HOIVDA. CB5D.J-XL50 - (c) 4-Stroke.net (c) 4-Stroke.net �HONDA � CB50J/XL50 FOREWORD This shop manual is prepared as a guide to service the HONDA CB50J, XL50. Exploded views are much used in the manual to show the servicing procedures, disassembly, reassembly, repair, adjustment and inspection, making use of the intuitive understanding of illustrations. Information is written as concise as possible only for the important items on service. Illustrations and explanations are closely interrelated so that the reader can grasp the meaning rapidly and clearly. ALL INFORMATION, ILLUSTRATIONS, DIREC­ TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED PRODUCT INFORMATION TIME APPROVAL OF MOTOR CO., LTD. MAKE CHANGES AT AND WITHOUT ON THE LATEST AVAILABLE AT THE FOR PRINTING. HONDA RESERVES THE RIGHT TO ANY TIME WITHOUT NOTICE INCURRING ANY OBLIGATION WHATEVER. (c) 4-Stroke.net NO PART OF THIS PUBLICATION MAY BE RE­ PRODUCED WITHOUT WRITTEN PERMISSION. HONDA� CB50J/XL50 � CONTENTS 11 SPECIFICATIONS .............................................. SERVICE DATA 1. SERVICE PRECAUTION . .... . .......... .. ................... 3. SPECIFIED TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. SERVICE DATA............................................ 4. 27 . · . . MAINTENANCE SCHEDULE .................................. INSPECTION/ADJUSTMENT ............................... ··· ..·· ENGINE 1. ENGINE REMOVAL/INSTALLATION ........................... 3. CYLINDER/PISTON ........ .................... ........... .. 28 41 42 4. LUBRICATION SYSTEM . ........................ ... .. ....... 55 6. A.C. GENERATOR .......................................... 60 8. CARBURETOR .......... ................ ................... 1. FRONT WHEEL/STEERING/FRONT SUSPENSION................ FRAME (c) 4-Stroke.net 2. REAR WHEEL/REAR SUSPENSION ............................ 50 56 62 67 71 84 3. FUEL COCK ............................................... 4. CABLE WIRE HARNESS ···························· 89 1. IGNITION AND CHARGING CIRCUIT.......................... 94 3. IGNITION SYSTEM .................................········ ROUTING ELECTRICAL 2. BATTERY CHARGING SYSTEM .............................. 4. SWITCHES ........................................····· ·· · 2 1B 2. CYLINDER HEAD/VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. TRANSMISSION/CRANKSHAFT/KICK STARTER ................ VI 8 8. . 5. CLUTCH/OIL PUMP/GEAR SHIFT . ............................ V 6 6. WIRING DIAGRAM .......................................... · 7. TROUBLESHOOTING CHART ................................ IV 5 9 10 11 SPECIAL TOOLS............................................ 5. LUBRICATION POINTS ...................... .......... Ill 3 90 95 97 99 �HONDA � CB50J/XL50 I. SPECIFICATIONS CB50J < > Belgian type 4 )> German type [ ) General type XL50 DIMENSION Overall Length 1,795 mm (70.7 in) <1,865 mm (73.4 in)> .[1,725 mm (67.9 in) <1,780 (70.1 in)> Overall Width 665 mm (26.2 in) 710 mm (28.0 in) Overall Height 950 mm (37.4 in) «965 mm (38.0 in) :I> 935 mm (36.8 in) 4950 mm (37.4 in) :I> Wheel Base 1,175 mm (46.3 in) Seat Height 770 mm (30.3 in) Ground Clearance 180 mm Dry Weight 1,115 mm (43.9 in) [1,105 mm (43.5 in)] 710 mm (28.0 in) (7.1 in) 190 mm 80 kg (176.4 Ib) (7.5 in) 73 kg (161.0 lb) [74 kg (163.2 lb)) FRAME Type Diamond frame Front Suspension, Travel Telescopic, Rear Suspension, Travel Swing arm, Front Tire Size 2.50-17 -4PR Rear Tire Size 2.75- 1 7-6 PR Front Brake Mechanical disk Internal expanding shoes Rear Brake Internal expanding shoes Internal expanding shoes Fuel Capacity 8.5 lit. (2.24 U.S. gal, 1.88 Imp. gal) 61it. (1.58 U.S.gal., 1.33 l mp.gal.) Fuel Reserve Capacity 1 lit. Front Fork Oil Capacity 100- 105 cc (3.6-3.7 ozs) 105-110 cc (3.7- 3.8 ozs) Caster Angle 64° 63° Trail Length ENGINE Type 104 mm (4.1 in) Telescopic, 126 mm (5.0 in) in) Swing arm. 95 mm (3.7 in) 74 mm (2.9 2.50-16-4RP [2.75-17-4PR) 2.75- 14- 4PR [3.00-14-4PR) (1.06 U.S.qt, 0.88 lmp.qt) (c) 4-Stroke.net (2.7 in) 69 mm (2.68 in) 68 mm Air cooled 4-stroke OHC engine Cylinder Arrangement Single cylinder 12° inclined from vertical Bore and Stroke 42 x 35.6 mm Displacement 49 cc Compression Ratio 9.5: 1 Carburetor, Venturi Dia. Piston valve type, 12 mm (0.47 in) [18 mm (0.71 in)) Piston valve type 12 mm (0.47 in) [15 mm (0.60)) Lubrication System Forced and wet sump Fuel Required Low lead gasoline with 91 octane number or higher Air Filtration Oiled polyurethane foam (1.654 x 1.402 in) (2.99 cu.in) Valve Tappet Clearance IN, EX, 0.05 mm (0.002 in) Engine Dry Weight 18.5 kg (40.8 lb) Air Screw Opening 1!1, Idle Speed 1,500 rpm Oil Capacity 0.91it (1.90 U.S.qt, 1.581mp.qt) � � � � 18.5 kg (40.8 lb) 1Y. [1%) 3 HONDA� CB50J/XL50 � SP E C I F ICATIONS < > Belgian type < > German type [ I General type CB50J XL50 DRIVE TRAIN Clutch Wet multi plate Transmission 4-speed [5-speed) constant mesh Primary Reduction 4.437 Gear Ratio 3.083 I � 4-speed constant mesh � � � 11 1.882 Ill 1.333 [1.400) 1.333 IV 1.041 [1.130) 1.042 V -- [0.960) -- Final Reduction 3.50, Gear Shift Pattern Left foot operated return system � Ignition Flywheel magneto � Starting System Kick starter 42T/12T 3.071 [3.384), 43T/13T [44T/13T) ELECTRICAL � Alternator Flywheel 0.058 kw [0.046 kw)/5,000 rpm Battery Capacity 6V4AH [6V2AH) Fuse Capacity 15 am [7 am) Spark Plug NGK:CR6HS [C7HS), ND:U20FSR-L [U22FS) � � � � (c) 4-Stroke.net 4 �HON'DA � CB50J/XL50 11. I . S E RVICE PR ECAUTION • Always replace gaskets, 0-rings, cotter pinsand cir clipes whenever reassembled. SERVICE DATA • Wash clean engine parts in/with solvent. lubricate their sliding surfaces whenever disassembled. 0 I • Tighten fasteners, beginning on canter or larger dia. bolts to specs, where sequence is not specified, in an X patter. • Grease by coating or filling where specified as such. X PATTER N • Use HONDA or HONDA-recommended parts and l ubricants. • After reassembling, check every possible part for proper installation, movement or operation. ( • Use special tool where so specified. • Always partner. check mutual ·safty (c) 4-Stroke.net when working with - S YMBOLS - These symbols are used throughout the manual to show specific k i nds of operation, sequence of serv ice procedures, etc. ( 1 ) , (2) . (3) . . . f1tj#il Apply o i l : I ndicates sequence of serv ice operations Apply grease t.Yii;@i�[ri I CAUT ION I NOTE Means the possi bi l ity of personal injury to yourself or others. Means the possi b i l i ty of damage of the mach ine. Prov ides torque values and special i nformation for more efficient and convenient serv icing. 5 HONDA� CB50J/XL50 � 2. S E RVICE OAT A Engine mm (in) Item 42.00-42. 0 1 (1.6535-1.6539) 42. 1 ( 1 .6575) Piston O.D. (STD) 41 .97 - 41 .99 ( 1 .6524- 1 .653 1 ) 41 .80 ( 1 .6457) Piston pin O.D. 1 2.994- 1 3.000 (0. 5 1 1 6-0.51 1 8 ) 1 2.98 (0.51 1 0 ) 1 3.002- 1 3.008 (0.5 1 1 9-0.512 1 ) 1 3.055 (0. 5 1 40 ) Cylinder I.D. Piston pin bore I .D. Piston ring end gap Piston ring thickness Piston ring side clearance Top/second 0. 1 - 0.3 (0.004 - 0.0 1 2 ) 0.5 (0.020) Oil 0. 1 -0 . 35 (0.004 - 0.0 1 4 ) 0.5 (0.0 20) Top/second 1 . 1 80 - 1 . 1 95 (0.0465-0.0470 ) 1. 1 2 (0.044 1 ) Oil 2. 480- 2.495 (0.0976 - 0.0982) 2.42 (0.0953 ) Top/second 0.0 1 5 - 0.045 (0. 0006 - 0.00 1 8) 0. 1 2 (0.0047) Oil 0.0 1 5 - 0.045 (0.0006 -0.00 1 8) 0. 1 2 (0.0047) IN 5.450 - 5.465 (0.2 1 45-0.21 52) 5.42 (0.2 1 34) EX 5.430 - 5.445 (0.2 1 38 -0.2 1 44 ) 5.40 (0. 2 1 26 ) Valve stem 0. D. INX 5.4 75-5.485 (0. 2 1 55- 0.2 1 59 ) 5.50 (0.2 1 65 ) EX 5.475 - 5.485 (0.2 1 55 - 0.2 1 59 ) 5.50 (0. 2 1 65) IN 0.010- 0.035 (0.0004-0.00 1 3 ) 0.08 (0.003 1 ) EX 0.030 - 0.055 (0.00 1 2 - 0.0022) 0.1 (0.004) Valve guide I.D. Valve·to·valve guide clearance Free length Valve spring OUTER 34.8 ( 1 .370 1 ) 33.7 ( 1 .3268) INNER 28.08 ( 1 . 1 044) 27.6 ( 1 .0866 ) Preload/length OUTER 1 3.8/29.65 (30.43/1 . 1 674) kg/mm (lbs/in) INNER 5.25/25.65 ( 1 1 .58/ 1 . 0098) (0.071 ) 1 .5 (0.06 ) (0. 1 1 02-0.1 1 42 ) 2.8 (0. 1 024 ) 1 . 1 -1.5 (0.044 Valve seat width IN· EX 1 .0 2.8 - 2.9 Cam heiqht - 0.060) (c) 4-Stroke.net 27. 697 ( 1 .0904) 26.6 ( 1 .047) 27.005 ( 1 .0632 ) 25.9 ( 1 .020) Belgian, German and Austrian type 27.560 ( 1 .0850 ) 26.5 ( 1 . 043) General type 27.005 ( 1 .0632) 25.9 ( 1 .020) 28.4 (1 . 1 181 ) 26.3 Belgian, German and Austrian type r--· General type EX -- (0.004) IN· EX IN -- 1 .8 Valve face width Clutch friction disc thickness - ·· ·--- · Clutch spring Free length Preload/length 1 5 - 1 7 .5 / 1 8 (33.08- 38.59/0.709 ) 0- 0.0 1 5 Crankshaft runout (0 - 0.0006) ( 1 .0354) -- 0. 1 (0.004) (0.5 1 24 - 0.51 3 1 ) 1 3.08 0. 1 0 - 0.35 (0.004 -0.0 1 4 ) 0.6 (0.024) Connecting rod big end radial clearance 0 - 0. 0 1 2 (0 - 0.00048) 0.05 (0.0020) Rocker arm shaft O.D. 9.978 - 9.987 (0.3927 - 0.3932) 9. 1 7 (0.36 1 0 ) 1 0.000 - 1 0. 0 1 5 (0.3937 - 0.3943) 1 3. 0 1 6- 1 3.034 Connecting rod small end I.D. Connecting rod big end side clearance Rocker arm I.D. Oil pump Inner-to-outer rotor clearance Outer rotor-to-body clearance Rotor-to-cover clearance 6 Service limit Standard 10.1 (0. 5 1 50) (0.3976 ) 0. 1 5 (0.006 ) 0.2 (0.008) 0.02-0.07 (0.0008 - 0.0028) 0. 1 2 (0.0048) 0.2 (0.008) 0. 1 - 0. 1 5 (0.004 - 0.006 ) �HONDA � CB50J /XL50 SERV I C E DATA mm ( i n ) Service l i m i t Standard Item Gearshift fork I. D. Gearshift fork guide shaft O.D. Gearshift fork end thickness 1 2.000- 1 2. 0 1 8 (0.4724 - 0.473 1 ) 1 2. 05 (0.4744) 1 1 .976 - 1 1 .994 (0.4 7 1 5 - 0.4722) 1 1 .96 (0.4709 ) (0. 1 94 1 - 0. 1 969) 4.70 (0. 1 850) 4.93 - 5. 00 mm ( i n ) Frame Standard I tem 0- 0.05 Front/rear axle shaft bend 1 1 0. 0 Front/rear brake drum I . D. Thickness Brake disc Wheel rim Rear shock absorber spring free l ength Front fork piston O.D. Front fork bottom case I . D. 0.2 (0.008) 1 1 1 .0 (4.37) (0. 1 93 - 0.20 1 ) 4 (0. 1 6 ) (0.008) (4.33 ) F latness 0 - 0.05 (0 - 0.002 ) 0.2 Face runout 0 - 0.5 (0 - 0.02) 2.0 (0.08) Eccentricity 0 - 0.5 (0 - 0.02) 2.0 (0.08) 4.0 (0. 