HONDA 50 MODEL C100 - C102 - C110 - C111 l l FOREWORD On ihe occasion of the debul oi HONDA MODEL 110 & H] as sisier MODELS wiih 100 & 102 which gained good repuiaiion around the world, rhis manual was com- piled as 0 "overall service Handbook" for these models. The main iniensian of ihis manual is to have you get foundamental idea for disassembly, inspeciion, maintenance and assembly operavion, An effort has been made to edit this manual avoiding lundamenral principle and theory by explaining ihe aclual mechanism and special emphasis has been placed in illusirai‘ion and pictures 10 make if easy for the service man io understand, how To handle‘ We heariily welcome your kind advice to revise or correct ihis manual 10 make if more compleie one. June 1, 1961 HONDA MOTOR CO., lTD. EXPORT DEPARTMENT No 575, YaesU-cho, Chua»ku, Tokyo, Japan MAINTENANCE STANDARDS . . DISASSEMBLY, ASSEMBLY . . CONSTRUCTION . . ELECTRICAL EQUIPMENT. . . MAINTENANCE STANDARDS For maintenance operation for HONDA 50, Maintenance Standards, specification and dimension are listed hereafter {or reference, EXPLANATION : Maintenance Items Items to be inspected, service-wise. Standard Value This indicates the manulacturer's standard size or the standard size after newly assembling or adiusting, and shows the size-limit of completed part in the permissible limit of adiustmentr Reparlng Limlt Unusable wear limit of ports requiring correction or replacement, function-wise. Remarks Unmorked numbers are run unit and inch unit shown underneath, and others according to the unit indicated UNIT IN CHART: Unmarked numbers are m/m unit and inch unit shown underneath, and others according to the unit indicated. " Model 100 ** Model llo No mark Common to all models. 'l. 2. 3. C O N T E N T 5 GENERAL PERFORMANCE ........................................... ENGINE A. Cylinder, Cylinder Head ...................................... B. Crank Shaft (Piston, Connecting Rod] ............................ C. Cam, Timing and Valve ...................................... D. Clutch .................................................... E. Transmission ................................................ F. Magneto, Contact Breaker .................................... G. Kick Starter, R. Crank Case Cover ............................ H. R. Crank Case and Change Gear .............................. FRAME A. Steering Handle ........................................... B. Front Cushion .............................................. C. Front Fork, Steering, Tank .................................... D, Frame [Main] .............................................. E. Saddle, Stand .............................................. F. Rear Fork, Chain—Case ........................................ G. Rear Cushion .............................................. H, Front Wheel ................................................ Rear Wheel ................................................ \oaooowmwm 10 12 13 1. GENERAL PERFORMANCE Maintenance Item Standard Repairing Limiv Remarks i Compression pressure * 7.0 kg/cm2 4.5 Check wim kick i 100 ib/in2 65 i“ 8.5kg/crn2 6.0 i 121 Wm2 85 Fuei Consumpiion i 90 km/ 4 51 30 kin/n (i9miIe/h) i 255 mile/gal. 140 Max. speed i * 70 km/h 50 The posmre is iedn. ; 44 mile/h 3] ing forward rhe ‘** 85 km/h 57 upper half of body 1 53 rniie/h ‘ 35 Braking disidnce 5 m i 10 25 km/h 1 16.5fi \ 33 (lémiIe/h) r 2. ENGINE A. Cylinder, Cyllnder Head Ma'imenonce irern Srondard Repairing Limiv Remarks 1 _ . Cylinder inner dia. * 400040.01 40.i Avieniion for eilepnn, 1.57487] .5752 1.580 'aper size 5* 400240.03 40,1 1575645760 1.580 Max. our of round 0.01 0.05 0.0004 0.002 ieper 0.01 0.05 0.0004 0.002 Oversize of cylinder Jumping guuge 02570.26 Three caregory 0.009 Cyiinder headwive Width 1.0 2.0 seer 0.039 0.08 Angle 45° Compression reiio * 8.378.!) ** 9,379.5 5.9 1‘ or less over 9.8 Cylinder head gasker Harness 0.03 0.05 surface 0.0012 0.002 Cylinder head gasker Thickness 0.5—0.6 00197700236 Cylinder srud rim Tighrness 0.44055 kg/m 04 2.94.0 ir ib i 2.9 i F, B. Crank Shufl (Plsion, Connecting Rod) Maintenance nern Standard Repairing Llrnll Remarks Piston Top diameter * 39,6373968 1.56024 .5632 Piston and cylinder Pistan pin Piston oversize Top, 2nd ring Top, 2nd ring and ring groove on ring Oil ring and ring groove Piston ring oversize Pisian pin Max. diameter Out of round Min. clearance Diameter Jumping gauge Thickness Width Tension End gap Gap Thickness Width Tension End gap Clearance Jumping gauge Outside dia. ** 395073955 1555145571 * 3998—400 15740—15748 ** 39.99—40.01 1 .5744715752 ** —D.1 6 —~0.18 00170.03 00003—0001 13.071 3.006 05118705120 0.25 0,009 1.8—2.0 00709700757 140071.495 0.0583~0.0589 04570.75 kg 0.99—1.65 lb 0.1—0.3 0.003001 0.017004 00003—0001 5 1.84.0 00709—00757 2.480—2.495 00976—00932 0507 kg 1.10—1.54 lb 0.1—0.3 00034.01 00170.04 00003—0001 0.25 0009 12.9944 3.000 (15116-015118 39.9 1.571 39.4 1.551 0.14 0.005 13.02 0.513 1 .4 0.055 0.3 0.66 1.0 0.039 0.15 0.005 2.4 00945 0.3 0.66 1.0 0.039 0.15 0.005 12.95 0.510 At the lower part at skirt perpendicular to piston pin axis Minus dimension lrom max. Diameter a- long axial direcr lion cl piston pin axis at the lower part of Skirt Selective insertion Tollerance etc. same as STD Tangential tension Perpendicular gap as l inserted in regular cylinder Tangential tension Perpendicular gap as inserted in regular cylinder l Allowance elc. same as STD l l Mainlenance Item Standard 1‘ Repairing Limii Remarks 23858—23937 l Taval lenglh 31.9—32.1 12559—12638 Pislon and pislon pin Clearance 0.006 0.05 0.00024 0.002 Connecling rod srnall Inner dia. 1301641043 1308 end 05124705135 Canneciing rod small Clearance 001670.049 0.08 and and pislan pin 0,000670.00l9 0.003 Connecling rod small SWing 3.0 Max. amplllude to end i 0.1 18 axial aireclians ai srnall end pin Connecting rod lower Axial clearance 0170.35 0.5 end 0.003—0.013 0.023 Diagonal clearance 0—0,0l2 0.05 7 grade of seleclive 0—00005 0.002 combinalion Big and and small end Arnauni a1 paralley 0.1 A1 8 rn/rn (3.2 in) al canneciing rod 0003 point irarn small ‘ end cenier Disvorlion i 0.15 0.005 Crank pln Oulside dlcl. 2109841107 2108 Perlecl circle 0.003 05306—08310 . 0.830 less R. L. crank shaft Dia. a1 shall 16397—17008 15.95 on, aia. oi bearing 06692—06696 0.667 sarne dlu. wilh R.L. Crank snail aearina Axial clearance 0.005 0.1 0.0002 0.003 Radial clearance 00144015 0.05 0000554300053 0.002 Crank snail coma. Max. swing 0.03 0.25 l 0.0012 . 0.01 . l l l ‘ l L—sicia 20 Reside 30 i i Arrowsign shows poe ‘ smon of measure- l C. Cum, ‘I'lming and Valve Maintenance hem Standard l Repairing Limil ‘ Remuvks . l l Ex. ln. valve guide inner dia. 1 550575515 ; 5.53 ‘ l 02167—02171 ‘ 0.220 l Ex. valve ‘ 60.6—60.8 l ‘ l l ‘ Overall lenglh l Molmenance hem Slandurd Repairing Limit Remarks Oul. die. of Siam 543575.445 5.40 0.2140702144 0.2126 Thickness of head 0.7 0.4 0.0276 0.0157 In. valve Overall length 61.17613 24055724134 Oul. did. of siem 546575.475 5.43 02152702156 0.2138 Thickness of head 0.5 0.2 0.0197 0.008 Ex. ln. valve Width 1.0 2.0 Check a denial cone 0.039 0.08 Iacling surface and llowing ihrough Ex. valve slam and Clearance 00670.08 0.10 guide 00024—00031 0.0039 m, vane stem and Clearance 0.03—0.05 0.10 guide 00012—00020 0.0039 Valve spring Outer Free leng'h * 27.0 25.6 1.063 1.008 ** 28.4 27.8 1.1 18 1.095 Load * 6,376.9 kg 5.36 Height 23.5%. 