~S||llP MANUAl

HONDA

: 0835M - 0340M

 

   

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This SERVICE MANUAL has been prepared as a “SERVICE GUIDANCE" for
the mechanic resoonsible for the upkeep of the HONDA CBJSOF and cams,
It is compiled into various functional groups and summarizes the procedures
for disassembling, inspecting and rcassemblmg the components of the machine.
Strict adherence to the instructions given herein will result in better, safer
service work.
All information, illustrations and specifications contained herein are based on
the 1972 model CBSSOF. At the end of this manual, the modified informa-
tion; and operation procedures of the model CB4OOF are given separately.
HONDA reserves the right to make changes at any time without notice and
obligation,
Courtesy of Homh4Fun (WW‘VLhOMUn.Cm - \tww.hondafour.com).
HONDA MOTOR CO.. LTD.
SERVICE PUBLICATION OFFICE

I. THE 8 RUlES FOR EFFECTIVE
SERVICEWORK ,, ‘‘‘‘‘

II. INSPECTION AND ADJUSTMENT

. Tappel . .... V
. Breaker poInI gap and Ign
Carbumor .V. ,,

 

1
2

J

4 cum-III. .

s. Cm (hain .

5. Engmc oil , .........
7

B

9

o

I.

 

Irronrbrake” .. ..... I
Rear brake ...... , V .....
I Ail cle.IrIr.-! H
DI'IVE chain ,
Irnnl Iorks . . V.
Ill. ENGINE ........

. On vchude sen-mug . .
lngine IEIIIOV-II and InsnllaxIIIII .
Cylmder haw Camshafl- Clendcr - Pmon
on pump - on filter .
. Clult'h. . .
. KIrk stirrer I ..
. Gear shun mecl’u sm ..
. Transmrsswn
, anary shall .. ,

10 Cam (Mm [manner

11 Crdnlrshan - Connurlmx rod.

12, Clankcace

1}. Carburetor
IV. FRAME.
. from wheel
. from dusc bake”
Rear wheel - Keir brake
chcr-ng handlebar
Sueung sleml .
from :quI-ns-on
Rear suspcnsion
Frame body . .
V. ElECTRICAl SYSTEM

1 Geneul descIIpIion
2. Igmnon system ..
S, Chargmg swam. ,,
4. Slamng syslem ,,,,,
5 Elc<mcel eqqumcnIs
III. SERVICE DATA I

Spun! xools

, Maintenance Ichedule
anque SpElIIIKIIIOn
Servxce: data, ,
Trouble shoox-v‘g .
wmng diagram
5pctlilcdllnny .,

1
1

    

Om\la~u5u~_

 

 

ca~.Ia\y._¢.I..-m_.

 

 

yourcuu.‘

 

 

CONTENTS ”

SSowammeu-aa. IN

 

 

 

  

 

SUPPlEMENT TO cuoor
I I. TECHNICAL FEATURE. ........ I . a?
II. INSPECTION AND ADIUSTMENT. ,I . 58
1 CIuI(h.. V
2 Re." hukc
J \N'hrcl .. . ...
4. Spavk plug . .......
' 5. Fun. Illiel ..
6 [\II CIEJI’IEI
7 anl suspcnSIon
3 Rue suspensron”
9 Side stand .. . .. .
I m. ENGINE... .. .. .93
1 PIIIon nngs . .. .. . 93
I 2‘ Clulch . .. . 93
3 Censhn'l mechanism . .... W
A. CaIbmczor .. . .. . 95
I Iv FRAME. 9r.
1 hon! suspenuon 96
2 Rear suspenuon. .. .. . 9a
3 him. body .. . . . 93
V. ELECTRICAl SYSTEM . . . . we
I 1 Chargmg Syslem .. .. . . ‘100
2. Smung system .. ...... I 100
3. “annual equmenls. ...... ..1l7l
VI. SERVICE DATA . . . 103
I 1 Special moi; ..... . 10}
2 Mame-Iona schedule 104
3 Torque \pccilicatvons I 105
I a. SEIIVIIP data . . . . .106
s. WIring d-Igram .. . .. , . ..... 109
6. Rourxng .. .. . , .. .. . 111)
7 Specn‘IcaIIunI. . .. .. .. I 111
h
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TLI- mfi'éf‘tiiakss “if: Efifi'cmififfsw ICE WORK

 

be: new pairings, gaskets, O-rings and cotter pins whenever reassembling.

when tightening belts or nuts for which sequence is not specified, begin on center or larger diameter
bolts and tighten them in a criss-cross pattern to specified torque in :wo or more steps if necessary.
Use genuine HONDA parts and lubricants or those recommended by HONDA

Use special service tool where use of such a tool is specified

Clean engine parts in or with cleaning solvent upon disassemblyi Apply lubricant to their sliding surfaces
when rcassemblingv

. Coat or fill pans with grease when: schitied as such

Upon assembling, check every posyble pair for proper installation and movement or operation.

. when working With others, try to give a signal or communicate for salary

Precautions for Readers

1‘

2‘

The procedures for reassemhling the engine and irame parts are not described Follow the revewe of
disassembling procedures carelully observing the titles “Reassembly” in each section.
All the service data tor each component are compiled on the last pages of this manual.

 

 

 

 

 

 

 

'm.» <errion darnbes Inc: inspeauon and adlustmcn:
naunlc’uflic 0' {he HONDA 330 Mcde‘ CUBSOF.
:n page 74,
n lhlS manual

1

 

vth-I . apum r."

: Marl. "T' ‘.-l

.3 mum; mm

 

3
3
Incl n,”
_- "mam; mm
vs,
5

leSPECffOV AVD ADJL

l.

2.

 

{flaw ;

 

racemres for the Important Items ov’ th‘: pprindical
Crass-r64?! :0 FERIODICAI MAINTENAVCE SCHEDL‘LE
Ior [lu- nxenn other than how c‘esmhul m thfi section. relc' lu "Inspection" of cach par:

‘I'A PPET

Inspecxirm 3m: ad,usrmen1 of the rappel clearanre should
b9 macs when the engine Is fold

Rcmovc [he [Jel tank
Remove he cigi‘t tappcl hole caps.
poin: cover.

Rer',‘ ova me

 

Route 1hr cunka .n'l (IfiCk'NMF :r the special nut
so a: w align {I‘c '1:qu “T" 1.4 w.lh Inc nmlrhmg
Hark.
Make 5.1m il NJ. I p.5zun Is at (Eu: 10C poslllou
nn rrmnpm If not. rename the crank-
s‘uuil I mm clm‘kwiar- m a; :0 make- propc'
ahgnmcnl

(Inack am: adlusl Inc lappe: clca.’ar'Lc 01' UN: "0"
pa. Refer :n #9 rabm below}.

To adjust. luusul‘ [he Inrk '1“: and mm the amusxmg

 

im‘ slrnke.

 

 

  

screw.

 

 

 

link: ”We 1]. u" lUuUmn ‘
‘Jppu cca';'tc ii

a: ”Ive L103 um 4.3 LIZZm.

 

 

\u4

C-,|w dcr \n. . 7m. 3

Imam mm

ExE-avsl ml“-

 

Rmalc [M 'i
align the man; 14 \ml!‘ :11? nun
1h) comm :hp .\n 4 pistu'l : al
(mnpressmn wow. am: (lip-Ck ,
wrrecr upper clearance.

Upcr. Lumfileron m :'
or :hc lap
artc pc-ml K'JVL.
Inaui. ['19 nci [an

 

g mar‘a €er
”DC of Me
" \alvcs fu"

 

6..

smaller 3rd dchitmefi:
|| [rc lac-pa: «we can;

 

   

tube tor prop-a

 

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|\S¢' CTICN ,‘~.\|:,

 

2. BREAKER POINT GAI’ AND IGNITION
TIMING

Breaker point [up

1. Reflch :he point coverI

2 Relate 13w crankshaft clack-v. a; (m: speu‘ul mil

Chem I'm: n]dX:l“\,'“ gap of the palms 1.4.
Maximum gap: I).3-0.-|mm (O.Dl2~l).016in.)

To adiml Ii‘e gap, loosen (h: screw "'a" and "ma-e

he bruake! base 1.4

Cl‘eck [1e pmnr gap or he pvlnts 2.3 in m: sa-we

:-* nner aa iuv In? (mini; '14.

To adjust, base" (1‘: srrr/u "b Md ‘nrwn the

breaker ha=., 1.1

 

w

 

 

Ignilion liming

 

7:5: and adjust us rig .1 :‘Jubun pm 1min; IIg-n ISL‘H‘IK'L‘
TCSIL" SRHEOJ. Tool ‘10. 07171 99900:.

1 Make Curmennn {0' Inc ECH‘ILC Iu>lcl .x~‘- inilruczcu
by the [CMC‘ ilid'KJL‘ICILIL-“l'.

Conn; l'uc [mung lig'n (rm: to he mm plug of
the Na 1 or No. 4 ndur

Sun the WSW“ . (I w: -s iclc speed in 1.2EJTer'n.
liiurnale {ne hing: mark Wil'l I'IC l-m’np lignl
and see i 1'“: walk "’ 1.4 is allg'r;d ' h :hn
"watching mar», 1i Aligned. luusun Irv.-
' d mm:- ['19 'nraapcc' base pldlt: "P”
'cuon.

 

 

 

m

   

 

     

   

     
 

mor d.
“Hung the plate lo we r 5m v.'||| .admnre ii-c igni-
:Emv {mung and m : ic lei: retard [we lming.
' \h.2 eng'nu pec'J up w 2,‘
w. "xiichmg mark. I! :i'e mavk
nee "mk‘ he gniciur‘. ti
- mmnccl m: l u Ii;h: cor: I.v Iiic :pavk plug of
2 or he 3 :- nde'. 1.1.0 the cngme ant.
mar» "l' " _ J i> ui gum-Li WI
if 'm: g‘ignedv i-Juse'l {i‘e [\
r-zme (hp breaku baa-t plate

 

     
  

 

     

 

   
 

   

   

   

: reu'uw

 

P’igzre 5p cc u: to 2 Tflrun'
F ’ 3 3 Hey: heme-2n 1“: mo .

   

 

 

U-‘m

 

    

Izuy um. gm
.me» hm 9m.

 

 

 

IhSPscTLON AM) ADJU

 

‘i. Ad-ptor A
_ Adaptc' a

5. Vnnmm gang:

 

 

 

muslin; ,t-ct,

 

 

 

3. CARBURETOR

Carburetor should be serviced after the engmets warmed
up.

Checking idle engine speed

1 To set the engine to 1,200rprn, turn the throttle stop
screw. Turning the screw clockwuse Ijin cirection
"A"; thl increase the engine idle speed, and vice
versa [m direction "B":.

Chuking synchronintion

1. Remove the ion! screws from the intake manifolds
of the carburczots. Install the attachment A {Tool
No.07068-30007l and B (Tool 50.07068 30012) and
Install the vacuum gauge-5 (Tuul hut 07064300011
Start the engvne and read each gauge.

Specified vnlue: 16~24cmHg

NOTE:

All the gauges shnuld register the same value within the
specification

i.-

Adiusting synchronization

1. Remove the luél tank ~'- In the machine. Connect
a longer luel tube at the carburator to the tank.
Turn the throttle stop screw to adjust the distance
lHi- bum-curt the throttle lever and stay to 56mm
(2.203 in.L Turning the srlew clackwxsc :in direction
“A": \Vlll increase the distance (H), and Vice velsa
lin direction "5"].

to

3 Start the engine and :6: all the value w:thir~. the
speciliatmnt I! out at thv: spentiication, loosen the
lug.- nut and turn the adwsttng screw to adjust.
Turning the suuw an directmr "8" mil Increase e
't-sguurt prcssuru, and rite \‘8353 {In dxrcxtvon "A"},

NOTE:

Upun adiustment, tighten the luck nut securely and snap

the throttle grip the: or tour time\ In vetheck the synchro-

niuhon

   

l INSF‘ECTIOE AMI} ADI.,§TN[\‘

Adjusting Inst idle speed
Tne 1d;u5:menx should be n‘adc durmg 1h: engne
warm-up alter synchromzahon of the (aer-‘elor: mus
been idJUSlCd
1. Place inc choke lmve' in the full open positon anu
check the clearance 1.1’1 between he link plate awe
adjust-mg screw.
Specified clearance: o~o.3 mm (04,012 in‘]
To adjust the clearance, loosen he luck nu and
mm the adlusxmg sciew, Tuning me screw clo§k~
wwsc (m dlrtxlvun "A' wall decrease [he clearance
and. vzgc \ a inn direcuon “3”).
1. Stan xhc U'Iglnc Slowly ope'ate the rhnixe lever up
anr. down lo fmd the maxrxma ungme rpm.
If within the specdicaLons o: 3,500~4,500 1pm, the
(as! adlc spew .s sallsiacrory. I? not, ad,usl bi «man;
of (he adluslzng SC'eW T ing the straw ClOL \vlsu
wn d:rcu.-un "A”J wull Ir.(r use [Hr engme rp 3 and
nice versa llm dlrL‘Lllul‘ "B

 

 

 

 

 

Adjusling overlravel slopper

‘. Reluru the throttle snp m the closed pusluonl
Loosen (he loLk llul and Man [he lurk pin [0 adlusl
:he clearance (HI.
Specular! clearance. 2.0~2.1mm (0.079—-0.0835n.)

Adlusling lhmllle (able

1. Cneck the thronlc grxp for play.
SpeClmd play. approx. lU‘ around the grip
To adys: the play. loosen the loo: nuls and turn
{he .Ad,us:m;3 nul Tur-uug ll‘P nul clonwxse [in
autumn “A": wvll vm'casc the play, arm mce wise
In“. c'I'CLKIoI' '

 

 

- imc ulmstmcr: .Uuwn (he cable lock m: and
:.-r szc cable adjuster. Tuning the .mjusrev ‘nck-
m durcznon “A , Wuli drumse the play, and
'm km darccnon "B”I.

- thronlc g-xp n [he .

 

 

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L‘ Iml pm Re
:l‘e Imar doc< “.ol

    

 

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n52 1: , L m gm:

: Amusing mew

 

 

Hg 24; . 1mm: my : Luck nul

    

Lock 'qu
djufllng nu:

i Cable zduszer

,»

 

 

\wn'lxm -‘.\D AUXLSIVE\I

4. CLUTCH

     

1 Align he rr mm: 713‘»; on :he curb .Wer win
1! m :P-e R. Cr Lau- v r anc lessen the iock
mt. fur-u the Llutd' dd|u>lc (oufiterclockwuc unm
n hammer: La and bank I: or' aboux 194mm.
Tlghr-en he Ir 1m.

     

    

Viz, 2718 I ‘vhld'mg Full. : CU|L|> “huh.”
: Lou ,ur

   

   

   

.‘ chk :ha [p n: me our icy-er for tree play.
Specified play. 10~2IJ mm 10.4~-0.8in.)
3. To us: <1 the pay, loose the lm-k nu! and turning
he low r adlnsirx (lm‘ .\‘|<:" fin diredlnn "A"; will
mgm: ll‘r pay, and vre \ffirfial‘x‘. citertirm '8").
LR .r w x (mm Imrr :- r \Iix'1l-‘n'0illn‘a rlA',
4, Fun: ":-.-«n[ mn l’n- made by méill“ m the unper

   

nu} le a: rhw rl..:c-| cab-a. When adiusring, loosen
II ‘ ICLk mu

2. Upon ( [rem mu; may ['le: (lush ant-qua;
pray-thy.

   

vix‘ 1-20 1 Lock ru:

Iu-wr‘ uhulcr
‘ MN, MW,

    

5. (AM (‘HAIN

1 Start the cngirc

2‘ Sc: :1”: crgirc Idu spew-.1 LJLXJIpI" Tonga-n [hr
lock r4: inc xcnslonc' adluszmg out usmg bux
“ranch crnlamsd ir mol «I.

{ Rel gher [ha EJ‘LSI '1: LIT-ll 31:1 :cLuru l'lc luLk 'Iul

VUIE:

Dn nnl pull or push th- lenuoner pm. Lm mm M issoliv

adlumng npr. .

 

6. ENGINE 0H.

Chucking oil Icvcl
Lox

        
  

’flall‘ *' 5.1' par: t“: mad' m-
,ngme sze
011 mm. d he

 

I’. ~

 

Chmging oil

 

Won-n H'c cu r 30,:
'oosumn: ils anrw

 

 

z’ankcase.

Rerig‘ntm he cram [13,“ am! n-Imtull llr L. HIL‘r

F113 wm 1 - '

inc-nu 3,

Capauz: 3.3 ; -IJ.7 US qt. 3.1Imp‘ ql.)

RtLUmIr'u'ldua 0 : SAE 1|] W40 [All u-Palher]
SAE 20 W750 [Almvr 5‘” or 151‘;

      

 

mnn‘uuuud cul than

 

TA FRONT BRAKE

Checking fluid level
' {L71

. Ch:

1h: 5le3 Luz; up 9' He nxa=rcr war.
0 9r»: xhc brmc rud In
If :hw Ivarl

 

   

uI-l SAP

 

w mad? ”1» (up
DOT 3 :T'lkx' hurl.

\dwsllng (Alipcrs

  
  
  

 

‘ull .znr. ".l '1

.unl 1'

Ji..=| '-

;,v..;: 'i Ll_III(¢L:b L' um.

 

,2 :u i.‘ 24'” {m . ‘.l|.~

._,r_. q”;

 

 

 

”nu Jr‘d sup operating :'u.-
,; . pruccjum Ln! n: bub~iu an. um; 1::
-' , '_‘:: L:rrirp mu r: th— aslu

 

 

rim Luv prupurlv ”Hrd duymg Hu- blu-xdmu

 

 

 

 

 

I:
'rrnrwt in r

 

 
  
   
 
  
 
 
  
   
 
    
   

 

nu 2-23 , Admilln; a

 

MK. :72» x A: dourm L4)! ,~ Au rnhh'l
. Sc: smug.

 

“3.2 ll) c1. mu 0 rhnr m;

Cazm gm .
.~ m! xul ;. 1r. mm
: 1mm r,x 2 am ml:

 

 

 

.2 32 rm: ruxl l‘,}[»
,h v

 

     

 

 
 

      

| at the Lp u: the nedal,
Luv 1; :hv nu! d Owns;-

EdJLSi mu ‘vws [m
e adwsung r4:

 
 

‘sa :1 d
.v:d [ILL :

 

9. AIR ('l. .ER

 

1 0:er l‘w scaz.

  
 

' al' (Icavxu- UJ'TI
.3 remove X'h.‘ .ll' dumm-

 

FIEI’I‘IC'IL
l|§,!'\‘.|'1‘ La: the cur -u-: by :m-ud Al‘fl Apply a ULM

m' (mm . mwlw

‘ hum-12* [.1 hr JI' LL'JIVL"

 
 
 

3 In—rk

<.-.- Mr 2.

111 DRIVE CHAIN

(‘Imrking drive chain lcnsion
'1 Chad; [nu L’hl 'I l

   

Jr by ii'u »d4_'pvu§:mb ll
\‘L‘C‘I l‘w sprocxels er J{ m-

    

swung Pm sag,
Spuaii‘uu 5.1;; 20 mm 13 4 in.)

 

   

   
      

2, I: Must, n.- :l « rum-4 mn, luusmv zm- axle
IL: 3rd LA :I c .. [mm (19 adiJskng mu m
L'IHu-l \hrern.
LpUn am :1an. allzw Ih‘ 1cm mm: m: we 'iih:
an: ' '5 mth Hm sd'w: 'mirl'es
m . . Tigf‘ '1 the “'1.- my and :m‘taJ
l"L' Luck-x um

11. FRONT FORK ,

Changing lurk oil

 

' - hm: ma ant: er Jul” hr. a
'IL‘ lI-IL :3“er r:.

  
 
 

   

trurl
.mruwm ( trans“ :5 on

 

 

'H (.
1n; n :3‘bozm pcv Lylinder
\urt:

um .4..‘uz<.. n.: mil m ch

 

d In will our imk “he"

dl\d~~€lnbl€l§
Tlnque ”In 2-um ior'. boll «n [he \pun’xufimm

ON-V EHICLE SERVICING

 

  
  

P IU L‘! ieV'IKl‘ti
wCYlivde' Fan an] 7 ,

(in-Am and unions
oz‘fiflvump an a. mi , 7

‘

    

 

barf—m. system’:¥1Em’u- and cumu 5mm; _ ‘l
ENGINE REMOVAL AND I; ALLATION
The pwllminary works fer the cngmv semm-a. are shown
m the dxagmm below. Procecd m :hc mmmica nrdev
shown. To unstail, nevese "we removal ordcr

 

5 v...” m 5mm ml.
.l'! ‘Iavra’! :runhu

    

 

l‘l

T'uutfle cw:

 

f Snark mg m.
,_ [mum-I um

 

r. :w» zunkcI-I 'mm 0- Hull :9
hum sprint umer

2 UL EVGINE

. CYLINDER HEAD. CAMSHAFT. CYLINDER AND PISTONS

 

 

"; Bvum-r cover

Brulhu lull:

.3, nrnlhu :ovor packing

(5? Cylinder head cover

"3 Selling hon: Hour]

3 Cylinder hand {over
packing

Q Valve nuke: mus
(eiihl)

1 Roam inn side
apviny (night)

G; Rocker am shall;
(1mm

@ me cham Ionslonnr
holder

@ Cm sprocket

a) Camsmll

0 VJIve couen Imloenl

8' Valve spring xualner:
mum

fl! Outer vllv: wring:
lam-n

33 lung: vulva :prlngs
lolghll

5} Omar Jul: (elshll

a Inn" mu (-Ilhr)

q] valve slam sellslelshll

& Inuke and uhwn v:-
lve suldes How uchl

8 O-vlnss mm). 10x15

8 Cum duln guide

a Inuk: Ind exhaus:
“Ives (low ei<hl

3 Tensionev dimpeu
mm)

3 I’uuioner slippev

‘8. Oil pipes (mo)

4.3 Cylmeu new

9 Cylindar head pike!

{- on annual orifice
valvas (mu)

:3 Cylindu

a Cylmdcv packmg

g: Pinon, «our:

 

 

 

rig, 3-1

wane 13
Disassembly
Opr‘n IIZr: wet. RENT/V? [he in: km"

 

 

 

2 Remov- l‘xc Igann rr; 5,
1. Ru me he breathuf uwcr
DISC-Unnefl’ 1hr lughofictcr cable

[-

   

=nu louscr l'u:
'u'nc'se (he
the rucx'er arm
I erL-w a 10 1m

Rcmo'
rock? arm ad;us|m§ scrrz
cymde‘ :2 av UJVEL Tn 1w
mar; rcmgvc (he can nut ul-
mtr'v 1 mTI bmr in :I‘,

:H eight lappc‘. hole mix
5 TI

   

       

 

 

     

3rd“ H; J 3 inn-J a'm an
“MIT 1|) 1.251111‘ :nx

 

C Remove {he "Kin-ICE
Rem . ‘qu spark plug up: and vummu NCR.
2 .qu 3 spark png.
c Runwn; the ran 1; um 1cn<znwr Huh 4
{Em-“H: [hr Lu'U Liur' ‘ rm 1 >.ppcr

 

 

 

and

 

     

C411 :‘um lrnmu-vzv iumu
5 33:0“:

 
  

'p h'n‘ pom! LU'I'CT.