1 6 ) 2.0 (0.08) Brake l i n i ng thickness Front fork spring free length 4.9- 5 . 1 (0 - 0.0020) Service l i m i t CB50J 396.6 ( 1 5.6 1 ) 370 ( 1 4.57) X L50 397.7 ( 1 5.66) 372 ( 1 4.65) CB50J 2 1 8.8 (8.6 1 4) 207 (8. 1 50 ) X L50 226 (8.898) 215 (8.465) 30.50 - 30.80 ( 1 . 20 1 - 1 . 2 1 3 ) 30 (1 . 181 ) 30.936 - 30.975 ( 1 .2 1 8 - 1 . 2 1 9) 3 1 .0 ( 1 .220) (c) 4-Stroke.net 7 HONDA � CB50J/XL50 � 3. SPEC I FI ED TO RQU E Engine O'ty Tightening point Thread dia. mm Torque kg-m ( l bs·ft) Camshaft hol der nut 4 6 0.9 - 1 . 2 (6.5 - 8.6) Flywheel nut 1 12 3.0 - 3.8 (21 .6 - 27.4) Drive gear nut .1 14 3.5 - 4 . 5 (25.2 - 32.4) Camshaft sprocket bolt 1 6 1 . 0- 1 .4 ( 7.2 - 1 0. 1 ) Cyl i nder head bolt 1 6 0.9 - 1 . 2 (6.5 - 8.6) Frame Tighte n i ng poi nt O'ty Thread dia. mm Torque kg-m ( l bs-ft) Steer i ng Stem top thread nut 1 22 6.0 - 7.0 (43.4 - 50.6) Handle upper holder bolt 4 6 0.8 - 1 . 2 ( 5.8 - 8.6 ) Handle Lower holder n ut 2 10 3.0 - 4. 0 (21 .6 - 29.0) F ront fork bolt 2 10 3.0 - 4.0 (21 .6 - 29.0) Bottom bridge bolt 2 8 1 .8 - 2. 5 ( 1 3. 0 - 1 8. 1 ) Front a x l e nut 1 12 3. 5 - 5.0 (25.2 - 36.2) Front brake disc nut ( C B 50J) 4 6 1 .0 - 1 . 8 ( 7. 2 - 1 3.0) Cal i per cover bolt (CB50J) 3 6 0.8 - 1 .4 ( 5.8 - 1 0. 1 ) Cal i per p i n nut (CB50J) 1 8 1 . 5 - 2. 5 ( 1 0. 8 - 1 8. 1 ) Cal i per joint bolt (CB50J) 2 6 0.8 - 1 .4 ( 5.8 - 1 0 . 1 ) Rear axle nut 1 12 3.5 - 5.0 (25.2 - 36.2) Rear fork bolt 1 10 3.0 - 4.0 (21 .6 - 29.0) (21 .6 - 29.0) Rear shock absorber nut 4 10 3.0 - 4.0 Rear brake stop arm nut 2 8 1 .8 - 2. 5 ( 1 3.0 - 1 8. 1 ) 4 8 2.0 - 2. 5 ( 1 4.4 - 1 8. 1 ) 6 8 2.0 - 3.0 ( 1 4.4 - 21 .6) Foot rest bolt Engine hanger bolt (c) 4-Stroke.net Torque specifications I isted above are i mportant tighte n i ng points. Other shou l d be torqued to standard torque below. Standard Torque Specifications Type 8 Torque kg-m ( l bs·ft) Type Torque kg-m ( l bs·ft) 5mm bolt and nut 0.45 - 0.60 (3.3- 4 . 3 ) 5 mm screw 0.35 - 0. 50 (2.5 - 3.6) 6 mm bol t and nut 0.8 - 1 .2 ( 5.8 - 8. 7 ) 6 mm screw 0. 7 - 1 . 1 ( 5. 1 - 8.0) 8 mm bolt and nut 1 .8 - 2. 5 ( 1 3.0 - 1 8. 1 ) 6 mm flange bol t and nut 1 .0 - 1 .4 ( 7.2 - 1 0. 1 ) 1 0 mm bol t and nut 3.0 - 4.0 (21 . 7 - 29.0) 8 mm flange bolt and nut 2.4 - 3.0 ( 1 7.4 - 2 1 . 7 ) 1 2 mm bolt a n d nut 5.0 - 6.0 (36.2 - 43.4 ) 1 0 mm flange bolt and nut 3.0 - 4.0 ( 2 1 .7 - 29.0) �HON'DA � CB50J/XL50 Description 4. SPEC IAL TOOLS Tool No. Ref. page Tool set case 07797·2920300 36 mm pin spanner 07902·001 0000 77 Tappet adjusting wrench 07908·00 1 0000 30 Clutch holder 07923- 1 070001 57 Flywheel holder 07925-001 0001 61 Flywheel pu l l er 07933-00 1 0000 61 Valve guide remover 07942-3290 1 000 45 Valve guide driver 07942-32902000 45 Ball race driver 0 7944- 1 1 5000 1 78 Bearing driver 07946-3640000 73, 74,85 Oil seal driver 07947- 1 1 80001 80 Driver handle 07949-6 1 1 0000 73, 74,85 Valve spring compressor 07957-329000 1 44 Valve gu ide reamer 07984-0980000 45 Tool No. Ref. page. Front fork disassem bl i ng tool 07959-2680000 79 Rear shock absorber compressor 07959-3290000 86 Spring attachment holder 07967- 1 1 50000 86 - Optional special tools Description (c) 4-Stroke.net 9 HONDA� CB50J/XL50 � 5. L U B R ICATION POINTS ATF 11!!!1! ..__ F RONT FORK 1#tt1ii (CB50J) A�#ii ST E E L B A L LS CON E R ACES BALL R ACES CAL I P E R P I N SIL ICON GREASE (CB50J) B R AKE PADS A/B (CB50J) B A L L B E A R I NG M A I N STA N D (CB50J) SP E E DO M E T E R G E A R B R AKE P E DA L D R I V E CH A I N (c) 4-Stroke.net ( X L50) S I D E STA N D B R AKE CAM ( X L50) 10 � < 0::: (.!) < 0069-ZS 1-Z 0£00 I 000-ZS 1-£0£00 Cl (.!) z 0::: •!� Wl ....., ... 14·, .... MO �I �Cl �� w >� _J < 0:: w z w <.!) 0 1.0 _J X ~ 2� 0� tau 81 11 !) O•Dp I"'" OlUOJf .. _..., ' OVOHO.J ... _.., ,..., 11 ..• -· HYlA9 ur;u>ou'''"'l' •p "snd 33M-=' or--f-0 , or--f-0 , . ., '" (N) 0f-0 • '" , ," ,. HrllRJ'llirft'biiY loQltaS llfiiiiiiO NlfOM 1'ftrii)IS W\1. , .. op•••nb•• � , .•_� _- ��-.�· � . -0] ·e,uo•q"'"I'•P ·"jUO 'Ouo)oq ·ero.,A •p •••old"•••l"l .•.•.. N • •"""'C!""" 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E N GI N E WI L L N OT START (OR HAR D STARTI N G) r---- COMP LAINT l , - --j L Gasoline reaches Gasoline does not carburetor reach carburetor CHECK O R ADJUSTMENT Chec k if gasol i ne reaches -- carburetor ________ _ L Spark occurs Remove spark plug and try spark test - _____ _ _ __ I - -- --- - -- -1 Test cyl i nder compression L _____ ____ normal and carburetor I (3 ) Clogged fuel cock (4 ) Clogged fuel tank cap breather hole , 1 __j No spark occurs Weak spark , Compression ( 1 ) Lack of fuel i n fuel tank (2) Cl ogged fuel l i ne between fuel tank , ---- ---- ---i POSS I B LE CAUSE --, I _j f ( 1 ) Defective spark plug (2) Fouled spark plug (3) Fou l ed, burnet or pitted contact breaker points (4 ) I m proper breaker poi nt gap (5) Defective condenser (6) Broken or shorted h igh tension cord (7 ) Open or shorted ignition coil (8) Defective igni tion switch , (9) I mproper ignition tim i ng I _j ( 1 ) Engine not cranked (2) No valve tappet clearance (3) Valve stuck open Compression l eak or no compression (4 ) Worn c y l i nder and piston ri ngs (5) B l own cyl i nder head gasket (6) , --- --- --- , Flaw i n c y l i nder head (7) I mproper valve t i m i ng (c) 4-Stroke.net - -----1 Start engine L _________ I Engine m isses Engine fi res but �-------1 (3) Air l ea k i ng through i n tak manifold does not start wet I - (4) I mproper ignition t i m i ng --- � Remove spark plug L - -, I _______ _ _ _j l l ( 1 ) F l ooded carburetor 1---------- -------tl--(2) Choke valve c l osed excessively Spark plug wet '-------' , --i --- - - --- Start engine with choke valve closed L 18 _j ( 1 ) Choke valve excessively open (2) Carburetor air screw opened excessively , --- Spark plug not I ______ _ _ _ ---, 1 _j (3) Throttle valve opened excessively �HONDA � CB50J/XL50 B. TROUBLESHOOTI NG CHART ENGI N E LACKS POWER C H E CK O R ADJUSTM E N T COMPLA I NT I Wheel s spin freely ��- -l - Raise wheels off ground a nd � pin by hand - Wheel s spin s l uggishly r---l I �.--------- -l - ----- - - POSS I B L E CAUSE j _j ( 1 ) Brake d ragging (2) Defective wheel bearing - --- - --- I Check tire pressure ---l L - _____ _ (3) Drive chai n too tight (4) Over torqued axle nut --, I _j Proper t i re pres- I m proper tire ( 1 ) Tire pu nctured sure pressure (2) Defective tire valve / I I - -I -_ J 1 - Not accelerated speed raised) / , Engine speed increased -----� � Ignition ti m i ng T _ _ _ __ - -- ---- - Rev up gradual ly (2) Worn clutch faci ngs (3) Clutch faci ngs uneven ( 1 ) Carbu retor choked (2) Air cleaner cl ogged (3) Clogged fuel l i ne lch"ec �1gn1t1on -:-_--:t1mmg 'l_( by t i m i ng l ight� - _ - (4 ) Cl ogged breather hole in fuel tan k -- I ____ 1 _j I m proper i gnition r- , -- - -- -l I m proper tappet correct clearance / r L l Tappet clearance I I _j ( 1 ) Clutch s l i pping (5) Clogged muffler (c) 4-Stroke.net � I r L -� L ______ ___ t i m i ng correct --i --- - - - - - _j Engine speed not i ncreased ( Test ride on paved road) I , l �cceleration - from low to second (with engine Accelerated I Try rapi - ____ I -- - - - ---- , Check tappet clearance _________ I _j : - - ------��Test cyl i nder compression Compression Loss of compres- normal si on - _j ---- -- -- (with compression gauge) L ( 1 ) I gn ition t i m i ng i mproper ( 1 ) I m proper tapped clearance (2) Worn valve seat (valve not seating on valve seat) ( 1 ) Valve stuck open (2) Worn cyl i nder and piston ri ngs (3) B lown cyl i nder head gasket (4) I m proper valve timing 19 TROUBLESHOOTI N G C HART Carburetor not r -- r Plug normal Engine oil level Check carburetor for L I clogging _________ I _j -- -- ( 1 ) Carburetor fou led , --- --- 1 Remove spark plug - L I -, -- _______ __ I _j (1 l Plug fou l ed (2) I m proper heat-range Plug fou led or discol ored r proper Lubricated pro- �------------, -- - -1 - Carburetor clogged clogged r- -- , ---1 L I -------- , - Check engine oil l evel -- -- - - _ - - I _j - - -- r - Not overheated r (2) L (3) ( 1 ) Level too h igh I mproper level or fou l ed o i l , -- --- ---- --, � Level too low O i l excessively fou led I L --- ----- - _j I Remove o i l check bolt and check for l u brication ( 1 ) Clogged oil passage (2) Poor del ivery of o i l pump Poorly l u bricated perly HONDA� CB50J/XL50 � (c) 4-Stroke.net - --- I �--- -i L - -- --- Check if engine overheats ____ ___ _ _ -, I _j ( 1 ) E xcessive carbon i n combustion chamber (2) Wrong or bad fuel Overheated (3 ) Clutch sl i pp i ng Engi ne does not knock r -- - I �------- --, Try rapid accel eration or run - -1 at high speed L Engine knocks __ _ _ _ ____ (4 ) M i xture too l ean I _j ( 1 ) Worn piston and cyl i nder (2) M i x tu re too l ean (3) Wrong or bad fuel (4 ) Excessive carbon i n combustion chamber 20 l (5) I gnition t i m i ng too early �HONDA � CB50J/XL50 TROU B L ESHOOT I N G C HART C. ROUGH I DL E OR POOR LOW'SP E E D PERFORMANCE COMP LA I NT 9 .