13.89—15.21 lb 11.82 (0.925 in) ** 8.45—9.25 kg 50 186372040 lb 17.64 Decline 0.3 1.0 Valve Spring inner Free lenglh * 27.8 26.5 1.0945 1.043 ** 26.9 26.0 1.0591 1.047 Load * 2.55—2.85 kg 2.17 Heighl 22.5%; 5.6276281b 4.78 (0.886 in) ** 4.17—4.75 kg 3.8 Heighi 21.5% 9.1971008 lb 838 (0.847 in) Decline 0.3 1.0 Cam shall Shaft diu. 18959718980 18.9 07464707472 0.744 30950730975 30.9 1.2185—12195 1217 Bend of shall 0.05 0.002 Heighi of cams 24,5 24.3 Base circle 20¢ 0.9646 0957 Cam shaft and iouvnul Clearance 004170.062 0,15 194) Shall pan metal 00016-00024 0.0059 Maintenance iiem Swndurd Repairing Limit Remarks 0.025—0075 0.15 31¢ shaft purl 0.0009B*0.0030 0.0059 Valve liming Ex. Opening angle *Beiore lower dead point 79u H“Before lower dead point 22.5" Closing angle *Afler up dead point 47° **Alter up dead A? valve lifl poim 25" Valve timing in. Opening angle *Before up dead * 1%, point 56° ”6* 1.14% “‘Belore up dead poini 7.5° Closing angle *AlVer lowerdeucl point 86° **Alterlowerdeod poim 12,5“ Corn gear Max. chord 29251—29268 No. of ieelh 44 1.15l6il.1523 _ Timing gear Max. chord ' 1380341818 ‘ No. 01 leelh 22 05434—05440 Max, chord 3 i Buckrosh wiih cam 00570.08 Les; mm 0.02 l gear Morelhan0.17 0.002~0.0031 Less man 0.0008 More than 0.0047 Inner dia. 16.99.347.011 17.02 06690—06697 0.670 Push rod Lengih In. 187.4 7.3779 Lengm Ex. 170.5 6.7126 Bend 0.6 0.024 Valve liner Our. did. 11973711934 11.94 04714704718 0.470 Clearance 10 case 0016—0038 0.08 hole 00006—00015 0.003 Rocker arm Inlel die. of axis 8.000~8.015 8.05 0.3150413156 0.317 Rocker arm pin Outside die. 7378—7387 7.95 ‘ ‘ 03141—03144 0.313 Maintenance Item Siandurd Rspulring Limi! Remarks Clearance lo 0013—0037 0.08 rocker arm 00005—00015 0.003 Ex. ln. valve adiusl. Tappei clearance 0.01—0.03 Cool scale rneni 000039700012 D. Clutch Mainienance Hem Slandard Repuillng Limii Remarks Clurch ouler : Clearance la drive 0025-0039 0.2 plale 00010—00035 0003 Clinch lriclian disc. Thickness * 2.7—2.8 2.3 0.1063—0.1102 0.091 ** 3.5 2.9 0.1373 0.114 Sirain 0.2 0.0079 Clulch plale A ' \Thickness * 16 0,0630 Slrain * 0.2 0.0079 Widlh of hook 15.7—15.5 15,5 ' 061817011220 02165 Clulch plale B Thickness * 1.6 0.0630 snain * 0.2 0.0079 Width of haok * 16.0716J 15.8 06299—06339 0.622 Thickness * 1.2 0.0472 Sirain * 0.2 0.0079 Wicllh of hook * 1.53 1.3 0.0622 0.0512 Clulch plale Thickness ** 1.6 0.063 Slrain ** 0.15 0.0059 Widlh of hook ** 15.7453 155 06181—06220 0.610 Drive gear |nrler diuc 20.00m20021 20.15 07874—07582 0.793 Mclx. chord 13950713930 1392 No. 01 leech 15 O.5496-0.5504 0.543 Max. chord No. 3 Mainlenunce Item Slondard Repulrlng lelt Remarks l Clinch cenler guide Om. die. 19930—19950 19.85 07846—07854 0.7815 inner din. 17000717018 17.10 06693—06700 0673 Lenglh * 21.5—21.6 08465—08504 ** 19.1—19.2 l8.95 07520707559 0.766 Clearance io crank 0.0087002 shun 00003700008 Clearance ro drive 0.04—0.052 gear 00016700032 Clulch spring Free lenglh * 23.23 22.07 0.9l46 0.869 ** 25.2 24.0 0.9921 0.945 Loud * 3.04—3.24kg Heigm 12.00% 6.70»7.15Ib (0.472 in) ** 5.17—5.71 kg 4.6 Heighr 13.6% 1 140712.590; 10.14 (0.535 in) 14% Lock nul Tlghlenlng force 1.6-2.0 kgm ll.6—l4.5lllb E. Transmission Maintenance nein srandard Repairing LimlI iiernarrs i . Lubricating oil Capaciiy . 0.6 5 ‘ Check wilh oil gauge Main shall Coumer shall Bull bearing of main siren and counler siren Primary driven gear Our. die. or shall bearan Axial play Clearance of main shun lo top gear Our. dlo. Clearance to low gear Axial clearance Rudlal clearance Max. chord l 13966—13934 l 05498705506 ‘ 0.17075 00039—00295 0022—0051 0.00087—0.0020 16933—16994 0668646691 I 0022—0051 ; 0.00037—00020 l 0005 0.0002 0.0100016 0000557000063 39755739011 i 1.5663715674 l3.9 0.547 1.2 0.047 0.2 0.0079 l6.95 0.667 0.2 0.0079 0.1 0.0039 0.05 0.002 39.68 1.562 l Check smooth rotor lion and noise , No. ol teeth 8 l Maintenance Item Standard Repairing Limit Remarks Buck rush to drive 004170.057 0.20 gear 0001640034 0.0079 Swing or gear end 01 1.0 SW'OCS 0.0039 0.039 Turing directional 0.413 1.0 At ihe outermost . play to main shaft 0 0189 0.039 poini oi ieeih Drive sprocket Pitch } 12.7 No. oi teeth 14 0.5 Turing directional 0.18 0.5 Measure at the and play to coun'er 0,0071 0.0197 or teeth shaft Kick starter spindle inseri hole outer 11766—11784 11,65 die. of R~crunk 04632704639 0459 case (pier 1 Kick starter ratchet Graded i 0.2 . pole ’ 0.0079 i F. Magneto, Contact Breaker Maintenance hem Standard i Repairing Limit Remarks Coniaar point ‘ Max. gap 0.34.4 ; 00118—00157 Ignition timing Crank angle Beiore upper Shift more Fixed advance angle 1 dead point 35° than 30° Magneto spark chars 3 needle gap ‘ 6 5 500 rpm acter B 5 3000 rpm Magneto charging Charging current 0.9A 0.5 6000 rpm (Day) character 03 A 0.1 6000 rpm (Night) Magneto lighing char- Lighting voltage 6 V 4 2500 rpm acter 9 V 9 8000 rpm Spark plug Article No. C7HW Gap 0.6—0.7 0.0236‘00276 G. Kick Starter, R. Crank Case Cover Maintenance Item Standard Repairing Limir Remarks Kick starter spindle and ‘ Clearance 0066-0111 0.25 R. crank case cover 00026—00044 0.0098 hole Kick starter spring ‘ Torque 270 kgmrn 200 J ‘ 2011: 1.4 H. R. Crank Case and Change Gear Mainrenance llern Slandara Repairing Liam Remarks Slim ariirn Our. dia. a1 shaft 41.95m41.975 41.9 bearing 165164.6526 1.650 snail 001. die. 1136641584 11.9 04711—04718 0.469 Shin drum and crank Clearance 0025—0075 0.15 case hole 0.00098—00030 0.0059 J Slim drum Groove width 6.1—6.2 6.4 I 02402—02441 0.252 5 Shin fork In. die. of hole 42.0—42.025 42.07 . 16535—16545 1656 1 Thickness ai end 4.86—4.94 45 l. 01913—01945 0.177 . Bend at end 0.3 0.5 1 0.0118 0.0197 1 Clearance to drum 002570.075 0.15 l 000098700030 00059 6% sma bolt Tighmess 3751111) 8% Stud bolt Tighmess 107131111: 1 R. L crank case sening Tighmess 0.44.6 kgm ball 2.94.3011: 3. FRAME A. Steering Handle Maintenance hem Srundard Repairing Limil Remarks Thrallle grip Play 377 Grip aurer surlace 011870.276 dimension Thronle wire aifiere Length * 82.0 4 since beiween omer 3.23 £113]; and inner ** 55.0 2.17 Clurclr wire ama Lengih ‘* 31.0 :——1 3.19 QM Broke lever Flay 15725 Measure a1 level end 0.69—0.98 Clulch lever Play ** 15725 Measure 0! Ieverend 015970.98 B. Fran! Cushian Maintenance item Standard Repairing Limit Remarks Front cushion Under Out. din. 11367-11384 11.85 distance coiior 04711—04718 I 0.467 Under dislunce collar Clearance 003670.090 0.2 and under bush 0.0014~0.0035 0.008 Pivot collar Out. din. 13967713384 i 13.85 05499415506 ‘ 0.545 Pivot coiior and pivot Clearance 003670.090 l 0.2 bush (10014700035 0.008 Front cushion Stroke 36.0 1.417 Front cushion damper Dumping force * 10715 kg Cushion speed 22.05—33.08 1b 0.5m/s ** 207251“; 44.10—55.13”) on capaciry 9.5 c.c. 1160 Spindle oil Front cushion spring Free isngrh 122.5 117 4,823 4.606 Tension 76784 kg Height 74.9% 167.58~185.22|b (2,749 in) C. Front Fork, Steering, Tank Maintenance Item ‘ Standard ‘ Repairing Limit Remarks 1 i sreering head stem hut ' Tightness 6.54.0 kgm ' 47751 frlb Steering head Angle 90D ‘ Angle between i trident & pipe Custer 63° 1 Trail * 70 E #* 75 Fuel tank Capacity * 3.0 fl ** 6.0 2 D. Frame (Main) Maintenance hem Standard Repairing Limir Remarks Steei ball Out. din. 3/16 21 each tor Upper and lower Rear lork pivot boliI Iniet dia. 10.1‘102 10.4 bush 03976704016 0.409 E. Saddle, Stand i Meinienence Iiem 1 Siandcrd inepomng LinrirI Remarks 1 1 1 Main skmd spring Loud 1519 When med 1 1‘ 33.07511: Reor broke pivot pipe om. dio 167046.78 16,2 (16575706606 0,638 Rear broke pivot pipe c1eorance 012—04 1.0 and mom scond 00047—00157 0.039 F. Rear Fork, Chain-Case 1 Muinrenance ham 1 Siundmd Repairing Limit‘ Remarks 1 r 1 1 Rear brake iorque iink 1 Hoie ‘ 12.271214 1 12.8 Rear 1ork side big end 1 048070.488 0504 Rear broke ioreue link Ho1e ‘ 10.17102 1 10.7 Torque bolt side smo11 end O.3976»0.4016 ‘ 0,42 Drive enoin Amouni of sag 10720 03970.79 6. Rear Cushion Maintenance hem ‘ Smndurd ‘ Repaiving Limil‘ Remarks ‘ 1 Rear cushion Snoke 1 * 633 r 1 2.5118 11* 62 ‘ 1 2.4409 Reor cushion spr1ng Free lengm * 205.1 1 193 8,0748 7,598 1 ** 211 206 i 8,3092 1 8.110 Tension * 48 kg Height 165.1% 105.84 lb (6.5 in) ** 46.2—51.019 Heigm 17%: 101.877112.46|b (6.7321n) * angle Devimion from righo 4 1 1 H. From Wheel Mainienanee irern srandara Repairing Lirnir Remarks From whee] hub bull Axial play 0.005 0.1 bearing 0.0002 0,0039 Radial play 001470.015 0.05 0.00055—0.00063 0.002 From brake panel oiir. dia. 1597645994 159 spacer 06290-06297 0.626 Free lenglh * 22.9—23.1 052016709094 ** 27447.6 10787—10566 From brake panel bush Clearance 0006—0051 0.4 and panel spacer 0.0002—0.002 0.016 Brake com Thickness 6.0 0.236 From broke shoe Om. did. * 118.8419] Cuner out die. 4.677—4.693 ** 109271095 4299—4311 From bloke lining Thickness 3.5 2.5 0.133 0.098 Broke drum In, dia, * 11934202 123 411774.732 4.543 ** 10913—1102 113 4323—4339 4.449 Brake shoe spring Free lengrn * 40 44 1.575 1.732 ** 23.7 33 0.933 1.299 From axle Om. die, 995—100 039270.394 Bend 0.2 0.5 Boltlh ends supporl on v block, mea- 0-0079 0-0‘97 sure bend a1 cen- ler part Fronr wheel rim Lareral deflection 1.0 3.0 0.039 0.118 From ryre Air pressure 1.5 Ira/cm2 1-2 zzlb/in2 17 I. Rear Wheel Maintenance Hem Slondavd Repairing Limil Remarks Final driven sprockel Rom diameter 154171546 1526 60669—60866 6.00 Rear wheel hub been Axial play 0.005 0.1 #6301. #6003 ing 0.0002 0.0039 Radial play 0.014—0016 0.05 #6301 0.00055A0.00063 0.002 Rear axle dislance Lenglh * 56.9—57.1 collar 2240—2248 ** 54.9—55.1 2161—2169 Rear wheel axle Oul. dia. 11957—11354 04708—04718 Bend 0.2 0.5 Bavh ends “V" block 0.0079 0,0197 supportmeasweal cenler pan bend Rear brake shoe Our. dia. * 1188-1192 Curler our dia. 4.677—4.693 1” 109271091: 429974.311 Rear brake lining Thickness 3.5 2.5 0.138 0.098 Rear brake shoe spring Free lenglh * 42 44 1.575 1.732 ** 28.7 33 0.933 1299 Rear brake cam Thickness 6.0 0236 Rear brake pedal Tread margin 20—30 078771.181 Rear wheel rim Laleral dellecion 1.0 3.0 0.039 0118 Rear lyre Air pressure 2.0 kg/cm2 1.5 2ESIb/in2 21 DISASS EMBLY AND ASSEMBLY In this chupier, mainly Disassembly operaiion was explained, and (or assembly special attention was only called lor where needed, as both operaiion are similar. Procedure for Disassembly operoiion For item if not clarified iis model, it means each model is common. Procedure for Assembly operation General and common cauiion Tools CONTENTS ENGINE: Mounving and Dismounling ............................... ENGINE: Disassembly and Assembly A. B C‘ D Cylinder ................................................. L Cover ............................................... ENGINE: Minor Disassembly and Assembly A Cylinder ................................................. Crank Case ................................................ Disassembly and Assembly Handle .................................................. From Fork ................................................ Rear Fork .................................................. Minor Disassembly and Assembly Front Fork .................................................. Rear Fork .................................................. 21 39 41 44 47 48 — NOTE — To disassemble any parts of engine, you should do it alter dismounting engine, except for the operation as A, B or C item where parts could be taken out without dismaunting engine to proceed the operation as related in the corresponding item. Parts which require disassembly are listed below. l . Operutlon 2 Item Model 100-102 l Model llO~lIl P'j’ffllure i Refer to 4? Front cover Fig. 2—] c 3 Carburetter ‘ inlet pipe Fig, 2—2 <. Dust guard l Fig, 2*3 i Exhaust pipe l Exhaust pipe Fig, 2—6 g a l Front cover . Fig. 2-1 5 Step bar ‘ Step bar Fig. 248 I 4 Gear change pedal Gear change pedal ‘ Fig. 2—12 l m L, Cover L. cover Fig. 2—13 l Front cover Fig. 2~l ‘ g Step bar Step bar ‘ Fig. 278 8 Exhaust pipe, Muffler l Exhaust pipe, Muffler l , . . Flg 2~6r7 n= [ (Ex. 110) 0' Kick starter arm l Kick starter arm Fig. 275 (Ex. l02) l Clutch wire (Ex. ill) Fig. 2—4 l 1. ENGINE: Mounting & Dismounfing Disassembly Assembly Precomion Operation Opemlion Tools 1. Model 100’102 From cover 10% Socks! wrench 17% Socket wrench 2. Model 100-102 Carburener selling Tighlen bolt rm! to When dismounling nut leak gas. carburener be shut Model 110-111 fuel cock. lnlel pipe selling Tightening Torque boll 0.65 kgm (60 ln. lb.) 10% Spanner 3. Model 100-102 Dusl guard ‘ 10% Spanner 4. Model 110 Clutch wire Cross head driver (53) 10% Spanner Fig. 244 Disassembly Operafiun Assemply Oparul‘oin Precmnion Tools 5. Kick smrfer arm 6. Exhaus. pipe ioim nut 7. Mufiler a. SVep bar To insen ihe serration fit the ma rk punched. Tigmen bolt no. leak exhous. gas. Tigmening Torque‘ 2‘7 kgm (18 n lb) lo 10% Spanner 10% Spanner 10% Socket wrench 14% Spanner Disassemb|y Assembly Precuuvion Operation opemnon Tools 9. Brake pedal spring Driver (cross or [are head) Fig. 279 Wiring ioini Model 100 Fig. 2-io Model Ho-‘Iil i Fig. 2-H ll. Modal 102 Wiring with Seren. LL High tension terminal b. Sicriing model cubie c. Cross head driver (#2) 10% Spanner Frg. 2—12 Disassembly Operation 12. Gear change pedal I3. Lt crank case cover Model 102 L. crank case rear cover 14. Drive sprocket Drive sprocket Cover t Fig. 2715 Assembiy Operatian Fixing angle. serotion inclination foreword from horizontolt To connect drive chain, be sure split part of iotnt clip to locate on the other side of rotational direction. (arrow marked) Precaution Tools i0% Spanner Be sure not to slide screw head. Cross head driver (#3) 10% Socket wrench Pliers Disassembly Assembly Precuufion \ Operation Operation Tools 15. Nui, rear engine Tigniening Torque unde! bol' a 1.5~2.0 kgm Nut, rear engine (IO/~15 ft lb) supper! boH A b Model 102 Earth cable is fined by nui and rear engine supperi be” A. 14% Sockei wrench Fig. 2‘17 16. Rear engine under Remove quietly sup- boli poning engine. Rear engine suppori hole A 2. ENGINE: Disassembly 8‘ Assembly Disassembly Assembly Frecauiion opemnon operuiion Tools A. Cylinder Oil iaint bolt A a Tightening Torque Cylinder head 0.7 kgm (5 ii lb) cover bolt b 10% Socket wrench 2. Cylinder head To fix cylinder head cover ass'y cover, confirm the push rod bull end fits properly to Rocker arm. Push rod T Long Push rod to be used on the righi sidetacing foreword. 10% Sockei wrench 3. Cylinder head To fit cylinder head, setting nut 4 nuts should be tightened succes- sively referring to Figure B waiching compression leak. 10% Sockei wrench Tightening Torque Measure wiih Torque wrench Tightening Torque 0.8 kgm (5.9mm Disnssembly Assembiy Opem'ion Operulion Precaullon Tools 4. Cylinder head ass'y )n case of assembly, be cauoious about oil leakage (rubber packing a., “O" ring b., and com- pression leakage (no! :0 bike the cylinder head gus- keo). 5 a Cylinder I inserting piston imo cylinder be sure to avoid cutaway of pision ring no! on me thrusfi diredion of pisfion and insert in 3 parts as top, second and oils 6. Pisvon Take special attention not to drop pislon pin clip info cases Thin nose pliels Disassembly Assembly Precumion ' Opewfia» Operation Tools In ussemblying piston, arrow mark on lhe lop surface of pis- lon should point along foreward. To m pislon ring on pisloh, Ring mark (arrow) should point upward‘ Fig. 2‘23 5. L. Covur Model IOO-HO-lll L Flywheel selling nul Tightening Torque 2.7—3.0 kgm (19722 lllb) Flywheel holder 17% Socket wrench 2. Flywheel Be carelul nol lo give shock lo crankshaft and llywheell Flywheel puller Fig. 2—30 Disassembly Assembly Pramurion Operation Operation Tools 3. Siarier uss'y Screws be iightened evenly. Cross head driver (#3) Model 102 I. Primary chord Cross head driver (#2) 2. L. crank case cover Cross head driver (#3) Fig. 2-33 3. AC. Dynamo siorter In assemblying sinner, ass'y be coreiul no! 00 blre eleciive wire sysiem, Cross head driver (#3) Fig. 2-34 r i Disassembly Assembly Operation Operation Precuufion Tools A.C. Dynamo roior seHing bah 5. Spark advoncer 6. A.C. Dynamo rmor Fig. 2-37 ’a 7. Skirting sprocket Fir woodrufl key set plane a securelyr Woodrufi key b 14% Socket wrench Dynamo holder Dynamo rotor puller 107‘. Socket wrench Fore head driver Disassembly Ope ra lion Slarling molor 9. C. Slarling sprocket R. Cover I. 2. R. crank case cover Washer Clulch lever Spring Oil guide Ball bearing Bearing shell Model 110 on guide Ball bearing Bearing shell Assembly Precaul'lon opemllon Tools 10% Sockel Wrench Tlghl cover evenlyl Cross head driver (#3) Model 100402-11! As clutch lever fixing is serralion syslem, be careful to locale it along AA'Jine as shown In the Figure. Fig. 241 Disassembly Assembly Frecauvion opermion Operarion Tools 3. Lock Washer Turn the end of Iovque offer iighiening the Locknul periecriy, if no! «he rorque and nut coincides each ooher lock it turning to ihe righrening direction wiihour Toosening nUL Fore head driver 4 Clutch ass'y | assemblying, slid- 3 ing pans of dutch center and drive gear shouid be oiled thoroughlyr C‘ufich outer holder 14% Lock nut pin spanner ‘k 5. Primary amen gear see ring pliers 6. Kick smrter spring 599 ring pliers Fore head driver ,fi Disassembly Operation Assembly Operaiion Precuuiion Tools 7. A smn drum stopper 3. ‘ Gear shin spindle ass'y 9. Oil strainer Cam gear, Cum shah Tigh‘iening torgue 0.7 kgm [5 ft lb) 10% Sockei wrench Fig. 247 Checkposiiionoigear On shm arm claw be disassembly, oil drains out thru hole even distribution on boih sides io ihe shift of gear shin spin- die, pan. arrange oil pin of gear drum. On assemblying gear shift spindle check the movement or 3 poznis (a mark) and no sign of shifi reiurn spring pin b. Fig. 2—49 Cam gear seiiing bolt Tighiening torque 1.a~2r1 kgm (13~15H|bl Fig. 2—50 Disassembly Operanon Timing gear D. Crank Cate Gear shift drum seHing bole Assembly Precauiion Opemvion Tools To combine cam, rim- ing gear, be sure to face to face each mark. Disassembly of R. Li Case, is possible wivhouv taking ofi timing geurr Timing gear puller 10% Socket wrench Knock in 1iming gear. Timing gear