- umc ‘h: Lrar'kshafr .1! :I~ 4mm 'qu unnl
.4: cam smorku! knuu bolts rnmm
51c bun Inner . I‘ (In:
5 MI nm' [0 remove anal-m mm

   

  

U- ‘ 0"

   

.p-\ yu, 3nd mmnv,

.‘M‘u'm

   

h5.15 ’ 5mm nJl
-_ «work hn'h

 

me mm pp-ukc: r-o-n m9 (.1Il‘\'|;lii and
. we ran~ chum.
- _ ".1 mu (a: man from m.- myu 5dr.-

 

   

  

I": um Lhain will. wile m me like to punenl Hu-
_ . - 'rnm mung m [he (unkrasl‘

rig-cum u|k~enr

   

mum-qr

 

_ amn: acre

   

 

‘ Remove the carburetors.
‘ 1S. Loosen the ryfinder head securing bolts in acriss-
1 L‘HJSS [)dHHn, startzng'n 9xlsrnal on:- .K shown 1n
I‘ F g. 3 a.
E 16, Take out :I‘r Lam (ham guide am: rcn'ow the
1 cylinder headl

   

-u Remowl mum“ n' (, nu», Iwu mm; 5
bolzs

1} Use \‘alw: Iliicr (7003 No [$7051 5290‘“ [0 com-
press me valve spring and remove 11: valve col-
:cvs Then lemme {- min! and valve spring.

 

2: Ruplacvng value 5mm.

Use Venn: guldc rcrr‘ovu: lTuol Nu 07046-32001)
(0 remove fin: vnlv guide.

Rsmove the cylinder.

 

16. Rc'nme :ne piston pin clips to pul' uul [he pnlnn
V pm Ru'nm-e :I‘.» piston.

NOYE:

I. Pu! A “'1le clolh or the like undcv the piuun nol [0

[All the pin (lips in lhc Kunqusr.
. him (are not In damage Ihc pismn when n-mnving the

piston rings

:4

3 ‘. .
stoa pm cup
“‘1‘” (Inlh

  

 

   

Inspection

Camshaft and cylinder head

'L L" ‘ 1h: kacv qnll- ‘ mue: ar'n shaft clearance.
3. C k the cylindu hem (arm‘naft bearmg smlace<

 

our «mm-95 am: exccssu: wean

 

 

 

 

n5. 3-12 Good

Measure lhc he gh: of each um,
Cnecx the camshaft Canter juurnal for defchtaor
Measure he valve $ual wu .
Coat the Valve seal wuh pruasm-t bluc thinly .mc
uniform \r Hold the valve against lhe >ea: an: relate
.t one urnt :' the prussian blLE shows a band ur'
. tiorm t-It all he way around bctn seat and
\' lwct lh: valve evnldct >5 proper Ir. (use the
contacl Is improper, lap the \‘d . and recite“
If still celect‘. e, retace me valve seat.

Non:

when using ¢ i'dlve seal gunder, be mm to follow the in-
struuium given by llte Iuol nuuul'aclmen

6. Muumru the uutsule diameter D! the VENE stern.
7V Cvrutk :lw vulvurlo-v-llvl: gmdu clearanre

a. Measure me free lengt't or Me -:-.\|- - :p’lllg

0‘ Cth the cylinder head surface t'or l’

lnhfa

 

 

 

 

 

   

 

   

 

  

' nder and piston:

1 Manure the inside diameter 00' L‘dLh {yl ado:
Measure [he lll):d(‘ durum-{Pr m cylinnpr witn J
cylinder gauge at 1)": top, {unwr and nnltam, in
parallel > 1 With, arm .I! “Eh! angles [VII :0, the
(enter hm: of the cylinder

   

 

   

2 Measure :he nulstde dtametcr u.‘ t'tL- prawn at ‘ii
skrrt,

3. Measuve the Hyde um elt-r nf l‘te piston pin hole.

4. Measure the outside duumctm cl the infirm pin.

5. Check the p:s:on ving-lu-ptston pvn 3“th- (Iéamnrp.

r3 Cnfick the plsmn ring and gap.
Inst-r: me cylincer skit: to Flake 'Tmasun. :01 (we
gap .mug .1 thickness gauge

Reammbl)

Piston rings

Y Lse the paiun m m the grill: tmk: .: a s ‘

 

lnsmll lhn: fines t: the pstu’t w:_l‘ :l‘crr

 

    
  

w; "g upward
' m,
\ \
t: (tux p 3

 

tlkOxU ‘

 

l5

 

 

 

 

M

 

 

 

F1534} Valve :ca: U'J'IISCI

    

Mg. 3 17

3 III.

 

 

Fig.3.“ l Piston ring gap

Piston mark

 

 

tttnn Ilnfl compressors
umn hum

 

 

ENGINE

2‘ When a new ring is used, Chuck it for proper fit
in the piston ring groove.

3‘ Position the rings so that their gaps ot’ the top,
second and oil rings are staggered 120‘, each being
apart from the direction at right angles to the piston
pm.

Pistons

Install the piston Willi the arrow mark on the piston
head toward the front lexhaust side) and “IN" mark
toward the mar (intake side; of the engine.

Cylinder

1.

2,

Rotate the crankshalt so that all the four pistons
wril fist: in a line and install the piston basess (Tool
No, 07033-33301: to the pistons Set the base in
the groove below the piston boss. Then install the
piston compresstxs tiool No, 07032—33301; on the
piston rings. Gradually lower the cylinder until all
the piston rings enter the cylinder borest Remove
the piston bases and piston compressors

NOTE:

Apply a (oat 01 engine oil In "It piston rings helm!
installing Ihe piston! into the rvlinder.

Check the Oil control orlftcc valve lor clogging
before installation.

Cylinder head

1.

1.:

When installing a new valve guide, drive It in using
\ralvc guide driver (Tool No. 07047-32901) and ream
with rcamer (Tool No. 0700840002].

Apply a mat of engine oil to the threads ol the
nut and tighten the nuts III a crvss-cross patiern.
starting at the internal one as shown in Fig. 3-20.
Torque specification :

200kg-cm (14.5fl-Ib5l

Valve timing
1 Rotate the uanlzsl i: and align the mark “T" 1.4

 

on the spark adv
shown in Fig. 3-11.

   

er With the matching mark as

 

2‘

Install the cam chain to Ilwe cam sprocket so that
the matching lines on [he sprocket will be ahgnec
with the uppel surface of the cylmder need.

Insull the cam sprocket lo the camshaft wu'w lwu
knock bolts.

Cylinder hud covet
“L Apply a lvquid packing to the cyl'ndcr heac cover

packing groom: lnslull the packing in place.
Replace paukmg If damaged.

2. Tighter. the bolts securing the cylmdev head (over
In the sequence as shown in Fig 3 24.
Torque specification .
70~110kg~cm (S.1~B.0|bs-H)
NOIE:

The sum... dinmm o! cuh boll should be wilhin 20
kw... “slum.

17

 

 

 

 

 

c m ‘ptoditl malvvin; I'ncs
Cylinder mm .Ipner sw‘au

 

 

 

 

 

my“ mmmn; lcqufinrr of (ylmder head
(over bails

 

8 m, [.xcnx:

-. OIL PUMP AND OIL FILTERS :9 Prusurs lubricauor. ”Splash :ubrnauon
~Tln: oil pump is a double trachoid 5: promo Emm- m
pump driven by the primary shaft. slip-:6?

-Onc ml fuller uses a screen and the ”"3“"- _ "

 

        

Rene: an. 5113!:

 

 

 

 

 

 

 

 

 

another, paper element to prowdu ' '

'WO-Slase “he'insv Canaan = consume —-{Fu=cn MMHFHMM |~~-“1
NIFLIIB KW hfliflfls!
Mn: "Hazy Pnnary shat".
‘Tnunzssmn taunt."
n at."

 

 

  

an puny mrransussmn n31: snarl.
|

l(1111133333 -—-—-1

Eenet
vulva

 
     

 

 

 

 

 

 

 

Fig.) 2; :uor|<::.ng (“I “gm
5 on slume' : on puff-P i o. - e: g 0.: coon o-inuvm: on pipe

 

 

{\LIN’: 19

Disassembly

Oil pump

‘. Remuvt Ihe gmr charge :c
look rcsl,

27 Ramon; llzu L, uanu‘nar {OVEL

Dlscnnnect me u:| p'cswrc sw:~

Run-aw m; on nu-np,

|e~ft-i‘..anc SICC

 

w

 

.r.

Oil screen filter

1 Dunn l‘rm rrankLasc.
Z. Ru'flovu hr- 0: pm
3. lit-mow :‘Iv: Lu! :r'u'fil’l I ‘

 

Oil iillcv
1. Lemon :h; o,| MIL" (clzlé’ halt In runuvu ll'u wl

       

“1:91.
Inspection
Oil pump
'1. Check :hc mllur folGr-(thlr‘fll) body- (finance.
2 Che-r1; the mnur row' a uuzcr rulu‘ clearance
5‘ Check :pr rel «4 Valve m dust unlry um,- (I)! warm: '3‘
mm. haul!!! . Oxl rcrccmerbul:

 

g c- irg.15
.\ LMI ‘l m ca
2 mung»; 4.:

 

   

Reauelubl)

1 Bu sun: :r ”we,” Orr 1:: ir
as shmw

_ Cull :lw u lyml m thr—

r nCLL‘

Make

r g 2

  

c w Mk”

m

 

CLUTCH

ENG-N}

 

 

 

 

('rmu‘nc tuve'. a cmch Icw'
Com pm.” 9‘ cum. mum; Irw'
Couu pllt,10 1; L (mu-I. I-Hev w:
the'. 10mm _ (mm Inn pIAle
(‘IuKh Amer «.m cxuur. sphng‘ no“.

 

Clutch lcvn' Ictlrn Mun): Snap nut. 25.“

  

..J—3l ': Emma-11:1 rng
‘1 0m». assev-Iuly

 

 

my 1-32 ~ rm-rr :peun as! m;

, quc‘n thllcr

 

 

    
 

cmch ccnm
is: spying Stu!
m- d. 'im

13 Clutch lucliun um:

>.Y Cluuh Dldles nix}

:L Clulcl- incunn dIEC) :su‘l
a} Chuck pyumc plate

c) Clumv ouler

Thrwl wuher, 25mm-

 

‘Jl‘ Irm

 

<3

Disassembly

1. Dram oil from the crankcase.

3. Remove the nghbhand sudc iuul rm: and kick Starkey
pedaL

3. Remove tne R, (Jankom (over

4. Remove the (lukh pressuvu plate.

5 Remove the 2Sr n was rm); and remove the clutch
asacvubiy.

6 Remove the 92mm mecml set 1mg from the clutch
center. Disassemb;e the clutch plalu B, clutch dxsc
spring and dISC Spring 5241.

7. Remove :Iuc glulch [ever and clutch adluster lever

from the R. cram‘case (over.

21

 

 

Inspection

1. Measure the thickness 0! the fr.c:ivn disc,

2. Check the clutcn plate for distortion

3. Measure the free length of the clutch spring,

4. Chuck the Clutch center-:o-clutch plate 3 clearance
(i), and If beyond specified hrmt. replace clutch
plate 13.

 

 

F134] 1. Clutch rerun
a Clulcl: plale s

 

Reusembly
1‘ Install the disc spring Sea: and c:u:ch dxsc spring in /

,-\ .
proper checker: as shuwn. -3/—"—‘|

 

 

 

 

 

 

man 1 3m: 501mg m:
Cluln a." Wm"

   
 

2. Be sure to Install the 23mm thrust wnhur.

3. Allcrnalcly install the inchun ducs and clutch plates
to the clutch outer. and finally install (he 8mm
friction difir (sen,- 131, fig. 3—30).

   

FILSJS If 25 mm Ihrml washer

MEMO

KICK STARTER

 

EN; as

 

 

\ Ku‘. mun n.”
; kc‘» arr. m m
. Km ,zulcv 3:11":

5 Colia'
a mu m-m Wm

kn“ want! <prng
: Kn mner sp m1:

 

 

; krk «mm €p|r

rig. J 'Jb
,- ,.m. ., ,, .umr
5 Sex In" .wm 33-m-

g 5:;m- -.-.-.~. nun-.4

 

m erlor mm mum

.rnri:

   

 

 

Disassembly

1 D'dm m5 hu-u (m: thnxk‘lt‘l:

2. Rumm-c :I-c R. my. rut ml Mk :LJUH pcddl

3. Ramon: the R umlku c Lurch

4. Remm-L- l ‘ kvc< sla'mr sprlr‘g and rt:"ow: we ML

  
 

:ta'mr Jssc

“bly.

 

|--_- LliL 5mm nininnr

 

kick damn 5p nzm

 

 

er: ti‘u I-dl' p-

 

~I:\l:u'l cl' :l-u 57.1191 mum
on spr ‘15 um :I-:: Lre. ‘n

     

my; :zuppur gmc

 
 
 
 
   
 

‘ m m;- \ (K it r'rr apnn; 3< vvuwn,
W!) ‘V‘ IN!

tr: Luv-Rug- rib as

  

 

k u the

5.! i“!

 

er [1 nior :93: .> prouufly
the ‘uw gnu

7, GEAR SHIFT MECHANISM

E\CIVE

23

 

( rcnp '\
Dnarhic‘c :
, B a
0..“an mm mum;

 

 

(,m rh 1;: :7th
: Guy I >vll‘Jl‘t
1‘ Ruw- 3pm“;
. (:qu mu :nm

 

 

    
 
  
     
  

, Rum-u {nu
th:1'.‘c quopcr
1le ”UV“! .‘m
ww c'nmrr'nr'
L wxhrn :lrrn
"(E 5rd” -cl Dlll':
14:» Lu” cu. nu
>lnrt um“
shat cw. R
mm e»: um—
mm Iur ,\
Shun um gunk-

 

 

 

u':

 

 

Disa’sumbly
'Cmup A
'l. Dmin il mu
Remove m. , .
‘ Remmn the q
4, RIan-vt- l' o
a. Runny.
u Um»
aloppu- 1rd neutral'
”’1: lth

    
    

 

 

 

 

 

 

 

.he crnnkcasu.

on I’Csl and <2c< 2w
cl‘anga pedal.

R. crankmsé n

 

_- H c 52m s-nn :pz-uulu

n‘ulu 1hr: pomvc :tuapu g
|UDDQY JHI‘E.
:m r: zrs 'r. neutral,

 

 

  

 

 

V'w-uw ,hu- km «.mlcl
y; Seconcm 571v: gm!

V‘tclh-II I:
Dill 3251mm
1 Lawn (olhr

 

Mg.) {5 \ Muv man

5

In; H“

 

 

u

 

Remove 'J‘c cowlacz breaker base and sparkaavancer.
Rem e oll pump,

Remove me secondary crivc gear ‘mm the prmury
anal: hv removing tne 12mm bolt.

 

anoue §

1. D‘s-"(En the cngvre Horn Iflr wrachuzu and follow

 

the atop: 1 t 9 above.
I'uII out the primary ihn': :0 the nghL

Rama-m the 52PM! mlcrnzi circlip, and dxsaascmbic
Mm 205 ball braving and 25mm rnllm.

Iowan :I-c bulls suculmg the. upper and Iowa
L‘rmlkwaus lo *cmovc the lower rmnkcasu

Rer‘uw [he tran>mi>sicn main {hail and [he counter-
-.h.ufl (II (in: wmc rmc.

 

R; 'u\-|: the gear shin w: pus, am: pull out mp
sh :1 'c'k gulco 5413!: ard guur :iuf: drum.

 

Inspection
‘L

Measun: the Width of MC gear )nltt rork finger

 

 

 

 

   

 

 

2 Measure the outstdc dvametar m the shut: ‘ork gusde
. aft,

3. Mun-arc the msn’te malnulu- or true '51:: rent.

4. Check :he gear 5. it for]; ngdeJo-gea: mn’: dun
groove clearance.

Reasscmbly

1. Install the -,;~‘< shal'l um and gears .n my neutral
positinnv

2‘ Install the guide set pidlc, d'lC bend the fund he
lurk washer ugamxl the flat at the Bmm bul'

3. Instatl the gee! shvl' forks pronc’ly in :hear 'r‘spertu-e
post‘tinnst They Are pwwdcd WI‘J" the mar R",
‘C and “L” fol IdL-ntxhgutxon.

4 Check the 3ch Nut: drum stopper. neutral sluppct
arm and pustlzvc steppe! are in th<-" prupur rus—
pndwu positions, and :Im check (hum for upcml‘onv

In Move [he gear shift spindle to (hack each tclalcd
part lnr smooth ODEFJUOIL

a

~1

Refer to page: 2b~27 for the xnstallatinn nt‘ :hr- transnussujn.

 

Fig. I 4:

    
    

Guide in: pluo
lusk winter
arm: hol:

Ruler la page 34 for the insuilatuun u.‘ [nu upucr and lower uankcasns.

MEMO

26 m. ENGINE

5. TRANSMISSION

 

 

 

 

 

 

n. 3.4-:

flea! shxl'r lurk guide pin; ilwa). 6mm
Needle bunny (xwol, 20mm

lkvusl washer: llhrae}. 20mm
Counlenhm low gear. 411
Counlualuh Inunh gen. :11

‘9 Cucl-ps new. 1'. mm

0; Thin“ washms lfaurl

 

a

a; on ml

    

 

i M: ball beam“;
1 9 mm bearing wt "-1;
.» lim'r ncerfle beanng
x bn'r sense 9,.

' 0|! mal

-; m nah

i: Coummhm mire my, :41
a) Counlclshifl (up guy, 2m

«'5 Counlushall. 37!

:3 hum; )el rings :mo'l, 52mm

53 Drn'c sprout. 171
a) Drive woke: fixing pme

 

:1? all buying, 5205 H5

   

Main emf: [owlh gear. 271
«'9 Main :hafl thud gen. 241'
g Ma-n )hal! lop per, 291

5g Mun ,hen mom: gen, m1
.5. on ml

Diussemhly

1. Remove the main shaft and counlcrshalr from the
upper crankcase. [See page 24)

Inspection

1. Check the gears [or backlash.

2. Replace any gear If its lugs are excessively worn 0!
damaged. Also check the gears for smoolh sliding
on the shaft splxnes.

3‘ Check each sear-lo-ils mounling shah cleamnce.

Russemhly

Main Shall

1. Install the 5303 HS bali beanng wuh its groove
iineo h‘l‘h the :3me bearing set ving in place

2 Inslafl the 20mm needle bearing with i:s pm hole
:“ned w:rh the 6mm guide pin.

3 lnsxall (he Ul' seal wkh Ar; dowel izltec mm lhe

:nn hole .n the upper crankcase

 

llL ENGINE 27

Countershafl

1. Install the 20mm needle bearlng with its pin hole
fitted wllh the 6mm guide pin in the upper crank—
case.

2. Install the 5205 ball bearing with its ring groove
fitted wllh 59mm bearing set ring installed in the
upper crankcase.

3. Install the oil seal with ll! dowal fitted inn: the
pin hole in the upper crankcase.

Rotate the aankshak to check each gear for smooth
moving.

MEMO

 

 

 

 

 

fl; NI ® mmm needlo burlnl
G) 6mm guide pin
® 533 lull buvln;
@ 50mm burl". "I rlnl
(9 on ml
0 Mn hole

 

 

 

 

 

 

 

28 :II E\C|\E
3.
HI. 1-52
x Inzrmu rump; gun-cw. ham: .; 1mm: dampers my.” :0 Spring; mam:
:; um bunny} :mm, 6205 _ nm-cn Gprnekc! ‘rILb 0;» Nnadle hezrmg
4 Culla'. 15 - ZIB Clulch uulcr - IQ Slallar driven gear
‘ Prmu'v drive um. _, Rullcu llhrul, 10233.5 35 Primuy mm
1 Pumarv "Imcn :pmem 1.! Laos 5mm»:
Diuxsemhly
1. Pull our the primary shah. (See page 24)
2. Remove the primary driven spmckel and inner
driven gent
Us. 1 :J : Frlv‘uurv drwon spvou

 
 
  

 

a 5mm dmm gnu

    

“3.55-

Pm rv :1 ve‘

: Dru‘n W g,-

 

Rumovc {he dnvcn sprocket hub from the primary
driven sprocket.
Remove the rubbec dampen.

IIL [AG'M

Inspection
‘|. Greek mu srartmg cut-J» and IIS related paras ro.‘
. we.“ “3" c' v other cam‘ge. Also cI'L-L' 'Iu: rul'lrfi for

     
   
    
   
 
   
 
 
   

amoum ro ng.
crack me surrey dmen gm: Hui-db: bn-Jnng for
an‘,',rz'am.-.g-.=r '

p

Reassembly

1. when me cluxcn outer body Pas been dusamcmblud.
xignmn tmee‘énmw “a: screws :0 sec- c the drum:
wrecker hub w quld‘ outer body, and stake escr-
V'bw l‘cad m (we poslrion; as >huwr',

 

u

   

Al'lc: .LSwmblmg {he uppx

 

mu crankcases

mm: :hu primary snair mu) lhu .ch- lmn‘ nghl
mac, and ‘nsmll the Cour.