----- ---'r _,1 __ ___ ___ _[ L C H E C K O R ADJUST M E N T C e ignition m i ng and - hd ti � �e�learance valve a _ _ _ i POSS I B LE CAUSE _j ( 1 ) Engine out of time Wrong Good L._ ./-1c. - ---- __ Adjusted properly (2) ,- - - - -l L - -- - - -- Check carburetor air screw __ _ _ __ __ _ ---, I _j I ( 1 ) M ixture too lean (To adjust, turn Mu l-adjustment (2) ,- -- -- -I L I Air l ea k i ng - I mproper tappet cl earance _ -Check -- -for air leak past �sket carbu retor - _ __ in air screw as needed) M i xture too rich ( to adjust, turn out a i r screw) -, _j ( 1 ) Defective carbu retor packing (2) Air not l ea k i ng Carburetor not tightened securely (3) Defective i ntake p i pe gasket (4 ) Deteri orated carbu retor 0-ring ,--------, Remove spark plug and try -l I spark test (c) 4-Stroke.net - --- I Good spark occurs Weak or inter­ mittent spark L __ _______ _j ,( 1 ) Defective or fouled plug r-(2) Fou led, roughened or pitted breaker point su rface (3) Condenser shorted (4 ) Defective flywheel magneto 21 TROU B LESHOOTI N G CHART HONDA� CB50J/Xl50 � D. ENGI N E LACKS H I GH SP E E D PERFOR MANCE CH ECK OR ADJUSTM ENT COM P LA I NT I � _ __ I r - -- --- l - r --- I Not cloggf:d I I I I - , L and check tor cl ogging ___ I _j 1 (2) l (3) ( 1 ) No fuel in tank - - -fuel ------i, Check fil ter, fuel cock and L carburetor jet for clogging __ - Fuel tube cl ogged Fuel tank cap breather hole cl ogged ,1 _j r (2) l (3) ( 1 ) Cl ogged jet - �----- ---iL - - Replace carburetor m a i n jet I --- -, _________ Cl ogged fuel filter Clogged fuel cock I _j r (2) ( 1 ) Size too small If i m proved with smaller size jet; (c) 4-Stroke.net r -- - l - , ---- - -I - Check valve t i m ing L --- , _j ( 1 ) I m proper valve t i m ing r , - ------ ---- I ---1 Wear or broken 1 a) Air cleaner cl ogged b) Choke plate not opened fu l l y I _____ ___ _ Wrong Correct I _j Condition i mproved Correct I _ __ Clogged Condition aggravated -� ---------1�-Disconnect fuel tube at carbu retor out I valve ( 1 ) Engine out of time out I �ppet�earance - (2) I m proper tappet clearance No fuel flowing I t IChoo�igoitioo tim iog ood Wrong Fuel flowi ng I 22 _ I Correct I _ POSS I B L E CAUSE - Check valve spring tension L -, __ _ ______ I j ( 1 ) Defective valve spr i ng �HONDA � CB50J/XL50 TROUB LESHOOTI N G C HART E. SMOKY EXH AUST r---- COMP LA I NT I I Th i n exhaust Make long runs at h igh speed L _ _ _ _ _ _ ___ , -- -----1 -- I I L I I _j - ------ -, emitted (2) O i l l evel too h igh (3) Piston ri ngs i nstal led u pside down (4) Defective piston or cyl i nder (5) F l aws in cyl i nder head i m mediately after ( 1 ) Worn i n let valve gu ide or valve stem retu rning throttle (2) Valve guide 0-ri ng deteriorator - - - - -[ -- I I _j _________ gri p I I Retu rn throttle gri p quickly 1 ( 1 ) Worn cyl i nder and piston ri ngs White smoke emitted No wh ite smoke Moko long I No colored exhaust l -� Black smoke I POSS I B LE CAUSE CHECK OR ADJUSTMENT ---------, � - '""' 01 l ow •peod J White smoke ( 1 ) Worn i n l et valve guide or valve stem (2) Exhaust valve guide not seated properly (3) Worn exhaust valve stem seal A (c) 4-Stroke.net F. DEFECTIVE CLUTCH COMP LAI NT r----------, �-----------i Adjust clutch properly L _________ I Clutch s l i pping 1 _j r (1 ) +L 1------------------- (2) �-------4 �------1 Motorcycle tends to creep with clutch off POSSI B LE CAUSE CH ECK O R ADJUST M E N T - , _ ---1 - ------, -- Weak clutch spring Worn or distorted clutch plate (3) Worn or distorted friction disc 1 i n 1 st gear L -- --- -- - - J With clutch off,rev up engine ( 1 ) Distorted clutch plate or friction disc (2) Uneven clutch spri ng tension 23 TROUBLESHOOTING CHART HONDA� CB50J/XL50 � G. I M PR OPE R SH I FT I NG P RO B A B L E CAUSE COMP L A I N T �- -- - - -- ( Cl u tch is normal ) I - - Hard shifting - - I Pedal not returned to neutral ( 1 ) Broken gearshift arm spring (2) Broken shift fork (3) Sluggish movement of shift drum and fork (4 ) B roken protrusion of shifting gear ( 5) Sh i ft arm pawl out of place from sh ift drum ( 1 ) Broken sh i ft return spring (2) Shift shaft i n terferring with case or cover I I (2) L (3) ( 1 ) Worn shifting gear Bent or worn sh ift fork Broken or weakened shift drum stopper spring Gears jumping out of position during operation H . ENGI N E NOISE COMP L A I N T POSS I B LE CAUSE I ( 1 ) Excessive valve tappet clearance Tappet noise I Piston slap (2) Worn tappet (c) 4-Stroke.net r L ( 1 ) Worn piston and cyl i nder (2) Excessive carbon in combustion chamber (3) Worn piston pin and connecti ng rod small end I r (2) ( 1 ) Worn camshaft bearing L (3) Cam chain noise I ( 1 ) Excessive backlash between clutch plate a n d clutch outer (2) Worn clutch center spl i ne Clutch noise I Drive and driven gear noise 24 Worn camshaft sprocket teeth Excessively elongated cam cha i n I ( 1 ) Worn or deteriorated driven gear damper (2) Worn gear teeth �HONDA � CB50J/XL50 I. TROUB LESHOOT I NG CHART MOTO RCYC L E PU L L E D TO ON ' E S I D E COMP LAI NT POSS I B LE CAUSE oE-- - ( F ront and rear tire pressures are norma l ) I r (2) L (3 ) ( 1 ) Steering head top thread excessively tightened Hard steering i n both di rections I (1 ) Bent steering stem Excessive play in wheel bearing (2) D istorted wheel rim (3) Loose spokes Wheel wobbl i ng (4 ) Twisted frame (5) Drive chai n adjuster not adjusted equ a l l y I � Motorcycle tends to be pu l l ed only to one side J. B roken steering steel bal l s ( 1 ) Unbalanced front a nd rear shock a bsorbers (2) F ront a nd rear wheels out of l i ne (3) Bent front fork (4) Bent rear fork DEFECTIVE FRONT AND R EA R SHOCK ABSO R B E R COMP LA I NT POSS I B L E CAUSE �--- ( F ront a nd rear tires properly inflated) 1 (c) 4-Stroke.net ( 1 ) Weakened spring (2) Excessive l oad r-(3) Lack of front fork oil Soft ride - I l (2) L (3) ( 1 ) Excess of front fork oil Defective front fork Hard ride I I Noise i n shock absorber (4) O i l l eak I Defective rear shock absorber [ 1 ) Absorber case interfering (2) Absorber case i nterfering with spring (3) Defective stopper rubber (4) Lack of oil in shock absorber 25 TROUBLESHOOTING CHART HONDA� CB50J/XL50 � K. DEFECTIVE BRAKE c 0M PL A INT POSS IBLE CAUSE ...:--------------- (Brakes are properly adjusted) Adjuster no longer effective (1) r (2) L (3 ) (1) Worn cam of brake shoes Worn brake cam Worn brake lining (2) Foreign particles on brake lining or pad Squeaking (3 ) Roughened brake drum shoe contacting face L (4) In effective brake Worn brake lining -i (1) or brake disc pad contacting face Worn brake panel bushing Front brake wire out of order (2) Brake shoe partially contacted (3 ) Mud or water in brake (4) Oil or grease getting on brake lining or pad (5) (6) Worn brake lining or pad Defective brake arm L. PR E MATUR E E LON GATION OF DRIVE CHAIN COMPLA INT �• 26 POSS IBLE C AUSE (c) 4-Stroke.net t ( 1 ) Improper adjustment motm• olon9'tion t----------+-- (2) Lack of lubricant (3 ) Worn sprocket used �HONDA � CB50J/XL50 8 . MAI NT E NANC E SC H E D U L E This mai ntenance schedule is based u pon average ridi ng condi tions. Mach i nes su bjected to severe use or ridden in u nusually dusty areas, requ ire m ore frequent serv i c i ng. Month M ile Km I N I T I AL R E GULA R S E R V I C E P E R I OD SERVICE P E R I OD Perform at every i nd icated month or m ileage i nterval whichever occurs first. 1 3 6 12 500 500 1 , 500 3,000 6,000 1 ,000 1 ,000 2,500 5,000 1 0,000 - ENG I N E O I L R O I L F I LT E R SC R E EN c R SPA RK P LUG c I CONTACT PO INTS I I GN IT I ON T I M IN G I I VALVE TAPPET CLE A R ANCE I I CAM C H A I N T EN S I ON E R I I (Service more frequently if operated in dusty areas) A I R F I LT E R ELE M ENT c CA R BU R ETO R I I TH R OTTLE OP E R AT I ON I I c FU EL F ILT E R SC R E EN I FUEL L I N E S I I CLUTCH **I &L D R I V E CHAIN I & L B R AKE S H O E S/PADS I B R AK E CON T R OL L I NKAG E I I (c) 4-Stroke.net WH E EL R I MS & SPOKES I T I R ES I I *** R F R ONT F O RK O I L F RONT & R EA R SUSP ENS I ON I ST E E R IN G H EAD B E A R I N G S I BATT E R Y I L I G H T I N G EQU IPM ENT I I ALL NUTS & BO LTS I I Clean L Lubricate ** R I I I I nspect, clean, adjust or replace if necessary Repl ace R C *** I I nitial service pen od : I n itial service period : 300 km ( 200 m iles) 500 km (300 m i les) 27 Ill. INSPECTION/ A D� USTM ENT HONDA� CB50J/XL50 � • Ignition Timing Static test (with a use of test lamp) ( 1 ) Remove the left cran kcase cover. (2) Rotate the flywheel in the counterclockwise di rec­ tion and a l i gn the " F " mark to the index mark. I f t h e lamp becomes dim when these marks come i nto perfect al ignment, no adjustment is necessary. I f the moment of point open ing is i ncorrect, proceed to Steps (3) thru ( 5) . (3) With the " F" mark al igned with the index mark, loosen the base plate l ocking screw about 1 /8 turn and carefu l l y rotate the base pl ate until the test lamp becomes dim. Retighten the base plate locking screw. TEST LAMP NOTE 6V 5W Do not l oosen the base pl ate locking screw more • than necessary. • Do not touch on the breaker points with the end of BASE PLATE LOC K I N G SC R EW ' the screwdriver. I - 1 34595 Hold the base plate w h i le the lock i ng screw is being tightened. I - 1 49754 (4) Rotate the flywheel one ful l turn in the cou nter­ clockwise d i rection and align the " F" mark to the i ndex mark. The lamp shou l d become dim when both marks al ign. ( 5) Check the max i mu m point gap with a feeler gauge. Replace the contact breaker i f i t is out of specifi­ cations : (c) 4-Stroke.net LOC K I NG SC R E W 28 �HONDA � CB50J/Xl50 • • I NSPECTION / AD� USTME NT Ignition Timing Dynamic test (with a use of stroboscopic l ight) Run the engine at the idle speed. The " F " mark shou l d be al igned with the index mark. IDLE SP E ED : 1 , 500 rpm Run the engine at speeds : General type . . . . . . . . . above 3250 rpm Belgian, German and Austrian . . 