn nmrng 30'1BTDC/fixed) FTonlaxIe Ioad 28kg 30kg m a [New “HA. car-1A 7 = Ignmon pIug Vemde W m a :1» (ND) U16FSVL u2qurL 9 Rear axIe Ioad 35kg 37kg g 21 T0131 63kg 67kg ‘72 5 Ignmon cIeaTance o 6—0 7mm «3 Passengers R1der UNIV 3 x: Type and number 9N2,» 2c,1 : Frpn1ax1e «a mad 42kg 44kg Q Capacny 2mm) We1 Iype Gross vemde body Rear axIe 76k m T e muIlTFpIaled. “WE‘VE; wergm had 9 a w “07 e511 5 PM 2 :enmlugaI P 9 T0131 11% 122kg § Operanng mempd MecnamcaT Frpn1wnee1 3 5073 ,2 PR Tyres Rearwnee1 3 507872 PR 1: E”9‘"e"°"’a"5m‘55‘°" a 722 A 312 g s eed reduenpn ramp 9 T pe FerpeluaH engaged Mmmmm ground cIeaTance o1sum g 1; Gear 3131 2 592 i d u 3 W »a g Brakmg drsranee [lnmaI speed) a 5m 120mm) 5 3 g) 2 Gear 1323 1823 2 = a o a g g 2 E , - R 1, E H1IIcI1mb1ng apnny u 32 g g 5 3 Gear 1 190 1300 M1n1muquTn1ngTad1us 14m Slamng Method Kmk s1an 4‘" Gear , a 958 Type 4 Stroke e Gear Iype Chem 3 :13? g Forward mung so ° 5 ‘5‘ A 5» Speed No and Incalmn p1 cyhnders 1mm, a = Q Mum” We a 083 2 583 Combusmon chamber type Helmsphere 1 oas1erangTe 25' oo- VaIve tram I meme“ ‘3’“ 9”“ g 3 fig Tran 42mm dnven - g m _ m Bore x s1roke 39 a x 41 4mm 3 3 Tyre From 1 OKg/cm’ Compressmn a a Pressure Rear 1 25kg/cm‘ 3 Cumpressmn pressure 12 0kg/cm’4flOOTpm s1eenrrg Angle Le“ 5“” ‘2_ Rrgm srde 42 “5 Maxrmum ou1pu1 2 Sps/IODOTpm From WTTe type Ieadmg Ilamng 7 Maxrmum Iurque a 3kgm/5‘000Tpm Brake Sys‘e'" Rear Rod type Ieadmg 1ramng < mm Open TIBTDCI 11mm 1m) Suspensmn From wheeT TeIesmmc 3 CIose IZ'IABDC) (Imm Iifl) system Rear wheeI Swmg arm “’ New Open 2213500) (1mm 1m) Frame Bad< bone «a , CIose ZTBTDC) (Imm 1m) Fvonl cushion oTI Grease < VaIve Intake 0 05mm [when com) , (u :Iearance Exhaust 0 05mm [when com) ce“"‘°a“°" ”‘7 I 1320 RPM under neToad (TGImgI 1.5ourpm g Cumbmalmn p1purnp1ng g “mm” “5““ and drupIel Iubncauon g on pump Trachmd g Fun flowmg mlralmn. a: OHM“ e aomprnanpn eccemncugaT a VP and slramer Mranon on capamly o a 2-1 2. MAINTENANCE INFORMATION Cautions for operation 2-1 Specialized tools 2-2 Tightening torque 2-3 Wiring diagram 2-4 Wiring 2-6 Fault diagnosis 2-10 Cautions for operation When disassembling, replace gaskets, O-rings, snap rings, split pins (divided pin). After disassembling parts, wash thoroughly before carwing out inspection and measurement. Apply oil to sliding surfaces when reassembling. ,"\ r0: .. \;J When tightening bolts, nuts, and screws, fit them lightly first, and then tighten to the specified tightening torque working from the one with the largest diameter to the smallest, and inward to outward diagonally. Apply or insert the specified grease or its equivalent to the designated areas. a i?! Always use either Honda parts or those recommended by Honda when replacing parts or using lubrication products. , Make sure that all parts are tightened and operate properly after assembling. ' ‘0 fi— 7‘» Always use the specialized tools or ones similar for such operations that require them. When there are more than 2 persons working on the bike at one time, always take the necessaw steps to ensure each others safety. $.11 00* “@i Symbols — the following symbols are used throughout this manual to indicate cautionary points or methods of operation. : Apply oil Unless otherwise specified use Honda GN4 or equivalent : Use specialized tools 7‘4 : Caution required w : Danger or important operation 512-3 : Refer to 12-3 2-2 Specialized tools Specialized tool Similar tool Tool name Tool No. Tool name Tool No. Oil gauge 72401-0010000 36mm spanner 07902-0010000 Pin spanner 07702-0010000 Tappel adjusl wrench 07908-0010000 Tappel adjusling (B) 07708-0030400 Tappel adjuslwrenoh 8x9 07708-0030100 14mm lock nul wrench 07716-0020100 r= Flywheel holder 07925-0010000 Universal holder 07725-0030000 Flywheel puller 07933-0010000 Flywheel rolor puller 07733-0010000 Valve guide remover 07942-MA60000 Bearing driver 07947-0450000 Bearing driver ouler 32x35 07746-0010100 Bearing driver pilol 12mm 07746-0040200 Driver handle 07949-2860000 Bearing driver handle(A) 07749-0010000 Valve spring compressor 07757-0010000 Valve guide reamer 07984-MA60001 Clulch holder 07923-0400000 Universal holder 07725-0010101 Rear cushion compressor 07959-3290001 r= Ball race driver 07944-1 150001 :- 2-3 Tightening torque Engine related Part to tighten No. of Screw diameter Tightening torque places (mm) (kg-m) Tappet cap 2 30 1.0-1.4 Valve adjust nut 2 5 0.7-1.1 Cylinder head Nut 4 6 0.9-1.2 Bolt 1 6 0.8-1.2 Cam sprocket bolt 3 5 0.8-1.2 Cylinder bolt 1 6 0.8-1.2 R. and L. crank case cover 11 6 0.7-1.1 screw Clutch lock nut 1 14 3.5-4.5 Shift drum stopper bolt 1 6 0.9-1.4 Drain bolt 1 12 2.0-2.5 Drive sprocket bolt 2 6 0.8-1.2 Flywheel nut 1 10 3.0-3.8 Frame related Part to tighten No. of Screw diameter Tightening torque places (mm) (kg-m) Steering stem nut 1 24 6.0-8.0 Front fork top bridge bolt 2 10 1.8-2.5 Front axle nut 1 12 3.5-5.0 Rear axle nut 1 12 3.5-5.0 Rear cushion nut 4 10 2.5-3.5 Rear fork pivot nut 1 10 2.5-3.5 Engine hanger bolt 2 8 2.0-2.5 Driven sprocket bolt 3 8 1.8-2.3 Standard tightening torque Part name Tightening torque: Part name Tightening (kgf m) torque: (kgf m) 5mm bolt, nut O.45-0.6 5mm screw 0.35-O.5 6mm bolt, nut 0.8-1.2 6mm screw 0.7-1.1 8mm bolt, nut 6mm flange bolt, nut 1.0-1.4 10mm bolt, nut 8mm flange bolt, nut 2.4-3.0 12mm bolt, nut 10mm flange bolt, 3.0-4.0 nut Wiring diagram 2—4 ooooi m8 iNomS i “a \ \ 2.2.5525: 5.1%... , ,, r _ . x \\ x ii. x > a ‘5. E ,. w I_.: , ask 2: g 4. u . / ._ 4 a , i 9:. _ .2 i __ i r i . 5.. 23 35;... 2:: 5.323 a E: :n» is“ 5 an. = .l. a a # r - a T r v j, a h d. i f : ,i _. _t._ moi LHHE , in, F , xmi 2E 2-5 Wiring diagram coa‘no— \Nomoc guy /_ . 5% 25 5:55 E: x 2-6 Wiring Schematic Monkey Q, ' Frame body earth Front stop switch [F Throttle cable Tightened with ignition coil firakf cabile 7 ‘ ngh tension lead Indicator, horn switch wire Ignition coil Engine breather tube / Clamp ‘ Tube inner connection A.C. generator wiring Ignition coil Rear stop switch Throttle cable Fuel tube \ / ’— 5 , //CarburetorF. ‘ 1/ overflow tube ’5’ Engine breather tube, Rear stopper switch wire\ \ \/ AC. generator wiri g Speemm;\l nition rima wirin Runs through above the high tension lead \ 2-7 Brake cable / Runs in front of horn ahd after Throttle cable the bottom bridge Front stop switch wire Lighting SWitGh wire (Runs along outer side’ofihandle) Indicator, horn s itch wire / The switch w g for front stop and in atorI horn both run along the pipe of the handle bar. \lndicator wire Clamp so that there is no slack. Install the horn to the top hole. Speedometer cable Indic After connecting wires lay the tube and clamp the center of tube Detailed diagram 0 Wire harness /' of tail light area \ / r . . Ensure there is no slack in wire "C3 2-8 Gorilla J , High tension lead Frame body earth Brake cable sg/ Install with ignition coil Front stop sWItch Wire Ignition coil Silicon ectifier Clutch cable . ‘3' ’7 ,Rjarstgp switch wire 5 S Engine ', 9 ’0' 7 Title inher wiring breather tube ’ ‘ A.C. generatorwire \ ' Ignition coil Rear stop switch a???” "443.2% / \ V , / ‘ W/ ,/' A.C. generator wiring‘ \\ lgnitionipflmary wiang y’ E - Runs throug anve upper ‘/ / \ Speedomethcable ‘brggTrhgr' high tension lead A! tube .7 Rear sttmr switch “fie //‘ / pr i , i i it ' in \ ix Q-v/ / Overflowtuihe \, 2-9 Brake cable Runs through the back of the horn stay, bottom bridge / Glut; cable \—‘7‘ Throttle cable let stgg switch wire / Indicator, horn: 3h wires Install the horn to the bottonmm < '_‘ _ \ Speedometer cable Indicator wire tail light wire Cover with tube after wiring; clamp the center of the tub . . '/ Indicator wire Induitor Wire c|a_mp / Ensure there is no slack in the wire 2-10 Fault diagnosis Unable to start or difficulty starting Condition ni Fli‘uvl Che-ii em. of Fuiure _ -._—j —cii.... i. i. .Mi .. ii" m in. rim.» m- “in bui! ‘ ' 7 i and chuck H mm" 1 mi ii mun-a in L m «mum.» L‘iaflim m m m. m. a: (mi mm i i ,4 Hjfliflflim a? m “on V.iii. 73‘2Wllive »i m Mi umk up mm- Final 1: annulled. nut swpl lei! Walnut ”mum-mu __Jurthm| m the swarm-ll I mm up an: minim m. I 13m mm“ ii 5 J M- nii. i, mum in. ”ii. i, Mi dun r..." mum. i lure ‘IE (mama: f. i..i. m u: SMYY'cHnVIUIK w m m» mum m -mw in gnu-giimiim m u: .iimiui “ii gm” mu» mi... Sunk in Ink. M mm H m snmk Souk is unernted mmll [y xiin.uimm..i= m. ziuu Brim-M ..i “m 4m mi \gixiwium .m m mi ni n: ciimi .m m; _ :‘JLAs mi... .74 o. cyiimi lash! mm W I Euimmmmii. v {ii/ii.E "ii. um i; m .1 W vim is in: Sign at c. . 1 i. "In pin: is on (x «um-i?" u: m __‘ “Minn. in": i, . w -f minim m In: mm m m mi. ma. , in. .W 2w. aim mu oi m (ubuuur . in, am it . um.” .i i Mi: .n mm. i. “Mimi" ml at m m Div: .5 m __ __ ’m k: the efllme m Lirnfl: . w- m.. m m Lin: nmlie mu 4- m can Poor acceleration or low power qufitmn nf iniure Check cause 0' Feilm .. _,__. __fl i w m mm.” mm : Liam-1w W"; -4 (gm huh: xx m Ifllusm} aiawii .m {MKKIN‘Y on em. lhezl helium is damn m meals sum smumly Aii i: fiiled nuvrecciy. "is engine rev mm: The engine iev does not mien the clutch is imar men the clutch reineacd i r i n ,_ |—|._ in“ up u: m ,iimiy: ,___" Iii: nrassun (chunk mm a we (sure) l a l L @lm: men ii Mn (2)!» mm um i. dun: {Wei—mi. [in ”min 4 u mum: in. mr mi . not to m ziia gear mine Mulch is m: mum nmneriy Ind nips (2m. timii disk is .m an mum." .i m. .imii iixh .in. (pm. kiwi .w ii.- m @Yhe calburetov .s mom. ®rhs an cleanzr Is chum ® Fuel .3 m supplxen prnvufly a) [he hm tank new new ‘5 waged a} m mm: .s clngged Dwv nut mvvmz an an 3 Hal mm mad [he rev mcmm ACh-ck m: \Knltmn mm?“ [mm a mm hum } L 4 ’DTV‘! \zmtlun twin! ‘5 nm of sync Qumran: fa>|ure r— —| 'Check (he must cleavame! m Tammi maladjustment m: mum m mm @Valve seal ‘5 worn out Alukml} rm arr m mm .m mumn m : “WWW wessme . . I mm mm the my 'fnr nunmxmmtely 5 “MA (D Poor contact M the WM seat Q7 War and ten of the uy‘ mder. rm: a; cwnvesmn w haw ma cum m m mm (mung ‘5 ant av Sync The” \s pmsure We? for any elm-H n the uamuretor. (D Chum: cf (ha port 9 ha plug .5 mean, and We mg ‘5 mm mm m <1.) mm“ sludge W “'“R as now! his ml chum Ils cDIur Ills Winged *Egy me mcrlral value nf t e plug fines not match rfiwuv: m ml um . ___. awe. and check m I . w .m‘ m m .n, : LmumLmuiad_J Emmw on sunny mare Is nut arm n m L Th: an Is tan a: armmad m: an mum Ii wrren €08 Remove the Linn“ 039.1 — and check the oonmtlml . :nf luhrlcztmn \__ a: Chain: of the on may <21 Clufifilflx uf (he ml mlflne (D mamm- —u.<. a my Snead mm H mama We" and tear af m: Dismn m Cylinder ‘23 n“ mu mm” m «an I.“ (D Fm rm detulurntud (Dcmun nmm—uu mum Ihs cambustlnn cmnmer (sum mmtmn mung rs tnundvunoed mm .s rm knack”! 2-12 cammun nr PM me 077m Cause uf 7:7 me - 7am 7 m 7 "123mm clearanc: may 7.. __ 73m upm 7s 7m «1.7m: mummy ' a 7mm amk x77: gamma: mnmmn M th: L_cmuremr u7r screw I, 7 A 7 7 (Dumm- 7s um mm". m scvu m 777) “”5“?“ ”WW" wmmu 7: 7m «7mm m, mm! to M heck 7r a7r 75 men“ 777 mm the 7mm f 771 m7 0 L... ©5an77n: a! 0.: 777mm. a rmg ems: flflmg or the vavhwemr A77 7s 7m taken 777 {Ram’cm‘n'I-Tg u. 7mn=cl earmmg to my A-A‘semndavy card can. ‘ 7 and (hen kink the new 7 {far mm: mm 4 $th pm; 75 mum my dirty @cmm point fmlur: sum 75 mm 1772 spark 7: weak. o7 3” ”1mm" ”"m $73777 7m coil 7.77m generated omner‘y. there Is no Snark @729“ .7 mortars-"hm“ m mm 7.7).." 7mm |_i @777; Mm swltm 7s mam 2-13 Bondillm of Failure Conant meanest mI IIIIIII III unmouy IIoI ciogm MII pIIIIIiaIs fmmd Banding ur smi IIII cumIquI III Failms - (IIII .III WWII.» III “I: r I m m“ In I II: m C EIIIIIII me fYOHL III 3 "II Imui IIIIIIIIIII Steam: an is In on: m: @ G (L a (E Q I. _ JignIIInII IIIIIrIg IIIo —~ Chapter15) 0 Charging the battery (:Chapter 15) SPARK PLUG Remove the spark plug. Check for any singeing and for any dust, grime, or debris adhered to the plug. If there is any clean with a plug cleaner or wire brush. Specified plug: NGK C5CHA CGHA, ND U16FS-L UZOFS-L Make adjustments to the plug clearance so that it is between 0.6- 0.7mm. COMPRESSION PRESSURE Warm up the engine. Remove the spark plug and fit the compression gauge. Open the choke and throttle fully. Strongly kick over the kick start approximately 5 times to measure the compression pressure. Compression pressure: 10- 12kglcm1 If the compression pressure is low, check the following items: Compression leakage from the valve : Maladjustment of the tappet Breakage of the cylinder head gasket 2 Wear and tear of the piston ring :1 Wear and tear of the piston, cylinder Clearance Wear and tear Grime Deposits Distilled water The fluid 1 level should i x /be between /‘ rthese lines. Any / 7/ deformities? Jl Any cracking or ///damage? Compression gauge If the compression pressure is high, this may be due to carbon build-up within the combustion chamber or the piston head. 3-7 IGNITION TIMING Ignition timing adjustment (with timing light) Remove the L. crankcase cover. Use a timing light to make sure that the alignment mark is in line with the "F" during idling. Check the point clearance after making adjustment. Loosen the adjustment screw, Alignmentmark and move the breaker plate to . . l make this adjustment. Breakemghtenmg ‘ /F mark screw Ignition timing adjustment (with lamp) Breaker plate \ ’ /" Remove the L. crankcase cover. Remove the battery from the frame, and connect one side of a 6V 5W lamp to the positive terminal and the other side to earth. Detach the AC. generator coupler, and connect it to the negative terminal and the primary wire (Black) of the coupler. Turn the crank in its rotating direction. The timing is correct if the lamp dims when the mark is aligned with the "F". 3-8 Checking the point clearance After making adjustment to the ignition timing, turn the crankshaft to the position where the point is at its maximum openingt Use a thickness gauge to measure the point clearance Point clearance: 0.3- 0.4mm Replace the point if the clearance is outside the rated valuet Attach the Lt crankcase covert Bakelite washer Point set Point replacement d— bolt Remove the flywheel (5 10-3) , . cw 06f Remove the primary wure of the i Breaks, contact breakert *67 “ plate #3??? ' Remove the breaker plate screw, and replace the contact breaker point After replacement, make adjustment to the ignition timing, and check the point clearancet ', Tappet adjustment Carry out tappet clearance check and adjustment when the engine has cooled down Remove the top and bottom tappet capst * Insert a waste cloth as a small amount of oil may seep outt Remove the Lt crankcase covert Turn the crankshaft in its rotating direction and align the alignment mark with the “T" on compression TDCt 3-9 Carry out tappet clearance check and adjustment. Tappet clearance IN: 0.05i0.02mm EX: 0.05-0.02mm Loosen the lock nut, and carry out adjustment using the adjustment screw. 9" After tightening the lock nut, recheck the clearance. CAM CHAIN ADJUSTMENT The cam chain is automatically adjusted by the spring when first the 8mm lock nut and then adjustment bolt A are loosened. If the cam chain continues to make noise, remove the sealing bolt while loosening adjustment bolt A, and tighten adjustment bolt B gradually until the noise stops. CARBURETOR ADJUSTMENT Throttle cable adjustment Check for play in the throttle grip. Play: 2-6mm appe adjustment wrench /( / 07908 DOIDODD 3-10 Carry out adjustment by turning the adjuster. If adjustment is not possible, replace the throttle cable. Idling adjustment 7" Carry out adjustment after warming up the engine. 1. Turn the throttle stop screw to the left, and adjust the idling ‘ ~ speed to the MIN speed that can be maintained 2. Turn the air screw to the left and right, and adjust it to the position where the MAX idling speed can be obtained. 3. Regain the rated idling speed using the throttle stop screw. 4. Turn the air screw further to check for any fluctuation of idle speed. If there is any fluctuation, repeat steps 2-4 to gain the rated . I THROTTLE STOP nggw - x ‘ , - idling speed. 5. Check for throttle response and IO 20% ‘ free play. 1 Standard value Idling engine speed 1,5000rpm Air screw reverse turn 1 1/2 CLUTCH ADJUSTMENT Manual clutch Check for any play in the clutch lever. Play: 10- 20mm 3—11 Loosen the lock nut so that the play in the clutch lever is between 10-20mm, and make adjustment to the clutch cable using the adjustment nut. 5’ Stan the engine when adjustment has been made and make sure gear changes can be carried out smoothly that the engine does not stall and that the vehicle does not move fonrvard abruptly. Automatic centrifugal clutch Loosen the lock nut, and turn the adjustment screw to the right by approximately 1 turn. Then, turn the screw to the left until it becomes slightly heavy. Turn the screw back to the right 1/8-1/4 turns from the position where the screw became heavy. Make sure that the adjustment screw does not turn along with the lock nut when tightening the nut. . Start the engine after making adjustment in order to check that the clutch is disengaged and has changed smoothly and that there is no slipping of the clutch. The clutch has to be disengaged when the tip of the change pedal has stepped down by 14-18mm. X’ If stalling or abrupt vehicle movement occurs, wear and tear of clutch plate A, the drive plate, or the roller is a possible cause. 3-12 CLEANING THE AIR CLEANER Remove the screw, and detach the air cleaner cover. Remove the element. Clean the element and dry. 9“ Do not clean with fuel or acidic, alkaline, or organic flammable oil. Soak the element in clean gear oil (SAE80—90) or engine oil. Squeeze the oil out of the element and reattach. FRONT BRAKE Check for any play in the front brake lever. Play: 10-20mm 3-13 If the play is outside the rated value, turn the adjustment nut to the left or right to make adjustment. REAR BRAKE Check for any play in the rear brake pedal. Play: 10-20mm Turn the adjustment nut to the left or right to make adjustment to the play. 3—14 CHECKING THE STOP LAMP SWITCH Adjust the adjustment nut so that the STOP LAMP swurcr-r stop lamp comes on when the tip of \ _ ‘7 the brake pedal is pressed down by 10mm. DRIVE CHAIN Put the gear in neutral. Check the tension of the drive chain in the middle of both sprockets. MAX free play: 10-20mm Use the following procedure to make adjustment: Loosen the axle nut and turn the left and right adjustment nuts. 9% Match both left and right alignment marks to the same scale position. Tighten the axle nut. Torque: 3.5- 5.0kg = m Further tighten the adjustment nut. 4—1 OIL LUBRICATION FLOW Fault diagnosis 4-1 Maintenance information 4-1 Oil lubrication flow diagram 4-2 Fault diagnosis Oil level is low 1. Natural oil consumption 2. Oil leakage 3. Wear and tear of the piston ring Oil quality has deteriorated 1. Oil has not been replaced 2. Damage to the head gasket Oil lubrication failure 1. Oil level is too low 2. Damage in the oil pump 3. Clogging of the oil filter, oil passage, or oil orifice Maintenance information Cautionary points during operating Oil pump: Chapter 9 Centrifugal filter: Chapter 3 Oil filter screen: => Chapter 3 Specifications Oil capacity 0.8! Oil used HONDA 6N4 or equivalent Oil 10W-3O 4-2 OIL LUBRICATION FLOW DIAGRAM 5-1 ENGINE ATTACHMENT] REMOVAL Maintenance information 5-1 Engine removal 5-2 Engine attachment 5-4 Maintenance information Cautionary points during operation The engine should be removed when carrying out maintenance on the following items: Conrod c Transmission c Crankshaft Engine weight: approximately 17kg 5-2 ENGINE REMOVAL Remove the L. side cover, and detach the battery couplers. Remove the AC. generator couplers. Drain the engine oil. AlfiLEANER MOUNF Remove the Inlet manifold BOLT tightening bolts. Remove the air cleaner mounting bolt, and detach the carburetor and air cleaner. Loosen the exhaust pipe tightening nuts and muffler mounting bolt/nut, and detach the muffler. 5-3 Remove the clutch cable (Gorilla). Remove the spark plug cap. Remove the gear change pedal and L. crankcase cover. Remove the drive sprocket, and detach the chain. Support the frame, and remove the step. Loosen the engine hanger nuts. Place a suitable platform underneath the engine, remove the hanger bolts, and then detach the engine. I r I) n / €311;qu , HANGER BOLT CLUTCH CABLE DRNE \ ' . SPROCKET 5—4 ENGINE INSTALLATION Engine installation is carried out in the reverse order to removal. Take care that parts are not damaged during installation. Run the wires and cables through the right positions (92-6). Fill with engine oil (23-3). Carry out the following checks/adjustments: Clutch play ( 3-8) Tension in the drive chain ( 3-12) 6-1 6. CYLINDER HEAD, VALVE Fault diagnosis 6-1 Maintenance information 6-1 Cylinder head removal 6-4 Cylinder head disassembly 6-5 Valve guide replacement 6-10 Valve seat check/ repair 6-11 Cylinder head assembly 6-14 Cylinder head attachment 6-15 Fault diagnosis Faults around the cylinder head can be generally assessed by measuring the compression pressure or by listening to the operating sounds of the upper part of the engine. Compression pressure is either too low or unstable 1. Valve Tappet maladjustment Burning or bending of the valve Damage in the valve spring Valve timing fault Valve seat sealing fault 2. Cylinder head Head gasket leakage Deformation or cracking of the head 3. Cylinder, piston fault (EChapter 7) Compression pressure is too high 1. Carbon build-up within the piston or combustion chamber Noise 1. Tappet maladjustment 2. Burnt valve or damage/ wear of the valve spring 3. Damage/ wear and tear of the rocker arm/ rocker arm shaft Maintenance information Cautionary points during operation Make sure that there is no clogging in the 0” hole and that O-rings and knock pins are correctly fitted when installing the cylinder head. When assembling the cylinder head, apply molybdenum disulfide onto the cam shaft bearing as an initial lubrication until oil comes up to the bearing. Pour plenty of engine oil into the cylinder head 0” reserve as well. Specialized tools Valve guide reamer 07984-MA60001 Valve guide driver 07942-MA6000O Valve spring compressor 07757-0010000 6-2 MAINTENANCE CRITERIA Standard value Usage limit Deformation of the cylinder head Repair or replace if 0.05mm or more. Valve seat contact width 1.0- 1.3mm Repair if 2.0mm or more. Valve stem IN 5.455- 5.465mm Replace if 5.40mm or less. outer EX 5.430- 5.445mm Replace if 5.40mm or less. diameter Valve guide IN 5.475— 5.485mm Replace if 5.50mm or more. inner EX 5.475— 5.485mm Replace if 5.50mm or more. diameter Valve- guide IN 0.02mm Replace if 0.10mm or more. clearance EX 0.04mm Replace if 0.10mm or more. Valve spring IN Inner 25.1mm Replace if 23.9mm or less. IN Outer 28.1mm Replace if 26.9mm or less. Free length EX Inner 25.1mm Replace if 23.9mm or less. EX Outer 28.1mm Replace if 26.9mm or less. Cam height IN, EX 26.07mm Replace if 25.69mm or less. Rocker arm hole diameter 10.000- Replace if 10.10mm or more. 10.015mm Rocker arm shaft outer diameter 9.978— 9.987mm Replace if 9.91 mm or less. 6-3 Sealing copper washer LD‘leg-m 0.B~12kg m Sealing copper washer 6-4 CYLINDER HEAD REMOVAL When disassembling the cylinder head when it is still mounted within the frame, place a supporting platform under the engine, and detach the front fender and front wheel before removing the cylinder head 'i BOLT a TAPPET CAP Remove the engine (5 Chapter 5) Remove the 2 tightening screws and the bolt on the cylinder head R. side cover to detach the R. and L. side covert Remove the tappet cap. Turn the flywheel, and align it to compression TDC (align the “T" with the alignment mark)t Remove the cam sprocket tightening bolts, and detach the cam sprockett CAM SPROCKET 6-5 Remove the 4 cylinder head tightening nuts and 6mm bolt, and detach the cylinder head. 7“ Pay attention to where the sealing washers and nuts are located. DISASSEMBLING THE CYLINDER HEAD Insert the 8mm bolt into the rocker arm shaft to remove the rocker arm pin, and then detach the rocker arm. Remove the cam shaft. 