1 3:. w 0203' sun bcarmg mm :| pnmary shark,

   

 

and wcun: 'A 1h :hc 25 mm inIe.

 

| circlip.
Ln mu Uunktascs with iI-(ur'ng bolts. (See

:32;- 34“

 

 

mrmayy _»i-au luck wasi—er wuh :he mJn
' Dong uuzwa'c,

 

 

 

Fig. 1-53

 

a: .mmam‘rr x!
In

x .
: um; lull huu l‘g
; 521m mm“ nn‘lup

 

30

 

10. CA)! CHAIN TENSIONER

 

rig.) so

firm» A On‘vchmlc ww‘u'xg
Quip i4 Owwovk “and mlwcmy:

 

C:m chm. :mmum halcu
Te'u arm mmpm mm:
Cam (hair

.emmnu shpau

Cam chnin guldl:

‘5 Cam (luin {em-mum um
1,7,. mm: n...

Tenn-mm ”mm ‘pring

y‘ rcmoner our” ._,m,;

   
 

 

 

 

Dimsembly

{Group A

1. Removu the cam chain guxdv; awd tenmumn alrppcr.
n.5cu page: 12-14:-

}. Mme :r-p lower wukme. ($99 pJgL's 13—24;

2. Remmn ‘hn [enguunur arm ans .t- :mr puin bar.

         
  

tuna-6| ;_ Trnzmnw Arm
-:- mm b."

 

Inspection

1. Chvc‘x ‘ Lam cnain gnde and :cnsinner sixppc:
‘0! wean

Reaswmbly

1 lvmall r‘. Hrs-1mm ppm bar wnb w;- mar< facing
vaam L-\\'H.
Ti‘ir‘ nn .

   
   

(Erfi ‘

 

Fig‘ 3 u:

 

‘r. by
‘hn

1 dezwnc' no Jana: bar
- Ln“ nn‘

k

 

 

31

 

  
 
 
 
 
 
 
 
  

r. 1-61

:, Cunneclmg 'udalfom)

2; Connecting rod hens
(mm

.3. Cunkshall belting)
(ten:

; Oilseak,311u'z.»n

s Cunkshall

G Cnnnecm-r. vod
bunny Imam";

g on teal, Ju.~ 45 ‘ a

 

 

 

 
  
 
 
   
  
  

embly
Remove H'c cylmdu: head, cylmdev and pismns.
(See page: 12714)
Pull out the AC gcncwlor rolor usung luror mm-
over. (“foal Na. 07011-333)“
Sepanxe the Iowa crankcase now me upper UH:-
See pages 23-24)

Izmove m: cam chain lcnsuoncr ar". [See page 3|)?
Move the camshaft,

 

 

32

  

h . 3-66

x, I’Iaalvga ,r

Fig. .1 st-

 
    

Ctiuckln; brawn: seat mm: dlnnlctc.’

m. E.\CIN'E

Inspection

1. Check the crankshaft center ,ournal fur runout.

2. Check the crankshaft-tmcrankshalt bearing clearance
as roilows:

1,‘ Place a plCLC or' plungaugc on the bearing as

shown, ard install the cranksnat‘: nn rt.
Assemble :hc upper and lower crankcases by
torqurng [hC securmg bolts to the specification.
Remove the upper crankcase and measure the
Clearance by the plastigaugev If beyond specified
limit, replace crankshaft bparmg wrth a new one
3‘ Select the crantshal: bearings m a selective set as
iollow'
Remove the trankshat: bearings and tighten the
uppcr and luwcr crankcase-s to the specified tor-
que. Check the inside diameter of each bearing
seat as showi

 

1

 

 

   

 

Measure the nursiue diameter of the crankshaft
:ournals.

Select out bearings on the bass ui the readings
taken In the steps 'Il and '1'; above.

The bearings may be rdun z'icd by a daub of cola!
punt an the side or tire mark {alphabet} stamped
on the rear side.

3

   

 

 

 

 

 

 

 

 

   

tiuJ 68 x (tumult: omnal amide dui'lil‘lN
Unit mm :inJ
‘ Crank-shalt A? >“ -_ V —‘- ‘7 r H
‘ Kuunml O 0 1113-32 no 31 95 5'. 99 “37—11 93
(Irankcase n 25944.2595I 2135934 25941 it 25864 2590:
beam I n .t _ ,__, _ _ _,,,
,3515%_-1‘5-3‘7“;§. D \yellrnvl g'r‘cn‘ a iblowni
35233235393; C Isrccnt t1 fibrownv A ”thick:
:fi‘zggg'ggg‘g, a .browrr: A .blackl AA miter
r ‘l A Measure the 'nslde diameter of the ccrxricctrng rod
7 , small end.
3. Check the side clearance at the mnncctmg roa big
Na , end.
‘ 7 ' 6. Chch the mnnectmg rod bug ultdttu-L'anksl‘ldt‘l
j _ ;x A ’ '

lists—99 g (mum ptl' outside fir-THC!

iuurnal (Is-arena as follows,

7: Remove the :urrncczmg rod bearing (an am: place
a piece ur' a piastrgauge on the hearing surface.
Furquc the nearing rap bolts to spenltcatmni
Rerot, 'he' cap and measure the cearance by
the pas > uge, 1! beyond me spec led fimit. '6-
place hearing With a new one

 

 

7. Select the connecting rod beatings ir. a seleclwe
set as follows:
1} Measure the oulsulc diameter ofthe crankshaft pm.
21 Check to make sure the code number {1, 2 and 3';
stamped on the connecting rcd big end side |§
properly malchud as shown.
3) After following :he steps 1) and 2) above, select
out the hearings referring to Ihe idenrificaiion
table below.

 

l a

 

fin 3—70 r Code My.

 

 

 

 

., ,_ UnIL mm tin}
“turf?"“hmvi” 0 D 31.99-12.00 3193-31 99 3197-31 93
Connecting rod ”*7 WSW-1 2596) :1. 259042594] 1145867125901
cadfiVwV , ,.V i
1 r (red. D (yellowl (: (gleam
2 L) iyellow] C igrecnl B {brown}
3 C lgrcenl n lhruwn'l A mum —

 

NOTE:
The beuings must be inslalled with Ihe lang lacing toward
[he lmnl (exhausl sidc).

8 Select the connecting rods
When replacing connecting rod Wllh a new one,
proceed matching (he code mark (alphabet) stamped
on the connecting rod big and side as shown.
NOTE:
The wrishl u! Ihe connecting rod does no! inrlul‘le Ihe
weigh! 04 line beatings

luaumbly

1. Apply a coat of lquId packing m the maxing sun’accs
of the uankcascs and mszall the beams; after the
packzns becomes dry.

1 Apply a coat of molybdenun (lvsullmu (orsoound
0: engine oil to thc bcanng wrr'aLus.

   
 

EXHAUST
-’ SIDE

n5 J 71

41- Buying

 

 

 

 

 

34

 

12. CRANKCASE

 

 

 

 

 

Hg J 7! x Uputv ualvk .i urmrl ums
: lower mnmg» a 0mm pm

   
 
 

-, Dowel pi'u {max 10 .. 1.:
Pumvy chain gmdc: Hwn)

Disauscmly

I. Separate (he upper Jnd lower Cranky-15c: from each
when (See pages 2314]

Inspection
1. Cneck the crarkcasc oil passage for Lloggmg.

.. Chpck rl-e prin‘ary chain gnudos for wear.

Reassembly

1 :nsldl' [hc pr ~\ ’y d‘
iacine the cans"

3 Amp , a unnorm coal 0- liqulc packmg m Ihe uank<
C5152 maing SLIYIJCES

3. Make sup all n'mwl pins 3:»: pmpe'ly "mailed m
'hmr ‘

I" nguu mth Its recessed rank
Uf‘:

 

    

 

  

L: nu ma cranlxase m the
Z '6

 

zrnJrzrc * . pcflllu'l.

Ill. ENGINE 35

13. CARBURETOR

 

 

 

 

 

fig, L77 a 10;: m 5 Sinw m
; Ln'. um m A g let "(my 5n
3 Lm 3:: r

 

o Carburetor Component Fans

The‘ carbureny componen: parts are available m a set
as shown in Fig‘ 3—77, It Is :ccomnacncrc' iha: Its
1e>peclive pans be replaccu‘ as a at! :u as In maintzrn
a sansiactcry pcn’oxmancc oi tl'l.‘ mrhureznr.

Disassembly
1 Remove the :1rbxclor .mumh \- ~r-:,rr m: "ugh-1:3:
{See page 11:

Stay plan: and (.nbuvelor body
2. Remove ('1: throttle 'emln gazing rrom :ha Z-nk icwy.

   
 

mm chambzr 3:: A u mu m
Adiusl halder 521 A ‘2 Screw m s
l Cubu'elm assembly .3 Suv pm: :2:
Float mu m

 
   

rig.3 73 a; 7mm. 'eIer :p'x’h‘,

36

 
  
   

Iii. 3 u!

I”; «as

 

   

I m JI'Iv

Trr;::'c

 

3. Remove the dust pizza B by Ioumnmg h¢x

 

 

. 111125.

er ‘ocsefi :Fe cap nus.

,m the adlusler holders.

   

karm.

 

l‘ZIusun IhL \. ghl 6mm ml screws and remove flu:

)u carburetors imm the my pljte.

Throlllc valves and jet needles

Ransom-a :hr: rsxbuwmr :op.
u ylllul- luv: lugs 01' [he Enck wamcrs lo remove-

 

aha “ 11m ard Gmh‘ hnlu.

out We .nk arm Iron: the :hroulu slut: in

..I'cc:ion A wxh a struwdrlvcr.

  

J -.:n snew; and remove the valve
byturqing the plate

 

'1, lutAulI Linc
piazc her no :hmnle Val'.

 

XE: iCV nucclc from He: 'hrolilc va§ve.

 

  

Adiuster hnhlers

‘ Karnve :i‘e carbu
the neg” 1 K‘r‘rugw
M Kcn‘ovu :ln: adi‘nl

Ti-en rcn'u'u: :le

Hg.) 3; 5.: um; :chw

Heal, nuiu IN and slow jet
1. Remove #3 f EhE’ZbPr.
2. Ra-nm'e :lm [EM spring, “main jet .u‘d :lcw _c:‘

5, n. m 1m- ‘70.“ arr'! pq m yum

   

H5.) m3 : Inn ar'n w ~ m :r

4. Rumm‘u inc mp plaza ant: r

 

mn I’la“ uu-r- sun.

   

  
 

Inspection

L Blow Tl‘r r. .1er alow jvl= ‘iz-m lu'
mg

3, Adiumng mt My.
Mmr' m >0 rm lhc (Ion w. M

    
   

 

5 igH r ' m
ch». 'k m:

   
   
 
 

ml I

 

up of If

   

. .uc: luv-I
(MORE-1451b:-

  

 

     

38

fig. J 99

[Emu-9| “mm 1:3: ‘mrl 14::
.' fuclmlrr A De}

   

h“ I ‘32 ' -u-rl ILlJ':
Hm tum

  

 

 

 

 

  

 

Reusemhly

l, Pm me am 3 er: mews caged-er wuh spring
wane” on El‘c valve plate, ard pre=s the plate down
rr' :l'u l.‘1ru.lc valve by alrgnmg the protrusion of
he van-e plate wilh the slurfil the throttle valve.
Then tum ma plan: 90‘ rowan: the link .xrm Md:
and :Igntan wnl‘ We 3:“: we»:

Ir'slall the :hruule valvr lo the carburetor body by
alrgrmg :l‘u Larbummr protrusion wr'l~ the chrome
valve SluL Check lu make mm lhc culawny pan
or the- VlerlTlv win- .5 lacing 'lw L‘Ioke valve side.

5. Insull 116 fuel tubes and incl lo m m xhu Larburemr.

J lnElill . r: muzu each carburclur tube .15 :l'own in

Fig, 3J1:

 

-., .V.-:|w- {no :l-ruule lawn: Jur, ( rnrraus rhé .1d]||\l-
w. am: (had me tl‘rljl'lc varVP-h‘r-lhrn'llx:
bu... Laura; 1: "’ mu 0' rpc Jlll)!‘ (0~I.IJ
mm D ~. INK-LL ad|u<r :l ; dca’anre by men: 52'

:ucw

 
  

 

 

 

 

39

 

l. FRONT WHEEL

53;. H
'1‘ Front whlzel :‘de
'1 Spredon-flev 3w
ban
111301” (four: 3 '30
m (mu bcx 'cla "er
mu.-
Ceu box rnamcr
' Roulncr O-riug
MIL} vncial nasl
brawn:
.5 From .1ch dunncc
:odar
Spaka) uhvny-sm
[mnl wheel huh
_ r-u-u whccl tube
F'ofl! wheel (IV:
a; ham :ire 'va
‘14. wnw humu-
mum
' Han! whne? 'im
"on! mu: dvk
3mm luck washa'
uwu)
43 61021. radial :all
bran-1g
5‘ mm wheel boa' n5
reui'm
q; Dun-urn] 21-56 5
M V. ==I aid: collar
~_ 5mm wheel uk-
nu

 

 

 

 

 

 

 

 

Disnssemhl;

1. Us 5 a jam; under I‘m

or’w' the ground.

Remove ‘he specdomutc' cable,

3. Loosen the:- AX ho‘der :cxaanmg mils and 'cmuve
ma iron: {mks wheel from :hc frux ‘ovkx

NOTE:

00 no! apeme (hr hon! huh: lever with xhc hem wheel

removed.

4. Laos": (he tron: whml axle "HI and rcmuw: the
fro-x: wheel at:

 

ngme, wise ll'c Iro'ul win-ml

 

p

 

 

   

 
 
 

hm the lugs 01 (ht: luu wasmas 3nd mum?
. irunl make «in:
1' When the mac disc "as bu.

um um r'H c, yer car 'uu n:

   

 

 

 

 

4‘3 Iv. FRAME

 

 

6. Remove the cust seal and remove the bearing re-
tainer with bearing retainer wrencn (Tool Nor 07088-
323013.

Inspection
1. Check the iron: axle inr bend.
Check the f'cnt wheel n. for face runout.
Check the spokes for looseness, bend or any other
damage.
Spoke torquc specifications: 25~30 kgicm (1.9~2.2
lbs—ft).
4. Check the tire for cracks, excessive wear or any
other damage.
5. Check the tube valve for air leaks.
6. Check the tire pressure.
Tire pressure specification: 1.5 kg;‘cm= (26 psi)

 

.ww

Rmumbly
'1. Fill thc ball bearings and the front wheel hub with
grease. Drive the bearings in the hub.
1.‘ Use the outur bearing driver attachment (Tuol NC.
07048-33301) and ball bearing driver handle (tool
No. 07048-61101] for the bearing installation.
2] Be sure to install the distance collar.
2. Stake the bearing retainer at two places as shown.

“ng . Stake

 

3. Cherk the retainer O-ring is properly installed. In-
stall the gear box retainer and retainer cove: With
the 8mm bolts. Then put the brake disr m the
opposite side of the wheel hub.

  

(3er mt chinzr
; Rum»: e.

 
    

w;

4. Install ms- brukc dist m the wheel hub thn the
nuts

NOTE:

3: sure to rrncw the luck wnhcrs. Bend the lugs 04 Ihc
washers properly aim iighirning the nuts.

 

 

5 Insra :he span-domain! hm \ slate m ”we

gear box reramcr

gear

6. lnsull the Iron: wheel to the frunr forks.
Trghten the axle holder at :he left side (brake dis:
sxdc) {ml and then the one .11 ( . rigm side.
To prevent mrsalxgnmcm. llg‘rlcn the from uxlc
holder nur first. then lighlen the rear nut unlll axla
1:. clamped securely m place.

 

Wheel balancing

 

1. lack up UH: uudunc lu dour (he whcul the
ground.
Mark the side orf :ru :irc and Lghliy 5pm the wheel
several 1: m.

 

 

2. It the mark Lunws Ir; :95! at 2hr,- same no. each
(me, :1 I: (u: indicahon that when] I5 out of balance.

3 H212“ a bahmu: 'A . Iu me l:.pp|r mu! m In:
spoke at 1hr.- lop u. “u: whml durcLllynnpnsi‘e :ne
'ncawcq pmm uh:- button" oi lhc \vhuull.

Thc b \Lu \chghie .rrr: “111"qu n {my divers?
‘.\'CngS 3, ll], 13 4’11: 203!

4 chual (h: mung buxum‘. :Im

atop: a( 0m: :lJLu ua

 

 

   

 

 

 

.ohmn

 

 

‘uud If; ”7.1.x mt.

 

bamr‘Lng
“:3!ch

 

ms;

 

i‘.‘ Hunt 4]

,3

(3:4! hm “mm
(panicrm‘h‘r m. box

    

{7m hams.-
: Ade 'Iulde' nus
\ (Au :1 w."

fig. a 10

 

 

Hg. 4-H Wheel mums

    

1.5 4 1: E341:

w rkn;
5.5.: e '

42

2. FRONT DISC BRAKE

”(AME

 

 

 

 

 

”5.“.- v. Gn'r bolt:
' 5mm nu!

 

    

Disassemhly

Front btakc disc
1. Dram the bvakc fluid.

fi;. 1—1:
’1; Soon noppn
L3, Soon
{a 13mm mtcnul
curcllp
Pifilon
7 Funny (no
" Owl (up up
u; nnphugm
7 Mum (yllndcr
Oil bolt
‘15 ham brake hose 5
q'b Slop much
a 3 way jam
3 non: mm In”: A
:3 mm hula.- pipe
:9 Caliper holdm ioinl
g (ill-pay hnldrr
:3 mum adiual hall
4;» cum: :4
q'g PM! 5
Q Conan pm LEVYZ
a} Pad A
('3 Pinon
g Calipcr A
9 Ileeder my.
:3) Caliperwtwmgbolls
llwol
{'9 Houl brake db:
:3 Czuper how”
:9 Disc mm

 

 
  

 

DIECDHHCCK :he from brake [ppm from the L'allpcr.

 

2.
3. Remove the from fem‘r-L
4

. Luosen :he came" adjusting bolt .mu‘ 8mm nut to
rcrrove [he cisr roves .Ard calipvr Assembly.

Im: kdllpClS A and 8A

a, Lonsen me lwu ulipcr secunng bun: to separate

6 Pull Out Km: wucr am at re-nm-e liir pad 5 nor.-
rlte (alipur 8.

7. Remove :lu: pad A row {be caliper .-\ by lightly
lapping ma lwc-Jd 00' me calxpct

     

H,” 17 . (ulxpt' .\
.- rm \

Maslel cylinder
l,

 

Remove the n'aslc' cylind -.
Remove (he master cylindev huntsnnn m'vwr (he
ml halt

  

25 luusun uu: hm hulls [Urumuvc LlIL'

 

aslu' L‘fllll-
dcr holder

31 Loosen the brakc cver plvnl bolt to rtmm-e :hp.
brake lcvur.

,
Q-l bcl:

: Vlad-1' xv u-dw

I Hm hum

 

2 Remove z‘nu 'uool now the cylinder, taking um not
in damlgc :K. Rcmuw: the circlip using an
pliers ool NC. 07673—323012.

 

nng

   

ri;.4 w l Manor .»_.l. M.

men

 

    
 

 

 

5, Rcrrow mp pmlow, pnnmy up, spr'ng an: cwcck
\‘.xlw: r'vum rm- Hm
NO”:
I. Apply Air manure ul 1kg mr I'm-.41 psi, to 1hr huh-
hme iuuu m remove Ihv: pnmm- (up,
1 Luke (.IfE nul In damazb lhr Chrt'». \alrr whim ym‘mvinv. ' ’ ~
1',

 

yr :1.- V‘dcr-II“ thxs 2::ar.

   

 

 

44 xv. rum:

 

 

Inspection

1. Check the pads A an: E for excessive wear. Re.
place the pad if it is worn down to its red<line
groove (wear limit line).

2. Measure the inside diameter of the caliper cylinder
and the outside diameter of the piston.

3. Measure the inside diameter of the master cylinder

1 and the outs:de diameter oi the piston.

 

 

 

 

 

 

 

Mammy
Caliper assembly

1. Apply a coat of silicone sealing grease to the slid-
ing surface of the calipers when installing the pads
A and 8.

NOTE:

1, Do not grease lire friction surlams of the pads.

2 hire care In prevent Ioreign rrralerial from entering the
caliper atumbly .it reassembly.

 

   

 

Fig, 4—22 1.. Caliper s
; Pad 3

 

Master cylinder

1. Apply a coat of brake fluid to the inside surlacc of
the cylrndcr.

2, install the check valve together with the return
spring to the cylinder.

NOTE:

Che-(It to see the valve l! inslalled properly in the cylinder.

 

 

 

 

Fig. H: 3 Check valve q, Return lpring

 

3. Apply a thin coat of brake fluid to around the
primary cup, and install it to the cylinder in proper
orientation.

Mott:

1. Mt: are not to damage lhe primary (up during installa-
lion.

2. Be sure to renew primary cup when it is dignitmbled.

 

 

 

 

ri5.4 24 ‘i_ thary cup

4. Install the 18 mm crrclrp. Check to see the circlip
is fitted in place.

5. Bleed the brake line and fill the master (ylindcr
fluid cup wuh SAE DOT3 brake fluid.

   
 

“pl-25 x Din:
3 Master cvlndfl

 

 

3. REAR WHEEL AND REAR BRAKE

   
 

 

  

 

N: mm:
m- um: .
~ Ray bub: pancl
; r (em!
bukr panel
Rm braxczhne LMn}
‘4: Rev [tune :13:
mung, (1‘.ng
Rut :nkn rm
om 'uuiJl Lu]:
hcnnrg
Cg“ Kw u c dulawcc
hull“ ,\
9: Rm! whrrl hm
:_ ch- whm :znwt'
rLzl» \Ian
of; Ram ado mumcr

   

 

 

 

  

colhv 3

N 6304 ”04 b3”
hr.” n;

wx‘ Du' 3cm)" - 15 “"3

    

:3 My mu l-«uvu‘u

m mrrn

[\lcv v..| c'leuu

55 ~

:\ Rcu wheel > :r
cud.”

q; <, IN rm: 161w.

