Sllfll' MANUAl

 

     

PREFACE i

.-.-«--m..-.....-.-.

This Shop Mlnunl details Rh: propc‘r servicing and repairing procedures for mechaniw
working on the HONDA 500, Model CB 500. Ca'eIully leading the complete section
before beginning uh: work and following ll“: axe-p: in the order given will result in berm
maintenance and repair will: less tumble and lime consumed.

Always keep fit: mmmmended sped-l Incl: at the weak bench when performing repliu
U51: only genuine HONDA mplwzmcnl perk

Service data {or lndividual pans is wnmlidznlal inla a single scmion at thn rear of the
turn {or quick relerence. I

The descriptions and sponifiufims in this manual are those in effect at Ll]: lime this

:quI was approved fur priming.

HONDA MOTOR CO. LID,

IICHNIIHL
CBSDOFWIER

CONTENTS

No. Plan

1. REPAIR PROCEDURE D

2‘ SPECIAL TOOLS

 

 

IV

9
I

 

mounted m Irame

2 Engine removal and installalion

  
 

   
 

(ler head.
pislon

9
!

4 Valves and valve springs
5 Oil pump and oil Iiller

5 Clulch

7 Gear shin mechanism

8 Cam chain lensioner

9 Crankshaft and connecting rod

9

   

n. kick starter

o

“-4
H
9-2
‘3
a
5:
m
a
m
-

ll Carburetor

 

I

5. CHASSIS

 

!

1 Front whccl and front brake

Rear wheel and rcar brake

999

 

g}

4 Front suspension

Rear suspensinn

In
9

6 Frame body

6. ELEFTRICM.

 

99

1 General descriplion
2 Ignition system
3 Charging system

4 Slarting system

5 Electrical equipmems

 

7, TROUBLE SHOOTING

PERIODICAL
‘ MAINTENANCE

1

99

9. TECHNICAL DATA
10‘ WIRING DIAGRAM

1]. INDEX

 

!'

  

    

m... ...u.».-...m.....

. I. REPAEH. PROCEDURE

u. .,..........1.............. .,.,.............««..L

 

1. When performing an overhaul, all (In: dissexmbluhmrls should be separated in their
ravecfive umupx m that they will 1101 bvcnme mixed.

2. Replace all pickings. gaskets and com: pins with new items when mammbling. “War;

rcpkux any datum-m1! snap rings with new Emmy.

Clean all engine pens after dismemhly. Cal! fiction surfauas of mmal puts and bearing:

with oil.

When making a: replacing the pans. use lhe recommended special lnnls for butter rmks.

’l'nngue :1] nuts. bolts and screws. sum-inn with thou: of lame (“INCMJN‘ from 1'1““:

to outside symmetfically.

a Refer to butane values shown in lhe follawing able.

5”

9".“

 

 

 

   

 

 

 

 

ENGINE
lum ’ a,” _ Tame uh.“
kg-u 11-11-
1 ram: Ifiufliu nul ‘ a 1.5-1.7 10.5-17.2
2. Cu rpm" hunk 1.01:, leZ ' 2 1.8-2!)
:. Cylbdxr hud am. a 12 10-23
0. A. u gamm- nlur nu 1.311 . 1 1.0-4.2 ‘ as Ho. 3
5 Swain: :Imh mw, uxza emu m mm 1cm ' 3 2.5-2.1 us 7. a
6. Um: mum-u MI. 8x160 he: bah z 2.3-2.5 16.61"} In
7. um.- makem boll. 8x125 m ml; 1 2.9-2.5 Ibis-1&0
3. Lcwu mnkmm bk. an!» M: bolt 10 2:; u 15.6—33.0
v4 C(mmfing md rm 8 20-12 14.5459
1:. on pump may. 6x55 cm: 11:: had mmw 5 0.8-1.2 5.7- 8.6
n. can-.11 Eker in'u 591:, 5x15 Ibex Inn 1 0.8-1.2 . M— 8.5
12. . Spur" mum hall. 6x55 I-u belt 1 0.8-1.2 ,. .
1:1 rum-am: gm hddcr wow. and (mm in! but! me: 1 L0—).4 12-13.:
11 Exhaust pin: [haw 11:11.63": 3 0.3-1.2 ‘5. - 0.6
15 Oil puma Iwildl 1 1.5-2.0 10. 11—11. 5
1a Gear 9131: lava bell. sun 1-“ M11 1 D. 5-1.0 57— 7. 2
l7. Oil film «an: ball I 2.7-5.3 19. 533.9
11 Spuk flux 4 1. 3-1. 1» 30-11. 6
19. on am: ball 1 2.5—” ' 25.3439
11 um: mink. sum 1-“ M11 0. 3.1.1 5.7-8 5
21. Eabaun llvngc. 6mm mu 8 0.3 L2 5.7 8.6
2:. on mm mm m: 1 11-33 1:15:43
23. Taiwan hole up u 1.0-1.4 12-1511
24. on pub up I , Lib-1.4 12-111
25. my dun mm am; am. boh 1 2.03.0 11.1-21.7
slums pun

ncu nu, «nu 0.5-1.2 M- a a

non m, am: 2. 0—2.4 1.1 5—17.:

5mm mu. 6mm 0.5-1.2 m— s a

 

 

 

 

 

2 I. REPAIR PROCEDURE

 

 

 

CHASSIS
l “a m, 1‘5““ values
i ig-m n-n»
. | Rm Lulu pea} M11, 3x92 in hm 1.3-2.5 15.9-13.1
Sup hr l 123m E.” Ii.” 3573-134

 

 

I.

2.

a. 1:",an mu ban A
4. Enginn Huger plate

5. Rm m1 93m mu, him.»

5. Real :uapsnuiun mu :u, 11mm W m
7 RN: “mm... law" 501:, mm I... bull

 

 

 

 

 

me but:
a on w: :c a 4-4. a
a Bnla: Slum mm. ‘ 1 s. H c
m Fm: huh dine nut. Sun a; 1.5-2. 3 110 1415
n ‘ Bnke on in |. has he: nu : as.“ 5.1% 1.2-
”. Brake ban . I fl.E-l. D .xa- 7.2
:a Mum :yllbiev lvln 5x2 he: ban 2
u ‘ k‘alipe: m w: 2 ‘
LS Huldvrpmk halt. 8x40. uxsu [m be}: a
15. From [wk b1: 2 5.5-0.9 25.5—
17. Sam; nu: m 1 3.942:- 5~ Hm

 

 

   

 

 

18‘ Send a (an Edi. 50x54} he. lmh 2 3.0-4.0 IL? 23-!
11'. Rear I‘ll“! uh: m ‘ ao—zo. C' 5?.8‘ -3
m, FInnl-Axk he‘d" Lui. 8mm ( 1.8-3.3 13.045 6
2L Handlebar fickle: tall. Ext) lu-x In]: ‘ 4 1.3-33 13.345 5
22 Fun: «Lu-l u]: ml 1 5.54.: 318 41.0
2... Km hula “mu am boil ml mu, 8mm 1 1. 2-2.: 1-10-ch
21. Pal: |np Irrhlgu hlf. 6x56 hnx huh 2 1.0-2.3 new“:
25. Orin chnln Adjmku 5n]! and mu, flmn llu kl: 2 L! "Q [0. Eifl I:
an. .Dn're cam nun-m Ilappe: tau 2 La :3 13 0-16. 6
22 Main mm pix‘dl mo be“. 81”!) )sz w: 2 1.5—2.0 "LE-11.5
28. Pfllim ,‘xp nut. 12nm 2 qLHO 31!. 5-43. \I
21 Caliper bid pin ) 1.8-3-3 ‘ l3.|J-ll.1
m “ultvm bridal f 3 H 0 1-30. I
31 Fwy! drivan zpaozhx ‘ 8 H. E 2‘. 7-3! I

Sun-dud nus

 

Boll hex. Emm Md. 2 5.5- 6.1.
Do}: hex. Emm 1.5-2.1 Ila—I5 r3

 

 

 

 

  

5% 2. SPEED-XL TO0LS_

 

  

 

 

 

 

I leecripdcn
5 ycclrl T001 Her, (m CBSCC
Valve 5w! 96” .
131:: val“: 5e
Exhaust. mlv
Inlet w 9. mar. inltrim' éuuur

 

     
 
   

   

 

 

 
  

   

OTOZIE- 'JIJI must val“: an: interior culu‘x
0700? 32331 Valve . ( cutter holdbr

MODS 39.3w Valve gLidc Mano?

[WINS 732301 Val-m gui‘c 'mfl remnvixg ma!
G7C‘J173CGH Valve . commas“:

(“OI-323i}! V pr: compress“: altaclunmc
CHEM-32.301 P .011 mu; Dampvtswr [2 gm)

UTCGIJ 30101 ‘ PIB‘OD ham; {2 pcs‘:

(MOI-32.201 Valve seal cum: rm

 

— 07$va6101 Valve scat cutter cum

 

 

SPECIAL TOOLS

 

 

 

 

 

 

 

Rif- No Tool No. I Description
Q4: ml—GL’FJ‘AI \alvc uppel 1:711: m_nt vlrmch
o:- WET—112301Cnrburnorsnchmnfzntiun adjusting wmnch
n (JAWS-112301 12mm cyli c: haul nu! wrench
Z D709#82'JDI Spud. plug wmnch
{a D7Dll-2lfiul AC muemem- rota: Idler
Qt WOW-32301 Sliding hammer shat tfprimary nlmh wmuvc‘r}
('3 07009-323U5 Sliding weight
41‘. 07073—323U1 Manet cylinder snap ring pliels
Q 07043-32301 Pialnn CLp guide
«3 (WOW-20901 48 mm steel-mg 23cm tap :Jnmul wmnch
9:3 07085-3230]. 6mm fork bomm we halt. wrench
— 07043-32366 Manet cvlindu' pinan guide

 

 

 

2. SPRC'ML TOOLS

 

 

 

 

 

 

1mm 1c»; Ne: 77
'—l——*_‘ vane—3351’

#:9393368

‘ 38-32335

   

I racial

 

nmyprim
. , mlsinrr wunrh
Begum mtainrr wlrnrh Is 3
anl fork nsvmfling
Ran cuskim dimmed:
“mans dn'm A
n arias :1
Ensuring dn' ., nus-1mm: A
Baring dri-m uuxclumn: T!
Vamm “we alnc'l'JDL-rl 5.x; :2_ ,
Yum-J: gauge aim} .nrrl in] {2 pg)
Va Ltfll mm: 1196)

'zuuua gauge w

on 2::
Menu! gang-.-
Di! Faun-1 mug: anmhnmm

    
   

 

 

auE mama.“ ltn1

 

 

 

 

 

3. MAINTENANCIL OPERATIONS l5

 

A Rem" any bnke fluid which may become
willul on "I: painted surfing, mllher may,
and male! I! 1: will prmluce Chandra! anion
and can” damn (a thug mm.

Brake Pad Inspection

Replace hath pads A and B with nnw on:

Whm cillm' all the pad: l5 worn in the ml

serviceable limit mark swung llu: pad.

 

 

 

 

 

 

lit. 31 3 Null ISM:

 

Bnh Bleeding

Bleed brakes to remove the air from Lhe
brake system when lhe brake lever acliun
fee]: many.

1. Fill lhe reservoir of the maswr cylinder
with brake 51qu to thc bright of the
level line.

2. Contact 1 hose to the blender on the
caliper aml ppm-m; :1 mm! m mlch me.
fluid.

3. Pump the brak: lever seweml time until
manure can he Ml, Will. [he brake
lcvcr held against the pmssum, 0pm (In:
Header about half a lum, nnd when flue
lever hoflnms against the handle bar,
immedhktl)’ close lhe Header. Rwenl
this operation swcnl Kim: until all
bubbles nu finger flow onl wl‘JI [he
fluid from the blade: hose

Null:

The fluld in the mmlr must be repleni-

uhrd nnd mu: he Illuwed. to become txllun-

fled during the. bleedlng npenlmn. "8- 1.1 G? cm?” (I)

-Thc rcacrvmr must bl: mppzd \vhm 931.313: @Vexxcl
pumping the brake lcvcr.
Rel! fluke Adinstmem.

I. Normal play at the and of [he llmlte

gedsl is 2-3:!" 'iu-1'."ain.].

 

 

 

 

 

 

 

In 1!. MAINTENANCE OPERATIONS

2. Perlon'r. the adjustment with the adjusze:
nul.

10. AIR CLEANER ELEMENT
SERVICING

1, Open Ihe :a-ak‘antl mmovu than")! (my‘

2. Pull on: (In: spring cilp and take out
the. cleaner nlemeul.

3‘ Clean the clement by tapping it lightly

Ad-WIRK DI“ -' - - - - - I
a 1:11:1ch n p 31") NOV-"m wmwmll aw I‘m lllslde‘

     
 

I

Fix. nr. V am Inn: :23 5m 1m

 
   

$7r Lelip

g 11. DRIVE CHAIN INSE’EC'I'ION AND
ADJUSTMENT

1, Check the slack in the chain by raising
and lowaling the chain at. the midmiut
hem-cm the sm' . The normal slack
la 1~2cm (3: .

2. Adjust lly lower ‘i: am rmr axle nut
and turning the adjust balls on ball:
Side;

Note:

The nun-1n on but]: adjnxlers nhould be at.

in: mm location when the chain is pro.

Duly «dilated.

 
  
 

 

13. BATTERY HI:I‘X}'|‘R.OI;YTE
INSPECTION

Remove the right side cover and check the

Bledrulyae he .. Th». have! slmuld lm .‘Il tlm

upper limit.

1.. If (he level is low, open [he seal and
man»: lllc on tray In and distill":
waler lo the lunely.

2. Rumovv Six but‘m-J lillcr caps and Ell
(he Wale: to each nell up In llm upper
limit.

 

3\ MAINTENANCE OPERATIONS

13. FRONT FORK OIL REPLACEMENT
1. Remove flu {ark boll and drum buIl,an.']
dam drain lhe nil.
Actuale up and down Ihe inzk to drain
the oil sunny-laid}
2 Plush interior with fine 301mm.
Note: .
Du nut mm gaml'uu 1m- flushing.
3. Tighter. \b: drain halt sccumly and add
new oil to the fork tllrngh the {on
of {01k Vim.
Rncmnmendod oil' SAE IOWA-'30
Cnpldty: 1600c \fxdazs)

 

1-1. COMPRESSION PRESSURE
CHECK '
. Remcvc the spark plugs
2. Insert the em! cf flu: camyrereinn gauge
inm the splrk pluy. hole
3. Set both the lhmulc and chuke to hill
0pm maiden and kick Lhe kick sun-per.
SInnth'l compresinn pressure:
12 Mfcm‘ [170. 6? psi)

,_

Noih:

- Fully oven the lhlotfle and choke m that
um (um mmvrqasim: manure will he in-
dicated on the gauge.

- Continue lh: ktckinz unlil (he mmnwmiun
readin: is It maximum Wm: Hm leldinz
will me with «nah kicking.

- To obtain the Mn prawn- remlinz, w
tom Hm measuremen‘ after wuminz up
lh: eufiim.

[lmw (omnrclfion pressure)

Whan the cnmprussiun menu: is bclow 10

km'cm‘ {142.2595}, [he probable cause: m'e

leaks amuml llu: valvus and plain rings, or

[mm [In head and cylinder gaskms.

Adjust fr», valve tzppct clsmmces, or (135415-

acmble flu engine and inspect the piston rings

3an gaskcu. ‘

(mm: compression plexaure]

When we pnssum is greater llmn 12 kglcm’

(1111me the mobablc cause is nxcruive

carbur- zlgpmis on r)“: amt-human chamber,

piston hold and the valves. Disassemble the
head and cyfimkr, to Emma die carbon.

 

fix. a u:- Comma-awn man

 

 

3° 4. mom;

1, SERVICE“; WITH ENGINE .MOIINTED IN FRAME

firms Paw-s

cynmie} Jae—Jon" and Camshaft 24 '—

 

l.

2. Cylinder Head ‘ 21 ‘
3‘ Cylinder and Pimn 21

4‘ Gun Chain Tensioner 25

5. Oil Fillnr and Oil Pump :55

6. Clmch 40

7. Gear Shift Mechanism 4'J

8. Electrical Syswm La. (Generator and Surfing motor] L15

2. ENGINE REMOVAL AND INSTAL—
LATION

A. Hanna)

1. Turn the flue] cock lo lhe "STOP" pusi.
Iicm. disconnect the fuel pi i at We hulk.
and dismount the fuel lan .

2. Unscrew Ike oil drain bah and the oil
ml!” manta? bolt, and drain the cngine
0| .

8. Remove (In: exhaust pipe and [he mufliur.

4. Dismnnccl the high le- Jun cords a! the
spark plugs.

5. Dismnnenk ihe mound table it the baneJy
:elminal.

G‘ Unacmw the 5mm snow and dimannect
(he mchmnelu cable at the cylinder hcml ————— 7h 7- ‘ -7...1
cover. "a. A! (3 Drain sol: I2, 0.] mm emu hill

7. One“ {he sent. take out Ike air clean“
elemunt. unscrew duee 6mm bolts and
remove the air cltancr case.

 

 

LA ,
I'I'l- ‘5 (D .\I: dwb" vl==mi '3'; An: :lnw
a) 6mm bolts cu:

  

m. u 0:- nmmw uU- .3 5mm 24m:

 
   

I. ENGINE 21

8. [Hammett flu: thruulc cable at the car-
burelor.

9. Louscn the two 5mm screws at [he
what-cm: insuhlcl and the 4mm nmews
:1: Ike air cleaner chamber. Remove the
carbumor.

lCL Disconnect lhe starting motor cable [mm
the magnetic switch. and than \he gcncr.
Mo: wiring.“ thu wuplar.

 

H: p , gum“ mum. .n.\ !. «Jam
r3 mu...- and muddy

11. Rumove ihe mar (:52ch pedal. unucmw
the nan-ting mam cover bolls, move
lbc halting molar cover, and 111m Imnvc
the Iell crankmee cox-en Disconnect the
rink}: cable en fin; ck-lch Mm.

 

I‘ll. d9 0 w; “Hahn": cover (1} Clutch Mm
G) Clutch cable

22 ENGINE

12. Remove the final drivvn sprocket and
’ mirth-AA the drive chain

..... Wu _ --

‘ .-.. .-— ' l3. Disconnect the ccmm breakerpoinl lead:
' ' (yellow and blue) :1: the connectors.

 

 

14. Unscrew lhe nuts fmm thccnginc han-

k gfl bulky. and dismount the engine [mm

Llle right side by raising it': mar slightly.

 

 

 

 

Inc. at Le]! xiii: mm hanger 2qu
(L1 "5:! hex bolt
3) 10x53 bu boll
{5:3 Rm npp‘r human Lu:
'3) lax») h: but:
La; km lam Luge: bah

 

 

 

 

 

Fig. 52 Right .54: main: has" bolu

(D 8x50 )nu ball.

a) 10x50 ht: ban

El.“ Reno up”! blast-r bolt

(«‘2 Sauce 2m Ink

6:- axqo he: bk

(9 Km hwnr mm: m:

(7) 10x83 hm: hm

L ENGINE 23

B. Ermine Installation

L

Rcmoum the engine in the NW unler
of dismvmling. huwevur, allenlinn should
he given to the Inllawing points:
Install the cngim: from the right side
and (imam um hunger bola; 'l‘hc but-
lery ground cable terminal is insullcd
«gather with on: near [mum-x Imh.
Make sum that the gtnualor Cord and
starting muwrcufd an: nol pinched when
the left crankcase cover is installed‘
Make sure that llm lwo nzul’flem nn each
ridc an: properly ounnnctcd with the
muffler connecting bond.