driver Hammer 10% Socks! wrench Disassembly Assembly Precaution Opemflon opmnon Tools ‘ 2. Crank case sefling Tighlen evenly, screw & bolt Cross head driver (#3) 10% Socket wrench ‘ / ufimnk case Check smooth rotation Kick starter spindle 90 be set in crank case a! a. b. locu- fion. Disassembly Assembly Precamion Operation Opevafian Tools Way 0! setting to crank case. Way of selling of gear shift drum. Fig. 2—60 3. ENGINE: Minor Overhaul and Assembly Overhaul Assembly Pracamion Opermian Opemlion Tools A. Cyllnder 1. Valve Valve lifler Rubbing of valve 3. l. Covor 1. Medal 100-102-111 Clulch Under fixing slew of clutch, check the drive gear rotates smoothly when lurnA ed to lhe arrow direclion and ad- heres when lurned to the opposile direclion. Valve seat Culler Cutter holder Model 110 To assemble cluvch, prepare lools shown In vhe picture. Fig. 2—63 Overhaul Operalion Assembly Precuulion Opemiion Tools C. Crank Case 1. Transmission gear 2. Gear shill drum pin Kick slurler spindl a In selling be cautious for lroni and back surface of gear‘ In case of rolulional dkeciiorl is fixed by spline be cau- lious in selling for fillness wilh spline groove, and in case of axial direclion is fixed, be caulious for spline washerl Ring center a puriAShorf pin} b porl~|ong pin are needed in fix- ingl Serruiion filling wilh kick svcrler rachet Check all hole of spindle be localed on the same line with rachel gap, 4. FRAME: Overhaul 8:. Assembly Disassembly Assembly Precaufion Operaoion Operulion Tools A. Handle 1. Thronle cable 2. From brake came 3. Model IOU-102 Speedomewr cable Pliers Hg. 2-69 4. Model 110 Clulch wire Dlsassembly Assembly Precaution Operation operulion Tools Figr 2-7l Fig. 2773 loinl of wiring Cross head driver (332) 6. Model IOU-IO? Handle serling rlul Tighiening Torque Model “0-1” 3.0 kgm (20 fllb) Handle serllng boll Model 100~102 14%. Spanner Model 110-111 10% Socket wrench Model llOrlll To m Handle, punch mark on lire pipe should be localed on lha border be- tween upper holder and Under holder, Model llo-ill As Hand selling boll, longer boll lacing driver in driving should be used posture. Sal and clip wire and cable securely. Disassembly Operation B. Front Fork 1. Model llO~lll From brake torque link 2. From wheel axle nu! ‘ 3. From wheel Steering handle uss'y Assembly Operalicn Tighlening Torque 3.0 kgm (20 n lb) Tlghlening Torque 3.54.5 kgm (25—35 H lb) Before filling, grease on ball bearing pelleclly, and also inside panel slightly. Refer. A. Precmmon Tools 14% Socket wrench 77% Socks? wrench Be careful for Bear- ing in the wheel hub not lo gel dirt on lhe ground. Refer, A. Fig. 2—74 Fig, 2—76 Dlsussembly opamnon Assembly Opeyavion Precumion Tools 5. Head lighl case 6. Model llO-lll Speedometer Fig. 2775 7. Model 100-102 Sleering head slam nul a Aher inserting each cable, set by spring. Tc: loosen siem nul, it is early done by tightening top lhread a little by pln spanner. 10% Sockel wrench Cross head driver (#3) Pliers Disassembly Opermion Assembly Operation PVSCO Hon Tools Mndnl 110 111 Sveering hem sum not Fcrk mp bridge plate sening bolv Steering head (0;) thread sreen’ng mp cone ruse On threning, be Carer ful not 00 have play on hand‘e, and also no! to be heavy. Wipe out diny grease and nu up new grease. 29% Socket wrench 14% Socks! wrench Fig. 2-83 Fig. 243: Dlsussembly Operalion Assembly Precaulion Operalion Tools C. l. 4. Rear Fork Rear brake torque link a Rear brake rod 1: Axle nul Rear wheel L. Rear cushion Don't forget ro'ch cllp afler lighlening nul of Torque llnk boll. 14% Spanner Sel lorque link on Wheel can be luken panel belore nut is our w‘llhoul lak'lng 'lgl’nenedl ofl Rear axle sleeve Axle nut Tighlenlng null Torque 3.54.5 kgm (25—35 ll lb) 17% Socke) wrench Afler greasing on Ball Bearing, and inside panel sligmly, fix ll pulling will. all seal and Orring. Tlghlening Torque 4,5 kgm (30 ll lb) nag, Sockel Wrench 17%. Spanner Disassembly Operufion Drive chain cuss 6. Finish driven flange ass'y 7. R. Rear cushion 5. Rear axle nut Rear fork pivoi boil Assembly Opemiion Rear axle sieeve mic Tigmening Torque 6.07615 kgm (misomb) Refer. CV4 Tigmening Torque 4.5ka womb) Tigh'ening Torque 6.0ka (40h lb) FrecauHon Tools 10% Scale! wrench 23% Spanner Refer. C—4 17% Socket wrench Figi 2790 Fig. 2—91 Disassembly Asssmbly Opevalion Operation Precuuvion Tools Drive chain case puckr ing should be fined securely. 5. FRAME: Minor Overhaul 8-. Assembly Disassembly Assembly Plecuufion Oparaiion Opelaliun Tools A. Handle 1. Model 100-102 speedomeler Pliers 9% Spanner I: 2. Thronle wire Belore assembly pm grease on rhrcme cable hinge and in ‘ throttle grip pipe. Before assembly feed oil rhoroughly wire and cable to move i lightlyi Cross head driver (#2) Fig. 2794 i 3. Fran! Fork r 'I. From fender Tightening Torque i 3.0 kgm (20mm r r r l ‘ 14% Spanner ; 2i ‘ From cushion, In assemblying don't lnslolling or removal Front arm oss'y lorge! io grease. is same spot as No. l 14% Spanner Disassembly Assembly Pvecaulion Opemllon Operation Tools 3. From arm Be caulious mere are R. L 14% Sockel wrench 4. From cushion C. Roar Fork l. Rear cushion Pan should be re- placed as unit if found delecl or (18‘ lormalion on Dum- per red of Damper or oil leak, Adiust angle wrench Pan should be re- placed as unit if found delecl or deformation on Damper rod also any grease or oil leak from rod purl. Model 100-102 19% Spanner Model 110-1” 21% Spanner CONSTRUCTION CONTENTS Lubricating System A. Kinds of Lubricating Method B. Lubricating system adopted by HONDA 50 Cam. Valve mechanism Transmission A. Operation and kinds of transmission B. Mechanism and function at Transmission at HONDA 50 Clutch A. Kinds of clutch B. Mechanism and function of clutch of Model 100, 102 and ill C. Same for Model 110 Shilt mechanism Coupling mechanism at Kick starter and Gear Auxiliary Equipment A. Breezer B. Starting mechanism of Model l02 Carburetor . A. Model 100, lOQ, Carburetor 8. Model 110, ill, Carburetor Front Cushion Rear Cushion A. Model l00, lOZ Rear Cushion B. Model l l0, l l l, Rear Cushion Brake System ... ... 53 53 55 56 56 59 59 62 64 65 66 66 67 70 77 78 78 79 'I. LUBRICATING SYSTEM A. Kinds of lubricating method There are several methods to lubricate engine, The first one is called spraying method by which oil sprayed simply by spoon attached on the big end of connecting rod, the next is called pressure method by which Oil is teeded by pressure to Crank shalt and Cylinder head etc, and the third one is pressure spray method combined above two methods. As (or pressure feed pump of Lubricating Oil, plunger pump ar gear pump are generally used. On the other hand we classify them Dry Sump method and wet method, the iarmer having outside oil tank with feeding, and returning pumps and the latter having crank case as Oil pump, 5. Lubricating system adopted by HONDA-50 We adopt wet sump method by connecting rod and mission gear and at cylindar head semi-compulsory lubrication IS done thru spiral groove on the camsholt bearing part. Lubricating system is divided to 3 parts. Cylindr, piston Lubricating oil is teeded by com gear rotation thru bottom at right cover to oil strainer complete, then to crank case sump, at where oil is scooped and sprayedto cylinder, piston and crank shaft by oil splasher extended from the big end at connecting rod. (Fig. 371] Cylinder head Lubricming oil feeded by spiral gmove on the bearing surface of com shun ihru oil pipe up to upper purl of cylinder head cover, to |ubricate rocker arm etc and return rhru rerumxng hole in Cylinder Head down Io crank case sump. (Fig 3—2) ‘ Transmission Each gear and lower pan of clutch are immersed In on and lubricared by spray on relation MEMO 2. CAM. VALVE MECHANISM . i inlet and Exhaust valve inclined each other opporedly in ihe dome shaped combus- tion chamber is operated by Rocker arm thru cam gear, valve lifter and push rod. This iundamenial mechanism of 4 cycle engine can endure high speed rotation by smooth operation and ample lubricaliani To male liming gear and cam gear, punch marks on each gear should be face to face to adiust valve timing. 