6-6 Use the valve spring compressor to detach the valve cotter, retainer, valve spring, and valve. 9% Do not tighten the compressor more than necessary. Keep IN and EX parts separate after disassembling. Remove carbon build-up within the combustion chamber. Remove the gasket material attached to the head gasket surface. al- Take care not to damage the gasket surface. Soaking the gasket in fuel will aid in the removal process. Valve spring compressor 07757-0010000 6-7 Checking the cam shaft Check for any damage on the cam face, and measure the cam height. Usage limit: Replace if IN 25.69mm or less. Replace if EX 25.69mm or less. Checking the cylinder head Check for any cracking around the spark plug hole and valve hole. Check for any deflection of the cylinder head using a straightedge and thickness gauge. Usage limit: Repair or replace if 0.05mm or more. Checking the free length of the valve spring Measure the free lengths of the inner and outer springs. Usage limit: IN Inner: Replace if 23.9mm or less. Outer: Replace if 26.9mm or less. EX Inner: Replace if 23.9mm or less. Outer: Replace if 26.9mm or less. 6-8 Checking the valve and valve guide Check for any bends, burning, or damage to the valves, and also for uneven wear and tear on the stem end. Insert the valve in the guide, and make sure that the valve moves smoothly. Measure the stem diameter of each valve. Usage limit: Replace if IN 5.40mm or less. Replace if EX 5.40mm or less. Insert the reamer in the guide before measuring the valve guide, and remove any carbon build-up inside. 9" The reamer should be only turned to the right. Do not attempt to insert or pull out the reamer when it is stationary. Measure the inner diameter of each guide. Usage limit: Replace if IN 5.50mm or more. Replace if EX 5.50mm or more. The clearance between the stem and guide can be gained by subtracting the outer diameter of the valve stem from the inner diameter of each guide. 9" If the clearance exceeds the usage limit, figure out if the clearance will be within the usage limit when replaced with a new guide. If it will be within the limit replace only the guide. Valve guide reamer 07984-MA60001 9" Make adjustment to the seat if the guide has been replaced. 6-9 Checking the rocker arm Check for any damage or wear and tear to the rocker arm. Check also for any clogging of the oil hole, and measure the hole diameter. Usage limit: Replace if 10.10mm or more. * If there is any damage or wear and tear to the rocker arm, check also for any damage or wear and tear on the cam face of the cam shaft. Checking the rocker arm shaft Check for any damage in the rocker arm shaft, and measure its outer diameter. Usage limit: Replace if 9.91mm or less. Wear and tear, damage 6-10 VALVE GUIDE REPLACEMENT Tap in the valve guide. 9" Take care that the cylinder head is not damaged. Fit the attachment to the valve guide remover, and tap in the valve guide. Finish the valve guide with a reamer after tapping in the valve guide. 2% Use cutting oil for reaming. The reamer should only be turned to the right. :1 Do not insert or pull out the reamer when it is stationary. Clean the cylinder head, and remove chipped material. Valve guide remover : 07942-MA60000 Valve guide driver : 07942-MA60000 Valve guide reamer : 07984-MA60001 6-11 CHECKING AND REPAIRING THE VALVE SEAT Remove carbon build-up within the head combustion chamber and valve. aw i " Apply red lead primer or bearing blue evenly and lightly to the contact surface of the valve. Align the valve using a valve grinder. Remove the valve, and check the contact surface of the valve. 5’ Replace valve if there is any roughness or uneven wear and tear on the valve face or if the valve is touching the top or bottom of the valve seat. Check the contact width of the valve seat. Standard: 1.0- 1.3mm Usage limit: Repair if 2.0mm or more. If the contact width is uneven, too wide, or too narrow, adjust the valve seat with a valve seat grinder. Repairing with a valve seat grinder Refer to the valve seat cutter manual Valve sea‘ minder for details. IN ' minimum 60' Ex : onaoroouenu IN : 07730 70013200 . EX: 0773073013100 31 IN I fl7790i00il000 :xumau oorliou W 6-12 Carry out dressing (alteration of the work surface) using a grindstone. Operate the valve seat cutter lightly, and make sure not to grind the seat too deeply. Grind the seat surface with a 45“ valve seat grinder until there is no roughness or pin holes on the surface. I Roughness on the seat surface 9“ Take care not to grind 45' [00 deep. ' Valve seat G ' d t i Adjust the flat surface with a "n 5 one 32' grinder. Valve seat 6-13 Adjust the inner surface with a 60° grinder. Adjust the seat surface with a 45D cutter until the rated valve seat width has been obtained. Valve seat width 1.1- 1.3mm Standard value (IN, EX) After adjusting apply compound evenly to the contact surface of the valve and smooth the surface with a valve lapper. Upon completion, clean the cylinder head and valve. 9% o Pushing the valve down hard on the seat while lapping will damage the parts. Push the lapper as lightly as possible. . Take care that the grinding compound does not enter into the clearance between the stem and guide when lapping. When all the adjustment has been made, make sure that the 45“ seat surface is touching the contact surface of the valve evenly by using red lead primer or bearing blue. Side dress . T7 Work su rface dress 6-14 ASSEMBLING THE CYLINDER HEAD Attach the spring seat and stem seal. Apply a small amount of oil to the valve stem, and insert it into the guide. 9% Replace the valve stem seal if the seal has been removed. Attach the valve stem seal to the IN side. Attach the valve cotter with a spring compressor. 5’ Do not tighten the valve cotter excessively. Tap the valve stem end with a plastic hammer a few times using a suitable tool to fit the valve and cotter into place. 9" Take care that the valve is not damaged. Attach the cam shaft. Attach the rocker arm and rocker arm shaft to the cylinder head. 9% Apply oil to the rocker arm shaft before attaching. A Attach the rocker arm shaft with its grooved side facing the outside. 6-15 CYLINDER HEAD ATTACHMENT Remove the gasket material from the cylinder upper face. 9% Take care that the gasket face is not damaged. Take care that the discarded gasket material does not go inside the engine. Attach the O-rings, knock pins, and a new head gasket. 9" Make sure that the oil passage is not clogged. Cap nuts Attach the cylinder head and then the head cover gasket and head cover, and tighten them to the specified torque. Specified torque: 8mm bolt: 0.9- 1.2kg-m 6mm bolt: 0.8- 1.2kg-m 9" Attach the head cover so " .L " mark that “ I " faces the EX side. Conner washer 6-16 Turn the flywheel, and align it to compression TDC (align the "T" on the flywheel with the alignment mark on the crankcase). Set the cam sprocket and cam chain, and attach the cam chain. 9% Apply molybdenum disulfide on the cam shaft bearing. Align "O" on the cam sprocket with the alignment mark on the head. Torque: 0.8- 1.2kg-m Check and make adjustment to the tappet clearance (=3-6). Attach the cylinder head L. and R. side cover. 9“ Align the L. side cover with the alignment mark on the cylinder head to attach. L. side cover .' o D O 7-1 7. CYLINDER, PISTON Fault diagnosis Maintenance information Cylinder removal Piston removal Piston installation Cylinder installation Fault diagnosis Compression pressure is either too low or unstable 1. Wear and tear of the cylinder, piston ring Smoke is coming out of the muffler (oil has run out) 1. Wear and tear of the cylinder, piston 2. Poor installation of the piston ring 3. Damaged piston, cylinder Overheating 1. Carbon build-up within the combustion chamber and piston Knocking abnormal operating noise 1. Wear and tear of the piston and cylinder 2. Carbon build-up Maintenance information Cautionary points during operation Maintenance of the cylinder and piston can be carried out on the vehicle body. Lubrication around the cylinder head is carried out with the oil from the oil control orifice of the R. crankcase that flows via the cylinder stud hole. Make sure there is no clogging in the orifice and that the knock pins are fitted properly before attaching the cylinder. 7-2 MAINTENANCE CRITERIA Siandard value Usage limii Cylinder Inner diameier 39.005- 39.015mm 39.05mm Upper face defecIion - 0.05mm Pision, pisIon Ring groove/ ring Top 0.01- 0.045mm 0.12mm ring, pisIon pin clearance Second 0.01- 0.045mm 0.12mm Oil 0.01- 0.045mm 0.12mm Ring end gap Top 0.1- 0.3mm 0.5mm clearance Second 0.1- 0.3mm 0.5mm Oil 0.1- 0.3mm 0.5mm Pision ouIer diameier (STD) 38.98— 39.00mm 38.90mm Pision pin hole inner diameIer 13.002- 13.008mm 13.055mm Conrod small end inner 13.013-13.043mm 13.100mm diameier Pision pin ouier diameIer 12.994- 13.000mm 12.98mm Cylinder/ pisIon clearance - 0.15mm Pision/ pin clearance - 0.075mm 7-3 7—4 CYLINDER REMOVAL Remove the cylinder head (= Chapter 6). Remove the guide roller bolt, and detach the chain guide rollert Remove the O-ring and knock pin. Remove the 6mm bolt, and detach the cylindert Remove the gasket material attached to the cylinder upper face Also remove the gasket material on the abutting surface of the crankcase and cylindert 9" Make sure that the discarded gasket material does not go inside the crankcase Checking the cylinder Check for any wear and tear to the cylinder inner diameter. Usage limit: Replace if 39.05mm or more. 7-5 Check for any distortion on the cylinder upper face Usage limit: Repair or replace if 0.05mm or more. PISTON REMOVAL Remove the piston pin clipt 9" Take care not to drop the clip in the case Remove the piston pin, and detach the piston. Checking the piston, piston ring Measure the clearance between the ring and groove Usage limit: Top: Replace if 0.12mm or more. Second: Replace if 0.12mm or more. Oil: Replace if 0.12mm or more. Check for any damage in the piston, uneven wear and tear in the ring groove, or cracking on the side. 7-6 Remove the piston ring, and attach each ring to the lower part of the cylinder to measure the ring end gap clearance. Usage limit: Tcp: Replace if0.5mm or more. Second: Replace if 0.5mm or more. Oil: Replace if 0.5mm or more. Measure the outer diameter of the piston skirt. Usage limit: Replace if 38.90mm (STD) or less. * Measure the outer diameter 10mm from the bottom. Calculate the clearance between the cylinder and piston. Usage limit: Replace if 0.15mm or more. Measure the pin hole inner diameter of the piston. Usage limit: Replace if 13.055mm or more. Measure the small end inner diameter of the conrod. Usage limit: Replace if 13.100mm or more. 7-7 Measure the outer diameter of the piston pin. Usage limit: Replace if 12.98mm or less. Calculate the clearance between the piston and pin. Usage limit: Replace if 0.075mm or more. INSTALLING THE PISTON Install the piston rings to the piston. 9% o Take care to ensure that the piston is not damaged or the rings broken. 0 Make sure that the mark on the ring is facing upward. Make sure that the rings rotate freely after attaching them. The ring end gap joint should be separated by 120° avoiding the piston pin direction and its vertical direction. Apply oil to each piston ring. Fit the piston, piston pin, and clip. 9" Turn the I on the piston to the exhaust side. The openings oi the ring end gap joints should be divided by 120° OIL 1] {055 sectiont ’Make sure the joints fit . properly. / ‘ )5 The mark faces .flx . upward. ‘Check for any clogging oi the ring groove and oil opening. 7-8 CYLINDER INSTALLATION Fit the knock pin, cylinder gasket, and O-ring. 9“ Make sure that the oil orifice is not clogged. Apply oil on the inner surface of the cylinder, and fit the cylinder. X’ Take care that the piston and piston ring is not damaged Fit the cam chain guide roller and roller boltt Fit the knock pin, head gasket, 0- ring, and cylinder head. Tighten the cylinder head tightening boltt Torque: 0.8-1.2kg-m 8-1 8. Clutch Fault diagnosis 8-1 Maintenance information 8-2 Removing the clutch filter 8-3 Removing the clutch 8-4 Disassembling the clutch 8-5 Assembling/ fitting the clutch 8-7 Fault diagnosis Clutch Most operating failures concerning the clutch are caused by play in the clutch lever. Check for any play and make the required adjustments before disassembling the clutch. The clutch slips when accelerating 1. Not enough play 2. Wear and tear of the clutch disk 3. Wear of the clutch spring The clutch will not disengaged 1. There is too much play 2. Distortion of the clutch plate The vehicle runs even when the clutch is disenqaqed 1. There is too much play 2. Deformation of the clutch plate Lever ogeration is heavv 1. Twisting of the clutch cable, damage or clogged with dirt, etc. 2. Damage to the lifter mechanism Clutch operation is unstable 1. Clutch outer grooves are rough 8-2 Maintenance information Cautionary points during operating This chapter explains how to disassemble the clutch. This operation can be carried out whilst mounted on the vehicle, but be sure to remove the oil first. Specialized tools Clutch holder 07923-0400000 Lock nut wrench 07716-0020100 Maintenance criteria Standard value Usage limit Lever play (lever end) 10— 20mm - Spring free length Centrifugal clutch 21.1mm Replace if 19.4mm or less Manual clutch 18.9mm Replace if 17.4mm or less Deformation of Centrifugal clutch - Replace if 0.2mm the plate or more Manual clutch - Replace if 0.2mm or more Disk thickness Centrifugal clutch 3.45- 3.55mm Replace if 3.15mm or less Manual clutch 3.45- 3.55mm Replace if 3.15mm or less Outer diameter of Centrifugal clutch 20.93- 20.95mm Replace if the primary drive 20.90mm or less gear bush Manual clutch 20.93- 20.95mm Replace if 20.90mm or less Inner diameter of Centrifugal clutch the primary drive gear Manual clutch 21 .000- Replace if 21.05 21 .021mm mm or more 21 .000- Replace if 21.05 21 .021mm mm or more 8-3 REMOVING THE CLUTCH LIFTER Remove the engine oil. Remove the clutch cable (manual clutch vehicle). Remove the kick pedal. Remove the step or loosen the step installation bolt so that the R. crankcase cover can be detached. Remove the R. crankcase cover. Loosen the 2 imbedded screws, and detach the clutch cover (manual clutch vehicle). Remove the pin with pliers, and pull out the clutch lever (manual clutch vehicle). Loosen the screws, and remove the lifter setting plate and clutch lifter plate (manual clutch vehicle). Screws Pr Clutchyvire Clutch lifter plate 8-4 Remove the R. crankcase cover, and detach the clutch lifter, clutch ball retainer, clutch cam complete (centrifugal clutch vehicle). REMOVING THE CLUTCH Remove the clutch outer cover. Lift up the claw on the lock washer, and remove the lock nut to detach the main body of the clutch. Remove the primary drive gear, clutch center guide, and collar. Clutch holder 07923-0400000 14mm lock nut wrench 07716-0020100 8-5 DISASSEMBLING THE CLUTCH Remove the set ring, and detach the clutch outer, drive plate, clutch disk, clutch plate, and clutch spring (manual clutch vehicle). Remove the set ring, and detach the clutch center, drive gear outer, clutch disk, and clutch plate (centrifugal clutch vehicle). Remove the 4 screws, and detach the drive plate and clutch spring from the clutch outer. ,/ Set ring , Set ring 8-6 Checking the disk Replace if the disk is damaged or if its color has changed Check the thickness of the disk: Usage limit Centrifugal clutch vehicle: Replace if 3.15mm or less Manual clutch vehicle: Replace if 3.15mm or less Checking the clutch plate Check for any deformation of the plate on a surface table: Usage limit Centrifugal clutch vehicle Plate A: Replace if 0.2mm or more. Plate B: Replace if 0.2mm or more. Plate C: Replace if 0.2mm or more. Manual clutch vehicle: Replace if 0.2mm or more Checking the clutch center and clutch center guide Check for any wear and tear or damage: Measure the inner diameter of the clutch center (primary drive gear if checking a manual clutch vehicle) and the outer diameter of the clutch center guide: Usage limit Outer inner diameter: Replace if 21 .05mm or more Clutch center guide Guide outer diameter: Replace if 20.90mm or less 8-7 Checking the clutch spring Check the free length of the spring. Usage limit Centrifugal clutch vehicle: Replace if 19.4mm or less. Manual clutch vehicle: Replace if 17.4mm or less. Assembling and fitting the clutch Fit the plate, disk, and clutch spring in the clutch outer in the order indicated in the diagram, and fit the set ring. (Centrifugal clutch) Clutch plate A Clutch friction disk Damper spring Clutch outer Set ring Drive plate “5)“ a‘ Clutch spring Drive gear outer Clutch center (Manual clutch) Clutch Spring " Drive plate Clutch friction disk / Clutch plate Clutch outer Damper spring Set ring 8-8 When fitting the set ring. use a hydraulic press. Fit the damper spring after fitting the set ring (manual clutch vehicle). In the centrifugal clutch, tighten the 4 screws to fix the drive plate and clutch outer. Fit the collar. primary drive gear, clutch main body, and lock washers A and B to the crankshaft. Tighten with the lock nut, and fix the lock nut with the claw on the lock washer A. Clutch Assy. - Fit the R. crankcase cover. and adjust the clutch (=3-8). Stan the engine after making any adjustments, and check for any oil leakage or malfunction of clutch operation. 9-1 9. Oil pump Fault diagnosis Maintenance information Removing the oil pump Disassembling the oil pump Checking the oil pump 9-2 Assembling/ fitting the oil pump 9-3 Fault diagnosis Refer to page 4-1 for oil pump fault diagnosis. Maintenance information Remove the clutch when carrying out maintenance on apparatus related to the oil pump. These operations can be carried out without the oil pump related apparatus being removed from the vehicle. Maintenance criteria Standard value Usage limit Clearance between the 0.15mm Replace if0.2mm or inner rotor and outer rotor more Clearance between the 0.02— 0.07mm Replace if0.12mm or outer rotor and body more Clearance between the 0.1- 0.15mm Replace if 0.2mm or rotor end face and body more 9-2 REMOVING THE OIL PUMP Remove the engine oil: Remove the Rt crankcase cover ( 8-3): Remove the clutch ( 8-4): Remove the three 6mm screws, and detach the oil pump: Disassembling the oil pump Remove the three 5mm screws, and disassemble the oil pump: Checking the oil pump Check the clearance between the pump body and outer rotor: Usage limit: Replace if 0.12mm or more. Check the clearance between the inner rotor and outer rotor: Usage limit: Replace if 0.2mm or more. Check the clearance between the rotor end face and body: Usage limit: Replace if 0.2mm or more. 9-3 ASSEMBLING/ FITTING THE OIL PUMP Fit the outer rotor, inner rotor, and pump shaft to the pump body, and tighten the gasket and cover with 5mm screwst * Make sure that the pump rotates smoothly after assemblingt Match the concave part of the cam chain guide spindle with the protruding pan of the pump shaft, and fix them together with 6mm screwst Fit the clutch Fit the Rt crankcase cover, and adjust the clutch Insert oil Stan the engine and check for any oil leakage and that the clutch is functioning properly Remove the tappet cap on the “IN" side, and check how well the oil is being fed 10-1 10. A.C. generator, cam chain tensioner Maintenance information 10-1 A.C. generator 10-3 Cam tension device 10-4 Maintenance information Cautionary points during operation Maintenance on the A.C. generator and cam tension device can be carried out without removing from the vehicle. Refer to Chapter 15 for A.C. generator check. Specialized tools Flywheel holder 07925-0010000 Flywheel puller 07933-0010000 1 0-2 3.073‘8kg-m Flywheel holder 10'3 o7925-oo1oooo A.C. generator Remove the Lt crankcase covert Hold the flywheel with the holder, and remove the 10mm retainer nutt Flywheel puller 07933-0010000 Remove the flywheel with the fly wheel pullert Remove the 2 imbedded screws that are fixing the statort Remove the coupler on the AC. generator and the neutral switch wiret Detach the stator from the crankcase. lmbedded screw ¥ 1 0—4 Check the contact breaker, and 33'9"” “£9" W Poim set b0“ repair or replace if there is any damage on the point surface. Fit the stator and flywheel. Connect the neutral switch with the AG. generator coupler. Stan the engine, and check the ignition timing. Make adjustment if there are any abnormalities (=3-5). Alignment mark ‘ ! l ,- i ‘1"- Cam tension device Remove the flywheel and stator. Remove the cam tension device pivot, and detach the cam tension device arm and roller. " \, /\Q ’/ Push rod ‘/ ’1- 10-5 Loosen the 8mm lock nut, and remove adjustment bolt A. Remove the sealing bolt, and take off adjustment bolt B. Remove the tension device springs A and B, and also the tension device push rod. Adjustment bolt B Assembly of these parts is carried out in the reverse order. 11-1 11. Crankshaft, transmission Fault diagnosis 11-1 Maintenance information 11-1 Removing the drum stopper and shift spindle 11-4 Removing the transmission and crankshaft 11-5 Checking the transmission 11-9 Checking the crankshaft 11-11 Assembling the transmission 11-12 Fitting the transmission and crankshaft 11-14 Fault diagnosis It is difficult to engage the gears. 