Yen‘clm the following adjustments after
the engine is
Clulr]: an},
Drive chain slack Idjuslmcm
Carlnxalnr adjustment

  

 

 

 

 

 

Fig. .1: IE: Grnmzov nor:
{5:- 5Iu|i:u: mvlot mrfl

    

f

11:. 56 u,

u wnncuiru 31rd

?‘ ENGINE

3. CYLINDER HEAD, CYLINDER AND
PISNX

A. Disunemhly

1. Turn the fuel mck (n the “STOP" peei-
tinn, disconnect the fuel line at the tank,
and dismount the fucl mnk.

2 Remove the exhaust pipe 1nd mufilen

3 Disconnect the inchumeler cable.

.1. IJEsmnnccl the high tension 00nd: at the:
spa]: plugs, unscmw six 6mm screws
and remove the brcathcr cover.

5. Remove the {applet huh: Guns, ’P-rl and
right side covers, unscrew twclvc 6mm
screws and ELY. bolts. and remove lhe
o indet hand uomn

Nut

- Loosen the sum" and bolt: Imiturmly lg
(clicw the ntnexx gradually,

 

 

 

 

 

 

 

Fik- 57-1? Cylin-‘er hon! rm"
:3: u'mn'. mam “than

6; Imogen the lot}: nut of the cam chain
tcnsion adjuster [lanve lhe wrench on
file nut), turn the. new» fully (appxoxi-
mntcly 90") clackv. se. and {hm tighlm
thz lock uul.

In this canditicn the urn chain tcn-
sinner is not applying lensinn to the cam
chain.

7. Unscrew two cent sprucliet mounting
bolt; and rcmcvc tho camshaft from the

sprocket.
8. Removc the cam chain from théunmcltet.

 

“In 59 fl} Cull I mm (1‘;
'23 Cam 1:. hi: '3‘

Cranial!
'1‘ at: bait

9. Separate ill: carbululor axzmbly ham )1:

10.

1).

l2.

4. ENGINE

lhe cylinder head‘
Unscrew lb: can: chain tmisiuner mount.
ing boll.

Unscrew (\vclvc cylindn baud malmling
nuts and two 6mm flange bolus. and
«move (he llcld. Loosm the mus uni-
formly in the "New: onler ol tighten.
ing shown in Fig, 53‘

Remove um um chain guide [mm the
cylinder by raking the 11):" chain guide
slightly. and mute the guide 90° and
“moving it toward [he (an.

Luring this opmlion. do nut (iron the
aim chain.

Unscrew the cam chain adjuslcx luck
nut (1%.qu and remnve the chin ten.
sinner from the cylinder.

To facilitate removal, raise Llle cylinder
about 20 max-'1. in, and remove the cam
Clmin Lensioner,

Fig. 63 (i) Cm (half. Iceman“-

 

3‘ 4. ENGINE

14!. Remove the cylinder,
If the cylinder is tightly stuck pry
the cylinder louse with a acmw'rlriver
placed in the groove 31 [he bass 0f the
cylinder.

15. Remove the piflryn [fin qlEp, pizza; pain,
ml the piston.
Nola:
When nmovln: flu: pin clip. exercise cure
nol lu ("up the clln halo um annkcnlc. ‘

16; Remove the pismn ringa

1?. Screw a fimm Ink into the rocker :rm
shaft and remove the mckcr urm shaft
fmm [he wlindcr brad cover.

 

3. Inspection

1, Inspect the camshah bcaring surfaces,
Canalhaix Malia}; surfaces should he
mum}! and shiny. If it is snatched or
excessively worn, it shuuld be mph/cud.

 

 

 

 

 

4. ENGINE 27

Z. Mmsure lhe height of the cam wilh
I micrometer.
Replace the camahall if beyond We ser-
vicuhle mm.

Mg. n ‘w Lama.”

 

3. Measure camshaft runom.
Support lcvcl ball! endsol lhemmslwh
on \thocks and with a dial gauge
measure radial runmxt 1|)- mlating (he
shall. Replace the camalull 5! beyond
the scxviemlale limit.

.1. (Heather): the camshaft for ecmtch. wear
and replace ll nemaaary.

 

Hg. 59 u nu luv 4 Cami-u

a Measure cylinder diameter at the top,
center and banana in hull: the X and
Y axes Reborn the cylinder if beyond
the serviceable limit at any point.
when whoring the cylinder. rebme il
In fit one of the lam stundatd ovcrdzc
pislnns m lable.

Srsm‘lan‘l oversize: are 0.25. 0.50, 0.75
and 1.00 mm (0.009, 0.019, 0.029 and
n.039inJ.

     

5. Measure piskm diameter.
Measure the diameter at the piston
skirt. 90’ m the piston pin wnh .1 micro-
meter. Replace the piston if flue diamcacr
beyond the serviceable limit

 

Mr. H u; Man-1mm

25 new:

7. Measure piston ring end nan.
Insert (he piston n'ng into the skin of
lhe cylinder so am: i: is squnrcly posi-
tioned, nml measure line “up with a
harder gauge.

 

a. Mcaaum pifion ring side chateau:
Install the rings on the piston and
manure the side clearance of the pi:-
ton ring in :11: ring groove with u Iva-(er
gauge.

 

9. Mcasum (be p‘mon pin hole using an
inside miltrumeler or cylimlar gauge.

10. Inspect the piston for dame. dialer-aim
and acmive wear.

  
      

“or .

Fla. :4 (A) Piston a) Cylinflct gauze

   

4» ENGINE 29

C, Rtassembly

1. Install lhe meimrurm suul Llur»: makers-m
shalt in the cylinder head cover.

2, Install the piszun rings on :11: pismn
will! line marking on the ring. mward
lb: lop‘

Nola:

When Installlnz mm mm on the pisum.

ml] (he ringu in the. ring gmlu'n massnre

Drone! elem-am. If the rims: to]! sum-

ouuly, the elem-an". h Iatixfucmri.

3, Inslall lb pisum on the cur-netting
red with the piston pin nml clips sun (hat
the A mark on the piston hcad poi:
mwanl lb: Emu! (exhaust side] .1: shown
in the figure.

Note:

Mun \in new pln clips.

 

IL Steamer the and gaps of the Ian, Zml
and oil rings 120” span.
Install so that none of the guns at: on
the piston boss ujs MW away from it.

5. Install the cylinder gasket, mo dowel
pins (oril'me valve) and ‘wu O-rings all
[he upper cmnkcasc.

Now:

Bela" Inn-mm: Illa dowel pin, Maw com-

prem‘l nir (hvouxh the hole to “sun that

it is MY. chalet

 

ram 75 LT; Mark: ’)J l'lsl

 

Plg. n (9 ; mm'a

 

 

 

 

 

on Dawel pin

ED 4‘ ENGWL‘

 

 

 

 

     

Pll- i: 6) Gym“: )mi sum (3: 0mm
8 Dowol pita

7

6, Turn the mnleshalz and pLace the piston
Kaye {'l‘nnl Nu. WLSEIDEJ vndcr
No. 2 and 3 1155mm. 'aml install the.
pism ring oompcmsnr: [Tool Na. (mm -
3009].) ml the [Iislun rinks, and insert
the pistons into the cylinder. When thlz
NH. 2 am] 3 nixmnx have enlcrcrl the
cylindcr. renew: lb: bases and piston
ring mmpmswm. Next mm the. crank.
shah slighgly and lnstnll the No. l. and
4 pizlnnz being camful nm'ln expose lhe
rings of (In: Nol 2 and 3 pistons. Raise
[he mm clnin at (he 53m: limu.

'With the cylinder held appmx‘ 20mm
from Ihe‘ crankmne, insmll the mm
chain lcnsioncr in (In: cylinder. hold [kc
tensions: down In! hand am] install [he
0 ring, and washrt. and tightcn the
lock nul.

8 Insert lhn mm uhuin Haida inlu [he
cylinder as shown in Fig. 81.

9. Install the cylinder head gaskemwo dowel
pins and lwo O—rings on the cylinder.

:, ENGINE 3‘

10. Place: 1hr. Cy under Ilt‘jld and hall] the film

chain with a screw driver to prevenL
mm chain fmm Arowfing.

r Tighlen Ike twelve 8mm mm unil'urmly
with the special tool [Tool Nor L'I'A'UIB'
32301) In a lurque of 2.0-4.2 kg-m.
[l'1.'15~15.63ft-Ihl} in the sequence
ahuwn in Fig. as.

Next, Install and torque two 6 mm flange
bolts.
Mum-t the cam (ha-in tcmt'omr an the

cylinder head with the aluminum
u'nsher'and 6mm bvlt.
Note:

Karenina care not to drop nuts: or washer:
intn the tylilldfl' hard nit will he difliflllt
to remove than;

12. Hold Ike cam chain sprocket and cm

13. Rmrwe the

chain together and alidc the camEI-aft
Ihmugh [hum {mm the finhl aide. and
at it on the hearings in the cylinder
head. Install the cam clmin ml the cam
sprvckct.

point wvur. mull: the

. crankshaft in lhe clnnkwise Ilinettlirm mul
align the "T" [1...“ mark of the spark
arlvanoer In the timing mark. chl,
vusl'tiun the camshaft no that Um center
cf the cutout match on the right end of
the camshaft, is aligned tn the cylinder
head flange surface.

14. Mount the cam sprocket an the camshaft

with two 7mm bolts,

L5. Mount the cubumtor assembly mt 1hr;

cylinder head.

16. InstaLl the two dowel pins and 25x smiling

rubbers on the cyfindcr hand.

 

 

 

 

 

 

 

 

 

 

 

 

 

   

  

1.:- E .g
Fix. st 01 Can 59mm (1) Camm
(a c": chain'

 

 

 

 

 

Pic. 35 [D Cylizvirr head Hinge surface
(c- Cutuu‘. nan-h 1}) Spark admm

 

32 1. ENGINE

 

rm valvc uppfl
_ adiuzlinnsnnw i:
an [windy

(in: in: the
vfl

 

 

   

 

Flu. E1

 

 

 

 

 

Fix. 8: cs) 8 mm ”new
{5) Ohm" vlalt‘d wle: Wad»:
Q? Hz: : wvur wt 7h“:
u} minimum “she:

 

 

 

 

a) Gum..-

17. Irma" the cylinder hear! cnver with
twelve 6 mm screws and six 5 mm hols.
and mm: to U.S~l.2 lag-m [5. TSP-8J5?
Ilsa-Ii.) m Ihut luv-Int: nlifferenm is not
over 0.2 kg—m (1.“ lbs-fl].

Note; .

Insert fingnm Into (Ice law“ hole can
cunning and lift flu,- value lappel adjusting
scum to duck that they are NM!!! Mul-
ing line um... _
U" the sixGmm cow?! “when u shuvrn
in Fig. :1.
up.“ the head side cover sci vlatc win!
Wuhan muunwd an huth uidesuf the 6 mm
Int-raw: (Chmmillm-plnlrd n-mm wauher on
top mud alminnm I'Mllfl' on llollnmj.

 

 

18. Install O-r w: the dowel pins of lhr
[in left and ri 1 side «Ireland inswil
[ha i u wvcrs on the cyiimier hem].
l9 install Lhr: breather cover with six I: mm
grows.
Note:
'1: “union can] dips are mounted an both
sides with the dine fucinz forward.
23. Mjusl Lhe cam chain by referring to
mac 12.
21. Adjust the uppels by referring to page
'3.

 

    

 

d. ENGINE 33

‘. VALVES AND VALVE SPRINGS
A. Diusaembly
1. Remove the cylinder head 1»- referring
m aeolian 3A.
2 Cumpnxs thu Villw. pring willl :1 valve
spring mmpresem (' nl No.0703173mu),
mmm‘cfihc va1vc mums. and xhc valws.

     

m. an :9 w“ apt-n! :camr
a: Crlmz'm +0.1

3. Drive [he valve guide on: of lhe cylinder
head using the valve guide rcmnvcr
(T001 No. 07046-32301).

Remove Ihe valve guide can from [he
Valw: guide,

;.

      

rill ,l 1]) Valve nude RHI‘VI‘I

 

Inspection

Measure Villw: slum clearance”

Insert the valve imo ille guideand measure
the t'lmrmwu in hm): the X nml Y din-c.
lion! using a dial gauge. chkcc the
valve and guide in 59.1. if clmlence beyond
the azxviccable limit.

Drive the I he ink: the cylinder head
using a valve guide driver and finish ream
the gnidc (n the proper sine. Standard
valve guide inside diamele: for both die
inlet Ind cxhauzl is E.-I75~5.485 mm
[0.2153 in.~0.215'1' in.)

1

   

14.... -_ -.___.

m. M :3) bml mi,

J A‘
Ill. 96_ 0) 3m.

   

 

ghx (due

t ENGINE

 

 

'2 Valve

  

.._-.. __..»4._4-

® F(Y'(" muse

 

2. Measure the vulva IE! canlact am.
Apply a Ilain 00.1! of bluing or red lend
on the valve face. pies the, valve againm
the 2&1! and mm. The imprint of die
Valvc test should be mnliuuuus amuml
the (are u! (11:: valve: if not. lap the
valvcnnzl minspecl. II slillunmu‘slmzhry,
recur Linc valee seat with a ‘11ch seat
cutter. First. an! the inside sent with
an inside cutter. the top scat w h a tap
cutter, and finally make the finish cut
with .1 93' cutter no product: a amt width
of 1.0-4.5 mm [0.039~0.059 in.)-

3. Measure Vllve runom.
Place the valvl: on \-'-'block and mature
the turnout of Ilm valve. with a dial
[gauge npplicd to the face of (In: valve
while naming the valve. Replace file valve
if the mum-l bcymlds the sen-imblc
limit.

4. Measure the valve spring.
L'lcuum thc free length of ihc valve
spring with a Vernier caliptr.

a. Measure Ilw. Ila-mm at Ll»: cylinder lltfld‘
Place 3 Insight edge on the cylinder
1mm! surlnoe and measure the (lam-mu:
at several paint: with I. feel“ gang;
ll there ism claimant: ol war the service-
able limit, lap llu: cylinder head audio:
on the surhcc pllle using lapping enm-
[xiund vr Npluu: the hand il it cannot

be rcpalmd.

-L ENGIXE 35

U. Realism“:

1. Wash all of (he compment part: in kumsene am] vmsxemble the pm: in the meme
nnler n! dimmemhly.

 

 

 

 

 

m. r: Campcncm gun at m cslinée: teas

m 2mm um (5') VII“ “.1"; mm- Kat a3; 'Rmainu

a: 1qu "he a) v.1“ spring imm mu a: (2ch

r3;- lllxlmzl 0 mg {9 Valve mm ml 6:: Valve nuke: Inn .m-
a.) Bah-x! vdve :ui'le (5) Inner ugh-c Iptlng a? Valve mclm an:

L5) )nlu nln 3qu (z, cum ulvc spring

Nata:
When installing the when, apply a liberal ummlm. oi oil on the valve Ilcm.

2. Install K11: cylinder head in «0:20:11an with main“ 3. C.

56 a. ENGINE
5' Oil Pump and Oil Labia-m: Swen bod: Duxnn

I-‘iltu- [Can mail-FIRE“: .um :nfil—Ilfig "wing—{Wm gun]
The oil lamp i; a Lroclmid (5|le win;
“We drum by (kc pn- CE Rrfiriclnr
may shift. Screen and
(”Per ekmcm filxm an:
user] to pmvidc dam nil
to the engine.

 

 

     
     
     
 

 

ICn-Jhuhh haul—l Cumming :04 buying H Pinon “w. HPiuon

TfinmivEEn-Twanm lhnll

 

| ‘—---~——P1imn:y:m
El” mpLIReErl win
on mm. Elli] 41 Cunt :0ng Pam”, cm.

 

‘ m—m‘] L. Txmmissim min dull
_ I —. V

 

 

 

 

 

 

. Pix: 9: on Lubviupa: Diarum
a) 0.1mm. clemcnl a; Oil yum; Q) Mic! mu 3: on mun elzer

A. Disassembly
Oil Pump

 

 

 

 

1. Drain the main: 0" in accordance with
section 2. A

2 Remorc the starting motur ‘vvnr and
the left crankcase (oven

3. Unscrew the 4mm bulk and remove the
plague swim}: wiring. Nexx mmuve
flint: 6mm screws null Illa nil pump,

 

nu. 99 @- Amm boil

.n u "mom“

4. Remove the cap and mnmmmble lb: rc-
lEel' valve. and spring.

 

 

seclinn 2. A.

Z. Unscrew ten 6 mm hulls {mm the oil pan.
Remove [he oil pan. and the oil scream
film can be removed-

    

. .

'm a) on mm Mm

 

33 L ENGINE

 

 

 

 

Oil Filter

1. Drain the engine oil in acoundnnce with
action 2. A.

3. Unsucw the center ho]: to remain: till:
oil filter.

3. Inspection

1. Measure (in: clumncc bnwccn (in: inner
and outer rotors.
Use a feelL-r gauge on musum le:
dim-awe beMeen the rulurs. ll' [he

3 3:72:32? "' clcsmnm beyond! the serviceable limit.

 

replace the nump.

2. Measure tin: clcsmnm: between the mmr
wlur and the pump body.
Us: a feeler gauge in mensum the
clearance belween (in: outer mlur and the
pump body. If the claiming imyunds
zl-e serviwn'blc limit. mplnue Ilia pump.

“n

    

. hm ‘
fix. in e, Pnlu flux! :5} Data tom
m i‘nmp tcdy

 

 

3. [mum llle upenuibn of the relief vnlm.
Make sun: that the relief valve is nu:
stuck in the pump body. Also check
for any foreign ulajeuls which may be
lodged bclwccn (hr: valve and sent.

4. inspect the screen filter
Wash and inspect the screen filter. Re.
place the filter ii thrnagell.

 

 

 

 

Fl]. "ll 3 Mid ralv: gut

d. ENGINE

C. “assembly

 

 

0" Elliot

 

 

1. lnserl the oil filter writer bolt through
ll“: all filter (as: and assemble the spring,
spring 3m aml element, Screw the
center bolt into the engine.

 

01] Screen Filter

1. Mount the scum) filter on llu: lower
crankcase.

2. vaunl the oil pan on the might: with
ten 6mm bull;

 

 

 

Oll Puml"

 

 

l. lnscn thc drlvc pump shalt into thc all
pump brxly nml inslall LlIr. dxive pin inla
the :l‘aft.

2. Align the (ruler and inner mtor punch
marks and install lntu tlu: pump body
[Lite xurlatws with the punch mulls my
be set to the pump body side or the
[lump cover side).

3. Install lhc 47 mm O-rinu on ll‘fi nil
pump body and inatlll thn oil pump
cut-er will: 1.11129. 6 mm screw;

IL lnatall (in: 1:1in vulva and spring inlo
the all pump holly, anti install the cap.

5. Install the two O-rlng collars. mo 14
mmO-rlmz: and a 47 mm 04ng into llIE
oil pump body Ind thm install the oil
pump on the crankcase with three 6mm
screws.

6‘ Connect th: pwswrc switch wives,

Install the left crankcase with lnur 5 mm

town. and the gear change pcvlal.

lnslalll ll": shrlitu; muwr cover.

2'4

8

 

  

Fla. lull g 01in: man

39

 

I‘l or.
<3 on mm mm halt
a: xsxzsmm min; 5min:
.1) on mm as: (a: m film” in; :uk
.11 ar.;xa..’...«.. Our"; 3) Oil film am:

25; Elm Itlflll'A'.“ m

  

In? (T; 4?an; (Hm

  

IE 4: mm 041a;

ll mm Grins

40 4.

V
II: no m 25 :1: “up [In

3 cum alum”;-

      

 

ENGINE

 

 

8. CLUTCH

A. llisuumhly

1. Drain ".c engine uil in amnnlanm with
wulion 2. A.

2. Remove the k‘ ”x :nrlnr ind-l.

3. Unrated! In“ I] sums and remove
the clutch cover.

4. Unslnuw llwrfmu clutch pressure pktc
mounting boltz. and remove lhe clutch
[Inmwe plnle and (our clutch swings.

5. Removu the Hutch like: jainl nine.

5. Remove “1225mm MAP! shims (some

 

mg'mc may not ham: shims mmllai", and
H1: clutch 3:201:51}! {mm the main shah

. Disassemble lb: clutch disc. cluldl pluc

and clutch (Junta.- {rum Ihe clutch outer.