7350 rpm The index mark shou l d be wi th i n the advance marks ( 11 ) . . H E X. B A R (c) 4-Stroke.net I · 1 4975 3 29 I NSPECTION / AD'-' USTMENT HONDA � CB50J/XL50 � • Valve Tappet Clearance The valve tappet clearance should be checked when the engine is cold. Remove the cylinder head cover. Remove the left crankcase cover. Rotate the flywheel in the counterclockwise · direc­ (3) tion and al ign the "T" mark to the i ndex mark on the compression stroke. (1) (2) NOTE The valve tappet adjustment should be made with the piston at T. D.C. (top-dead-center) on the compres­ sion stroke. I n this position, the inlet and exhaust valves are fully closed. ADJUSTING SCR EW LOCK NUT Check the clearance of both valves by i nserting a feeler gauge. If clearance is correct there wil l be slight drag or resistance as the gauge is inserted. Proceed to Steps (5) thru (6) if i ncorrect. (4) VALVE TAPPET CLEARANCE ( I N/EX ) : 0.05 ± 0.02 m m (0.002 ± 0.0008 in) (c) 4-Stroke.net TAPPET ADJUST I NG W R E NCH No. 07908-00 1 0000 Loosen the l ock nut and turn the adjusting screw until there is sl ight drag on the feeler gauge. (6) Hold the tappet adjusting screw in that position and tighten the l ock nut. (5) NOTE Be sure to hold the tappet adjusting screw when tightening the l ock nut. (7) 30 Recheck the clearance with the feeler gauge after l ocking the nut. LOCK NUT ADJUST I N G SCR EW �HONDA � CB50J/XL50 I NSPECTION / ADJ USTME NT • Carburetor Adjustment I D L E SPE E D Before making adjustments to the carburetor, warm up the engi ne for about 5 m inutes. With the air screw at specified opening, turn out the stop screw to obtai n the lowest steady engine rpm ( below specified idle speed). (2) Turn the air screw to find the highest engine rpm . (1 ) I CAUT I O N I Do not turn the air screw i n excess of the standard opening below. ±% turn for (3) Adjust the stop screw to set the engine at the proper idle speed. (4) After the idle speed has been adjusted, check the 1 , 500 rpm response to the accelerator. I D LE SPE E D : AI R SCR EW OPE N I N G : CB50J . . . . . . . . . . . . . . . . . . . . . . X L50 General type . . . . . . . . . . . . . Belgian, German and Austrian type . . . 1 500 rpm . . . . . . . . . 1 - 1 /2 1 - 1 /4 1 - 1 /2 turn turn turn • Throttle Cable (c) 4-Stroke.net G R IP F R E EPLAY mm (0.04 - 0.24 i n ) 2-6 I NC R EASE PLAY Major adjustment is made with the lower adjuster (carburetor top). LOCK NUT I - 1 49543 Minor adjustment is made with the u pper adjuster. NOTE • • Make sure the rubber cap is tightened securely. When adjusting at carburetor top, loosen the u pper adjuster enough to facilitate the final adjustment (at the grip ) . Replace the throttle cable if both adjustments are no longer effective. 31 I NSPECTION / AD� USTMENT HON'DA� CB50J/XL50 � • Cam Chain Adjustment LOOSE N STANDA R D T I G HTEN PUNCH M A R K . LOCK BOLT LOCK BOLT I - 1 34596 TENSION E R LOCK NUT (1 ) (2) 1 - 1 49577 (3 ) • Oil Filter Screen Cleaning (1) (2) Adjustment should be made with the engine running at idle speed. If the chain is noisy, observe the fol lowing: Loosen the lock bolt at the cyl inder head and turn the adjusting bolt until noise is ceased. If the chain is still noisy, stop the engine, loosen the lock bolt and set the adjusting bolt at STAN DARD position. With the lock nut loosened, then loosen the adjusting bolt once and retighten. The chain will be adjusted automatically by means of the tensioner spring. Retighten the lock nut. Repeat Step ( 1 ) . (c) 4-Stroke.net Remove the drain bolt to drain oil from the engine. Remove the step bar, muffler and kick pedal. NOTE On XL50, support the frame with rigid mount or block and metal bar, prior to removing the step. Remove the right crankcase cover. (4) Remove the oil filter screen from under the right crankcase (5) Clean the screen in solvent. (3) O I L F I LT E R SC R E E N 1 - 1 49575 32 �HONDA � CB50J/XL50 • Clutch Adjustment I NSPECTI O N /AD� UST ME NT If ( 1 ) Loosen the clutch cable adjusting nut fully and press the clutch lever down. (2) Loosen the l ock nut slightly and turn the clutch litter adjusting screw in the counterclockwise direc· tion until a sl ight resistance is felt. From this position, turn the adjusting screw in the clockwise direction 1 /8 to 1 /4 tu rn. (3) Tighten the l ock nut. (4) Loosen the clutch cable lock nut and turn the clutch cable adjusting nut so that there is 1 0 - 20 mm (0.4 - 0.8 i n ) of free play at the end of the clutch lever. Tighten the lock nut. (c) 4-Stroke.net NOTE After adjustment, start the engine and make sure that the motorcycle does not creep with the clutch disengaged. Readjust the clutch if the engine stalls or shifting is difficult. 33 I NSPECTIO N / AD� USTMENT • Air Cleaner Maintenance HONDA � CB50J/Xl50 � ( 1 ) Remove the right side cover. (2) Remove the three nuts on the a i r cleaner cover and slide the air cleaner tube band back. Pult the air cleaner cover out. [3) Remove the element from the air cleaner cover. Do not use gasol i ne or low flash point solvents as these are highly flammable. E L E M E NT �­ �� .. � (4) Wash i n clean stoddard solvent. (5) Dry (6) Soak in gear oil. (SAE # 80-90) • Engine Oil Level I nspection Change Oil Level (7} Squeeze out the excess oil. Oil Change (c) 4-Stroke.net ( 1 ) Place motorcycle in an upright position. ( 2) Shut off the engi ne and check the o i l level after approx. 3 m i nutes. OI L LEV E L GAUGE • To check oil level, insert gauge, but do not screw (3) If the level is low, raise to upper level mark on the gauge. Drain the oil and pour fresh oil if the oil is contami nated. O i l change is preformed after the engine is warmed up. ( 1 ) Drain engine oil by remov­ ing the drain plug. ( 2 ) Reinstal l drain plug and re· fill up to the upper level. Upper Level Mark Lower Level Mark OI L SPEC I F I CATION Drain Plug 2.0 - 3.0 kg-m ( 1 4.5 - 2 1 . 7 1 bs-ft) 34 Oil Capacity : 0.9£ ( 1 .9 U .S.qt. 1 .58 1mp.qt. ) I Use HONDA 4 STR O K E O I L or equivalent. API service classification-SE All temps. Above 1 5° C ( 59° F ) 0° C (32° F ) - 1 5° C (59° F ) Below 0° C (32° F ) SAE 1 0W-40 SAE 30 SAE 20 o r SAE 20W SAE 1 0W �HONDA � CB50J / XL50 I NSPECTION / ADJ USTME NT • Measuring Cylinder Compression Before testing cyl inder compression, perform the following operations. Warm up the engine thoroughly. (2) ( 1 ) Open the choke fully Open the throttle grip fully FULL OPEN TH ROTTLE G R I P CHOKE LEV E R STANDA R D CY L I N D E R COMPR ESSION 1 0 - 12 kg/cm 2 ( 1 42 - 1 7 1 psi ) • If the compression does not come up to the specified pressure, check the fol lowing items : Leaky valve I mproper valve tappet clearance Blown cyl inder head gasket Worn pistion, piston ri ngs and cyl inder Improper valve timing • If the compression reads high, th is could be due to excessive carbon in the combustion chamber or on the piston head. • (c) 4-Stroke.net • • • • 1 - 1 4957 1 K ICK (3) Operate the kick pedal several times possibl e. Tighten securely to prevent leaks from the gauge connection. 35 I NSPECTION / AD� USTMENT HONDA � CB50J/XL50 � • Front Brake Adjustment F R ONT B R A K E LEV E R F R E E P LAY D I SC B R A K E TYPE ( CB50J) t 20-30 mm (0.8- 1 .2 in) Loosen the lock nut and turn the adjuster until there is 20-30 mm (0.8- 1 .2 in) of free play at the end of the brake lever. D R U M B R AKE TYPE ( X L50) 1 0 - 20 mm (0.4 - 0.8 in) • Front Brake I nspection If adjustment is necessary, make the adjustment by turning the adjusting nut. (c) 4-Stroke.net f\ WEAR I N D ICATO R ARK (X L50) Replace the shoes if the arrow o n the wear indicator al igns with the mark 4 on the brake panel with the brake lever fully pulled in. See page 73. " 36 " (CB50J) If the pad wears to the red l i ne (maximum wear limit). replace the pads with a new set. See Pages 75 and 76. �HONDA � CB50J/XL50 I NSPECTION / AD� USTME NT • Rear Brake Pedal Adjustment Adjust the rear brake stopl ight switch after the rear brake pedal free play has been adjusted. If adjustment is necessary, make the adjustment by turning the rear brake adjusti ng nut. • Rear Brake Inspection WEAR I N D ICATO R MARK Replace the shoes if the arrow on the wear i ndicator aligns with the mark """" on the brake panel with the brake pedal fully depressed, see page 85. (c) 4-Stroke.net • Rear Brake Stoplight Switch Adjustment B - 09'054 1 Adjustment of the rear brake stopl ight switch should be made after the rear brake has been adjusted. • Adjust the stopl ight switch so that the stopl ight will come on when the brake pedal is depressed to the point where the brake just starts to engage. To adjust the stoplight switch, turn the adjusting nut. 37 I NSPECTION / AD..J USTMENT HONDA� CB50J/XL50 � • Front Fork Oil Change Remove the front fork drain bolt at the bottom of the fork cyl i nder. Drain the oil by pumping the fork. s 1 49564 NOTE ·Change the oil for both forks at the same time. · Receive the oil from the forks in a pan. · Remove the fork bolts to assist in draining of the oil. FOR K BOLT 3.0 - 4.0 kg-m (21 .6 - 29.0 lbs-ft) (c) 4-Stroke.net s - 1 49564 ATF O I L CAPACITY 38 CB50J 95 - 1 05 cc (3.5 - 3.7 ozs) XL 50 1 00 - 1 1 0 cc (3.6 - 3.8 ozs) �HONDA � CB50J/XL50 I NSPECT I O N / AD� USTME NT • Drive Chain l nspection/Alljustment D R I V E CHAIN Check for proper l u brication. If the chai n slack exceeds the l i mit, the drive chain must be readjusted : ( 1 ) Remove the axle nut cap (2) P u l l off the cotter pin. (3) Loosen the axle nut. (German type only). (4 ) Turn the drive chain adjusting nuts until the proper cha i n slack is obtai ned. NOTE Al ign the i ndex marks with the same side scale graduations on both sides of the rear fork. (5) After m a k i ng sure that the i ndex marks are al igned wi th the side graduati ons, tighten the axle nut. (6) (6) (8) Aga i n ti ghten the adjusti ng nuts. I nsta l l the cotter pin and spread the ends as shown. I nsta l l the axl e nut cap (German type ) . • Side Stand I nspection ( X L50) CHECK F O R SMOOTH OP E R AT I ON (c) 4-Stroke.net .,._ _ _ _ _ C H E CK F O R W E A R X R EP LACE 39 I NSPECTION/ A D� UST MENT HONDA � CB50J/XL50 � • Spark Plug I nspection CHECK FO R : WEAR GAP FOU LTI NG DEPOSIT CHECK F O R C RACK O R DAMAGE I - 1 4976 1 NOTE First finger tighten the spark plug, then tighten securely with the spark plug wrench. • Battery I nspection If the spark plug is carbon or wet fould, clean in a spark plug cleaner or with a stiff wire brush. NOTE If the spark plug is sanded, blow off remaining sands from the plug with compressed air before instal· lation. BATT E R Y E LECT R OLYTE LEV E L I cAUTION I • G RAVITY The battery electrolyte contains sulfuric acid and should be handled with care. (c) 4-Stroke.net Hydrometer �'-----4- The level should be between these two levels. • • Use distilled water to raise the level. D o not overfi l l beyond the UPPE R level mark. I - 090809 • • 40 Replace the battery if sulfation is evident. Replace the battery