 
   

 

 

 

 

 

 

 

     

Disassemhly

'l, anm'x" th nmhlcl a1 Lucia slcc.

L" Rc'uow he 'cur b'akc rod and v brow \lUupL‘r
arr-x

5‘ Lumen I'm arm: was :djusrirg hm .mnl Imk nut
on cm.“ szdc. Remove the mum pm and Irma-cw
the MIA: Hut.

4. Remow- rl‘e rinvo, rl‘ m frum the iina Li? cu
wrurkm Them Lake off the rear wheel {age :ur
wulh 1qu char adjuster stoappr and rear wwccl
axle.

3. Rem enema. circlic and fame
final dr. L The Inrk -.

b»: (Punched.
Now.
1, \\‘hrn yepluung xhr :innl damn upruLLL-l, len..|<x- n

a

 

gum. mm m rixing hon;
\i‘he-n lhl' 10A Lushcr ha: been wmuvn! Irlerr :l nith
ncn nnr .ul wasscmblx,

  

\ (hm ad um» :luuuer

     

um C1 .n attuflifl; mm
c chm :‘fimw

46 IV. RAM:

 

b Rmnnvr: the we.“ wheel bgal‘mg retamur wnh hear-
Ing rclamer awn-rich (Too: No. 0708842901}.

 

Inspection
'lt Chugk the rear wheel axle t'cv bans.

2. Chuck :he ball bearings ior excesswc playt

3. Chuck the r w for face rumour.

4, Check tlm spake: for lameness. bend a? any other
damage.
Spoku torque socciiicatior‘: 20~30 kg-(m l1.5~1.9
lbs-ll).

 

 

 

 

5. Check the final criven sprocket for
vt‘ncr damngc.

6. Cl'c:k the time chain for nxcesswc wear, elonga—
tion or any olhcr damage.

7. Chuck the we for cracks. ex:
other damage.

El. Check the :ire prns‘sure.
Tire pressure specmcatinn. 2.0 kggch (23 psi).

9. Chad: tl-c hrake limng 5m excessive wear.

10. Chuck the brake panel [or cracks or any othL-r
da'xage.

11. Cficn the brake drum (or excesswc wear

car m any

 

 

w: wmr or any

  

um
3mm; ”Mm

 

Renunembly

'1. Fill the hall hnarmgs and the whpel hub with
grease. lnsert tht: d:star.ce collar into the hub and
rim-u ir the bearing usirg bed ‘fig (lnvcn nann’lt:
[Tool ‘10. 3mwm-tot; and drlver .zluL-hment lTuul
No. 07048 3331)“.

2. Install 1-14: bear-r5 rolamcr mung rnzain wrench
lTuoI N 07068322017. Stake the blur}. L retmrm
a: luu.v placeS as shown A Fig. 4—31

3. l‘t):all the ariwn sprocket to the pwut bushing m”
the whccl th .mu secure IL with (In.- 69 mm Ctr-
(In:

 

   

4. Apply a 1:02: n7 gruase m the anrl‘ur pm '52er
‘ "Illng the brake shoes.

\OTE: '

The hvakr sllue |imng must be "re from .my greasr or oil.

 

.2. Unm' wmnlptmn or reassmrbly, cnerk :hp dnw
len Sun ard ales’t property

AK," . .v:(\ :hc rn hraLc pedal in'
he: and yrce n 5: pm;

 

        

-/_ In! 40‘

   

 

   

 

4. STEERING H ANDLEBAR

Fig. 4 3a

Disnsscmhly

 

_ cum-

, chu:': it upccr Fan-Jig nmdwl

.; anr mix-um

Thrnulc grip pm:

‘Vuwfl new! ”I‘ll
r'rrvgency swllch
Upper hanul: hank.—
V" o! IJK'ID

swung mama."
m-n nlgnnl, hnrn
aw‘lrh

Thrn‘Jl: :Jblc A
"vol 5 Lable H
funk mo h'uln»
norm; "(:1 mn

 

   

 

 

 

Rxmmn- :lzp 'r’dSIur L‘y'lmuuf. lakll'g Law not to will
hmxu Jum,

 

I‘mmm-uu xl-I: alum-u cable a! ‘J‘u Inver.
hum-um! m: thruulu cables A Jun: 3 rmn‘ :I-u
caxburuor r to cab'e my.

 

Rmnu' A- I!“ New] lighl ur': mm me ("2 am: cw

 

guru.

 

L‘u: wvnr‘g :1 1h? “mules

 

stre r: hard e'unr,

 

‘ g

 

 

 

 

 

 

 

. 1—37

 

 

 

 

( LlLl‘ (1b r
'afm v'clur abm

 

 

   

 

   

   

6. Cami}! !3\ ' ou: llw: ‘~l‘mg swuc‘u assen‘blv ad
:-.r: :ignal sumcw assembly from {he steerzng héndle-
mv

Inspection .

1. Check the steering Hanclébdr r'cr :vm: or any other

damage.

2. Chem ouch w:r'n: for hruaxage or ar'ycmer dam-
age.

3. Cl‘rck each cable for damage.

Reaucmbly

1. Install the lighting swam assembly and turn signal
swucn nsacn‘bly .n r u steermg 'rwndichar. In lhlS
me use .1 WW: or .. r Ivke to he the ends of {he
wvr ngs to pass Karma}: .n [Cw plpc v-uthrml binding
or kinking

2. Insmll c szecring, land! r. aligning In: punch
mark: u'l the l'afidluua.‘ mm the manng edges of
ll‘m- l'v. JCI’ an lark [up br'clgc.

NOTE:

1. when lightening flu: upprl holder In Ihrlovk Iup hridgr,
liglllcn rhr hex. hum :1 mo I'mna firs! Am] Ihrn 0m
mm at Ihr may.

2. Yakr (.m- nul I0 hind or kink lhr whinx».

3. Chock lo he er0 max wlnng and cable Is flue [mm

  

IL"! lur

 

g the? stucnng handlx;-~
- .u lcn or ngiu sidp.

5.

Disassembly

wwe

y:

I)

 

STEERL G STEM

 

Remove the from whet-l drd CJIIPC.‘
Remove the stcermg undiebgr
Remove me hear. :Ight unit from the has; Ilghl
case anr. mscocncu {he wnring at [he ramess II‘
:lzc Laue, hen ramcve the LdSC ‘rurr :hu dean‘flg
Slum.

DiscnnnPc: the brake rose at (he 3 way |clnl J! the
«saying 51cm,

Rcrnuvc l‘w speedometer and :achnmerer. D scar.-
ncu li‘w 'fictc’ cabVCs a! the engu—e and irnnr wneel
:Idcs,

 

l-Juwn the from fork but .
hr L lid gist.) 'CC'SVC‘I'. [he 9‘.er

~.~-mg sic" bouu—a
.>.LJ-' wg 'J'u was

     

.L' U".- n'o-Ex lop bridge. Tlxm~ pull 1.:th um trrn :mk
J>5cr"b7y,

Inuzm [he staring 5mm “HI ”'1 [an n: [12' s:.--n.
and ru-~:m-c Kim Mk mp bnugc.

 

\Ulk:
late (uc nul [0 :me [hr ilccl lullx Iuppcv: lvpn and

Inner: IH pm»

Infipeclion

 

   

   
 

 

w [Jr my

H In: suc'mg huh

 

 

  
    

 

. n IX." nghe‘f
my! m
:Lp (an! us.»
new lult mum at ‘
mun-1g bnncm cum.- tau:
\luurl'lg nu: 4..” m4

\ mu m wafl'cv

‘1 <lrcrl1u urm

.IL‘I‘H'I

 

   

 

   

-:.

 

Swrl r): “:1 my
‘ur'p. n p u! d.;.«

‘ mp r-v-cm

 

  

Fig‘Lli 3 Tm) mm» Ht:
1 :3 alccl balh

mu M : um mo blvdg:
x {mm lnrk uwvu-hly
, slum; stem

6. FRONT SUSPENSION

   

 

Reassembly

1, Install :6 steel balls (upper: 19 mm and Eower:
18pcs.J : udch race properly‘ FuEIy tighten :hc steer
mg head top thread and [um 1: off so that the stem
rotates casuiy without rartles when turned‘w either
to left or right side.

NOTE:

Be sure lo (lean lha rune Ian-s, ball racts and steel ball;

in (Inning mlven', and apply a coal ul yeast: hefore te-
asscmbly.

 

2, The fork mp bndgc should be insafled afler lem-

porarily nghremng the steering stem.

 

 

 

 

 

 

 

Tum: lurk :mll
191k ‘Iui

“0N loV( Luve'
um 10% p1):
.Hflfl “mm mm.»

 

 

 

Fig. Hr

    

; Ua'npcr
F'Oh! Ile 'ID
. on: lurk UIICE' cux'c'

 

 

:_1/ Oil mi: 33 (46 4. I05
_ Cnnmn $9M"): seal
:5 .ronl fork hoxcom use

g Ballom cm mm 1 sum nan 8mm
.g ~17er imml r mm [2 Axla hum».-

Disassembly
1, Remow the front wheel.

 

 

 

2. Remove :he calip r assembi‘ and tronr {anger

3 Loosun the 8mm bolts at the slér‘rmg :lcm bnxmm
bridge an: a. .ne mu mn budge, wluui secure the
"WI! ion. 2 ablv Pull cut the assmubly from
under: dc.

NOIE:

Beim: lnnsfning the abme balm anr the iron! ior‘L bolls

hunt '

~ mum» 2hr.- ‘

 

' :uspersmn mL

 

 

 

>, Remove ms: on the rent fork pipe. it any, ‘A'lll‘ iznc
emery cloth.

5. Lnoser‘. the 8mm socket bait at the bottom or the

fork bottom case using hollow wrench [Tani .\n.

07085-32301),

The front em pipe complete With the dampe.

can be removed from :he bottom case as slam»... in

Fig 4—30 :-

     
     

Fig. a 49 ,i ‘riullow a.n:h

Remove the front fork bolt on :np or the rork pipe
to remove the from cush:on spring and spring seat. l-A—l

3. To remove he oui seal, take 061' the bottom use »..- W1.- -r
Lover and remove :hc circlipr

\I

 

Inspection

1 Measure the “88 length of the iront cushion spring.

2. Check lhu front lurk pipe and bottom use ior
looscncss or any other damage.

3. Check the oil seal lnr scratches or any other darn-
age,

4. Chuck Iho [rout iork pipe sliding put [or damdgc.

Reassembly
1. Install the irnnr iork [1pr complete With the damper
unil mm the fovk button case.

NOI'E:
Apply locking sezlanl In "no flmm soda-I bollt

 

Hg. 44) i‘ iurk bottom use
i: hum :an [not

2‘ Apply a coat of ATP (automatic transmission fluid}
to around and inside the oil seal below installing
ll to the front lork pipe. Press-lit (iiu sml usmg
writ scal driver iTonl Nor 07054 43301:

NOTE:

1. Be surr lo inslall the circlip in plan.

2. Replace lhc oil xQ-Il will: .1 new one at reassembly

3. Fill r—Jrfii iron! lurk botmn‘. case with [.3ch tin-Lily
ATF of 125 (c (4.2015).

NDIE:

when changing uni] .ndd lusu H.601” 3 inn zed u'nr'

 

32 w.

 

T. REAR SUSPENSION

FRAME

 

 

 

Hg. t-Sd

41: 04“. chain use

[two]

1f Rn: wwemmn
l'wol
Upocr lam! uwo)
Spllnx seal scappu
flour)

'1 9mmlmkn4l11wo)
, Rur cuxHon stop-
pe. rubhel (Mo)

.3 Ru! cushion
upper case “on

in) Ken cumon
spying mm»

3 5pm; under scax
Itwni

{9 kn! cusl’uon
uppnr nul llwa)

{11. Hex boll 70x12
Ilwol

@ Rn! amp” uwn)

53, Rear folk

5; [car (ark pwox

bush :Iwol

Rear fork {Infidell

up :Ion

RI?" lurk ccnxu

roll"

Ran lurk ph‘ol

bun

1'0 Ru: bulm steppe!
mu

 
   

 

3;, M

“3!

 

 

   
     

'Kea' bumpu
3mm bnir
‘Rnal (mm: Juper m:

I fig. 4 3:

 

Diunssemlfly

Rear suspension

1. Remove :hc rear bumper by loosening the 8mm
bolts and luu (UShOn uppcl nuts.

2. Remove Il‘u ruuv suspension by removing 10mm boizs‘

3. Compress [he reu wspurmon using )u'vxce moi
lTool No. 07035 32901] and remove I'm.- spnng SEA!
stoppers to It'uovr? the rear cushion :prinq.

Rear fork

J Refl'lOVe the r23! 'Io'WéFI.

J. Lumen the self lock nu: 2:) pm“ aux tin: rear fork
pwm hm! Them", rcmow the rear 'ovk from 'J‘e
(fame

 

l'-'. [RAME 33
Inspection
L Measure the free length of rear cushion spring,
2. Check the rear cushion damper [or deiormanon or

0:1 leakage

3. Chuck the rear cushlon stopper rubber for damage.
4. Measure the rear lurk center collar-to—bus'nlng clear-
ance.
Check the rear fork swzng arm for bend.

VA

  

Upper cur
- in: z shxon 59m:
par ‘n'n:
ock nu!
. rapper ”our
‘5‘ Run dampcr um!

 

 

Rammhly
1. Apply a coal or grease to [he rear mrk center collar
balm installing it to lhe rear fork.
2. Install the rear fork.
lnsen me rear inr< pivol bull from lluu lull side.
3. A550”\hl<: the vuar :uwcvmon.

1) Corv‘prcss the rear suspensmn with me sen-Ice
xool {Tool Ixo. 07035—32901) and pull up the upper
ininl m Install me «pnng scat slappers m pidce.

23' Apply locking sealant lo upper |olnl bclore ug'nl-
clung,

4. Install [he re." >u>pcn>on :0 Eli: rremc.

 

   

fig. J 53

B. FRAME BODY

 

 

 

 

 

fig. 159 Pm»?! me.

 

 

, lc‘mm

; [.qu'v:l

    

   

a: ing hand! ar.

mlur

 

1;. Rcr"uvc (Fe
1') acsrren :hn mu» I
cm] 1:; 5p .Ip-n.
Looacl' I: b and 9.3"“. I'm bclrs wmcl: )L‘CIJYL‘

my lancar.

'5 or the rear luff} :Igr‘dls

 

 
  

 

.1
(Km-u hm bu
3‘ mum mu 'm I:

 

 

;' Rumu': \ :I‘Ie . rimlrtu case am: I U

 

ry bux.
cwmuuor and

 

Unmnnrc:

 

rl‘ wrung at 1
wuplur
Ru—‘cvr I‘m Hlkul' rycrir'm'. wgu
“Agni! c mm -|
Loosen ll'v [‘m
c art
8. Dm'um

 

u," anc smrmr

 

bnt< :ccurc [he 2r

 

      

r0. harm-9.

 

‘3. Ram». the mum and side ennui

'10. R “flow I' up 1rd ha n bul' ra _'-3 (mm the
m5 hum e Ming bal ram removi- ,m
\'u u}'L\-l-U-333'l

   

       

 

{.5 un ‘ hi «4;: vn
“.1vi:7-

 

Inspection

1. Chum the wcla Ir tl‘e my] MIN (3;:
1‘. Ch (A tho nan
r. m

c‘oggvng.
darn-'11.»

      

mnly :L-r bard. \

       

 

 

 

3, 0‘9er m9 fieu—mg Nu: plsu r'ur ‘Vladllg‘
dcfummixun.

4. Check w'ru urns-fix, Counler 1nd
pmpur rrnneadm m .mv nth).— dun

NFC

       

 

I")! 4 '3‘ 'L :lvn-nc- suen

5. Check me Ouny u" U-u t'uu (<ch drain and
«miner up [ct r'JLguu u.— ar'y ul'lcr damage.
6. (had he 'uel p‘pe for any damage.

Installation
1. Urwc (In: iup .xm: hulmm ha. have». inla :f‘e steer-

 
 

ing was pvpc prupcvly and uvunly uwwg hml
nlwc'r .limrfimr‘nl I'Tool ‘10. 07348—33371}? and 0'!“
halul'c (Tm)? Nu 07043 rmm: Em A M.

    

{all um mm
5:” ”cc:

 

Cuv'wckl {he Wm: 'mHIuss
km": the \-.'r~'u_-:-; Jud rch'L‘ 1|:an u-Iih l'll.‘ CII'JN

 

nu! r

   
  
 

3. Install 1m; .m H <1 n.\:w:-,- a
Remuvu my ILI'I {um In- I!

mam Jam» I‘m fur r “Ming, nm-Iru n~.n|..-liun.

 

 

n-r

 

4 Install W. bqury L\-;\.
(in 1 :[u
am: wen Me q

 

ur ‘ L'

mrd 'Jbie‘ .0 . .. new '

   

:- ml q:

 

   

ii; I fill

fig. .4 u

Ham mud mounhng no“)
» 34“ch 3w w 'ub. 5m.-
3 we :ler :pvvrs

Mn my
. meu tunnel

, Conner: m :nch

‘ ~.m‘-tz~v L :ch'
; 6411 m.,

 

    

 

 

 

 

S. Inga” [He *1

NOTE:

L Do no! m-cmghtcn the main mud maul-ling boll; ac
sure to install [he ballerv over Pow lulu- guide In [he
lei! side of the bull,

1

.. Inmn 1h: ‘id: mud <pving will: in longev honk par!
upward.

 

sia'ui ard sice sla'ld.

FL

Clean Ifc 3i! CIFEL"
l-glui-g tap n—e rlen clams anu aaply .2 hm:
ul‘ :nrrpre<-'m'l ur from" 'niifii‘ Io rcrnnvé Gut oux‘

   

 

nlufvlersv

u upper amt luw -- r-uufilnn $ugu1m‘y With my
.11; why, and Ilg‘uun :hr cum-ccxing pin.
a. n) the Iran-e mlL :I-c brackrra
(on zhn .1. A nuts.

Imlull
jun: '

 

.ome

 
  
 

 

Mm:

 

um; tlgu'

 

 

 

1.

  

v. ELECTRICAL ‘ .1

 

 

 

 

m

 

~ I

‘f? m

  

 

 

“CW”

9 HeIngh!

E Tnillsroplighl

$ from rum mm! l-ghu

4 ‘ kw mm slyul um;
‘ rum signal indium lamp
Oil mum warning lamp
Neural mdlcalot Imp
man bum indium! Imp
® Speedomerev lamp
3 hehomexn lamp

W

m

(-3 SQ

m, 5—!

SWIYCHES .

(E Main switch

@ Emergency swirch

1h Hudlishl control swileh

0 5mm switch

1; Tu"! ulnal conuol swflch

g Morn button

13 Slop mm

’13 Neutral Iwiteh

'1‘; Oil pressure )wlleh
CHARGING SVSTEM

3 A-C generator

:3 Regulllor

9 Silicon Name!

9 Battery
IGNITION SVSTEM

0 Ignlllon tolls

B Conn" break"

3 Spark plug:
srAnING SYSTEM

:59 Starling molar

.9 Mann: swild‘
ELKC‘VKICM. [QUIPMEN‘I

3 Horn

3 Wlnhl relay

53 v. ELECTRICAL

2. IGNITION SYSTEM

 

 

 

 

 

 

 

 

 

 

Fig. 5-1
G) Spark plug; 3 lgnltion mils v3, Contact breakers @j Capadlors =3. lattery

The ignition system lites the 4-cycle, ficylinder engine in a sequence of 1, 2, 4 and 3 of the cylinders at
each 180' of the crankshaft rotation. The combustion strokes ol all the cylinders are completed each time
the crankshaft rotates two turns.

To the right end of the crankshaft are installed spark advance-r and contact breaker housing which contains
two contact breakers. The contact breakers are 180’ out or' phase and connect _to two ingnition coils
which provide each two high tension cords connecting {our spark plugs as shown in the diagram above.
Since no distributor rs used, the system is of simple construction and iacilitates servicing.

 

 

 

Ignition coil _
3 pom! spark gap Opemng i 7mm l027rnJ. min
Spark plug '
Yype lstandardl D—BESL lNCKl. X-Z‘ES lDENSD)
Plug gap 06-0.? mm loud—0.0mm
Contact breaker
Point gap ' 0.3»0A mm 10012-0016 in.)
Spring r'orce 650—330“ I1.¢3-1B7ibsi I
Capldfc'lf .
Caper-iv 012.1? —,ro~..

Insulation resistance 10 MU Hmo‘.’ With a meggerl

Snark advancer
Stan oi admncc Ilclankslur: folailun 1400-16410 'pm .
Fu‘l admrlcr Irranksnatt rotatzom 2 300». mum l

we anqlc

 

   

V. ELECTRICAL

Ignition coils

Inspection

1. Continuity test
1) Primary corl

Check for continuity between the two terminals

of the primary Call with a radio tester.

Right coil: yellow. black lead to white lead,

Left corl ‘ blue, black lead to white lead,

Secondary coil

Check for conttnuity the high tension card termi-

nal and primary side terminal on eech cord. Ir’

there is no continuity. the corl has an open-circuit

and must be replaced.

2)

2. Performance test
Even though continuity is ensured, an ignition (oil
may provide poor performance after a long period
of use. Check to determine its performance as
follows:

1) Turn the service tester selector knob to IGNITION
TEST and make connections oi the tester followv
mg the instructions furnished by the tester menu»
lacturcr.

Connect the~ lesler power supply cord to a fully
charged battery.

Measure the maximum distance where spark jumps
across the gap regularly, thing a 3—point spark
appears as B In fig. 3-5. connect the high tens-on
cords in reverse to make measurement under the
condition of A in Fig. 5 5.

2)

 

 

umtm ..
oil parlormance lest

 

lgmlron c

Fig. 5 5 3—point spxrk mm

Spark plugs
Inspection
1. Check the spark plug for worr- or pitted electrodes,

 

excessvvr: gap, and damaged rusulatw
1) Clean dirty spark plug using a plug cleaner or
Wire brush.