3. TRANSMISSION ‘ A. Operation and klnds of transmission Transmission to transmit power is the media to convey torque by meshing gears of difierent teeth each other. In case of combination of small gear (teeth A) of driving side [as Fig 3—5l and larger gear [teeth Bl of driven side, the driven side rotation decreases with transmitting large torque. We define this ratio of each teeth of gear as reduction ratio. l Reduction ratio=A/B ’ Torque ratio : B/Ar Fig.37 5. There are two kinds in meshing transmission gear used for autobicycle, ie, selective sliding type and constant meshing type. The former type is to change reduction ratio properly by changing meshing gear each other by sliding shift gear operated by gear shift fork. And the latter is to do by operating arbitary gear thru a kind of clutch where each gear rotates freely in meshing. B. Construction and function of Transmission of Honda 50. Advance 3 steps of constant mesh type was adopted so to develop climbing and acceleration performance fully corresponding to engine power. 5 sets of mission gear gear set on main shaft and counter shaft are fixed to the rotational direction by spline or are fixed to the axial direction by set-ring. For the former type need pre- caution for mating with spline groove, and for the latter be sure to fit thrust washer and smooth running. FUNCTION OF TRANSMISSION Low Main Shaft —>Low gear‘arransmission gear shiftter —>Coumer shaft. Fig. 3— 6. Second Main Shah—>Trunsmission shining geuHSecond gear» Transmission gear shifler—>Coumer Shaft. Fig. 3 - 7. Top Main shcfl—> Transmission shifting geu£—> Mum shah top gear—> Counter shun 00p gear—> Coumer shun. Neutral Fig. 3 , 9. CLUTCH Kinds of Clutnh Clutch is located between engine unit and transmission gear to change speed, also to cut or connect power at any time as starting. Therefore it is important feature to have smooth Cutting or smooth connection in the course of changing without slipping. There are several type of clutch as cove clutch, centrifugal clutch, single plate clmch, multi-plates clutch, and they are classified as wet system or dry system according to its use of oil filled inside or not. Construction and function of clutch of Model 100, 102, III. This is a centrifugal type automatic clutch, the clutch can be disengaged and engaged by operation of the change pedal. This is also connected to the transmission for shilting gears. Fig. 3—10. The clutch assembly can be broken down into 3 sections described below. Clutch center & drive gear These serve to hold clutch stationary when ushingkick starter and when enginevbruking, and has screw-spline type operation in order to disengage clutch when engine is re- volving at low speed (when centrifUQal force is smallli Fig. 3-114 Centrifugally operated parts & clutch free spring The special feature of this clutch is that when it rotates faster than a certain speed, the mechanism The 8X10 roller pushed out by centrifugal force, move in the direction of arrow l| along the tapered face of drive plate and press against the clutch plate, This centrifugal force action is stronger than the spring of clutch springs and furthermore the faster the revolution the stronger this force gets. Something is needed to resist this centrifugal force in order to disengage clutch at low speed re- volutions, as this centrifugal force operates as soon as the crankshaft rotates, The clutch spring does this operation The operation diagram, concerning to the engine r.p.m. torque and centrifugal clutch is shown in Fig. 3-12. 0.34 (2,46) XATorqve curue Y—Ciutch operation curve a—Clutch starts to engage b~C|utch engaging point. 3. Clutch outer & drive plate The drive plate fixed to the crankshaft is the main component of the clutch assembly. The clutch arm, which is attached to the drive plate through the clutch spring by tour 5X8 hex. head bolts, is connected to the shift arm which operates by the change pedal when pushed in the direction of arrow III in Fig. 3— 10. This disengages the clutch, regardless of ' V the relations described in previous paragraph Fig. 3’”. A and B. In this case the clutch lever can be moved up or down in the direction of arrow IV, and the changing of trans- mission gears is theretore done by always disengaging the clutch, without causing under strain during operation. Construction and funfllon of clutch of Model 110. The clutch ol Model 110 is wet single plate type. You will find clutchvouter (D by opening varanck case cover as shown detail Figure 3—H and cross sectional Figure 3—15. In clutch»outer, clutch spring ®, drive plate ®, clutch plate ® and clutch friction desk @ are assembled. Teeth inside of friction desk mesh with spline cut on outer periphery of drive gear ©, and combined as Unit along rotational direction with drive gear which is mounted on crank shalt through clutch center guide ®, and can rotate freely. Fig. 344. Fig. 3715. On the other hand, groove inside of drive plate mesh with spline cut on crank shaft end, and combined as a unit tighten to Crank shaft by Mmm locknut. As Teeth an oufer side of drive plate & clutch plate, mesh with teeth inside of clutch outer, clutch outer, drivevplate and clutch plate rotote as a unit with crank shaft. It clutch is not disengaged, @. @, (4) are combined as one unit due to mutual friction by clutch spring. MEMO Accordingly rotational force of crank shalt is transmitted to drive gear. As drive gear mesh with driven gear, power is transmitted to Transmission. When handle clutch lever, lever turn to the right through clutch wire, and clutch litter ® moves inside by action of clutch cam plate (3 and’clutch ball retainer ., acordingly as clutch outer pressed through oil-through-complete @, function clutch spring become functionless. So that drive plate clutch plate and friction desk become free respectively. Therefore rotational motion of drive plate and clUtch plate is not transmitted to friction desk and drive gear remains stationary not transmitting power. Here clutch damper spring ® is fitted laterally for the purpose of prevention from knocking sound due to play at rotational direction between drive plate and clutch outer and also from wear of gear teeth. Oil sprayed by gear and clutch outer is sumped in clutch oil throngh and poured into crank shalt thru the end to lubricate drive gear and crank shaft. 5. SHIFT MECHANISM Pushing down change pedal (Fig, 3-16], gear shift Spindle ® is rotated, Then gear shift arm ® turn drum at the end of claw by pressing dOWn drum pin fitted on gear shift drum ©. As shift fork ® is fitted on shift drUm and the end of shift fork guide pin ® fixed on shift fork meshed with central 2 grooves on. drum; shift fork moves to and fro . —l6. 9 3 along the groove by drum rotation to let shifter and shifting gear move, Here gear shift retUrn spring © serves change pedal to restore original position and prepare the next operation. Shift mechanlsm of Model 100, 101, 11 I. By pushing down change pedal, engaging 8: disengaging of Clutch and changing of mission gear can be operated at the same time. By amount of 10° operation of change pedal ® engaging & disengaging of clutch is done and by 9°15’ changing of mission is operated as shown in Fig. 3—17. Clutch lever (2) is operated with change pedal to rotate cam plate ® and disengaging and engaging of clutch is done firstly by lift on plate and cam. =:.. ‘L_I7 6. TRANSMISSION MECHANISM OF KICK STARTER AND GEAR This type meshing kick starter pinion into low gear makes kick starting easy and iight and can by Utilizing the transmission gear causes very linie troubie. Fig 3—18 shows the gear train from crank shaft and the rotational direction and shaft position. (1) Timing gear ® Cam gear @ Drive gear @ Primary Driven gear (3 Main shaft © Shining gear {7) Main Shaft rap gear Fig. 3—13. Counter shah ® Low gear (19 Second gear ® Counter shatt Iop gear ® Drive sprocket ([3) Kick starier spindle ® Kick sIarter pinion. l l I l 7. AUXILIARY EQUIPMENT Breegar The path of breezer opens inside of drive sprocket thru center hole passing 2 holes of 1.5125 inside Transmission main shaft and back pressure is released thru 395 gas hole. As this 3¢ hole is con- nected with center part of main shaft, oil inside the shaft can be separated by centrifugal force due to rotation. Fig. 3—19. Slaning mechanism of Model 102. For the model 102,7it is not equipped with kick-starter but is driven by over running clutch by action of starter motor. The over running clutch is fitted on the crank shaft and can transmit rotation of starting motor but not transmit rotation of crank. As shown in Fig. 3»20. (ll When the sprocket ® rotates to the direction of arrow the roller ® bites on crank shaft ® and crank shaft is driven. (2) When the crank shaft rotates faster than sprocket, rollers are pushed outside by centrifugal force, pressing roller spring @ due to taper inside groove of clutch outer © and become stationary with no connec» tion to crank shaft. 