1. Maladjustment of the clutch (play is too large) 2. Bending of the gear shift fork 3. Bending of the gear shift spindle claw 4. Damage to the shift drum cam groove 5. Damage to the guide pin The gears become disengaged by themselves. 1. Wear and tear in the gear dog area 2. Damage to the shift drum stopper 3. Bending of the shift fork Engine noise 1. Looseness in the main journal bearing 2. Looseness in the crank pin bearing 3. Looseness in the piston pin and its pin hole Maintenance information Cautionary points during operation Apply oil on to the gears when first assembling the parts. Maintenance on the drum stopper and shift spindle can be carried out without being removed from the vehicle. The procedure when the engine is assembled, however, is explained in this chapter. 11-2 Maintenance criteria Slandard value Usage llmll Transmission Gear lnner M2 17.016717.034mm Replace if 17.1mm or more dlameler (for 3 c1 17.016711034mm Replace if 17.1mm or more speeds) c3 17.016711034mm Replace if 17.1mm or more Gear lnner M2 17.016717.034mm Replace if 17.1mm or more dlameler (for 4 M4 17.016717.034mm Replace if 17.1mm or more speeds) c1 17.016711034mm Replace if 17.1mm or more c3 17.016711034mm Replace if 17.1mm or more c4 17.016711034mm Replace if 17.1mm or more Main shafl auler For 3 speeds 16.983716.994mm Replace if 16.95mm or less dlameler For 4 speeds 16.983716.994mm Replace if 16.95mm or less Counler shafl For 3 speeds 16.983716.994mm Replace if 16.95mm or less paler dlameler For 4 speeds 16.983716.994mm Replace if 16.95mm or less Shlfl drum ouler dlarneler 33.9507 33.975mm Replace ll 33.93mm or less Shlfl fork inner diarneler 34.0007 34.025mm Replace if 34.065 rnrn or more snm fork claw For a L 4.867 4.94m Replace if 4.6mm or less lnickness speeds R 5.867 5.94m Replace if 5.6mm or less For 4 4.457 4.55mm Replace if 4.2mm or less speeds Crankshafl Conrad smaH end lnner dlameler 13.013713043mm Replace ll13.100mm or more Conrad large end shafl dlrecllon 0.107 0.35mm Replace lf 0.6mm or more clearance Conrad large end peanng or omzmm Replace lf 0.05mm or more dlrecllon clearance Play ln lhe To lne shafl , Replace lf 0.10mm or more journal direclldn bearlng To lne bearing , Replace lf 0.05mm or more direclldn Deflecllon of crankshafl Replace lf 0.10mm or more 11—4 REMOVING THE DRUM STOPPER AND SHIFT SPINDLE Remove oil, and disassemble the engine. Remove the kick pedal, and detach the R. crankcase cover. Remove the clutch (-8-3). Remove the circlip, and detach the primary driven gear. Remove the pivot bolt, and detach the drum stopper. 1? Drum stop Remove the 6mm screw, and Shift drum 5‘0”” ’ 6mm Screw detach the drum stopper plate PM" \ a and pin. Remove the change pedal, and take out the gear shift spindle. * The 6mm screw is fixed by screw lock. Loosen with an impact driver. 'p I. , D Gearshift ‘ 11—5 Removing the transmission and crankshaft Remove the cylinder head cy'im’e' head and cylinder( Chapter 6,7). Remove the flywheel ( Chapter 10). Remove the neutral switch wiring and 2 screws, and detach the stator ASSY. 11-6 Remove the circlip of the kick starter spindle, and detach the Kick starter Spindle , kick spring retainer and kick k/fl :tfi spring. _ ~ Kick spring .‘~ ‘/U Remove the rubber cap, and detach the bolt that is fixing the shift drum. Remove the cam chain tensioner pivot bolt, and detach the cam chain tensionert Remove the cam chain tensioner push rod and cam chain. 11—7 Place the R crankcase downwards, and remove the screws. Then, face the L crankcase downwards, and detach the R and L crankcases apart. Remove the crankshaft and kick starter spindle. Kick starter spindle Remove the set ring, and detach the kick starter spindle. 11-8 Remove the transmission and Main shaft Shift drum shift drum simultaneously. Remove the guide pin clip and shift fork guide pin, and detach the shift drum. Shift fork 9“ As the shift fork has L and R setting directions. They should be kept in order for assembling ease when they are removed. Pull off the crankcase gasket, and check for damage on the gasket surface and case. 11-9 Detach the gears from the main shaft and counter shaft. (3 speed transmission) C top gear ‘ CZ gear M top gear (4 speed transmission) M2 gear Main shaft CZ gear Checking the transmission Checking the gear Check for abnormal wear and tear of the gears. —-" i Measure the inner diameters of the gears. Usage limit (for 3 speeds) M2: Replace if 17.1mm or more. (:1: Replace if 17.1mm or more. (:3: Replace if 17.1 mm or more. (for 4 speeds) M2: Replace if 17.1mm or more. M4: Replace if 17.1mm or more. (:1: Replace if 17.1mm or more. (:3: Replace if 17.1 mm or more. (:4: Replace if 17.1 mm or more. 11-10 Measure the outer diameters of the main shaft and counter shaft. Usage limit (for 4 speeds) 3‘ ~ M shaft: Replace if 16.95mm or less. C shaft: Replace if 16.95mm or less. (for 3 speeds) M shaft: Replace if 16.95mm or less. C shaft: Replace if 16.95mm or less. Checking the shift drum Check for wear and tear, and damage of the drum. Measure the outer diameter of the drum. Usage limit: Replace if 33.93mm or less. Checking the shift fork Measure the inner diameter of the shift fork. Usage limit: Replace if 33.065mm or more. Measure the thickness of the fittings (tips) of the shift fork. Usage limit For 3 speeds: L: Replace if 4.6mm or less. R: Replace if 5.6mm or less. For 4 speeds: Replace if 4.2mm or less. Replace if wear and tear or ' damage is significant. 11—11 CHECKING THE CRANKSHAFT Measure the inner diameter of the conrod small end. Usage limit: Replace if 13.100mm or more Measure the clearance of the large end of the conrod axle direction Usage limit: Replace if 0.6mm or more. Measure the play in 2 directions vertical to the large end of the conrod shaft. Usage limit: Replace if 0.05mm or more. Measure the play of the journal bearing of the crankshaft. Usage limit Axle direction: Replace if 0.10mm or more. Axle receiver direction: Replace if 0.05mm or more. 11-12 Measure the run out of the crankshaft. Usage limit: Replace if 0.10mm or more ASSEMBLING THE TRANSMISSION Assembling the shift drum Fit the shift fork to the shift drum, and insert the shift fork guide pin and guide pin clip. Assembling the kick starter Kick starter pinion 59‘ ""9 Assemble the kick starter spindle \ /- in the order indicated in the Friction spring \/ .© ,, diagram. , Set ring \A ’ 9v 9" Place the friction spring in the groove of the kick \‘Qj starter pinion. V‘ Kick starter spindle 11—13 Assembling the transmission C top gear ’01,]? C 2 gear £305 C 1 gear fig Counter shaft Mi: deg}? @fo EJCCER M top gear 0! ”\\ M 2 ‘3‘ L37 5% gearMain shaft @ ya“? 2" > “g C 2 gear C top gear Q‘s/p7 L40 _ g C 3 gear Qé/Edjé $0 I (@Q 0%?R Counter shaft M top gear %~’ '@ C 1 gear M 3 gear @fif; £\‘\ \\\\ M 2 gear \\\\\ Main shaf>fi§ééj~ Fit the gears on the main shaft and counter shaft, and fix with the set ringt 9" Apply oil to the gears after assembling. 11—14 FITTING THE CRANKSHAFT AND TRANSMISSION Fit the shift drum and transmission simultaneously to the L. crankcase. 9% The neutral switch rotor and neutral switch are fitted easily if they are placed together. Fit the kick starter spindle. 5’ Fit the friction spring in the case. Insert the crankshaft, line up the R. crank case and have the L crank case facing up wards secured with a screw. Counter shaft 9% Make sure that the knock pin and gasket are placed correctly while tightening the screws. Main shaft 11—15 Fit the cam chain and the other parts needed for the cam chain tensioner. Fix the shift drum with the 6mm Cam chain bolt, and replace the rubber cap. Cam tensioner arm 5i 5’ Apply oil to the crank bearing and also its large end. Set the kick spring and spring retainer after joining the cases. Kick spring Spring ~ / retainer Tighten the gear shift drum pin, shift drum side plate (4 speeds), and shift drum stopper plate on the gear shift drum with the 6mm screw. 5’ Apply screw lock to the 6mm countersunk screw. Insert the gear shift spindle, and fit the shift drum stopper. Torque: 0.8- 1.2kg-m 9" Fit the change pedal temporarily, and make sure that the gears engage correctly. 11-16 Fit the primary driven gear and clutch, and fix the R. crankcase cover (—>Chapter 8). Fit the stator and flywheel to the L. crankcase. Make sure to fit a new O-ring on the other side of the stator installation screws. Connect the neutral switch wire. Fit the cylinder ( 7-8). Fit the cylinder head ( 6-15). 11-17 Fit the drive sprocket, and mount the engine (= Chapter 5). Start the engine, and check if there is any oil leakage. ' L.Crank case cover I 1 2-1 Z5OJ Carburetor Fault Diagnosis 12-1 Maintenancelnformation 12-1 Removal of the Carburetor 12—3 Assembling and Disassembling of Carburetor 12-4 Installation of the Carburetor 12—5 Fault Diagnosis When the engine doesn't start: Fuel-air mixture is too lean 1. No fuel in the tank 1. Fuel jet blockages 2. Fuel isn't reaching the engine 2. Ventilation hole on fuel cap is blocked 3. Fuel is traversing past the inside of the 3. Fuel filter blockage cylinder. 4. Fracture, collapse or blockage of the 4. Plugs are not sparking (ignition fuel tube system) 5. Poor function of the float valve 5. Air filter blockage. 6. Float level to low Rough engine idle, poorly adjusted Fuel-air mixture is too rich 1. Rough idling 1. Choke is closed 2 Poor ignition 2. Poor function of the float valve 3 Low compression pressure 3. Float level is too high 4 Fuel-air mixture is too rich 4. Air jet blockage 5. Fuel-air mixture is too lean 6 Air filter blockage 7 Air leak into the manifold system 8 Dirt in Fuel Maintenance Information Cautionary Points for Operation When siphoning fuel be very careful of any fire hazards. Take care to position the O-ring correctly and replace with a new O—ring. Before disassembling, discharge the fuel inside the carburetor through the drain plug in the float chamber. . Exclusive Tools Float level gauge 07401 , 0010000 Maintenance Standards, Specifications Venturi diameter 11mm Setting mark PA03B Float level 12.721.3mm Air screw slack (standard) 1% turns Idling RPM 1500:100rpm Throttle grip play 2-6mm 12-2 CARBURETOR 12-3 DISASSEMBLING THE CARBURETOR Turn the fuel cock to the off position and open the drain cock. Once the fuel has drained out remove the fuel tube. Remove the throttle valve from the carburetor. Detach the throttle valve from the throttle cable. Cable end I ‘ 1'7 Detach the throttle valve from the jet needle. Needle cap plate . Throttle valve , 7‘ Jet needle 12—4 Detach the inlet manifold and the air filter from the Carburetort Disassembly and Assembly of the Carburetor Remove the float chamber and loosen the screws that fasten the float pint Remove the float and float valvet Remove the throttle stop screw, the air screw and the main jet and clean with solvent * Use clean solventt Screw Float chamber t\, \ 46 ’ > J- ' , ‘13::7‘ Main jet Airscrew .4. & W Throttle stop screw 1 2-5 Using an air nozzle, clean the body and ports of solvent and foreign particles. 9“ Check for any blockages. Assemble all of the parts. Float level Check Remove the float chamber. Check that the float is at the specified height when the tip of the float is in contact with the float valve. Float height: 12.7:1.3mm Replace the float if it is outside of specifications. Float level gauge 07401-0010000 if Attaching the Carburetor Assemble the throttle valve and the \Q‘ jet needle and then secure with the throttle cable. 1 2-6 Install the inlet manifold and the air filter to the carburetor. Assemble the throttle valve into the carburetor. 9“ Align the groove of the throttle valve with that of the throttle stop screw and insert. Connect the fuel tube to the carburetor and turn the fuel cock to the ‘on’ position. Stan the engine and then make adjustment to the carburetor as required (=3-8). —‘-— Throlt valve 13-1 13. Steering, Front Wheel, Front Suspension Fault Diagnosis Maintenance Information Headlight, Speedometer Steering Handlebars Front Wheel Front Fork, Steering System 13—1 13—1 13—2 13—4 13—6 13—7 Fault Diagnosis Heavy Steering 1. Head top thread over tightened 2. Damage to the bearings of the steering stem 3. Damage to the bearing race or cone race 4. Low air pressure in tyres Loss of Steering Control 1. Unbalanced left and right cushions 2. Warped front fork 3. Warped front axle, flat tyre Front Wheel Run Out 1. Rim deformed 2. Loose front wheel bearings 3. Tyres in poor condition 4. Axle related parts Front Cushion too soft 1. Spring fatigue Front Cushion too flexible 1. Bent front fork Abnormal Noise from Front Cushion 1. Cushion casing uneven wear 2. Cushion parts loose . Maintenance Information Maintenance Standards Standard Values Usage Restrictions Bent Axle Shaft Replace where exceeds 0.2mm Front Wheel Run Out Replace where exceeds 2.0mm Internal Diameter of Brake 110.0mm— Replace where exceeds 111mm Drum 110.3mm Thickness of Brake Lining 4 mm Replace where less than 2mm . Specialist tools 36mm pin spanner Ball race driver Bearing driver Bearing driver handle 07902-0010000 07746-0010200 07947-0450000 07749-0010000 1 3-2 1 fl HEADLIGHT, SPEEDOMETER ;‘ ; Headwlighl‘ Removing the headlight casing Loosen the screws and remove the headlight Remove the neutral and speedometer lamps (Monkey only) Remove the speedometer cable and set spring, and then remove the headlight (Monkey Only) Disconnect the main switch wiringt Push the clip that supports the main switch body in toward the centre and remove 1 3-3 Push the wire harness out from the light casing, remove the light casing set bolt and then the light casing itself. Removing the Speedometer (Gorilla Only) Remove the electric bulbs from the pilot and speedometer lamps and then remove the speedometer cable. Remove the speedometer set nut and then the speedometer. 1 3-4 Remove the front carrier. Remove the two screws pictured and disconnect the main switch. Remove the indicator panel. Attaching the headlight To attach the headlight, reverse the procedure for detachment. Hang the hook from the upper part of the headlight and fix in place with screws. 9" After assembly, perform a check of electrical component functionality. STEERING HANDLE BARS Removing the Steering Handle (Monkey) Remove the cable. Light switch " ‘1 Handle holdemob Remove the handle holder knob followed by the handle pipe. Remove the R. combination switch and the throttle grip simultaneously. Remove the light switch. 13-5 Removal of the Steering Handle Bar (Gorilla) Remove the brake and clutch cables. Remove the light switch. Remove the upper handle holder and then the handle pipe. Pull out the R. combination switch and the throttle grip at the same time. Installation of the Handle Bar Reverse the above procedure for removal. Install the light switch wire using a passing wire to draw the cord through the handle pipe. Install the R. combination switch and the throttle grip. 9" Apply grease to contact areas on the throttle grip. Punch mark Affix the handle pipe to the upper handle holder (Gorilla only) . Align the punch marks of the handle pipe with those of the upper surface of the lower holder. :1 Place the punch marks of the upper holder at the rear and screw down the front side first. Torque: 0.8-1 .2kg-m 1 3-6 Connect the brake and clutch " * .‘l cables and adjust as required. * Alignment position Check that the switches function normally. Align the handle holder knob with the handle taking care to position correctly, and then fix in place. Front Wheel Remove the speedometer and the front brake cables. Remove the front axle nut and then draw out the axle shaft. Remove the speedometer gear and brake panel. Take care not to get oil on the interior of the brake drum or on the brake lining. ‘ Inspection of the brake shoe and drum. Usage Limits Lining thickness: Replace if less than 2mm. Brake drum diameter: Replace if _ more than 111mm. ” (Front) Check for any distortion of the rim. Usage Limit: Replace if more than 2.0mm. Check for any bending of the axle shaft. Usage Limit: Replace if more than 0.2mm. 1 3-7 FRONT FORK, STEERING SYSTEM Remove the headlight and Headlight casing disconnect the wire harness and then force the headlight out of the casing. Remove the pilot lamp and the speedometer cable. (13-2) Remove the indicator panel. (13-4) Remove the speedometer and the Light casi 9 main switch, followed by the light 56* b0“ casing. (13-3) Remove the front carrier and the light casing simultaneouslyt (Gorilla) Remove the front wheel and the steering handle bars. 1 3-8 Remove the top bridge of the front TOp bridge fork and the top thread of the steering head followed by the front fork itself. Put the steel balls from the ball race in a safe place so as not to lose them. Remove the dust shield and the circlip and then draw out the front , Dust seal cushion. ' Circlip Pull out the spring pin and disassemble into component parts. Check parts for presence of abnormal wear and tear or damage. Check for warping of the steering . . . stem and front forks. % #4 E”; If warped replace or repair. Spring pin 1 3-9 Rub any grease off the ball raoe using solvent, and then check the surface for damage or wear and teart * Replace if signs of damage or wear and tear are present. Use a punch driver when removing the bottom cone race. Drive in with a steering stem driver when assembling. Use a ball race remover when removing the ball cone racet Ball race remover 07944-1 150001 13-10 Attach the ball race with a ball race driver and bearing driver handle. 9" Make sure that it is tapped inward in a straight fashion. Assemble the front cushion, and attach it to the steering stem. 9" Apply grease thoroughly to the front cushion spring. Apply grease to the ball race thoroughly, and then attach the steel balls. 9" Clean the steel balls with washing fluid before attaching. Care must be taken so that dust does not stick to its surface. Ball race driver 0774641010200 Bearing driver handle (A) 077490010000 4/ Steel ball 13-11 Attach the front fork to the steering head, and fit with the top ball race and top thread. air - Attach the front fork taking care the steel balls do not fall out. Tighten the top thread lightly and reverse approximately 1/8 turn, and make sure that there is no looseness but moves smoothly. Attach the steering top bridge and front wheel. Attach the steering handle, light case, and speedometer. Attach the clutch cable and brake cable. 13-12 Reconnect the wire harness and assemble the headlight. Check that the headlight, switches and cables are all functional. 14 Rear wheel, rear suspension Fault diagnosis 14-1 Maintenance information 14-1 Rear wheel 14-2 Rear cushion, rear fork 14-3 Taillight, rear carrier 14-5 Fault diagnosis Looseness of the rear wheel 1. Deformity of the rim 2. Looseness of the rear wheel bearing 3. Tyre defect 4. Axle related parts not tightened properly Soft rear cushion 1. Settling of the spring 2. Settling of the rear damper Ineffective brake . Brake maladjustment . Unclean brake shoe surface . Wear and tear of the brake shoe . Wear and tear of the brake shoe cam . Wear and tear of the brake cam . Wear and tear of the brake drum . Poor brake arm serration connection \leUI-wa—x Abnormal operating sound of the drive chain 1. Lack of oil or grease 2. Wear and tear of the chain, sprocket Maintenance information Specialized tools Rear cushion compressor 07959-3290001 Bearing driver 07947-0450000 Bearing driver handle 07949-2860000 Maintenance criteria Standard value Usage limit Bending ofthe axle shaft - Replace if 0.2mm or more Looseness of the rear wheel Replace if 2.0mm or more Inner diameter of the brake drum 110.0- 110.3mm Replace if 111mm or more Thickness of the brake lining 4mm Replace if 2mm or less Free length ofthe rear cushion 192mm spring Replace if 182mm or less 1 4—2 REAR WHEEL Remove the rear brake adjustment nut. Remove the axle nut, and detach the axle shaft. Remove the chain from the driven sprocket, and detach the wheel. Remove the brake panel, and check the brake shoe and brake drum. Usage limit Lining thickness: replace if 2mm or less Brake drum inner diameter: replace if 111m or more Make sure that oil does not get on the brake drum interior or the brake lining. Check for any bending of the axle shaft. Usage limit: replace if 0.2mm or more Check for any looseness (wear) of the rear wheel rim. Usage limit: replace if 2.0mm or more 14-3 REAR CUSHION, REAR FORK Remove the rear wheel and rear cushion. Detach the chain case. Chain case Remove the pivot nut of the rear V fork and the pivot shaft, and I , \ detach the rear fork. . Pivot nut Compress the rear cushion spring with the rear cushion compressor, and loosen the upper lock nut to disassemble the rear cushion. Rear cushion compressor 07959-3290001 Check for any leakage from the damper, and measure the free length of the spring. Usage limit: replace if 182mm or less 1 4—4 Fit the rear fork to the frame. Rear fork pivot bolt Torque: 2.5- 3.5kg-m Reassemble the rear cushion, and fit it to the frame and rear fork. Fit the rear wheel, and make adjustment to the drive chain and brake (=3-12, 3-11) 14-5 TAIL LIGHT, REAR CARRIER Remove the stop switch and tail light wiring, and then detach the 2 tail light mounting bolts to take off the tail light case. Removing the indicator stay Detach the tail light case after removing the wiring, and then loosen the 2 bolts located at the back of the case to take off the stay. Removing the rear carrier Remove the tail light case and indicator stay, and then detach the 4 carrier mounting bolts to take off the carrier. 15-1 ELECTRICAL DEVICES Fault diagnosis 15-1 Maintenance information 15-2 Battery 15-3 Charging system 15-4 Ignition system 15-5 Switch inspection 15-6 Fault diagnosis No electricit main switch is "ON" 1. The battery is not charged - There is no battery fluid - The battery is totally discharged - Charging system fault 2. Disconnected battery cable connection 3. Main fuse blown 4. Faulty ignition switch Power voltage is low main switch is "ON" 1. Inadequate battery charging - There is very little battery fluid - Battew is discharged - Charging fault 2. Faulty connection Power voltage is low (when engine is turning over) 1. Faulty battew charging - There is very little battery fluid 2. Charging fault Intermittent electrical current 1. Faulty battew cable connection 2. Faulty charging system connection 3. Faulty ignition system connection or short 4. Faulty lighting system connection or short Faulty charging system 1. Fault, disconnection or short to wiring or connector contact 2. Faulty commutator 3. AC. generator fault 15-2 Maintenance information Cautionary points for operation Regularly inspect the battery fluid level, fill with distilled water if necessary. Do not carry out rapid charging except in an emergency. Wherever possible, carry out battery charging with battery removed. Always remove the battery cable connection first when undertaking battery charging on the vehicle. Hydrogen gas is produced during charging. Do not allow open flames around the vehicle. Inspection of the charging system can be carried out with the battery on the vehicle. Specifications Capacity 6V — 2 AH Battery Fluid density 1.280 / at 20° C Charging current Less than 0.2 A Lights off 1 .510.3A/ 4,000rpm (at 6.5V) A.C. Charge efficiency Lights on 0.4:0.3A/ 4,000rpm (at 6.5V) generator Lights off 2.410.3A/ 8,000rpm (at 6.5V) Lights on 0.7:0.3A/ 8,000rpm (at 6.5V) N (U with» (D @ /Meter lamp \\ \\\\\\\\ \\ \\\\\\\\\\\\\\\\§\ \‘3. .