 

2) Measure the electrode gap wrtl' a thickness gauge,
and adlust if "BCQSSJWE
Gap spec ton ’ 0.G~0.7mm 40.024-0.02 n)
3) Replace the spark piug \V'tl'. a new on the

 

insulator or gaske: .s damage: or (“$10”ch

 

 

 

 

n: 3 s i Sper'x clue : has drawn

 

law}?

MEMO

  

.\ in)“ A\1\‘JI\(«"

 

 

Contact breakers and capacitors
‘1. Comact b x'ers
Fr>' the
“mung
:USTerI

    

[u

Capacitors

Measure :he c.‘.pa<il‘mcg~ of the ”packers uamg :hc
sen-ice tester.

Capacitmce specification : 0.22;:
NOIE :

the point mus! he kepl open when measuring.

 

_- 100,-;

Spark ndvanccr

Inspeclion

1. Wine 0 any [may rmlzcr from the {union surfaces
and x «K fur olh operarimL

2. Chuck .w- dih‘d .LL" pin far rncus~ vu wear.

l Take mu ruddlngs of me rmkaghafl rpm .11 iniml
,mn I'u'I udvarcc arglc-s mung Xhu lxrn'ng lighl cl
”-1: :urvuc luslc!.

 

 

Vi ELECTRICAL 61

3. CHARGING SYSTEM

 

 

   

ml

 

speak“;

 

 

 

 

 

 

fig. 5-10

,3; silicon iecuiier . Regulator 5“, lower contact 03 Field coll
it Battery 35. Upper comm 6) Relay coil 3:; load

a) Maln switch iii Moving contact 6) Stator coil

The charging system consists ol .1 J phase A-C generator, silicon diode rectifier, voltage regulator and storage
battery. The 3phase A C generator, a brushless exciting type, is capable to generate high volume output
enough to operate all electrical units of this machine, it features compact construction, light weight and
reduced wear parts to tacilitzte its handling and servicing. A dual-contact type Tirrill regulator is used
in the charging circuit.

1. Charging lest

1] Use a Iully charged battery for the test. tThe
specific gravity of the electrolyte In each cell must
be 1.26~1.28 at 20 C' or HP.)

2] Canned the negative probe of an ammeter to the
pnsitive terminal at the battery and the positive
probe to the harness.

3) Connect the probe: at a voltmeter to the battery
terminals in similar polarity.

4) Run the engine under the conditions of MC?”-
TIME RIDING by switching the headlight on. and
DAYTIME RIDING. with the headlight off and take the meter readings. If the readings are'out of
the charging characteristics as specified on next page, check the generator for condition. If it is
normal, check and adjust the regulator.

NOTE:
Remember the generator output may vary with a Iempzraturel

 

 

 

 

 

 

rig. 5.“ Charging mt

V ELECTR|CAL

 

 

 

 

 

n5. 5—12 Chnrs‘ng um r mm

  

C genuine!
Iran run-1w:

 

   
  
  

 

   

 

MN I: ‘1 5mm my
3 ”1:. col

‘1‘ Dynmw vae'

 

Mg, 3.1-:

:Fel: m"

Chirfl'lgfilfenl (in: _ ..
NIGHHIMt klulM; 1 6
OAYYIME RIDING
Emery mmmal “Huge 12

 

n Rrgulaim
Muin mm

hgnnng iwian
Lay:

    

3.000 3000 4 L‘CU 5 :00 GOCO [an 6,000 ‘

 

1.9 2(‘. 1-5 16 1.5 L4 1“

 

4 j : 2 15 1.4

”(S 15 15 15 15 15

 

 

 

 

   

 

 

Rucr: tharfiinfi sptcd 5pm 1pm

Gruund puluxly I:

lmspcction

1. Checkmg field coxl (or cowtznuny
Chen for continuity bclwccn the Mn |eads (WWW
and green} with a radio :esler.
Rusx .utcc apccxficak'on: 4.s~s.nc2

 

 

 

03

 

 

me, 5

2‘ Checking rcsistanc: of the slalo' coil wincu‘gs:
Using an nhmmnmr so: to its lnwesr «ale range.
.lSun: [he remia'ice betwccvi ur‘c yellow Wire
lead and each of (lvu rcnumirg :wu. feel all three
leads in this manner.
Specifmalion: 0.61—0.69 ohms resistnnce
helween lequ

 

Silicon diode rectifier
Tcsi each diode for forward and reverse Conlinuily‘ wilh
an ohmmeler or ms: light. Toucl‘ mic of ihe yellow
wire coupling, pm, _ wuih either of :l‘c (cs: Ivlslrumclll
u's, (hen loud! (In: wcond lcsl land to pins 1- and
in turn Nuic ihc Cunlinuil‘j mdicaiion. chcai
l s procedure a: each 0" the [we remaining yellow
wire muplinfi pins ‘:n (Fig. 5-18)
Reverse :he [95: insrmmcni lead: and repeal :he above
protuc'ur -
1h: rcui. er I} good if ilu: but shows continuity ~n om:
dirccxlon only at All dlodca l Liiiicr Is dcicclivc if:
a. View 13 continuity In both civu‘crons a: any diode.
b Them ‘5 '10 coniirmii in sunny cimcfinn :ii any
(liodo

 

 
  

 

 

CAUTION:

Do not use an ulimn'ctcr': 'negcmm range {ohms \
1.0110(1)) for this [mil

Do nal operate the engine w in (he red -
lead cisconneuedi

hilE rectifier

 

 

\thn installing a battery, be caiuiu. KO ccnncct bnliL
letmina| wires .n conecl polamy,

 

 

Disconnect :l-e zegiiiicr :cupling -|-
the bunny "or an external now.»

 
  

hnn chug-‘1;

 

 

raw: tncsc antaun.

dissed

\ 3-.- I'L‘.\L:|l .

 

 

: V-LL Hzi'eiuuv ~ S|i|rnn CIDdC 'rrm'nu

3' Mining.

 

“g. S 15

 

‘- 5mm roll

ml -,

 

 

 

aim-on diude mailei
Comm.

 

 

 

 

v ELECTRICAL
Regulator

internuttent opening of the regulator contact points
u'urmg operation creates a resistance in the field circuit,
reducing alternator Output. The voltage level at which
this «curs may be adjusted as necessary,

Testing

Test regulator with battery fully charged

1. Connect a DC voltmeter from regulator ignition
rig. 5—19 ' up”. tom“: pmn- terminal ll} ll) ground. Remove the white lead From

J’s-mien the tield terr'wial {F}. and connect an ammelcr

 

  

 

    
 

 

 

‘ ”MW—mm “m" between the wire and the terminal.
rhltxll'lt ule adtstmen: arrr r . A _
“a“! H, 2. \Mth the engine Idling, note the trcld current. It
Armin-u gap value exceeds Mode l l:mxts in the table below, lhe
a, item !

regulator or alterntlor iicld cml is faulty

3. Slowly increase engine speed until the ammeter
ncudlc deflects .o halt the Mode | mluu. Notethc
voltage reading at the moment the ammeter needle
dellertfi and compare wnth Mode ll in the Iable
below.

4t lnneuc engine speed to 4000mm or niorct and
Hal: the maximum voltage reading Field current
and voltage should agree with Mode III in the table

 

 

 

   

be

moat HlLD CLRRENI vulTA E
I no .‘J—EOA m 13'

. 1.2 1JA 13 5-I4.SV

m 0-1.:A tea-130v

ll iieic cunt-n! does not decrease at voltage increases.
the regulator is faulty

[1' held current to voltage value$ are higher or lower
lhdn tnc E'mirs in tlic table, adiustmcnt is indicated.
ll' vultage exceed: lEDV a: any speed, (yslcm is every
charging:

 

Adjustment

1. Armature gap: 0.671.0mm (0.020—u.040in4)
l5 adjustment is required. loosen the pawl base
Scre'. and film: or lower the POINT 3., rnblv to
obtain the (orrcu armature- gdp

2‘ Angle ga 0.0mm (0.024in.)
Adlusimcnt oi the armature gap simultaneously
ud|u>ts the angle gap

. t , 3. Point gap: 0 mm {0.012in.)

“:45 21 (tuna-n}; m: ad‘uslin: arm to adiuxt m» !f adiuitme“ I} ruqui'ed‘ rm it: y bend the lower

“"5”"- ’="-‘ pom: bracktt to abtar. :lu- correct point gap

4. Adiusling arm
A‘u credit-g nature zap and paint gapl bend
the adiu .in r': up "r down [0 obta-n the correa
voltage reading; 5.: me aciustng ar-n \.p :n
:‘l( arc li‘c cl‘ are or an“ orient-me the

(hr: 1-; '&?~

   

    

   

 

    

 
   

4. STARTING SYSTEM

The starzing motor IS located on the upper crankcase.

l: is of a drip- and dust-proof type.
The torque developed by the mater is transmxned

through reduction gears, driven gear, and overrunnzng

clutch to the primary shat;

V. ELECTRICAL

    

51 um; mom!
51mm; molar thafr gem
i Nailing mulo' veducuan go.-

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

’l‘ '6
fi\ k)
xA
(ax '4 - =n=
,
9
I
r n:
“\5) r~ _._.
h
I: ®
d!) i.
"5.5-2.1
“j Slaibng 11020! ’A‘; Pole: :7. Sunny wean-
; Bvushu , um um : Plan“!
'2. Armin": a Magnellc swimh :3 Mam swizc‘l

 

Starting mnlor

Specifications and characteristcs

Ramd output vollaga' 12 V

Razed ouxpul 046kW

Ramd operating (ime 3052c, icoutinuouat

 

 

‘ 0,140.“: \c-IwJ mm. In: mi:
N # '_ V ' i ' ~=
‘\.ufl:g« v: ‘x E ' -
‘ Ampemge rm 3:. no :33

.. C' 26
‘ 1.. mm ‘ am

 

spew «pm

 

 

 

Sla'lmg Mule! redncnon ;e.:-
SIa-z n1 mmcv

8v ’
5' ~h

5:Hr;:

.. MM.

 

66

 

 

C: I-v-uLHLV

 

~1 Carmn h'uslVES \
; arm

 

Lngn

.LTRICAI

 

 

lnspccliun
1.

C viking carbon brushes

C cck the brushes and spnngs to: condmon Bru-
sl'rs \vlt h arc vNCL‘Mxvcly worn and nat ) ting
pmpe'ly on LUIIH‘LAIBIOF and weakened brush spun:
may muse ‘u: xla ‘ing motor inope’alve, ch‘aca
the hwy: 0.’ :prlr' -: out m We spenr’m trons bdow.

 

   

 

  

 

 

Eur-dard \alne Ke'pawr h-nx

 

 

   

 

 

Crimp hrux‘ lawn" “~13 5 30.221 ‘
r-u- ‘ 21]. 4. ~n. :1. max.
Itsmh vp'lng honor- a s~u. o
L 15;. I] 1-13‘
Clc.~.:m.g, wmmuzuwr

a

   

     

“g. 5 16

 

(he-J. m; IcI

 

[15,: 27 alum; . I'm! m. . ”I lu‘ Ljnlnl

 

   

Ch [rm no
I‘m sun'qcu -
Inc:

uldwr surface in! rurrdxnun. Pohsh
h .1 fine emery [lul‘n u dirty, and
ugnl‘; w pr; L clean hr‘l'qrz: .‘bhELmbl‘f.

 

 

Check ng riaxc ccil for (anllillxl'l'
Check For m

     

ushr (UnnIKCL‘d
n) :I -- iuuid gull a J starun' '1om' cablc‘ H mm
may. : inniraluu: :lmx 2h: field
LUII inn an open Li'CLIiK.

’ may m-M'L-cn “L"

 

s nu Lun Is an

   

(.Iwciir ar—éture (ml for conkinuu
Inc arn'arch coll vmn .3 Sth’K-CIFCUrC wrll 'esul'. n‘
a r’arlurc or [ha surfing more: to Opélnl‘: properly
Cneck ior mnzmu. _,- haw. '1 [hr LUIH'IUXMO.’ 54:.
73:0 and rn'c ll ll-u-re n any (unnuunv, e sramr
cm: x: grnunm-ti

 

 

Starting magnetic switch

The surfing mcIr-r chm-s a large «wuum cv'
approx 100.-\ v. wen cram-mg the mug-re,
This ‘5 why a big:- Lapaclw elux‘lwmagner.“

W'1ich m elPrniLuEIy 'cmme ‘ontrolled by 1 sepamle

svmzch «lshr‘er :w km: :5 used‘

lnspl‘lliun
I. (Ihorkmg pummry
1: Mon:

'Axh'WIIILJIL Th- ruI n

'I mr wnunuuy

 

 

'm cnnillzmly,
d (mumm-

    

,, (lick-

 

arm» l'u: lwr» h

s of 1m: CDII.

 

 

.1 It»
‘ mugv-uvc 4w”. '1 \-|[‘ uncomp nil
duo :v a LU"- :m‘nurk cf chrénr

're'mt wrl‘ nc‘r Hm

:mru‘

          

 
      

Ld)L
VCSlstif‘CC.

Check mr x mmir
primary m by town.
mm :m’l ~ I: K
incirat‘nn [flax l'l': wid’illlg [TERRPLC Myth ,5

     

 

:"n:-- he lwu kn

 

 

 

a V5 nu rum

 

(an

 

 

 

pr r4113" «all 'm: a"

sun: .5 I'muu y Jppillng n 13\-‘ betl‘

 

m use. :hp rnnlucl [Imnlx‘ m
m hurnl
' I: I'm“ war}!
I. m [u u:m_-.nuc'

‘5 m [ha
1;“: balm; .vuh :I-o
ll l‘: an

6') 9

a.
@

‘

)(U?)

@‘

 

:53, $43

Comm ,wm;
wr-hi':
2‘! mm».

 

 

  

; Ccrurr Fm...

)‘ukc

(ml ”in,“
cm cannula

r )phhg

  

68 V.

 

 

 

 

 

 

Fil, 5-31 315mm: 5min
3? Relation btlween specific gravity
and rnsrdual charge
at Residual charge

 

 

“3.5.x: cg. Sediment
_ Plates
‘5‘ Battery cue

 

 

 

 

 

 

 

ti

 

 

 

ELECTRICAL
Batter!
Specifications
Type 12 N 12 A-4 A l
Voltage 12 v l
Capacity 12 AH ' j

 

Measuring specrlic gravity of electrolyte.

Using a hydrometer, measure the specific gravity of the
electrolyte in each cell. When the reading taken is
below 1.200 at 20°C or 65°F, recharge the battery. When
reading the hydrometer, hold the gauge barrel vertic-
ally as shown.

Inspection

1.

re

Check each battery cell for correct electrolyte level
semi-monthiy or monthly. If the level is low, add
distilled water up to the upper level.

When the electrolyte deaeases rapidly, check the
charging system.

Periodically check each cell for correct specific
gravity. After adding distilled water, charge the
battery by operating the engine, and then check
the specific gravity.

Check the battery terminals for corrosion. Check
for separated battery paste and for sullatlon. T‘nese
detects arc the symptoms ol a run-down battery.
Periodical inspection is always necessary, espccu’tlly
the battery is kept ll‘l storage [or an extended period
of time.

Charging battery

1.

It is advrsable that the battery be charged as slowly
as pots-ble smcc quick charging IS the surc way of
shortening the battery start-ice In'e. Where the bat:
teiy has to be charged qu|<kly the charging current
should be held :3 2.03 maximum.

Hydrogen gas .5 prodJced during charging opera-
txon keep away lmm lire.

After charging, flush the battery dean and grease
the tern-rituals.

 

5. ELECTRICAL EQUIPMENTS

 

Main xwitch

Wah the key ‘
:wndv {w cmmw ,
r.

 

C\ or OFF, Lhcck (he mun
If 1M": > L0 may In [‘10 cr»
gigfi, :f‘r: HMKC’I l5 ll'. :ccd cmmuan, Ii (‘1ch
anv :Vonum... In :[I’ief

h la a: vault.

.vt‘xm

    

 

 

is no cnnrmuny or If :nere
rflrru :: shown sci-7w, me

 

 

“’0' H"

 

Km:

    

   

PJHfli‘I'T l , , 7'

\ Km
ll

   

Fran! slop switch

 

Pu: me taster prnoes on he :e’minlls or rum Hop
swm—h (arcs lb an, we .
Opera. . he. banks 1qu . rmn my manw.
The up lug-n shmgd m an with :hr 3
5 nm‘ 41 5~1fl mm (0.2~0.4 In.) .-.\ mmiur v

  

   

 

c on:
- l p

    

 

    

no Um Ivy-3'

Non:
Nun: Ilul the level pl.“ is 2--3mm u)nw»-u..‘m..- .n (he
lever uml.

Rear stop switch

 

Pul tl‘c 12M” n

    

mm Ig'yul: with
mum The» up.“ «op :gr: ~, ,
nun hmu- pm‘lal IS ‘ -pro=§ec‘ 20 mm (0.31m)
uvvd .n xm 1|“. at me :mzal.
.Mjlhhug m: : rm

, W.

 

     

.-'\r:j,.‘\‘i by 4mm :,

 

Horn

Ci‘L-Lk in” Urdu"
or d‘czk :u ”\d

connuucd m m y L‘u’gcd 1: V but: -.

 

n ma rurr‘ LON: '~ '

 

Jr PC rc'r nuns:

     

 

V [.[C‘RICM t)“

 

  
  

       

lug. : 1'. run: mu m um

     

Fig ;—3n . 2m 2m; mm

  

 

7" V. ELECYRICM

 

 

 

 

 

ties.“ c; Turn tisrul control Swllcl‘l
@ Light blue cold
3; Guy cor-.1
3; Oran“: cord

 

 

 

 

 

 

 

lg: suck mm is, Blown. white card
3‘. time cord '5 WhIN’ <ord

 

 

 

 

  

t mergency switch

 

_, Black Card :3: White cord

   

 

 

 

 

 

 

mm

 

 

w. red w-d

Tum signal control switch

Disconnect the cord oi the turn signal control switch
in the head light case. Check lot continuity between
the terminals oi the gray cord and orange cord (left
turn signal) and between those ot' the gray cord and
light blue cord (right turn slgnal). The switch is in
good condition it there is continuity in the circuits
lO—O) shown below:

 

     
 

Cord color

 

 

Knob | Light blur: Gray ‘ Orange
Potltton ‘
R
OFF
L : c~———-O ‘

 

 

 

Head light control switch

Check for Cortllnuity between the respective terminals
of the switch cords in the head light case.

The switch is in good condition if there is continuity
in the circuits (0—0} with the switch selector knob
set in each position.

Any continuity in other circuits shown below is the
symptom ol mallunction oi the switch.

 

 

 

to 1 H3 1 Tl LR
Cord color Black i Blue “'23:" “‘hllc
.-- , -- l— ‘ w____
' H
ON N

 

 

 

Emergency switch end starter switch

Check for continuity between the respective terminals
of the swttch cords In the head light case. The switch
is normal it there is continuity as specified below (O
—01 with the switch selector knob set In each posi-
tion. Arty continuity in other circuits shown below
indicates malfunction of the switch.

Emergency switch

 

Cord colm

 

Starter sthch

 

Cord color \‘ellow red Buoy xroanctmg‘

 

 

O.\ " *7

 

OFF

V. ELECTRlCAL

 

 

Horn button

Chedc for continuity making Contact the tester lead
probes respectively on the terminal of the light green
cord in the head light case and on the handlebar
with the horn button pushed. If there is continuity.
the horn button is normal. -

Oil pressure control switch

The oil pump supplies lubricating oil to the engine
under a pressure of 4.5 its/cm? (“lbw-fl. When the
oil pressure drops below 0.3 Its/cw (4.3 ijin’), the oil
pressure control switch operates and the warning lamp
comes on, indicating the oil supply is insufficient.
Check the oil pressure control swltch located on the
oil pump for continuity. The swrtch is normal it there
is continuity. The oil pressure pilot lamp will come
on when the main switch is turned on and should so
out alter the engine is started.

If the pilot lamp remains on with the engine started.
and the pressure control switch in good condition, the
cause of trouble is suspected in the hydraulic system.
Locate and correct the trouble with the engine stopped.

Neutral switch

The neutral switch is located on the lelt side of the
crankcase. With the transmission gears in neutral, the
neutral switch is grounded and the neutral pilot lamp
COMES on.

Place the transmission gears in neutral and remove the
left crankcase cover. Check the neutral switch ior
continuity. The switch is normal it there is continuity.

 

 

 

 

'1'. s42

G3 Horn button
6) mm lleen coin

 

 

.3 Oil pressure control switch

  

"g \A

 

 

 

 

 

 

 

~:
I.)

l.

 

SPECIAL TOOLS

 

 

 

‘ Rr'

\u

 

    

m
thlycc

    

 

   

 

    

u.
:1 um- rm; ;
, 51m 1,4,.