. Remove the 1d: crankcase cover.
t. [Xmmem the chunlu cal-Ea 1mm Ike

clutch Him.

. [metmw Lhe clutch mljusze: Imk lmll and

(wave the chm-h adjuster from the left
crankcase. nwnr.

I'u“ w: the clutch lifter rad.

B.
l.

C. Reunion-bl;-

t- ENGINE 4|

Iillpeclinn

Measure flu: t'lliekncss of ll»: fiifliondisc.
Measure the thickness with a vumier
caliper and mniace if beyond'the een'icc-
awe limit.

Check the clutch plnle for warp.

Place the clutch plan: on Il-e suxiacc
plan and measure the amount of warp
using a leeler gauge. If m warp he-
ynnds the scrvim'flc limil, replace the
clutch plum.

Manure the clutch spring.

Nleasure the free lcnsfll of live. nlutch
swing with n vcrnim' caliper and replace
if beyond the servitenhlc limit.

Inspuc: the rival: mounting the cluluh
onicr lo 01?. dziven gear (or Iocemess,
and mplaon the child) outer if any of
rivets are huge,

          

, J
fig“).

11;. us {2 u veu uur 3 mm:
3, cum. oukr

 

 

Asscmbk do: clumh lifter rod into lhe
main duh an the: the wheriml and is
toward the right side.

Anni; memo to the cluwh lifter and
aszcmblc it to lhe left crankcasc raw-I
Ingeme: with the adjuster. Tighlcn the
10:): ball: and in" meet the clutch «Able
In the clutch 13f
Install the clunzh er rod, 9c: flu: me]
[,3]! ;nm the clutch lifter. and mount
thclcfl crankcase (war will: {our 6mm - . ,
screws. . Fig. 116 6) Chuck line: WW Adjuhu‘.’

 
  
 

41 a. mum:

 

 

 

 

 

Fig. 119 (1:- Joinx pin»: .‘r 95m:- :01}: ring
‘ a: sum

  

3; Clank pmuum 91m,-

. \ '

 

4‘ install the clumh cum: in [he nuinalialr.
and then, install [he nlubch ember.

:3. Apply enninc oil on the friction diau
~11 1:43.} and assmnlule than on ‘hc clutch
center dtcrnaacly with the clulrJI plnxs
(6pm.), and then. assemble imo dis:
clutch outer.

Nola:

Whm assembling "m friclion dis“.
aunembl: Nil-m on the clutch «nu: nu
that the oil grooves: are fuming as per
Fig. 118.

fi. Alter nsqcmbling the fricfion :li : and
clinch plalfleg mt than with the snap
ring. Place 3 al um: agilnzclhccnd
of LlIP- CIVIC): humbly ID check {at
lemmas. If the mmsumd value of
lumiess is greater than 0.1mm (0.004
in.), install a shim on the inside clithe
mznl ring. Shims 2:2 .4 ' l: in; 1hr.
lhicknm MI 0.1. 0.3 and 0, mm. ‘

   

7. Initn the clumh Iil‘k-r juim pfme inm
‘lIC mainshufi and fix the clnmh ll‘nles
with {our pas. much of the clutch spring,
waslm and [ham screw.

8 huh-ll the clutch cover.

t. ENGINE 43

7. GEAR SHIFT MECHANISM

A.
17

2.
I]

.L

10.

  

. Unscrew

. lJimssmMe [he upper illil‘ Iuwm-

"m: m u;- am. [4" till).

Diullunhly
Disassemble the clutch in accordance with

the attic: 6.A.
Remmve the gear change pedal.

. Rcmaw: the gear shilt arm while holding

the ”ear shill am; down.

Remnve llnr. sloilt nlmm slappar lmll nml
shift drum neutral stopper ball, and (hm.
mmovc the shit drum slamm- nml shift
drum Izmitru'l savmwr.

the [3‘ mm screw and (I‘m,
renznvn (he. uil mid: plan; and ham-r1:
act plate.

Unsacw the G mm ecmw and can: pktc.
“It.
cal: and disasxmble llu: unnamisaion
guts in woo arm: with the ecstion 9‘ A.

 

   

, Rem-Ive lhe "Ruth-II S'OIIEK'I’ svn'h'h {mm

lhc: gear shift drum.

Remove the shill drum uuide screw {mm
thc “ppm crankcaic and then remove
llue ullille screw nullur.

Remove the. fluids “in 1:11}: nml guide pin
and pull out ((1: gear 5115i: drum from

' the cranktage.

i . ' ' u
6} Ga: zHII an“:
m Guiie air.

 

m. tzz' w '

 

 

   

n drum mum
L? b ' hum swipe: MI:

" huh dun: neutral supper

G) Ehln- .m mum: unp‘w nu
(a Purim: “I plate

'18 E m: smw

:Y'J Di! Kuiie all:

:3 Com 91m

   

I‘lz- ‘l1 (D

 

4‘

“v

I n}. m (9 am .mn 4...";

 

 

 

 

 

 

l‘lx. I18 G Guide yin cliyu

t. ENGINE

13. Inspection

1. Measure the diameter of the gas: 2:fo
:lrurn with a mimelcr and the . '
{ark with an inside micrometer. Replace
any part whirl: exwu‘ls the mrvimablr.
limit.

  

2. Manure [ht width of llle gear shift
lurk Eugen with n nficmmclcr.
Replace it beyond nerviowblc linn'l.

C. Masmbly

I. Sel LII: left, right and comer gear shift

I forks into the upper crankcaseasshnwn
in Fig. 125, HIGH install the near shift
drum.

2. Irma" llu! guida pin inln (he shill folk
and fix it with the guidc pin ub'p.

Nolc:

Make nun Elm. Um guide 11in (lip is in.

stalled in the Mop" dimvtion.

A. ENGINE ‘5

3. Place the. munmrbomul aeolian of LI":
51151: drum ”shown Fig 123, and inns“
[he slur] ball, The spring cap. and lb:
spzing (hm lock with due slu'fx drum
mm».

Nun, bend up the 1.11: an the guide screw
lock washer to lock the guide scww.

d. Align the neutral switch to thu grown:
in the gear shift drum ul luck in “luck!
wilh the 8mm screw.

 

y-

Ascmlflc flu: transmission into ihc uppcr

nmnkmm in «cum! cr with suction 10,

C. and anmlhh; my upper and lower

trankmse

6. Install the cam plate on file pin of the
gear sIIiIL dlum will: the 6mm (ls-l hum}
screw which has hm coated with tlutad
lnch nan-mu.

Note:

This [fill and m.- pin hule in the cum vme

mun. Ine allgned.

 

7. Insert thu spring into the. shift drum Hop
per: install the cm] of the spring inm [he
cunkcam gnaw: as them: in Fig 131,
and lighter. (he :hifl dmm mpper boil.
After vighmnini:
llml the shift dlnm amp. 1- one
ante ‘ 3'. If there is cxcmvc vcmml
lawman the shit] ulrum s.lnpper would
be replaced.

   

  

 

 

 

 

 

     

the be", make sun:-

 

Fig. 1?! 616m]: su:w .3) 5
G; Guidz suew
lads rake:

   

I: Neural :m'ch

Pi! 1311 1: Gen :hlx an.»

46 L ENGINE

3 Install the gmr shift an" and mnkr, sum; Hum it upcratm smoothly in both diroction.
5|. Inslull the clutch in accordanc: with amnion G. (I.

8. CAM CHAIN TENSIONER

The cam chain lensiuneris constructed of spring stccl on which a layer of hen msislanl
rubbur is vulcanizd mu! 1 («1199.1 ol kl'lun Demenwd. It applies pressum ng
cam chain and absorbs the :hock: pxoduccd by the clmin. Thu mm uhm'n
tension side ci the cam clain film mmlruls chefin 'braliun.

Au adjustment sucw is locmcrl at the rear of thy. nyfinder block.

  

 

 

 

 

 

:3; Lack M
a: San.

 

A. warm: 47

A. Disauembly

1. Remove lhr: cam chain ansinncr and the
chair. guide in anomdancc with seclinn
U. A.

II. Inspsctiun

I. Make sme that the gear of the cam chain
tcnsioncr adjuster is prulmrly maxi-zed
wiih "I: ruck, am] inspmt for smooth
opcnlion.

U. Huaiemhly
L I‘crform measurably in accordance wilh
Gecliun 3. C.

a. CRANKBHAPT AND C(INNm‘rING
BOD
A. Dianswlnbly

L Dis-mount the engine in accordance wzrh
secliun 2. A.

2. [)isnraemhle the cylinder hem], nylimler.
and piston in acmxdancc with action 3.
A.

3. Remove [he general": cnver mu] mauve
lb: rotor using a generator rotor puller.
(rum . u mom—21601)

-1. Remove lb: point covu‘ and the special
washer by mum-Eng the 6mm bolt.
Next unzcmw flute 5mm scrcws
and remove “It: wulucl bmulze: assembly
and the spark allunccr,

 

   

1')
Xx‘ Mari-J w

J, 5 cu m.
no Oman bulk" "rnllfl'

 

5. Remove the clulch ml (1:9. mm shill
arm in accm’danoc :h scm'mn 6. A.

6. Remove thc surlinn mom «over, and
Llixt’lflul)‘ [he starting ntcaor.

    

 

 

4. ENC-INT!

~x

. Plane the engine upside down and un-
cmw :hc [mi (imzn balls to [more the
n! pan.

E. Unscrew tan 8mm hall: and twelve
6mm bolts [mm 1h: loNcr cmnkciwr.
1.009911 the 8 I bolls in le reverse
order shown Ln Fig. 151.

EL ‘l‘lneu, put IF: ruin: in (vi-rum nusilinn

and unscrmv :bmc cm 8mm and 6mm

bola. Tap the upper \zmnkmsn Iiglxlly
with a wocdcn hammer 1nd separate 1hr:
ummr and luwz‘r crunkcascs.

 

 

 

LU. :scmw lwn I'nmm halls and remove

the burning set. plaza

ll. Pull out lb: wimrj shaft using a

primary shall puller (Tun-l Nu. (ETER—
32301]. “
Holt:

fisnumblyof the pzimary 2M1, tram.
miszion, and kick slnrlvr mu be per-
formud without zcmon'ng ihc cylinder
lvaad, cylimlnr nr [:inllm. Wlmu remuv-
ing lower crankcase, follow the sequence
1'), 1.1. 9 and 8 shave,

l2. Remove flu: starring elucch from the

 

primary r.

13. Remove the pn'nmry chain and the cam

chain from {he cmnkadml'l.

13. Inspection

1. Measure crankshaic nlnout

Support bolh emls of the crankshaft on
V-blozk and measure the mounl cf beml
in [he crankshaft by :leying a dial
gauge m tlm center journal and mlaling
the cruukchnlm If the runoul beyonds
[he zcrvxozible limit on (he dial gaugse,
lhc cnmlm'lmft should bg; replaced.

2“ Inspucc lhscmukshah journals for soaring

aml unrv wmr w. I - imam-Jar.
or Klpcmd
llmcrnnkshah

 

    

   

should he replied.

l. ENGINE 49

(1 Measure the crankshaft journal “‘cax.

Cut n Ianglh nl plaxLi gauge to the
width of the bearing cap. Place Ilic
name on th: butting pamflr-J In [Me
cmnkslmfi, asmmlnle Llle crankahafl and
Iurquu down the crankcase: I'll unmnlanc:
with Fig. 151.
I]: «31111: the crankcase and mmn: .
lhc plasti gauge using 11m Mal: provided
If :llure L alumna/cc in mm; ol 0.08
mm 10.00311"), [he bearing ghould I»:
replaced.

Nola:

\wu-n measuring: with the 11111!“ gauge, 11»
not mm the clan-hm“.

Selectinn of The llenring

1. Remnva lelmriun, :nrsemhle and ligh-
ten the upper and lowercrankcascs. Refer

   

 

 

 

2‘ Measure (h: inside diameter of all the
beating mm in Lhe veruml llirecliml MI};
:I cylinder gauge and sclcct out the
canasmnding alphebeL (mm Lhe [able
Ine|0w.

   

 

3. Measure 1hr: dianmm all the nrnn'kshnh
joumzl \viih a micromctvr nnd also select.
oul Ll»; cor-expending figure 1 o: 2 from
Ike table below.

I 3

 

 

34 W22 9!:
(i. awn-1. 2w)

3193-433 5'0
IL 2257-119”;-

 

 

 

4. According to the alphabc: and On: “HUN
lrum ilrn: 2 mul 3, pick am the page:
hating {mm A. B, C and D.
x—rf—

 

—n— ' ' .-\ ,
mum.) {Black}
.c‘ ' n

{am-J. Jays“;

 

 

 

C
'VA'Ian'I (film-J

 

  
 
 
 
 
 
 
  
 
 
 
  
 
  
 
  
 
 
 
 
 

 

 

 

 

fix. 1.“

Note:
The lower :nnkuase And crankshaft are
mu'km Wil'l chu-raornumher at the factory.
Time an producticm «7ch «ml th-ld m!
be used or mien-d In during servicing or
repair.

4. BNGINE

5. Measure mnnecling rod Large and wear,

Sepamrc the cap {mm the wnneciim; rqu
and nfler valuing the Illnxli gauge in
plant. torque the two rod nuts tn 2.0 2.2
Int-m (14.46-15.911lu-fl3.

Disassrmblc the cap and mnsun: the
plan? gauze Replace the hearing My}:
new onc if lmyond [he atlviccah. limit.

    

Hole :
no nol lum UH: rmnluhal’l W'IHI: Hue phat;
Anna» is inmalltd.

 

 

 

 

 

 

 

 

m. “7 I'D Xe)- fumiezu'an.‘

 

Selecfinn uf The Baking

L Manama cmnkslnll pin diameter with

a micrvmeltr and Meet out tin: norm»
spending slpluhct from the table bclow.

 

A I n

M. 9365.03
(1. 8779-] . 3731‘}

5/1. SMJ'L 83
(I. E7Tl~l . 5775)

 

 

 

 

. Select out the bearing {mm flu: table

Inflow which minckles with 1he-. numlmr
(l. 2. 3) Emmpt’d on the large and of the

 

    

I 3
m (cm: .\'o. \ ,,
,n lBNWu} la (“he'd
C (than) W (Fla-urn)
n (Ycl'ow) 1c (Cm-‘1

 

 

3
2
1

 

 

 

Nulc:

.‘l‘lue numben marked on (he cnnkshafl
Me pmductinn «Lulu and xhould nol he
refund 1» during ulvicilur.

~1'II1: hurlngx mull be inniullld an the
cmnutinz led with the he! toward the
hind.

4‘ ENGINE 51

6. Method cf designating cementing Ind
\veigI-L
Whm replacing cnnnccfing 10d. rc-
Mame with one having the same weight
code. The weighl mule. is gun-4m] al

_:hn large :35 of (he canxmrirg rad.

When replacing all nl the cunnenl ,1
Ind). 51:: (cleaner of the menact'wc rods
shauhl 'lm within 5mm.

Note:

In lhc mum-fling and n \t. that wail”

of cap aml two halts are Incllflhd but {Inez

rml include the human.

7. Max:135 axial clearance using a fault:
gauge.
Replace ii beyond the saviceshle lEmil

 

8. 31:215an: (1): connecting rod email end.
Mus-mum I}: diamflm of the (anncct-
mg (ml small cnd \vELI. an inxidp. (EL-II
fizuugv. Replace if beyond scyviccahlc
Jimil.

C. wanth

1. Install the primary chain mid ('nm nhnin
on the crankshaft

2. lush“ [he cmnkslmh.
crankcase.

3. P1753601! t'lnc slurfin" clutch and starter
gas: as in Fig. 150,1l'gn drive the pn'mmy
shah in from die n 12x to left. Exewise
mre in the needlc bearing asscmhly
sequence shelvn in Fig. 115,

mm Hm luwc'r

 

 

! ml; way)” (1..)

:\ WINK-u

   
   
  
  
   

 

ya.)

  

I ~12“
21
OJ

'0
GS

 

 

 

 

 

 

”’9' 0/
.713hA3-i (K

.x,

. 7....3;
I'Lr- 151 (:0 Su '
(a 5 Her gear

9) himu! :lhal'l

52 4,

4.

p.

6,

  

rum 1:: 3. 5...". M .
'y Mum lul‘l

7.

3.

 

ENGINE

. lnzlall the clutch

Inallll (he hearing as! plate with two
6mm bolls.

Apply .3 th'm cast of gasket {Male on
the humming flung: cf the lower crank-
iln‘nvy cunt will cans: flue pm»:
to fail inside t'r.c crankcase].

Install kwu dowel pins, mount the up.
pcr crankcas; on the lower eardrum.

 

 

fix. m cm. mun-1...; Mu

Place the engine ugside down an as not
rule tE-c mrtiru: surfaces by hold-
in; lb. f by hands and instzll the ten
8mm hols. Tomue the 8mm bulls I'll
lh: sequence shn'ml in Fig. 151 to a
Iumuc ol' 2.3-2.5kg—m. {16.63-15.03
lbs-ft).

Next, tighten tlfimw finnn lnullx. (Fig.

III 30‘.

 

 

Km pmltlrm (If Ilte two 2mm halts which
are stunned on llue boll. head will: numeral
'9’.

Pcsitiur. the upper crankcase ontup and
install with three each. firm: and Hmm
hells. (Fig. 153]

Nola:
Note maltion at (hm hm 8mm lmllx which
an: slam-ml an "m bull lluld with numeral

 

Install the oil sateen filler and mount
lae nil pan ' ll: len 6mm hulls.
Mon-n, l c aning mom: with two 6
mm smwz.

Install tlvz.gcar ahlk aim in accoldanne
with action 7. C.

 
  

in :Iccordanm with
«ac-lion 6. C.
hurt: the spark advancerdowel pin into
the pin hole in the crankshaft. um] llxeu
muunt thz mm: bmakcr with three 5
mm comm.

k ENGINE. 53

 
 

13. l'nslzzll llw. spacill Idvnnccr w'
the 6mm bolt, and inaull 1.1::
mvur.

3.. Mount the genemior mm: “HI the.
16 mm ball.

15. Install the gcncrawr nuval.

15. Assemb‘.e v.1»- pisum, cylinder. cylimlpr
head, and tend cowr in accordance with
suuiuu 3. C

10. TRAKSMBSIOX. KICK STARTER
AND PRIMARY SHAFT
A. Dlsauemhly
l. Diamalmt the engine from vhe burns in
:Icmrdance with scukvn 2, A.
2. Ramove clutch in “cardinal-n wid)
admin“ 5 .
3. Sammy: the ummr and lawcr crankcase:
in “to: “.9: with sculinn 9‘ A,
I1. Ramon: the Irnnmn‘usicn Ind disassemllle
flu). gear: from the. {capeclive admits.

 

 

 

 

Kick 3mm:

5‘ Removc xhc 18mm map Kids am! flu:
Mum :quing.

E. Removc Klv: 12mm :map ring and dis-
lsscmlfle 11m kick 2mm! shaft [rum [he
Inwcr cnnkcasc.

    

 

viz. 1;»; I; 151:: mu m.
J. Km.“ rpm;

Kick mm: 11‘ xl

_ 12mm saw viflfl

54 4. ENGIXE

- ’1' mnrySlIa“

7. Remove the primary shaftinacmtdmec
wilII section 9. A, nml remove: the 20
mm sup :ing and primry drive gear.

 

 

 

. Remove the aide calls: and pull oul [be
#6205 ball bearing

, Remnve the 50 mn may thug. primary
drive: sprockm, gaming clutch. and pull
(ml the ulnmnzr ruhhuzra.

 

Unacmw Ihc (hm: 6 mm flat head mews
null renuve Ihe taming clutch outcr.

m flu bud mun

Inspection

. Menu": gear Inacklnah.
Sc! (he pninux of .1 xlinl “nuns ugainir
um wvlh of the goat and measure Ike
backlash.

L ENGINE 55

2. 1:15ch L113 dog: and mph-0e any gun
with «massively worn dogs. Aka, mks
22m: that Ihe g :5 slid: zmoolhly over
[he snlincd limit.