‘c\\\\\\\ N\ ® Spark plug ® Rectifier ® Ignition coil (53 Battery (6V2AH) ® A.C. generator I Load 15-3 Battery Removal Remove the earth cable from the frame. Remove the rubber band. Remove the + positive cable. Pull out the battery. Relative density check Measure the density of the battery fluid. Density (at 20°C) 1.260~1.280: Fully charged Less than 1.220: Insufficient charge 7% - Charging is necessary if less than 1.220. - The density will vary depending on the liquid temperature as shown in the diagram. - Replace with a new battery if a white coating (sulfation) has appeared on the inside of the battery. - Replace with a new battery if any deposits appear on the lower area of the battery (paste). gauge \f T ‘ Electrolytic l solution Relation between battery fluid temperature and density 5. 10“ 15° 20' Fluid temperature 25" 30' The densitywill change by 0.007 for every 10°C difference in fluid. l - Battery fluid is a deadly poison. Handle and store with utmost care. - lf battery fluid should come into contact with skin, eyes or clothing wash off immediately with large quantities of water and consult a doctor. 15-4 Charging How to connect: Charger + and battery positive terminal Charger — and batter negative terminal Charging current: Less than 0.2A Charging completion: Charge until the density has risen to between 1.260~1.280 (20°C). W - Remove the battery caps. - Strictly no flames in the battery vicinity. - Always turn the charger ON/ OFF using the charger switch. Turning ON/ OFF at the connection point will cause sparks possibly causing an explosion. - Do not allow the fluid temperature to rise above 45°C. 5‘ Avoid rapid charging as this may damage the battery. Connect to the\fi blue cord. BAernv 9“ The batter breather tube passes through the part as indicated on the caution label. Charging system Charging efficiency test Warm up the engine. Connect the voltmeter and ammeter. 9% Carry out this test when the battew is fully charged. Charging efficiency Main switch Lighting switch RPM at start of 4,000 rpm charging ON OFF 1,000 rpm 1.5:0.3A/ 6.5V ON 1,000 rpm 0.4Il0.3A/ 6.5V 15-5 Stator coil conductivity test Conductivity is normal if there is conduction between the green wire (charging, power generation, coil) and vehicle body earth. Conductivity is normal if there is conduction between the black wire (ignition coil) and the vehicle body earth. 3“ Carry out the black wire test when the ignition points are open. BLK=EIack V=Vellow G=Green Ignition coil _ Condenser . \ Rectifier conductivity test Conductivity is good only under the condition shown in the diagram. Replace if there is conduction when the (+) and (—) connections have been interchanged. IGNITION SYSTEM Condenser capacity inspection Measure the capacity once the system has been shorted. 9“ Measure when disconnected from the stator without earthing the condenser. 0.27-0.32 uF 1 5-6 Ignition coil conductivity test Conductivity is good when under the condition shown in the diagram. The ignition coil is located on the underside of the frame. To remove, pull out the cover and remove the 2 nuts securing the coil. Efficiency test Carry out a 3 wire spark test using a service tester. Usage limit: Replace when less than 6mm. Each wire connection should be done in accordance with the service tester instruction manual. Switch inspection wG“ Conductivity is good if at 0—0. Main switch Terminal IG E ‘ EAT HT ' L‘ £23310" W a, mi: Green Red Black OFF as H i 0N @7 ,~ O——O s4 ‘ 1 5-7 Indicator switch Terminal R w L . . . Conic Svntch pOSItIon 0/0,. sky Blue Gray Orange _ Um.“ o——o Horn switch Terminal H0 E Cor m Smtch position Cleo/0’ Gizen are“ 312m fl Push 0‘40 W Lighting switch Terminal H C co _ Switch position rd Color Brown Veilow 0N O——O OFF 1 5-8 Sta p switc h Front stop switch is good if there is conduction between green/ yellow \ and black when brake lever is held _ - on. Front stop ‘2 switch wire Rear stop switch is good if there is conduction between green/ yellow and black when brake pedal is engaged. Horn inspection Check that the 6V battery activates the horn. 16-1 ZSOJ MONKEY ZSOJF - 7 SUPPLEMENTARY VERSION TABLE OF CONTENTS Specification Sheet ................................................ 16 — 2 Maintenance Standards .......................................... 16 — 3 Tightening Torque .................................................. 16 — 5 Common and Specialized Tools ................................ 16 — 6 Wiring Diagram ..................................................... 16 — 7 Wiring Schematic ................................................... 16 — 8 Inspection and Adjustment ....................................... 16 — 10 (Engine) Cylinder head, Valves ............................................. 16 — 11 Cylinder, Piston .................................................... 16 — 14 Crankshaft ............................................................ 16 — 15 Carburetor ......................................................... 16 — 16 (Frame) Steering ............................................................... 16 — 17 (Electric) Electrical System ................................................... 16 — 19 16-2 ZSOJF-7 0 Specification Sheet Specifications Make and Modei Honda AZSDJ Air niier deyiee Ureihane foam! pe Lengin 1 360m 2' Euei 1ank eapaeiiy areadin 0 600m ‘3 Type PADS Height 0 850m w Gas vaive diameier 13mm wneeipase 0895m E 2 : Veniuridiameier 11mm Engine Modei ZSOJ E 3 E Air vaive Iype Piston vaive lype Engine Capacily o 049 a Type Magneuc igniiion Fuel Type Pelmi E Igniuen ume ao'i1,5oo(3TDc/rpm) FTonleie Load 28kg m 5 [NGK) CSHA. OSHA. cum 3 a igniiion piug (ND) U16FSVL UQDFSVL‘ Venicie Weigni Rear Me [Dad 35kg E g U22FSVL Tolai 63kg %’ a Igni1ion ciearance o 6—0 7mm 3 Passengers Rider oniy a u, meAX‘e 42k § Capacily 2An<1uHr) Load 9 ‘2 Gross Venieie Body Rear Axie Wei 1ype singie disk coii W619i“ Load mg a Type spring Tolai 11akg E g Operaiing meinod Mechanicai Eroniwneei 3507872FR Tyres Rearwneei 3507872FR g: E"9‘”e‘°RTa’::S"“SS‘°" A 312 E T pe Gons1an1mesn _y Minimum ground eiearanee 01mm 3 1g Gear 2592 a d 5 m o m g Braking distance ilniiiai speed) a 5m [20km/h) g 3 u, 2 Gear 1323 g a 2 s 5 Minimumiuming radius 14m g, g g 3" Gear 1 300 Starling Method Kick sian 3 4‘" Gear 0 958 Type Pelmi/A Stroke ,, 1 Gearlype Gnain ? 3 icyiinder iransyerse g m Einai reduciion No oleimdeTs and iopaiion We mowed) g .2 We 2 583 Compus1idn chamber tyne Hemisphere 1 easier 25' 00' Vaivelrain OHC enain 2’ $3 Traii 42mm '" Bore x simke 39 a x 41 4mm é Tyre From 1 DOKg/Gm‘ : Compression 10 a Frassure Rear 1 25kg/cm' Len side 42' 0 140m 21000 51 A I . a ompression pressure g cm rpm eering nge ngmm 42 Maximum ou1pu1 3 1ps/7500rpm From Lead‘"9"a“‘”9 “/pe' , Brake mechanicai Maximum iurque a 32kgm/6.000Tpm Rear Lead‘"g"a“‘”9 ”99' e mechanicai opens TBTDC From wneei Teiescopic 0* < make cieses 12'ABDC ”Wm" Rear wneei Swing arm “’ Exhaus‘ Opens 1013500 Frame Back pone - Cioses O'TDC Certification nos I-1321J < Vaive iniake a 05mm ieoidi n, :iearance Exnausi a 05mm ieoidi Reyoiuiion speed (wnen idiing) 1.5ourpm ,_ Compinauon ouoreed 5 Luprieaiion system pressure and spiasn g iuprieaiion S g oii pump Trachmd m 5 Compinauon uHuiHiuw g Oiiliileriype and eeniriiugai Sieve mlraliun Luprieaiion oii eapamiy 0 8| 16-3 ZSOJF-7 Maintenance Standards MAINTENANCE STAN DARDS ENGINE |tem Standard Value Usage Limit OIL PUMP Inner-outer rotor clearance 0.15mm >0.2mmRPL Body-outer rotor clearance 0.03-0.08mm >0.12mmRPL Outer rotor edge face-body 01-021 mm >0.3mmRPL clearance CYLINDER . . . >0.05mmRPL HEAD Cylinder head distortion or RPR . >1 .6mmRPL or Valve seat contact Width 1.0mm RPR Valve guide IN/EX 5.000-5.012mm >5.03mmRPL ID VALVE Valve stem IN 4.970-4.985mm <4.92mmRPL OD EX 4.955-4.970mm <4.92mmRPL Valve-guide IN 0.015-0.042mm >0.08mmRPL clearance EX 0.030-0.057mm >0.10mmRPL VALVE Free Inner IN/EX 32.78mm <31.1mmRPL SPRING length Outer 'N/EX 35.55mm <33.8mmRPL CAMSHAFT Cam Height IN 24.982mm <24.584mmRPL EX 24.015mm <23.714mmRPL ROCKER Rocker arm ID 10.000 -10.015mm >10.10mmRPL ARM Rocker arm shaft OD 9.978 - 9.987mm <9.91mmRPL CYLINDER Inner diameter 39.005 — 39.015mm >39.05mmRPL (Upper) Warpa e - >0.05mmRPL PISTON Pism" ””9' 7°“ 0.015 — 0.050mm >0.12mmRPL ring groove clearance sewn" 0.015 — 0.050mm >0.12mmRPL PISTON Piston ring Top 0.05 — 0.20mm >0.5mmRPL RING end gap Second 0.05 — 0.02mm >0.5mmRPL Clearance Oil (Side Rail) 0.20 — 0.90mm >1 .1mmRPL PISTON Piston outer diameter (STD) 38.975 — 38.995mm <38.90mmRPL PIN Piston pin hole inner diameter 13.002 —13.008mm >13.055mmRPL Piston pin outer diameter 12.994 — 13.00mm <12.980mmRPL Cylinder— piston clearance 0.010 — 0.040mm >0.15mmRPL Piston- piston pin clearance 0.002 — 0.0014mm >0.075mmRPL CLUTCH Clutch spring free length 18.9mm <17.4mmRPL Clutch plate warpage --- ----- >0.2mmRPL Clutch disc thickness 3.45 — 3.55mm <3.15mmRPL OD of primary drive gear bush 20.93—20.95mm <20.90mmRPL ID at primary drive gear 21.000 — 21.021mm <21.05mmRPL > - Greater than < - Less than RPL - Replace RPR - Repair 1 6-4 ZSOJF-7 Maintenance Standards 0 ENGINE > < ITEMS STANDARD USAGE LIMITS CRANK SHAFT Small end inner radius of Conrod 13.016 713.034mm >13.10mm RPL Conrod large end clearance in axle 0.10 7 0.35mm >0.6mm RPL direction Conrod large end clearance in axle 0 - 0.012mm >0.05mm RPL receiver Crank shaft deflection ------------- >0.10mm RPL TRANSMISSION M 2 17.016 717.034mm >17.1mm RPL M4 17.016717.034mm >17.1mm RPL C1 17.016 717.034mm >17.1mm RPL C3 17.016717.034mm >17.1mm RPL C4 17.016717.034mm >17.1mm RPL diameter Main shaft outer 16.983 716.994mm <16.95mm RPL diameter Counter shaft outer 16.983 716.994mm <16.95mm RPL Shift drum outer 33.950 7 33.975mm <33.93mm RPL diameter Shift fork inner diameter 34.000 7 34.025mm >34.065mm RPL Shift fork tip thickness 4.86 7 4.94mm <4.6mm RPL u FRAME ITEMS STANDARD USAGE LIMIT Warped front axle shaft >0.2mm RPL Front wheel rim play >2.0mm RPL Front brake drum internal 1100 —110.3mm >111mm RPL diameter Thickness of front brake 4mm <2mm RPL lining Warping of rear axle shaft >0.2mm RPL Rear wheel rim deflection >2.0mm RPL Rear brake drum '“tema' 110.0 —110.3mm >111mm RPL diameter Thickness of rear brake 4mm <2 mm RPL lining Rear cushion spnng-free 192mm <182mm RPL length 16-5 ZSOJF-7 TIGHTENING TORQUE o TIGHTENING TORQUE ENGINE TIGHTENING PART NUMBER SCREW DlAMETER TlGHTENlNG (mm) TORQUE (kg-m) Tappel cap 2 30 1.0 — 1.4 Valve adjusl nm 2 5 0.7 — 1.1 Cylinder Nm 4 6 0.9 — 1.2 head Bol‘ 1 6 0.8 — 1.2 Cam sprockel boll 3 5 0.8 — 1.2 Cylinder boll 1 6 0.8 — 1.2 L. crank case cover 3 6 0.7 — 1.1 screw R. crank case cover boll 8 6 0.7 — 1.1 Clulch lock nm 1 14 3.5 — 4.5 Shifl drum slopper boll 1 6 0.9 — 1.4 Drain boll 1 12 2.0 — 2.5 Drive sprockel boll 2 6 1.1 — 1.5 Flywheel nul 1 10 3.0 — 3.8 . FRAME TIGHTENING PART NUMBER SCREW DIAMETER TIGHTENING (mm) TORQUE (kg-m) Sleering slem nul 1 24 6.0 — 8.0 From fork Top bridge 2 10 2.5 — 3.5 bolx From axle nm 1 12 3.5 — 5.0 Rear axle nul 1 12 3.5 — 5.0 Rear cushion nm 4 10 2.5—3.5 Rear fork pivol nm 1 10 2.5 — 3.5 Engine hanger boll 2 8 2.0 — 2.5 Driven sprockex nm 3 8 3.0 — 3.6 D STANDARD TIGHTENING TORQUE TYPE TIGHTENING TYPE TIGHTENING TORQUE (kg-m) TORQUE (kg-m) 5mm Bolx, Nux 0.45 — 0.6 5mm Screw 0.35 — 0.5 6mm Bolx, Nux 0.8 — 1.2 6mm Screw 0.7 — 1.1 8mm Bolx, Nux 1.8 — 2.5 6mm Flange boll, Nux 1.0 — 1.4 10mm Boll, NUT 3.0 — 4.0 8mm Flange boll, Nux 2.4 — 3.0 12mm Boll, NUT 5.0 - 6.0 10mm Flange boll, 3.0 - 4.0 Nm 1 6-6 COMMON AND SPECIALIST TOOLS Specialist tools Tool Name Tool Number Remarks Valve guide driver Valve spring compressor allachmenl Universal bearing puller Sliding weighl Remover handle Bearing remover Snap ring pliers Spring holder allachmenl Rear cushion allachmenl (A) Ball race remover 079427MA60000 079597KM30100 076310010000 077410010201 0793673710100 0793673710300 0791473230001 0796771180100 07967VGA70101 0794471150001 For punching and hammering in lhe valve guide Attachmenl for disassembling/ assembling ihe valve spring For removing lhe counler shafl bearing For removing lhe main shafl, counler shafl bearing For disassembling/ assembling ihe fronl cushion For disassembling/ assembling lhe rear cushion For removing ball race Common tools Tool Name Tool Number Remarks Float level gauge Tappel wrench 8X9mm Adjusling wrench (B) Valve spring compressor Valve guide reamer Luck nul wrench 20X24mm Extension bar Universal holder Flywheel puller Bearing driver ouler 37X40mm Bearing driver pilol17mm Bearing driver allachmenl 24X26mm Bearing driver handle (A) Pin spanner Bearing remover shafl Bearing remover head 12mm Bearing driver ouler 32X35mm Bearing driver pilol12mm Rear cushion spring compressor 074010010000 077080030100 077080030400 077570010000 079847MA60000 077160020100 077160020500 077250030000 077330010000 077460010200 077460040400 077460010700 077490010000 077020020000 077460050100 077460050300 077460010100 077460040200 079593290001 For carburelor oil level measuremenl For lappel ad juslmenl For disassembling/ assembling lhe valve spring For valve guide adjustment For allaching/ removing ihe clulch lock nul Supplemenlary lool for ihe luck nul wrench Whirl slop forthe clulch and flywheel For removing lhe flywheel For hammering in ihe main shafl, counler shafl bearing For allaching/ removing ihe lop lhread For removing lhe fronl/ rear wheel bearing For hammering in ihe froni/ rear wheel bearing For disassembling/ assembling lhe rear cushion Valve cutter Tool Name Tool Number Remarks Seal Cutler 22mm Flal cutter 22mm Flal cutter 19mm Inleriur culler 22mm Cutler holder 5mm 077800010701 077800012601 077800012700 077800014202 077810010400 For adjusting lhe IN, EX valve seal surface For adjusting lhe EX valve seal surface For adjusting lhe IN valve seal surface For adjusting lhe IN, EX valve seal surface Valve seal culler holder 16-7 Wiring diagram acvuxmo—i Nance E5 95 58.1.: =&, 3393 :23 ink 33m 5 E g $5 23 535:. 3; .1 J _, El a: . é a . @ 2.; {2m WWW—H El as r r. H m g: a.” 13:5 8% $3. E m @5233; :5. 58:2: E .33 a: :5: In] :5 .2. a, :3” 5% 9E 55;: to: 4 a I u .5 S I v z 3E 25 .3865 to; x 1 6-8 Wiring schematic Front brake cable Clutch cable Engine breather lube Front brake cable Wire band Clutch cable Lighting! indicator] horn wire , Speedometer cable Throttle cable Speed warning unit 1 6-9 Regulator] rectifier Sp- edometer cable Battery breather tube Ignition coil Regulator! rectifier Battery Fuse box Clamp 16-10 CHECK, ADJUSTMENT Check and maintenance method Check and Check and maintenance timing C riteria maintenance item Before 1 month For personal use operation Every 6 Every 12 months months Lever — Play at the tip of the play clutch lever 10- 20mm Power transmission Clutch 16-11 Cylinder head, valve Sealing aluminum washer 1.0“].4k2'm 0.7*I.1kE-m o.9~1.2kg-m Sealing copper washer 16-12 Maintenance criteria Item Standard Value Usage Limit Distortion of the cylinder _ Repair or replace if head 0.05mm or more. Pu Contact width of the valve Repair or replace if 1.6mm 0 1.0mm .: seat or more. \- . . . g Valve gulde Inner IN 5000 5.012mm Replace If 5.03mm or 5 dIameter more. 3. EX 5.000- 5.012mm Replace if 5.03mm or 0 more. Valve stem outer IN . diameter 4.970- 4.985mm Replace If4.92mm or less. EX 4.955- 4.970mm Replace if4.92mm or less. Clearance between IN Replace if 0.08mm or g the valve and guide 0015' 0.042mm more. E EX 0-030 0.057mm Replace If 0.10mm or more. Valve sprlng free IN 32.78mm Replace if31.1mm or less. length Inner 5 IN . E Outer 35.55mm Replace If 33.8mm or less. % EX . 32.78mm Replace If 31 .1 mm or less. 0 Inner 3 EX g Outer 35.55mm Replace if 33.8mm or less. C h ' ht IN ' am elg 24.982mm IRepIace If 24.584mm or ess. a: EX - fig 24.015mm Replace If 23.714mm or Q a; less. 3 Rocker arm hole dIameter 10.000-10.015mm Replace II 10.10mm or € more. 5" a dRizfl'l‘:{e:'m Sha“ “‘9' 9.978— 9.987mm Replace if9.91mm or less. 16-13 Attaching the L. Side Cover Attach the L. side cover to L. side cover the cylinder head. 7“ Match up the alignment points when attaching the L. side cover to the cylinder head. Tighten the 6X112mm bolt. 16-14 CYLINDER, PISTON Maintenance criteria Item Standard value Usage limit Cylinder Inner diameter 39.005- 39.015mm > 39.05mm RPL Upper face distorlion - > 0.05mm RPL Piston Clearance between the Top 0015- 0.050mm > 0.12mm RPL ring groove and ring Second 0.015- 0.050mm > 0.12mm RPL Piston ring Ring end gap Top 0.05- 0.20mm > 0.5mm RPL clearance Second 0.05- 0.02mm > 0.5mm RPL Oil (side rail) 0.20- 0.90mm >1.1mm RPL Piston pin Piston outer diameter (STD) 38.975- 38.995mm <38.90mm RPL Piston pin hole inner diameter 13.002-13.008mm >13.055mm RPL Piston pin outer diameter 12.994-13000mm <12.980mm RPL Clearance between the cylinder and piston 0.010- 0.040mm >0.15mm RPL Clearance between the piston and pin 0.002- 0.0014mm >0.075mm RPL > - Greater than RPL - Replace < - Less than Attaching the piston Attach piston rings to the piston. 9% 0 Take care to avoid damaging the piston or breaking the ring. The side of the ring with the marking faces upward. Make sure that the rings rotate smoothly after attachment. :1 Make sure the ring end gaps are offset by 120 degrees and not facing any thrust surfaces as per diagram. Apply oil to each piston ring. Top Second Oil 16-15 CRANKSHAFT Maintenance criteria > - Greaier man < - Less lhan RPL - Replace Item Standard value Usage limit Conneciing rod small end 13.016-13.034mm >13.10mm RPL inner diameier Conneciing rod large end axle 0.10- 0.35mm >O.6mm RPL direciion clearance Conneciing rod large end axle O— 0.012mm >0.05mm RPL bearing direciion clearance Defleciion of ihe crankshafl - >O.10mm RPL 16-16 CARBU RETOR Maintenance criteria Vemuri diameier 11mm Sening mark PADS FIoaI level 12.7mm Standard number oflums for av screw 1 3/8 Main jeI #58 Slowjei #35X35 Idling rev 1,500rpm Thronle grip play 2- 6mm 16-17 STEERING Removing the handle bars Brake cable Throttle housing Remove the brake cable. Remove the screws, and detach the throttle housing. Disconnect the throttle cable from the throttle grip, and detach the grip. Screws thottle cable Throttle grip §witch housing Remove the clutch cable. Remove the screws, and detach the switch housing. /. Clutch cable Screws Handle pipe Remove the handle holder knobs, and detach the handle pipes. Handleholder knob 16-18 Attaching the handle bars Alignment positions Fitting of the handle bars is carried out in the reverse order of its removal procedure. Take note of the following items. Make sure that the alignment positions are matched when attaching the handles. Throttle grip Apply grease to the sliding face of the throttle grip. Punch marks Align the punch mark on the handle bar and the matching surface of the housing when attaching the throttle housing/ switch housing. Tighten the front screw first. Make sure that the . throttle grip moves smoothly after attaching the throttle housing. . Make adjustment to the throttle s ,t h h , cable, clutch cable and front w' c °"s'"9 Throttle housing brake cable after attaching. 16-19 ELECTRICAL SYSTEM REgulztuV/Rectlfier M w Mack/Whit: mm mm m : | “W" Fuse” mm a1 }_ ; Batten gum -, (mm; Human/l Swim: JPN: / W um. i L ignlllon AC Benemor Cmi Meter LIZM 6m .7w ialHigM Gvaw Specifications Battery Capacity 6V- 2AH Fluid densiiy 1.26- 1.28/20- Charging eleciric curreni 0.2A or less A.C. generator Charging capaciiy Lighis off: 1.0A or more/ 4,000rpm (8.6V) Lighis on: 0.6A or more/ 4,000rpm (8.5V) Lighis off: 2.5A or less/ 8,000rpm (8.8V) Lighis on: 1.8A or less/ 8,000rpm (8.7V) 16-20 Regulator/ rectifier Remove the seat, and detach the regulator/ rectifier. Measure the resistance value between terminals referring to the table below. mm s A B c D my , 0.51m ~ A 5° 1am °° 10KQ~ m m B mm c m m oo 1m ~ D °° 50m °° Sanwa: (xKQ) analogue Kouwa: (X100 9) digital 7% o Correct checks cannot be carried out if the tester is not suitable or if the measurement range is different as a semiconductor is built in within the circuit. r1 Use Sanwa (07308-0020000) or Kouwa (TH-5H) tester. 17. MONKEY ZSOJM (MONKEY BAHA) ADDENDUM CONTENTS Specifications ----- -- — —— — .. .. .. .. __ 17.2 Maintenance criteria --------------—————————————————.................________________ 17.3 Tightening torque -- -- -- —— —— .. .. _ .. 17.5 Specialist! general tools---------------————____————___——..................._.____... 17.5 Wiring diagram -- -- -- —— —— .. .. _ .. __. 17.7 Wiring schematic -- -- - .. . .. 