if there are excessive sediments (pastes) settled to the bottom of each cell. 1 .260 - 1 .280 Below 1 .250 Below 1 .220 I - 1 49764 Fully charged Undercharged Recharging necessary For relationship between specific gravity of battery electrolyte and electrolyte temperature, see Page 96. �HONDA � CB50J/XL50 • N. ENG INE I . ENG I N E R E MOVAL / I NSTAL LATION Remove the right and left side covers. (6) CAR B U R ETOR NOTE • • • (5) CLUTCH CABLE Turn the fuel cock to O F F. Drain fuel from the carburetor by loosening the drain screw. Receive fuel in a pan and return the fuel into the fuel tank. ( 1 ) A.C. G E N E R ATO R COR D NOTE ( 1 0) ENG I N E HAN G E R BOLT Adjust the clutch free play after the en­ gine has been installed. See page 33. NOTE · Use a proper metal bar, inserted instead of the hanger bolt, to facilitate the engine removal and (4) M U F F L E R (2) LEFT C RAN KCASE COV E R NOTE muffler on the engine and frame, then tighten se­ curely. (7) • TACHOMETE R CABLE (CB50J) (8) FOOT R EST • Loosen the chain t o facilitate removal and installation. Adjust the chain after install ing the engine. See Page 39. (9) G EARSH I FT PEDAL (c) 4-Stroke.net ( X L50) I - 1 49578 Support the motorcycle with rigid mounts before removing the foot rest. E - 1 34588 41 HONDA � CB50J/XL50 � 2. CY L I N D E R H EAD/VA LVES (2) CAM SPROCKET ( 1 ) CY L I N D E R H EAD COV E R Suspend the sprocket with wi re to prevent the cam chain from dropping into the cran kcase. Valve timing adjustment, Page 43. (3) CAMSHAFT H O L D E R ROCK E R A R M Disassembly/assembly, Page 43 6 mm BOLT 0.9 - 1 .2 kg-m (6. 5 - 8.6 l bs-ft) (4) CAMSHAFT Install on compression (rocker arms rest on the base circle). NOTE Temporarily tighten this bolt at the time of cylinder head installation. Then, tighten securely after the camshaft holder has been installed. VALVE D isassembly/assembly, Page 4 4 (6) CY L I N D E R H EAD - (c) 4-Stroke.net (7.2 - 1 0.0 l bs-ft) (5) ADJUSTI N G BOLT Install the adjusting bolt after install ing the cam sprocket. P - 1 49538 Perform the fol lowing operations after the cyl inder head and valves have been installed : Valve tappet clearance adjustment . . . . . . . . Page 30 0.05 ± 0.02 mm (0.002 ± 0.0008 i n ) Cyl inder compression test . . . . . . . . . . . . . Page 3 5 1 0 - 1 2 kg/cm 2 ( 1 42 - 1 7 1 psi ) Cam chain tensioner adjustment 42 Page 32 �HONDA � CB50J/XL50 CYL I N DE R HEAD/VA LVES A. DISASSEMBLY/ASSEMBLY • Rocker Arm Shaft p 1 49532 USE R EACTION TO R EMOVE SHAFT CAM HOLD E R ROCK E R A R M NOTE Before disassembli ng, mark the shafts and rocker arms so they can be placed back to their original places. P - 1 4953 1 ROCKE R ARM SHAFT ( I NTAKE S I D E ) • ROC K E R A R M SHAFT (E XHAUST S I D E ) Install the shaft with the threaded end outward. Insta l l the shaft with the cutout outward. · Push in the shaft as far as it wil l go. • Valve Timing Adjustment • • I nstall the cam shaft so that the rocker arms are not pushed up by the cams. I nstall the sprocket on the cam shaft with the rocker arm holder attaching nuts tightened. · Align the cutout with the bol t hole as shown. (c) 4-Stroke.net P - 1 49534 P - 1 49539 ( 1 ) Turn the flywheel in the coun· terclockwise direction and al ign the "T" mark to the index mark. (2) Align the two holes i n the sprocket with the cover mating face of the cyl i nder head and then place the cam chai n over the sprocket. NOTE Use caution i n rotating the flywheel to avoid fal l ing the chain into the cylinder block. P - 1 49536 CAMSHAFT 6 x 1 0 mm bolt (4) I nstal l and tighten the 6 mm bolt on t�.e ex· haust side. (3) I nstall and tighten the dowel bolt on the i ntake side. 43 CYL I N DE R HEAD/VALVES HONDA� CB50J/XL50 � • Valves VA LVE SPR I NG COMPR ESSO R No. 07957·3290001 NOTE Compress the spring just enough to remove and install the valve cotters. N - 0005 1 2 NOTE • NOTE • After installing, check that the valve cotters are seated properly by l ightly tapping on the stem end with a plastic hammer. Do not mix the inlet and exhaust parts. During disassembl ing, mark the valves so that the original combination can be restored at assem bly. NOTE (c) 4-Stroke.net VA LV E G U I D E -------...J --ffi�Gif' 0- R I NG --��� OUT E R VALVE SPR I NG SEAT ---- NOTE When new valves are used, lap them in the valve seats. B E FO R E ASSE M B L I NG, C LEAN A L L TH E R EMOVED PARTS IN SO LVENT. 44 P - 1 49533 �HONDA � CB50J/XL50 CYL I N DE R HEAD/VALVES NOTE Replace the valve when the valve gu ide is replaced. • Driving Out Valve Guide VALVE G U I D E R EMOV E R No. 07942-3290 1 00 • Driving in Valve Guide I - 1 49556 VALVE G U I D E D R I V E R No. 07942-3290200 NOTE Avoid damaging the gasket surface whi le driving the guide. Make sure that the guide is not damaged after installing. (c) 4-Stroke.net I - 1 49555 I - 1 49554 • Valve Guide Reaming After i nstal l ing a new guide, it is necessary to ream it to size using the valve gu ide reamer. VALVE G U I D E R EAME R NOTE • • • Rotate the reamer clockwise. To keep the reamed surface from being scratched, rotate the reamer clockwise as it is pul led out. Otherwise, leakage of oil from the cyl inder head i nto the combus­ tion chamber would result. After reaming to size, remove all traces of metal particles from the gu ide with sol­ vent. No. 07984-0980000 VALVE G U I D E I . D. ( IN/EX) 5.4 75 - 5.485 mm (0. 2 1 55 - 0.2 1 59 in) 45 CYL I N DE R HEAD/VALVES • Valve Guide 1.0. • Valve Seat Width I NSPECTION B. Measure the valve guide at the top, m iddle and bottom and in two directions at right angle to each other. Take measurements at several points. I N/EX HONDA � CB50J/XL50 � STANDA R D SERV ICE L I M I T 1 .0 mm (0.04 in) 1 . 5 mm ( Replace or repair) (0.06 i n ) • Valve Stem O.D. I N/EX STANDA R D SERV ICE L I M I T 5.4 75 - 5.485 mm (0. 2 1 55 - 0.2 1 59 in) 5.50 mm ( Replace) (0. 2 1 65 i n ) • R ocker Arm Shaft 0.0. (c) 4-Stroke.net 1 - 1 49574 I Measu re the valve stem at three points along its sl iding surface and in two di rections at right angle to each other. Measure the rocker arm shaft O.D. in two directions at right angle to each other. STA N D A R D SERVICE LIMIT IN 5.450 - 5.465 m m (0. 2 1 46 - 0.21 52 i n ) 5.42 mm ( Replace) (0. 2 1 34 i n ) STANDARD S E R V ICE L I M I T EX !?.430 - 5.445 mm (0. 2 1 38 - 0.2 1 44 i n ) 5.40 mm ( Replace) (0. 2 1 26 in) 9.978 - 9.987 mm (0.3927 -0. 3932 in) 9. 1 7 mm ( Replace) (0. 36 1 0 in) 46 �HONDA � CB50J/XL50 C Y L I N DER HEAD/VA LVES • Rocker Arm • Rocker Arm 1.0. P - 1 49535 Check the tappet co �tacting surface for wear and damage. I - 1 49557 Measure the rocker arm I. D. in two directions at right angle to each other. • STAN DA R D S E R V I CE L I M IT 1 0.000 - 1 0.01 5 mm (0.3937 - 0.3943 i n ) 1 0. 1 mm ( Replace) (0.3976 i n ) Cam Height IN EX • Valve Spring Free Length (c) 4-Stroke.net STAND A R D S E R V I C E L I M IT Belgian, German and Austrian Type 27.697 mm ( 1 .0904 in) 26.6 mm ( Replace) ( 1 .047 i n ) General Type 27.005 mm ( 1 .0632 i n ) 25.9 mm ( R eplace) ( 1 .020 i n ) Belgian, German and Austrian Type 27.560 mm ( 1 .0850 i n ) 26.5 mm ( R eplace) ( 1 .043 i n ) General Type 27.005 m m ( 1 .0632 in) 25.9 mm ( R eplace) ( 1 .020 i n ) I - 1 49547 STANDA R D SE R V I C E L I M I T OUT E R SPR I NG 34.8 m m ( 1 .3701 in) 33.7 m m ( Replace) ( 1 .3268 i n ) INNER SPR I NG 28.08 mm ( 1 . 1 044 i n ) 27.6 m m ( Replace) ( 1 .0866 in) 47 I CYL I N DE R H EAD/VALVES C. HONDA� R EPA I R • Valve Seat Refacing VALV E SEAT G R I ND E R To determine where the valve contacts the seat, apply a thin coating of Prussian blue and a small amount of engine oil to the seat then put the valve in place. If the valve seat is u neven or exceeds the lim"its, the valve must be replaced and valve seat refaced with the valve seat grinders. VALVE SEAT WI DTH SERVICE LIMIT 1 . 5 mm max. ( I N/EX) (0.06 in) t ' PI LOT B A R A 07783-001 0 1 00 P - 1 34547 ( 1 ) Dress the gri nding stones to the angle. (2) As a fi rst step in the operation, remove all the roughness or pitting from the seat using the 45° grindi ng stone. Grinding Stone Part No. O.D. IN EX 07783 - 0040300 26 mm ( 1 .024 i n ) 07783 - 0040100 21 mm (0.827 i n ) PITT I N G O R ROUGHN ESS G rinding Angle (Color Code) (c) 4-Stroke.net 45° (white) 45° (white) P - 1 34548 (3) Cut away the upper edge o f the seat using the 37. 5" grinding stone. IN EX 48 Grinding Stone Part No. O.D. Grinding Angle (Color Code) 07783-00301 00 2 1 mm (0.827. i n ) 07783-0030300 24 mm (0.945 in) 37.5° (blue) 37.5 ° (blue) G R I ND I NG STON E VA LVE SEAT P - 1 34549 �HONDA � CB50J/XL50 C Y L I N DE R HEAD/VALVES (4) Grind the lower edge of the seat using the 63.5° grinding stone. IN EX Grinding Stone Part No. O. D. Grinding Angle (Color Code) 07783-0050200 26 mm ( 1 .024 i n ) 07783-00501 00 23 mm (0.906 i n ) 63.5° (pink) 63.5° (pink) S I D E D R ESSI N G SEAT D R ESSI N G P - 1 34550 (5) Bring the seat to the correct width and location on the valve face with the 45° grinding stone. NOT E : Use the same grinding stone as in Step (2) above. The stones must be dressed frequently with the dressing tool to insure even, uniform grinding of the valve seat. STANDARD VA LVE SEAT W I DTH · . · .· ; . . . 