C. Ileanaemhl)’

‘ Primary Shift.

1. Instali flu: slanting dumh cum and prim-
lry driven npmckel hub wilh lhg duct
5 mm flat hear] screws cunlml with thmad
leek ccmcnt. null then sukc flm screw
heads with .1 [much to pruvenl humming.

 

2. Asnnble the damper rubbcrs on [he
yriumw driven sprocket. and install on
\he starting clutch with 30mm set. ring.

3. Dfiva “IE 26205 bull bearing into thu-
primry limit.

 

.....,. - .- V...) »
‘65 (a hiaury drivul was“.
'3) Human nb'xrs

 

4. Mount the xlming clutch mar on the
(waning clutch. inml [be needle bcarilzg
and 25 mm spucar inlo the awning clutch
gear, I}: the 25mm (hum washer and
the snap ring on the primar shalt, and
man-m liae primal}: shaft in fine mank-
man.

 

 

 

Fly. 156 CI) ilarling c'hzlzh :m
a, “mu, Ind»; {zsxmxm
a 23mm ”Ker
a) 2.1mm m. .. .ulmr

w 25 an my . .«g

G: 22 mm dune! wulm

56 4.

Kick Starter

 

5: Reasacmblc the kick xkurler cumpnncm:
En avocnlemoe with Fig. lfifi.

Note:

Do mll loud to install the 13mm washer.

 

 

Tmnmislion

 

 

fl. Assemble it: transmission "9.1.1 on the
mapeczive mu?" and county shafls.

ENGINE

 

 

 

 

 

fun") 1}:
::3 5mm u
3! Kick nut:

 

 

 

 

 

ml unim-
m m min:

“ha!

.-.u durum: wuhu

K m mm spring
97 1mm guide pin:

a, C'mir. and: cum
1,":- saw rinz

as. 332-: man“

an 18:: :up ring

a m .m
(I KScl xxx:

 

  

 

  

  
 

.m mm“; m mg

may rinz

935 weld bull bean-in:

~10 3L5“: o-rmg

:3: Tnnam'mlnn mnnlnl
ulmia

«I ssxsvx? nil m:

(a Brit: )prmkel (WT)

fig. mm "my... r..:.,,
him

'11) Gun shin my. pin

is in an new: bunnz

a;- Caunm mu low can
1401-:

m

. ,

:2 Col-mm xlull l'uu-nh
gcnr (23’1")

a; [mum mm: wuhu

3 (Imam aha: mid gem
cm) ’

.3 5m. lock Mal-c:-

{0 25m: than wash:-

fl? Caulk: mun mar-d
8m (35'?)

03: Com-1:: shaft ton [ear
(1’7 T]

B‘ 52:": kuhfi set ring

to 52:5115 baa bearing

fl- Tnuxmiuiml min xlmll
(2.11)

6 Main alull rum”. um
man

(1 10:1: ullx‘l bur/J. "in!
um :22 '1'. 2: T)

S: NinfluhmguL-{OJT}

5: 23mm “mm ”alm-

a) 22 mm malls hula):

Q! sxsws ed xzd

“C- 165

 

7, Install {he two each bearing 5:! rings
aml Ilm don-cl pins in the upper Crank-
caxc, and install the lrnnsmisaion,

8‘ Renw’mhlc the upper and the lower
crankcn n accordance will: section 9, C

9. [nslall (he clutch in accordance with 9:0
lion 6. C.

10‘ Mount the engine in the frame in ac-
cordance with 2 B

  

 
   

Hg. 159 .1 Boiling m ring: (i: Dowel pm:

ll. CARBURE’I‘OR

A. Diuawmhly
1. Remove rllc Carbun'lor unit from the

engine in accordance Willi sveliou 2 A.

Sky Plne And Carburetor I

2. Unhook lllc lhvollll‘ mxurn spring all
the link lcvcr.

Nate:
Exercine are not to dim-n the hook end

of file Iprinl.
3r Unscrew the hex. nuts. and remove the
dust plnle B. Remove the cap nms.

 

      

Fig. 17: w ch nuts '5. Cup mm

11 pm plaxe a

58 L ENGlNB

4‘ Remove the adiusler holders from the
link arm.

a, Unscrew the eight 6mm flat head screws
from (he stay plate and remove [he carbu-
retor uniL

 

“1.17: u; Link .“m : Mme: holder-

’l‘hrome V e And let Needle

6. Unxmw the lwo carburetor mp mounl-
ing scrcws from each carburetor and re-
move the tops.

 

 

m. m u, Cnrhumlal lop

7. Fashion the lhmlllc valve to full open
and slmighlcn the mb of lhe lwo longucd
washcrs.

V 8. Remove the 6mm boll from the shaft
end and remove the link arm in dimer
lion A using a screw driver,

 

I’ll. 175 (D Link um

At ENGINE 59

9. Loosen the 6 mm bolt on the throttle side
about 112 turn. insert a screwdriver be-
tween the throttle shaft and link arm and
pry loose in direction A

6mm bolt .3: Link um
Throttle shalt

 

ID. Unscrew the two 3mm screws» rotate the
valve plate 90’ in either direction and
align the uh an the valve plate to the
groove in the shaft. and remnve the
valve plate.

11. Remove the jet needle from the throttle
valve.

      
    

:1:- Valve plltr

fix. I" '1', 3mm screw:
. _ ‘

Adm ter Holder

1. Remove the carburetor from the stay
plate in accordance with section [—5

2‘ Remove the adjusting screw lrom the
adjuster holder.

 

 

Adjusting Krcw

1;) Adiuuer holder

(i

3. Position the throttle valve at the inter-
mediate position and remove the adjuster
holder.

 

Flu. 179 G) Adluuu holdu-

6° 4. ENGINE

Float. Main Je And Slow Jet

1. Remove the float chamber body.
2. Remove the leaf spring and the main jet.

 

  

3? Main jet

 

3. Pull out the float arm pin and remove
the float.

4V Discngagc the clip plate and remove the
valve seat.

 

mg. tsz uJ Valve m: an Clip plat:

B. Inspection

1. Fuel level adjustment,
Position the lloat so that the flat arm
barely touches the tip ol the float valve.
Measure the distance from the flangt to
the top of the float with the float level
gaugc. The standard value is 22 mm
(0.89 in.)

 

Fig. I& ll.) Fluu (2 Flat level page

L ENGINE 6]

    

0- Russell”! Carburetor selling an.
Float, Main Jet, Ant! Slow Jet , “wimlm‘i N“
M“ ' oo
1. Install the valve scat with the clip plate. L U
2. Install the float. A" I“ 7 "5°
3. Place the leaf spring on the main jet. Slaw pt no
:ldhzltltea" them on top of the needle “mm “M ”'5
I'. , 7
4. Install the float chamber hody. "i' 'm' “Wm“ It“

 

 

Adjuter Holder

 

 

1. Insert the coil spring B and spring seat
8 into the adjuster holder. Pmition the
throttle valve to about 1;? open and in-
sert approximately 1/4 at the connector
shaft into the holder windawt install
them while holding the spring scat down
with a thin screwdriver.

2 Mount the carburetor on the stay plate
in accordance with motion 7 and S.

 

Fit. In

  
  

Mum" holder at: 59mm m n
Coil tying n

I Throttle Valve And Jet Needle

1. Install the jet noodle on the throttle valve.

2. Place two each opting washers and 3mm
screws on the valve plate. and the" place
the tab of the valve plate to the slot
of the throttle valve and push down to
the bottom. Then rotate the valve plate
90° toward the link arm and inatall the
3mm screw;

 

I’ll. us ti) Valve plate .23) Spring wnlm
® 3 mm betra- tit Throttlo valve

3. Install the throttle valve in the athur-
etor body so that the throttle valve cut.
away section is toward the choke valve.

   

PM. 136 ED Cutaway mien til Choke valve

62 J‘ ENGINE

v 4. Unscrew the 6mm bolt from the throttle
shalt and push the spherical and oi the
link am into the throttle shalt while
pulling up the throttle shalt.

  

I13. [3" Q”, 6mm holt ‘
(it? Thank lhttlt

 

 

5. Install the tongued washer with the
tongue positioned as shown in Fig 187.
tighten the 6 mm bolt. and then bend up
the washer tongue against the bolt head.

6. Install the carhumtor top with the two
5 mm screw;

 

 

 

7. Combine the two carburetors with the T
type joint and the rubber piper

 

Pl]. 189 ([4 Rubber pipe ‘11 'l' I"): joint

8. Mount the spring set plate. and then
hook up the return spring.
Position the four carburetors. install the
set plate. and tighlcn with the eight
6mm flat head screw;

1? Staring at pluu:

 

d. ENGINE 63

9, Install the dust plate A. and mount the
adjuster holder to the link arm.

  
    

 

\~

11; Du” leo A :1 Link Inn
.2, Adjuster holder

10. Insert the coil spring 8 and lighten il
wilh the cap nut

 

11. Install the special “-35th D. dual plan:
B, and flat washer on the adjuslrr screw.
and lighten will: the nuns

  

“I. I” | Special wullu l) Iv Washers
’1 D01! plum H I Nuu

12. Connect the “mills relurn spring on the
link lever, being careful not lo damage
Ihe book

13. Install and route lhe lwu Iucl tubes as
shown in Fig. 193

14. Mount the carburetor unit on the engine
in the reverse order as described in section
2. A.

 

[’63. 190 nix Fuel who

    

5 CHASSIS i

l. FRONT WHEEL AND FRONT BRAKE

 

I‘ll. I”

'11 Axle limit

@I 5113mm an] Krew

a) Specdamuu 3m box

a) axlozmm boll

IE. Gear lax retain" cow"

(9 Cut box "miner

@ Owing

ii; men lull beating

G) Flo!“ axle diulnc: cell"

{a Flam lpok: B

'30 From wlitcl hub

a F10!“ whcd lube

a From wheel lit:

64 From lite 3.9

3 \"Ml hillncer

a From .pnke A

it From wheel rim

8 $172K ball bearing

Fl 22368 dim mil

8 Fm“ whxcl baring
rouivm

53‘ From wheel collar

:9 rm“ wheel "I: nu!

 

 

 

 

Front Wheel
A. Dkunmbly
1. Place I suimblc block under the engine to misc the from wheel oil the ground.
2. Disconnect the s edameler cable from 1he spccdomclcr gear box.
3. Unscrew the axe holder mounting nuts and remove the from wheel assembly from
the from fork.
4. Unscrew the from wheel axle nut and remove the from axle.

\\_ /

        

9»
Flu. 197 I]: From lei run (i) From Ax]:

66 5. CHASSIS

5. Remove the bearing retainer from the
wheel huh, and the dust seal from the
bearing rmniner.

  

Fig. ms .. Fm“ mm In

h. To mmovc ihv: brake disc from (in:
win-L rim. slraighicn Ihc mngues on (11:
lonuurd washcrs, and unscrew the disc
mounting nuts.

7. Rcmovr the specdomcwr guar box and
retainer cover from the opposite side,

8. Remove the from wheel bearing.

 

. nix mourning mus
. Tons-ml I‘nahtm

 

B. Inspection

1. Checking the brake disc.
Place the disc on a surface plan: and
measure the (menus: using a dial gauge
as shown in Fig. 19'). Replace the disc
ii beyond the serviceable limit.

 

1-1:. zoo .. Dial Kluge 2 From bake dix

, v 2 Checking rim wobble and wheel runoul.
Spin the wheel hy hand and check both
wobble and runoul using a dial gauge
as :dmwn in Fig. 300.

    

Pix. 201 1:: ml gauge

5. CHA§LS

Checking the wheel bearing;

Measure bearing wear in both axial and
radial directions.

Check [or loose or bent spakfi.
Tighten loose spokes, and straightcn or
mplwc bent spokts.

If tire pressure is low, check for leaks
around the valve stem and also the valve.
Check the condition of the (ire both
inside and outsidc fur cuts. bruises, and

Embedded nails.

Rmembly
Drive the 6302R wheel ball bearing into
the hub using a bearing driver.

. Install the dust seal in the wheel hear-

ing retainer, mounl the retainer into the
whccl hub. and install the O-ring into
the hubi

. Install the gear box retainer cover on

the gear box retainer so that the cover
matches the dot

. Mount the brake disc on the wheel with

bolts. tongued washers, and nuts. Alter
tightening, bend up the tongues on the
washer: to lock the nuts.

pip-235 a; ngum “um

67

 

    

63 5. C HASIS

5. install the speedometer gear box on the
opposite side of the brake disc. and
insert lrvnt axle into the hub through
the speedometer gear box.

6. Mount the front wheel on the front fork.
install the axle holders, and tighten the
nuts.

Note:

Make sure that the speedometer gear box

is mounted in the proper position.

l-‘imt tithten the axle holder on the Icl’t

ear box retainer aide {hr-kt- disc sideit and than the l'lllll
Sand-meter gear box aide.
7. Connect the speedometer cable to the
gear box.
8. Checking the wheel balance
at Mark the side of the tire and rotate
the wheel lightly tteveral times and
observe the position where the mark
comes l0 [EL

b. If the wheel in not statically balanced,
the mark on the tire will come to
rtst at the same position. (lmvier

, , section will be at the bottom].

I’ll- m u: Balance mullinl x? Edam weittltt 1:. Attach a balance weight on the spoke
at the lighter section (at the top).

ll. The wheel is in balance when it does
not stop at any definite position after
rotating the wheel several times.
The balance weights are available in
[our dillerent weight sizes (5, tot 15
and ZOgr].

e The front wheel should be balanced
with the brake disc installed,

    

 

 

 

 

 

 

Pix. 203

Front disc brake

he disc brake system consists of the brake lever and master cylinder on the ri ht handle
bar, cali r mounted on the front fork left side. and the special stainlefi steel rake disc
moon on the wheel hub.
(Operation)

1. When the brake lever if) is gripped. the cam Lit at the base of the lever actuates a
film)“ of the master cylinder.

2. he piston moves the primer cup @a which blocks the passage to the reservoir and
pressurizes the fluid Within the master cylinder, This pressure is transmitted to the
caliper chamber through brake hose B (D. 3 we ‘oint LE, and brake hose A Iii. Also,
the stop light pressure switch it) mounted on t 3 way joint is actuated.

3. The hydraulic pressure within caliper chamber A applies pressure a ainst piston In , which
forces d A (It) against the brake disc. Since the caliper asem ly is mounted on an
arm w iclt pivots at the front fork. it is free to swivel. therelot'e, the reaction from
pad A Qt) is transmitted to pad B, resulting in equalized [treasure being applied by the
pads to both sidt: of the brake disc.

 

5 CHASSIS 69

 

 

 

 

 

 

1 anx bake lel'cr is Three my loin! [57 man
‘5‘ Fronl huke lever um r. Slurp much 'u: l’ul r'\
u) Primary cup gr l-‘mm brake limo A
(gr Fran! brake hose H n: C-lipu A

Fig, 209

A. Dlsuumbly

Remove the lronl wlml.

Unscrew the oil joint bolt and disconnect
llir brake have.

ya:-

l'l'. 110 (ii Oil join!

3. Unscrew the rhrcc caliper mourning bolls
and a caliper adjusling bull, and remove
the caliper assembly

‘I. Unscrew the two Calipcr w! liulls aml
separate caliper A and B

r mounting bnlrs
r animating Mr .3 Caliper is
a, Caliper A

 

70 5. CHASSIS

5. Rune“: pad A and piston from caliper
A.
6. Remove pad 8 {mm calipcr B.

      
  

m. 212 m mum :\ m Pun».

7r Unscrew lhc maslcr cylinder join! bolt
and remove the hmkc lwac.

8. Unscrew the master cylinder mounting
bolts and remove the maner cylinder
unit from rhe handle ban

. Disascmhlc the master cylinder.

'0

Pin. 213 ID Joint boll

q) Mule: cylinder unfit

@ fluke he...

:3; Mum cylinder mourning bol-

 

 

 

 

 

 

® fluke level up ‘3 pm" a; Rama m. 55 6mm hu bolt
a) sake I m Smudary (up u Mum cylinder um 30 Joint hall washer
Lg) Smmr wnhu m Primary Cur as Diaphragm @ Join: ball

:1) Ecol _ a} 5f” @ Mane: mun" lody a Fm: brake line
:5. mm Internal uup rung a; c «k «m: 03 Mater cylinder holder

@ w 5mm “a." a "mu. 1cm pivM bolt 3 6mm spring wnhe:
Pix. zu

5. CHASSIS 7‘

10. Remove the boot and remove the snap
ring from the master cylinder body.
Next. remove the 10.5mm washer. piston.
secondary cup. spring. and check valve

  

Pix. 21! fit MastcrtylindflW)‘ ‘
I: Snap ring

 

B. Inspection

1‘ Cheeking the wear of the disc brake pad.
Red grooves are provided lor both pnd
A end B as a wear limit indicator.
When the pad is worn to this re) groove.
the pad should be replaced. Alter re-
placing thc pads. adjust the clearance
between the brake disc and pad to 0.15
mm (0.006 in.) with the caliper adjusting
bolt.
Adjust by turning the caliper adjusting
bolt until the pad drags slightly against
the bake dim, and from this petition
hack oil 1;? turn and tighten the lock
nut.

 

 

 

 

 

m. m m m B .5; 3mm d'sc
:j; Pad A (5‘; w." 1mm indicator

2. Checking the caliper cylinder and piston. V
Manure the inside diameter oi the caliper
cylinder and the outside diameter of the
piston using a cylinder gauge and a micro-
Ineler. II the clearance is greater than
lcrviccable limie replace the part.

 
     

! ,, i,
Fig. 211 (n Caliper cylinder a) Piston
@l Cylinder gauge (D Micromctcr

72 S CHASSIS

3. Checking the master cylinder and piston
Measure the inside diameter of the cylin.
dcr and the ouindc (linmulur oi the
piston using cylinder gauge and a micro‘
meter If [he ClL‘Iln‘lllCC is greater than
scrvicmhlr limit. Nplztt‘c the part

C. Reusemhly

1. Perform rmmmhly in Ilu- r’t"\‘(‘l.\c‘ (mlur
of digmmhly.
.‘ lbemhlr: pad A .1:th B.

Note:
Apply xilieone ruling grease on the puds
:lldlng :urt‘nm of the e-I' r brl’ore us-
uemhlying paid A Ind II. This server I!
a dual preventative as Irell as water H.
pellent. Do not Ipply grease on the pld
friction nurture.

a

 

 

 

 

 

 

 

3' Mount the caliper assembly on the front
fork.

,1_ Mount the master cylinder unit on the

lmmllc liar.

Fill the master cylinder reservoir with

l
® © @ SAE 11703; Imke nutd.
m. :19 u; any" n i m A
ijv Pul B a; Caliper A

   
    

 

 

1:!

 

 

 

D. Brake adjustment
When the brake has lrt-n rligawmhlml al-
ways perform the air bleeding owmtion ml
the hydraulic brake and thou adjust the brake.
1. Brake lover free play
Lev — {we inlay ni 2~5mm {0.08~0.2
in.t mtu'mirul ztt t'nc cml of the lever :5
normal ii the play is excessive. inspect
the brake .K‘jv‘SlL‘m and replace any worn
(it delective part
'.’ Brake lluid lcvcl
Fill thv msurmir with hralm lllllll it: lin-
lrwl hm:
Note:
Brake fluid will dam-Kc paint flnixh. rubber
parts. and meter flimwnenlt, therefore.
HI w Duplmsgm m Mum, ”MI" exercise rare in handling and immediately
6; Brake fluid wipe in are of spill-n.

 

5. CHA§IS 73

3. Air bleeding the brake syslem

When nir enters Ill: brake hydraulic

sysum, braking ellcrhvcnas degrades

and creates a lumrdous cundilion. ll

brake lever action becomes soft or

spongy,or if the fluid rsen'oir is allowed
lo become dry, perform lhc bleeding in
lhc following manner.