17.3 Checks, adjustments- 17.11 (Engine) Detaching/ attaching the engine ------------------------------------------------17-14 Cylinder head, valves--- Clutch, gear shift linkage AC generator, cam chain tensione Steering, front wheel ------------------ Rear wheel, rear cushion ---------------------------------------------------------17-50 (Electrics) Electrical system-- -- —— —— .. .. .. _ __ 17.55 17.2 Specifications Make and Mode Hunda Aezsod Ar Mer s stem Uremane (Dam! pe cnassTs make and mode Honda ZSDJ Fue‘ ‘ank ca m 4 0! Leng1n 1 330m g D V wTd1n a 735m , 0 Type PADS HeTgm a 875m %’ o Gas vawe d1arne1er 13mm Whee‘base a 895m 3 Q Ven1un d1arne1er Approxuma1e1y 11mm Engme Mude‘ ZSOJ E g mr vawe lype Mama‘ya‘ffflag’ 9‘5“)" Engme Capacny a 049 1 T pe cm 1ype magneue Tgmlmn FueT Type Pe1ro1 7 \gnmon «me 2713mm z‘mo rpm «3 m a FromAxTe Load 28kg E S [NGK) CRSHSA. CRSHSA. fi % ”mm" ”“9 (igHSaanR u uzquR Vemc‘e WeTgm RearAxTe Load 31kg ; 3 [u [2235“; V ' V 2 1 mm 5% g Ignmon dearance o 6—0 7mm From/We Load 3% E Capacny a 48 [101 or a 50110)» Gross Vemde Body WeTg n1 Rear Ax‘e Load 75kg Type We11vpe$2g1ged15k 001‘ T 1 114k 9 ma 9 5 g Operaung me1nod Mechamca‘ From wneeT Tyres ssoeaasd Rear Whee‘ V Ennge1oRTar‘agssts1on 4 312 g T pe Cons1an1mesn s o 1 L M 1 MH'wlIum gmund dearance 0150rn S We ‘0" e 0” 3 a 1“ Gear 3 272 m e g 3 5 ( 1 1 d g 3 § m W a spee 3 m _ a g Erakmg d1s1ance 20mm) 9 E g 2 Gear 1 937 a - 5 annumurmng Tadms 14m %’ g g 3"Gear 1 350 6 B Stamng Memod Kmk s1ar1 3 3 4‘" Gear 1 043 Type Rem/4 snake g Gearwpe cnam 5i No omynnders and Tocauon Wm“ "E”M’SE E Dece‘erauon ra1e 2 334 see moumed) g Compusnon chamber [ype Hestpnere _" Caster 25' oo' Va‘ve Ham OHC Chem :7 %§ Tran 42mm ore x s1ro e x mm a we ron1 g em ’“ a k 390 414 g T F 100w I 3 Compressmn 1n o 3 Pressure Rear 125kg/cm’ Compressmn pressure 14 Dkg/cm‘sLODDTpm 5:65:51 $15”: 2: m lg s e Maxnnurn ou1pu1 31FS/7.500Tpm From Leadggggi‘n‘ffavpe ' ’ Brake : Maxnnurn 1ordue o 32kg/6JJODTpm Rear Leadmgégi‘n‘vfawe ' Wake Opens TBTDC From whee‘ TeTesoopTc m < (mm W moses IZ‘ABDC ”PM” Rear wneeT Swmg arm r» Exnaus1 Opens 10'BBDC Frame Back bone _ (mm “M C‘oses OlTDC < Vawe Make 0 05mm eTearanee m We” mm Exnaus1 a 05mm Revu‘ulmn speed [when Tdhng) 2000mm Cumbmalmn ouoreed Lupneauon dewce pressure and spTasn \ubncalmn on pump TTochmd Cumbmalmn ufluHrfluw OHNleHype and cemnTugaT sTeue mlralmn Lupneauon on eapacny 0 at Couhng me1nod Arcoonng 17-3 MAINTENANCE STANDARDS ENGINE Item Standard Value Usage Limit OIL PUMP Inner-ouler roIor clearance 0.15mm >0.2mmRPL Body-ouler roIor clearance 0.03-0.08mm >0.12mmRPL Outer rolor edge face-body clearance 01—021 mm >0.3mmRPL CYLINDER . . . >0.05mmRPL HEAD Cylinder head dislorllon or RPR Valve seal conlacl widlh 1.0mm >1.6m;|13§PL or Valve guide ID IN 5.000-5.012mm >5.03mmRPL EX 5.000-5.012mm >5.03mmRPL VALVE Valve Slem OD IN 4.970-4.985mm <4.92mmRPL EX 4.970-4.985mm <4.92mmRPL Valve-guide clearance IN 0.015-0.042mm >0.08mmRPL EX 0.030-0.057mm >0.10mmRPL VALVE Free Ienglh IN 33.34mm <31.8mmRPL SPRING EX 33.34mm <31.8mmRPL CAMSHAFT Cam Heighl IN 20.005mm <19.67mmRPL EX 20.063mm <19.66mmRPL ROCKER Rocker arm hole diameler 10.000 -10.015mm >10.10mmRPL ARM Rocker arm Shafl OD 9.978 - 9.987mm <9.91mmRPL CYLINDER Inner diameler 39.005 — 39.015mm >39.05mmRPL Upper face dislonion ___ >0.05mmRPL or RPR PISTON P'5‘°" OD (STD) 38.975- 38.995mm <38.90mmRPL Pislon pin hole ID 13.002-13.008mm >13.055mm Ring groove- ring Top 0.015 — 0.050mm >0.12mmRPL C'ea'ance sewn" 0.015 — 0.050mm >0.12mmRPL Cylinder— pislon Clearance 0010- 0.040mm >0.15mm RPL PISTON Pislon ring end gap Top 0.05 — 0.20mm >0.5mmRPL RING clearance Second 0.05 — 0.20mm >0.5mmRPL ggiff'de 0.20 — 0.80mm >1 .0mmRPL PISTON Pislon pin ouIer diameler (STD) 12.994- 13.000mm <12.980mmRPL PIN Pislon- pislon pin Clearance 0002- 0.014mm >0.075mmRPL CLUTCH Spring free Ienglh 18.9mm <17.4mmRPL PIaIe dislorlion >0.2mmRPL Disk Ihickness 3.42- 3.58mm <3.1mmRPL Primary drive gear bush OD 20.93- 20.95mm <20.90mmRPL Primary dr'Ve gear ”3 21.000— 21.021mm >21.05mm RPL > - Grealer Ihan < - Less Ihan RPL — Replace OD- Ouler diameler RPR — Repair ID- Inner diameler 1 7-4 ENGINE ITEMS STANDARD USAGE LIMITS CRANK SHAFT Email end inner radius of 13.016 713.034mm >13.10mm RPL onrod Conrod large end clearance in axle 0.10 7 0.35mm >0.6mm RPL direction Conrod large end clearance in axle 0 - 0.012mm >0.05mm RPL receiver Crank shaft deflection - 7 >0.10mm RPL TRANSMISSION Gear inner M 2 17.032 717.059mm >17.1mm RPL diameter M 4 17.016 717.043mm >17.1mm RPL C1 23.020 7 23.053mm >23.1mm RPL C 3 20.020 7 20.053mm >20.1mm RPL C1 bush ID 20.000- 20.021mm >20.08mm RPL OD 22.970- 23.000mm <22.93mm RPL mflifimfier 16.989 7 16.994mm <16.95mm RPL 90””19' Shaft outer 19.952 719.980mm <19.94mm RPL diameter (C1) SW“ drum omer 33.955 7 33.975mm <33.93mm RPL diameter Shift fork inner diameter 34.075 7 34.100mm >34.14mm RPL Shift fork tip thickness 4.86 7 4.94mm <4.6mm RPL FRAME ITEMS STANDARD USAGE LIMIT Bending of the front axle shaft ---------------- >0.2mm RPL Deflection of the front wheel rim -- --------- >2.0mm RPL Front brake drum inner diameter 110.0 7110.3mm >111mm RPL Thickness of the front brake lining 4mm <2mm RPL Bending of the rear axle shaft >0.2mm RPL Deflection of the rear wheel rim >2.0mm RPL Rear brake drum inner diameter 110.0 7110.3mm >111mm RPL Thickness of the rear brake lining 4mm <2 mm RPL 17-5 TIGHTENING TORQUE ENGINE RELATED TIGHTENING PART NUMBER SCREW DIAMETER TIGHTENING (mm) TORQUE (kg-m) Tappet hole cap 2 30 1.0- 1.4 Valve adjustment nut 2 5 0.7- 1.1 Cylinder Nut 4 6 0.9- 1.2 head Bolt 1 6 0.8- 1.2 Cam sprocket bolt 2 5 0.7- 1.1 Cylinder bolt 1 6 0.8- 1.2 Guide roller pin bolt 1 6 0.8- 1.2 lntake manifold bolt 2 6 0.7- 1.1 Clutch lock nut 1 14 4.0- 4.5 Drum stopper arm pivot bolt 1 6 0.8- 1.2 Shift drum stopper bolt 1 6 1.4- 2.0 Clutch lock nut 1 14 3.5- 4.5 Shift drum stopper bolt 1 6 0.9- 1.4 Drain bolt 1 12 2.0- 2.5 Push rod sealing bolt 1 14 2.0- 3.0 Tensioner pivot bolt 1 8 1.3- 1.8 Drive sprocket bolt 2 6 1.1- 1.5 Flywheel nut 1 10 3.8- 4.5 Kick starter pedal bolt 1 6 0.8- 1.2 FRAME RELATED TIGHTENING PART NUMBER SCREW TIGHTENING DIAMETER TORQUE (mm) (kg-m) Handle bar lower holder nut 2 10 3.5- 4.5 Steering stem nut 1 26 6.0- 10.0 Fork bolt 2 10 2.5- 4.0 Headlight stay bolt 4 6 0.8-1.2 Front axle nut 1 12 4.0- 5.0 Rear axle nut 1 12 4.0- 5.0 Wheel hub bolt 8 8 2.4- 3.0 Driven sprocket nut 4 8 3.0- 3.6 Brake arm nut 2 6 0.8- 1.2 Rear fork pivot nut 1 10 4.0- 5.0 Rear cushion 4 10 2.5- 4.0 Step bar bolt 4 8 2.4- 3.0 Muffler Bolt 1 8 2.4- 3.0 Nut 3 6 0.8- 1.2 Side stand pivot Bolt 1 10 0.5- 1.5 Nut 1 10 2.5- 3.0 STANDARD TIGHTENING TORQUE TYPE TIGHTENING TYPE TIGHTENING TORQUE (kg-m) TORQUE (kg-m) 5mm Bolt, Nut 0.45 — 0.6 5mm Screw 0.35 — 0.5 6mm Bolt, Nut 0.8 — 1.2 6mm Screw 0.7 — 1.1 8mm Bolt, Nut 1.8 — 2.5 6mm flange bolt, nut 1.0 — 1.4 10mm Bolt, Nut 3.0 — 4.0 8mm flange bolt, nut 2.4 — 3.0 12mm Bolt, Nut 5.0 - 6.0 10mm flange bolt, nut 3.0 - 4.5 1 7-6 SPECIALIST, COMMON TOOLS Specialist tools Tool name Tool No. Remarks Clulch spring compressor 07960- 0110000 For disassembling/ assembling lhe cluich Universal bearing puller 07631 - 0010000 For crankshafl removal Clulch ouier holder 07923- 0350001 For clulch ouier removal/ allachmem Siem bearing driver 07946- GC40000 For slem race aflachmem Valve guide driver 07942- MA60000 For valve guide allachmenl Valve guide reamer 5.010mm 07984- MA60001 For valve guide removal Common tools Tool name Tool No. Remarks Floai level gauge 07401- 0010000 For checking ihe carburelor floai level Pin spanner 07702- 0020001 For lop ihread removal/ anachmem Sockel wrench 20X24mm 07716- 0020100 For clulch ouier removal/ anachmem Bearing driver ouier 32X 35mm 07746- 0010100 For rear wheel dusi seal allachmenl Bearing driver inner 17mm 07746- 0020300 For R. crankshaft bearing allachmem Bearing driver inner 20mm 07746- 0020400 For L. crankshafl bearing anachmem Inner driver B 07746- 0020100 For crankshaft bearing allachmem Valve seat cutter Tool name Tool No. Remarks Seal curler 24mm 07780- 0010600 For lN/ EX valve seal surface adjuslmeni Flal cuiler 21 .5mm 07780- 0012800 For lX valve seal surface adjusimem Measurement tools Tool name Tool No. Remarks Digiial circuil lesler (Kouwa) Circuii iesier (Sanwa) Circuii iesier (Kouwa) 07411- 0020000 07308— 0020001 TH- 5H For eleciric componeni checks Peak voliage adaplor 07HGJ- 0020100 For peak voliage measuremem 17-7 oooo.x<0.~onoo a. ,3 sans 52a :3»: s , in SEE xx _ mus wWEfiEJ 2: ESE . L. E 52 as a 3:22. I 5.523 3 m x w - m _ a 5:5 A 2 Z. is E z z a a Pay 00 .9. 00 x ‘ I. 0.0 H $255... .35.: .235: :95 52:26 33:25 5:: :5 z; :5 ; 55:2. MW .3 .55: “SAW—m MN. _ uh ww— Ezzgaiag 5:.“ 2% Ex mww Wm , mm gm} 3 ,5 .3. BMW 5: : x9 3 3L? 3 Rd a |wll [295; fivia a: 5.5;: E: y. 1 7-8 Wiring schematic From brake cable Clutch cable Front brake switch wire Combination switch wire Throt‘ile cable Main wire hrness Main switch wire - - - - Meter lam wire - - Indicator wire Combination sWItch Wire p Pilot lamp Wire Front brake switch wire Headligh wire Horn wire Main harness 1 7-9 thottle cable Clutch cable Fuel tube Main wire harness Speed meter cable High tension lead Carburetor drain tube . . , Main wire harness lgnltlon coll primary wire ,1 F tb k bl Clutchcable . ,;Y ran ra eca e High tension lead Speed meter cable 17-10 Yaill stop light wire Main wire harness Resister Indicator relay Battery connector AC generatorwire AC regulator Rear stop light switch wire Crankcase breather tube 17-11 INSPECTION, MAINTENANCE Inspection, maintenance method (Note) 1. “0" indicates a check period. 2. “i?“ indicates safe replacement periods 3. The replacement timings as shown below are set for when the vehicle is used in normal circumstances. If the vehicle is used in a harsh environment, the replacement timing will be shorter than what is stated here. lnspection, maintenance lnspection, maintenance period Criteria items Before 1 month Personal vehicle operation or EveryG Every 12 1,000km months months Loose rear 0 “E" E a wheel bearing = 2 a: t: :0 5 a”: v7 ; Damage 0 lndicales cushion spring E '3 E" n _ 2 g a a o "’ n ,5 Loose ioint and o g '5 arm damage or "’ 2 (I) 5 Lever play 0 0 Play: Lever type: 10207th at g the lever end 5 Operation 0 O 0 oil leakage o 0 oil amount: Bar gauge type: g 5 and oil amount Between the upper and lower 1 3 limits :1: '2 Loose O E 2 operation :3 g mechanism E g _ Loose chain 0 o 0 MAX fluctuation tor 20mm at E g the center of the iront/ rear 3 § sprocket when using the side 0 Q stand EL o o t: to g installation and l 5 wear and tear of the sprocket 17-12 lnspeclien, rnainlenanee lnspeclien, rnainlenanee peried Crlleria ilerns Before 1 mdnlh Personal vehicle operallon er EveryG Every 12 1,000krn rndnlhs rndnlhs : E lgnilion plug 0 0 Plug gap: 0.67 0,7rnrn E 9 a, eondilion .9 E a a 9.7 w E E Locseness and O ’E _0 c» damage eilne L) = E . 2 6 = jolm ul 2 3 DJ Engine slanrup o O Condlllon, abnormal dperaling noise Low speed, 0 o o ldling rev: 2000:100 rpm g acceleraling g eondilion E Exhausi O Q g Condlllon Aireleaner o o a) elemenl E Condlllon 2’ Cam chain 0 O 0 Lu . adjuslmenl Engine oil 0 l rnenln er l,000km ierlne g replacemenl iirsl replacemenl, every '5 g 3,000km ailerlhis '5 g 3 w 4 Fuel nose I Every 2 years 7, g replacemenl = 0 LL > m 17-13 Checking ignition timing . Check the ignition timing after warming up the engine. The ignition timing cannot be adjusted as an electric spark advancer is used. If the ignition timing is out, check the installation conditions of the pulse generator and exciter coil, and measure their peak voltages. If the peak voltages are normal, replace the CDI unit. I: Read the operators manuals for the timing light and engine rev counter to operate these devices properly. Remove the L crankcase cover (—>5-3). Warm up the engine. Yiming light Alignment mark "F" mark Connect the timing light to the high tension lead. Connect the engine rev counter. Start the engine. If the “F" on the flywheel is aligned with the matching mark on the L crankcase, the ignition timing is normal. Ignition timing: 27° BTDC/ 2,000rpm Lighting device Headlight (head lamp) Loosen the headlight guard bolts, and make adjustment to the light axis for the vertical direction of the headlight. Tighten the bolts after making adjustment. Torque: 0.8-1.2kglm 17—14 Detaching/ attaching the engine 0.8- 1.2kg-m w . - ~ 0.3- 1.2kg-m) \ \0.8-1.2kg-m 2.4- 3.0kg-m “\ s.) 17-15 Seal Removal Remove the rubber retaining band, and remove the tool kit. Remove the nuts, and detach the seat. Fitting Fitting of the seat is carried out in the reverse order of its removal procedure. Rear fender] side cover Removal Remove the seat. Remove the protruding part from the rubber grommet. Remove the protruding part from the sub-frame, and detach the rear fender/ side cover. Fitting Fitting of the rear fender/ side cover is carried out in the reverse order of its removal procedure. *Align the protruding part of the cover with the holes on the rubber grommet and sub-frame. Rubber . grommet NIB" Sub-frame \g‘ ,A Rear fender! side cover Align 17-16 Cylinder head, valve 1.0- 1.4kg-m 0.8- 1.2kg-m 0.9- 1.2kg-m 0.7- 1.1kg-m 17-17 Removing the cam shaft Tappet hole cap Remove the plug cap. Remove the tappet hole cap to allow some play in the rocker arm by turning the adjustment screw. Loosen the 6mm bolt, and tap its head to lift up the L side cover slightly. Remove the bolts, and detach the L side cover. ,/ 6mm bolt Alignment "O" marking Bolts Remove the L crankcase cover mark , , (65—3). Turn the crankshaft, and align “I" on the cam sprocket with the matching mark on the cylinder head. Remove the cam sprocket bolts, and 1 detach the knock pin and cam sprocket. X‘ It is recommended to fit a wire on Cam sprocket the chain so that it will not fall inside the engine after removal of the sprocket. 17-18 Screw in the cam sprocket screws lightly into the cam shaft, and pull out the shaft. Checking the cam shaft bearing Turn the bearing outer race manually, and replace if there is any abnormal operating noise or looseness. Check if the bearing inner race has been press-fitted securely onto the cam. If there is any looseness, replace the cam shaft Assy. Fitting the cam shaft Align "T" on the flywheel with the matching mark on the crankcase. Bearing Alignment mark marking 17-19 Cam shaft Fit the cam shaft while pushing the rocker arm onto the valve. Fit the knock pin. "O" marking Set the cam sprocket and cam chain, and then fit them to the cam shaft. 7“ Align "O" on the cam sprocket with the matching mark on the head. Tighten the cam sprocket bolts. Torque: 0.7-1.1kg-m Alignment mark Cam sprocket Plug cap Tappet hole cap Fit the L side cover. Tighten the 6mm bolt. Fit the plug cap. Fit the L crankcase cover (—>5-4). Make adjustment to the tappet (-3-6), and fit the tappet hole cap. 6mm boll 17-20 Clutch, gear shift linkage 1.4- 2.0kg-m .. g, Q Q W E A \ \ 4.0- 4.5kg-m g, (3 \A> \ 6) ° @006, as 17-21 Removing the clutch Remove the R crankcase cover (=8—3). Remove the oil feed tube and spring. Remove the oil feed tube guide and bearing. Remove the clutch outer cover screws, and detach the outer cover and gasket. Spfing Oil feed tube guide Gasket Clutch outer cover Bearing Screws 1 7-22 Pull up the claw on the lock washer. Remove the L crankcase cover. Fix the clutch Assy with the clutch outer holder, and remove the lock nut Remove the washer and lock washer. Remove the clutch Assy. Lock washer COMMON YOOL Socket wrench 20X24mm 07716- 0020100 COMMON TOOL Extension bar Clutch outer holder 07716- 0020500 07923- 0350001 Lock washer Washer 1 7-23 Remove the primary drive gear and clutch center guide. Remove the collar. Remove the circlip, and detach the primary driven gear. Disassembling the clutch Set and tighten the clutch spring compressor, and remove the set ring. Remove the clutch spring compressor. Remove the clutch plate, friction disk, and drive plate, and detach the damper spring. 9“ Take care not to lose the damper springs as they will come off when the drive . Clutch spring compressor plate is removed. 07960.0110000 Primary driven gear 1 7-24 Clutch outer Damper spring Friction disk Clutch spring Set ring Drive plate Clutch plate Assembling the clutch Place the springs on the clutch outer, Drive Plate and align them with the spring supports on the drive plate. Then, fit the drive platet Clutch spring Fit the friction disk and clutch platet Clu‘Ch Plate 9“ Apply engine oil to the new friction disk before fitting Friction disk Set ring 17-25 , , Clutch spring compressor Compress the spring With the 0796041110000 clutch spring compressor, and fit the set ringt Set ring Fit the clutch damper spring. 7“ Take care that the springs do not fall inside the clutch when fitting Damper spring Removing the gear shift linkage Bo“ Remove the change pedal installation bolt, and detach the change pedal. 7“ Clean the splined part in advance so that dirt on the tip of the change pedal does not enter inside the engine when removing the spindle Change pedal 1 7-26 Remove the drum stopper arm. Remove the drum stopper plate and shift drum side plate. Remove the shift drum pin. Remove the two 3X 8.5mm knock pins. Remove the gear shift spindle. Checking the gear shift linkage Carry out the checks indicated below: Settling of the shift arm spring Settling of the shift return spfing Settling of the stopper arm spfing Bending of the shift spindle - Wear and tear, damage of the shift spindle claw Drum stopper arm Knock pin 3X 8.5mm Shift drum pin .,45 Drum stopper ide pl Claw Shift arm spring \ '3. Stopper arm spring ( ate ‘ Gear-shift spindle Shift return spring 0 Gear shift spindle 17-27 Fitting the gear shift linkage Insert and fit the gear shift spindle. Gear shift spindle Knock pin 3X 3.5mm Shift dmm pin Fit the two 3X 8.5mm knock pins to the shift drum. Fit the 3 pins to the shift drum, and fit the shift drum side plate. Fit the drum stopper plate. 9“ Align the pins with the holes to fit. , A. ,. - Drum stopper Side plate Drum stopper plate Apply screw lock agent to the screw pan of the bolt, and tighten. Torque: 1.4- 2.0kg-m 1 7-28 Fit the stopper arm, and tighten the socket bolt. Torque: 0.8-1.2kg/m Fit the change pedal. Check whether gears can be changed properly by operating the change pedal. Fitting the clutch Fit the primary driven gear and circlip. Fit the collar to the crankshaft. Fit the clutch center guide and primary drive gear. Clutch center guide Primary drive gear 1 7-29 Fit the clutch Assy. 9“ Make sure that the groove on the primary gear and the claw on the friction disk are engaged. Fit the lock washer and the washer. - Replace the lock washer with a new one when fitting. = Fit the washer so that “OUTSIDE" mark faces towards the outside. Tighten the lock nut. Torque: 4.0- 4.5kg-m Bend the lock washer claw, and fix the lock nut. 9" If the lock washer claw does not fit in the groove, turn the lock nut in its tightening direction to align. Clutch Assy Lock washer Clutch outer holder COMMON TOOL “7923'035°°°1 Extension bar 07116-0020500 COMMON YOOL Socket wrench 20X 24mm 07716- 0020100 1 7-30 Fit the gasket to the clutch outer cover. - Replace the gasket with a new one when fitting. - Make sure that no foreign object or dust is found in the oil filter unit. Fit the clutch outer cover, and tighten the screws. Fit the bearing and oil feed tube guide. Clutch outer cover Gasket Screws Bearing Oil feed tube guide 17-31 Fit the spring and oil feed tube. Oil feed tube 17-32 AC generator, cam chain tensioner 2‘ D~3 . OKE-m 17-33 Push rod Washer Removing the cam chain ,5 (I , tensioner push rod 1' I . t ' Remove the sealing bolt and washer, and detach the tension spring and - ' push rodt _ - : i \ Yension spring Sealing bolt Checking the cam chain tensioner push rod Push rod Measure the free length of the tension spring / Usage limit: replace if 77.0mm or \ less WW)? W sisrtszzzi‘igsmfi:mf /7 ”WWW, stone or other device if there is damage or any signs of scratching “mi/0,. spring Measure the outer diameter of the rod. Push rod Oil bolt Usage limit: replace if 11.94mm or less Fitting the cam chain tensioner push rod Fit the push rod, tension spring, and washer, and tighten with the sealing bolt. Torque: 2.0- 3.0kg-m Tension spring Sealing bolt Make sure that there is no clogging in the valve part of the push rodt Make sure that the smaller side of the spring is facing upward. Pour engine oil through the oil bolt hole. Pour more than 1cc. 17-34 Steering, front wheel 6.|}~ln.Dkg-m 4 V o~5 .okg-rn 17-35 Handle Removal Remove the L and R rearview mirrort Remove the screws Remove the nut, screw, and collar to detach the Rt knuckle guardt Remove the brake cable from the levert Remove the brake levert Remove the screws, and detach the throttle cable holdert Mirror R. knuckle guard Screws Throttle cable holder 17-36 Throttle cable end Remove the throttle cable end from v; the housing unit. - Remove the throttle grip from the handle. Thrott e grip Front brake holder Remove the bolt and wire bands. Remove the front brake holder. Knuckle guard Screw Remove the nut, screw, and collar to detach the L. knuckle guard. Remove the clutch cable from the clutch lever. Remove the clutch lever. Collar Nut Clutch lever 17-37 Remove the nut, and detach the combination switch. Remove the wire band. Handle grip Remove the handle grip. i Bolt Remove the bolt, and detach the clutch lever holder. 17-38 Remove the 4 bolts, and detach the handle upper holdert Fitting Align the punch mark on the handle bar with the matching surface of the lower holder, and then fitt Turn the punch mark on the upper holder to the front, and then fitt Tighten the front holder bolt and then the rear holder bolt Fit the clutch lever holder to the handle bar. 7“ Align the punch mark on the handle bar with the matching surface of the holdert Tighten the bolt. Handle upper holder Punch marks Punch mark Clutch lever holder Bolt Punch mark 17-39 Handle grip rubber replacement Remove dust or oil on the bonding surface of the handle grip, and make sure that the surface is completely dry. Apply a small amount of Honda Genuine “Honda Bond A" or “Cemedine #540", and fit the grip while rotating it before glue is dried. 7“ After fitting the grip leave it for several hours until glue has hardened. Fit the combination switch to the handle bar. 9“ Join the protruding part of the holder and the handle bar hole securely when fitting. Tighten the cap nut. Torque: 0.5- 0.8km-m Fit the wire band. Fit the front brake holder to the handle bar. X’ Align the matching surface of the holder with the punch mark on the handle bar. Tighten the bolt. Fit the wire band. Handle grip Hole ..I\‘ Protruding part Punch mark Bolt 1 7-40 Fit the throttle grip to the handle bar. Protmdins Pa" Cable end Apply grease to the sliding surface / of the throttle grip when fitting. Fit the throttle cable end to the throttle grip. Fit the cable housing to the handle bar. 0 Join the protruding part of the holder and the handle bar H°'° Thmme grip hole securely when fitting. [1 Tighten the front screw first and then the rear screw. Knuckle guard Screw Tighten the screw. Torque: 0.5- 0.8kg-m Align the L. knuckle guard and . clutch lever hole with the hook when fitting. Fit the collar. Hook Tighten the screw and nut. R' k""°k'° guard Screw Connect the brake cable to the brake lever. Align the R. knuckle guard with the brake lever hole when fitting. Fit the collar, and tighten the screw and nut. Fit the screw. 