 

 

 

 

 

 

 

‘3;

Mr \J

’V'mvuzw

‘41:}: umv— m 47‘
I \

  

 

74 Vi. SERVICE

2. MAINTENANCE SCHEDULE

DATA

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

mmnmcs SCHEDULE |N|T|Al “WU“ SING "“00 5
This maintenance sehndule Is based upon average riding 33%? 3:12;: |::‘:vv:lryw::cd:'r:‘:;d 02:33 I: K
conditions ' ‘ ' 5m molnllI I _fl|0l3illl___l_ ‘ months ‘ mttEtlu
311:'§f2.§."‘3$§1‘3;§'§1;3§11.521: ‘" "mm" mm “:2, 2 fif gr»: fig—
Engina Oi|~change. . O
—E)il filter Element—nulace. O 7 I
on fillei Screen—«learnt ‘7. 2‘77“ 0—
Spark Plug—clean and ad;usr gal; V fl , —-—
"Contact Pointil-ched, and adjust gap. 0 V
‘lgnition Tuning—cheek, and adjust If necessary. _. O 1
'Valve Tapper Clearance:check, and adjust I! nele'ssary.h ¥ i 1 I
70in Chain Yensmn ~adIust. ‘ ' é—M I l O i;»
Air Cleaner—clean. _‘:§L::M:%TWTSIOW O I
"inrClanoI—replacet R I O _
Carburetors—check. and adjust ll neeessary — I i A i O
Throttle Operafion—glsagecl cables, chedr, land adiusl tree . iiiii A 0—
"Fuel Cock Filter Screen-eclean. - N -
_—r‘u—l lines—check —-—- _ — — ‘
"—Clutch— —dtecir operation, and adjust II necessary _ O :
Drive Chain—check. lubricate. and adjust il necessary. 0 O i _ _ l
linker—law tenet—check, and add fluid il necessary. — o i C ‘1
cht. and replace If won! 7 i I 1‘ O _
7 Brake Control Linkage—check linkage. and adjust free play - . A_ _ A? ‘1 C
if necessary. .
‘wheel Rims and Spokes—check. ‘7 —. I — O
Tighten spokes and true wheels, if necessary. I
Tues—Inspect and check air pressure. A 7 O r 7 EJ— _‘¥V
Front Fork on—éaie and refill. A > V o l V C1 J
Front and Rear Suspens ~chc<k operation. : i O _ A
Rear Fork Bushing—grease: 7 A I ‘
I 'Steerrng Head Bea'rmgs—adgusiA 7 — — '
jaJeI;:ehcck electrolyte level. and add water il necessary 7 6 7 :3. '
Lighting Equipmzll-éhcck and adiust Il necessary if; C W
Ali Nuts, Talia :I'Ii'l Fasteners check IecuiityAand tighten . C ‘7 7

it’ necessary

 

 

 

item marked ‘ should be serviced by an authorized Honda dealer, unless :he owner nas proper tools and is met-un- callv
woiit ent All other maintenance items are wnple to perfarm and may be ranked by the owner

 

VI. SERVICE DATA 75

 

3. TORQUE SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 
  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ENClNE
Tisha-int point 'l'hnu din. (In) L- Tom-n '
V | Ru- 1 mm
Crnnkusa and (unkuu com: 5, PM) 70-110 § $14.0
._ an“: __
Cyllnder had 0. n5 ‘ $11,313: fighgmlnvnun 14.5
‘Eavburelor Insulator—(Gunner he“! s, no .. 70-110 5 1-5 5. -
Cm wvodtet s 7. no mm 11. $14. 5
A-C nuance rotor 10, ".5 M 11149.0
Timuy dllvo “at 12. 71.25 M 21.7-29.0
hype! “in“... mu 5, PM 70-110 51-50
Upper ma Iowa! cunmm ! a. ".15 mm 11 mag
Cylinder new new 6, no 70-110 51.”)
FRAME
‘I'lghtufll: poi-l Tin“ lb. (II) I‘ T"... ‘
'smnn. mm nul M I 14, no aux—wan 51mg
‘ . __. f
Fork lop hrldge In from lulu : 8, PLIS mm 13.1-16.7
u—nnd—Iaiai {Qua l __I.VP1:2A5‘ 7 I _' “wig—h— Wm
‘7Lan—_ 7 1 u a. ".15 M 111-157 ‘‘‘‘‘ _
spam—v ’ — _ '
hon! wheel , 1. 9—1 2
Ken whnol —— | 1. 5-1.9
' luv lork pivofbou — 14. In ‘ sue-50,7
WivBm I‘M-«I axle nul 11. M. s ' 17.6-39.6
mm 105k ul- holder_ A '7 I. ".25 '7 7 13.|—16.7
_ mun. hangar ball-—" 33. ".75 — 21.7—29.0 _
Rnr QEJQIQMI 1: 15, 11.5 N 57.9.12IV4’A7—
Tim dviven spvockfl _ 10. PM! 21 7-3.0
“Brake um i I ‘ 5.5-1.3 -
mm: And an brake “mu; iinlu V 7 Fl 5. ".15 11.1-16.7 _
nu: :Lspension “. ' 10. P1.5 21.1.3.0 _
Step bar 12. I125 ‘ 316-39.!
5 an: chum pedll ma klck arm # '7‘ s, n? ——'" 1 5.9.7.:
5m hand 77777 7 6, no 1 5.9-7.3 7‘ K

 

 

 

76

l. SERVICE DATA
ENGINE

VL SERVICE DATA

Unit: mm (in.)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

lien A—hly MN Service limit

Rocker Irm—Io-rockev arm shat: cum-nu E nms-anszmooos—omzov E 0.1 mum
Cam helgln oi camshafl f ‘

Iniake Inns-13225 (nose-1.1112) 230 [1.1020

Exhausi hint-H.224 (um-1.1m) 2m (1.1030
Camshnli cenur mum-i mnoui — l‘ 0.1 moan)
Valve sen wldih n7 «m 1510.06;
Valve stem 0. D.

inc-kc SAD-SA! (01153-01161) $35 [021ml

Exhaun 5.46-5.47 W215!) 515 [0.21%]
Viln-lu-valvo "Id: elnunce

Inuke E omMmm-ooom 0.3 mom)

Exhaust | mm («mammal ‘ DJ (0.0113)
Vzlvo sprinl pnlond ' ‘

Inner 19.211104“ kg «1.155933565411930 lbs) —-

Ouur 211137-0414 k5 111W1m lbs) “-
Vulvn spun; [rec Innuh

Inna: an "Mm 27.1mm

Oulel ‘1 M5 (1393) 315(1-1795)
Cyflnder hud nan-m ‘l — 0.3 (0.0115)
Cylinder I. o. ' 47.004701 GW-1.m 47.1 mm:
Plllon skin a. D. I £974“) ii.m<um 4655 [1546i

i_.,_ _

Piston pin Mal. I. D. 11002-13003 (0510945121) I105 (051131
Plslon pin 0. D. I 119M411» "15116-051163 . 12.9mm!)
Plslan vinl4o-pi:Ion vlng [move clnuna _

Tap n'ng mums («mu-anon) 0.15 (00059)

Second tin; (1.me mama) 0.15 (away) .

O" ring 0015 mm 0.15 (aims)
Pinon rln; 2nd up ‘ i :

'03: ring m-cummnvomw D) "10276)

Second Ila; 0.1-0.1 (emu-4mm) 01mm»)

on via; uni-0.3 (om-mil) : n.7(unz76)
Out-r low! 0. D.-Io-p\l;lp body :iuranu I ‘

Mlin puma 0090.12 (on-12mm) 0.15 «1on

Aullliary pump mmaoiomsmomm 0.3510013!)
Ouxoi rotor-io-innu Ioior clelunce ‘ I -

Main pump 0.15 (0.0359). mu 0.! inmmi ‘

Auxiiiuy pump 1 0.15 (0mm mix. 0310mm ‘
Friction an: mick-ms 2.61‘17llfl.1032~0.1WSI F 13 010906)
Cinch plate mriacq mrpage 7 , 0.1 mom mu. W WW9)

 

Clulch spring puma

(lunch ion"; tree icnuh

 

ISO-‘Islm 7 kg ’09211357-45 643 lbs!

33 5 (13975.-

 

 

 

VL SERVICE DATA

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

77
Unlt: mm lln.)
Ik- I Asa-My M Sank. lime
cum»: untemulutch plate I dunnco ! 0.1-0.5mmm) ‘W
Cur mm fork fin“: man. i 533-60) «mas-c.2352) J ssmzuss) , fl
Cur mm ‘uido mm b. n. 11957-12354 mun-05m) i 12.9mm:
6w amt: lurk I. o. 1m1mam1mzs) I 11mm»
Kick iumr pinion-tub!!! cluum _—no'u.\nn toms-om 0.1 [0004)
Gear mm (on damn-comm move clearance ! o‘mzzmmmm f nJmoIm
Tnmmlsslon gear backlash
1:: ma 2nd 1 mmmmw-omm mums)
m, «n Ind Slh I mu: mow-0m 0.2 tom»
Yunsmis‘lon gen-lodha" eleulncv '
c4 coo—mm («mus-om) 0.1 (mam
Other luvs coo-om (mum ”(QM
Cam chaln lonslonee :llpplr thickn-n (canted ‘ «Mums» 3.0 mm MIX. ‘
Cam In; guldn lhickneu m-‘Jmmm 59101-97)
Cnnbhall runou! (camel) MIMI). mam l 0.05 mm
Cunmnll iounul zlcannce (IMO-0M («mow-om) muwom
Connuun' rod maxi Ind Ln \ umz-umz mmosm) Rm (0515:]
Connmlil rod bl; em: aid. cluunn . tam—w (0mm msmnm _
Connnnn-{Ed bl; end-manhunt {our-m '7 Mmemmm ans mm;
:Iunnu
~Inimny mm gum; Bantams «Ian-m1 _ sou (man; 759 mm) ‘

 

 

 

VI. SERVICE DATA

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FRAME
um: mm (In)
“ll Ann-Ill! mind i Sufi“ uni.
Ink: dlic lm runoul as mm Max. § a: «mum. min.
nuke disc thlcknm 5,-7.1 «1171742799 I‘ —
whul vlm he: runnlll Q5 «1mm. mu. 20 (0075)
When haul... and play am (am. mu. a.l (mural
Wheel belrln] udltl plny (mi (00712). max. 0.05 (00mm
Front all: runoul om (ml ? n2 [0.00791
Calipu cylinder I. D. , Ala-mo (I.5u31—1.3!39-)_K ms (15w) h
' Caliper plnon o. o. sumac (woos-1.5150) ‘ suns [lsoozl
Muster gum, l. n. 1im-1Wl0551245529) 14.0” [0533)
mm.- cylindel plslon o‘ D. 1199-139“ (OW) 13.9w laml
um axle mnoul '_ om loom A n2 lawsl
3:» mu. llnlnl llllzlums - 4.9-5» rams-mm 15 (am
Kur beak. 11mm l. o. W moo-1w: lam-£3110) 7‘ »

hon! suspcnalon spring prelond

W26“; (15.3129/582hlbs)

l

161 [6.3386,

 

hem susptnslon sprln; tun length

«:5 (16.7917)

416 [16.370]

 

1m imam

 

 

 

 

 

 

 

 

 

Real nuspomlon wllng hoe lcnuh ‘90 (7.4”)
m. lonivoz hulhlnl-Ia-(CMCI collar clun‘nca out: W170; _ as mm» “m
Roar fall: bum»; E if ‘qumssz «mes-1mm __4 21in masts)

! Cnnlnr colhr o. o. _ V iaii—nao 105436-0840] ~ _ 21.35 (nuns)
Flam lurk bonom me 1. v. j ”mo-m; man-1m _ nu (1.3053) #~__
flunl lurk bottom plmn o. o. 7 [ 3192542350 (135—12973) 7%

1 ms (1.8“)

 

VI. SERVICE DATA 79

 

5. TROUBLE SHOOTING

 

 

ENGINE
Tumble . Prob-He Cllfl L Endle- ‘
Eng-Ln do: mat| 1. ixcetslva wear ol piston ring or cyllndet. ! Replace.
star: 1 Z. Seized valve In valve ”Ida. Replace.
3. Solzed piston. Replace.
4. Faulty valve nmlng. Adiut.

5. low or lack ol companion prassuto.
. vussura leak
Blown aux cylindar head gasket.

5.
. & Warped gnketu'np surface of the cyllndu and
‘ cylinder head.

Lap the valve lo ohlain pond valve seallnl or replace

Replace.
ROM" or replace.

 

Poor eight. 1. Incorreet kappa! zharanco.
idling 1 Low or lack o! compreuion prenure.
3. Exceuive valve guldc clearance.

La- nl none 1. Valve nlckln; apen.
1 2. Inennecl seating ol valve.
} 3. Weak or broken valve sprlnl.
a. faulty valve tlmlng.
L s. Blown out eyllndu head mm.
I a. Exceulvu well 01 cyllnder and piunn
7. Worn, weak or broken pliton Hug.
a. llama spark plug.

Overhaul: 1. Heavy carbon depot“ on camhunion chamber
and plalon head.

2 lean luel mlxlwe.

3. Retarded Ignition llmlng.

4. Low oIl level. poor quilixy.

5. Extended operation In low [can
1.

2.

1

&

 

Bukin Incollecl aeatin‘ ol Inlet valve.
' faulty valve timing.
I Incurrecl ignlllon llmlng.
j Ere-“Ive spark plug gap.

5. Improper luel.

 

I _ __. ., ,

. Adjual ta slindald value. ‘
Repair.
; leplaee valve and xulde.

! “place. 5

| up valve.

1 Replace.

| Check vaIve “ml". and mm: ll neceuary.
Replace.

I Replace.
Replace.
leli‘hlen

 

‘ Remove carbon.

Adlurt the cavhulnlol.
1 Adjust Ignition llmln|.
Add [and [tide on.

Check the valve sealing.
‘ Adivil. .
Adjust.
Ad‘usl the up to ”24mm. lair-0.7 mm).
- me goud duality luel.

 

Whlu uhmt ’ 1. Exuu-ve wear 0! cyllnder and plslon.
min 1 Overltlled onuna oil.

I J. Excessively high all praasure.

I A Poor quality all.

Keplaee the plum.
Allin“ [he nil level.
Check the brealher.
Kepllce with pod qualilv oil.

 

 

Black exit-Ill I 1. Rich luel mixture.
amok.

Adtusl the carburetor.

 

Dilalt [Mr 1. Improper clutch dlsenlaumenl.

 

Illnin: 2 Damaged sealaelole nobiectlod'ed in Ihe gear.
‘ 1. Gear stun lolk‘lltcperatlve.
I 4. Incorrect operation of the gear shift drum nopper
I and change pedal.

‘ S. MaiMhall and counterslzalt out ol IlllnmenL

l a 1 oil viscosilv

   

Exec-Ii" Men 1, exam»: gear backlash
- Warn mam and (ounlershait baa.

. ‘é

 

 

 

Adiusl the clutch.
. Replica the deleenvl parts.
' Repair or "place.

Repair or teplacl. ‘

 

Repair ar replace. 1
Change In: oil. 1

Repair or "place. I
Repair ur replace. ‘

 

 

 

 

 

 

80 vx. snvlc: DATA
I‘m-Ne Prob-tale Clue W J
Gen! Illn out 1. Worn linger: on “up :hill fork. 3 Replace. 4
' 2. Worn nu do] hole. ' Replies.
3. Warn spline. : Replace.
1. No play In me clutch Imr. 5 Adjlm me clutch. —

Cllldl sling":
.

2. Week or none unllorm cluleh spring.
3. Wm. or grazed lriction disc.

Replica lhe week Alvin].
“place. 1

 

 

 

Poor dutch 1. Excessive play of clutch lever. dint! cluKh lever play.
uni-men: ‘ 2. Warped Mellon disc. ; Replace.
1. w.rped preuuu plne. Replace.
4. Bern maln shell. ‘ Replica.
Pedal do“ not i 1. fully relurn spring. Replace.
"(In l 7. Unhook return spring.

I Hook relurn wllng.

 

Ki mm: 1
[cu don lull
rot-u

 

1. Exceslive wear 0! kid: mm: pewL

i Replace.
r

 

Elwin llou not
«an

Poor one-lee
ldliu

 

l

Cuburelor

Choke lully open.

2. Carburelor alr saew improperly RL

.1. All leeling into an cyllnaer held.

4. Cloned ezrhurelor slaw in.

s. Cloned luel valve or plplnp

6. Clould vent hole in the fuel lenk cap.
7. No luel in "so tank.

:‘

Carburetor

l. Clogged or loom ("burner llow lel.
z Improper llou leveL

a. Incurred all screw Idluflmlnl.

A. Cllburelol llnhge mullvnflion.

5. Ali lulu.

Close choke.

Adllm Ii saw.

I Religlmn carburetor connecting lube.
: Cheek, clean and "lishlen.

I Diuuemble and dean.

' Dlnuemble and c In.

1 nu uni wllh ‘uoline.

Cheek, (Inn and "lllhlen.
: Milan.
5 Adiusl.
| Adjust.
- Tighlen all m pessege :onnofllon.

 

l-llmlur mm
min: 0' enzlne

I

l
l

 

 

Cnburelor

1. Jul size [no wall.

2. Improper "on level.

3. Cloned urhurelor main jtl.

4. Carburetor Imus: mullurrulon.
5 Alr lulu.

Replica wlm Ierser six: "I.
. Adllm.
, Clem and lelighlen.
l Adlusl.
Tighlen all Ii: punge :onnoclloq.

 

 

VI. SERVICE DAYA

 

 

 

CHASSIS
Trouble ‘ Prob-bk clue “at.
navy nteeri-g‘ 1. Steering stem exuflively tightened. : town the steering skin rulL ‘
2. Damaged rteering Hem steel bans. Replxe. >
3. lent meFmg. l Replace.

4. low lronl tire pressure.

1 Add II: to the specified pressure of u kglcm’
! [25 psi).

 

 

wheel Ie

1. loose main; Item mounting bolt.
2. Worn (rant and rear wheel bearings.

3. Front at rear wheel runour or distorted.

 

‘ letomue.
. Replace harm.
Rena" or replace.

 

 

 

 

 

 

}

>
w
i
l
>

 

- lmulfiunl brake Hula.

~Alr in the brake :ystem.

-Worn brake pad.

- Warn piston.

- Worn or distorted brake dim.

- Brake lever out 0! idluflmenl.
7. Rear brake.

- Worn brake llmnI.

- Worn brake shoe or poor COMIC“.

~ Worn Duke cam.

- Wet brake from water or oIL

- Worn bake the".

- Brake pedal out ol adjuument.

Ketorque.
L Keplete.
Sol: eupeuleu; 1. ton of spring teminn. Replace.
Exceulve Iced.
Eu! Inuflective from lack Jumper. Repair.
eleven!” . lnefle<t|ve leer damper. Keplare.
gum "on! use or rut damper rubbing. 1 Impact cushlon spring and use.
uh- Interierance between cushion use and sprln‘. 1 Repair or replete.
Faulty fork' stopper rubber. “ Replace. _
. lnanlfident Iron! lorlt oil. Add ATP.
Belem" mo? 1. mm bake.

Add brake fluid.
Bleed bulte system.
Replue pad.
KepI-ce platen.
Replzce due.
Radium

leplne.
leoleu.
Replace.
‘ Clem.

Repllce.
ludluu.

 

 

 

32

VI.

ELECTRICAL

SERVICE DATA

 

lehlu . Pink“: Calla

Engine in: m 1. Battery
Stu: - Dlschnrged.
-Poot <onln<t al balmy terminals.
1 Z Mzin switch

1 1 -0pen or menu: circuit, disconnected
(onnlfiliolu.

~ Poor contact botwun main switch wlre Ind
win tut-ten.

J. Ignition coil
. lmpvnperlv insulated high tent-on eail.

‘ ~0pan or ihomd cttcutt tn ignitian coll.

i c. Conutl breaker

. -Open circuit in thn put-my colt.
.oiny ground point with oil at dun.
.9 nt up out ol Idiustntent
. tmpwpulv chugcd condann

 

’1. Dtlntlvn battery.
. 2. Pow count! of magnetic switch.
.1. Poor «mull of starting mom: ezrbon hunk.

Slnni 5 nor
am not over-Kn

cm.” or mplm.

Bel-4h:

Rectum: or replace.
Reva-I.

“watt.
Repair.
Regine.
Replue.
Input.
Clan.

lendjlul.
kept.

 

Repair oi "place.
[repair or replace.

 

 

 

 

 

 

 

 

Hon. II n - l. Ham .
Human: "and i Cracked diaphragm. Replace.
or Ian reel: 1. Hum button.
and ‘ ~ Pool grounding. ! Repair
1 5. Winn; i
-Pont contact. l Renal:
‘ ¢ Adjusting “few
1‘ - Out at Adjustment . Kenditul.
' 1.1mm mi 1. rm !
timing-t Jim... flu: or burn! bulb filament j Rlplue.
Inountlve 1 Bulb -
. Burnt bulb filament. ' Rlphce.
1. Swllch
‘ -Poot cuntact ot li3hlin| witch. I Repair.
[4. Wiring :
3m Iiflil *1. Bulb i -
lnopnnllw ‘ . Burt“ o! mum bulb filament. I neplue.
I 2. From Ind ml slop Ilghl Swilch I
f .mttuncuan 0' switch. i nun-m.
3. Wivtn;
. Poor Cantu! at leads. Repair.
winter In]: ‘ 1. Hull: 3
bum in run L - Blinks unululllv last: ampioguiv connectedtelnv.‘ Repliu
‘or loo IIOW E2. Wiring

' t - Bllnki loo lust bulb with unsuitable watt-5e.
- Blink! Inn flow: burnt 6! broken bulb filament.

]. Dclectlvc relay

 

 

 

 

Kenna.
Replace.
"plan

 

 

 

 

 

 

 

 

 

 

 

VI. SERVICE DATA 83
humor Prat-bl. Cclnu nun-air. J
V Wink" lamp ' 1. Wink" Imp writer- ' J
‘ out-luv. rPoor serum 0! winter relay. Keplue. J
~ Open circuit in winkcr relay coil. : Replace.
1 Bulb 9 i
- 3th wattage ls smaller than rated wartage. I Replace. J
‘ 3. Kelly '
J . roar contact at winker relay. ! Replace.
J . lmprnperly :orlnuted Ind. ; Replace.
I No eludin- ‘ 1. Broken wrre or shorted, loose connection. I Repair or rephfl.
! J 2. rauliy coll due to shall or grounding. teprm.
J J faulty or shorted tillccut diatle. Julia.
1 ‘. Broken or ahorted lud wire at regulator. Repair or replace.
‘5. Regulator volla‘e u no load is too low. J ludjun.
Mulch“ ‘1. Will";
chafing * -Brokan wllo. lmumlllenl shorting at loose I Rep-it.
i connection.
2. Generator
J -sltor|in; acre-a layer ln the field coll. Replace.
J (ruistanu Indicated In continuity mt)
J -Shortin| anon llyer in amor cuil. Replace.
- Open clrcuii in one 0! the ruler (oil, leplace.
. faulty or shorted ,illcnn diode. lepllee. .
a. lesulalar
- Voluu below specified value A! no load. leadiun.
, - Dirty of plum: polnls. rerun or replica.
J J ~ Coil nr minor internally allotted. replaca.
4. Gallery I
J .Law electroly" Imi. “Add dmllled waler.
J -0Ilo(llve bullery gram 1 Replace.
Wu J 1. Winn.
Ellll'hll’ 7 terminal drum and r tarmln-I circuil shorled kepair
rerulxinl In rpm wound 3enentor. J
‘ z emery ‘
lnlurul mart. l Replace.
3. Regulator i
- Excesslvn voluge at rm load voltage. 1 Irpair.
- Improper grounding. Provide proper ground.
J rlralmn coll lead wire. Repair or replace.
Unable 1 Wiring |
ehulilll - Bare wire martin. intermittently under vibration' Repair or replace.
"n". ar broken wire Initial partial contul.