8. CARBURETER A. Carburetor of Model 100, 102. This is a down type carburetor, which draws down towards the horizontal type cylinder and the venturi is of unique elliptical shape, increasing stability at low speed and high speed performance. The carburetor :5 installed onto the cylinder intake through the carburetor insulator, with packing and a ”O" ring between the insulator and carburetor, which prevents intake air leakage. The air travels at speed at about 15 m. per second through carburetor at 5,000 rpm and as this is delicately constructed to insure proper air»tuel mixtures, special care is required in handling. 1, Throttle apenning adjustment Fig. 372] illustrates crank revolutions and carburetor operating parts in proportion to the throttle opening, against venturi, which is most important in developing fuel-air mixture. Adiust the operating part, according to rpm when revolution is not smooth. A B C 5m 4/4 ‘ a a i l - l “M my AiNo. ot revolution of rank l 2% b B—Throttte opening momma ceommiing parts l _ aiMaln is. l 74 7 ‘ 41500—50170 / c b Jet needle Hall—M00 v } d diPilot iet fl Fig. 372]. 2. Idle speed adiustment \l Fig. 3723 illustrates the necessary lunction to stabilize idling (up to 2000rpml. This is odiusted by the air screw (D and throttle stop screw (2) shown in Fig. 3—22. Idling revolution is 800~1000 rpm I Turn to the right Turn to the left I CD Mixturewill be richer will be weaken l ® Revolutionwill be higher will be lower 3. Accelerating adjustment (Fig. 3e23llll. Engine trouble during acceleration is caused more in the ignition and valve system and it is wrong to attribute this only to the carburetor. When the trouble is in the carbureter, adiust this by throttle valve cutaway ® and let needle @ and needle let ©. 4. High speed adiustment (Fig. 3723(1)). Almost all the trouble at high speed is caused by the main iet ©. I Check ignition and valve systems first before adiusting, as in the case of acceleration. 5. Others (Fig. 3723 (i) (2)) (ll On the bottom (D of float chamber, there deposit a chemical compound of 4- ethyl lead which contained in gasoline and toreign ingredients, if these are not removed it causes failure due to stopping gasoline teed. Therefore it is favorable to clean carburetor assembly once within 6 to 8 months. [2 It the slottle valve is weared or the pilot iet ., air bleed opening (53 in chocked it causes failure in idle runing. For carburetor trouble (not only the case of failure of idlingl clean with air blowing. (3) This carburetor has fuel cock on the float chamber. Also clean the filter in the cock and passage oi gasoline. NotestiAs Carburetor is like human respiratory organs it works very sensible. Arid iust like human catches cold Engine occurs blowing-back or failure in suction at carbureter. In handling carbureter Special attention is needed and advisable to consult with ex- perience servicemen. Air rouce Fuel name 1 I ”h \ $7M *‘ 4 li/iflflflflfl __1 ,” a EU t/Wtruvflg» \ V. ,. ¥ m 9 @/fi , O“ 6 r I : Fig‘ 3723(1). Om, r Fig. 3—23 (2). 1. Carburetor of Model 1 'IO, 1 10. Construction ll] Mei” syiiem (Fig.3:2i Air passing through the air cleaner is inhaled into engine side from the suction throat ® as main air stream passing under the throttle valve (6) and .. By this air stream there occUrs negative pressure at needle jet (AD, and fuel in the float chamber ® is sent to the needle, iet holder ® through the main iet .. Here it is mixed with air (bleed air), which comes in through the holes ® arolJnd the needle iet holder © passing through the air-iet ®, and pours out under the throttle valve passing through the gap between needle iet Q1) and let needle CD. 12} SBw-isystem‘jf’ilot systemtiig. 3724). Air passing through the suction throat ® flows through outer side ® of air screw ® by which volume of air is controlled and then flows into slow iet ® through its holes ® and mixed with fuel from fuel-hole ® underside of slow iet @, this rich mixture spray out at the base of throttle valve and again mixed with main air stream from the suction throat I to charge into the engine. (3] Float chamber (Fig. 372“. As explained above caburetor produce suitable mixture gas corresponding to each throttle opening and engine revolution. For this purpose it is required to keep surface of fuel level constant. To do this function is the duty of float chamber. Explanation for this function is as follows. Fuel feeded from tank passes through passage (IE, to the float chamber ® through the valve sheet @ and the valve .. As amount of fuel increases the float ® get buoyancy to stop more fuel flowing in by action of the valve at valve sheet which was pushed up by the float arm @. On the contrary, if fuel in the float chamber is consumed the float comes down as the fuel level goes down. This causes to open the gap between valve & valve sheet to feed fuel into the float chamber again. Repeating this operation the float chamber can keep constant fuel level. In this valve a spring is set at the float arm @ to increase vibration resisting charactar. (4] Choke (Figigfl When engine is in coal state or siarting in cold season, rich mixture of gas is needed Iernporarily. For ihis purpose we use the choke. We experience engine stop right char sianing or over sneiion by ihe conventional type of choke, But «his choke has not such irouble and can get adequate rich mixture according to the Ihronle opening during choking, and makes ii possible to warm up engine without iniricate hondiing, and upon finishing warming-up put Ihe choke full open simply. Mf“ Pushing the choke lever up to the full shut position the choke @ comes down to shut tully. The relief valve (3) usually stays to shut the window (5) by the Fig. 3—25. spring ©. When the throttle valve (9 is opened about 1/4, and kicked, fuel sprays out lrorn the pilot outlet © and the needle iet ® due to suction negative pressure, and at the some time the relief valve G5) is opened [dotted part .1 properly to negative pressure to allow air flow in through the window © to give most adequate mixture tor starting. After the engine started, suction negative pressure increases, accordingly the relief valve '3' will open widely to feed ade- quate mixture to the cool engine, And the relief valve C8) opening will vary correspondingly with the throttle valve (D opening. {dotted part @l. 2. Function of each part. ll) Main let lFig.lE-'L.l Main obiect of the main let is to adiust to give adequate mixture rate of flowing quantity of tuel while throttle is tully opened (running at top speed), and not only at the fully opening, but this will aflect mixture rate to some extent at nrntInH 1/0 nnAninn (2t Air iet lFig. 3~24 ®) 13 {4 l5 (6 To prevent to be richer mixture at higer revolution (Throttle wide open) or to be weaker mixture at slow revolution, air is feed into the needle iet holder. The function of the air iet is to control amount of this air. At constant throttle opening, the more the air iet the less difterent of flow between higher revolution and lower revolution will be and absolute amount of flow decreases. Needle iet (Fig. 3—24 (D) At throttle tully opened and at medium speed the needle iet once more works to control luel alter controlled by the main iet. Its adiustment is done at the same time with the let needle which will be explained in the iollowing item. lts orit‘ice diameter is specially manufactured precisely. Jet needle (Fig. 3—24 (7)) The function of the jet needle is to control mixture ratio at the medium throttle opening (mainly l/4~l/2 opening) cooperating with the needle iet explaind above‘ The iet needle having a long taper port is fitted in floating state on the center hole of the throttle valve] and the taper end is inserted in the needle iet. There- fore it moves up and down according to the throttle valve, and due to tapering amount of flow of fuel is controlled to get adequate amount of flow, ie, adequate mixture ratio. These are 4 grades of groove to clip on it (from upward ist grade, 2nd grade, . . . 