17—41 Mirror Fit the L. and R. rearview mirror. After fitting, turn the steering handle to the left and right to make sure that the cable harness is not pulled and moves smoothly. Carry out the following check and adjustment. - Throttle cable (—> 3-7) Clutch cable (= 3-8) Front wheel Removal Remove the speedometer cable. Speedometer cable Return spring Brake cable Front axle nut Remove the front brake adjustment nut. Remove the brake cable from the brake arm pin. Remove the return spring. Remove the front axle nut, and detach the fork cover stay. Remove the front axle shaft. Remove the front wheel along with the . brake panel and speedometer gear. Brake arm pin Front brake ark cover stay adjustment nut 17-42 Disassembly Remove the dust seal. Remove the snap ring. Remove the L. and R. wheel bearing. Remove the distance collar. Snap ring r «,I Dust seal COMMON YOOL Bearing remover shaft 07746-0050100 COMMON YOOL Remover head 12mm 07746-0050300 Distance collar 17-43 Hub bolts Deflate tyre before disassembly of wheel bolts and nuts Remove the hub bolts, and detach the front wheel hubt it! I Assembly Hub bolts Fit the hub to the wheel Tighten the hub boltst Torque: 2.4- 3.0kg-m h U 1 7—44 Apply enough grease to the bearing. Tap in the L side bearing. Fit the distance collar, and tap in the R side bearing. Make sure that the bearing is tapped in on a straight line. Make sure that the sealing surface of the bearing is facing outside when tapping in. Fit the snap ring. Tap in the dust seal. w Make sure that any oil or lubricant does not touch the brake drum as this will degrade the brake performance. If any oil or lubricant touches the brake drum accidentally remove it completely. Fitting Align the front wheel with the brake panel and speedometer gear when fitting. Align the brake panel groove with the protruding part of the R. fork when fitting. COMMON TOOL Driver handle A 07749-0010000 COMMON TOOL Driver outer 32X 35mm 07746-0010100 COMMON TOOL Driver pilot 12mm 07746-0040200 Snap ring i—fi ~53 Dust seal Speedometer gear 17-45 Put the L. fork cover stay through Brake cable Axle nut Return spring the axle shaft. Then install the axle shaft and then the R. fork cover stay. Tighten the axle nut. Torque: 4.0- 5.0kg-m Fit the return spring, brake cable, brake arm pin, and adjustment nut. Brake arm pin Front brake adjustment nut Fit the speedometer cable. Check for any play in the brake lever when all the parts are fitted (—3.10; Fit the speedometer gear so that the angle between its cable and the fork pipe is 45'. Speedometer cable Bolts Headlight Removal Remove the bolts, and detach the front fender. 1 7-46 Remove the headlight globe (-17-67) Remove the screw and collar located under the headlight to detach the headlight Fitting Fitting of the headlight is carried out in the reverse order of its removal procedures * Align the protruding pan of the headlight stay with the headlight groove when fitting Screw Meter visor Meter / gr- Removal Remove the screw, and detach the meter visort Remove the bolt, and lift up the meter. Boll 1 7-47 Speedometer cable Disconnect the speedometer cable. Disconnect the coupler connection of the speed indicator and meter pilot lamp. Remove the nuts, and detach the meter from the meter stay. Fitting Fitting of the meter is carried out in the reverse order of its removal procedures. 9“ Referto the wiring diagram (=17-8), and put the speedometer cable through the right position. 1 7-48 Top cone race Bearing Steering stem Fitting Apply plenty of grease to the bearing, and attach the steering stem to the head pipe. % -_ l . , -\\ l, . ‘ Yo ball race Bottom ball race Bottom cone race Pin spanner Top thread Attach the top thread, and tighten lightly as when fastening manuallyt Turn the steering stem to the left ‘ "k f and right 5 times until the bearing is , ‘ b in place. “ ‘ 9 1 7-49 Manually tighten the top thread all the way, and reverse 1/8 of a turn. Make sure that the stem is not loose but moves smoothly. Steering stem nut Fork bolt Attach the top bridge, and temporally attach the steering stem nut and fork bolt. Tighten the fork bolt. Torque: 2.5- 4.0kg-m Tighten the steering stem nut. Torque: 6.0-10.0kg-m 17-50 REAR WHEEL, REAR SUSPENSION 2.}‘4 Dkg»m 17-51 Rear wheel Disassembly Remove the rear wheel (=14—2). Remove the side collar. Remove the nuts, and detach the driven sprocket Remove the dust sealt bust seal Side collar 17-52 COMMON TOOL Bearing remover shaft Remove the L and R wheel bearing 0774641050109 COMMON TOOL Bearing remover head 12mm 0774641050300 Remove the distance collart a Distance collar wheel bolts and nuts Remove the z‘ ‘9 hub bolts, and detach the rear wheel , - ( Deflate tire before disassembly of V? r ~ hub. ’ ’ 1' Hub bolts 17-53 Assembly Fit the hub to the wheelt Tighten the hub boltst Torque: 2.4- 3.0kg-m Apply plenty of grease to the bearing Tap in the Lt bearingt Fit the distance collart Tap in the Rt bearingt Make sure that the bearing is tapped inwards in a straight fashion * Make sure that the sealing surface of the bearing is facing outside when tapping int Make sure that any oil or lubricant does not touch the brake drum as this will degrade the brake performance If any oil or lubricant touches the brake drum accidentally, remove it completely Hub bolts COMMON YOOL Driver handle A 07749-0010000 Distance collar COMMON YOOL Driver outer 32X35mm 07746-0010100 COMMON TOOL Driver pilot 12mm 0774641040200 17-54 Fit the dust seal. Fit the driven sprocket Tighten the nuts Torque: 3.0- 3.6kg-m Fit the side when Side collar Dust seal Driven sprocket 17-55 Electrical system Fault diagnosis Battery failure (weak battery) one“ cw“ Fallure cond on Carry oul a pallery leak Iesl H1 7-591, Puorflmng or wlre harness ~ Puorflmng or connector Nol leaklng Slarllhe englne‘ and measure we eomrol vollage belween baflery 1ermmals ( 17-60l Baflery rallure Vollage does nol lncrease from the ballery vollage. Normal level Measure me reslslance value orme AC generalur (917-60) - Lamp Cull lNormal level IDevlaledlargelyfromlheslandardvalue l— ralure Measure me conlrul vullage oflhe DC power supply (a Puorflmng or _ 17-62) cou ler l Dewated largely from lhe slandard value I l Normal level l— . BmSK‘ng orwm ~ DC power supplyrarlure Battery failure (overcharging) Check Cause Fallure con on 4— Check lor any louseness DI the AC regulalurcunneclur - Poor rlmng or Measure we cumrol vollage or the AC regulalur( 17-61) | Normal | l Devlaledlargelyfromlhe slandard value l— -ACregulamrralure I a DC power supply rallure 17-56 Spark plug does not spark Abnormality status Possible causes (check from G) in order) lg (ion coil primary side voltage Peak vollage is low. :‘ Tesler wilh low inlernal resislance is used. [2) Cranking speed is slow. - Kick-slarl power is weak. Effecl of lhe sampling lime of lhe lesler (normal if vollage is more lhan lhe slandard afler measuring several limes). {37‘ Disconnected wiring or poor filling of lhe ignilion Ignilion coil failure © Exciler coil failure (measure lhe peak vollage) CDI unil lailure (when lhere is no abnormalily in ilems l - bul spark does nol reach lhe spark plug) There is no peak vollage/ lhere are few peak vollages. l Misconneclion of lhe adapler Main swilch failure 8) Poor filling oflhe CDI unil coupler Broken or poor filling of lhe CDI unil earlh cable 5 Exciler coil failure (measure lhe peak vollage) Pulse generalor failure (measure lhe peak vollage) 5? Peak vollage adapler failure CDI unil lailure (when lhere is no abnormalily in ilems :‘- O bul spark does nol reach lhe spark plug) Peak vollage is normal, bul spark does nol reach lhe spark plug Spark plug failure or leaking of ignilion coil secondary currenl ® Ignilion coil failure Exciter coil Peak vollage is low. (D Tesler wilh low inlernal resislance is used. [2) Cranking speed is slow. - Kick-slarl power is weak. Effecl of lhe sampling lime of lhe lesler (normal if vollage is more lhan lhe slandard afler measuring several limes). é‘Exciler coil failure (if lhere is no abnormalily in ilems ®-®) There is no peak vollage/ lhere are few peak vollages. Peak vollage adapler failure (2) Exciler coil failure Pulse generator Peak vollage is low Tesler wilh low inlernal resislance is used. [2) Cranking speed is slow. - Kick-slarl power is weak. Effecl of lhe sampling lime of lhe lesler (normal if vollage is more lhan lhe slandard afler measuring several limes). {37‘ Pulse generalor failure (if lhere is no abnormalily in ilems ®-®) There is no peak vollage/ lhere are few peak vollages. Peak vollage adapler failure (2) Pulse generalor failure 17-57 Maintenance information Cautionary points on operation Do not run the engine for a long periods in a confined area with bad ventilation as exhaust gas contains toxic components. Over-voltage supply is generated if the terminal or coupler is connected or disconnected when the electric device is electrified, and this may damage electric parts such as the AC regulator. Turn OFF the main switch before operating these parts. A Maintenance Free (MF) battew is installed in this vehicle. Beware that MF batteries and open type batteries are not compatible with each other as their charging devices have different properties. Replace the MF battew when it has reached its lifetime. Turn “OFF" the main switch when removing electric parts. . Disconnect the negative connector of the battery when storing the battew on- board. Rapid charging is for emergency use only as this will shorten the life time of the battery. Repeating full charging/ discharging or leaving the battery discharging continually may adversely effect the battew, shorten its life time, or lower its performance. Batteries with lowered performance (lowered capacity) will regain voltage when recharged, but the voltage will drop significantly when a load is applied causing the battery to run out immediately. . Check the ignition device according to the fault diagnosis table in the order specified (—>17-56). Electric spark advance is fitted within the CDI ignition device unit, and its ignition timing is not able to be adjusted. . Many ignition device failures are caused by poor fitting of the coupler or connector. Make sure that all connecting parts are fitted properly before carrying out maintenance procedures. Use a spark plug with the correct thermal value. Using an unsuitable spark plug will cause engine malfunction or breakdown. Refer to 3-4 for information on checking the spark plug. Refer to Chapter 10 for information on fitting] removing the AC. generator. - Refer to the illustration on 17-58 for information on the arrangement of electrical parts. Specifications (20-) Battery Capacity 0.48A, 0.50A Charging current 0.005A AC generator Charging start rev Lights off 2,000rpm performance Lights on 2,000rpm AC regulator Type SCR half wave short- circuit system Control voltage 13-15V DC power unit Output voltage Speed warning lamp 2.5- 3.5V Bat‘lery 2.0-2.5V 17-58 Electrical system layout Ignition Coil DC Power Supply Main Switch 0 \> Realster ,, \Mr/cmumt Kg» i@\ , Snark PIuE éattery / .‘y O / \—/ Neutral AC Generator Switch AC Regulator Pulse Generator Wiring diagram Ignition Switch ELK=Eiavk , a/c G V:Veiiow CDI Unit W . R=Red Battery —_— BL:8iue H 1 ELK/V BUY ELK/R BLK/w To Speed Warning EM l a I l ELK R a 7 wxv W/V (I; mi, I I |_,—\_i Spark | Plug AC Reguiator DC Power Supply ~ _ f Pulse : T : : ignition Coil Geneyamy 17-59 Battery Nut Battery stay Removal Remove the rear fender] side cover (17=15). Remove the bolt and nut, and detach the battery stay. Remove the battery and battery holder mgether' Battery holder Battery negative cable Disconnect each of the battery wire connectors. Remove the negative side of the connector first, and then disconnect the positive side. Fitting Fitting of the battery is carried out in the reverse order of its removal procedures. Checking the charging device Battery leak test Turn OFF the main switch, and disconnect the negative connector of the battery. Connect an ammeter between the negative connector and the negative terminal of the battery, and measure the leak current of the battery- Negative cable X‘ If the measured electric current exceeds the upper limit of the range, the tester fuse may be blown out. Measure electric current by gradually switching from the largest range to smaller ranges of the ammeter. If there is any leak current, there could be short-circuiting within the circuit. Disconnect each coupler/ connector while measuring the electric current, to locate the part which is short-circuiting. 1 7-60 Checking the charging status of the battery Battery positive cable 7“ The amount of electric current fluctuates depending on the charging status of the battery in this check. Use a good fully charged battery. Warm up the engine. Fit the fully charged battery. Connect the digital circuit tester between the battery terminals. Battery negative cable ’{4 Do not run the engine for a Negative probe Battery positive cable long period of time in a confined ' area with bad ventilation as exhaust gas contains toxic components. Fit the ampmeter as indicated in the diagram. 7% Take care so that the wiring does not short-circuit during measurement. Excess voltage can be generated if the tester is either connected or disconnected when the wiring is electrified, causing the tester or electric parts to fail. Make sure to turn “OFF" the main switch before operating. Start the engine and gradually increase the engine rev, and measure the charging voltage and electric current at the specified rev. AC generator 4P coupler Control voltage] electric current: 2.0- 2.5V/ 0.005A and below (5,000rpm) AC generator (charging coil) Disconnect the AC generator 4P coupler. Measure the resistance between the white/ yellow and green terminals. Standard value: 0.9- 1.59 (20° ) Replace the AC generator if there is any abnormality. 17-61 AC regulator AC regulator Removal Remove the rear fender/ side cover ( 17-15). Remove the connector. Remove the bolt, and detach the AC regulator. Fitting Fitting of the AC regulator is carried out in the reverse order of its removal procedures. Connectors Check Warm up and then stop the , , engine. Green terminal Negative probe Set the AC voltmeter to the AC regulator connector (positive probe to the white/ yellow terminal, negative probe to the green terminal), and start the engine. 7“ Take care so that short- circuiting will not occur. Control voltage: 13-15VI , 5,000rpm White] Yellow terminal Positive probe If the voltage is not controlled at the specified value, check for any looseness in the connectors. If the voltage control has not been improved when re-checking, replace the AC regulator. DC power supply DC power supply holder DC power supply Removal Remove the battery Stay DC power supply 4P coupler ( 15—59). Disconnect the DC power supply 4 P coupler. Remove the DC power supply from the DC power supply holder. Fitting Fitting of the DC power supply is carried out in the reverse order of its removal procedures. 1 7-62 Check Remove the rear fender/ side cover (—> 17—15). Remove the battery stay (a 17-59). Set the DC voltmeter to the DC power supply 4P coupler (positive probe to the red terminal, negative probe to the green terminal), and start the engine. Red terminal Green terminal 7“ Take care so that short-circuiting will not occur. Control voltage: 2.0- 2.5V! 2,000rpm Peak voltage adaptor 07HGJ-0020100 Digital tester f If the voltage is not controlled at the specified value, check for any looseness in the connectors. If the voltage control has not improved at the re-check, replace the DC power supply. Checking the ignition device If the spark plug does not spark, check for any abnormalities such as disconnection, looseness or poor fitting of wiring, and then measure the peak voltages. Some testers have different input resistances and indicated values, and correct values can not be measured. Carry out measurement with a genuine digital tester or a digital tester with the input resistance (impedance) of over 10M 0/ DCV. Connect the peak voltage adapter to . . the digital tester. Normal PINS Ignition coil primary voltage Leave the spark plug on the cylinder head, and fit a good plug to the plug cap. Then, earth the spark plug to the engine. Connect electric wiring correctly to carry out measurement. Correct measurement may not be able to be carried out if any wiring is disconnected. Make sure there is cylinder compression pressure and that the plug cap is fitted properly. 17-63 Black] Yellow terminal Leave the primary wire lead of the ignition coil connected, and connect the negative probe of the peak voltage adaptor to the black/ yellow wire terminal. Then, connect the positive probe to the body earthing. Turn ON the main switch, and crank the engine by the kick starter. Then, measure the peak voltage on the primary side of the ignition coil. Negative probe posmve probe Connection method: Blackl yellow terminal- negative probe, body Black] Red terminal earthing- positive probe Peak voltage: 140V and above X’ Do no touch the metallic part of the probe while measuring the voltage as this may give an electric shock. Exciter coil 9% Fit the spark plug to the cylinder Negative eeeee peemve eeeee head, and carry out check with compression pressure. Exciter coil connector (Black! Red) Remove the rear fender/ side cover (—>17-15). Disconnect the CDI unit 4P, 2P couplers. Connect the peak voltage adapter between the 2P coupler exciter coil wire (black/ red terminal) and the body earthing. Crank the engine by the kick starter, and measure the peak voltage of the exciter coil Positive probe Negative probe Connection method: black! red terminal- positive probe, body earthing- negative probe Peak voltage: 140V or above 7“ Do no touch the metallic part of the probe while measuring the voltage as this may give an electric shock. If the measured peak voltage of the unit coupler part is abnormal, carry out the following checks: Disconnect the exciter coil connector (black/ red terminal) of the AC generator, and connect the adapter between the AC generator-side connector and body earthing. Carry out the measurement again using the same procedure used for the unit coupler, and compare the result with the peak voltage on the unit coupler. If the measured value on the unit side is abnormal but the measured voltage on the exciter coil connector side is normal, poor fitting of the connector or a broken wire harness is suspected. If both values are abnormal, refer to the fault diagnosis table and check each item to decide whether this is caused by an exciter coil failure. 1 7-64 Blue] Yellow terminal Pulse generator 7“ Fit the spark plug to the cylinder head, and carry out check with compression pressure. Remove the rear fender/ side cover (617-15). Disconnect the CDI unit 2P, 4P couplers. ' Connect the peak voltage adapter "993”“3 Pmbe POSI ive probe between the pulse generator wire (blue, yellow) 0f the harness'Side 4P Positive probe AC generator 4P coupler coupler and the body earthing. . ‘ Crank the engine by the kick starter, and measure the peak voltage of the pulse generator. Connection method: blue] yellow terminal- positive probe, body earthing- negative probe Peak voltage: 10V or above Negative probe Pulse generator wire (Blue! Yellow) 9“ Do no touch the metallic part of the probe while measuring the voltage as this may give an electric shock. CDI unit 4P coupler If the measured peak voltage of the unit coupler part is abnormal, carry out the following checks: Disconnect the AC generator 4P coupler, and connect the adapter . between the AC generator- s—ide ‘ ..1 pulse generator wire (blue/ yellow) and the body earthifigl Willi/We measurement again in the same procedure used for the unit coupler, and compare the result with the peak voltage on the unit coupler. If the measured value on the unit side is abnormal but the measured voltage on the AC generator coupler side is normal, poor fitting of the coupler or a broken wire harness is suspected. If both values are abnormal, refer to the fault diagnosis table and check each item to decide whether this is caused by a pulse generator failure. System circuit check Remove the rear fender/ side cover (—>17-15). Remove the battery stay (= 17-59). Disconnect the CDI unit 2P, 4P couplers, and check if there is any abnormality such as poor fitting. Use a circuit tester, and carry out conduction test between the terminals on the harness side. 17-65 Item Measured points Standard (20°C) Main switch Black] white» Green/ white No conduction when the main switch is ON Ignition coil (primary coil) Black] yellow— Green] white 0.1» 0.4 Pulse generator Blue/ yellow» Green/ white 50» 200 Q AC generator (exciter coil) Black] red» Green/ white 400» 800 Q Earth circuit Green/ white» Body earthing Conducted If there is any abnormality, carry out check individually according to the conduction table on the wiring diagram (—>17-7). Ignition coil Check Primary side Disconnect the ignition coil primary-side terminals. Measure the resistance between the primary terminals of the ignition coil. Standard value: 0.1- 0.49 (20.) Secondary side Remove the spark plug cap from the plug. Measure the secondary-side resistance value of the ignition coil between the spark plug cap and the primary terminal. Standard value: with the plug cap: 6.5- 9.7k Q (20-) Ignition coil Primary terminal Primary-side terminal Ignition coil Spark plug cap 1 7-66 Primary-side terminal Ignition coil If the measured value in the check above is abnormal, remove the plug cap from the high tension lead, and measure the resistance value on the secondary side. Standard value: without the plug cap: 2.7- 3.5m (20°C) ' I! High tension lead Removal! fitting Primary-side terminal Bolt Remove the plug cap from the spark plug. Disconnect the ignition coil primary-side terminals. Remove the bolt, and detach the ignition coil. Fitting of the ignition coil is carried out in the reverse order of its removal procedures. Exciter coil Check Disconnect the AC generator connector (black/ red). Measure the resistance between the exciter coil-side connecter and the body earthing. Standard value: 400- 800 Q (20°C) Replace the AC generator as an assembly (= 10-3, 17-32). 