3. Fill the reservoir with brake fluid up
[0 the level line

b. Install the diaphragm lo pmvcm loss
of brake fluid.

cl Almch a hlcedcr lube lo lhe blccdcr
scmw and place the opposite end into
a vml lo calch the fluid.

d. Pump the hrake lever scvcral limes.
and open lhc hlmdcr screw .1 half
rum while maintaining a grip on
lhe brake levers Whtn (he lever bol-
roms, first. close the binder screw
before releasing lhelcver. Repeal (his
opcrnrion several lime! unlil there are

 

 

 

no air bubbles in llre fluid
flow: out 01 lhc blccdcr lube.
Non:

Replenish the fluid in the reservoir Ind dn
not allow (he narrolr In become dry u H
wlll permit air in curler Ihe brlke hydnn-

Ilc Intern.

2. REAR WHEEL AND REAR BRAKE

which

 

 

 

Flu. m ”1: Blade! lulx' C le a! madam-10W

 

ri‘- mlu lull mans
(i; Dislnlm mllu

13‘ When-l balnnccr

._ 1"

 

(9 Tim flap

(1) “(hell huh

(I) Rim

0) Owing

l3 “'lkrl damper A
a} Wine! dunk: B
9 Final driren flange
0) Dinuna coll" B
8‘ “EU hull lat-ring
0,0 Benin: nuincr
0) 10) 48 driven sprocket

boil
it} Side roll-r
a; Fin-1| amu. ”meta
ll! 34556) oil ml
@ oil-lg
‘8 Sprocket lid: plale
Q} Tonxued washer
a 10mm run

 

 

 

 

74 5. CHASSIS

A. Disassembly

1. Remove the rear brake rml

‘3, Rcmmc the war lurakv: panel stoppcr
boh to (“:L‘OHnm‘l Ihu hmkc sroppcr armr

   

 

Stopper um cuslmn rubbu

to 8mm nu!
m Panel mm. 2.0:.
5 my. pm

3. Homovc the both left and tighl mufflers

J Luown the derL' chain adjusllllfl huh on
hath sink-s. runovc (in: matter pin, and
10mm the axle nut,

5 Push fllc wheel forward, and Mt [hr
chain on \hc dl'|\'(‘n Sprocket. Remove
\hv: hx‘k hollsxhain nd}usling slappers and
pull the wheel marward to remove the
wheel nml axlu from the rear wheel.

fir eruiuhlcn the (ongucd washers and
unscrew the four nuts to remove ibc
driven sprnckol.

7. Remove the ronr wheel bearing rcminer

 

¥

i_ with the bearing rclaincr remover, and
5 . _ drive out ihc hearing from the hub.

is Lhnm blunting 1.1mm ane'

The Marin: retainer Rm 3 left hand I'm-ad.

   

 
   

 

“1.259 ‘. Boning "mm mum.
at Bearing am"

Pix. 227 m Dviu-n mark-1|
2‘ Tnngunl navhur
9‘ Led: nul

B.

shy-#950

s cmmns 75

Remove the two cotter pins and washer
from the brake shoe anchor posts.

lnlpection
Chock rim runoul Ind wobble.

 

Check rear axle shah rumm. "L m u.- we mm j: Com: pm-
Check brake lining wear. {1‘ Fm wait.” 19 “ml: ihuc “my,“
Check brake drum wear.
Check ball baring wear.

Check (or loose spokes, bending and da-
mage. Tighten, straighten or rcplace as
necessary.

Check (in: on both inside and outside for
cuts, bruisu, and imbcddcd of nailr
Repair or replace :5 necessary.

Flt. no I Vernizr caliper Jr [lulu- lime

 

 

r... m g; um my rj: 9.11 bunting

76 5-. Cl IA$IS

C. Reasonably

L Perform reassembly in the reverse order
of disasscmhly,

2 Install the brake shoes on the brake
)Imtcl

Nine:

l'se thread loch cement when installint! the
bearing ret-iner.

APvI." grease on the friction surfaces ol’
the [Image and wheel link

2!. Mount the brake panel on the hub and

Fig. 2:: thn drive chain on thc sprocket Insert
1hr \\'llL‘t:l axle through the assembled
whet-l hub, and mount the wheel on the
rear fork

1 After completing the t't".'L\\t‘ml)ly, fidjuhl
tltt! slnvk of tln- drive chain

a. Nmnml t'hzu'n slack is lU~3(Ivnm
l3 S~3_'l in} with a :lligltt form.

b. Lawn tho nxh- nut :llltl ntljusl the
drum chain with [hr :ttljuxlmg lxilt,
making suit- tln- adjuster marks on
but): hides are in lht: smnu position
when completed.

 

 

I’il. 23‘ ll‘ Comm pl“ 4‘ Lick nut
in Axle nut S l.n:lt hull
ti Adjustin: ball

it install the rear brake stopper arm, and

adjust the height and play n! the brake

ptdal,

:i. Adjust the height of the pedal with
the adjusting bolt

li Adjust the [new play of the pmlnl to
20~311mm Ifi".~l -" ,in; With the
adjusting nut on the end 01 [hr limltc
rod.

 

.
Fig. 236 w Adlumng nut

 

s cmws 77

 

3. STEERING
The steel tube handle bar is mounted on the (D Q)

from (or): top bridgc with thc handle [m , n~
holders The top bridge is boltod to the from I
fork and stccring sum, The stccring stem
is mounted on (it: frame head pipa

 

 

 

 

H1. 257 m 5mm; immut- t...
2 mil: in: holder

  
  
  
  
     
   

n 5 mm tap m
I 5' mm; M. mm- m»

mp Pull rat:
hunt

mm

hnttnm hall not

A. Dinnumbly
l. Unstrcw two bolts to remove the master
cylinder unit,

.. Disconnect the clutch cable at the clutch
lover.

3. Remuve ll“! lighting switch and (llSCOX‘r
ncct the throttle cable from ‘lltc throttle
grip pipe

4. chwVe the head light unit from the
head light case and disconnect the Wiring
at the harness within the v St.

5, Unscrew [our bolls. remain: the handle
bar holders and diswtttttxt the uirt‘
Imme‘s.

‘
Fig. 259 q. um." 1mm h" holdvn 7 Handle but

78 5. CHASSIS

6r Unscrew the two mourning bolts and
remove the xrmdumctt-r and tachometer
Unscrew the stem nut. remove tht 8mm
halls and the fork top bridge.

  

R my budge 2 stem nu:
i: Fork mp rm. 1 Hum. [min

   

8. Remove thc front fork
1'. Unscrew the steering Mr!“ htuid nut with
the stem wrench.
lU. Romnw the starring sicm out the bottom.
Nolr:
Slot-I hllll will drop out. tlterefore. eu-n‘isr
rare ml to loot": them.

 

Fix. 2" Steering mm wromh

L" Stttrini itcm hmd nut

B. Inspection

1 Check the handle: but for twisting and
damage
Chock ti»: steering stem (or lu'islittx and
cracking.
3. Check the steel balls for cracks and wear
4. Check the cone man [or vicar.

 

Fig. 242 it Site! bulk

C. Relmmhly

1. Mix the sit-cl balls in grease and assem-
ble 18 into the uppcl tact: and 19 into
the lower comm

2. Inst-1" the size-ring stem into the head
pipe being careful not to drop the steel
balls

3. Assemble the top cone race and tighten
the steering sttm head nut.

 

Note:
lit-fon- assembly. wash Iht cone :nd bull
Fix. it: i, '«ring stem wrrnch rams nnd steel ball; Mix the hllln in new

 

‘1‘ Steering mm head nu: gum.

5. cmssts 79

-l Asemblc the front lork.

:‘ chmblc thc from lork top bridge. and
mount the speedometer and tachometer.

6. Install the handle ban

Nate:

Align the punch Inlrks on the handle bur to

the putting suffice of the holder.

 

m. In .3, mm mm

 

 

7. Reconnect lllv clvclr tl wiring.

8. Reconnect the clutch and throttle cablcs.
and the brake hose to the master cylinder
unitt

Nate:

- Hike an" the able: Ind Iht- elu‘lricnl
wiring: Ire free from binding when the
handle is turned fully to both rides.

» Adjust the pl in the tablet.

(Tluteh lever: 10.0~20.0mln 1393~33ling
at the end «If the lever. Fig. 2| .. Clutch cut-Ii- ii. th‘ hum

nuke lever: 2~5lnm [5,‘Gl~l3;61ln.t me hm hm: '- Ferk new bridge
el Ihe end of the lever. ‘3' “mm" “b"

   
   

  

at!)

®h

 

 

 

 

 

4. FRONT SUSPENSION

The front fork unit consist at a lightweight aluminium lront lurk bottom case with a
dual action telescoping shock absorber oil dmnpur. Cushioning travel is 91 mm [3.15in.) on
compression and 31 mm (1.22m) on extension strokes.

 

 

 

3x9 ©© ® ®@ ® ammo;
~.‘1§_:fi~ ' , mflgg
,7 — u ‘ Wir~ .7 , 5;»

 

 

 

 

 

m. m From (out mm

Li) From loilr bolt ‘3 Hulda

@ O-ting @ Calla!

t3) Lock nut 31 Front lozk bottom case
9) Front lurk pipe 3 Damp-u can:

in Front Iu-pennon spring :3 Am holder

@- Ftont fork boot :3 l‘hin wuher

i3 mmper rod .pmm washer

 
  

up Sup ring .. Nut

® cm nul

5. CHA$IS

 

 
 
 

 

A.
1,
2r
3.
Caxign mourning boll:
m Adjusling screw
' Calivtr slut bobs
Caliper B
3', Calipu A
J.
5.
6,

 

Disassembly

Loosen the fork bolt. remove the drain
plug and drain the damper oil.

Remove the from wheelv

Unscrew the (hr-w calipcr mounung bolls
and an adjusting screw, and remove
the cnhper from rho left from fork.

Unscrew the Sasfimm and (he lU-’
35 mm bolls and pull the forks off the
borrom.

UIIKR‘W the from {ark bull, lmsr frnm
(he pislm’l ml lock nur, and rmnon- rho
from fork spring and cushion spring.
Mal.
Separate the from {ork pipe and bottom
case.

Unscrcw rhc 8mm bottom casc boll using
a spccial [001 and remove rhc damper
unit (mm the bollom case.

 

 

fir

Pil- M9 1 Sum mu: Pl]. 750 | From fork bolr If] 5mm bu]:
x! Lock rull I]? Dumper unil
‘jw Cushion springs”! r9 Fm spring:

14', Sup ring a Fork pp:
‘5: Oil as] Iljl Spezial real

UJ Bottom we

5. CHASSIS 8|

 

B. Inspection TM
1. Check the front suspension spring. . "
2. Check the fork pipe and bottom case for

damage or loosencxx

3. Cheek the oil seal for scratches and

damage.

4. C heck (or t~xcessive clearance between

the shock absorber piston and the cylinder.

      
    

7 Square

Free length

 

 

 

C. Renasembly

I. Rwssemhlc in the reveme order of disas-

scmbly.

2. Assemble the damper unit and cushion
spring with the lock nut, and install
the unit into the battom use.

Install the front fork pipe.
install the snap ring.

Apply thread lock cement around the

threat] of the piston rod, and tighten the

lock nut. Next, lighten the (ark bolt on

the piston rod and screw the fork holl

inlo the fork pipe.

f» lllslnll ll».- lront fork unit through the ,
steering stem and mount it with the 8 r“. 32 m 0.! m, M" “w; m 31;,
mm and lOmm bolt. c3031.“: drive gnu. "

 

9‘5.”

 

Pix. 153 (i) 8mm selling holl
ti: ll) mm uning bolt

 

 

 

 

"\ t ‘t
"J . 2(3) 7. Fill the fork bottom case with 1600c
_':¢ "m ”0‘." , (5,4 015] SAE l0 W—HO grade oil through
the for}: top bolt hole.
Fig. 234 (y 7...: n 8. Adjust the from brake caliper.
(Q :‘dkAd_ Adjust the clearance between brake disc
LB N23 "‘ and pad B to 0.15 mm (0.00“...) with

@ Caliper ndyuiling mew the caliper adjusting scrcw.

82 5 CHASSIS

 

5. REAR SUSPENSION

Th: mar susgnsion is equipped wilh dual
action (ck-scoping shock absorbers

Rear fork is a swing arm type of tubular
construction which pmvidrs was!" rigidixy.

A. Dialuemhly

 

I Rem w: the mumm
3 Remove the rcar whcc‘
1]. Remove the mar suspension mounting

nul and bah. and dlcn remove the
suspenson from (h: frame and rear fork,

4' Compress lhc rcarsuspcnsivn spring using
a sprcial suspcnsion wmprcswr luv]. and
disasumblc

 

 

 

 

’1‘. 235 I‘ Rut Em" 1m (0113:

   

m. m 1. R ‘ . Fig. 257 1, Rm “4...“... a“. “1.1,
1‘ Suspcnxlcn mmpressc: [to]
n Spring 2m slupk.‘
z Ru: ....».\~...m uppr! mm
: Spring be.“
c 1 ear 1
‘7 I ml ru
5 Jmm
a: N4: -1: Jim dampu
m Ruhbcr

 

 

'vrsion spriu;

    

i CHASIS 33

Remove the rear fork pivot nut and
shaft, and scparalt: the fork {mm the
harm:

g:-

B. Inspection

Check the rear suspcrm'un spring.

Check damper [or oil leaks.

Inspcc! ll": damper upper use and rod

[or den! and ilflld. Make sure the Oil

dumptr opemlc‘s smoothly in both dircc»

lions,

4. Inspect due damper case and stopper for
damage and dent.

5‘ Check the clearance between (he rear
for): pivot bushing and shaft.

6. Check the pivot shaft for bending.

Check the rear fork swing arm {or bend

-ing, twisting. and cracks.

why—-

‘1

C. Runembly

1. Mount [he rear brake arm stopper (0
ll".- rcar fork.

I! Apply grcasn: on Ilue fork pivm hushmg
and install the mar fork on ihc frame
With the pivor shaft.

3, Moum the rear suspension bclwccn Ihc
frame and fork on both sides and tighmn
ll|e mp Iluls and bolts.

4 Mounl [he rear wheel.

N :

when [he "crumbly is completed. ldjuu
the rear brake and me drive ch-in tension.

 

Pix. 250 ‘1 Run.- fork

7 km 1...; pix-m shalt

 

 

     

)‘J I m

 

/Vl's |

. 1?. -mn

 

' m. 2H .3 Almsdr

I‘ll. 253 Rear vi

vac:

  
   

~11 plumb” Lnring
c

“1.260 .1 M...-,\.m.-r.», 4 anr [mk piwxnhah

 

pug:
m Rur Fork buflumr

84 E, CHASflS

 

   

Fig. m 1 5m munm x 1: ,
. (mu-r M .»
: m. w!

  

 

1" 2M 1 in'u ‘nY‘ : imrr 1L1:

 

V 3143‘1'1-17'Tl021

Fix. m _
7 Ccurr cm

 

6. FRAME BODY
A.

Construction
’l‘ln- [lullMx' .-
' lwl In!

[ram 15 c ucmd
Tltc head plrx
‘ \\'n using com-.rmmn

   

nv-ul plum

       
 
 

 

ronglh

 

“guilt? and

   

tandlmg a! high ”my ,1 ml,

Diunssembly

Pmi Am 12% I'm-I cock Icvvr m ‘
I mix from

tlw furl tank

    
   

‘x:

crs. and Jnmuum iha'

 

ll".- (rum WI, am] (hi: hunt

Igrk
Run._..c ‘I‘I: h
ricm from (]I(' frame.

   

. lc Mr and Kim amt

Rem-m4 m “hm-I. {nu-Ir mu, mu!

w; mm.-

 

.k‘mxznw Hm I, |Ezo u-nI :my, am] [hr

 

nu rh-

 

 

\nml r:quiplllc:'.L

 

‘I'u rrmr-Vr I'm- ..a n stand. :umru l'nc

 

rumm- flu: :cr

stand pivot

 

luu inn-”Hing In;
‘ am: vxtmcx lhc m

      

5. CHA§lS 85

9‘ Remove the top and bottom bell races
from the steering head pipe.

Note:

Use a wooden drift to prevent dun-1e when

drh'inz out the ball neesl.

C. Inspection

1. Check the frame main unit for twisting,
deformation. and cracks around the
welded areas. unll the pipes for bending

    

and cracks Flu. m Ij; Wooden arm
2. Inspect the top and bottom races [or 11‘" El“ me
scoring and wear. [D H”! ”i”
3. Check the head pipe for misalignment.
Al. Check scat cover {or tears. .57
5. Check luel tank for leaks, fuel tubes for

aging or damage. and fuel cock gasket
and strainer cup O—ring {or damage.
Flush the tank interior with clean
gosolinc.

S. RemDVe dust from the air cleaner ele
ment by blowing compressed air from
the inside. Check element [or damage.

7. Replace exhaust pipe gukct if damaged.

 

I’ll. #1 I'D Fuel lmlncr cup

[9 thing

D. Reusembly ngm‘LTiumsx“

1. Install the main stand on the frame. 9 g“: C“: W:

2 Install the rear lender and the electrical 3 F3, 5:1 5;,“
equipments on the frame. (3) Cock lever nptlng

3. lnaull the rear lork. rear cushion and [’3 5““"5 Pl'“

® 6mm acre-

rear wheel.

4‘ Install the steering stem. lmnt fork and
[mm wheel.

5. Mount the air cleaner case. the battery,
the seat. and the fuel Hulk.

 

 

F-Irzis (9 Air HQ" (lemfll—I

,“MM..-

 

. M
I s. ELECTRICAL l
"WV-l

.w.~......ma......m

l. GENmAL DESCRIPTION

 

 

 

 

guy 4. q; @q. xi) q; .3, hp

 

I‘ll. as Con-plan electrical anten- diagram

(D Tulane!“ pilot lamp (I COMM! breaker assembly
6) Speedometer pilot lamp Q Battery

:9 Head light o‘n Ham

(4) Position lamp (except USA type) 8 Main when

(S; Front hula atop switch 0 Smlk plug

(9 Front 'lnlm lamp 0 M: generator

a) Elnugulcy when 0 Oil pea-um awiteh

Q1 Hard light awitch 8 Starting mm:

(D Slum nwileh 9 Neutral I'ildl

@ High hum pilot lamp 9 km brake atop uvhch
CD Nata-l lamp 8 Fate holder

0 Oil warning lamp 8 Salem: rectifier

@ mum pilot lamp 9 Wicker relay

8 Speed taming lamp (exctpl USA type) 0 Magnetic twitch

Q Winker awilcll 9 Voltage test-law!

8 Horn Milton 9 Tail/hop lamp

0 Isnifion coil 0 Rear winter lamp

0 59ml uremia. ante-ammo! USA type)

 

38 a ELECTRICM

2. IGNITION SYSTEM

 

®

 

 

 

 

FII. 210
(9 Spark plug. 1)) Condtnreu Ii: Battery
is Ignition will (i; Contact breaker

The ignition system consists of two ignition coils, two contact breakers, four Ipark plugl.
an ignition switch and a bathery.

The current lrom the battery flows through the primary winding ol the ignition coil, and
circuit is completed by grounding through the contact breaker. Contact breaker is contained
in the contact breaker housing at the right end of the crankshalt. There are two Contact
breakers which are 1K!" out of phase. One oi the breakers furnisha high voltage current
to spark plugs l and 4; the other breaker fumishea current to plural and 3. The contact
breaker: ignite the spark plugs in a firing sequence of l, 2, 4 and 3 which is indicated on
the high tension plug cords. Since no distributor is used. the construction is simple and
the system is my to scn’icm

SERVICE DATA

 

 

 

Ignition coil
3 point .wk pp opening p 7mm min. (0.27m
Saul vlux
Trpe nuns...” NGK 0-153. DENSO xwrs
P ug m 0.6~0.7mflg.0£3~:9.0. n)
Curran brake:
Point 3.9 «1.5—0.th (moth-0.0mm.)
Spring levee , ciao-.gagn‘wqaum
Condmm i
Ccpocily Mt P:10%
”hairline.- resirfltf 7 i Om xo Md‘UJOOmeufl) 7
Souk «lancer ‘
Start at adv-nee (mnhhm . d) [.193 a:
Full «sum (ennhhatt moi? non-.2 350 rpm
Adv-nee mule \ 5-

 

 

at ELECTRlCAL 5"

Ignition Coil

The ignition coil consists of a primary coil
with 420 turns oi copper wire wound around
am iron core of laminated silicon steel sltrclfi.
A secondary coil with 13.030 turns of wire
is wound rm top of the primary coil Each
sct'mitlztry catl has two high tcnsion cords to
two spark plugs.