4 grade). As position of clipping is lowered from lst down to 4th, the mixture will be richer, Throttle valve (Fig. 3—24 (Q) The throttle valve controls amount of air suctioned by engine ie, engine, revolution and horse power. On the other hand its important lunction is to control mixture. There is a cut- away on the air suction side of the throttle valve. By changing the size of this cutaway {cutaway No.) negative pressure on the needle iet can be varied to change amount of flowing fuel accordingly mixture ratio can be changed. BUt this range ol function is between idling opening and around 1/4 opening and not efiective above 1/2 opening. Slow iet (Fig. 3—24 @l The slow jet controls flowing amount of fuel at idling state and lower opening of the throttle mixture is made by air coming through the orifice of the air bleed to make it mist state. “w [7i Air screw (Fig 374 @i The air screw controls air amount flowing in the slow system. It controls air to be mixed with fuel which passed through the slow iet to get adeqUate mixture and it pours from the end of the slow iet, 3. Adiustment Carbureter has to serve to develop fully the engine performance For this purpose it is needed to adiust to get most adequate mixture ratio for all stages of engine from idling to maximum revolution, aad have to keep this state all the time. To satisfy this purpose, special attention is paid to increase accuracy of all parts of carbureter and also friction resting character. These 4 parts of iet needle, needle iet, throttle valve and float valve are moving parts and are manufactUred to endure for use of long run without performance change by using special material to resist friction, and by fine machining and surface treatment, Adiustment and fitting of each part of car— bureter is dome by Us and carbureter maker thru strict performance test, So it is advis- able not to change them without sufficient cause But in case of newly adiustment, engine repair or of replacing with new part due to friction attention is required as related belowt (it Be sure each part of engine duely under adiustment. [Zl Check air leakage from fixing part of carbureteri (3) If found anyzwear in adiusting part due to friction, replace with new part. 4. Top speed adjustment Adiustment of mixture gas for the stage of throttle between futl open to 1/2 open is done by the main iet. To iudge rich or weak of mixture is done by the procedure shown below. [it While running with throttle valve fully opened, if speed increases by shutting the choke a little, as this is effect of weakness of mixture, you need to replace with next larger size of the main iet and check again, [2) On the contrary if speed decreases by shutting choke, this main iet is littable or too large the size. Judgement for this case can be done as follows. lat Fittable: if you take small main jet speed decreases, and increases by closing the choke, it means the original main jet is fittable than the small one, (bi Too large; Replacing smaller main jet consecutively to reach the condition like (at ease. 5. Intermediate speed adiustment From the throttle opening 1/8 to 1/2, the mixture is regulated by the height of throttle Cuttingaway and iet needle. But individual intermediate speed Control is dangerous as the Cuttingaway will also afiect lor the state under throttle opening 1/8. Fuel consumption becomes more economical when iet needle is lowered as much as intermediate speed accerelation be not worser. lll Jet needle (a) While runing at intermediate speed if unusual black smoke comes om in ex- haust, it means too rich and you must take one step lower of iet needle. lb) While accerelating or mnning, it you feel engine braking, raise one step upper of iet needle. (2) Cutaway ol throttle valve The more punched mark number, the weaker the mixture and vise versa. 6. Idle speed adiustment From the throttle opening US to idling, the mixture is regulated by the air screw and throttle valve cutaway. (it Air screw The mixture is regulated by air screw while in Idlingt Turning to the right mixture becomes richer and to the lelt becomes weaker. For adiustment of air screw not only idling case, but you have to warn also uneven revolution due to rich or weak mixture while throttle is opened slightly from idling. l2 Cutaway 0t throttle valve: At about, throttle opening 1/8, mixture regulation is hard sometimes. In such case take higher not of cutaway il mixture is richer and vise versa and adiust air Screw again, 7. Adiustment of Float position (it Placing the carburetor up side down, this is not correct float position of regular fuel level as the spring in the float valve is shrinked due to thrust from float value end at the flood arm by float weight. MEMO (2i Then tilt carburetor so as the float pin 69 stay Upper and the float (9 lower [3 position and hold position right before the float arm ® leaves from the float valve end '37 as shown in Fig. 3~26. [leaving point is about 70° from upside down position favorable margin is 50°~70°; within this margin the end of float valve ® does not shrink) Measure the height difierence h between lower end of carburetor CD and cure buretor body ©. There is no trouble abOUt performance it the accuracy of float position stays within 0.5mm up and down. lt deviated from this amount adiust the float arm part @ to bend with special attention. [719.5mml a ‘ Perpendicular line 9. FRONT CUSHION The shock absorber of the front wheel consists of oil pressure damper and coil spring around it, and spring is protected by spring case of polyethylene, In the front cushion damper 23 cc of spindle oil #60 is contained, and it works damping action to vibration by action oidamper piston with valve. Surface ol piston rod is chromerpiated machinedil smooth and titted with double lipped oil seal to prevent oil leclk. ® Bollom melal (zfi Bottom lock nut @ Spring case @ Front cushion spring © Stopper rubber © Damper rod ® Front damper fining nut (punch alter lightening) Front damper oil‘seal ® Damper rod guide ® Damper piston (13 Damper pision nut @ Upper metal complete ® Rubber bush ® Upper color Fig. 3—27. MEMO ,9, 'lO. REAR CUSHION At intermediate position connecting the rear fork and chassis it acts as cushionl The cushion is covered with metal botlom case and Heizex Upper case. Rear cushion of Model 110, 102. Rear cushion of Model 110, 1 I 1. ® Bottom metal (2 22mm washer ® Bottom case @ Spring © Rear damper inner pipe © Spring guide ® Rear damper valve stop ” piston ® Rear damper valve ® Rebound stopper spring (11) Rear damper rad guide ® Rear damper colar ® Oil seal ® Rear damper nul ® Upper case 03 Rear damper rod ® Stopper rubber ® Upper locknut (19 Rubber bush cover ® Rubber bush (2]) Upper metal ® Rubber ring ® Main pipe ® Grease nipple ‘I'l. BRAKE SYSTEM Reliability and endurance is the supreme condition required for Brake system. For this purpose, it is so to designed to increase friction coefficient between brake drum and its lining and made it easy to discipate friction heat. For iront brake right hand wire system is adopted and for rear brake, right leg rod system thru inside expansion shoe is adopted. = I/w, n ® Lever Rear brake arm iaim © Front brake wire (53 Rear brake adiust nut @ ” adiusr nut ® Brake com (4) Brake pedal ® Brake shoe ® Rear brake rod ® Brake lining @ In spring (13 Brake drum ® Rear brake arm Fig. 3730. Fig. 373‘. ELECTRICAL EQUIPMENT 2‘ Charging Circuit A, B‘ BoHery A. B. Model 100, 110, 111 Model 102 Model 100,110,111 Model 102 CONTENTS 85 87 91 93 ‘I. CHARGING SYSTEM A. Model 100, 110, 111. Alternating current generated by magneto goes to head lamp, tail lamp and meter lamp and a part at this tiows to charge battery. Alternating current is rectified to half wave current by selenium rectifier before going to battery. 