 

1. Genelllur
. layer rhori (intermittent droning).
3. Genlrllnr
. Intermittent open circuit In the earl.
- Improperly adjusted voltage.
- Defective mun switch.
- Dirlv perms.

‘ Kerr-ii or replace

r

- Repair or replact.

. Rradlurt.
Replace.

; Clean.

 

 

 

V l. SERVICE DATA

8. WIRING DIAGRAM

84

 

 

 

 

 

       

5:3 .8;

. . gfimis. .1 55.25: _.... .._ . .. 5
ES. .93 L! A w. 5 ELWH: ILIHHMI.

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. g. _ I1?” ll . j. fies
, __

.5555... L m5fl_l,t I:

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. n t

. 5 5 x .5 u 4
0 a G 6——

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.2335: 83g: \ 5.1....- 553! 6.5 .33.... ,§.§§P5.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

 

 

3:55. .HL 5,. s. ._ 2 m
,j._5.a 5 5L1} LL 5L5 .53.. L55...

 

 

 

 

 

 

 

 

 

 

 

 

 

. , 34:. =3

. q 3.: 3:: K2
, £5 .
a 5—35: =5 3..—

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

If» ; .5~Z§§§: i=5

. s 5.5.» ,
5.5L. 55...... ELL. 5:5LLLXLL55l n55... “5,55...

Edam g ID— 55.!

 

 

 

 

 

 

 

 

 

5| d
‘P #1 I
é
a

 

 

L5

6:.»
93¢

 

 

 

 

 

 

 

. 5 .25.
5: .5 an o .3 .3. 3..
52:33:33 5:28 a E 3r Lg £2: a _ :

 

 

VI.

1. SPECIFICATION

 

SERVICI DATA

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

i n:- i Mule lulu:
mum“ Dunn mum > 1060mm ' 3 01.1 In. ' .
I Overall mam I nonm- 1 Jan... I
Oveull heiIht I 1.0!) mm dZQIn.
Wheel hue ' 1,355mm 51 3 In.
Seal height 5 Mann 30 1 In.
Fool m mum ' mom... i 11. -.
Ctound clnranco 155 mm ' a 1 In.
Dry wli|llt ‘ ‘IN I; 37] lbs.
Fun l 1’19: Semi-double uldk '
F. susunslon. naval , Telescopic lurk. Tum 11-k6mm Kiln.)
R. summation, ("vol I 5min] um, Travel 91.0mm [JJinJ
T F. tin uzo, unwr- Lm-‘ll (4"). Mr prenur: LORI/«1F (fl piil
E It. «Ire Aim. prawn ' 153-10 (4"). Mr 91mm: Lowe-n: m pail
1' F. nuke. linlnx nu Dlsc brake. Lining "up! nus mun“ [44.911.an
IL bake, Iii-In; uel lnlemll almndlng shoe», lining swap: um 150 cm“ (23 m. In.)
fuel upuily 12 Ill. 1 2 U54“. 2.6 Imp.|ll.
fuel mam clplclly '7“ “ 2m. 11 5 mm o 4 lump.
5 Cam: Angle 63‘40' .
‘ Trill Innnh “ 35mm _ ‘ 3.3m.
nan: (ark o' capacily_> 125:: (m Ml if a") 4.1015. ..
l mu (all 0 «Lay lam man um drllnlng) 3.0m.
Eng-Lu Type | An cool“, 4-5"qu one Inflne
Cylindu arrangement 1 VquI [our parallnl _
lore and “loin: ' 47.0x500mm 1.350x1.969in.
—Di pal-1:11;th ‘7 7—: 147cc nun-In. 1
Cnmprluion ulio I 9.3:1

 

VIIve lain

Cha|n drivln avu hlid ulnslull

 

‘ on «puny

Luhllcauon synom

pun-no

> Cylinder hudTompcm-on '

 

um. I. 7 my. J.1lmp.ql.
loved and we! sump

12 ky’cm' [1m 7 mi)

 

 

 

 

 

Open: In 5' [heme lop dud centu)
- lnukc val»! > - ‘
- Closei AI 35' (aim bouom dud comer)
Opens W A! 35' (how: bottom dud (omen
Exhaust «In W -~ . ~ —-
Closes In 5' (alter lop dead unmx

 

Valrc upon damn“

xcle xpeed-

“vi! 0 05 mm

 

1. 200er

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

86 VI. snvnce DATA
{ mu 5 mm Bull-h
Ouhnur Type Pinon valve
V Selling milk 864:
’ Maln m , 375
‘ Slow in i 315
[7k scuw Openln‘ 'L _ ’(At'l-
Flual Might . 21 mm 0327”,
min train Clulch [ Wel.‘mulll-ph" type
Tunmlssinn 7 H9006, :onslam muh
1’ Plinury uducllon ' 1423
Gear rnliu I 2.733
‘ em rule 1: ‘I 7 ' use
1 Gear rallo In ’ 1‘16
l Gur mlo VI ‘1 : ¥ 1.10
Our Illio V 0.”
Final Ieduclinn A 7.115 _
’Gur mm plllcrll > H 7 l." loo! open!“ ulurn svllem
Blutrk-l l lgnlllon

 

Inlay and Ignition coll

 

Slafllnl cynem

Stming mom and ml: mun

 

Alumna:

NC general! 0 156 kWI5.W)rpm

 

lulny “gully

IIV—‘l! A)!

 

 

 

 

 

Spuk Flu; NCK Dem Nb ms

Hudlim ‘, low/n15». dam 12%;;me

numopngm F Inn/sup uv-znch (SA! mun M), 1151)
I

Tum :qul liglll

12V—12m [SAE TRADI NO. 1073)

 

Snider-mu llghl i

Tachomcm lulu I

11V-1cp “ISA! um: no.
12 V-ICD ‘5‘: TKAD‘ NO‘

 

Neuml indlcnor lulu '

11V-2tp (SAE TRADE NO,

 

Turn si|lul Indium um

 

129.2» (SA! nun: NO.

 

 

my. bum indlular um I V 1zv—zq; (SA! TRADE no.

§§§§§

 

 

 

 

 

SUPPLEMENT T0 CB 400 F

  

   

BMW-BY GAS CIRCULATOR

 

 

 

 

I‘\

 

 

fig. 14 ,1, Brenner lube a: on dlain lab! ‘3. Au (lunm olemn:
v; mum: me 3. meme. element

 

I‘hc blow—by gas lrom (he mndc o! the cylinder
head lhrough breather lube amen [he breaxher box,
the oil IS separated by the breathe: element and the
gas is the" led :o the :m cleaner. The gas enters the
an deanel and as fxltcred zuguhcr wuh Ihc fresh air
by [he aiv cleanev clumcm and IS (hen again led to
the combustion chamber: through the carburclms
Therefore, [he blow-by gas is reduced by recombusnon
of the unburned gas,

fig. 1 2 mum be.
OII dvain lube
it claim! can:
we: elemeni |\uldcr
mm element
e'e'em‘ heldnr
.- (leaner meme“ ‘ '

 

,M n44

 

  
 

   

 

 

 

 

 

 

 

“3.24 ‘1 Bulk: panel
, Relemncr mark

 

 

 

 

 

; (enter mm deem

 

n were :

l. CLUTCH

1‘ Check the clutch lever for free play at its tip,
'Standard play: 10~20mm lo.to.Bin.l

t Screw the clutch cable adiuster located at the clutch
lever, all the way into (Al the clutch lever bracket

3. Turn the clutch cable adjuster located at the clutch

housing, tn the direction (A) to loosen the clutch
able

4. Remove the clutch cover. Loosen the clutch litter
adjusting screw lock nut (see Figs Zn”) turn the
clutch adjusting screw in the clockwise direction
N until a slight resistance is felt From this posi-
tion, turn the adjusting screw in the Cuuntcrclockwise
dtIECIIOfl [B] 1:4~1,‘2 turn. Tighten the lock nut.

. Turn the clutch cable adiuster located at the clutch
housing side of engine, tn the (Al direction so that
there is approximately 354" of free play at the end
of the clutch lever. than tighten lock nut.

6 The remaining clutch lever free play ts ubtairtcd by

the clutch cable adjuster at the clutch levcr.

,- After the adjustment has been made check to see

that the clutch Is not slipping and that the clutch
IS properly disungagtng.

After the engine starts, pull in the clutch lever and
shrit Into gear, and make sure that the engine does
not stall, and the motorcycle does not creept
Gradually release the clutch lever and open the
throttle, the motorcycle should start smoothly and
gradually accelerate.

u

 

u.

2. REAR BRAKE

Blake shoes

'1. Check the aistance between the arrow adjacent to
the brake arm and reference mark on the brake on
the brake panel of lull application of the brake.

ii the arrow aligns With the reference mark on full
apphcatmn ul the brake. replace the brake shoes
and check the brake drum for wear.

u

3, WHEEL
Tire tread wear
Tire should be replaced when center tread depth is
worn to lite: lullowmg l-—uts.
Center tread depth:
Front —— 1.5mm (0.06-in.)
Rear 7 2.0mm {QM-int)

lg

SPARK PLUG
Remove the spark plus up iron". the spark plug,
bnscrew the plug, uszng a spark plug wrench. and
remove the spark plug 1mm the cylmdcr new.
Check the spark piug for deposits, elemrodc crosron
and damaged gasket. A spark plug with burned
clecxcdu. bristered insulator or damaged gasket
shoulc be replaced wrtn a new one. Fouled spark
plug can be cleaned in spark plug cleaner or wrth
a mu: brush
Usmg a feels! gauge .uliust the gap to true spew
“(anon

Specified plup gap: DJ-lLBmm (0.028—0.032—in.]
To adnrst. bend the side electrode only
Clean the plug >cdt In the cylmdcr head, Screw
the plug 'ntu tnc thread hole m two steps: hm.
linger-trght. and tncn use a spark plup wrench to
trghren I‘ll: plug an addmonal 1‘2 to 35-1 turn or
wml tne sealing gasket ‘5 compressed.

FUEL FILTER
Place tho fuel roc‘x lever III [ln- "OFF" prwtion;
dlstunncct Iht~ fuel tube: Tdkc (Jul (‘1;- I'uel :ank.

 

 

lumen tlu- luel cork imng nut .nnl then remove
fin: luul cod and lucl l'vltcv l'rorr' the fun] tank

Chwk rho gruket to see ..- n I} not damnsen.
Replan- with .1 new on, r: louml [u be damaged
too badly beyond me

W‘MI' thc fuel llllcv m pun-cu: and dry wrth Lorn-
prcsscd .m Any flighlcst damage can not be tolnr-
am: here Also ruplanc the HM with a new one
If round to be (logged.

Imrnll the firm: filter [a the rml cork vnlh [hp
xllll

Du not lursvl (0 mm]! tvu- gasket mm (In: groove
olJllu llxulg nut

Install the fuel cock tu :Iru lucl rank wnh t'nc
txxrng nut.

Install Inn luel rank in paca on the lrame: connect
lubm and :t‘CtIH.‘ wnl‘ me- rlrps.

lrll 1'10 tank wrtér fuul \ 1 the fuel rmk lever
in the "UN" pozlilul‘ 61ch for any Iwkage past
the :ubc rows or Lorlncctwns

 

'mg

 

 

INsvrcrzo .-\ so ADJUSTMENT 5,

 

    
    

 

Spuk plug (as! a 5rd: electrode
(mkct

Hg. 2 s

(a 4—l

el cud level '5‘ fuel lubr

__ lurl (otk :3me m

 

“5.24 r rm Luck 1 (mm
: lung m: e rut mm

 

'3‘: —\\D \DlL'ST\l[\T

 

 

6. AIR CLEANER

1 Rmc ll‘e seat and remuvc the tool ccmpart‘nerz
Ingmher \wtl‘ the wt cleaner cave:

2 {:11 out the a.r cleane- element rcla'mn; gltp.
Remove the a r cleaner clement,

3' Clean Iht‘ a-r Llca‘u‘r clcmc-n by tappmg t llg'llly
tn Icowr‘ dusi. T'nc 'emaimng dust can hr: brushed
iron the outer element surfnce u! blow-r - ay hv
applyirg ccmpreszec Mr from :he iflildn or the
€|E"1€1nl

    

l: Rmmmg (‘13
All (‘elncl E errant

 

 

 

4. Remove 1‘1: clement. Holders and brL-dlhcr element

§ Was‘t the breather elemertl m clean solve Squeuw
out eKcess solvent out: then dry the element
Xhorognly

WARNING,

     

- Gasoline 0: low [Lulu pninl mlvcnls are highly flunmablr
and mus! nul b: med m tlun lhe breather nlemcnl.

‘ .Do not use ma, man or organic wlvcnl «a. washing

‘ ”gay” the helmet clement.

 

 

 

 

Fig.2 9 5 Whitney vzmrn' -.- [emcm mm-

 

0 Squeeze to open lower end of 1th drain rnhe, and
remnvt- any ml or waltr whlch may have accumuldlcd‘
To rmrhldll 1hr: arr cleaner. reverse the removal
procedures.

 

 

 

 

rig.2 w l mm no:

7. FRONT SUSPENSION

Cherking

'1 Wm th.» tron: brake applied. check {hr JCIICH of
”it shuts :‘nsorbcrs, This can he done by munczng
[he sI-urk :hsorbers Ln arm down 3 mm: “r-gg by
l: H mm cnsrk rm 'éak», twist er b Is mm
’E—plaC-J, u an ' ww- u' damagad he

_‘ Chen : . tmnl :L'k'; 2m: wandlabar mmnrvtg bolts

 

   

     

 

  

rm Jag-r

   

 

Changing front fork oil

L Rum t‘w dun [)1ugsn-va21ac uol'
Me h. mil-=1: r 21:5 ‘DJ'ILL‘ Lp and c:
“No 10 md v1 dug 1m: :P‘u: :‘é‘nmurg

A chhch‘ the main p‘u
urdcr the Pu5v
:10.de

       

    

raléé ?

 

A .I a .
' ¥u1l rm mm pm

   

ed

3 Run-ow l‘u' ml r r pug; 3m: nwr me 8m
M'ounl at AT? ‘,p€'l“'hllh"li L:\..x|xi‘,' .mlumnw IYJnS-
msss‘ou mud) mu rm: huh-3

Cnparily: 1457150tc (4.8»43025.)

  

rd .mluunl OI fluid will he rennin-d In fill one I'm}.
whenever dxuncmbled.

Spn- NI .mmum 160 165(r 5.63.802»!
4 Repaw! 'uEe' 1);.159 am'l mn'nm the stand wdcv

1hr c~m_.u,

 

 

   

S. REAR SUSPENSION
Inspccliun
I Kuw' l'w w. ' "
2hr rc.-.r v.,.
r 1’ {wk bunn
7rd use, 'cpwdtL‘
i Clrnk 1th

  
    

~| u: .mll mm W:

m; wurn n umr («ma-9y

 

 

 

apxnsun "uur‘:ir’_:~ mr Ir. son

   

Rear 'Olk Bushing Luhviralinn
Twnv IS a Ihbl can” pm '1'

   

'- mr m x... ngn‘ I:

 

‘\ wmuuw: {1-2.1 : ‘-

nuty ui .- -.-r maul»

.u \IQI m .v ‘

1-1» paws: .1 u'

     

v» I":_m”~ In \CXI

   

 

vxmivpu‘CIm- . ..

   

92 INsptc-rzou .4 ND ADJUSTMENT

9. SIDE STAND

‘L Check the entire stand assembly I'srde stand bar,
bracket and rubner block) for installation, deforma-
tion or otherwrse excessive damage.

Check the spring for freedom from pamage or other
defects.

ta

 

t, Side stand
12 Rubber alnck pivot bolt

3, Check the side stand tar proper return operation:
a. With the side stand Jpplred, raise the stand on‘

the ground by using the main stand.

b Attach a spring scale to the lower end of the
stand and measure the force with which the
stand is returned to its original posrlron.

c. Ihc stand condition is correct II the measure-

ment falls \vrthin 2-3ltg (5.! 6.6lhs.)
It the stand requrres force exceeding the above
lnmt, tins might be dur: to neglected lubrzcatlon.
ox-urtrghtuned siec stand pivot bolt, \vurn slind
bar or bracket, or otherwise excessrve tension.
Repair as necessary.

4. Check the rubber block fur deterioration or wear
When the rubber block wear is exressive so that
it IS worn down to the wear line, replace it With
a new one.

 

 

 

 

 

h“, 1.17 q sac: um: by g Sprtng «are

 

Rubber block replacement

1 Remove the 6mm bolt,- separate the rubber block
from the bracket at the sldl: stand.

Alter making aure the Collar is installed. put a new
rubber block in place in the bracket with the arrow
mark out.

NOTE:

Us! rubber Mod having the mark "OVER 2.50““. ONLY"
3 Secure the rubber block With the 6mm bolt.

 

 

 

 

nu, Ho 3 Wear 1m

1.;

 

 

 

 

tit; ‘

L PISTON RINGS

Assembly .

1. To install tlu: ml ring, first place the spacer and
than the rails in position The spacer and tail gaps
must be staggered 20-30mm l0.8—1.2-in.).

2. Install the second and top rings in this order in the
piston with their markings facing upward,

NOTE:

.. on nnl mix the lop and second rings.

b. After inflallin‘ all ting; in the piston, hand-route than:
and (heck to be state they move smoothly without any
sign oi binding.

3. The rtng gaps must be staggered 120 deg. and must
not be in the direction of the piston pin bossor at
right angle to (ht: punt

NOTE:

0n the gap ol lhc three-pies; type oil tin; teler lo that at

the sonar.

 

 

til, 3.1 ‘ Top 1mg 5- Spam
. second "n; -'; Piston ring mukinx
t3: Rail

2. CLUTCH

 

 

 

 

 

 

 

 

 

 

 

 

Hg. 3-?

(y Clutch cover

.11 Lodz nut

q) Clutch Illlcr lzvct

’5) CIuKh lent iprlnig

' Oil sul

Igltl nanltcaso

covet

Clutzh cam plate

Ball retainer

Clutch Iiller

Clutch Idlustmg
Stlew

Clutch lint-r plate

,ctutch spring

Lock nut

luck washer

lock washer

Clutth cent»:

Dtst swing tut

Elutch disc will“!

Clutth nine 3

sumt set ting

Clutch luction disc

Collar

Clutch plilo tstxi

Clutch Itiztiou disc
45ml

Clultlt pressure
plat:

Clutch outer

thusl washer

    
   

[i

HHS 'h‘, Eudbfl'd-l'fi'fi‘fii'fi'in'Ifig'IE'Q “(@5993

5 Cluxéh-lyllcr

  

: mk mum pchl Iem
3 mm cunkam a Sun";
fun” '5' led; flul

g cmw auxualcr

h.
h“. :4 m Ihnlm lm.
Inn wash-:1

3V luck wnhrr

 

fig. 3 3 ;‘ LlulU' u-uu
’2 5|me rarcml m ..n7_

7 1
FISJ I. 1 Sup
5' cmvmr‘r x;

 

  

 

 

Disassembly

'1. Quinn :ne engine :i-roughlv 1') :cmavmg the drain
piug.

1 Remove (He rear branu amuazing nun

3 Rc—ove me ugh! ‘00: fat and kisk starter pedal.

A Remove :he clutch cover f-am :x-e rxght crankcase
CDVEY.

2. TJrn the clutch admzcrs lo loosen the clutcn cabler

6. DISLDnneCl’ the dumb cable from (he clutch lifterr

lever.

Remove [hr ugh! crankcase (MEL

8‘ Screw ol'f the clutch adjusting, s<rcw lock nu: and
remove the clutch Inflcr lever and aprfngr

9. Remove the (luldv cam plnle, ball retainer, clutch
him and adjumng screw lrum the rign: crankcase
cover.

10. Scew off zl-e bolts and remove ll'c c.uxc1 lifter
plate ard clulc'I sprungs.

11, L‘smg :«pctdi loul "Lock \m Wrench" iTool No
07910 039mm loosen 011' [he 16mm lack nu: and
rcmovc the clutch assembly

12. Remove [he 92 mm spacial :el (mg from [he clmh
acmur. Uisassemblo (he clulch pram B, clutch dmc
spring and d;sc sprung seal.

3. GEARSHIFT MECHANISM

Gear<hifl pedal

Remuv I

1 P'y off the rap :In; and Ionser‘. Lt'i lhe geavshxn
lever iocung boil

3. Remun— rhr 3L:-.]'Shll:
lnsiallanm‘

 

 

.11 as>umblv

   

 

gr «LII anerbs,‘ wur- the punfl‘

lfl lever “mud up - rh that rm

 

.‘ Adm: the guars'mr penal p0

lever (5 m canine-i w :31 the ngrifi-H km“ or he

murdle

Tm: «Idlublmcl‘t IS made by Au [hi-

 

after Inowmng 'he lmk nus. Ash» Jlil-Al'f-C’IL

nghren rhs Ion mu r-vrnly

I. CARBlle—Z‘I‘OR

 

 

1:qu
:HMV if"? ,_
burzmg numlm 0,4
Mm;- in :7; v 7
Slow M' '
m "mile wum; _ .3”.

g'ncve

Au straw uprmvx
Hoar hug“! Vbiugu.