1 .0 mm ( I N/EX) (0.0394 in) (c) 4-Stroke.net P - 1 3455 1 (6) Perfect the fit between the valve and valve seat by lapping. To lap-in the valve, apply a thin coating of lapping compound to the valve face. NOT E : Do not allow the compound to get into the valve guide. NOTE Again check the contact between the valve face and the seat with prussian blue. To grind the valve seats, fol low the i nstructions described in the operation manual furnished by the manufacturer. R OTATE W ITH L I G HT DOWN PR ESSU R E p - 1 34546 49 HONDA� CB50J/XL50 � 3. C Y L I N D E R / PISTON 0- R I NG CY L I N D E R CAM CHA I N TENSION E R Assembly, page 52 CAM CHAI N G U I D E PISTON P I N C L I P NOTE Replace whenever disassembly PISTON Disassembly/assembly, page (c) 4-Stroke.net 51 . P - 1 49530 50 �HONDA � CB50J/XL50 A. D I SASSEMBLY/ASSEMBL • Piston � CYLI N DE R / P ISTON Place the mark " I N " on the intake valve side. CUTOUT ! cAUTION I C L I P END Take care not to damage the piston. p 090565 each pin clip so that the end portion of the cli p i s not aligned wi th the cut· out in the piston. NOTE Cover the crankcase opening with a clean rag to prevent the clips from fall ing inside. P - 1 49537 • Piston R ing Remove the piston rings in the arrow direction. ! CAUT ION I Avoid damaging the piston when i nsta l l ing and removing the pis· ton rings. (c) 4-Stroke.net P - 1 49529 Stagger the ring end gaps 1 20° apart. Install the rings with the markings facing up. N 0 p 1 49526 {1 ) TOP R I NG (2) SECOND R I NG (3) O I L R I NG Check for clogged ring groove or oil hole. NOTE When new rings are to be installed, roll them around in the grooves to make sure that they rotate freely. 51 CYL I N DE R / PISTON • Cam Chain Tensioner HONDA � CB50J/XL50 � NOTE Press this end down to facil itate instal lation of the adjusting bolt. LOCK NUT ADJUST I NG BOLT CAM CHA I N TENSI O N E R NOTE TENSION E R SPR I NG After the engine has been in­ stal led, adjust the cam chain. See page 32 . • Hook the spring end over the recess in the cyl inder. P - 1 49520 Cylinder 10 NOTE x (c) 4-Stroke.net 1 6 mm DOW E L P I N 7 mm R U B B E R R I N G NOTE Check that it is not dis­ lodged during assembly. CAM CHA I N G U I D E NOTE wire as shown. E - 1 49577 52 �HONDA � CB50J/XL50 CYL I N DE R / P ISTO N • Cylinder I . D. Measure the cyl inder I . D. at the top, middle and bottom and in two directions at right angle to each other. STAN DAR D 42.00 - 42.01 mm ( 1 .6535 - 1 .6539 in) S E R V I C E L I M IT 42. 1 mm ( Replace or repair) ( 1 .6575 in) CY L I N D E R TAPE R/OUT O F ROUN D : 0.05 mm ( Replace (0.002 in) or repair) If the wear is beyond the service l imit, the cyl inder must bored and honed to the next larger size of oversize piston. Four oversize p istons piston rings a re available: be OVE R S I Z E 0.25, 0.50, 0.75 a n d 1 .00 m m (0.01 , 0.02, 0.03 and 0.04 i n ) P - 1 49527 Take measurements a t point 1 0 mm (0.4 in) up from the bottom. (c) 4-Stroke.net • Piston R ing Side Clearance STANDARD S E R V I C E L I M IT 4 1 .97 - 4 1 .99 mm ( 1 .6524 - 1 .653 1 i n ) 4 1 .80 mm ( Replace) ( 1 .6457 i n ) 1 - 1 49770 PISTON R I NG STANDAR D 0.0 1 5 - 0.045 m m (0.0006 - 0.00 1 8 i n ) SERVICE LIMIT 0. 1 2 mm ( Replace) (0.0048 i n ) 1 - 1 49564 53 HONDA � CB50J/XL50 � CYLI N DE R / P ISTON • Piston R ing E mJ G.:p • Piston Pin Bore 1.0. I - 1 49565 I - 1 49566 Measure the piston pin bore ( both ends) in two di rections crosswise of each other. STANDARD SE R V I CE L I M I T 1 3.002 - 1 3.008 m m (0. 51 1 9 - 0. 5 1 21 i n ) • STAN D A R D 1 3.055 mm (0.5 1 40 i n ) ( Replace) Piston R ing Th ickness SE R V I C E L I M I T TOP/ SECOND 0. 1 - 0.3 m m (0.004 ...,. 0.01 2 i n ) OIL 0. 1 - 0.35 mm (0.004 - 0.01 4 i n ) 0.5 mm ( Re place ) (0.020 i n ) 0.5 mm ( R eplace) (0.020 i n ) • Piston P i n 0.0. (c) 4-Stroke.net I - 1 49568 J Take measurements at several po� ---- TOP/ SECOND OI L STANDA RD SE R V I CE L I M I T 1 . 1 80 - 1 . 1 95 mm (0.0465 - 0.0470 i n ) 1 . 1 2 mm ( Replace) (0.044 1 i n ) STANDA RD SE R V I CE L I M I T 2.480 - 2.495 mm (0.0976 - 0.0982 i n ) 2 . 42 mm ( R eplace) (0.0953 i n ) 1 2. 994 - 1 3.000 mm (0. 5 1 1 6 - 0.51 1 8 i n ) 1 2.98 mm ( Replace) (0. 5 1 1 0 i n ) ----- 54 Measure the piston p i n O.D. at center and both ends in crosswise di rections. �HONDA � CB50J/XL50 4. L U B R ICATION SYST EM • Oil Flow (c) 4-Stroke.net 55 HONDA� CB50J/XL50 � 5. CLUTCH / O I L P U M P / G EARS H I FT Drain oil from the engine by removing the drain plug. Remove the tachometer (CB50J) and clutch cables. Remove the gearshift and kick starter pedals. O I L TH ROUGH (9) D RUM STOPPE R PLATE Assembly, Page 58. NOTE During assembly, check that the 0-ring is installed properly and is not dislodged. D isassem bl y Iassembly, Page 57 . 3.5 - 4.5 kg-m (25.2 - 32.4 l bs-ft) ( 1 0) D R U M STOPPE R Assembly, Page 58. Disassembly/assembly, Page 57. O I L F I LTER SCR E EN NOTE Clean the filter screen whenever disassembled. TACHOMET E R G EAR (CB5DJ) Avoid damaging the left crankcase oil seal when installing. Assembly, page 58. CLUTCH ADJUST I N G LEVER (7) 20 mm I N N E R TOOT H E D WASH E R (c) 4-Stroke.net CLUTCH ADJUSTER (6) CLUTCH Disassembly/assembly, Page 58 . v (5) 20 mm C l RC LIP Remove the 2o mm circl ip to remove the clutch as an assem bly. (4) CLUTCH LI FTE R PLATE NOTE Tighten the bolts in a criss-cross pattern. E 1 49579 After assembly, adjust the clutch, see Page 33. clutch lever free play 1 0 - 20 mm (0.4 - 0.8 in) 56 Be careful in disassembl ing the cover to avoid damaging the kick spindle oil seal . �HONDA � CB50J/XL50 CLUTCH/OIL PUMP/GEARSH I FT A. D I SASSEM B L V I ASSEMBL V • Drive Gear 14 mm LOCK NUT 3.5 - 4.5 kg·m (25. 2 - 32.4 l bs·ft) CLUTCH H O L D E R No. 07923· 1 070001 • Oil Pump NOTE Remove the bolts by having access through the large hole. Rotate the gear to align the hole and bolt. c 1 495 1 6 (c) 4-Stroke.net J . 1 49504 J - 1 4950 1 J .. 1 49502 Fit the dowel in the cutout as shown. J - 1 49503 Align the cutout on the gear shaft with the flat on the i nner rotor. 57 HONDA� CB50J/XL50 � C L UTCH /OI L P U M P / G EA RSH I FT Clutch • F R ICTION D ISC CLUTCH CENT E R • CLUTCH P LATE Clutch Arm CLUTCH L1 FTE R CAM NOTE During assembly, use care to rest the adjusting lever on the cam and spri ng on the adjust- CLUTCH P R ESSU R E PLATE • Gearshift Spring c - 1 495 1 7 Place the ends of the spring over the return pin shown. as CLUTCH L E V E R C LUTCH ADJUST I NG LEVER (c) 4-Stroke.net STOPPE R P I N R ETU R N SPR I NG • Drum Stopper Plate C - 1 495 1 9 • Drum Stopper G - 1 49545 ·; I G - 1 49547 NOTE After assembly, check oper­ ation of the stopper. 58 \ I nstall the stopper spring as shown. • Align the holes in stopper to their respective pins. G - 1 49546 �HONDA � CB50J/XL50 C L.UTC H /OI L PUMP /GEARSH I FT B. I NSPECT I ON • Oil Pump NOTE Check the i nner and outer rotors and replace if worn or damaged. I N N E R-TO-OUT E R ROTO R CLEARANCE J - 1 345 1 2 OUT E R ROTOR-TO-BODY CLEARANCE J - 1 49506 STANDARD SERVICE LIMIT STANDARD SE RV ICE L I M IT 0. 1 5 m m (0.006 in) 0. 2 mm ( Replace) (0.008 in) 0. 1 - 0. 1 5 mm (0.004 - 0.006 in) 0.2 mm ( Replace) (0.008 i n ) • Clutch Friction Disc Thickness • Clutch Spring Free Length (c) 4-Stroke.net I - 1 49547 c - 1 495 1 8 STANDARD SERV ICE L I M I T STANDA R D S E R V I CE L I M I T 2.8 - 2.9 mm (0.1 1 02 - 0. 1 142 in) 2.6 mm ( Replace) (0. 1 024 in) 28.4 m m ( 1 . 1 1 81 in) 26.3 mm ( Replace) ( 1 .0354 in) NOTE Check the clutch facings and replace if damaged or discolored. 59 HONDA� CB50J/XL50 � 6. A. C. G E N E RAT O R NOTE Check that the key is seated pro­ pe rly. CONTACT B R EA K E R Disassembly/assembly, Page 6 1 . (3) STATO R (c) 4-Stroke.net (2 ) F LYWH E E L NOTE • • Make sure no metal parts are attracted inside. Do not hammer. Disassembly/assembly, Page 6 1 . ( 1 ) LEFT C RAN KCASE COVE R 60 A · 1 4950 5 �HONDA � CB50J/XL50 A. C . GE NERATOR A. DISASSEMBLY/ASSEMBLY • Flywheel F LYWH E E L R EMOVAL F LYWH E E L HO LDER No. 07925-001 0000 F LYWH E E L PU LLER No. 07933-001 0000 • Contact Breaker After assembly, adjust the con­ tact breaker point gap and igni­ tion timing. For adjustment, see pages 28 and 29. • Neutral Switch Wire (c) 4-Stroke.net SPR I NG Point i nspection, Page 98. A - 0905 1 7 I · 1 49757 I nsert the end of the switch wire through the termi nal while com­ pressing the spring. 81 HONDA� CB50J / XL50 � 7. TRANSM ISS I O N / C RAN KSHAFT / K I C K STARTER ( 1 ) K I C K STA R T E R SPR I NG GU I D E Assembly, Page 63. (3) R I GHT CRAN KCASE (2) K I CK SP R I NG Assembly, page 63. (4) KICK STA RTER Assembly, Page 63. (5) SH I FT F O R K G U I D E SHAFT / (9) SH I FT D R U M Assembly, Page 64. Disassembly/assembly, Page 63. �------- (6) R I G H T SH I FT F O R K -=----:;.-£-- (7) CENTE R SH I FT FO R K (8) LEFT SH I FT FO R K (5·speed only) (c) 4-Stroke.net (1 1 ) CRANKSHAFT TI M I NG SPROCKET NOTE Prior to disassembl i ng, read the i nstructions de· scribed in page 64. NOTE D u r i n g assembly, check that the gas· ket is in place. TH E PA RTS (6) TH R U ( 1 0) CAN BE D ISASSEM B LE D AS A N ASSEMB LE D U N I T 62 LEFT CRAN KCASE �HONDA � CB50J/XL50 TRANSM ISSION/ CRANKSHAFT / K ICK STARTER A. D ISASSEMB LY/ASSEMBLY • Kick Starter ( 1 ) A L I G N TH E PUNCH M A R KS STAR T E R RATCHET G - 1 4954 1 (2) I nstall the ratchet u nder the guide plate by moving i n the arrow direction. (3) After assembling the right and left crankcases, put the starter spring over the starter spindle. (4) I nsert one end of the spring in the groove in the spring guide and hook the other end over the crankcase abutment. NOTE • Transmission After assembly, check operation of the kick starter. G - 1 49544 G - 1 49543 (c) 4-Stroke.net When new shafts and gears are used, apply molybdenum disulfide to the gear sliding faces of the shafts. (4·SPEED) STARTE R G E A R 2ND GEAR M - 1 345 1 1 _!(®floo�oo�gg� ,.,� i[!io® COUNT E R SHAFT \ STARTE R G E A R p \ r J R D GEAR 4TH GEAR 5TH G E A R ��@�oociro� 1 ST G E A R ( 5·SP E E D ) 2ND GEAR M A I N SHAFT 63 TRANSM ISSION/ C R A N KSHAFT / K I C K STARTER HONDAr:::iff\ CB50J/XL50 � • Shift Fork • Shift Drum R ight and center forks are used for 4-speed transmission Position the neutral switch rotor in the arrow direction, and then install. Instal l the forks with the markings facing up. NOTE • Timing Gear Disassembly G - 1 45488 Rotate the main shaft to make sure all gears rotate freely without binding. Assembly (c) 4-Stroke.net Scribe an al igning mark over the crankshaft from the center between two teeth as the reference. Then, remove the timing gear. Scribe an al igning mark over a new sprocket at the center of two teeth. I nstall the sprocket on the crankshaft with the two markings in l i ne. TEETH CENTER ALIGN I N G MARK ALI G N I N G MARK about 20 mm (0.8 in) ! cAUTION I Never scribe across the oil seal contacti ng face of the crankshaft. 