17-67 Pulse generator Check Disconnect the AC generator 4P coupler. Measure the resistance between the AC generator-side pulse generator wire (blue/ yellow) and the body earthing. Standard value: 50- 200 l) (20“C) Refer to 10-3 and 17-32 for information on replacement. Removal] fitting of the CDI unit Remove the rear fender/ side cover (617-15). Remove the battery stay (=17-59). Disconnect the CDI unit 2P, 4P couplers. Remove the CDI unit from the CDI unit holder. Fitting of the CDI unit is carried out in the reverse order of its removal procedures. Headlight globe replacement Remove the socket cover. Turn the light globe socket to the left to remove. Pulse generator wire (Blue! Yellow) CDI unit Socket cove r AC generator 4P coupler /g’ CDI unit 2P coupler Light globe socket 17-68 Replace the globe. Fitting of the globe is carried out in the reverse order of its removal procedures. Neutral pilot lampl Globe socket indicator pilot lamp Neutral pilot lampl indicator pilot lamp Remove the bolt, and lift up the meter (—> 17-46). Pull out the globe socket, and replace the neutral pilot lamp and the indicator pilot lamp. Meter illumination lamp Globe Remove the meter from the meter stay (-1 17-46). Pull out the globe socket, and replace the globe. I Globe socket 1 7-69 Taill stop light lens Taill stop light Remove the screws, and detach the tail/ stop light lens. Turn the globe to the left to detach. Fitting of the tail/ stop light is carried out in the reverse order of its removal procedures. Indicator globe Indicator case Join Detach the indicator lens by inserting a thin wiring screw driver in the gap and lifting up. *Take care so that the case or lens is not damaged when removing. Indicator lens 1 7-70 Globe Turn the globe to the left to detach. Fitting of the indicator globe is carried out in the reverse order of its removal procedures. Resister Check Remove the rear fender/ side cover (—>17-15). Remove the resister connector. Measure the resistance between the resister-side connector and the body earthing. Standard value: 5.6- 6.2 [2 (20C) Removal! fitting Remove the rear fender/ side cover (-17-15). Disconnect the resister connector. Loosen the bolt to remove the nut, and then detach the resister. 18. MONKEY ZSOJN ADDENDUM CONTENTS Specifications ------ Wiring diagram — Wiring schematic--——— Check and maintenance methods——- Carburetor _________________________________ 18-1 Specifications Mode1 HONDA A1504 Armercype Uremane 1oarn1 pe cnass1s mode1 HONDA ZSOJ Fue1 tank eapacuy Lengm 1 360m 1. Wm a 600m 5 Mode1 RAus He1gm 0 850m u a Gas vaue 13mm E 3. mameler wnee1pase 0 895m 3 § Vemund1ame1er 11mm (equwa1em) Engme mode1 1504 E g An vaue Iype ManuaHy operated p1s1pn uawe 1ype Engme capacny o 0491; Type cm Iype magnem: 1gnmun Fue1 e umeaded me1 lgn1l1onl1mlng 27' BTCD/Z‘DOD rpm Ven1c1ewe1gm From ax1e 28kg m; Breaker 1ype Np comaa 1ype Load a Rear ax1e 35kg m 9 Spark p1ug (NGK) CSHSA‘ CSHSA‘ cmsA Load 3 m g 71 (ND) U16FSRVU.U20FSRVU1 m g u22Feru To1a1 63kg 2 1gnmon 0 am 7mm 3 a1earance w Capacuy 2 3 An Gross vemde body From ax1e 1oad 42kg % we1gm 2 Rear ax1e1oad 7ng T pe We! 1ype s1ng1e p1a1e con spnng Tp1a1 118kg o Operalmg Meenan1pa1 E rnemod T1res Fron1wnee1 a 507 a 353 9 Rearwnee1 Engme4u4ransm1ssmn 4 312 'u speed reducuon rauo Mmmum ground c1earance 0150rn 2 Type Cons1an1mesn 2 Operalmn LeMom opera1ed 5 A method Brakmg msiance 3 5m 3 3 1 Gear 3 272 5 (ma speed 20km/h) 3 3 Q a Z 2 a 2 Gear 1 937 i 3 3 E 3" Gear 1 350 R Mmmumlummg radms 14m g 3 5 s1an1ng Mempd Kmk s1an g 4 Gear 1 043 Type FemflM Snake Gearlype cna1n No and 1ocauon o1ey11nders 1 cyhnder‘ (1ranversa1) E 345’ Speed reducuon 2 384 § %§ ra1e Compusupn enamper type Henn1spnere Casterang1e 25' oo' Va1ue1ra1n OHC cna1n dnven :u E g‘ Tran 42mm 5 E 2 Bore x stroke 39 a x 414mm ; T1re From 1 on kg/cm' Compresson ram: 10 a “9 Rressure Rear 1 25 kg/cm‘ Compress1on pressure 14 071.000kg/cm' a rpm % Sleenng Lefl side 42‘ E Ang‘e mm 42' s1de Maxmmm ou1pu1 31FS/7‘500rpm Brake From Meanamea1 1ead1ng (73111715; Max1n1un1 tor ue o 32kg/6.000rpm Rear Meenan1pa1 1ead1ng 1ra111ng Intake Open 1' name) Suspens1on From Te1esepp1c e < 11mm 1111) m :- type wnee1 , m s m E g c1oae 12' (ABDC) :81; Rear Swmg arm 2 o a wnee1 ax = e. a Exnaus1 Open 10' (BBDC) Frame Backbone (1mm W) C1059 0' (TDC) Vawe e1earanee Intake 0 05mm (wnen ep1d1 Exnaus1 0 05mm Engme under no 1pad 1d11ng 2.oourpm Lupneauon sys1em oomp1nauon o1pump1ng and sp1asn 1upneauon § on pump Troeno1d % 011 Mar Iype FuH flow Mrauon‘ = aomp1nauon p: -‘<” aemnluga1 and save g mlralmn 5 on capacuy 0 8t Cuohng mempd An cuohng =oun-E—-Nan== in 4: 55: ”.55me 2E \ _ am: > , QM. ”mm—m: El :3 35w 5:5 .225: A W 3.29;” n < BL ’R—oDBL A? ma: ‘5an :6 5525 gsmumngnT;Jg 2.1:. :2. sum z WIRING DIAGRAM 1 8-2 w W K Race _ _ a m a gale a; man: BL E i :23: :3 IXHTKEZ 1I$Lnr 2. re A Q a: 9.5 "ES; 23% 2:: «:52. EB” buss 62$ 5 @GéloD—G’V | 1 I s. is.“ a.“ can UI simflk .5: 18-3 WIRING SCHEMATIC Front brake cable Clutch cable _ Frame body earthing Throttle cable Wire harness Fuel tube \,\ / Rear 513p switch wire (Clamp the area with the white tape.) w Change pedal (Stand the vehicle to make level in order to attach.) Overflow tube Main wire harness (Clamp the area with the white tape.) Wire harness Throttle cable ’ (Align the joint and handle horizontally and Indicator wire A ./ Collar Carrler (The washer faces the carrier side) 1 8-4 Front brake cable Clutch cable Wire clamp _ IndIcator horn switch wire Indicator wire (Take up slack after clamping) Frame body earth (Tighten to the hole on the upper side of the horn) Speedometer cable Front brake cable Speed warning unit Headlight case nut Headlight case bolt \\\ Wire harness 18-5 Engine breather pipe G rorn met (Set securely) Neutral switch Swing arm pivot nut Flywheel Pulse generator Clutch cable guide Fuel tube Regulator rectifier CDI unit Rear brake switch wire Kick arm (Align with the R crankcase Engine tightening bolt) breather pipe Clutch cable Ignition coil Rear brake switch Brake pedal spring (Place the spring to face downwards) 1 8-6 Check and maintenance method (Caution) 1. "O" indicates the check period. 2. "X" indicates that the item does not apply. 3. "if" indicates that regular replacement of safety parts is required. Replacement periods are based on the performance of vehicles used under normal conditions. If the vehicle is used under signi cantly different running conditions, replacement needs to be carried out accordingly. Check and maintenance item Check and maintenance period Before For personal use Unit operation Every 6 Every 12 (1 ,000 months months km) C riteria Note Braking system Clearance between the disk and pad 0 Wear and tear of the pad Wear and tear and damage of the disk Brake disk and pad Running system Tire air pressure r: O (um kg/cm‘l Front wheel Rear wheel 1 person on board General l on road 125 Tlre use 3 507 a 35.1 Cracking and damage of the tire Residual groove Front wheel: up to 0.8mm Rear wheel: up to 0.8mm Depth of tire groove and abnormal wear and tear Wheel 18-7 Check and Check and maintenance period Criteria Note maintenance item Before For personal use Unit operation Every 6 Every 12 (1,000 months months km) Metal 0 O 0 fragments] stone in the tire Looseness O O O Tightening torque of the Axle ofwheel front axle nut 3.5- 5.0kg m nut and nut] b°lt Tightening torque of the rear axle axle nut 35- 5.0kg : m holder are shown Damage of O >fi<1 Wheel rim deflection on the side ring rim end: and wheel Horizontal deflection of the disk front: 2.0mm or less Vertical deflection of the front: 2.0mm or less Horizontal deflection of the rear: 2.0mm or less Vertical deflection of the rear: 2.0mm or less Backlash O E of the front ‘5 wheel 5‘ bearing 2‘ _ Backlash I 'E ‘9 ofthe rear : m :i -= wheel t! 3 bearing Damage 0 Cushio oz n E spring % is .9 shown m m as .= 0 E Backlash I E E of the joint 5‘ E and g g damage of '3 '5 the arm = s 3 a. m m = :1 U) U} 1 8-8 Check and maintenance Check and maintenance period Criteria Note item Before For personal use Unit operation Every 6 Every 12 (1 Y000 months months km) = Oil leakage O O X .2 or damage 2 E ‘n'. Backlash of o x a 3 a: e the 3 g 8 % attachment "’ "‘ 5 % part Play of lever O O O Play 3 Lever type 5 10- 20mm at the lever tip ‘5 Operation 0 0 >241 0 Oil leakage O O 0 Oil level or oil level Slick gauge type: the oil level should be between the upper and lower limit lines. Backlash of O Cushi the on 3 operation spring g mechanism is 'g shown 2 E Looseness O O X 'g of the is joining part E Backlash of o x m a: the splIne E, g Backlash of O X E — W the ‘3 «8).; universal 5' E ‘6 joint : Looseness O 0 >26 0 MAX fluctuation 10- % E» of chain 20mm at the center of the I! 8 front and rear sprockets E a when using the side stand. 5 "‘ Installation 0 E E condition g c and wear 0 '5 and tear of n. 5 the sprocket E Condition of O O 0 Plug gap 0.6- 0.7mm 2 the spark ‘4 E plug 1‘ E Ignition o o #0 a: I g m timing No 7‘; .3 adjust 2 Pg ment '" 9 type 1 8-9 Check and maintenance Check and maintenance period Criteria Note item Before For personal use Unit operation Every 6 Every 12 (1,000 months months km) Condition of — #0 # >< SE: the contact No g breaker adjust ”1 ment .5 type 95' Spark o x 9 advance Fluid — #0 3 amount >< Direct vent type Fluid 0 # # relative >< density Direct vent E‘ type 0 Connection 0 fi condition of m the terminal Looseness O E» .E or damage g .‘E- of the joint 1‘ _ part a as .2 .2 h r. 0 t5 2 2 u: u: Start-up O 0 condition and abnormal operation noise Low speed 0 0 >241 #0 # and Idling rev: 2,000i100rpm accelerating condition >| EXhay?‘ * 0 'u condItIon o .E .a Air cleaner — 2’ .5 element in a . . 5 condItIon 18-10 Check and Check and maintenance timing Check maintenance item Before For personal use Unit Replacement method 0 operation Every 6 Every 12 (1,000km) timing (every and ‘5 months months year) criteria 2 1. Engine oil >241 c replacement 3 .9 ‘1‘? s .: 2 .n In 3 i 1. Fueling =4 hose replacement Engine system Fuehng system 18-11 Carburetor Maintenance information Watch out for fire when handling fuel. Make sure the installation positions of the O-rings and other parts are correct and that they are replaced when assembling. Discharge fuel within the carburetor via the drain bolt of the float chamber before disassembling. ' Do not twist or bend the cables forcefully. Deformed or damaged cables may cause operating malfunctions. Venturi diameter 11mm Setting mark PA03P Float level 12.7mm Air screw standard tumout 1 turnout Main jet #58 Slow jet #35X35 Idling rev 2,000rpm Play of the throttle grip 2—6mm Tool Float level gauge 07401- 00100000 Fault diagnosis The engine does not start. There is no fuel in the tank. Fuel has not reached the engine. There is too much fuel within the cylinder. The air cleaner is clogged. Engine idling unstable rev malfunction Idling adjustment malfunction Air-fuel mixture is too rich. Air-fuel mixture is too lean. Air cleaner is clogged. Air has entered within the inlet system. Fuel is unclean. Air-fuel mixture is too lean. The fuel jet is clogged. The ventilation hole of the fuel tank cap is clogged. The fuel strainer is clogged. The fuel tube is bent, crimped, or clogged. Operating malfunction of the float valve Oil level is too low. Air-fuel mixture is too rich. The choke is closed. Operating malfunction of the float valve Float level is too high. Clogging of the air jet 18-12 Maintenance standard Resistance value Check terminal Exciter coil resistance value 400- 800 Q BlaCk/ Red- Green Pulse generator resistance 507200 Blue/ Yellow- Green value Lighting coil resistance value 0.1- 0.8 Yellow- Green Charging coil resistance value 0.2- 1.0! WhilB- Green 19-1 250R P Addendum Contents Specifications ----- -- Tightening torque -- -- Wiring diagram -- -- Wiring schematic-- -- Check and maintenance -- Assembling the kick starte 1 9-2 Specifications MooeT Honda A302 A1r o1eahertype Urethane Toam type ChassTs mooe1 Honda ZSOR Fue‘ ‘ank ca m 4 0! Length 1 285m g D V W1dlh a 605m 5 Type FAu3 Hwy?“ a 31m 3 g Foe1ya1ye mameter 13mm WheeTpase a 895m g 3 Vermm mameter ApproxtmateTy 11mm 5 E Engme Mode1 2qu E 5 5 ATM/awe type MEWEW ”65:" ”‘5‘” ”we Engme Capaoty a 049 ( Type cm Magneuc 1gnmun Fuel Type Unleaded (uel lgnmon l1ming 2TBTCD/1y700fpm , oohtaot breaker type Nowcumad type FromAxTe m to 22 0kg 3 .3. [NGK) CRSHSA. cat-15A. = a cRn—tsA Veh1o1e WeTghl E 3, SW“ ““9 [Nmon Denim) u1aFSRru Ream“ 22 ”‘9 a is. U2DFSRVU‘ u22FsReu o Tota1 49 Sky 3 3 Ignmon c1earahce a one a 7mm FrohtAxTe 42 4kg 0 Gross Veh1c1e WeTgN Rear Ax1e 521kg E Type Autumauc oerttthpgaT type n ma 94 Sky EngmerloFTranSrmSSmn A 058 T Froht Whee1 3 507 a 35 J Speed Redudmn Ram) 1res 11 Rear Whee1 g 3 Type Cunslanl mesh MWW’“ ”9‘9“ "0’" 9’0““ a “5”“ E OperatToh method 3 speed returh 1eMoot operated 3 j 1 Gear 3 272 1, Erakmg mstahce 3 5m (20km/M a g 2’“ Gear 1 323 n: a w a a o 3 m g 5.5 a — T a g Mmmumlummg Tadms 14m 2 g E 3 Gear 1190 8 5 5 Startmg method Kmk start Type Fetro1/4 Stroke a Gear type cham gee No and 1ooat1oh ot cyhmters 1 transverse Cyhnder § 3? § Smeargfgmm" 2 542 Combusnon chamber lype Hestphere w 1‘ Casterartg1e 25‘ 00' Va1ye tram OHC oham dnven 5 $3 Tra11 42mm Bore x stroke 39 o x 41 4mm 2 We Pressure Front 1 now/cm: Compressmn ram 10 o g Rear 125kg/Gm’ Compressmn pressure my o “1- 14 04.000 g Sleenng Lefl 45- Turn) Ang‘e Rtght 45 Mameum output (PS! rpm) 31/a.5ourpm From Meonamoa1 leading Irallmg Mameum torque [kg/ rpm) 0 34/4 oourpm Emmy new” We Rear Mechamca11ead1hgtra111hg 2 open 1 5'(BTDC) U, Front Te1escomt: a n_> e a g, Intake 5 g Suspensmn § (Wm M) C1052 12 51mm) SE type Rear 5w1hg arm = E’ 3 Exhaust Open 22 515590) Frame Beat bone 0* (1mm “'0 Chase 2 5'1TDCF Va1ye c1earahce Intake 0 05mm (wheh cooTeo oowm Exhaus1 a 05mm Under ho mad who rpm «morpm ,_ Cumbmalmn o1 g Lubflcaflon system pressure aha sp1ash i 1ppr1cat1or1 g 011pomp type Trachmd E 011t11tertype GemhtpgaT Mralmn E Lubncanl Gapamly y n a Couhng s tem A1rcoo1mg 19-3 TIGHTENING TORQUE Engine related Location Number Screw diameter Tightening torque (mml (kg-ml Tappet hole cap 2 30 1.07 1.4 Valve adlustment nut 2 5 0]. 1.1 Cylinder head Nut 4 6 0371.2 Bolt 1 6 0.87 1.2 Cam sprocket bolt 2 5 0.77 1.1 C llnder bolt 1 6 0.87 1.2 Guide roller bolt 1 6 0.87 1.2 Intake manifold installation bolt 2 6 0.77 1.1 Clutch lock nul 1 14 4.07 4.5 Drum stopper arm pivot bolt 1 6 0.87 1.2 smfl drum stopper bolt 1 6 1.47 2.0 Drain bolt 1 12 2.07 2.5 Push rod sealing bolt 1 14 2.07 3.0 Tensioner pivot bolt 1 8 1.3718 Drive sprocket bolt 2 6 1.17 1.5 Flywheel nut 1 10 3.87 4.5 chk starter pedal 5pm bolt 1 6 0.87 1.2 smfl pedal 5pm bolt 1 6 0.87 1.2 Frame related Location Number Screw diameter Tightening (mm) torque (kg-m) Engine hanger bolt 2 8 2.9- 3.5 Handle lower holder nut 2 10 3.5- 4.5 Handle bar lever bolt 1 5 0.2- 0.4 Handle bar lever nut 1 5 0.2- 04 Kill switch screw 2 5 0.2- 0.4 Steering stem nut 1 26 6.0- 10.0 Fork bolt 2 10 2.5- 4.0 Front axle nut 1 12 4.0- 60 Rear axle nut 1 12 4.0- 60 Wheel hub stud bolt 8 8 1.5- 25 Wheel hub nut 8 8 1.8- 22 Wheel rim nut 8 8 1.8- 2.2 Driven sprocket nut 4 8 3.0- 36 Brake arm bolt 2 5 0.4- 07 Rear fork pivot nut 1 10 4.0- 50 Rear cushion 4 10 2.5- 4.0 Step bar bolt 4 8 1.8- 25 Chain case bolt 2 6 0.8- 1.2 Air cleaner case bolt 1 6 0.8- 1.2 Connecting band screw 1 4 0.05- 0.15 Ignition coil bolt 1 5 0.5- 0.7 1 9-4 Location Number Screw diameter Tightening (mm) torque (kg-m) Muffler Bolt 1 8 2.4- 3.0 Nut 1 6 1.0- 1.4 Exhaust pipe joint nut 2 6 0.8-1.2 Muffler drain bolt 1 10 2.0- 3.0 Muffler protector bolt 1 6 1.3- 1.7 Exhaust pipe cover screw 4 5 0.5- 0.7 Side stand pivot Bolt 1 10 0.5- 1.5 Nut 1 10 3.0- 4.0 Front fender bolt 2 6 0.8-1.2 Sheet nut 2 6 0.8-1.2 Rear pipe stay bolt 2 6 0.8- 1.2 Fuel tank bolt 1 6 0.8- 1.2 Fuel cock nut 1 14 1.5- 2.0 Standard tightening torque Part name Tightening torque Part name Tightening torque (kg-m) (kg-m) 5mm bolt, nut 0.45- 0.6 5mm screw 0.35- 05 6mm bolt, nut 0.8- 1.2 6mm screw 0.7-1.1 8mm bolt, nut 1.8- 2.5 6mm flange bolt, nut 1.0- 1.4 10mm bolt, nut 3.0- 4.0 8mm flange bolt, nut 24- 3.0 12mm bolt, nut 5.0- 6.0 10mm flange bolt, nut 35- 4.5 19-5 WIRING DIAGRAM Kill Switch CDI Unit I RUN . o BL IW—l>D-BL /w G—DEl-G 9 9 1a a m Eq— a nu A /na 7 Pulse Generator é Kill Switch Changeover Connection Chart E IG lE—‘él A.C generator N m OFF ,_ _ U lgnmon COII BL=Black RUN G=Green j t V=Vellow 0;; Spark Plug —— R=Red . T : T BU=Blue "I" W=White Color 1 9-6 WIRING SCHEMATIC tholtle cable Front brake cable High tension lead {H be Throttle cable Fuel cap breather lube Kill switch wire Carburetor drain lube High tension lead 19-7 Check and maintenance Carry out regular check and maintenance on parts according to the table below in order to make the most of 250R performance. Life time of part differs greatly depending on the condition of use such as when used under dusty or rainy condition. Refer to the table below and carry out check and maintenance earlier if necessaw. l: Replace if check, cleaning, adjustment, or lubrication is required. R: Replacement C: Cleaning L: Lubrication Item Timing First check (After 1 month) Regular check (Every 6 months) Note Fuel tube Fuel strainer screen Throt‘lle operation Air cleaner Note 1 Spark plug Tappet clearance Engine oil Engine oil strainer screen Carburetor idling speed 402440404 Drive chain l L Note 1 Wear and tear of brake shoe Braking system Clutch system Side stand Suspension Spark arrester Tightening of parts Wheel/ tyre l l l l l C l l Steering head bearing Note 1: Carly out check earlier than time indicated above if the vehicle is used under a condition with much dust or rain. 1 9-8 Kick starter spindle Kick starter pinion Set ring Driv- ratchet Was her Assembling the kick starter Assemble the kick starter spindle in the order indicated in the diagram. 7“ Fit the friction spring in the kick starter drive ratchet groove. 20-1 20. ZSOJN (MONKEY BAHA) ADDENDUM Contents Wiringdiagram-- -- -- -- -- -- -- - -- - -20-2 20-2 WIRING DIAGRAM gum- s < a .Nanaa a; 2:“ a; E; :53. 5:2: 2 mvnwmun : __ 5:} s... 21-1 21. ZSOJPADDENDUM Contents Wiringdiagram-- -- -- -- -- -- -- - -- - -21-2 noun. —3 inane: a . m IE. aneflla' 2.. $2351 A $ fl , ._ A . .35 + 5 ii , _ a s... 3 . 3m 1 EOWESL .5153} K 7—1111.— \ g : 2 a : 5:. WIRING DIAGRAM 21-2 22-1 22. ZSOJP (MONKEY BAHA) ADDENDUM Contents Wiringdiagram-- -- -- -- -- -- -- - -- - -22-2 WIRING DIAGRAM 22-2 Sun. x:— .32.: E5 5.5259 Basis , 23 Si: .29: g .9: 2; 3.. :. I _ _IH inil ,w (MW 1 a WHAmmpEESE: QWUI. Emmy“ .l 7 “I. _ E S, i. a a i g. as: .3 AW; =L i. Wtw um ”mm“ “a a. i AMEN 5; § .5. liéxs .Tawfi‘ 3..., ; 23-1 23. ZSORw Addendum Contents Check and maintenance --------------__————____———____—................._...____....___23_2 2 3-2 250R (W) Frame No. AB02-1500001 or later I: Replace if check, cleaning, adjustment, or lubrication is required. C: Cleaning R: Replacement A: Adjustment L: Lubrication Timing First check Regular check Note After 1 month Every 6 months Every 12 months item or 150km or 1,000km or 2,000km Fuel tube - - l - Fuel strainer screen - - C - Throttle operation - - l - Air cleaner - C C Refer to the note below Spark plug - l l - Tappet Clearance | l l - Engine oil R R R - Engine oil strainer screen - - C - Carburetor idling speed | l l - Drive Chain | L l v L (Every 3 months or 500km) RBfeHO We note blow Wear and tear of brake shoe Braking system Clutch system Side stand Suspension Spark arrester Tightening of parls Wheel/ tyre l l l l l C l l Steering head bearing ._.o. Note: Carry out check earlier than time indicated above if the vehicle is used under a condition with much dust or rain. 24. GORILLA ZSOJ (W)-6 ADDENDUM Contents Specifications ----- -- — —— — .. .. .. .. __ 24.2 Wiring diagram -- -- -- —— —— .. .. .. .24_3 Wiring schematic-- -- -- —— —— .. .. _ .. _ 24.4 24-2 Specifications Mode) Honda ArZ 5m A1re1eaner1ype Ure1nane1oam type Gnass1s mode) Honda 2504 Lang“ 1 365m 2 Foe) (ank eapacny 9 at wmn a 625m g Type PADS He1gm a 880m n g Foe) va1ve mameler 13mm wnee1pase a 895m g s Vermm o1an1e1er Approxlma1e1y 11mm Engme Mode) 2qu E 8 5 mrvawe lype MEWEW ”65:" ”‘5‘” ”we Engme Capamly a 049 ( Type cm Magnenc 1gnmun Fuel Type Unleaded (uel lgnmon “Ming 2TBTDC/ZDOOrpm MN Ms W m «5‘: Comacl preaker (ype Noncomaa lype g a g (NGk) CRSHSA. Car-(SA. 5 w s ark m OWNS“ Vemde Wewm B < p p g (ND) U16FSRVU. HQDFSRFU‘ Rear Ax1e 37kg g g U22FSRFU a To(a1 67kg g Ignmon c1earance a 507 a 7mm FrontAx1e 44kg 3 E: Capacny 2 3An Gross Vemde We1gn1 0 THIS WeHvRe “we was cm‘ SRW Rear Ax1e 78kg g 3 Operanon rne1noo Meenamca) To1a1 122kg EngmerloVTransmssmn A 312 T1res Fm” Whee‘ 3 50' a 35 J Speed Redudmn Ram Rear wnee1 3, 5 Type Cunslanl mesn WW” ”9‘9“ "0” 9’0““ 0 “0”“ E: Operanon memoo Le114oo( opera1ed a _( 1 Gear 3 272 ra mg 1s1ance m e 2 ear 1, a k a 35 20km/n g m 2’“G 1937 m g g a E 3" Gear 1 350 § Mmmum lummg radms 14rn g g g e a 5 1» m 3 A Gear 1 043 s1an1ng memoo k1ek snan Type PelroV 4 Gyde a Gear lype Gna1n E g 1% No and 1oea11on ol oynnders 1 (ransverse cylinder 5'; g 3 Smeargfgmm" 2 384 Combusnon chamber lyne Hem1sphere JV > 1‘ Casterang‘e 25’ 00' Va1ve1ra1n OHC ena1n dnven § g3 Tran 42mm Bore x s(roke 39 o x 41 4mm 2 T re Pressure From 1 Dow/cm“ Compressmn ra11o 1o 0 g V Rear 1 25kg/Gm’ Compressmn pressure (kg/ e "(k 14 071000 a Sleermg Le" 42' rpm) ‘ 3 Mg“: ngm 42' Maxmum uulpul (PS! rpm) 3117.5ourprn Bram 5 “am From Meenamoa) leadlng Irallmg Max1rnurn1orque(kg/rprn) o 32/6.000rpm g V Rear Mecnamca)1ead1ngtra111ng = open 7'1BTDC) U, From Telescomc a n_~ e a g, Intake fig Suspensmn 3 (1mm N1) Chase 121mm) 3 a 1ype Rear Swmg arm ., _ = g 3 Exnaus1 Open 1013300) Frame Bad< bone a» (1 mm 1111) c1ose o'(ATDc) Va1ve c1earance In(ake a 05mm (wnen coo1eo down) Exhaus1 a 05mm Under no 1oad 1o11ng rpm) ZODOrpm Cumbmalmn o1 g Lupneanon system pressure and sp1asn g \ubncalmn g on pump lype Trachmd w Cumbmalmn o1 (ma) g 011mm e flow 1111ra11on and 3 VP aemnluga) mesn mlralmn Lubncanl eapamw n a Couhng s (em A1rcoo11ng 25:. mm“ .325 . a , z a a L; i {inn Oé é.“ 2, Efia “E ; Ema Emil: E :- .. - x 5 i a. / mafia E is. 5:; 2 a: s, . , 53$ :5 5285.8 :25ch 5:3 \ 321, 2%.: E5 ”:53 ”51:32.3 : 5.: 2,5 .55.: 2:5 M 5:; :2 as; 55%. fiEmumm. M h h 5:; 2.5 "Em 3; {am ‘22; . .1 2.; Eujufi @ 52. u 3:»); , ‘ _, a? @ [a E53 335 2:3. , . u a a 5;: 2" :SM a 23 N o < fl « eriEI a k u z ,i _. m in; 3:35 a; . u ,w I m J: gym i... u a ‘ s au m m J” Hum ESE, amiss i . _ _ _ . y m 3 Ease: :2 u u ,w 35;: w x v w w x u a u y > w w u Wu ”Emmi”. u n _ \ E; i _ _ 2A WITvaL _ m a; a: _ _ fl :— uwm :11» H m ; fig, ,. . _E_ m .2 u A _ . I a w g I ma lw E man u an an ‘ "SE: uugm D c e . : . e E |.m - EEi 13.33 5.5 ,8 E: Exam 12% sq. IEIUAI; E5 m €23 2n; :2. 53. ,, 583.: 6:...” «5: 22a is: 5.: 55:2. .5; x 24-3 24—4 WIRING SCHEMATIC l X 7* r , / Headlight case boll Speed warning unit \ x V \ ’ \\ 0‘ m 6/ \ / K 07 ‘ Wire harness \@/ \e/(i ‘ Throttle cable Front brake cable Indicator horn switch wire Rubber Collar Indicator wire (Take up sl after clamping) 24-5 Front brake cable cable Ignition coil primary wire Clutch cable High tension lead / Speedometer cable 24-6 Tail/stop light wire Indicator relay Throttle cable / Fuel tube CDI unit Regulator rectifier wire Carburetor drain tube 7/ / Grommet / // (Set securely) ”r Pulse generator \ Neutral switch Battery Side stand switch wire Ignition coil \“ High tension lead Crankcase breather tube Clutch cable 25-1 250J[Y] ADDENDUM Specifications ----- -- . .. _ Maintenance criteria -- -- .. .. _ Specialized, common tools __——__.........__....__ Wiring diagram -- __ .. .. .. __ Wiring schematic-- -- —— ._ __ Toxic gas emission prevention system Check& Maintenance ___—..........____.