1. Changing Coil Low tension coil separated into coil tor lamps and for charging. For night driving this generates atlernate current l6~8Vl direct to the head lamp, tail lamp and meter lamp to light these and the charging Coil generates alternate current day and night to charge battery. EELLOLFEPLQ‘USfl“ To iudge quality of the Charging Coil (Fig. 4—H connect the ammeter (reading about 2A] in series at the (use connecter (red line} and alter starting engine measure corresponding current to each crank revolution. l The standard charging volume corresponding to each revolution is shown in the lollawing chart. Comparing with this standard it there is excess or short at 20~30%, replace the coil. ML 1,500 3,000 6,000 8,000 ‘ Daytime ’ Charging current (At 0 0.2 1.0 1.5 '1 Charging current w o 0.2 0.4 0.5 , Night time : Lamp voltage (Vt 4.5 6.5 3.0 8.5 . N013: Be careful to center iron coil with stuter base, as with high tension coil, when installing. l i l i i i 2. Selenium ‘Rectifier This rectifier works to charge battery rectifying alternating current generated to one direction current, and consist of AIUminum plate or nickel plated steel plate on which, alloy of refined highly pure selen and rare element is painted or vacwm sputtered and after heat treatment under adequate pressure and then alloy electrode sprayed on the surface. Here on the boundary surface between selen and alloy electrode there raises special layer to act electric action as shown in Fig. 472 lAl and it conduct current easily from base plate to allay electrode through selen, but not almost to reverse direction. Therefore putting this mechanism on the alternate circuit, direction of current is rectified to one direction. a rtl w l m“,/ y .” )V A l . fAl [Bl u—lnsulating membrane biElecttic pole c—Selenium d—Ease plate of nickel plated or aluminum Fig. 4< 2. By removing the battery at daytime or running long distance at high speed without a fuse will cause reverse flow current towards selenium rectifier causing it to lose its rectifing efficiency and if this is continued for a prolonged period the rectifier will get hot and may break, Be Sure to check that fuse is not blown out and is properly installed, If battery discharges too often, check not only the coil, but also discoloring of rectifier and for short of terminals. After replacing parts, securely tightens terminals, a—lnduction voltage of generating coil b~Rectined current by selenium rectifier. Fin. 4— 3. 1. Model 102 Alternate current is generated by rotation of alternate current dynamo which is connected with crank shaft when engine is revolued. Putting the selenium rectifier between battery and alternate current dynamo, AC is rectified to DC to charge battery. The circuit of charging is shown in Fig. 4*4. BAT DY Dynamo Alternate current dynamo is at the type safe from any trouble, and can change power by switching combination switch. Point at diflerence of Model iOO from flywheel is that magnet is revolved inside the coil instead at magneto placed on OUterside of coil to generate current. That means magnets are formed as one unit having 6 extended electrode as shown in Fig. 475 (Al and wiring is shown. lBl. On the other hand for the stoter, the magnetic circuit is made of iron core having corresponding pole with that of magnetic steel pole, One coil for each pole, totally 6 poles is wound to make circuit and terminals are drawn as shown in Fig. 4—5 (Bl. Magnetic steel which is fixd directly on the crank shaft rotates at high speed while running, and generates Alternating current in the coil as the direction and strength of magnetic flux in the stater iron core varies 3 times in one revolutionl Electric power generated lrorn the dynamo can supply all electric equipment amply tor Model l021 but as the head lamp is not lighted usually on daytime, it is required to control generating power to be about AC 30W at 5000 rpm to avoid overcharging on the Battery. During night, it is so to destgned to generate AC 90W at 5000 rpm using all cails by combining yellow lead wire and white one. This current charges on battery through the selenium rectifier being rectified to DC. In cheking current by inserting ammeter at Battery terminal l-l—l, starting at l500~2000rpm l.5~3A at 5000 rpm (both Crank rev.) is standard lor day and night. (A) (B) a—stater [iron core and coil) eiyellow (generl use] b—coil t—white (available tar night use] c—rotar (magnetic steel) gebrown (common linel dvcrank shalt Fig. 4— 5. AC Dynamo Power Checking (Fig. 4—6) Preparation for tester: (1) Connect the Dynamo with load (2 res!stcnce tor dynamo power by cable. Connect lead wire of brown to), red lb] and white 1c] of load resistance with the ieod wire from the Dynamo. (Take out short piece in resistance box of the tester) Dynamo lead Test ieod yellow — red white — white brown brown Measurement : 2) (at 2000 rpm crank rev.) mm rum 0 gm (Al [B] Fig. 4- 6. at Dynamo (D position of Tester Knob; OK, if the needie of Tester indicates 3,6V or more for the NIPPON DENSO MADE. at (2) position, OK if indicated 7V or more for the some. 2. Selenium Rectifier There are 3 systems lor wiring to con- vert AC to D.C. by selenium Rectifier, and lor Model 102, single phase»al| wave circuit system is adopted. In this circuit as shown in Fig. 4e7, initial hall cycle of current generated from coilflows to the arrow direction (P), and the next hall to the direction (0), and this 's most eflicient system to apply as charg- ing current always flows to the same direction. Measurement of Selenium Rectifier (Fig, 4—8) Preparation of Tester: (1) Connect battery (D [2) Turn switch ® to resistance side [3) Put source of electricity on G) (4) Let the end of testlead otherminal short. (5] Put meter needle on O by adiusting knob (9 Measurement: a—A. C.Voltage biall wave rectified ciDC. Fig. 4— 7. (i) can measure positive resistance by attaching the lead wire (Redl + [a] of X—terminal to the selen + (red mark a'), and the lead (black) —- [bl to brown mark b' of selen terminal * favorable resistance lO~4OQ (2) negative resistance can be measured by attaching reversely lead lblackl (red) of X- terminal. Resistance be 1,000.0 or more. (3] Check with disconnectina selenium wire. a $1, a ( ab (B) 2. BATTERY A. Model 100, 110, I'll. Horn, directional signal lamp, neutral lamp and others are run by the direct current flowing from the battery. The battery used MBCl-é, GlH, MBCliéA type are which have three cells, whose plates are connected in series. Capacity is 6V72Ah, and have discharge capacity of lo hours at 0.2A. This is connected from selenium rectifier through Fuse lred lead linel, and black, terminal is grounded to frame through main switch. DISPECTION & MAINTENANCE 1. Inspection for fluid level * fluid level should be between upper level and lower level. * To supply fluid take all three caps to fill distilled water up to the upper level. Never supply dilute sulphuric acid except the case when the fluid in the cell was spilt over. * Alter supplying fluid lighten up the cap securely. 2. Inspection of specific gravity (This should be checked on delivery or periodicallyl * The condition of electric volume of the battery can be checked by measuring l l specific gravity [but not be checked by voltage only.) (Fig. 4—9) l 12.09:: LZJJ’ ________ 7100 . 100 90 80 ’70 60 50 40 30 20 10 0 X (7.} X—Electric Volume in battery (%) Y7$pecilic gravity of electrolyte (20"Ci a—charging state b~half charging stale c—iully discharged i Fig. 4— 9. 3. This value is that lor standard 20"C, and needs corrections for temperature difierence by the following formula. 5p. gravity at 20°C=lsp. gr at i°Ci+0.0007 (t°*20°) ll 40~50° discharged, charging is needed, An example ol a simple hydrometer is shown in Fig. 4—10. This meter serves to check the specific gravity by Floating red and white balls, ® ® ® 0 float sink sink 0 float float sink Rate of charging 100% 50% 0% Charging There are small battery chargers, which makes charging easy and sure. or more batteries at one time. onlet and let set. when charge is completed a red light shows. with a O.2~0.3A current to recharge. (A) Fig. 4—11. at 0| (B) Fig. 4—11 (A) shows one and usually these are for charging one battery, but some can charge two Connect as shown in same fig, lb) and plug into lOOV It takes 10 hours 4. ll 5. Model 102. For Model l02, volume was raised from 6V72Ah up ta 6VeiiAh, as it is needed to revolve the starting motort Construction is same lead cell as for automobile use (Note) To make it easy to understand, it is shown on the plan View, and actually both electrodes are extended straight outside of cap oi fluid inlet which was shown horizontally. Anode plate : Cathode plate: Separater 1 Glass mat : Others : MEMO Within lattices oi lead alloy, lead peroxide is filled up, and made it easy electrolite fluid to penetrate ireely into plate through porous lattice. B-plates irom one anode group, Sponge torm lead is filled within lattices 0t lead alloy and 9 plates from one cathode group. To avoid shorting between anode plate and cathode plate, there is inserted separater made of porous ebonite plate or plastic processed pulp plate. a—Anode plate b—Cathode Ciseparator d7Ce|l eiPole tiDilute sulphuric acid Fig. 4-12. Between the separator and anode plate, glass mat made of glass fiber is inserted to avoid falling off anodic materials Each group is packed in Battery case (electric celll and 3 pieces are connected to terminal in parallel to make 6V. On the upper part of case the black cap is fitted and on its base plug [filler cap] is fitted‘