A.

1.

L.)

Dialsunbly

Opcn the seal and rcmove the fuel tank
Disconnect the ignition coil leads.
(yellow, blue and blacklwhitc)

Uttscrcw the twn ignition coil mounting
bolts. and separate the IRlllliDn coil lrom
the frame.

Inupection
on coil continuity test

 

l’rirnnry mils.

Check for continuity lit-twwn tht: tcrnti-
nals oi the primary l‘0|l

Right coil: yellow and blilfkt‘wllih‘ loads
Lei! coil: blue and blackg'u'ltnr Imds
Secondary coils

Check for continuity bctwctu the tenni.
nals of the high tension cords

ll lhere is no continuity, the coil is open
and must be replaced.

 

 

 

 

 

Fig. 211 u: rnmm cod

3 lion cot:

' - Bobbin

chomizyy wn
Primary trtmiml
High union card

‘2. High team tcxmirtnt

 

 

 

272 I lfl‘lllll’tll n'nl : Holu

 

 

 

 

 

m. 2:: IBM..." mu continuity mt

90

6t ELECTRICAL

Ignition coil perfomlnce mt
Coil may test satisfactarily for continuity but
it may not perform satisfactorily due to dete-
rioration from long use, therefore, perform
ance should be Checked to dctcrminc its con-
(litiun,
Cunnvct the: schicc tcstcr power cord to a
12 V battcry and ground the ground cable.
Connect the ignition primary test [cad to
the luster and connect thc opposite terminal
'\ ends to the primary terminals of the coil. Can-
Fig. 214 umnon 00.1 [xllormaxll-‘E “:5! rice! md test lead to the black terminal of
the ignition coil and the white tell lad tn
the yellow cord of the left coil (to the blue
cord {or the right coil).
Position the selector knob to COIL TEST
Adjust the (hm point spark tester to the

' “ A maximum distance spark is maintained and
then mensurt: this distance. Thc coil is mtis-
, factory ii the distance is greater than 7mm.

(0.27 in.)
Note:
:5: 3 Since a dual warning ignition coil in med.
not: the spark condition. If the upnrlt lp~
“ near- as B in Fix. m. the connection to the
prlmary coil u rover-ad.

 

 

 

 

 

m. m Spark mtumnoe

6. ELECTRICAL 9|

Spark plug

A. Removal

1. Remove any dirt from around the spark
plug by using compresed air.

2. Remove the spark plugs with a plug
wrench.

B. inspection

Inspect the spark plug [or worn electrodes,
excessive gap, fouled condition and damaged
poroelain insulator.

ll Clean llirty spark plug with a plug
cleaner or win: brush

2. Measure the electrode gap with a feclur
gauge and, if necessary, adjust to the
specified gapr
Standard gap: 0.6~0.7 Inn (0.023~
0.027in.)

3‘ Replace the spark plug if the porcelain
insulator is damaged, or the gasket if it
is damaged or distorted.

Standard spark plug: D-7ES (NGK).
X22- (DENSO)
C. Reinaullltlon

1. install lbe spark plugs in the reverse
order of removal.

Torque: l.5~2.0kg-m (ll~ldft~lbni

Note:

I. Exercise can not to drop the plug (lulu-L

2. Loose plug will not properly diuipatu
the but and may mull in engine Incl-
function.

Flt. 276 1' Spark plug ti) Spark r’luu cleaner

Mg. 211 Q) Fulex gauge

92 a ELECTRICAL

Conllct Bunker Ind Condenser

A. Dialuerany

1, Remove the point covert

L, DISCODHQCI the loads inllnw. hlue'p a!
the connecmm lmL'IIt‘d .11 the center of the
frame.

3‘ Unsctvw llm 6mm boll, remove the
special washer, loosen the basic plate
mourning sauna and lhun rt'muvr [he
t‘tmmcl ltrcnkcr assembly.

B. Inspection

For adjustment of the breaker point and

ignllion liming, ruler to the section

" Mainlcnancc Operations ",

Condcnscr

Measure the capacilnnoe of the condenser

using tin: service leslcr.

Slntttlztrtl value: 0.22~0.26yF

Nola:

The point: would be open when tulinl.

 

 

 

 

 

Spark Advancer
A. Diuuernbly
1. Remote the point mver and Colllacl
breaker asscmbly.
Remove tbc spark advanccr {tom the
spark advanccr slult.
B. Inspection
1. Clean dust and foreign matters from
lricrion surfaces, and nssum lhnl opera-
tion is smooth,
. Chock spring tension. and ndvnnccr pin
wear.
Smndard spring tension:
680~8503L HAS-4.87“»)
C. Runembly
1. Install the dowel pin by aligning the
holc.
Roasscmhlc in lht) rm-crsu order of re-
moval

w

w

 

6. ELECTRICAL 93

8. CHARGING SYSTEM

The charging system (or the C8500 is made up of the aciter field 3-phasc AC generator.
rectifier, voltage regulator and the (use. The generator consists of the field coil. stator coil
and the manor; it does not contain slip rings or hrusheat

In order for the stator coil to produce a constant voltage. the current from the battery to
produce the exciler field is regulated to very close limit: by tlte dual contact regulator. The
output from the generator is rectified by the silicon roctifier belore being sent to recharge
the battery.

The generator pcrlomu two functions depending upon the charge condition oi the battery.
The electrical current lrom the battery flows through the switch and into the regulator. When
the battery voltage is lower than normal (less than 13.5V at the battery terminal), the
current flows through the upper contact and to the field coil. The strength of the magnetic
field is dependent upon the strength at the battery voltage. When the battery terminal
voltage is 12 V. the field coil current is L6A. This produces an output Wltage of com
pending strength which it used to charge the battery.

When the battery voltage cxccodt approximately 1-4.5 V, the armature coil pulls the armature
away from the upper contacts and closes the lower contacts to insert a 100 resistance into
the field coil circuit. The current to the field coil is thus nxlucui to 0.7 A and. consequently.
a lower voltage is produced by the generator, limiting the amount of charge to the battery.
This function of inserting or removing the resistance into the generator field coil is performed
by the voltage regulator in accordance with the charge condition of the battery.

 

(D ®

    

®

 

 

 

PIC. 32
0 Silicon rectifier ® Regulator ® Relay call
19 Coupler Qt Upoer contact a Stator coil
«'9 Battery 12 V. IZAH (3 Moving contact 63 field coil

6 Main witch (9 Lower mom! a) To loud

94

6. ELECTRICAL

 

‘4

 

 

Chiming Test

1. Perform the test using ammeter and volt-

meter.

2. The battery charge condition is dctth
mined by measuring the specific gravity
of the battery electrolyte. II the specific
gravity in lower than L26 (at BOT/68°F).
recharge the battery so that the specific
gravity is up to I.26~l.23 (at N’CJGS‘F).
and then perform the following test.
Disconnect the battery cable from the I?)

 

3.

 

"I. 2:; G7 Redhthite lad
a) Ammter

g) Voltmetet
a) Battery

terminal of the hattevy, and connect it
to the 2'1; side of the ammeter.

Next, connect the 6 side (II the ammeter to the 3) terminal ol the battery,
Connect the (5? side of the voltmeter to the lit end «I the battery cable, and ground the

G aide of the voltmeter.

conditions and check to see if
table below.

(Fig. M)
Start the engine. operate the engine under both the NIGHT RIDING and DAY RIDING

the musuretl values conlorm to those specified in the

II the values are lesa than those specified, adjust the regulator.

Note :

The churn mnditlon ol‘ the battery my clue the churn current to nry slightly.

 

 

 

 

 

 

 

 

 

 

 

 

 

. C, Cute-nut
5 con Inclifit-r

, Voltage regulator

xi; Volt meter

  

Flt. m
:‘u Animate!
it Main switch
13: “finely
.g/ Headlight twitch

® llcadlighl lo- beam
$1 Headlight high beam

 

* Engine RPM

margins mm“ (A)
my 1' ‘

 

Buttery terminal voltage M

 

‘ ‘ l
1.030 “to 7.000 3000

 

 

won 3.000 4.000 5.0%
as a l 2.4 l 1.3 7170 1.0 «.3 M
24 l ‘ I t l I I 1 1

12 in . 13,: l us 14.5 14.5 14.5 . 11.5

 

 

6. ELECTRICAL 95

A.C. Genet-tor

 

Specifications
Type and maker LDIlOvOI, Hitachi
Output 150 W
Battery voltage 12 V
Polarity ground
Charging speed IOUO-SXJUO rpm
Weigln 3kg (6.61bs)

“1.285 I Rotor ruller 2 Ikltor

A. DInnembly

1. Remove the generator war and pull out
the rotor using the rotor puIIcr (special
too] No. 07011—21501}.

2. Unscrew the three 6mm screws from
inside the generator covcr and remove
the stator coil.

3. Unscrew the thrcc 6mm Screws Irom
the outside the generator covcr and
remove the field coil.

 

 

 

 

B. Inspection

 

 

It Field ooil resistance test In" g gifzefz‘:;’mm
Check resistance between the two tat-m -' '
coil Icads (“‘hitc. Grccnl using the Sun
vice Tester OIIMS function. (a ,—
STANDARD RESISTANCE VALUE} _’

4311:1076
NOTE: Tent Inu' he performed without
“moving (It-Id mil.
2. Stator coil resistance tea
a. Check resistance hetwmn any two of
the thmc yellow alternator (stator;
leads.
Leave either tcstcr Icod connected to
yellow wine. Attach other [Ester Icad Flg. :87 Had ml
to Ihind yellow stator wire.
'ANI)ARI) RFSIS'I‘ANCE VALUE:
0.35Il.L10% at .1.
0.359210% at b.
i: To“ mly be performed without re-
in: stator.
trZST RESULT INDICATION

‘ l (Iicld coiI‘ No reading or

’ low reading “flea"?

 

2 (stator) a No reading or , ,. . ..
or I) Iow reading ”hm“

I‘ll. DE Stator cod

96 it

 

 

 

 

 

 

 

 

 

@® ®

 

 

 

 

Pix. 239
7 Paint gap 1-» Voltage adluulflfl :(rcw
. Upper come: in Loflt nut
t.» Ammutc ,tt Cm:
1 Com m. 1: rum 2:}: .I4i unit. 5
C a gap lullusiiflg'
CLH 1" tel

‘ hm. r t‘tvfilm‘l

 

 

Fig.2” 1 Regulator

 

ELECTRICAL

Regulator

The regulator is a dual contact type If

maintnim :l vunsL‘ml voltage by placing

the rcsislancc circuit into the livid coil circuit
when [hit HPnPrating voltage rises to i| certain

vztltlc. zttttl Culling out the resistance circuit

when the voltage drops below .1 not limit

A. Dislasembly

1. Disconnccl the leads at tltu connectors
and unsrmw the two 6mm regulator
mounting bulist

2. Unscrew tht: two art-ens and remove the
regulator cot-er.

B. Inspection and Adjustment

Regulating voltage ntljustttt

1, To adjust [or low chmgt- current or low
battery toltngt- loosen e luck nut on
the \ol ye adj iny rw nntltutn the
adjusting scrc'a clockmsc When tltt-
nyul. ttnr i-t :A‘l too high, turn the utlius
in; screw mutttt‘rclutluviw.

.t Upon {Jilll'lil'lil ‘ tht- adjustment, recheck
regulator pcrlo u'tIHL'C after ittstttllnlitit:

 

   

     

 

 

 

Curt: gap inljnsunmtt

.\l mt tltt torc 1p tiitha lccltrgnttgu
it rcqttirt~< Illiiltxl HUI”
mljlh , arm and min-t- tht- [null iK'liV up
(IV tl-mn

lmrl mrv gup \‘aluc

0.6~l.0 mm L0.02~0.40 in.II

 

     

 

 

 
  
 

 

- lill . with n iuuicl gauge.
it-t fltfjllwlnlcl1[,imscn the point gait
re“ nrd mo c the l L'l’ punt: up
Standard point gap \‘ililll"
0.2 mm 10.008in.3
Note: If the point: are nillrd or fouled,
polistll will! u .fl0~64l) rllu-r)‘ paper.

    

 

 

Fig. ZSI it; \‘Litapze adj»:
t2 l/xlt ttut

 

[13.291 can my
3 Point m.
ctm gait at“; nz icrur
_ I‘cém SAP :djuslits we»
3 Lower point

   

t1. ELECTRICAL

Silicon Rectifier

Inspection

The condition of the silicon rectifier is tested
lty diswnnecting the vlrclricnl connections
and testing the rcctilying [unction in both
the normal and reverse directions, Continuity
in the normal direction only indicate-s good
condition. Continuity in both dtrccrion indi-
cates a defective rectifieri

Note:

I. Do not me a megger for the test I! the

high voltage will dnrnnge the silicon

tlioricn.

Observe the pol-rity of the battery. Con-

necting the Intury trrmirulx in reverie

will Ihorten the life of the buttery u I!"

n culling n lnrge current to flow lhrolllh

the electrical system, rattling dlllllll to

the silicon rectifier, and Ilm deatmyinz
the wire harnm.

IL Do not operate the genentnr at I high
RPM with the “P“ Ierminll ‘_l'€d[lllllil£
cord from the mine“: twitch; of the
silicon rcctificr dimmnccled. The high
voltage xrncntrd nu: lillnl'e the uilicon
rectifier.

I. When rhnreing the buttery mounted an the
motorcycle from In external lonrce with
high churn rue xuch u I “quick ehnrge".
the I'irintr to the nilicon rectifier xhonld be
disconnected M the coupler to prevent
dlllllll'.

1+

Pin. a: Sllirofl rectifier impaction

 

 

 

 

PIE. ZSI m. 2.4- Yellow
" Yellow,‘Wh.ir
Cs, nmm

 

 

93 6t ELECTRICAL

4. STARTING SYSTEM

The starter is a device which converts the electrical mergy ol the battery to the mechnical
enemy to crank the mgine for starting. The starting circuit consists of I push buttan switch
mounted on the right sidc ol the handle bar which, when the starter button in pressed,
energizes the starter magnetic switch and closes the contacts of the starter circuit. This
permits approximntely 120A of current In flow from the battery to the starting motor,
which then mtates the engine to perform the starting.

 

 

 

 

 

 

“I. M sulllflfl Circuit

I1. amt. m Field mil 61 5mm button
11') Ann-Inn "f Sulfur nugnelic twitch an [Lutery

é) Suiting motor xi) Elecltomagnel tip l'lunger

© Pale r lgniliofl rw-Ich

 

 

 

 

 

Fix. a 5mm; mom insullation
.1 Slnrlinx molar (i; 5mm reduction may

 

.TRIC.-\I. 99

 

Startinx Motor

The mining molar is mounted on the crank‘
arse behind (he cylinder and drives \hc
crankslmh through the naming clutch,
Specifimlions

Rate-J \‘ullzlgu l2 \-'

Rare-l Oulpul 06 KW

Ran-d upcmlion Continuous {or 33
seconds

 

\\'Ill)oul de “'nh lax!

'ahagc s 5 v n V
An-rcxc 35 A :23 A
I'.- I) ll! kg-‘m

 

"X“ _ w as lulu)
l lufm~

 

vaululwn

 

 

 

03 rpm

Tim 3? Starring more: duauemhly driving

A. Disassembly

1, Iiimuum-I Ihu- rim: mumr cable :11
(he nmgm-m- swnrh.

2. Rt-mnn- the starting nlnlur mwr, M'l
rmnkrnsr cm‘er and ltht‘l‘l‘W [he um
G 1m signing mmor muumilm bolus

3. Slarlmg mmor can mm I» pullud um,

‘I. Umcrrw the l\\'0 lilmn wrrws am! n.‘-
mow Ilu' starring nlolor sidv: wvcr.

      
  

Pll. 25“ u Msgw L- mild:
r, mun-.3 mmor um:

   

“I. m I Surfing n‘ouvr

i 6mm Mu.

100

 

Flt. 3W tit Cuban Muslin
m 5 ins;
m Cam

 

utalor

 

 

 

 

 

 

 

Pix. 302 Armlurf coil imitation

l,

6. ELECTRICAL

Inspection

Carbon brush inspection

Wom carbon brush. pitted or rough con-
tact surface and weakened brush spring
will cause starting difficulty. thcrclore,
they should be replaced.

Commutator cleaning

Dirty commutator will give poor starting
motor performance.

Surface of the commutator should be
polished with a fine grade cmery paper
and completely wasbal before reassembly.

Stator coil inspection

Check continuity between the brush
wired to the stator coil and the starting
motor cable. Lack of continuity indicates
an open stator coil and should be replaced

Armature coil inspection

A grounded unnature call will tender line
starting motor inoperative

Perform a continuity test between the
mtnmumtor and the core. A continuity
mmlition indicates a groundtd stator coil
and should be rcplaetd.

6. ELECTRICAL IOI

Starter Magnetic Switch

The starting motor requires a large current of
approximately [WA to operate. To minimize
resistance. a large cable is used for wiring,
also. a switch with heavy duty contacts is
required Sparking across the contacts will
result, as well as resistance depending upon
the contact pressure, when the contacts are
openud suddenly to shut oil the flow oi large
current. To cope with these conditions, a
magnetic switch is used separately which is
operated electrically by a small current
through a push button starter switch.

Inspection

ll Primary coil continuity test.

If there is no continuity, the primary coil

is open.

If a clicking noise is heard when a 12V

battery is connected to the two leads of

the coil. the primary coil is satisfactory

2. After long use. the magnetic switch con.
tacts will become pitted or humt from
the large current which flows across it,
and gradually build up resistance which
may prevent the current from flowing.
Connect 12V to the primary coil lmda
of the magnetic switch. ll there is no
continuity across the switch contacts.
the switch is defective

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pit. 303

«tr Stopper or Contact butt
tr. Stwprr tutti" it C»:

t. whim it's Contact plate
«23 Rent: A [y Yoke

I5. Contact sprint: lil- Cail bobbin

' Flu I'nhcr 51$ Coil complete
ji) Plunger holder «2; Return ipllng
-? Plunger shit 02‘ Body

(E: Plunger

Flg. 804 Primary coil continuity tut

l0! 6. ELECTRICAL

 

 

 

 

Buttery
A. Specifieetion
Type 12N12A-4A-t
VoTuxe 7 r: x? ’
Cap-city 7 '12 AH i

 

 

 

B. Specific gravity measurement

Battery electmlytc is measured with a bulb
type hydmmctcn When the s cific gravtty
is below 1200 (at ZU’C), the ttcry should

 

 

he mchargidr d h d
.7 . " ~ . When m in a re: ing, the ) mmeter
Mg. m Efyaxttlflltr ’1 muddy“. should be bed vertical with the electml te

 

liquid level, held at the eye level and the va tie
on the floating scale read at point where the

    

 

I30) ® liquid separates from the stem of the Root.
:5: C. Inspection and replenishment
rm 1‘ Electrolyte itt each cell of the battery
® {:2 Should be inspected every half month to
, in; a month. and distilled water added to
"““ :3: bring the level to the upper mark whent

ever thc electrolyte level is below the

 

 

l '10
v mo level mark.
'0 N M m in a: m to 9° W 2. Whenever then: is rapid lowering ofthc
CD A electrolyte level. the charging system
” should be inspected.

 

'. ' ' . ' ' it '.
Pin. a“ ‘1‘ Smmc "my J Pcrtodtmlly mcature the specific rav )
xx: Rrhuan tween bplxific 3mm,

After adding distilltxi water, 31 ow the

«it Residual charge p"; battery to be charged and the electrolyte
sufficiently agitated before making the
mcasummcntr

«L Primary battery troubles are due to cor»
ration around the connetors and terminals
causing poor convict. separation of the
battery paste. and sullation (battery which
is left Ill is discharged condition for a
long period will have lead sulintc formed
on the plates and recharging will not
restore it to its original condition) them-
lore, the inspection should be per armed
periodically and thoroughly.

Note:

When uedlment ere fanned II the bottom

"It 807 u: Sediment 5! V'lI-t-‘n as ahown in the figure, the battery should

4‘4: Battery am- bg replaced.

D. Buttery charging
(Cnutionl

l. Relmin lrom charging the battery at a
fast rate (quick charge) as it shortens
battery- life. When rapid charging is
necssary. limit the charging rate to maxi-
mum of 2.0 A.

2‘ Hydrogen gas is generated during the
charging process, therefore, keep fire
away.

3. After battery charging is completed, wash
the battery with water to remove spilled

. .- .__ ._ electrolyte. and apply grease to the termi-

r . m cum.» hook-up nals.

 

 

 

 

 

 

5.

1‘

[a

u

G ELECTRlCAL

ELECTRICAL EQUIPMENTS

Main switch inspection

Willi die switch in both ON and OFF
posiiions check 10 see the: the continuity
mmli s in the chart below are satisfied.
Tl): switch is (lefoclive if there is no
cominuily whcrc specified, or if there is
continuity when: not specified.

 

 

 

BAT 15 TL) "(1..
22'3“ w m “3:35 W
OFF
Kay
L: v i

 

 

Fruni stop swixvh inspection

Apply luszer lend probes to [lie icrminals
oi the {mm slop swilch cords [black
gmwiyrllnwj, (ipt'mlt‘ brake lever and
check {or cunxinuily,

Take into Consider n llw li-ver play
2~5 mm {0.08412 ma,

Tlm smp light should come on when the
limke lever unrcls beyond the play in
llie lever.

Rem slop :m'ixclx inspection

After making sum that ilic siop swiicil
spring is diswnnmml, apply mswr load
probes to Kl": i Incl) (t‘l'fllillflls IMrm-n;
yellow, black conls) ("Hi L-lm'k fur
mniinuiiy. When \hc lira-kc puilnl i<
rlopmsscd 20mm main; al the from mu]
oi the pedal, 1hr stop light slmulll cmm:
un nl Iliis mini.

Adjuslmem,

If the slop liglil is lnu‘ |n coming (in,
turn (ht: adjuxler nu! clockwise, and if
too early, (urn municrclm‘kwisfl

llom Inspection

Check {or coniixuiity :icmm l'm- lmm
lead terminals.

Allomale mcxhod is to connect lhv: horn
lo a fully charged 12V battery and check
its operation,

   

I03

 

 

 

 

 

5' Rd

.o
I’ll. 310 F

Fll. Sll

, an” m.“ ;

 

 

 

 

 

 

Hz. :12 Km. continuity mi

104 t ELECTRICAL

 

5. Horn button inspection
With the tester lend pmben contact the
light green cord terminll within the head
light use and the the handle bar, and
then prus the horn button to check for
continuity. lf continuity exists, the horn
button is satisfactory.

 

6. Winker switch inspection.
Disconnect llu! winker switch wiring
within the had light case. Check eun-
Pl" 5“ (D "P“ b“"°" tinuity between the gray cord terminal
0 I’m,“ are!!! a"! and cringe card terminal (left winker).
and between the gray card terminal and
light blue cord terminal (right winker)
mpectivcly of the winker lWllCll. Con-
tinuity (or the respective tats should exist
according to the switch connections

shown in the table below.

 

 

 

 

 

 

 

 

 

 

Knob 2;"; Guy curd 0'“?
R O——O
OFF (cum!)
11'. In (D \Vinlter lwitch L O——O
G) Lleht blue cord
<9 Guy cord
@ Orange and

7. Lighting switch inspection.

Inspect for broken win: and defective
contact between the respective switch
cards, using a tester. Continuity between
the diflerent cords 1-ll0llltl exist in accord-
anoe with the switching position table
shown below. If continuity exist: where
not indicated the switch is defective.

 

 

Cord an" “‘31

 

 

 

 

 

 

 

 

 

t . G <9 i n
m. :15 8 withs'dmtch on 5’ jigginio
8 an «an: L I 0 “
Buy-uh 'lc rd # '
0 White curl! a 0” l

 

 

6i ELECTRICAL 105

8 Emergency switch and starter switch in.
speetion
Inspect {or broken wire and defective
contact between the respective switch
cords Continuity between the different
cards should exist in accordance with the
switching position table shown below:
If continuity exist where not indicated,
the switch is dclcctivc.

 

 

 

 

 

Emergency Iwilch

Cord mt.» Black Nach'white
7 ON 0 (3
on:

Fig.8“ @ Emelgencyswitch (a) Black/white
@ mm

 

 

Starter watch

7 Cord color Yellow-fired

ON (3 I},
OFF

 

 

 

9. Oil pressure switch inspection
Lubricating oil is supplied under presure
oi Al~6|tgfem1 (56.8~85.3lbc,-‘in.‘) by
the oil pump to various parts of cnginc.
When the oil pressure drape, the oil
supply becomes insufiicicntt The oil
system is dsigned so that when the oil
pressure drops below 0.5kg/cln’ (7 “In,"
in.’). the oil pressure switch operates and
the waming lamp comes on.

Check the oil pressure switch for conti.
nuity without starting the engine and
with the main switch on. I! there is
continuity, the switch is satisfactory it
is normal [or the wanting lamp to gu
out when the engine is started.

if the warning lamp does not go out
after starting, and the pressure switch

i mlisfactory, the oil system should he

inspected for trouble.

 

 

 

 

 

 

Pil- 817 I51 Suite! twitch
:1; Yellow-rod

    

Pig. m zit on mum switch

IOG 6. ELECTRICAL

 

 

10. Neutral switch inspection

The neutral switch is mounted on the left
side of the upper crankcase. When the
transmission is in neutral, the switch be-
comes grounded and the neutral pilot lamp
comes on, Position the transmission in
neutral, nmovc the left crankcase cover
Ind check the continuity oi the neutral
switch The switch is satisfactory if
there in continuity.

 

 

 

Flu. 8|!) New-ml Iwiu‘h inspection
0 Neuml n-iuh

  

_ 7 TROUBLE- SHOOTING

    

 

ENGINE
THIN. Pub-Ne Cnuu will
Englm in: not
“I" l. Exes-iv- ~ur oi able" ring ox- cylinder Replica
2. Seiud valve in "In guide Replace
a sand pillon \ Rnl-ce
4. Funny valve (inning ‘ Adjust
a Low or lack ol companion pmm Lap the "In lo obi-in good vnln nailing
- Plum: Ink 0: ml»:
5 Blown on! cylinder laud gush: Real-to
0. Warm guleling mix: 0! the cylinder Rep-it or replace
‘ nnd cylinder hand
Put null-o Wm Mechani-
Mllng L lwmt um" dunno. Adiufl Io mod-n! val-n

2. In- or Ink nl communion prawn
3. Excufivo vulva gnidc clan-no:

 

lama.
Replue ulve ma gill—d:

 

 

‘;;h [uel millun
Incl.

 

Lou .1 mm 1. anve sliding cg... ‘ Raul-en
2. lnmm Elli“ cl vnlve l4; ulve
3. Wall: or hmken val" wring Raul-OI
l. Faulty v-lve liming Check valve liming Ind Adjunl ll my
5. Blown out qlindu head sake! ‘ Replace
6. Exec-live war 0! cylinder Ind vixen ‘ Regal-cc
1. Wm. wk or kulun piston ling chlwe
& lam mm plug \ Rummy.
Ova-hull" 1. Navy urban dcpooil on combo-lion Ramon when
chamber and piswn had
2. lam llul minun Adjnn [be arbumor
3x Rem-dad ignition lining Adjust ignilion lining
4. Low oil luan pom qualily Add good and: oil
5.. Extendd ope-lion in low gen
nun" \ 1. [man man. of ink! um ,check lhe rnlv: lulina
i 2. FIuIIy um limlng Mix-x
‘ 3. lacunae! ignition Lin-ling Mil-x
4. Emiva mrk plug up Adios! flue sly lo mow-0.0mm (0.5~D.7nm)
5 Improper fuel Real“:
Wilt. "Jill. L Muir: tur cl cylinder Ind yinwn Replace the plum:
Inch 2. Overfilled engine oil Adluu the oil level
‘ :. Wrcly high oil pram! Chuck the lumber
‘ 4. Poor unnlily oil Replue Iiih good qullily oil
mun uhnnt Mina lln ammo:

 

 

1. TROUBLE SHOOTING

 

 

 

 

a

 

 

 

3
A
PMII do“ M! L
"turn 2
[let rum ‘ L
gen Inc In! ‘
mm ‘
BIIIM du- I1)" Cub-"tn
Ihll ‘ l.
‘ z
3
L
a
6.

   

 

 

rmu. Probable Gum r knell:
mm: .e.r l, Improper clutch (liar-gamma“ l Minn the dutch
Armin; z Damaged sent or Ionian object lodged in ‘ Replace ilre delectivc pm.
Ihe gear
3 Cur rhill (ml: inmrllitl Repair 0v replace
a. Incorrect «per-lion or rlre gar dim drum Repair ox reybee
uopper Ind elm-g: pedal
5. ”Air-dull Ind mntmh-[Iaulohli‘mnl Repel: or mine
Sr High oil vicinity Chang. (ho oil
Exec-l" ugl- l. axe—ire gut hcklnh Regal! or replace
(III ulna 2. Wotn main and comma-lull bruins Rrvuir ox rrphcu
Gen .le out I. Worn finger: on your shift lurk Replace
2. Wm. .eu do; bale Reglm
l a. Worn epllne l Revues
(II-uh lllpml I. No play in II» clulch lover ‘ Adina: xhu clutch lever

Week at [lane nnilnnn elmlr prawn Reylue [he ml eyeing
pluo min:

 

r Worn ow glued Mellon din: nephee
Exte-ive play ol clukll lever Adjuu clinch lever 91-;
\Vuped hiclion dine r Replace

. Wuped pie-um pine Repllf.‘

. Bun nlin than l chlm
rum,- nlum spring l Repleee

. Unhoolr nlurn wring l Hook mum wring
Examine weu or kiek mner pawl nephee

Click: lully open
Cubumw rir new improperly an
Air lacking inlo Ibo cylinder had
Clogged albufllu arm 5::

Clogged [ml vulvc or piping

Clqged venl hole in the lucl unk up
\lo [lid in lhe l-nk

Clue :hoke

Adiuu uir mew

Rerlgluen urburem «annexing zube
Cluck. dull and "llflhlcfl
Din-tumble And dun

Din-um“: Ind clean

Fill hull with gasoline

 

‘ C
idling l. Clngged or loan: :nrhumwr IlD'Il fie! Chuk. claim and mliflhlen
2. lmpmper flan level Ad'pu
1 lmrreu Air New ndjmlmenl Mine:
‘ { Carburetor link-3v mullundion Adjun
a Air leek. Tiabun Ill .ir pause connection
Improper m- Curl-rem
lulu 0! will. l. I“ nine loo mill Rah“ with lunar nln in
z lmympu our level Mime
a Cloned carburetor main jet Clan and nllghun
L Cub-Ann)! linlnp null-rum Mir.“
5 Air Ink: ‘Tiglllen all air m oonmclion

 

 

 

7. TROUBLE SHOOTING

 

 

CHASSIS
Trouble \ Plot-Ho emu Ito-uh-
any null-x I. Suaing Ilem usua'vvly lizhlenrd Lumen (he [luring nun mu
2‘ Damn! main; um nul nu: ‘ kept-o.
3. Ben! marina [ Replace
J. Law In)!“ [in {an-um l Add lit lo [ht Ipoclfiod DIE-III! ol llkgfm'
(25.5 w’)
Pm! and In: I. Loon uuring Men: munling boll Remmu
when! Iubhlo Z. Warn [tom Ind mu whul baring: Replace having
3 From or my wherl lumul o: dimmed Rzpni: or main.
4‘ Loan wok: Rumque
5. Defeclin Ilu Replue
3m nun-nu} 1. La- »: npving Icmion " new.“
2. Extend" land
Bud I. lneflocllva heal lurk damper l Replil
uunulon 2‘ helaclive m: dlmpor Replica
Bambi: l. Front we on my dun-pet rubbing lmpafl culhion spying and m
loll! 2‘ Interference human cushion cm 1nd Repuir a! replica
wrinl
8. Funky (or! noppu ruhbu Replace
4‘ lmnficiem lmnl (oak oil Add damper oil
Mon!" huh L From hnh lluid
- lnmlfiunt link: III-id Add balm fluid
- All In Ill. balm ny-lem Bleed huh lynun
- Warn lat-Ice pld Regina and
- Worn pilot: Rtpluc gluon
- Worn or dillouod {mm brake din: Replace dis:
- Balm Ierer on! n! Idiulmmt Radian
2. Ron huh
- Warn huh lining Replace
- Worn huh shot or your «mum: Rtpl-ae
- \Vom huh elm Replace
- We! huh (tom wile: w oil Clan
- Worn link: Ill-h Replace
dank. pedal on! at Idiuouncnl ‘ my“.

 

 

 

 

 

 

 

HO

ELECTRICAL

7. TROUBLE SHOOTING

 

I’m-II“ Prob-bk nlm

Engine doe- “I; L Bunny
um ; . Diochnmul
~ Poor comm cl lunar term-ml.
‘ 2 Mgin "(itch
~ Open or Ilwrml dn‘uil. dimwnecwd
‘ commie-u
- Poor comm bclwfln nuin
switch win and win lumen:
a. mum coil
> Improperly msulald high Icnmn ml
.09". or shoned cimuil in ignilian coil
4‘ (Janna lat-wk"
-opm circuil in the primuy mu
\ - Dirly ground point with oil or dual
‘ » Poinl up oul ol dlulmml
. lmplopuly ch-rgcd umdemct
sum-g .uur‘ 1. [klu‘uve bum!
don Io! opal-u 2. Poor rum-u of mwelic II'iKll

I]. lmuw l. Horn
fin. poor unl‘ - Cash-i d'uplungm
or "I. Ink 1 2. Horn human
and } . I'm grounding

‘ a wan...

1 - I'm! mun

l. Adjusting ”flfl
-Out of ldjumnun

’l‘nll Huh! “I I. I'm:

 

had llglt - Blown [use or hum! bull: Elunenx
limpet-live 2 Bulb
- Dulnl bulb filament
& Swilch
- Poor cor-ml ol “gluing IWiKlI
L “living
Sm light 1. Bull:
Ilowullu - Bum or hmken bulb élnnmn
2 Front and Iul flop light switch
- Mllluntlion ol Iwilth
3. Wilinu
- Poor mum: of leads
winter law 1. Bulb
mm, m g... mum unusually (m: impmperly
“ M II»! connected why
2. Wiring
- Blink» loo ll“: bulb wilh umiuhk
uuue

. Blink: Ion 40": burn! or baker: bulb

 

a. Defective why

Bundles

Rxlnrg: or replace
new:

Ramir

Repiir

Replace

‘ Replace

a Poor cont-u of muing nuxor urba- blush

Repair
Clean
Rudjuu
Raglan

Charge or "plane
Repair or replace
Repair or «plug

Replxe
Rmh
Revuiv
Rudjun
Replace
Radius!

Radium

Replace
Radix-M
Radian
Rtplnce
Replu:

Rephc:

Replica

 

 

1‘ TROUBLE SHOOTING

 

 

“I'm-bl. Pub-bl: an. “Ml.
whim 1m. L wanker Imp “with
human" - Poor cor-um ol wink" may Rrplnce
-Open limit in iinler relay (VII Replace
2 Bulb
- Bulb van-xv i5 mullet Ihm mad wings Ron!»-
1 Relay
‘ - P001 comm of winler why Res-lac:
. lupmpuly connected lads Replau

 

 

I. Duh-1 wire or shot-ml. loo” eta-menial Remir a: replace
2. Fully cull due to 9h“! w grounding Replace
3. Fully or thulod Illlcm dlodc Repllce
g 3mm ar shorted Jud wit: u "3mm 1 Repair ar “plan:
5. Rem-Inn voluzc u no load in loo low l Rudjuu
l. \Virlnu ‘
- Broken yin. inmmimm shouting or loose ‘ Rep-if, "lighten
mun-emu
2. Gamma:

l
-snmin. ma» Inn in m: field coil ‘ Replica
(ruin-m indialtd in conllnully nu) ‘

 

 

- Sharing new layer in mm: cuil ‘ Rtphu
. Open drum in am of Ila mm coil l Revlon
-F.-.hy or Ibonad Kilian M \ R291“.
:. Rmhlar
- Volt-st bdaw lpedfied ulue n my land Radius:
. Dim or glued poi-m Polk). or nylon
- Coil ow minor inunully Iharled Rrphce
l. Bum-y
' law dulmlyle level Add distilled water
- Deluliv: huuy phla- Reuben
Elan-In 1. Wirin‘
auxin. P Icnniul dmuil And F terminal cirruix Rep-ix
than“! lmllln: in wlil wound mull"
2. Inlay
lama] nllan Replace
3. Regulator
- Elusive volt-3e II M loud volnm Rmir
4..me grounding vaid: proper amnnd
- Baku nil lull win ‘ Renir. "phat
nun-bu 1 Wiring ‘
chain; ~ By: yriu thofling intermittently undu ‘ Rmb w vaxe
"m“ why-Inn 01 broken wire flaking pmm
com-cl
2. Gum-tor
- layer Ihotl linluminml lhoflllnfl] Repair or mph“
3. Gena-um
- hmnillflll open cimm in Ihv coil Remir or "pl-ca
- humped, myunad voltage Readies:
- Detective h; wilcll Real-cc

 

. mny poinu cum

 

 

ll!

7. TROUBLE SHOOTING

 

Troubl-

Sell dlIeII '0

Battery diachrges in ad‘
dltion to Ilul ecu-ed by
Ila connected land.

C. Lug. lining. nu

Speeiliczuvity gradually
later: And nmnnd LIW
(5.0.). Iho wlnknr and
horn no longer lumnn.

 

The electtolylo
dmpn nyirlly but Ilte
chug. ll eln'nyx unin-
nlnud at 100% nod Il‘.
and on nppem ut‘n-
leelovy. [Spuific gravity

level

over 1m)

 

Swell: mvllr n;
Electrolyte ev-pamnu

Bull-don
The electrode place no
covernd with white lnyu
0: ln Ipol.

Spark plug donni-
eoelod vlth rum
“W“

Burl: pl lemu-

fnled fill: all

 

Burl: plug Ikelroll
overt-tel 0r hunt

 

Dunn

_\ ll. Should

1 Put-u. u.—

1. Diny min-u um: and me. I
2. Communism] elccuolyieorelccimlyte 1
enamel, metal-Ind. ‘

l. Thelnsundihewiyingutmuuwy. l.
but loath such as winter Ind how do
Ml lunetion
In this condition [he mmotcycle will
mum lit“ «in. long m m». $-
nnd a pine: will react will! Ill: lul‘ ‘
(uric ncid Ind [nun Ind :ulfidt db
wilt. (null-lion) linking il impuille : 3.
m recharge. ‘

 

 

2.

n the bottom and vnll can»: lnlflml
ultorlinu m1 damage the Luxury.

1
2. lmufl'io‘enl clinging. ‘ 2.
l 3. “killed Inter nurfillnd.
‘ 4. Conn-minted :kdmlyle. l
l. Chrilflfl In: is too null or rlnel l.
excuively huge.
12. n. wific guvitr 01 me mixture
til the electrolyln i1 improper.

 

a. Bill", kl: in A dichlrg! condition 2,
[or I long period. (leli ‘l'illl Ihe
l'lllch "mud on]. 3.

l L Expand lo neg—iv: vibntion due

l Io iinpxnner insulation.