64 ALI GN TH ESE TWO M A R KS I - 1 49562 �HONDA � CB50J/XL50 TRANSM ISSION / C R A N KSHAFT / K I C K STARTER B . I NSPECTI ON • Gearshift Fork 1.0. • Gearshift Fork End Thickness Measure in two directions at right angle to each other. STAN DAR D S E R V I CE L I M IT 1 2.000 - 1 2.01 8 mm (0.4724 - 0.4731 in) 1 2.05 mm ( Replace) (0.4744 in) STANDARD S E R V I CE L I M I T 4.93 - 5.00 m m (0. 1 941 - 0. 1 969 in) 4 . 70 mm ( Replace) (0. 1 850 in) • Connecting Rod Small End 1 . 0. • Shift Fork Guide Shaft 0.0. (c) 4-Stroke.net Measure in two directions at right angle to each other along the sliding surface. STANDARD 1 1 .976 - 1 1 .994 mm (0.471 5 - 0.4722 in) Measure in two directions at right angle to each other. SERV ICE L I M I T STANDARD SERV ICE L I M I T 1 1 .96 mm ( Replace) (0.4709 in) 1 3.016 - 1 3.034 m m (0.51 24 - 0. 5 1 3 1 i n ) 1 3.08 mm ( Replace) (0.51 50 in) 65 TRANSM ISSION/ C RA N KSHAFT / K I C K STARTER • Crankshaft Runout • Connecting Rod Big End Side Clearance I STANDARD 0. 1 0 - 0.35 mm (0.004 - 0.0 1 4 in) HONDA � CB50J/XL50 � - 1 4956 1 SERVICE L I M I T STAN DAR D SERVICE LIMIT 0.6 mm ( Replace) (0.024 i n ) 0 - 0.01 5 mm (0 - 0.0006 i n ) 0. 1 mm ( Replace) (0.004 in) • Connecting Rod Big End Radial Clearance • Crankshaft Ball Bearing Play Measure i n two directions as shown. I 1 49549 AX I A L D I R ECTION RADIAL D I R ECTION PLAY (c) 4-Stroke.net Q - 1 49504 STANDARD 0 - 0.01 2 mm (0 - 0.00048 in) 66 S E R V I CE L I M IT 0.05 mm ( Replace) (0.0020 i n ) STANDA R D SE RVICE LI M I T AX IAL 0.004 - 0.036 mm (0.0002 - 0.00 1 4 i n ) 0. 1 0 m m ( Replace) (0.004 in) RAD I A L 0.01 0 - 0.025 mm (0.0004 - 0.00 1 0 i n ) 0.05 m m ( Replace) (0.0020 i n ) �HONDA � CB50J/XL50 8 . CAR B U R ETOR lfe'@;@l�@l I Do not bri ng open flame near gasoline. • RUB B E R CAP Turn the fuel cock to O F F. Drain the fuel from the carburetor by loosening the drain screw. Receive the fuel in a pan and replace it i nto the fuel tan k. NOTE Check for cracks or de­ terioration and replace if necessary. (2) TH ROTTLE VALVE ( 1 ) F U E L TUBE NOTE Check for cracks or deterioration and replace if necessary. Disassembly/assembly, Page 69 . (5) F LOAT CHAM B E R NOTE (c) 4-Stroke.net Return fuel drained i nto fuel tank JETS Disassembly/assembly, Page 69. D R A I N SCR EW After assembl ing, adjust the carburetor, Page 3 1 . I nsert the throttle valve i nto the carburetor body, aligning the groove in the valve with the stop screw. K 1 49539 Align the lugs on the carburetor top with the grooves in the carburetor body. 67 C A R B U RETOR HONDA � CB50J/XL50 � A. DISASSEMBLY/ASSEMBLY • Throttle Valve/ Caburetor Top N E E D L E R ETA I N E R Set the retainer in the bottom properly at assembly. Remove the cable end from the groove in the throttle valve. � TH R OTTLE VALVE N E E D L E R ETA I N E R JET N E E D L E K · 1 49540 (c) 4-Stroke.net +--- JET N E E D L E NOTE Handle the needle and jet needle as a matched set. T H R OTT LE VALVE K 1 49538 After assembl ing, adjust the throttle grip free play, see Page 3 1 . 2 - 6 mm (0.04 - 0.24 i n ) 68 When assembling, turn in the adjuster fully. Check that the end of the outer cable bottoms in the adjuster. I nstall the rubber cap and tighten securely. �HONDA � CB50J/XL50 • CARB U RETOR Float/Jets The float and float valve are separated by removi ng the float pin. NOTE Check for cloggi ng or wear during assembly. N E ED L E JET H O L D E R E MAIN JET H O LD E R ( X L50 only) SLOW JET N E E D LE JET H O L D E R (c) 4-Stroke.net NOTE • • Avoid damaging the carbu retor jets when insta l l i ng. Clean in solvent and blow with compressed air. K 1 49542 NOTE • Handle the needle jet and jet needle as a set. 69 HON'DA � CB50J / XL50 � CAR B U RETOR Float Height B. I NSPECTI ON • F LOAT H E I GHT ===;:>H • Measure the float height with the float valve closed and the float tip just contacti ng the valve. F LOAT VALVE Float Valve K - 1 34558 Check for wear contacting face. • on • seat Bend the float l i p carefully to adjust the float level. K 090563 Carbu retor Setting � (c) 4-Stroke.net CB50J Bel gian, Austrian and German Type General Type m X L50 General Type Belgian, Austrian and German Type Setting Mark 07A A 1 3A 08B A 1 4A Mai n jet #85 #65 #75 #62 #38 #35 #35 #35 3rd 2nd 2nd 1 Y2 1 '!. 1 '12 n Slow jet Jet needle setting Air screw opening Float height Idle speed Leap t - 2od Standard t R ich 1 Y2 i 20 mm (0. 7874 in) 2 1 . 5 mm (0.8465 i n ) 20 mm (0. 7874 i n ) 20 mm (0.7874 i n ) 1 , 500 rpm 1 , 500 rpm 1 , 500 rpm 1 ,500 rpm K - 1 4954 1 70 �HONDA � CB50J / XL50 V. FRAM E I . FRONT WH E E L/ST E E R I N G / FRONT SUSP ENSION (4) HANDLE BAR S Disassembly/assembly, Page 72. (5) STE E R I NG STEM Disassembly/assembly, Page 78. 3.0 - 4.0 kg-m (21 .6 - 29.0 l bs-ft) (3) F RONT FOR K Disassembly, Page 79 Assembly, Page 80. (2) F RONT F E N D E R (c) 4-Stroke.net (1) Disassembly/assembl y : Disc type (CB50J) Page 74. Drum type ( X L50) Page 73. BRAKE CAL I P E R (CB50J) Disassembly/assembly, Page 75. After assembly, perform the following operations: Brake lever adjustment Page 36 free play: CB50J 20 - 30 mm (0.8 - 1 .2 in) X L50 1 0 - 20 mm (0.4 - 0.8 in) Clutch lever adjustment . . . . . . . . . . . . . . Page 33 free play: 1 0 - 20 mm (0.4 - 0.8 in) Throttle grip adjustment . . . . . . . . . . . . . Page 31 free play : 2 - 6 mm (0.08 - 0.24 in) . • . • . . . . . . . . . . . Install the cotter pin and spread the ends as shown. 71 HEE L / � STEE R I N G / FRON SUSPE NSION V FRONT �VI A. D I SASSEM B • Stoe,;ng Handl e ASSEMBL rs NOTE HONDA� CB50J/XL50 � Tighten the screw ( 1 ) first. FORWA R D <;::=J Align the d owel 0n the lower . th e hole in · w1th switch hous mg the handlebars. . Inspecting the I ever 0 perat1on smoothness' t"19h ten the b0I t . th e Iock nut. then f"IX With Align th e dowel on the lower . switch housi With the hole in the handleba s �� � BOLT LEV E R LOCK � (c) 4-Stroke.net I 19 ten the bolt ( 1,) first. UPPE R HOLD E R PUNCH MARK NOTE Align the punch mark on t he handlebars with th e clearance between the upper and I ower holders. 72 Install the u pper holders with the punch marks to the rear. �HONDA � CB50J/XL50 FRONT W H E E L / STE E R I N G / FRONT SUSP E NSION • Front Wheel D R UM B RAKE TYPE (X L50) TI R E PR ESSU R E 1 . 7 5 kg/cm 2 (25 psi ) f£14;1111�(01 Be careful to keep Ol. I or grease off th , , ; " ; " " 0' b"k' DUST SEAL W - 1 49547 (c) 4-Stroke.net WH E E L BEAR I NG D R I V I N G BRAKE CAM I I A L I G N TO TH E CUTOUT WEAR I ND ICATO R BEAR I NG D R I V E R No. 07946·3640000 NOTE • • W - 1 49548 . . . to allow it to Use caut1on m driving the bean·ng not tl"lt. I nstall the bean. ng Wl" th the shiel d en d outward. 73 FRONT WHEE L/ HON'DA � CB50J/XL50 � STEE R I N G / FRONT SUSPE NSION D I SC TYPE (CB50J) SPE EDOMETER G EA R BOX SPE E DOM ETE R CAB LE T I R E PR ESSU R E NOTE Tighten the axle nut to the specified torque after placing the gear box not to force the speedometer cable kink or twist. W - 1 49544 D I SC PLATE WH E E L BEA R I N G I NSTAL LATION D R I V E R HANDLE No. 07949-61 1 0000 • • 74 1'i4i;@i�[ij (c) 4-Stroke.net Drive the bearing squarely, not allowing it to tilt. Install the bearing with the shield end facing the outside. � Do not allow oil or grease into contact with the pi DISC PLATE I NSTALLATION 1 .0 - 1 .8 kg-m (7.2 - 1 3.0 lbs·ft) W - 1 49546 �HONDA � CB50J/XL50 FRONT WHEE L/ STEE R I N G / FRONT SUSPE NTION • Brake Caliper I cAUTION I • • Be careful to keep oil or grease off the brake pads. After assembl ing, adjust the caliper. See Page 7 7 . (6) CAL I P E R CASE NOTE During assembly, clean the cy linders thoroughly with solvent. (4) PAD 8 S I L I C O N GREAS E (3) PAD A ( 1 ) CALl P E R COV E R PAD A (c) 4-Stroke.net • Coat the outer periphery of the pad A with sil icon grease before the pad can be reinstalled. PAD • • Pul l out the pad by screwing in the 6 m m bolt (cal iper cover attaching bolt). 8 Apply silicon grease only to the back plate area of the pad 8 before assembly. • Push out the stopper pin using a screwdriver. 75 FRONT WHEEL/ STEE R I N G / FRONT SUSPE NSION HONDA � CB50J/XL50 � • Brake Cable ( 1 ) Loosen the lock nut and turn in the adjuster fully. ( 2) Compress the return spring with a pai r of pl iers. (3) Extend the cable enough to clear the joint pin to remove the pin then pul l off the cable. JO I NT P I N • Brake Arm (c) 4-Stroke.net ( 1 ) Align the punch mark (.2) Turn the adjuster counterclockwise u ntil resistance is - felt. 76 (3) I nstall the ratchet and check for operation. (5) I nsert the pi n on the brake arm i nto hole in the pad A. �HONDA � CB50J/XL50 • Caliper Adjustment FRONT W H E E L / STE E R I N G / FRONT SUSP E NSION (1 ) Loosen the adjuster until the brake lever is spring loaded. Turn the adjuster out 2-3 turns from the position, then secure with the lock nut. NOTE Check that the brake lever is returned fully by means of the retu rn spri ng. (2) Self·al ign the brake by operating the brake lever about 1 0 times. NOTE STANDARD B R AKE LEV E R F R EE PLAY: 20 - 30 mm (0.8 - 1 .3 in) t (c) 4-Stroke.net (3) Raise the front wheel off the ground and spin it by hand to make sure that it rotated freely without binding. Also check the brake for function. 77 HONDA � CB50J/XL50 � FRONT WHEEL/ STEE R I N G / FRONT SUSPENSION • Steering Stem STE E R I NG STEM NUT 6.0 - 7.0 kg-m - 50.6 l bs-ft) TOP TH R EAD NUT ASSEMB LY (43.4 36 mm PI N SPA N N E R No. 07902-2400000 R 1 495 1 6 First tighten the top thread snag agai nst the steeri ng stem, then back it out about 1 /8 turn. Make sure the steering stem rotates freely without play. BAL L RACE D I SASSEMBLY BOTTOM BALL R ACE STE E L BALLS [ 2 1 ] in solvent and coat with grease before they can be reinstalled. BOTTOM CON E RACE (c) 4-Stroke.net DUST SEAL I 1 49628 (3) STE E R I N G STEM 1 . 