 

   
  

 

i‘ Rdmuttr
;‘ To open
fund thread) .. lu dun
5‘ Lock nu

 

I. FRONT SUSPENSION

 

m 4-:
Rig‘nx (rant “wk :hsmhw
; Imk bnu

mm ,nuLk :bmbu mm;

 

 

 

.' Rzuuunda ._
=. lrrm: :an [brie
l'vu'Zul'I can: 037:“
g on .ack pmrn

: (.J‘l mil 3WD

 

    

[5‘ sen-Lu mu
p. mm. “I: hmdcx

 

 

Disassembly

1 Removr- the Iron! wheel

2. Re‘nu «- he (.IJIpL” usscmb‘y from [he lei: from
tork

3. \-\"11h [ht hor‘z bcll icoscned, £0059 :he bniKs
at the [ark inn hridgo and sxeering swm, whlrh
sour:- :qu Pun: iork. Pm the (mm lmL (award
lhu button"

4 Dunn liIL‘ I'mnl wapv'wawn u.L

j Rumuw ‘Ju: nu: on [M from :mk pI'JL', vi any
with fine emery cloth.

   

6 Remove ms- «or ‘t holy and separars [19 :ron: fork
pipe and on? k pmfl? am Ina hon-VT rase‘
Us: “Altnn Head W-cm I “Tool Ma D791? 323MB
to rum-3w: m: smkc: bah.

Protcu {he {now absorber wth mg when hold-1g
It or a yum.

RP'me me Ira
p‘pu, run
593: pxpe and re curd >p'mg

   

 

 

l (k nnlr an mp cf the“ [rum :m"
r: mack ghmrhi‘l :pn'vg mum

     

3. Rernw rm- bultcm Case mu»- PH,-

éml flop and rcmcve :lw I) sun 70‘, F hutm-n

idN.‘

Inspection

1 Chad lln: My: length of “It: hum shock absorber
spung,

. Chuck {he seal p.pe rm m. - or the p.smn rmg.
Cl'cgk the barren, ms: am: .Cfn pupa Inr wmr,
crack or an-,- mho' dufcu

~1, Check Inc ml ‘6.“ I'm wear or rum:

 

 

Assembly

 

I (Isnm all pub In sou'wni m
2 Apply a UJJU'lg, L- AT! Lulu
10 (“c crn'»: sun nl a r

on: assc:~l)ly.

   

=..~ un {lull}.-
.« Irazml

‘ ll’ Immn.

 
 

 

    

w ml

       

 

ml “1.11 m Il'u- honor-w case. Dru: 1|: hc ml seal
Lmn.’ ‘Fnrk >udl Drlvm ' lTug:l Nu. 979~7—333Cl‘.l‘fll.
lmml _ ol scal slot) ._ ui lJollom can! (mu-r.

 

  

Imml mu vcbound spring .uu; gm: pipo .n:

from: inrk pipe.

J Amer maullv
mm |).[_IL‘ {u
unicl bolz,

NOTL

Apply linuid acnlull (0 [he lhrnds oi \hu mum hall.

5 Full uh 'r'mt l-yl \-.-:|~ M1 162‘“ 38:..s in
All ‘Umm‘: un»' ll

9 msml Klw nun

, . rm In lurk n) pl: .3 :rxK

m m VJ! ~ p lm

Ill

   

- ml loLk pler' mw-t : c 'urt

I: bone-n raw .xnu 5CL.:n: wn. :he

   

 

 

   

an ,m- div )0 [rm r'v

   

   

.pgvl “wan,

     
     

  

  

g 0} ml :m:
5. on v.4.)l

5:5. 44

‘u.

 

. r' xlur 'Irg

 

“3.: r, ,| on m1

‘va :un ‘Jm‘u

 

 

 

2. REAR
SUSPEN SION

Fig, I s
1 Rear :huck absurbar

memhxy

Imnt rubbu

Unner ,mnt

Spnng “a: :IOv

Spun: um):- slut

Lock nut :mm-r...

Slap mobs!

,_ Rear )huck mmw
5pm;

.. Spring lower seax

Spun; Idlmlcl

" Rea: dance,

Dm- rum (no

' Rea: e '( pwol bull

- Dual seal (-10

Rear t'ovk plval

bushing

‘10 Rear imk renurr
(ollav

fr. Sllanhns nul
(14mm

in [car lurk

{a Run hmkc map arm

a) (inane llliiru:

 

 

 

   

       

 

 

 

3. FRAME BODY
Fuel Cock

‘1. Place the fuel cock lever In ll": "0”" position;
dxsconnccllhu he! tubes. Take out the I'ucl tank.

.. loosen the fuel cock fixing nut and then remove
ihe luel cock and fuel lillcr from the fuel tank.

3. Dlsatsemblp the2 fuel cock Lossun off the screws
and remove the plaze, washer, lever, sprung, O-nng
and valve rrom the fuel'cock body.

4. Check the valve laces or the fuel cock for sgurc:

o( any other damage. Replace with a new cock

ds>ulnb|y, :l necessary.

Check [he gasket to see If II I: nol damaged.

Replace wuh a new one. il’ found to be damaged

too badly beyond use

6 Wash the luel lilte! in solvent and dry mm mm-

pvussud axr. Any :lxghleul damage can not be

tolerated here, Also replace the filter Will: a new

um: :i iuund to be clogged.

Install the luu! (Illa! [0 the fuel cock w.:h the

{hang nut. Do not forge: :9 install the gasket

mm the groove of the nxmg mu.

3 Install thP luPl rock to the el tank wuh {he iuxmg

nul
'3. ln>la|l the fuel :ank place on lhc irame. connect
tubes and setue - n the clips.

10 F.” the tank '- u fuel with the lad (:th lL'xur
H“: "O\' pos ton. chuck for any eaklge‘ past

l r ml)? loans at connuzmne

    

run mx lever
Funl (Mk flung nu!

 

J.

\1

 

 

 

 
 
 

 

     

no

Muffler

Removal

1 [omen
frame

 

 

hvn bolts :hal :ccure

 

Hm:

I. Lassen on exgh! 37'“? mi; and 'c'no"

 

:f‘c muffler
mblv, 0mm: pus:- :umls dnu mm collars.

 

   

3. ECOSOV‘ 1hr 'nul‘f‘cr band bolts and mmm'u liH: lwu

exhaust mm and scaling gum-n mm um mm" __.7-P¢"
unumbly

ln‘perlinn

l, Chwl IP'c cxhausl p:pc gaske‘ls lu- uurndgr.

2. (In-(k 1h.- mur‘lc' scaling gau-‘z. |':_ur “r".uu \

 

 

 

ri;.4 u 1 mm. uncnlfly

 

Installation

:11 In: mhafi: DPS—>2

   
 
 
 

l'nr' ugh (Fe sealing
H |">:

 

. «L»: :mv'Li

 

 

.mpur p.

 

w

- ‘1 2hr ,n» m m» mh ,

100

3 v. ELECTRICAL-SYSTEM 3
I. CHARGING SYSTEM

 

(:3)

11)

Ly
ligJ-l ; u: aonmzm

    

 

) Pumlhtn 'uuulalm { [no
. mom drodr Iouiher

. 3. L m1
_ l Batu-IV '
STARTING SYSTEM

 

r, win ,wan
'7

I

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

[an
N

 

 

 

 

 

hg. :72

 

 

'Irlr «PM ~\\.~:.-. 1m

L‘luh‘h iwilrh

 
  

     

.L t", mm: mm J r cu
in :E» . i.? .ty

  

 

v .miy '/.‘l':‘x l r: LIUKLI x;

Starting switch

Flux

 

 

‘.~snr>- hH‘ r“! “a,

 
   

 

 

cm I Punt: [um

Silicon diodt‘

('m‘u :

 
 
 
 

‘w‘l' nu

 

:I‘H‘IH r. .H'! :m' '|r ,n'ln
II
"nhuvmw' UV tl’L
Volt:

IJU
mcuucr will dun

 
  

 

m 1m h h

     

 

ul u)? .. m .. 4, {a high -.fiH4'.;-' gcnvmrd m Hm

,4, Ilw diudv

   
 
 

my. 1 , , ; -,Iw- 4mm,-

 

Mu I shiltll
LK-y w {.IFF m: .x‘

\w'. 'vinx‘ Hum". Kin-n.

 

 

.u ‘5» v II.KL

   

I ‘ mmwmg v ,I -v .7

 

 

   

'Rk \L 95

    
 

 

: "Mp
:mr cnve' 3h; smtch
G apcgmcc balmy
'~. on m earn pawl

2cm»; ‘vr‘vlu‘e: ;(

 

 

 

 

‘ m a.
I E'( up w.
hhu “ma um»

 

l 3”,“. Wm

   

Tm :wn‘ mmal «mu-r \

 

   

‘ Lu! JKLE‘
[tukwflv ‘ - ‘

w “(a

   

Horn switch

I) HIV“. V the u "r -a| n: In» I’m-'- mum mm In rhc
Lu‘llmdur (nu-r. Chm-k 1h:-
grt'; | '
Corn
D'csst

 

 

ru-uuuy rm: '

 

err me

 

 

:mnr‘n x; m.-

 

Enzine Mop switch

   

103

     

L V1. SERVICE DATA

   

1 SPECIAL 10018

 

No. tool No. | Destriplion '

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

‘
moo—37m 1 cams ma: tool so!
1 ‘ (”NZ-m .-' Pin spanner Mann!) A
2 J onus-mom .‘ Box wrench (12mm)
3 , emu-com hppel Idluflin‘ wreath
: 4 : 2901—3210101 'l V. Front wheel heal-n; maiw mend: ’_‘_
s 079me . Rear wheel bearing rel-Inc! wrench
_- e I- m-xzf’ 7 Snap ring Fen-7 ¥ _
‘— _7 0791;651:0507 __] locl; nut wrench 16mm] ’fr
1 a -,_ omr—amqm 7 Allen head wrench (6mm) '—
; 9 '1— man-mouse?“ w _ lolo’ljpullcl _- _ _j
10 } 079424290100 1 v.I»¢ guide «rim
W: _____ 0 7942-3290200 —L Valve guide couples“): > .—
4 0795-3314110) L —-- —A Beating duvet anathema! mm) —
F—u' ' 1' _ Rsfi— 1 _. _ I31fi.v:&.lfiéfiofi.i_‘—'_ "—7
_ M; W {Reaga— __" _. Tuba—acme . Eu};— _. U U V " _
7 T'fim—ysfim—l" " — ‘
Y T a;;ma.rf‘—*"— ___f_.
_ T7— 17— oTx'meTm _ Ball Ian—mm
— ‘ll— 1— 07—955‘1503 ‘- — r—Vfiislou ring toting-$071 q— I—-— 7— 7rd—
? 19:Hi— 0mil—Zflo—_l :- Valve swing Comfll€550;—: -
10 07956-331101) ‘, Piston base '
— '5 _ T_ 375—933;: _, _ Shad “79.535117“? ‘ W— _‘ — —"
— ‘2; j— INS—+201)!!! Y r — VII—ve.gv;Teanu-v (Inukel A A— _»
— 13 7— ’ Neda-.1}; ' 7 _ _ A Val—Vt guidt reamu (Exhlvul —_P
— 24"?- Tagzmlam — — — _- Flat; mu mth ‘— “i- -fi...“ N —k
1—‘— Elm "' - Dnve Jul“ hoiéu -_ ' ’1
r—A z: _.. 01797—293300 _ Special will» ’-_‘- —_— — '— I
—o7uoTJL_ --—‘#"'_‘ in”, " - 'fl
.: =7: ‘: @7532: 7: : EQIEE. } _ i: : if : 71
L28 079091230510 , Carbuteror wnchronuation wreath sel .-

 

 

1“ Vl. smwc: DATA

2. MAINTENANCE SCEDULE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

INITIAL REGULAR SEIVICE PERIOD
Thu maintenance schedule is based upon average rldtng SEEKIY‘IJC; $5122: Ilig‘lielxmgfiwn‘tzgmgi
conditions. Machines subiecled to severe usa, or ridden _ ‘ 3 . 6 12
in unusually 'dusty ateas, .requive mwe frequent sen/Icing mama “so?" : '1";me
miles miles ‘ miles 1 miles
Engine OlI—Change O ' O i ‘
oil mm Element—Replace O . v ‘3
Oil Fllter Screen—Clean ‘ 0
Spark Plug—Clean and adjust gap or teplau if necessary ‘ O
:Eiontan Points and Ignition ‘llmjng-Clean, check. and . O
adjust at replace if necelsary
‘Vttlvc Tappel Clearance—Check. and adlust K necessary. — O C‘
‘Cam Chain Tension—Adiust O ' O 1"
Paper AilrFiIlel Element and breather Element—Clean. _C;,;" mole "mum“, if] ‘_ 0
Papa Mr rllter [lament—Replace Mm“! I" dIfllY area; 0
'Cart-auretot—Chedt, and adjust If necessary. C) —
Throttle Opuation—I‘Eizgzfit aunz’eatljust free play. . 0
‘Fuel It'ltct Screen—Ele'an I C H 7_‘
Fuel Lines—check . C
T(Iflrulclt—Chedt titan-ration, and adiutt if necemr—y. O I- ——l ——’3 ‘ ——
Drive Chaim—ctiéé'fiubaicaie, and adjust it nevccssary. "o ‘ Io A _ 7
Brake Fluid Level—Check and add nuid it necessary. ' V o ; 7 ‘_ H O I ,
”Brake ShaeHPadr-Inspect, and replace it worn. . - '3
Brake Control Linkagew-Check Iinltagunnd adjust lree r - . I “-5
play if necessuyt | _ ‘
'We' “m “iiiizzm—im‘; wt . .i n s . . | ‘ o .
ig spa es a e: s. «as ary
‘lttes-—Ifispect and check airwessure. 0 Al O r I —
Frunl roittbit—ouin and rellll: ' ' .. o ' 0
from and Rear Suspension—Check upstation. I 7 wt A 4
Rear Folk Bushing-Greaseicheck lot excessive looseneu, ‘y A__
.TStL-uing Head Bearings—Adlust, ‘ '- _ 7 :3
“Side Stand—Check installation, operation, delormation, ~ 7" 7 a_
mug: and weart ‘ " ‘
-—Brl\llcry—Ch€<k electrolyte IcVeL and add watet if necessary. -7 O 7- I: _ 7
Lighting [quipment-Chcck and Idlusl it’ necessary. “- . 7 f.- “,7 At
All Nuts. Bolts, ind-O"!!! Fasteners \Caer‘: security and 7 7A. J A i 7
tighten if necesnvy -

 

 

 

 

Hem matted ‘ should he S!’VI{:d by m :uthcnzed Honda duly Lnim trte owner r.“ proper mot: and u rut-mo
it» moi-clam Ot'wer 'flalnllflifiL: item ue slmpl: to povim-n .nci .av :e sen-iced av the owner.
amt :evwz: perxud m) mil-:5. -- Initial mm: period 1500 miles.

     

 

VL SERVICE DATA

 

3. TORQUE SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ENGINE
riglmnlng will E mad as. in) Tm"
lit-:- 1‘ . um
Crankcue Ind crinkcno cover: l 6, no i 70-110 5.1—8.0
Cylinder had 0, P115 (Apply .33 III: mm. 115
I Dolor. lighunlnfl ‘
Cal-humor lflsulllur—Io—zylindu hue ; 6, no . 70-110
Cam bprackcl ; 1m: ‘ 100-200
A.C In..." mm 7.77 10, v1.25 1 M
Primavr dllve gel; 7 7 12, 0125 1 300-400
Tapper adluulnl mu 5. P05 | 70.110 5.1-0.0
Uppu and Inwar clanknus i a. 9125 1 210.200 151.109 7
Cyllnder had com i 5,910 70.110 5.1-0.0
Clutch mm 7777 , i 15. no 7? 29.0-32.0
Connecting '06 O, PLZS l 14.5-15.1
FRAME
'I‘illlulu pol-l ! TIM III. (II) -~
i ‘ in. IhI-fl
smrlng mm mu 7 77 24, 91.0 i coo—1.200 573-009
Fovk lop 0mm [0 'loano1-ls i' a. 01.15 7 100230 111—107
7 7Handlebar hold" 7 a, 71.15 100-230 13.1.1”
rnoni Iovk bollum hrldlt In iron: (mks 77777 a, 91.25 . 150.110 13.1-15.7 777
Spoku ! ——
mm wheel — 25-30 1.9-2:
um wheol , ._ 20-25 1.5.1.9
xéai lork pm: ball I7 11. ns 550—700 a 390—507. 7'
From wheel all: mu 7 I 11, 915 450-550 7; 325-39.!
non: lurk ul. holder 7777 71—77 0, n25 100-230 13.1-16.7
7 Engine hangar boll ; 10. 71.25 777 Jon-400 21:49.0
7:; Ln}; 47:1! 7“: g 16, P15 000-1000 $542.1 7
Flnal armn sprocku 7 10 "1757 400-500 ‘ 290-36.!
Buke Inn 77' 6, no 7 10.100 ‘ 59-7.: 7
Front and real bukc lorqul links 77 a, 91.25 1le 13.1-16.7
Rur suspension _77 10, 91.15 303400 77 77 117-290 7
7 7s77l=p7bu 77 7 12, H.725 450550 316-3910 _7
Our clung. pedal "in; inn. 77 7777 7 ~ 6. no 7 77 001:0 5.9—7.3 7

 

 

 

106

VI.

SERVICE DATA

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4. SERVICE DATA , .
ENGINE
Ural; mm lin‘J
n.- . ' Jun-Hy sud-rd 1 smla u-le
Rocker arm-Ioaocur um shall. clnlanu 00W! (ammo) 1 0.1 mm»!
Cam heiflll of camshaft ;
lnnk. mas—2:225 (nous—1.11m ‘ no mow
ixhlusl i manna limo-null 2w mum
Cumin“ (enlu jaurnal — 0.! 10.0039)
Valve m: mm 1 a: mm E 1.5 (0mm
Valve mm on. .
lnllke ' 5.45:3 lazlsuuml , 535 lame)
uhmx 537-5» «um-02ml 5.15 mm»
VllvO-lo-vllve guide clearance
Inuke (mi-om mom-mom a: (mu)
mum ' I om-nmmmmm ' mama)
Val" :pring prllmd i |
Inner mum-nu. lonssmees-mmlhn —
om- I awn-nu; mama/mm 71mm) .—
Vain spun; 1m lenglh : !
mm . no man ‘ 27» (Loan)
cum , us 11.3505) _ 37.5 ".2799
Cylldu ind flat-ll“ : - — I In lumml
Cylinder m. sunsml lané-Ml V 51.1 [mm
Pluon sklrl 0.0. _ sun—sol” Kim—1W5] ‘ seas (2.0030)
mm pill hola IDl ’ mam—1m msumsnll 1305 mm)
"mm pin 0.0. l lawman msfimml 119 mom
Yuvon rlng-lo.piuon rinl uouve :Iunncc I
lop rlnl «0190‘le l ms lamsal
Second ring ommms lemma) 1 ms ltLoossl
_ _ 4 _____ _ l
Piston ml. and gap l
lop ml. . cams tom-«mm ‘ a: [00276]
Second rill; , 015—on lawn: 1 n7 loaml
Oil ml; . 024x; tummy" 1 my lawn
Ouler relur ovum-pump body eluunc: ?
Main pump (mum mwzwwm < nus mm)
Auxlliaiy pump : ms—uommnmnl i nas «1mm
Ouur roloHo—E‘Iner relur <qunce E ‘
min pump t 0.15 mom mu. n3 lam-ml
Auxlllaw‘pump 115 («0099), mu. 03 lum‘lsl
Friction diK mime“ m-m «um—moss; 7 >13 lomosl
Clulch phi: mlm warm“ cu new). flux. n2 loomsl
Clulch span; tree length _ :13 4123031 29.75 1712;
Elmch <enler-lo-clulch plan I zlnalanu M. 0.1415 (MM-om u 7 :fiflfd‘mm'flY
Gearshik lurk rm“. mm A“ 5.93.500 lam-Hum: 55 (0.2155.-

 

 

 

 

 

VI. m DATA

107

um: mm (In :

 

 

In.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Asa-u, «mind 5mm um: I
Gunhlfk gulde shit on. K was» mum-0.5112) 119 mom ’
Gennhifl fork I.D. ‘ min—mm mun—awn 12.95 10509:)
Kick 5mm p-nionJo—nhafl clearance l W Wm ' m (omu
“691nm" fovk dowel-Io—drum groove clam-c: j: ans-an aim-om n3 «mm ‘ W
Transminian 3m backlash ! — I n2 [c.0079] *#
Transmimon gear-104M" :qunu : f
C—I W4 (My; § M m)
cm: "m ; mom (mo-m2) 1 0.2 mum
Cm chaln mnsionav shape} lhltlmegs (mum ! All nus/s; 3,0 (um) um.
cm chain Inf. Ihldtnen Lam: (um-0.2m: i 5.0 «mm
Cunkshm "mun: [comm - 0.03 (00012). mu. 1 ans mm)
mama" lournal SIS-um am.“ (am-acme! m (mom) fl
Connnzin; m1 mun ma I.D.V V ‘ “mums: «mu-M131) “um (0.515!)
Connecting m} his and sud: elm..." i V ‘{ ms M59)
52:21:63": 104 big end-lmcunkshan journal ! “mm lwm” ! 0.05 mm”
Plimavy chaln gum. Imam; («an am (more) \ 5.0 «mm

 

 

lul-

VL SERVICE DATA

MN: mid-"l

Unit: mm (inJ
I pom“ Halt

 

lulu dlsc lite runnul

03 {0.01“}, InllL

Lu: (0.0118), mill.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

mke dis: Ihlckneu - Lawn (mums) —
Whul mu «m mom ': 05 («mm mix. i 21: mm)
vmel burlng and play my mum Inn. on toms)
wheel bearing radial phy um (0.0012), mu‘ ’ 0.05 lama)
mm axle runuul ‘ om (allow { a: manual
Clllpel :yllndu l. n. lulu-sun (13012-1501!) 1:21: (1:015;
Callper mm o‘ n‘ nus—moo hams—1.5m) . mos (1.90m
'Masler cylindu I. u. wan-mm (05512-055291 Mass (0553:)
Mm" cylinder plnon o. of 1' luv-mu (050mm) 1m lama)
Rent axln runoul cm (W) 02 W9)
lu- brlk: lilllnl lhlcllllul . 49-50 mummy) ‘ — 2.1 mm
in: lmke drum I. D. N ‘ mm: (61992-63110) 16| [53306)
from suapenslon sprinl in. length m Haw) 451(17717)
Ru: suspemion 1min; he: Ienllh I 110.4 (I280) '90 0.4m
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