\ 5 Mmrcyclu mud dining cold “sun

‘ with buttery connected. l

l. Tau rich I [utL

2 Ems-ire idle and.

3. Poor qmllly gasoline.

‘ t. Clogged nix damn

15.11;.on m: plug.

1. Wain pimn .

2 Worn piston llld cylinder.

3. Ewe-tire clam»: between v-lve
guide ml "Ii-e Men.

I. Uni.- ol' liol lpnvk plug. ‘

2. En‘ine overlie-ling.

l3. Improper uni-m liming.

A. loose Ipul: plus or elem-pd spilt
plum hell Ihrud.

5. Too lenn I hid mlxlun.

‘Sp-rl plug minmqm. .

 

 

  
  

I'll-Ili-
Almy: minnin me exterior clan.

Handle the review-shin: clecuolyxe
willi one.

Who me man: gnvily hu- helm!
IJXI (20C: my. the battery should
be recharged immedilwly.

When the hutery (mi-emu 1mm.
dixhargtd while «putting nr normal
speed. (lied: the :rmtalor (0t propel
ourpui.

If [he butler] duh-Ian undu unr-
nul charge ampul. it in an indinlion
of overloading. remove lame ol the
exam lend.

’"Ti‘he dep’un will heavily lungulni: 7, black w annm ptoperchuging nie,

. Check specific gravity muwnnem"

u the .ddnioa ol willed um um.
. drop in was: gnvily. odd mimic
«a Ind mm m m nine.

\vm niointqcle it in Home. Ilia
buttery Ilwnld l:- mhumd one: A
momh mu though (he mnmyclt
is not wed.

Check the electrolyte perindially and
nlnyu Heinlein the proper level.

[n n lightly discharged condition,
perform Itch-ruin; Ind dilehugina
Ievenl linin- lay tuning Ibo engine
my in Infieiem.

Adpn arbuntov. '

up“ idle weed.

Us: good quality gasoline.
Service the air cleaner,

Ute propet but nut: plan

Replace 9 ion ring.
Replue pinion or cylinder.
Replica nlu guide or valve.

UN now but image plug.

Wu lgnilioo lining.
Religluen plug or mall:- cylinder m.

Adinn whomor.
Revlm wilh a new ipult plug.

 

 

(a..................,....4i.t..

{ & PERIODICAL MAINTENANCE

MAINTENANCE SCHEDULE

The following list indicate the items and
time interval of preventive maintenance
by which the best riding conditions are
assured.

The operating procedures [or individual
items are explained in the section of
MAINTENANCE OPERATIONS.

The “months" in the list represents the
Ilpse of months since the purchase of a
new motorcycle Ind the “mileage" is a
reading on the odometer.

After 24 months or 12.000miles (20.0mm),
repeatedly perform all items which are

 

 

described in the column of 6, 12. 18 and

(M months at every 6 month: or 3.000milc5

[5,000km] intervals

The following parts should he severely in-

spected at the time 0! 24 months garage

service

' Front brake hose

‘ Brake cable

‘ Front brake stop switch

‘ Brake master cylinder primary and sec.
ondary caps

‘ Brake disc caliper piston real

‘ Carburetor rubber caps

‘ Fuel lines

 

 

 

 

   

 

   

 

 

 

 

 

 

 

 

 

 

Kw °' "‘"e‘ $3322: Month — e r: 18 at
Mile «on menu .noo 9.000 1100» “3" “mm“
Service required “-\ Km 1.000 5.009 HLDOO 15.500 20.000

Scull-e
ChnngI engine ail c. h'figlgbgflgmtf'lu In
Cluns: oil any element c: E"1g‘,,;,§°ffl,’f“° u
Clean nil mu mm C) 31
Service mitt plus! “ r;- o is. it
5min comm lire-hr point- (z- ll)
Adj-m ignition timing I} .it in
Chad: ign' ‘on winnry and mndnry able! 3 as I
A<ljuat valve tnppet clennncu Q 1:: O ‘i
Adj-m m. cluin O f,- o o 12
Service Iir dun" 5- 0 O to
Adjust arboretum I) O O 5
Check Ihroltk valve operation .: o (:v :3 ID

cm.-
Miuu elutth | it r). O o 0 I 12

Battery
5mm battery | o :3 r n 1:; | 15

Fuel mue-

Clan Intel um “mm in L- O C; 35
Check in; unit and luel mm o o c- C- as

 

 

 

Ill 8 PERIODICAL MAINTENANCE

 

Mun”: m mike. whicnmi
(m6 fill! Lia",

Mile

5mm nnqnigd Km

—- 6
GUI) 3. 00)
LOW 5. 00°

12

6. M
10.0)0

sung. nnd min Supt-aim

us

9.0m]

2‘
l2. am

15.00“ 33. W0

Plg: Reference

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Cbxk .iming hm hatinpl - - :3 TB
Elma}: nearing mun lock 0 C V 75
cinch ham". In: holder 0 .3 0 -
Check from (wk mp phle n, :3 'C —
Chock Ivvnl [wk bollom (an 1; C- “J 4". 71
Change from [on]: on i ». v.7,- n
In: nun-.1.-
Gm: in: lock :17 :3 z.) 88
Cindi mr [ark :3 I] Q .9 53
Chuck um nu-pmnion mounning Min 2"; I“; O 53
Wheels Ind linke-
Clvsk no.“ and nut wheel woken . -. , i:- 66
Chm: from .na mu ~an rims and hub .7; 1:: If; an
Check {mm md m. wneeii. bunny ind uh: ; . i 81
.. (Judi {mm and nut llru :1 u —
' Cited [mu bake caliper .nd pad lining: U \j, c; 14.7:
Check {your brake line: U u
cud him fluid 1ml 0 » . 3 in 3, in
Check “inn-nu but. pal-l o {J ; o o is
75
Check my huh: mm m. o 7 0 —
m... m Flu! Drlv:
regimei 7 7 W}:- ’2 r: or m 7 —
shack uhnuu mum - ’n 1:) ._
finch in]: mud .3 3 _
‘S;;‘vice And Adina Era-II driu chain r; :7 0 .7- o is
Chetk am an». .nd driven spark!“ .3 —
”(his and Accused”

Check lighu and when“ c: Q Q: G —
1 Check ho;n if» 0 O :7; ~
mink Win." and \achomcm i; . . r- r3. _

 

 

4...-.. .

 

 

9 TECHNICAL DAT-AH

     

 

 

 

 

A. Specific-tin!“
Imn English MIIIic
70m." Lang!!! 7 83. o in 2, "15 «III.
‘ Oman wiIIIiI 3min. I 325 IIIIII
2‘ Own” Hniuhl .u om I 1,1[5mm
% Wheel Base 555i" I 7 7 1.406mm 7
E San Heigin 31.7fm minim 7
E F7001 Peg7 Htigh: :2 4m 1315 mm
Ground Clearano: a. 5 iII 1675mm
D" waghI ‘ m 5 lb 13: kg
1 Type I “cum: cudk IIIIIIIIII mi 7 7
F7 53mm. 'r7m7I-I ‘ Tclmpie rm. um: L8in47 7 m min
RI Suapemion. mm a 7 52527.: I7I.-IveI 3. I .II.. 7 73 5mm
r. The Sin. Type 7 3717570115011“: IIII. (it: III pnfsllre7257épci \ l.3kgl:ln'
11. Tire Size. Ty; 7 3 no Is :4 PR) mock Iim Iim IIII oft-sum 2&5“; ‘ Eokycm' 7
g F. Brake. Lining Am D'nc brake. 7 7777 mg m. 32.362n’x2 7 as scm'x2
E 7R7. Bub). Lining AIQ: I IIIIIjIIIuWIIIIIIg um. lining In. as 23mm 2 m Bem‘xi:
Fuel Cup-city I 3 7 us pl. 3,: Imp. an! 7x4 OIiL
Fuel Reeve 9!”:in l6USyI o Olmpgul 420m
CHZATKI; 7 764‘ 7 i 7
Trail In...» a l in. i m5 m7m
l 7?qu PoIII on cm: 17 540.4 I 7 wow
Type 7 7 777 Aitmld. J7nroh. one. engine 7
C;h’nder Amwem Lanna; ianm‘ 7 7
Bon- Ind Sunk; amnmm I saoxso. 5mm
7 370.38cu1n. «as cc

ENGINE

 

 

 

anu Tram

i MaIIImIIuI “output

 

 

Maximum Town:

on Cauchy
Lubiiulian Syslem

 

7 9.70
Four. pium valve. 22mm din,
Clmin drive m'crhsd7umslult7
523 am! (sustain-m rvm
In. 4 mm. 500 rpm 4, 2 kg-mfl. soc IpIII

3.0m.

mus,“ 2 slmp nl

 

Forced Wum Mld ch sump

 

 

I16

0. TECHNICAL DATA

 

1mm

 

\ Ail Puma”

 

v.1“ Tim; czar-7m ‘

 

N
5 Engine weight
2
fl

 

 

TunTmauim ‘

Ptimry Raduglion

 

 

DRIVE TRAIN

 

77ml mama”.
Gen shill Pumn ‘

Ian on
sunning Srllem

[CA].
I
3:
I
5
i
Z

Tall/Mopliuhl
Tm Sign-l um

Speedmutu Light
Tnehomcler “(ht

 

 

Neuml 1ndicuo: Light
Tum Sign-I )ndiulor Liam
Hi5)- Bum India-tor Ligh-

 

 

 

English Manic

Pap" elemenx
‘ooz.Ex:o‘min. v1N:0.S.EX:QDBnn
:52". ask;

 

1:”! mm:
Imam.
wéu. mulli-pl-I:
$1de. 5mm}. :9
210m
2.353
7 1.636 7
7 1.269 7
1.036
0‘ MD
2.000. drive mode: 17. am... Iprockel :41-

Lefx {ml mum type
_ BulaJ‘n; 31mm“ «an
Electrical molar "1:! kid: pedll
Thl‘le plus: A1C 12 V~0.2Kw,|5,:mrpm
12 V-lz AH
NGK 0-755. 021650 x-zzss
law/hi h. 12 V40 WE.) w
1‘. Us»; 12 v- 7 Wm w #
anuRe-r 12 V45 was w
:2 \r. 3 w
)2 V< 3 \V
12 V- 3 \V
12 V- 3 \\'
x2 v. a w

 

 

9. TECHNICAL DATA "7

 

 

 

 

 

 

nun fin.)
8. 3mm Dah nun ‘s'ud-rdul“ “m“
4. ENGINE r J cfl'fi“ 5"“ -— Mb?"
m. m,
um Snndud m... XSetvicubklimix nun Swag I... 5‘15?“
M h?" Xug‘IEZer 35.550.4M5) 1:32:22!“ 3:: $2.23; 329315;)

 

 

Ex!» I
c... fiiglu (135:5-135m) 34450.35“)

Rum! X a . 70.1 (0.004)

 

 

lmn Stand-rd vnlut Suvicublc limil

c lindzr 56.5w:
bgu (2 m2 205) 5" ' (2' 2“”

 

 

1m XSnnd-n'l "In Seniouuelimil

mm 4;. (fingg) 5555(1196)

E m 1508(506)

     

 

hem XSImduvl "In: Sen-Bull: uni.

Pinon x' 44.19-44.35
end ppm X (44.009.41.013) “7‘“ “17)

 

 

PM” ""5“? Sum“! n1... Service-Hahn“

 

 

7“? '5“ me‘hgl'swi ma) "L 1' (‘1 “7’
, 0. 025-0. 06
SIM 0. l5 0. o
""5 X(a 004104.001» ‘ "5’

. . o.Izo~o.oss
o-Inu X(0»00M “1m”: o.15(o.na5)

 
   

 

 

Item Sand-rd value Suvimbla limll

in; mm 15.002.45.003 X Replm il om
lat-m (05W.W)X 15 M (Q 5037’

()qu
21. omyms. baa c kg
X (Loin!
w... mu 54411511341)

relevanee)‘ [mm
X232" 2mm/19 1~21 n;

(a 0m
421.15%“ 51b» [I]

l Ich
E3“ ".1, — as (a on)

on pump Sundud vulue Savicublc “mil

Inner :an cum
mm dunnce — 0. 25 to. 0):)
044m «not 4nd

body datum , 0- as (0.013)

 

 

hem Sand-rd value Suviceablz limil

SSE-fig; - 3.54mi” “(0.11)

 

Standard "he 31"."?-

hymn
Iulch
pxins 31.90.25] M5(L2l‘n
view"

. 31.4-33“ ll 3mm
59"" 221.u~zsa.6
unnuh X u 0. 90 in )

 

 

hem Sundud "III: Servicuue limit

Gur Ihiil X 39. 975-30“ .
drum 0.1) (1. Mas-.1 5m: ”Ml-5"”)

fig: (on: X[4:73:‘| 9-5335?) 40.015 (1.57?!)

 

X Sundnrd v.1... ‘5‘""fl'u'

lulu
II. IMO-J). (15 (I. am
v.1" um <°-°,°°°;S~°-°°‘3?l town
ale-um

 

mono-.mm 1 0.10
(moon-0.0010) . 40.70053)

.lnln

X s. {so-vs. «is
Vllve um (0. 2145-41. 2150)
dictum: Rah-nu

5. W5. “5
((1 21314-4. 2142) .

Vllve [we X __ a. [,5
nmmn (a. m)

 

 

 

“in?“ lSund-rd nlu: Serviczublellmil

 

ma no 5. a)

cm“ X5 (0. '233-0 236) (o. an)
4m 49

“WNW" (0.1M M) X (0.151)

 

 

 

he... 1' Sundnd n1... XScn'iu-hlelimil

pnnmm mm
3‘31!“ (0.0007941 4mm) “WWW"

 

 

 

 

Runoul X — 7X7 0 06 (0.0019;
mm — X o 06 (11.0019)

and taper

 

”B 9. TECHNICAL DATE

 

11m 511111.111 1.11.. 15en'icubklimil

 

 

 

 

 

NM ND 01 2
sun bncfluh 1(0. 001341. MG) {0. 0078)

“1111:1151 0 022-4! 046
15: . .
mxl (0.001171141011511 0.0301003”
elm-1m
mm (in-3
11.111 1511111111 111qu Snvicnhltl-mh
’CEIWJIHT i
. . .1135
mm; (n.m7:o.om) 10.01am
11.1.1 15111111111 11111.1 Suvitenble 11.1111
Com-«ling '
151 old-45034 15107
11111111121111»: (awn-159131 (0.5980)
V 711111 151.111.“: 1.1111: 5"};‘3‘175"
111. 211d. 3111 0 NM 0.2
gun b-dluh (0 00114111151) «um;
4111 1111a 5111

 

 

 

 

5. CHASSIS
Wheel 151111111111 11.111. gamut 1111111
Rim wobble 1 0.503.021» V _2 «(11.03)
'WF' 1’ ' ' _'
1111131 1 0.501.020) am as)

 

 

WM, 11-11111 1 Sun-ind amen».

7 11.111. 111.111
P111111 11111 beui

axial ditflioze Tl
mm W I! I

1.1-1 111mm. W 1 (no-100121 1° 051010112;

 

ml 10.011uazs1 a 110 004)

 

 

Front bake 1 Sand-1d v-lue Servimhlelimil

 

 

 

 

 

 

 

 

 

| Sen
. [fem 7 gnaw ulna| ":1":

Disczrucness 1 — 0.310.111)
c.1111" and 1
pimn dunno: 1 °~ '1 “‘- ”'30
Mum ”11111111
.1111 piston .. 0.1110101)
clan-ace

111111 1111.)
11m .111: 111.11 51.11.11 11.1111 1 1111:1111.
11.111. TIR 0.010) mm 11.2111. m1

 

 

Bmlrglining Sunfiud "In: Scn'icuhlelimil

 

Thickmu 5.010.200) I 20101160)

 

 

Balm Drum Sundanl value Servimblclim-l

. . 1n.s~1ao.o
["111de 11.079.41.137] 131.017.1253

 

 

hem 1 Sundnd vllu Suvimhlth'mil

 

Ax: TIR 0. 07(0. 0023] 0.1“). 0011

 

1511.1 111i_ 1110311011011) 110510.1an

 

 

‘ Sand-Id vAIue Suvicuhltlimix

 

 

FIM‘

aumnu'on IZKIJE]

19111111 1.13.

Fret knell! 1 451.7[l'1‘,73) £25063”)

Tull 1 5 [0. 02] 8(0. 06)
[Ian 1 51.1.1111 "11.1 151.111.1111. 1111111

121..

wmnsion ZID ‘ (8. an) 205 (B 010)
(It:

 

 

 

 

 

 

 

 

 

 

 

'cuapu .
”25“? 1113313233311 3121511501) 1am 151111111111 v.111e15u111mue1111111
11: e 111. 7,-
951111? 0. o.
1‘ [38 5335:1335 1?. )1 m 11,611,500, Chan“: (0.0050312) 0.510.on
cullid: din. Ru: Mk 7’ ,
1111911111 138‘ W115i) 1 21. :10, use)
Flam 1111111: 1 511111.11 vllue 1S:n'kubhlimit Ins-d: u- ‘ . . 7.,
M11. 11. a 11 on 1” 7 3711‘? ““7”” I 21.11am)
cylilndzr (11. 5511-0 5523)‘ “ “55‘“ am) 01m“! 111.. (o “N1 844)
PM," “1’3 5E3: 523:)1 13.94010. 5191 s. ELECTRICAL
hem 511mm 1111111.- ' 3:113:11.
\thl Stand-rd vulu: Sen'kuble 1111111 Cuban brush 1241111111 5.5.11...
R1111 "mo-11 . . 77* 1.115111 [0.174.51111) 10.22111)
TI ' ' ., 7» ¥
, 0.510.112) £010.08) Blush 1 11 11.54.5113 11111;
33ml and‘ 1.11.1011 P" 8 (1.1.4.3151) (0.815s)

 

 

 

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07$?

 

 

 

 

 

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Minx ignition lining ,1]
— vulva "wet cleum . 7

    
   
   
  
   
  
 
  
   
 
   

— an: (Ia-in .
— aubumo: .
Alum-Io: ammo
Air (Inner

Bum-y
Bleeding lat-kc mm
link-

Bnlu ulipu Idfiflmnl
Bnh hum unnl .
Bnh podnl lrIVd.

Can chin Ionian:
Cubamar

Chains um.
Chung. oil and oil film

Cumming nod .
Cantu: bunker .
Ounbhch
Cylinder
— unnmt.
— bow
Cylinder hut!

-D—
Displwmn: ..

Drive :hlln

 

 

Engine luulllllen .
Fagin removal .

  

M.......................~.—.,

11. INDEX i

 

 

_.p__

Final driv:
Final rduclim .
Prom bah .,
From wmon. ‘
From wine! Ind m:
Fuel mm ap-cily
Fuel Mflhlev
Fuel an!

  
     
 

2252:3232

 

 

 

Gar ulia
Gut shill drum ,
Gen Illill drum unwer
Gena-m

 

 

 

Hun.

 

Idlin‘ weed
luliliun liming .
[gallon true-n .
lpliu'au sail
~5—
chl mm: mm .V MS:
_ L—
Luhlcuion mun...
_ M __

Min ignilian witch
Mnimcunw openlion

 

 

 

—N—
Numl winch

 

_ 0—
Oil filler
— demon!
Oil pump
GI 9mm" swimh
Oil wining Imp .

 

   
 
 

 

Piston
Piston pm
Pinon ring
I'n‘mry chain
Primary Ahul'x

_ R _
Rut link ..
Rur ingestion .
Rear lorlt
Ru: wind
unhm
Rolid nlv.
Rocker mn
— ulnh

   
 
  

$913325!

88387453:

 

 

  
 
 
 
     
 
 
 
  
 
  

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Suvin air ale-Mt .
— 5-way

Tuhniul du-
Throul- vulva
Tmbk lhunin.
Tuwlulm.“

_ v _
Valve ..
Vncuum page
Valru liming

_ w _
“linker Iwilab ..
Wiring Jinn-n.