8 - 2.5 kg·m ( 1 3.0 - 1 8. 1 l bs-ft) R - 1 495 1 7 78 �HONDA � CB50J/XL50 FRONT WHEE L / STEE R I N G / FRONT SUSPE NSION • Front Fork Disassembly/assembly DISASSEM B LY ( 1 ) Remove the drain bolt and drain the oil from the fork. (2) Remove the dust cover and take out the 37 mm circl i p. FOR K BOLT 3.0 - 4.0 kg-m l bs-ft) ( 2 1 . 7 - 28.9 37 mm CI RCLIP (3) Set up the fork in the " F RONT FO R K D I SAS SEMB L I NG TOO L" and disassemble. F RONT F O R K DISASSE M B L I N G TOOL No. 07959-2680000 FO R K PISTON (c) 4-Stroke.net FOR K SP R I NG NOTE NOTE Loosen the fork bolt before setting up the disassembl i ng tool. Insta l l the spring with the narrow pitch end up. FOR K BOTTOM PIPE NOTE Use care in assembl ing to avoid dust and dirt entering inside. S - 1 4957 1 79 FRONT W H E E L / STE E R I N G / FRONT SUSP E NSION ,fp-� ASS E M B LY • HONDA � CB50J/XL50 � F O R K B O LT 3.0 - 4.0 kg·m c__ � 0- R I N G ( 2 1 . 7 - 28.9 l bs·ft) � ( 1 ) Tighten the dra i n bolt. (2) I nsta l l the fork piston to the fork pipe then i nsert the above assembly into the bottom case. NOTE During assembly, be careful not to al l ow dust and dirt from entering i nside. (3) I nstal l the oil sea l . OIL SEAL DRIVER No. 0794 7- 1 1 8000 1 O I L SEAL ATF NOTE Before assembl i ng, apply smal l amount of oil to the oil seal . s · 1 49567 (4) I nsta l l the 37 mm circlip. NOTE 1 �;;�lf.- BOTTOM (c) 4-Stroke.net I Cl RC L I P PIPE Place the sharp edge u pward (5) I nstall the dust cover and pou r the speci fied amount of ATF (Automatic Transmission F l u i d ) i nto each fork. D R A I N B O LT Check for leaks. 0.3 - 0.6 kg-m NOTE • • 80 (2.2 - 4.3 l bs·ft) After assemb l i ng, check for operation and signs of leaks by pu mpi ng. Wipe clea n excess fluid from each fork. ATF CB50J : 1 00 - 1 05 cc (3.6 - 3. 7 ozs) X L50 : 1 05 - 1 1 0 cc (3.7 - 3.8 ozs) �HONDA � CB50J/XL50 B. FRON T WH E E L / STE E R I N G / FRONT SUSP E NSION I NSPECT I ON • Brake Lining Thickness (X L50) • Front Axle Bend B - 1 4952 1 Take a measurement at the maximum wearing section. STA N D A R D S E R V I C E L I M IT 0 - 0.05 mm 0.2 m m ( Replace) (0.008 i n ) (0 - 0.0020 i n ) STAN DA R D S E R V I C E LI M IT 4.0 mm 2.0 mm ( Replace) (0. 1 6 i n ) (0.08 i n ) Take 1 /2 o f T. I . R . (Total I ndicator Reading) • Brake Drum 1 . 0. (XL50) • Brake Pad Wear (CB50J) (c) 4-Stroke.net Replace the pads A and B as a set if the red l i ne (maximum wear l imit) aligns with the wear indicator. MAX I M U M W E A R L I M IT ( R E D L I N E ) PAD B � J R E P LACE + PAD A '0 . ' ' ' I R EP LAC E W - 1 49543 STA N D A R D SERVICE L I M IT 1 1 0.0 m m 1 1 1 .0 mm ( Replace) (4.37 in) (4.33 i n ) 81 FRONT W H E E L / STE E R I N G / FRONT SUSPE NSION • Bra ke Disc (CB50J) • Wheel R u n STA N D A R D F LATN ESS T H I C K N ESS . HONDA� CB50J/XL50 � 0 - 0.05 mm (0 - 0.0020 i n ) 4.9 - 5. 1 mm (0. 1 93 - 0.201 i n ) S E R V I C E L I M IT 0.2 mm ( Replace) w- 2a3536 (0.008 i n ) 4.0 mm ( Replace) (0. 1 6 i n ) S E R V I C E L I M IT 0.5 m m R U NOUT (0.02 i n ) 2.0 m m ( Replace o r repair) (0.08 i n ) ECCEN· 0.5 mm (0.02 i n ) o r repair) (0.08 i n ) FACE T R I C I TY • Front Wheel Bearing Play STA N D A R D 2.0 mm ( Replace • Front Fork Spring F ree Length (c) 4-Stroke.net s - 1 49566 CB50J Replace th� bearing if p l a y is excessive. · Replace t h e bearing i f it is noisy b y spinning b y hand. • 82 X L50 STAN D A R D S E R V I C E L I M IT 396.6 mm ( 1 5.6 1 i n ) 370 mm ( Replace) ( 1 4 . 57 i n ) 397. 7 mm ( 1 5.66 i n ) 372 mm ( Replace) ( 1 4 .65 i n ) �HONDA � CB50J/XL50 FRONT W H E E L / STE E R I N G / FRONT SUSP ENSION • Front Fork Piston 0.0. STAN D A R D 30.50 - 30.80 m m ( 1 . 20 1 - 1 .2 1 3 i n ) S E R V I C E L I M IT 30. mm ( Replace) ( 1 . 1 81 i n ) S - 1 34583 • Front Fork Bottom Pipe 1 . 0. STAN DAR D S E R V I C E L I M IT 30.936 - 30.975 mm 3 1 .0 mm ( Replace) ( 1 . 2 1 8 - 1 .2 1 9 i n ) ( 1 . 220 i n ) (c) 4-Stroke.net S - 1 34584 • Front Fork Pipe «I [ Check for bending, scores or scratches. 83 2. R EAR WH E E L / R EA R SUSPENSION REAR WHEEL (CB50J) HONDA r::iJ\ CB50J/XL50 � .....---- Disassembly/assembly, Page 85. D R I V E CHAI N ROTAT I N G D I R ECT I O N R E A R SHOCK ABSO R B E R Disassembly/assembly, Page 86. 3 . 5 - 5.0 kg-m ( 25.3 - 36.2 l bs-ft) R ETA I N I NG C L I P R E A R SHOCK ABSO R B E R ( X L50) R E A R WH E E L Disassembly/aS!embly, 3.0 - 4.0 kg-m ( 2 1 . 7 - 28.9 1 bs-ft) (c) 4-Stroke.net 3.0 - 4.0 kg-m ( 2 1 . 7 - 28.9 l bs-ft) 1 .8 - 2 . 5 kg-m ( 1 3.0 - 1 8. 1 1 bs-ft) Insta l l the cotter pin and spread the ends shown below. After assembly, perform the fol l owing operations: • • • 84 Drive chai n adjustment . . . . . . . . . Page 39 Drive chain slack 20 mm (0.8 i n ) Rear brake adjustment . . . . . . . . . Page 3 7 B rake pedal free play 2 0 - 3 0 mm (0.8 - 1 .2 i n ) Rear stoplight switch adjustment . . . Page 3 7 �HONDA � CB50J/XL50 REAR WHE E L / R EAR SUSP E NSION A. D ISASSEMBLYIASSEMBLY TI R E P R ESSU R E • Rear Wheel GENERAL G E R MAN, B E L G I AN, TYPE AUST R I AN TYPES CB50J 2.25 kg/cm 2 (32 psi ) 2.8 kg/cm 2 (40 psi ) X L50 2.25 kg/cm 2 (32 psi ) 2.0 kg/cm 2 (28 psi ) Be careful to keep oil or grease off the l i n i ngs or brake dru m. D R IV E N SPROCKET I (c) 4-Stroke.net D R I V E N SPROCKET D R I V I N G IN R EA R W H E E L B E A R I N G DRIVER HANDLE No. 07949-6 1 1 0000 Install the sharp end facing outside. I A L I G N TO T H E CUTOUT I \ • Do not a l l ow the bearing to tilt while driving. · I nstal l the bearing with the shield end facing the outside. A L I G N T H E PUNCH M A R KS 85 R EA R WH E E L / R EA R SUSPENSION HONDA� CB50J/XL50 � • Rear Shock Absorber (X L50) (CB50J) R EA R SHOCK ABSO R B E R COMPR ESSOR No. 07959-3290000 Apply sealer to the threads 2.5 kg-m 1 5 ( 1 0.8 - 1 8. 1 l bs·ft) . - I nstall the springs with the narrow pitch ends facing u p. SPR I NG ATTACHM E NT H O L D E R No. 07967- 1 1 50000 (c) 4-Stroke.net s . 1 34585 REAR SHOC K ABSO R B E R SPR I N G ADJUSTME N T NOTE .-------� • • I I Ill N y SO F T 86 <====:>H A R D The adjusters shou l d be set at "I" average under ridi ng condi tion. Set both adjusters at the same p os i t i on on the scales. Otherwise, loss of control or other dangers cou l d result. After assemb l i ng, check for operation. �HOND.A. � CB50J/XL50 B. REAR WHEE L / REAR SUSPE NSION I NSP ECT I ON • Rear Axle Bend • Rear Wheel Bearing Play PLAY W - 090562 Take 1 /2 of T. I . R. STANDARD S E R V ICE L I M IT 0 - 0.05 mm (0 - 0.0020 in) 0.2 mm ( Replace) (0.008 i n ) • • • Rear Wheel Rim Replace the bearing if play is excessive. Replace the bearing if it is noisy by spinning by hand. • Brake Lining Thickness (c) 4-Stroke.net B - 1 4952 1 Take a measurement at the max. wearing section. STANDARD S E R V I CE L I M IT FACE RUNOUT 0 - 0.5 mm (0 - 0.0020 i n ) 2.0 mm ( R eplace or repair) (0.008 in) STANDARD S E R V I C E L I M IT ECCENT R I C ITY 0 - 0.5 mm (0 - 0.0020 in) 2.0 mm ( Replace or repair) (0.008 in) 4.0 mm (0. 1 6 in) 2.0 mm ( Replace) (0.08 in) 87 R E A R W H E E L / R EAR SUSPENSION • Brake Drum I . D. HONDA � CB50J/XL50 � • Rear Shock Absorber Spring Free Length W - 1 4954 3 STAN D A R D 1 1 0.0 mm (4.33 i n ) S E R V I C E L I M IT 1 1 1 .0 mm ( Replace) (4.37 in) S - 1 49566 CB50J X L50 STA N D A R D SE R V IC E L I M IT 2 1 8. 8 mm (8.6 1 4 i n ) 207 mm ( Replace) (8. 1 50 i n ) 226 mm 2 1 5 mm ( Replace) (8.898 i n ) (8.465 i n ) • Rear Shock Absorber • Final Driven Sprocket Check for bend or damage Check for leaks. (c) 4-Stroke.net GOOD NOT GOOD Also check the drive sprocket Check and drive cha i n for wear. should be felt only when the shaft for is extended ) . W - 1 49549 88 operation ( resistance �HONDA � CB50J/XL50 3. FU E L COCK • Fuel Cock llJ4i;@i�[ij Do not bring an open flame NOTE I near gasol i ne. . Dra i n out all sed•ments f rom the fuel tan k whenever disassembled. F I LT E R SCR E E N NOTE Clean i n gasol ine or solvent. ��0�-----GAS K ET F 1 49537 LOCK NUT FUEL TUBE NOTE j NOTE After · insta l l atiOn, Check for any evidences of cracks or deterioration. check for J leaks past the gasket. (c) 4-Stroke.net 89 HONDA� CB50J/XL50 � 4. CAB L E /WI R E H A R N ESS R O U T I NG (C BSOJ) Cable Routing • I cAUTION I Route the cables as shown. Otherwise, B R A K E CABLE sudden or complete fai l u re cou l d resu l t. B R A K E CAB LE CLUTCH CAB L E TH R OTT L E CAB LE TACHOM ETE R CAB L E SPE E DO M E T E R CAB L E TACHOM E T E R CAB L E (c) 4-Stroke.net fti"�---- F RO NT B RA K E CAB LE -......�+---C LUTCH CAB LE SPE E DO M E T E R CAB L E T H ROTT L E CAB L E 90 �HONDA � CB50J/XL50 CAB L E /WI R E HARN ESS ROUTING (XL50) Cable Routing • I cAUTION I Route the cables shown. Otherwise, sudden or complete failure coul d result. F RONT B RAKE STOPL I GHT SWITCH W I R E ( X L50) CLUTCH CAB L E F RO NT B RAKE STOP L I G HT SWITCH W I R E F RONT B R A K E CAB L E F RO NT B R A K E CAB LE F RONT B RA K E STOPLI G HT SWITCH W I R E (c) 4-Stroke.net F RONT B RA K E CAB L E C LUTCH CAB L E SPE E DO M ET E R CAB L E 91 CAB LE / W I RE HAR NESS ROU T ING HONDAr::iJ\ CB50J/XL50 � (CBSOJ) • Wire Harness Routing I G N I T I O N COI L @ S I L I CON O I O O E R ECT I F I E R R E A R B R AKE STO P L I G HT SWITCH TO A.C. G E N E R ATOR (c) 4-Stroke.net S I L I CON D I ODE R E CT I F I E R FUSE TA I L L I GHT LE FT TU R N S I GN A L CLAMP 92 �HONDA � CB50J/XL50 CABLE/WIRE HAR NESS ROUT I NG (XLSO) • Wire Harness Routing I G N I T I O N CO I L TO H EAD L I GHT F US E S I L I CON D I O D E R ECTI F I E R T U R N S I G N AL R E LAY (c) 4-Stroke.net BATT E R Y R I GHT TU R N SI G N A L G RO M M ET LE FT T U R N S I G N A L C LAMP Route rear harness beh i nd rear fender 93 HONDA� CB50J/XL50 � VI . E L E CT R I CA L I . I G NITION A N D CHARG INGCI R C U IT I G N ITION COI L S I L ICON DIODE R ECT I F I E R BATT E R Y A.C. G E N E R ATOR • Wiring Diagram (Belgian Austrian and German Types) @--- � 0 A.C. G E N E RATOR F"' nom