___ Fuel system ----- __ .. . .. _ __ _ 2543 Blow-by gas reduction system---————---____...._________ ____25_14 Disassembling/ assembling the carburetor ....................................... 25.15 2 5-2 Specifications MooeT Honda BAVABN An deaner type Uretnane Toarn type Honda Hunda ChassTs mooeT A327 A327 WW6” (Gum) 7‘ he tank oapamty 4 5 9 a Lengtn 1 360m 1 365m 5 W1dlh 0 600m 0 625m :9 Type FESJA HeTgm 0 850m 0 880m 2 3 he vaTye mameter tarnrn wneeTpase a 895m 3 G Ventun manneter ApproxunateTy 11mm Engme Mode1 A5275 3‘ Av yawe type MEWEW ”65:" ”‘5‘” ”we Engme Capaoty a 049 ( Type cm Magnelu: 1gnmon Fuel Type Unleaded Iuel lgmhon hming 27‘BTDC/2,000rpm From Me 28k m m ‘15. Contact breaker type Nowcumad type 9 9 a g [NGK) CRSHSA. car-15A. V n 1 w nt % "‘ Spark We CRMSA e we e19 ; < (ND) u1anReu. u2quRru1 Rear AxTe 35kg 37kg % g u22Feru TotaT 63kg 67kg 3 Ignmon dearance a one a 7mm FrontAxTe 42kg 44kg 3 g Capacwy 2 WT Gross Venme WeTgN 0 Type WeHype sTngTe p1ate con spnng Rear AxTe 76kg 78kg g 2 Operauon rnetnoo MeonanTcaT TotaT 11mg 122kg r Fm" WW 3 50' 8 35 J §”§::'§;§L:TZTL§::S A m V Rear wnee1 1, p g Type Constant mesn WWW" ”9‘9“ "0’“ 9’0““ 0 150m $3 Operauon metnoo Leflrlool operated 3 j 1 Gear 3 272 Erakmg mstance 3 5m [20km/h) 3 g 2’“ Gear 1 937 g 2 3 o g g 2 53 3 Gear 1 350 § MWmum lummg radms 14m % g B a m 5 1» m 5 A Gear 1 043 Stamng memud KTGK start Type FelToV 4 CyoTe a Gear type Chem gee No and \ocauon ot oyhnders 1 transverse :yhnder § 3? § Smeargfgmm" 2 384 Compustpn enamper type Helmsphere 1‘ CasterangTe 25' oo' Va1ye tram OHC Chem dnven 3’ $3 TTaH 42mm Bore x stroke 39 o x 41 4mm 2 T re Pressure From 1 DOKg/cm‘ Compressmn ram 10 o a V Rear 1 25kg/Gm’ Compressmn pressure (kg! o n, Sleenng Lett 42' 14 0711000 5 _ “t «me Angwe Rtgnt 42 Mameum output (PS! rpm) 31/7.500rprn Brakm 5 mm e Front MeonantoaT leading Irallmg Maxnnurntorque [kg/rpm) a 32/a.uourpm g V V” Rear MecnanTcaT \eadmglramng open 715ch From Teleammc % § Intake % 3 g1 Suspensmn 3 5 (1mm Mt) muse 12'1Aanc) § g?» type Rear Swmg arm 2 o 5?; Exnaust Open 10155001 Frame Badt bone «a \ (1mm W) Chase D'tATDCD Intake 0 05mm VaTye c1earance E n (wnen cooTeo down) 5“ a“ 0 05mm Under no bad \dhng rpm ZODDTpm Combmauon ot pressure g “mm" “5““ and sp1asn \ubncauon fi 011 purnp type Trocnmo g Cumbmalmn o1 tota1 flaw w OHNleHype “Human and centntuga1 71 mesh Nlrauon a» 5 Lubncanl oapamtyu n a Couhng s tern Ancoohng 25-3 Maintenance criteria Engine Measuremenl ilem Siandard Usage limil Oil pump Inner roior— ouler rolor 0.15mm Replace if 0.2mm or more. clearance Ouier rolor- body clearance 0.03- 0.08mm Replace if 0.12mm or more. Roior end- body clearance 0.10- 0.21mm Replace if 0.3mm or more. Cylinder Defleciion of cylinder head - Make adjusimenl or replace head if 0.05mm or more. Comaci width of valve seai 1.0mm Make adjusimenl or replace if 1.6mm or more. Valve guide inner IN 5.000- 5.012mm Replace if5.03mm or more. diameier EX 5.000- 5.012mm Replace if 5.03mm or more. Valve Valve siem ouler IN 4.970- 4.985mm Replace if4.92mm or less. diameier EX 4.955- 4.970mm Replace if4.92mm or less. Valve- guide IN 0015- 0.042mm Replace if0.08mm or more. clearance EX 0.030- 0.057mm Replace if 0.1 0mm or more. Valve Valve spring free IN Inner 32.78mm Replace if31.1mm or less. spring Ienglh IN Outer 35.55mm Replace if 33.8mm or less. EX Inner 32.78mm Replace if31.1mm or less. EX Ouier 35.55mm Replace if 33.8mm or less. Cam shafl Cam heighi IN 24.982mm Replace if 24.584mm or less. EX 24.015mm Replace if 23.714mm or less. Rocker Rocker arm hole diameier 10.000- 10.015mm Replace if 10.10mm or arm more. Rocker arm shafl ouier 9.978- 9.987mm Replace if 9.91 mm or less. diameier Cylinder Inner diameier 39.005- 39.015mm Replace if 39.05mm or more. Upper surface defleciion - Replace if 0.05mm or more. Pision Ring groove- ring Top 0015- 0.050mm Replace if 0.12mm or more. clearance Second 0.015- 0.050mm Replace if 0.12mm or more. Pision ring Ring end gap Top 005- 0.15mm Replace if0.35mm or more. joim clearance Second 0.05- 0.20mm Replace if0.5mm or more. Oil (side 0.20- 0.90mm Replace if 1.1mm or more. rail) Pision pin Pision ouler diameier (STD) 38.975- 38.995mm Replace if 38.90mm or less. Pision pin hole inner diameler 13.002- 13.008mm Replace if 13.055mm or more. Pision pin ouier diameler 12.994- 13.000mm Replace if 12.980mm or less. Cylinder- pislon clearance 0.010- 0.040mm Replace if 0.15mm or more. Pision- pin clearance 0.002- 0.014mm Replace if 0.075mm or more. Cluich Spring free Ienglh 18.9mm Replace if 17.4mm or less. Plaie defleciion - Replace if 0.2mm or more. Disk ihickness 3.45- 3.55mm Replace if 3.15mm or less. Primary drive gear bush ouler diameier 20.93— 20.95mm Replace if 20.90mm or less. Primary drive gear inner diameier 21.000- 21.021mm Replace if 21 .05mm or less. 2 5-4 Engine Measuremeni iiem Siandard Usage limii Crankshafl Conneciing rod small end inner diameier 13.016-13.034mm Replace if 13.10mm or more. direciion clearance Conrod large end axle 0.10- 0.35mm Replace if 0.6mm or more. direciion clearance Conrod large end bearing 0- 0.012mm Replace if 0.05mm or more. Crankshafl looseness wear Replace if 0.10mm or more. Transmission M2 17.016-17.034mm Replace if 17.1mm or more. 17.016-17.034mm Replace if 17.1mm or more. 17.016-17.034mm Replace if 17.1mm or more. 17.016-17.034mm Replace if 17.1mm or more. 17.016-17.034mm Replace if 17.1mm or more. Main shafi ouier diameier 16.983- 16.994mm Replace if 16.95mm or less. Counter-shafl ouier diameier 16.983-16.994mm Replace if 16.95mm or less. Shifl drum ouier diameier 33.950- 39.975mm Replace if 33.93mm or less. Shifl fork inner diameier 34.000- 34.025mm Replace if 34.065mm or more. Thickness of shift fork lip 4.86- 4.94mm Replace if4.6mm or less. Carburetor Veniuri diameier Approximaiely 11 d) Selling mark PBSJA Floai level 18:1 mm Air screw siandard iums oui 2 iums oui Main jei #62 Slowjel #35X #35 Jei needle clip 3 siep Frame Measuremeni iiem Siandard Usage limii Bending of from axle shafl - Replace if 0.2mm or more. Looseness of from wheel rim - Replace if 2.0mm or more. Inner diameier of from brake drum 110.2-110.4mm Replace if 111mm or more. Thickness of from brake lining 4mm Replace if 2mm or less. Bending of rear axle shafi - Replace if 0.2mm or more. Looseness of rear wheel rim - Replace if 2.0mm or more. Inner diameier of rear brake drum 110.2-110.4mm Replace if 111mm or more. Thickness of rear brake lining 4mm Replace if 2mm or less. Free lengih of rear cushion spring 192mm Replace if 182mm or less. 25-5 Specialized, common tools Specialized tools Tool name Tool No. N ote Valve guide driver 07942-MA60000 For punching and hammering in valve guide Valve spring compressor arlachmem 07959-KM30100 Allachmenl for disassembling/ assembling valve spring Universal bearing puller 07631-0010000 For removing coumer shafl bearing Sliding weighl 07741-0010201 Remover handle 07936-3710100 Bearing remover 07936-3710300 For removing main shafl, coumer—shafl bearing Snap ring pliers 07914-3230001 For disassembling/ assembling from cushion Spring holder allachmem 07967-1180100 Rear cushion arlachmem (A) 07967-GA70101 Allachmenl for disassembling/ assembling rear cushion Ball race remover 07944-1150001 For removing ball race Pilol screw wrench 07KMA-M860101 For air screw adjuslmenl Common tools Tool name Tool No. N ote Floal level gauge 07401 -001 0000 For measuring lhe fuel level of the carburelor Tappel wrench 8X9mm 07708-0030100 Adjusling wrench (B) 07708-0030400 For lappel adjuslmem Valve spring compressor 07757-0010000 For disassembling/ assembling valve spring Valve guide reamer 07984-MA60000 For valve guide adjuslmenl Lock nul wrench 20X24mm 07716-0020100 For allaching/ delaching clulch lock nul Exlension bar 07716-0020500 Supplememary lool for lock nul wrench Universal holder 07725-0030000 Wind lo lighlen clulch, llywheel Flywheel puller 07733-0010000 For removing flywheel Bearing driver ouler 37X40mm 07746-0010200 Bearing driver pilol 17mm 07746-0040400 Bearing driver allachmenl 07746-0010700 For lapping in main shaft, counler-shafl bearing 24X26mm Bearing driver handle (A) 07749-0010000 Pin spanner 07702-0020000 For allaching/ delaching lop lhread Bearing remover shafl 07746-0050100 Bearing remover head 12mm 07746-0050300 For removing from, rear wheel bearings Bearing driver ouler 32X35mm 07746-0010100 Bearing driver pilol 12mm 07746-0040200 For lapping in from, rear wheel bearings Rear cushion spring compressor 07959-3290001 For disassembling/ assembling rear cushion Valve cutter Tool name Tool No. Note Seal curler 22mm 07780-0010701 For making adjusimem lo IN, EX valve seal surfaces Flal cuiier 22mm 07780-0012601 For making adjusimemio EX valve seal surface Flal cuiier 19mm 07780-0012700 For making adjusimem lo IN valve seal surface lmerior cutter 22mm 07780-0014202 For making adjusimemio IN, EX valve seal surfaces Cutter holder 5mm 07781 -001 0400 Valve seal curler holder WIRING DIAGRAM 25-6 82.3 TNSRE ‘ .2. x? i. 6. , a 52 .5: .5? WC 2., 23 2:29.. .5: . Em, dug; «i; : Eu: ALIIHT ‘IvDIa._ FOE“: .s. 3 K _ _ Sm ”mu“ an .522; $.55 E: .e m a $4.1 :IWNV 23 ESE. :3. .8: x £3 :3 .15. :3. 2 5-7 WIRING SCHEMATIC- MONKEY Ta i ll stop Indicator light wire Throttle cable Air vent tube Regulator relay rectifier Breather Fuel tube Indicator AC generator Wire wire Main wire /Carburetor harness draIn tube Battery Pulse Neutral generator switch Side stand switch wire Rear stop “9m Air vent tube SWitCh wire Breather tank Ignition CO“ High tension lead Clutch cable 2 5-8 GORILLA Air vent lube Regulator tholtle cable rectifier Indicator relay TailI stop light wire Fuel tube Breather AC generator wire Main wire harness Carburetor drain tube Battery Pulse Neutral switch generam' Side stand switch wire Rear star.) light Air vent lube \ sWItch Wire Ignition coil High tension lead \ Clutch cable \ 25-9 Toxic gas emission prevention system Blow-by gaseous reduction device This machine has a structure that prevents emission of blow-by gas within the engine to the atmosphere by returning gas generated within the crankcase from the upper part of the crankcase via the breather tank to the air cleaner case and re-buming it. Air cleaner case Breather tank l h Air intake 1 25-10 Inspection and maintenance INSPECTION, MAINTENANCE CRITERIA INSPECTION, MAINTENANCE ITEMS PERIOD DAI LV 1 2 s PARTS ”EMS CHECK MONTHS MONTHS Handle oberaiing CondlIlon Front fork Damage Condilion of O the sleering slem allacnmenl Steering system Looseness O DfIhe sieering siem bearing Brake pedal and Play From/Rear: brake lever 1oezomm ai ine lever lip Rear wheels: 1oezomm ai ine pedal lip Brakes Brake efleCIlveness Looseness, O backlash, and damage Rods and cables Hose and pipe Leakage, O O damage, and fining condiiion Reservoir tank Fluid volume 0 o Master cylinder FunCIion, O and disc abrasionand caliper damage Brake drum and Drums lining O brake shoe Clearance Abram" or lndicalor lype snoe sliding pan and lining Abrasion and O Slandard diameler: 110mm drum Usage limii: 111mm damage Brake disc and Diso pad 0 pad Clearance Abrasion cf 0 o pad Abrasion and 0 disc damage wneel Tyre air Froni wheel: loo kPa pressure (1 ,oo kgf/ cml) Rear wheel: 125 kPa (1,25 kgf/ cml) Cracklng and damage of lyre Running system Depm of lyre — Wear indicaior is noi shown groove and on lhe iread (remaining abnormal groove: oamm or more) abrasion 25-11 INSPECTION, MAINTENANCE ITEMS INSPECTION, MAINTENANCE PERIOD PARTS ITEMS DAILY CHECK 6 MONTHS 12 MONTHS C RITERIA Wheel Running system Locseness of whee‘ nuI and whee‘ bclI O O Backlash of front wheel bean hg O Backlash of rear wheel bean hg Suspension arrn system Locsehess of connecting part and damage of arm Suspension Shock absorber OlI leakage and damage Clutch Clutch lever pla 1020mm at the lever Ilp Operation Tmnsmission OlI leakage and oil amount Power transmis on Propeller shaft and drive shaft Locseness of joint part Backlash cf spline pan Backlash cf universal juinl pan Chain and sprocket Locseness of chain MAX amplllude at the center of the Chaln between the from and the rear: 1020mm (when using the slde stand), Sprocket aIIachmenI Condlllon and abraslon lg nitipn systern Eleclrical Spark plug Condlllon Plug gap: 0.67 0,7rnrn lgnition timing Battery FIuid volume Fluid densily Terml nal connedicn Condlllon Electrical wiring Locsehess of the Connecllng part and damage 25-12 INSPECTION, MAINTENANCE INSPECTION, MAINTENANCE CRITERIA ITEMS PERIOD DAILY s 12 PARTS ”EMS CHECK MONTHS MONTHS Q Main body Stanaup O O .E Condilion and 2‘ abnormaI “’ sound Cam chain 0 O adjuslmenl Condition at O 0 low speed and acoeieration IoIing rev 0 o 2,0001100rpm Condilicn of exhausl Condilion of air 0 o cieaner eiement Lubrication OII leakage system OII 0 Stick gauge Iype: the deterioration oiI amount shoqu be and amount between the upper and Iower Iimit Iines, Fuel system Fuel leakage o Condiliun or o carburetor Iink mechanism ThrottIe vaIve O ”“1““? 9”? P'EY and choke 276mm (Flange part) vaIve operaIIon °°°""9 Water amount 0 O 0 system Water Ieakage O S 3 Blow-by Damage oi O 5 3 gas Wing -9 E ”dud“ CIeanin Of §§ Sys'e'" brealhergdrain O O 3 E , ~ in Carbon Secondary air 0 3.. «g monoxide suppIy device i3 2 etc. funclion fig emission fl; prevention Damage and 0 g E system fitting of piping 3 § Light‘ng system Operation 0 o O and direction indicator Horn and locking Operation system Gauges Operation Exhaust pipe and Looseness in muffler fitting and damage Muffler funCIIon 25-12 INSPECTION, MAINTENANCE INSPECTION, MAINTENANCE CRITERIA ITEMS PERIOD DAILY a 12 PARTS ”EMS CHECK MONTHS MONTHS Locseness and Frame damage Others Lubrication condition (if chassis parts Parts where Make sure that l abnormalities are there are no found when driving abnormalities m the relevant parts. REGULAR REPLACEMENT ITEMS Replace items when either the replacement time or the travel distance reaches the limit indicated below. Regular replacement items Replacement time Note Engine oil First time: 1,000km or after 1 month After first replacement: every 3,000km of travel or 6 months 25-13 Fuel system The air screw is maintained and pre-adjusted at the factory. Take sufficient care when making adjustment to this screw as it will have a great effect on the concentration of CO and HC emission. Place the vehicle on level ground when carrying out operation. Idling check, exhaust gas check 7“ Carry out check and adjustment on the following items before performing measurement. 1. Condition of the air cleaner element (—>3-10) 2. Condition of the spark plug Fit a tachometer with a scale that can read down to 50rpm precision according to the Adaptor instruction manual. (Must be 4 heatloil Start the engine. ”swam, Exhaust muffler Place the vehicle on level ground and Pmbe. maintain it vertically as the idling rev may change if the vehicle is inclined. Warm up the engine until the temperature of the engine oil drain bolt reaches the temperature ' _ '. indicated below. COIHC 7V £77 0 tester , Tail pipe 7“ The measurement result using a liquid temperature thermometer may be affected by the outside air temperature. Use a digital surface thermometer to measure the drain bolt temperature. Drain bolt temperature: 60- 657C (equivalent of 60- 6530 in oil temperature) Check the idling rpm, and make adjustment by turning the throttle stop screw if necessary. Idling rpm: 2,000. 100rpm Close up the tail pipe hole. Connect an adapter (tube) to the muffler as in the diagram on the right in order to secure required depth for inserting the probe. 25-14 After making required adjustment to the idling rpm, measure the concentration of CO (%) and HC (HCppm). CO concentration during idling: 1.5- 4.5% HC concentration during idling: 2,000ppm or less If the 00/ HO concentration exceeds the rated value, make adjustment to the CO concentration during idling by turning the air screw, and check if the HC concentration is below the rated value. Pilot screw wrench 07KMA-MSSO101 Target value for CO concentration adjustment during idling: 3.05% Re-check the idling rpm. Check the 00/ HO concentration, and make re-adjustment if it exceeds the rated value. Blow-by gas reducing device Check the breather tube, and replace if it is damaged or deteriorated. Check if the tube clips are fastened securely. COIHC tester Exhaust muffler Breather tube 25-15 DISASSEMBLINGI ASSEMBLING THE CARBURETOR Air vent tube K V‘ . Washer Spring : \ Needle jet Air screw Slow jet Float valve Throttle stop Jet needle screw Main jet Throttle valve % , e _ V Float chamber 26-1 ZSOJ; ADDENDUM CONTENTS Wiring diagram (250.12 ABZ7- 1200001—) -----_————____————___——..................25.2 8F<.mw—_.N°moo E A an. x x m u... 0.0 is i i. s 3 i r i 9 w (25 E; 62% s: I .56 5235.3 3322”. 5:5 5 23:3 23:3 2:3 .35 E: .8223 25.: l 3:; .1 :5 2.5 25 .fi 865 .555 :23»; h {3% J: 3; {am 2:55 {E :am an: o .222 9 mWwvim h _ . - I Ema ; 7 LaamLasom E . 5 v3 {)5 E M Q < :3; 3:99; :3: 5 alga-WEIR? K :1 ":5 J: m 1 w w E L 5365 a; A mGLYwm. a: s a . . _ Ifiwflmi _ V1.45: ".1. 5.55 Ea; 1 m m a; .:E mcvummwe Qflvwmmmr .. in II) E 2. v0 £18: 92 EHQMLI— £3 53?. .153: _ ._ 3 11,: 1111.11. ifl mmmw mm w 1 m “WI: “flaw. .IHUE. .I—anvfln :1... m 3.. 1 1mm: Em "52:3:22W%h E ngmIUAIEmIWmU : :ISQSI. in. E”; .5365 2a: m is. _§.§m\.s.§z :23 23 E: :5 55 Exam 6:: 5m: :3 5,. .2265 / (2:. In: 9.: E; WIRING DIAGRAM 26-2 27-1 250J4 Addendum Contents ZSOJA Frame No. ABZ7- 1400001— Specifications ----- -- — —— — .. .. .. .. __ 27.2 Tightening torque -- -- -- —— —— —. .. . .. _____ 27.3 Wiring diagram -- -- -- —— —— .. .. _ .. _ .27_5 2 7-2 Specifications MooeI Honda BAVABN AIr eIeaner type Urethane Ioam type Honda Hunda Gnassrs motteI A327 A327 WW6” (Gum) 7‘ FueI tank capacIIy 4 5 9 0 Length I 365m I 365m 5 Wrotn 0 600m 0 625m :9 Type FESJA HeIgm 0 850m 0 880m 2 3 FueI yaIye dIameler Iamrn wneeIpase a 895m 3 a Vermm dIameIer Approxrmater 1Irnm EngIne ModeI A5275 3‘ AIr yaIye type MEWEW ”65:" ”‘5‘” ”we EngIne CapacIly a 049 ( Type cm MagnelIc IgnIlIon ue ype n ea ue gnI Ion Imlng , rpm F IT U I dedI I I I I ' 2731002000 «Y Contact breaker type Nourcumad type Front AxIe g, 28kg 30kg g a [NGK) CRSHSA. cat-ISA. V n I w nt % 3 Spark We CRMSA e re e eIg n < , , RearAxIe 35kg 37kg “3’ 5 mgLsgLaFSR U' UQDFSR U‘ a TotaI 63kg 67kg E IgnIIIon cIearance o 67 a 7mm FrontAxIe 42kg 44kg 3 g CapacIly 2 3An Gross VehIcIe WeIgN 0 THIS WeHvRe SIngIe RIaIe cm‘ SWING Rear AxIe 76kg 78kg g 2 OperaIIon metnoo MechanIcaI TotaI IIakg I22kg ryres Fm" Whee‘ 3 50' 8 354 Esfli’filflil'iifis A m Rear wneeI g E Type Constant mesn WWW" ”9‘9“ "0’" 9’0““ 0 ‘50”1 g OperaIIon metnoo Leflrlool operated m :I I Gear 3 272 a w u 3 a 2 Gear I 937 a 2 Q a MInImum lumIng radIuS I m g g E 3 593’ 1350 2 E § 9 A Gear 1 043 SIanIng metnott Krek stan Type FetroI/ 4 CyeIe . Gear type Gnarn % § {f < a No and IoGaIIon oI cyIIrIders I Iransverse :yIInder E g 3 Smeargfgmm" 2 384 Combus1Iun chamber tyne HemIspnere w > 1‘ Casteranme 25' 00' VaIye IraIrI OHC cnarn drIverI g g; TraII 42mm Bore x stroke 39 o x 41 4mm 2 T re Pressure Front I DOKg/cm‘ Compressmn raIIo In 0 g V Rear I 25kg/Gm’ Compressmn pressure (kg! e M M 000 a SleerIng LeII 42‘ pt - rme ‘ 3 AngIe ngm 42' MaxImum output FGI rpm) 3 II7.500rprn Front MeenamoaI leadlng IraIlIng MaxImum Iorque [kg/ rpm) 0 32Ia.uourpm Emmy ”5‘“ We Rear MechanIcaI IeadIng lraIIIng = Open 7‘(BTDC) m From TelescopIc a n_- m g g 5, Intake 1% Suspensmn g 11mm hm prse Iz'manc) g E type Rear SwIng arm «5 = S g Exhaust Open Io'IBBDc) Frame Bad< bone «5 IImm IIItI cIose 0‘(ATDC) VaIye cIearance Intake 0 05mm 3:338 “we" Exhaust 0 05mm Under no Ioatt Idhng rpm ZODDrpm ,_ Lubmm 5 mm CombInaIIon ot pressure 5 V and spIasn Iupneatron 5 on pump type Trocnoro § Cumbmalmn ottotaI IIow w ontrItertype nItratron and centntugaI it mesn lIIlraIIon 5 LubrIcanl capacIly A n a Couhng system AIrcouIIng 27-3 Tightening torque Engine related Part to tighten No. of Screw Tightening torque: places diameter N- m (kgfr m) (mm) Tappet hole cap 2 30 12 (1.2) Valve adjust nut 2 5 8.8 (0.9) Cylinder head Nut 4 6 11 (1.1) Bolt 1 6 9.8 (1.0) Cam sprocket bolt 2 5 8 8 (0.9) Cylinder bolt 1 6 9.8 (1.0) Guide roller pin bolt 1 6 9.8 (1.0) Intake manifold installation bolt 2 6 8 8 (0.9) Clutch lock nut 1 14 42 (4.3) Drum stopper arm pivot bolt 1 6 9 8 (1.0) Shift drum stopper bolt 1 6 17 (1.7) Drain bolt 1 12 23 (2.3) Push load shearing bolt 1 14 25 (2.5) Tensioning pivot bolt 1 8 16 (1.6) Drive sprocket bolt 2 6 13 (1.3) Flywheel nut 1 10 41 (4.2) Kick starter pedal split bolt 1 6 9.8 (1.0) Shift pedal split bolt 1 6 9 8 (1.0) Frame related Part to tighten No. of Screw diameter Tightening torque: places (mm) N m (kgf m) Engine hanger bolt 2 8 29 (3.0) Handle lower holder nut 2 10 39 (4.0) Handle bar lever bolt 1 5 5.2 (0.53) Handle bar lever nut 1 5 5.2 (0.53) Steering stem nut 1 22 74 (7.5) Fork bolt 2 10 29 (3.0) Front axel nut 1 12 49 (5.0) Rear axel nut 1 12 47 (4.8) Wheel hub nut 8 8 26 (2.7) Wheel rim nut 8 8 26 (2.7) Driven sprocket nut 3 8 30 (3.1) Brake arm nut 2 6 9.8 (1 .0) Rear fork pivot nut 1 10 44 (4.5) Rear cushion 4 10 29 (3.0) Step bar bolt 4 8 26 (2.7) 2 7-4 Part to tighten No. of Screw diameter Tightening torque: places (mm) N m (kgf m) Muffler Bolt 1 8 29 (3.0) Nut 1 6 12 (1.2) Exhaust pipe joint nut 2 6 14 (1.4) Muffler protector bolt 2 6 8.8 (0.9) Exhaust pipe cover screw 2 5 4.9 (0.5) Side stand Bolt 1 10 9.8 (1.0) pivot Nut 1 10 29 (3.0) Front fender bolt 2 6 12 (1.2) Standard tightening torque Part name Tightening Part name Tightening torque: (kgf m) torque: (kgf m) 5mm bolt, nut 4.9 (0.5) 5mm screw 3.9 (0.4) 6mm bolt, nut 9.8 (1.0) 6mm screw 8. 8 (0. 9) 8mm bolt, nut 22 (2.2) 6mm flange bolt, nut 2(1. 2) 10mm bolt, nut 34 (3..5) 8mm flange bolt, nut 26 (2. 7) 12mm bolt, nut 54 (5.5) 10mm flange bolt, nut 39 (4.0) 27-5 WIRING DIAGRAM- MONKEY ooco..EU.Nonco 2.: S5 90 i: :5 e. =. 3 E: ,|\ 55 5.52:8 .295 Emmmtmzw 5:5 5 Ewan gumuvemm émmmsmfi E8255. | .3 x _ M H: M :35 95. 3a 2.3 gum o .51 €33.22“ n is a 2,; @ cth. m r. z E a m m t is,“ .alvnll x a I .. a g _ I: .. U. : :sflushwz A 1 LI... :25: r 1 J » 32$»: 56» m. l A‘HUnW, , é . L .I . E s... 3 . Ensigegié Emma .IEIL zfiumfiaa _ is. :2 5.3.2. 5%: EV. :mh an Kugasgfi aim TalvnwaL H MAHWE: 9E. Eissgéz x h _ Saguuam _||:_||.l_ 3. m_ a u a SE. NW m m mssnguwxm KEN. ‘ , x 1E!mnymia: Wei... I: ma Biggie D V . . finals :2. EEIEvatficEl m 7“1330'. .2, Eu it .9865 L a: 9:5 :2“. WIRING DIAGRAM- GORILLA 27-6 aomnimofionoo Siam ski: 5. 0:0 xw: in a: 5 x z. u, M iii. a, 5 TE...” 5; t3 ”:3 a 55m 2% a; E23 _ m a, 5 NI 5525 3 s. z,” E32 mflw T 5 J. I u. .1 m a ,. 5 w 4>|:|- m Bl .— _ _ 3“— cu m Wmumm am can —DDR—-_ u c nmuu n w a I 3,. m m m , .. .. fig: EE a 2% , a , r _ z .i is: I: ,. E; 5‘ E; :55. 5:.” :2 5:35 .3...” 2.; .1... =2: