03650 é HONDA C 3650 IMPORTANT SAFETY NOTICE .ui INN/M; Indira/es a pussi'bili‘ty a f personal Injury or lass of life If Instructians are not fullowed. CA UTION Indicates a possibility of equrpmem damage if instructions are not followed. Detailed descriptions of standard workshop procedures, safely principles and service operations are not included‘ it is impartant to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable ways in which service, whether or not recom- mended by Honda might be done or of the possible halardous consequences 0! each conceivable way, nor could Hunda investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda must satisfy himse/Hhoroug/v/y that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected, HONDA C B650 HIIW TO USE THIS MANUAL This manual is based on the ED (Europian direct sales) model. For other than ED model, descriptions are preceded by any of the follow- ing abbreviations whenever discrepancies occur: DK (General export KM/HI, DM (General export MPH), E (U, K), F (France), G (Germany), and U (Australia). Sections 1 through 3 apply to the whole motorcycle, while sections 4 through 19 de- scribe parts of the motorcycle, grouped accord- ing to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration, service information and trou- bleshooting for the section. The subsequent pages give detailed procedures for the section. If you don't know what the source of the trouble is, go to section 20, TROU- BLESHOOTING. ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS IN- CLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT IN- FORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO, LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITH- OUT NOTICE AND WITHOUT INCURRING ANV OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. HONDA MOTOR CO., LTD SERVICE PUBLICATIONS OFFICE CIINIENTS GENERAL INFORMATION II LUBRICATION n INSPECTION AND ADJUSTMENT ENGINE FUEL SYSTEM ':I ENGINE REMOVAL/INSTALLATION [I CYLINDER HEAD/VALVE Ii CYLINDER/PISTON II CLUTCH ':l GEARSHIFT LINKAGE I CRANKCASE I|:| PRIMARY SHAFT/TRANSMISSION CHASSIS EL ECTRICAL I l i FRONT WH EEL/SUSPENSION CRANKSHAFT IE] REAR WHEEL/SUSPENSION HYDRAULIC BRAKE BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER SWITCHES TROUBLESHOOTING n:l HONDA C3650 MIJIIEI. IDENTIFICATION (1) The frame serial number isstamped on theright side of (2) The engine serial number is stamped on the top of the the steering head‘ crankcase. (3) The carburetor identification number is on the right side of the carburetor bodv. (4) IDENTIFICATION NUMBER 112253 GENERAL INFORMATION] GENERAL SAFERY 1—1 SPECIAL TOOLS 1—6 SERVICE RULES 1—1 WIRING DIAGRAMS 1—8 AREA CODE 1—1 CABEL & HARNESS ROUTING 1—11 SPECIFICATIONS 1—2 MAINTENANCE SCHEDULE 1—14 TORQUE VALUES 1—4 GENERAL SAFETY \‘0' If the engine rnast be running to do some work, make C The battery electrolyte contains sulfuric acid. Pratert sure the area is well-ventilated. Never run the engine your eyes, skin and clothing. In case of contact. flash in a closed area. The exhaust contains poisonous thoroughly with water and calla doctor if your eyes carbon monoxide gas. were exposed o The battery generates hydrogen gas which can be w .1 RJVM G highly explosive. Do not smoke or allow flame: or Gasoline ls extremely flammable and is explosive sparks near the balmy, especially while charging IL under certain conditions. Do not smoke or allow flames ar sparks in your working area. SERVICE RULES 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalent. Parts that do not meet HONDA's design specifications may damage the motorcycle 2. Use the special tools designed for this product. 3. Install new gaskets, O-rings, cotter pins, lock plates. etc, when reassembling. 4. When torquing bolts or nuts, begin with largercliameter or inner bolt first, and tighten to the specified torque diagonally, unless a panicular sequence is specified 5. Ciean parts in cleaning solvent upon disammbiy. Lubricate any sliding surfaces before reassembly. 6, When installing a new oil seal, make sure that the sealing lip is lubricated with grease. ll an oil seal and related parts have been washed, apply proper grease to the lip of the oil seal. . After reassembly, check all parts for proper installation and operation . Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners. The use 07 incorrect tools and fasteners may damage the motorcycle. mu AREA CUBE CODE AREA (TYPE) CODE AREA (TYPE) DK General (kilometeri ED Europe DM General (mlle) F France E U.K. G Germany U Austraila 1-1 HONDA GENERAL INFORMATION C3650 SPECIFICATIONS ITEM AREA (TVPGI DIMENSIONS Overall length 2,135 mm (84.1 in) DK. DM, U 2200 mm (83.6 in) E. G, F, ED Overall width 855 mm (33.7 in) DK, DM 775 mm (30.5 in) E, ED, F,G,U Overall height 1.170 mm (46.0 in) DK, DM 1,1‘lomm(43.7in) E, ED, F,G,U Wheelbase 1,430 mm (56.31n) Seat height 795 mm (31.3 in) Ground clearance 155 mm ( 5.9 in) Dry weight 195 kg (429.9 lb) DK, DMI U 193 kg (436.1 lb) EDI E G, F FRAME Type Double cradle F. suspension, travel Telescopic fork 141.5 mm (5.6 in) R. suspension. travel Swing arm 91 mm (3.6 in) F. tire size, cold tire pressure 3.25H19 (4PFI) 200 kPa (2.0 kg/cmz, 28.4 psi) R. tire size. cold tire pressure 3.75H18 (4PM 200 kPa (2.0 kg/emi, 28.4 psi) F. brake Double disk brake E. ED, F, (3‘ U single disk brake DK, DM R. brake Leading trailing shoe Fuel capacity 18 liters (4.8 U.S. 9a|., 4.0 lmu. gal.) Fuel reserve capacity 3.5 liters (0.9 U.S.gai.,0.8 lmp.gal.1 Caster angle 27°ao' Trail 105 mm (4 in) Front fork oil capacity 170 cm3 (5.7 ozsl 150 cm3 (5.1 015) at draining ENIGNE Type Air cooled 4vsImke Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Maximum horsepower Maximum torque Oil capacity Lubrication system Air filtration Cylinder compression Intake valve Opens Closes Exhaust valve Opens Closes Valve clearance Engine weigh: (dry) idle speed Vertical parallel (our 59.8 x 55.8 mm (2.354 x 2.197 in) 626 cm3 (38.2 cu in) 9.0 : 1 Chain driven 0.H.C. 44,0 KW/9,ooo min" (59 BHP/9,000 rpm) , 50.0 NM (5.1 kg-m, (1.2 (dbl/8,000 rnin" (8,000 rpm) 3.5 liters (3.7 (1.5. qt., 3.1 Imp. qt) Forced pressure and wet sump Paper (1763:1961 kPa (120:2.0 kg/cmi, 170:28 psi) 5° (BTDC) at 1mm lirl, 55° (BTDC) at 0 lm 35° (ABDC) at 1mm (in, 127° (ABDC) at 0 lift 40°(BBDC18t1mmlift,121° (BBDCIatOlift 5° (ATDC) at 1mm lift, 65° (ATDC) at 01in IN: 005 mm (0.002 in) EX:0.08 mm (0.003 ini 71 kg (156.6 lb) 1,050:100 min" (1.0501100 rpm) 1-2 HON DA C3650 GENERAL INFORMATION ITEM AREA (Type) CARBURETION Carburetor type Piston valve, 26 mm (1.0 in) venturi bore identification number PD51 A Pilot screw Refer to 4—14. Float level 125 mm (0‘49 in) DRlVE TRAIN Clutch Wet, multivplate Transmission 5-speed constantvmesh Primary reduction 2,737 Gear ratio | 2.500 Gear ratio II 1722 Gear ratio lll 1.333 Gear ratio IV 1.074 Gear ratio V 0.885 Final reduction 2500 (16/40) 2313 (16/37) ED only Gearshift pattern Left foot operated return system ELECTRICAL lgnltion Trensistorized Ignition timing "F" mark 10° BTDC at 1050:1013 n‘iin'l (1,0501100 rpm) idle Full advance 23°3u' BTDC at 2,725 min“ (2,725 rpm) Starting system Starting motor only Generator Three phase A.C, generator 0.26 kW/ 5,000 min“ (5,000 rpm) Battery capacity 12V — 12 AH SW" ”'“9 TY” e, G, F, ED u DK, DM Manufacturer Demo X24ESH~U X24ES-U X22ES~U NGK DRBES-L DEEA D7 EA Spark plug gap ore—0.7 mm (0024 — 0.028 in) LIGHTS Headlight (low/high beam) 40/50W DK, DM, U 55/60 W Er ED, F; G, Tail/stoplight 5/21 W ED, E, G, F 8/23 W DK, DM, U Turn signal light (front/rear) 21/21 W ED, E, G, F 23/23 W EK, DM, U Speedometer light 3.4 W Tachometer light 3.4 W Neutral indicator light 3.4 w Turn signal indicator light 3.4 W Hight beam indicator light 3.4W Position light 4 W ED, E, G, F 3.4 W DK, DM, U HONDA. GENERAL INFORMATION C3650 TflRflUE VALUES ENGINE Item O'ty Thread Dia mm Torque N'm (kg-m, ft‘ib) Remarks Breather COVEr 5 6 8—12 (0.8—1.2, 6-3 ) Tachometer gear holder 1 6 8712 (0.84.2, 6—9 ) Cylinder head cover 20 6 842 (QB—1.2, 6—9 ) Valve adjusting mu 8 12—16(1.2— 6, 9—12) Rocker arm shaft cotter pin 4 6 10—14(1l0— 4, 7—10) Rocker arm shaft cap bolt 4 8—12 (0.9~‘l.2, 6—9 ) Cylinder head bolt 12 8 24—410 (24—31), 17~22l Apply molybdenum disulfied 2 6 10—14 (1.04.41 7—10l grease to the threads and underr side of bolts. Spark plug 4 12—16(112—115, 9~12l Cam sprocket 2 7 14—18 (1.4—1.8, 10—13) Cam chain tensioner 2 6 10—14 (1 iii—1,4, 7710} Crankcase 13 8 22—25 (2.2—2.6, 16—19) Apply molybdenum disulfied grease to the threads and under~ side of boltsl Oil gallery Cap 2 10—14 (1.0—1.4, 7—10) A.C. generator 1 ‘ID 50750 l5.076.0, 36'43) Spark advancer 1 25~29 (2572.9, 18—21) Connecting rod 8 24728 (2.4728, 17—20) Starting clutch 3 5 12—16(12—1l6, 9—12l Apply locking agent (0 the threads. Clutch 1 20 47—53 (4.7753, 34—38) Oil filter case 1 27—33 (2.7—3.3, 20.24) Oil pressure switch 1 10720l1.0—2.0, 7—15) Apply liquid sealant Neutral switch rotor 1 6—10 l0.6—1.0, 4—7 l Primary chain tensioner l 6 10—14(1,0—1.4, 7-40) Primary chain nozzle 1 5 8—12 (0.8—1.2, 679 l Gearshift return pin 1 23—27 (23—21, 17—40) Carburetor intake manifold 16 5 3—5 mm l1A3—1/4inl gap Throttle cable adjusting lock nut 2 678 (0.6403, 4—6 ) 1-4 HONDA. C 3650 GENERAL INFORMATION CHASSIS Item O’ty Thread Dia mm Torque N-m (kg-m, ftrlb) Remarks Steering stem nut 1 24 80~120 (SD—12.0, 58—87) Steering handlebar 4 E 28~32 (2,8w32, 20—23) From fork top bridge 2 7 9—13 (DB—1.3, 7—9 ) Front fork cap bolt 2 30740 (30—41), 22—29) Front fork bottom bridge 2 1O 30'40 (3.0—43, 22—29) Front axle holdEr 4 8 18—25 (18—25, 13—18) From axle nut 1 12 55765 (5.5—6.5, 40—43) Fron’tbrakedisc 5 8 27—33 (2.7—3.3, 20—24i UBS Brake hose bolt 2 10 25735 (2.5—3.5, 18—25) DK, DM 5 10 25-85 (2.5735, 18~25i E, ED, F, G, U Front brake caliper carrier 2 10 30410 (3.0—4.0, 22—29) DK, DM 4 10 30740 (3.0” .0, 22—29) E, ED, F, G, U Front brake caliper A 2 10 30—40 (3.0‘40, 22729) DK, DM 4 10 30—40 (3.0—4.0, 22—29) E, ED, F, G, U Rear axle l 18 807100 {Bo—10,0, 58~72) Final driven sprocket 4 12 80—100 (SD—10.0, 58—72) UBS Swing arm pivot nut 1 14 60770 (610—713, 43—51) Rear brake torque link 1 8 18—25 (1 .8—25, 1371B) Rear shock absorber 4 10 30~40 (3.0—4.0, 22—29) Engine hanger bolt 5 10 30—40 (3.0—4.0, 22729) 1 12 80»100 180—100, 55—72] 8 8 26—32 (2.6—3.2, 19723) Foot p89 1 10 30~40 (3.0—4.0, 22—29) Gearshift pedal 1 6 8—12 (0.8—1.2, 6—9 ) Kick starter pedal 1 6 8—12 {OB—1.2, 6—9 ) Brake fluid reservoir cap 4 4 1—2 (0.1—02, 0.7—14) Fasteners not listed should be tightened to standard torques listed below. STANDARD TORQUE VALUES 8 mm bolt, nut 10 mm bolt, nut 12 mm bolt, nut 1B~2511.872.5, 13—18) 30410 1311—41), 22~2Qi 50~60 (5.0761), 36—43) 6 mm flange bolt, nut 8 mm flange bolt, nut 10 mm flange bolt, nut Type Torque N-m (kg-m, ft~lbl Type Torque N-m (kg-m, ft-lb) 5 mm bolt, nut 4.5—6 (OAS—0.6, 3.574.51 5 mm screw 3.5—5 (035—05, 2.5—3.6) 6 mm bolt, nut 8—12 (0.8-1.2, 6—! 1 6mm screw 7»11 (0.7711, 5—8 ) 10~14(1tO—1.4, 7—10) 24‘30 (2,473.0, 17-22) 30—40 (30—41), 22729) 1-5 HONDA GENERAL INFORMATION C3650 SPEEML TflfllS/CflMMllN TlllllS SPECIAL TOOLS (Other models) Tool Name Tool No. O’ty Rel. page Valve adjusting wrench 0790873230000 1 3—6 Spark plug wrench 0790973000000 1 373 Snap ring pliers 07914—3230001 1 1576 6 mm hex wrench 0791773230000 1 13— I, 13—22 Sliding hammer shaft 0793673740100 1 10—3 Sliding hammer weight 0794573000500 1 1073 Ball race remover 07953—3330000 1 13725 Piston ring compressar 0795473740000 2 7—8 Piston base 0795872500001 2 77B Torx driver bit 0770370010200 1 11—4, 11—1 5 Driver attachment 0794673290000 1 13726, 14—8 Valve guide reamer 0798472000000 1 6711, 6-12 Carburetor throttle wrench 0790874220100 1 3710 Carburemr pilot screw wrench 0790874220200 1 4-14 Cylinder head bolt wrench 0790673230000 1 6—9, 6715 Oil pressure gauge attachment 07510—4220100 1 273 Bearing driver attachment 0794776710100 1 11716, 13726 Valve seat cutter 129 mm) 077130—001 0300 1 Valve sear cutter (30 mm 0778070010400 1 Valve seen flat Cutler (30 mm) 0778070012200 1 6—13 Valve 5861 1131 cutter (35 mm) 0073070012300 1 Valve seat interior cuner (30 mm) 0078070014000 1 Valve seat cutter huider [5.5 mml 0078170010100 1 1-6 é HONDA C5650 GENERAL INFORMATION COMMON TOO L T001 P871 No. Q‘tv Alternate Tool Farl Nu H91. Page F108! level gauge 074DlvDO1ODUD 1 4—5 Retainer wrench 1A1 07710—0010100 1 Bearing raramer wrench 07910—2830000 14*4 Rerainer wrench 1B) 07710—0010200 1 Bearing relmner Wrench 0791073230101 13—14,13—|6 Retainer wrench (C) 07710—001030!) 1 Bearing retamer Wrench 07910—39300“) 14- , Heminev wrench body 0771070010400 13—14 13—16 144 Look nut wrench sucker 07716—0020400 1 13—24‘ 23-27 (30 x 32 mm) Lock nut wrench Snake! fl7716i0020202 I 373, 8*7, (1‘6 X 30 mm) Extension bar 07716~0020500 l 3,3, 54 13—24, 13—27 Universal holder 07725—001010] I 8—3, 8—7 Valve gulde remover (545 mm) 077.42*OD1U100 1 Valve guide driver 07942—3290100 6‘12 Valve guide driver {31 07741—0020200 1 Valve guide drlvar 0794273290200 6-42 Bearing driver outer (42 x 47) 07746—0010300 1 Eearmq dnver 07945-333010!) 13‘15 Eearmg driver cuter (62 X 681 07746—001050!) 1 Bearing driver 07945-3600000 14—8 Bearing drwer handle (Cl 07745—0030100 1 11*12 Hearing drwerinner (25 mm) 07745-0030200 1 “*12 Bearing dnver pilot (15 mm) 07745—0040390 1 13—16 Bearing driver pllul (20 mm) 0714670040500 1 14—8 Bearing driver pllct (22 mm) mus—comma 1 11-15 Bearmg driver all!“ (25 mm) 0774670040600 1 14—8 Bearing driver handle (B) 07746—002010!) I 1 1_15 Rotor puller 07733—0020001 1 164; From fork all see! driver body 07747—0010100 1 Fork sew driver 07947—3290000 13—21 Front fork oil seal attachment {E} 07747—001060!) I 13—21 Bearmfl drivar handln 1A) 07749—0010000 1 Driver handle aflachment 07949—5110000 11—16, 13—15, 13-26, l4~8 Valve spring compresxor 07757—0010000 1 Valve spring compressor 07957—329001” 6—9, 6‘14 Shock absorber compressor 07959—32900!“ 1 14*“), ”‘11 Pin spanner 07702—0010000 1 Pin manner 07902—2000000 13‘24, 13.25 1-7 HONDA. C3650 WIRING DIAGRAM DK, W, E, ED, F, U me 30x rusE Immuvmm» mm um: naqu mama: mu my mm m: mmwmv mm am mum mmuwmw on mm: mm mm: mm flit wumsmwam ma a-n‘mv L 1mm swat. mm anmm _ w mm sum am up» mau- wmv mswm-nsmumhuu mm sum 5m wzsmm "Wm umwzvuwxr 5mm mm: swm mu ms: amsm 6 mm m a «M w sum um :5er mm mwmmnw is) man new u u; £§ mamas. um umwxz ‘ W” mum -N< ,1: ‘1 mus: LWIEF m uzvmw mm! mm 2 mm mm sum um [rimzvzw mm um inmvwzuw mm mm 0: u r “’ “Em-mo 59: mm msu 40w mum (rum) 0 mm mm swan "ill m m a sum aux. mo 2 .0 4 ussma 4qu Wm mum .mw 5mm "'0‘“ W“ , max 0 L mom mm 5mm. new 2mm” w m L um mm mm mm anmzvzw mnw 5mm mauve: mum mmrm om. sum W m“ Auznlwon p « "mm mm 00 mm s m 5: mm v m». ‘ a. m 5 Im : mum 5mm commwv Momma-mans smmsmm: swan mmv mm swan-WMDI-Mnamnssm 5mm comm" * "W W “W as _ m mm LE um am am m u m r Em n. m u. m n w n L m. u u: no a a an 0 mm W 5 , Gum v m m 003024261383 HONDA GENERAL INFORMATION C5650 CABLE & HARNESS ROUTING (2) THROTTLE ' CABLES (3) LEFT HANDLEBAR SWITCH Q-P COUPLER gm L A (1) INSTRUMENT 1" £321“? 4-: 9-12 COUPLER ‘ V .-l.' ‘- [Ell L , «J \ l (2) RIGHT HANDLEBAR SW|TCH 9‘? COUPLER {4) FUSE HOLDER 6-P COUPLER 1-11 éé? IICDDIIDIL C3650 GENERAL INFORMATION E, ED, F, G 11) LEFT TURN SIGNAL LIGHT CORD (2) FRONT BRAKE HOSE { (3) SPEEDOMETE R CABLE (1) RIGHT TURN SIGNAL LIGHT CORD . - x, u. [y (3) SPEEDOMETER fi/ CABLE 1-12 / HONDA GENERAL INFORMATION C3650 MM) GROUND CABLE TERMINAL (I) WIRE GROMMET BATTERY TUBE (3) CLUTCH CABLE STARTER CABLE I2) PULSER GENERATOR (I) REGULATE RECTIFIER CORD I2) SPARK UNIT (3} STARTER RELAY SWITCH HONDA C 3650 MAINTENANCE SCHEDULE PerIorm the PRE RIDE INSPECTION In the Owner' 5 Manna! at every maintenance period . INSPECT CLEAN ADJUST, LUBRICATE OR REPLACE IF NECESSARY. GENERAL INFORMATION |' C. CLEAN R: REPLACE A: ADJUST L: LUBRICATE WHICHEVER \\ FREQUENCY OCCURS -. FIRST @ ITEM EVERY ENGINE OIL YEAR R R H Page2- Z W ENGINE OIL FILTER YEAR R R R" “maga- 2 AIR CLEANER NOTE (1) C R Page 3- 2 ‘ FUEL LINES I I Page 3- 3 SPARK PLUGS M A I’ ”R ’IiagMeE-Ta‘ ' VALVE CLEARANCE I I I Page 3- e ‘ CAM CHAIN TENSION A A A Page 3- 7 * THROTTLE OPERATION I I I Page 3- 7 ‘ CARBURETOR CHOKE I I Page 3- E ' CARRLIRETOR SYNCHRONIZE I I A Page3 9 * CAREURETOR IDLE SPEED I I Page 3-11 DRIVE CHAIN I, L EVERY 1,000 km (600m M Page 3-12 BATTERY MONTH I I I I I I Page 3-13 BRAKE FLUID (FRONT) MONTH I I I I “R I I Page 3-13 2YEARS R BRAKE PADS/SHOES WEAR I I I I I " Page 3-14 BRAKE SYSTEM I I I I I I Page 3-14 “ BRAKE LIGHT SWITCH I I I I I I Page 3-15 * HEADLIGHT AIM I I I I I I Page 3-15 CLUTCH FREE PLAY I I I I I I Page 3-16 SIDE STAND I I I I I Page 3-17 * SUSPENSION I I I I I I Page 3-18 * NUTS. BOLTS, FASTENERS I I I I I I Page 3-19 ” WHEELS I I I I I I Page 3-19 ” STEERING HEAD BEARING I I I Page 3-19 ' SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED. ” IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLV BY AN AUTHORIZED HONDA DEALER. NOTES: (1) SERVICE MORE FREQUENTLY IF OPERATED IN DUSTY AREASI (2) FOR HIGHER ODOMETER READINGS. REPEAT ATTHE FREQUENCV INTERVAL ESTABLISHED HERE. 1-14 HONDA C3650 LUBRICATION 2-0 HONDA C3650 LUBRICATION ENGINE LUBRICATION SYSTEM (13) ROCKER ARM 0/1 (12) CAMSHAFT «I, I'll) CYLINDER HEAD HO) CRANKSHAFT (G) PRIMARY CHAIN TENSIONE (4) OIL PRESSURE SWITCH (2) OIL PUMP (5) OIL FILTER (3) OIL ‘ ORIFICE (s) TRANSMISSION MAINSHAFT (9) TRANSMISSION COUNTERSHAFT I1) OIL STRAINER ‘ 7' 2-0 LUBRICATION ENGINE OIL LEVEL SERVICE INFORMATION 2—1 OIL STRAINEFI CLEANING 2—3 TROUBLESHOOTING 2—1 OIL PRESSURE 2~3 ENGINE LUBRICATION OIL PUMP 2—4 2—2 CHASSIS LUBR ICATION ENGINE OIL 8i FILTER CHANGE 2—2 LUBRICATION POINTS 2—8 SERVICE INFIIRMATIIIII GENERAL INSTRUCTIONS Tlie oil strainer and oil pump maintenance and inspection can be accomplished without removing the engine. SPECIFICATIONS Oil capacity Approximately 3.0 lit (3.2 US £11., 2.6 Imp. qt) at change 3,5 lit (3.7 US at, 3.1 Imp. all at engine assembly Recommended oil HONDA 4.stroke oil or equivalent API service classification — SE General, all temperature SAE 10Ws40 Alternate Above 15°C (60°F) SAE 30 ~10" (015°C (15° to 60°F) SAE 20 or 20w Below 0°C (32°Fl SAE 10w OlI pump delivery Oil pressure (at oil pressure switch) 21.3~26:3 lit (22.5—27.8 US qt” 19.6—23.2 Imp. all/min/SJJDO min'l {3,000 rpm) 372574118 Was/3,000 min" (3.8—4.2 kg/cmq, 54—60 psi/3,000 rme SPECIAL TOOL Special Tool Oil Pressure Gauge Attachment TORQUE VALUES oil filter case Oil pressure switch Gearshlit pedal IRIIIIBIESIIIIIITIIIII Oil level too low 1. External all leaks 2. Worn piston rings 3. Worn valve guide or seal Oil contamination 07510—4220100 27733 N-m (2.7733 kgrm, 20724 ftrlb) 10—20 N‘m (1.0—2.0 kg-m, 7—156t-Ibl 8712 Nm (0.84.2 kgrm, 679 it-Ib) 4. Oil pump worn 5. External oil leaks High 0” pressure 1. Pressure relief valve stuck 1. Oil or filter not changed often enough 2. Plugged oil filter, gallery, or metering orifice 2. Head gasket faulty 3. Worn piston rings Law oil pressure 1. Oil level low 2. Pressure relief valve stuck open 3. Plugged oil pick-up screen‘ 3. Inoorrees oil being used No oil pressure 1. Oil level low 2. Oil pump drive gear broken 3. Oil pump faulty 4. Internal oil leakage 2-1 HONDA C3650 LUBRICATlON ENEINE LUBRICATIIIN ENGINE llll LEVEL Run the engine and allow to idle for a few minutes. Stop the engine and Support the motorcycle on the center stand‘ Check the oil level with the filler cap dipstick after a few minutes. Do not screw in the cap when making this check. If the level is below the lower level mark on the dipstick, fill to the upper level marki Check the oil pressure warning light, This light should go off when the engine starts. If it does not, check the oil pump function and/or oil circuit. ENGINE lllL & FIITER BHANEE Warm the engine to normal operating tem perature, Stop the engine. Place the motorcycle on its center stand. Remove rhe oil filler capl drain plug and oil filter bolt and drain the oil. Make sure that the sealing washer on the drain plug and the Olrings on the oil filter bolt and oil filter are in good condition. After completely draining, replace the oil filter and install the oil filter bolt and drain plug. Fill the crankcase with 3,0 lit (32 US at. 2‘6 Imp qt) of the recommended oil. Reinstall the oil filler cap. Start the engine and let i! idle for 2-3 minutesv Add the recommended oil to the upper level. Make sure that there are no oil leaks‘ (1) DRAIN BOLT I1) O-RINGS flll. STRAINER CLEANING The oil strainer can be removed with the engine mounted in the frame. Remove the oil filler cap, drain plug and oil filter bolt. Remove the oil pan bolts and oil pan. Remove and clean the oil strainer, lnstall the oil strainer and oil pan, Fill the crankcase with the recommended oil (Page 2A2). ”fl W, ,,,,,,,,,,,,,7 Align the slot m the strainer with the Erfnkcase ribs l3) RIB (2) STOPPE R OIL PRESSURE Warm the engine up to normal operating temperature (approximately 80°C, 176°F). Remove the oil pressure switch‘ Connect an oil pressure gauge to the pressure switch hole. Check the oil level. Check the oil pressure at 3,000 min" (3,000 rpml, STANDARD: 372.6—411.8 kPa at 3,000 min" (3.8—4.2 kg/cmz, 54—60 psi at 3,000 rpm) 80°C (176°F) Apply a liquid sealant to the pressure switch threads and install. Check that the oil pressure warning light goes out. if the oil pressure warning light stays on, stop the engine immediately and determine the cause. LUBRICATION 2-3 HONDA. C3650 LUBRICATION fill. PUMP OIL PUMP REMOVAL NOTE The oil pump can be removed with the engine mounted in the frame. Drain the oil from the engine, Remove me gearshift arm (gearshift pedal: DK and DM) from the spindle‘ Remove the left crankcase may cover. Disconnect the oil pressure swiich wire. Remove the oil pressure switch, Remove the oil pump. :l1l0lL Fags URE $1an ‘ PRESSURE RELlEF VALVE DISASSEMBLY/ASSEMBLY Remove the sealing bolt. Remove the pressure relief valve spring and valve. (1) PRESSURE RELIEF VALVE (2)5PRING (3) O-RING l4) SEALING 30 Check me relief valve, spring and O-ving for damage. install the pressure relief valve, spring, 04—an and sealing bolt. 2-4 HONDA C3650 LUBRICAT|ON OIL PUMP DISASSEMBLY Remove the oil pump body cavsr‘ Remove the inner and outer rotors‘ Remove the O-ring‘ Remove the drive pin and drive shaft, (1) OIL PUMP BODY COVER 0 (1 ) OUTER ROTOR (3)0—RING ) INNER ROTC (”BODY COVER (2) INNERROTOR (3)0u153 ROTOR (6) BODY HONDA C3650 LUBRICATION OIL PUMP INSPECTION Measure the rotor lip clearancev SERVICE LIMIT: 0.15 mm (0.006 in) Measure the pump body clearanoeI SERVICE LIMIT: 0.35 mm (0.014 in) Measure the pump and cIearance. SERVICE LIMIT: 0.1 mm (DJIMin) HONDA C3650 LUBRICATION OIL PUMP ASSEMBLY Insert the drive shaft‘ Insert the drive pin into the drive shaft. Parallel the drive pin with the square boss on the pump body. (1 I SQUARE BOSS Align the punch marks on the inner and outer rotors and install them by aligning the slots in the inner rotor with the drive pin. Install the O-ring in the pump body groove, Install the pump body cover. (SIC-RING OIL PUMP INSTALLATION Remove the oil control orifice from the crank- case oil hole and check it for Clogging. Install the orifice into the crankcase oil hole. NOTE Note the oil control orifice direction. (1) ORIFICE Install the (Ming: and collars‘ (2) COL LARS HONDA, C3650 LUBRICATION Install the oil pump. Anply a liquid sealant to the oil pressure threads and install. Connect the pressure switch wire. Install the lefx crankcase rear cover and gear» shift arm (gearshift pedal: DK and DM). Fill (he crankcase with the recommended grade all (Page 2—2), CHASSIS LUBRICAIIIIN PIIINTS ’"fi (5) CLUTCH AND BRAKE ! I (4) THROTTLE GRIP LEVER FIVOT I7) SPEEDOMETER AND TACHOMETER 12) FOOT PEG _@ ’ “ELSE PIVOT (3) SWINGARM (6) CLUTCHKTHROTTLEE l AND CHOKE CABLES PIVOT BUSHINGS (8) STEEnmefi HEAD BEARINGS (II WHEEL BEARINGS RONT FORK IT.F‘I GREASE GHEASE (15I DRIVE m M) BRAKE mm (13) Sega/222mm ems: .fi CHAIN PEDAL (12) FOOTPEG PIVOT (11) WHEEL 11o) SPEEDOMETEH PIVOT pwo-r BEARINGS DRIVE GEAR 2-8 HONDA. 3. INSPECTIIIN AND ADJUSTMENT C 3650 SERVICE INFORMATION 3—1 DRIVE CHAIN 3—12 AIR CLEANER 3—2 BATTERY 3—13 FUEL LINES 3—3 BRAKE FLUID 3—13 SPARK PLUGS 3—3 BRAKE PADS/SHOES WEAR 3—14 IGNITION TIMING 3—4 BRAKE SYSTEM 3—14 SPARK ADVANCER 3—5 BRAKELIGHT SWITCH 3—15 VALVE CLEARANCE 3—6 HEADLIGHT AIM 3—15 CAM CHAIN 3—7 CLUTCH FREE PLAY 3—16 THROTTLE OPERATION 3—7 SIDE STAND 3—17 CHOKE MECHANISM 3—8 SUSPENSION 3—18 CARBURETOR SVNCHRONIZATION 3—9 WHEELS/SPOKES 3—19 IDLE SPEED 3—11 STEERING HEAD BEARING 3—19 COMPRESSION TEST 3—11 NUTS, BOLTS, FASTENERS 3—19 SERVICE INHIRMATIUII GENERAL INSTRUCTIONS SPECIALTOOLS Engine oil level check See page 2—2 Carla. Throttle Wrench 07908—422010!) Engine oil change See page 2—2 Vacuum Gauge 07404—0020000 Engine oil filter change See page 2—2 Valve Adjusting Wrench 07908—3230000 Spark Plug Wrench 07909—3000000 SPECIFICATIONS Spark plug 0.6—0.7 mm (0024—0028 in) Drive chain free play 15—25 mm (5/8—1 in) Spark plug type Clutch Iree play 10—20 mm (3/8—3/4 in) Tire Model E, ED, F, G U DK, DM Cold tire pressure Fwnl: 200 (2.0, 28) ND X24ESR-U X24ES-U X22ES-U kPa (kg/0m1, psi) Rear: 280 (2.8, ml Driver only Front: 200 (2.0, 28) NGK DRBESi DBEA D7EA Rear: 20“ (2‘0. 23) . Tire brand Front: BRIDGESTONE MaG. MOPUS~S703 ND: Nippondenso (20., Ltd. T . v NGK: NGK Spark Plug 60., Ltd. ubeless only Rear. BRIDGESTONE MaG. MOPUS S710 Ignition timing Initial 10° (BTDC) TORQUE VALUES Valve clearance IN 0'05 mm “1002 ml Breather cover 8—12 N-m (0 8— 1 2 kg-m. 6—9 11-11)) EX 008 mm ID 003 in) Valve adjusting nut 12—16 N~m 11. 2— 1.6 kg-m, 9—12 ft-Ib) Idl d ' 50:100' . ., Spark plug 12—16N~m 11. 2— —.1Gkg-m,9—12ft-Ibl e We“ "0 110 m'” Cam chain mnsioner 10—12 N-m {1.0— 1. 2 kg-m, 7—10 mu) . . “105° 0 “’m’ . on filter case 27—33 Nm (2. 7—3. 3 kg~m, 20—24 ft-lb) Synchronization leference of each cylinder Throttle cable vacuum _ 60 mmHg (2.4 ianl or less adjusting lock nut 6—8 N-m (0.6—0.8 kgim, 4—6 bel C°mF‘"’“‘°" "75-3 1 ‘9“ “P3 Rear axle nut 80—100 N'm (13.0—10.0 kg~m, 58—72 mm (12: 2 kg/cm¢,17o: 28 psi) 3-1 HONDA C3650 INSPECTION AND ADJUSTMENT MR CLEANER Remove the left side cover. Remove the two air cleaner cover screws and cover. (Z'Y'U F'iREOW ' » »” MARK Remove the air cieaner element Ciean the element by tapping it lightlv to loosen dust Blow away we remaining dust by applying compressed air from inside the element. Replace the element if it is excessively dirty, bruken or damaged. Reinstall the element, cieaner cover and left side cover. NOTE Piece the "up ARROW” mark upJvard. INSPECTION AND ADJUSTMENT HONDA C3650 FUEL LINES Replace any parts which show deterioration, damage or leakage. SPARK PLUGS Disconnect the spark plug caps and remove the spark plugs. Visually inspect the spark plug. Discard the spark plug if the insulator lS crack- ed or chipped. Measure the spark plug gap with a wire- type feeler gauge, Adjust the spark plug gap by bending the 0.6—0.7 mm ((1024—0028 in) (2) Check: Sealing l1 ) Check: Gap : Deposi! : Wear side electrode. Damage SPARK PLUG GAP: 0,6~0.7 mm (000244.028 in.) RECOMMENDED SPARK PLUG M d ° 9' E,G,F, ED u DK,DM Manufacturer ND X24ESR-U X24ES»U X22ES-U NGK DRBES-L DBEA D7EA Manufacturer: ND: Nippondanm Co., Ltd. NGK: NGK Spark Plug 00., Ltd. Install the spark plugs making sure the sealing washers are in good condition and reconnect the spark plug. NOTE First tighten the spark plug fingertight, lhen tighten with a spark plug wrench. \ (3) Check: Cracks 3-3 HONDA C3650 INSPECTION AND ADJUSTMENT IGNITION TIMING DYNAMIC Remove the pulser generator cover. Connect a stroboscopic timing light to the No 4 cvlinder's high tension cord. Stavt the engine and let it idle. IDLE SPEED: 1,050 1100 min" (1,050 1 100 rpm) Aim the timing light at the timing mark‘ Ihe "1.4 F-I" mark should align with the index mark, ADJUSTMENT Adiust by loosening the three pulser base plate screws and rotating the plate, Tighten the screws and recheck the timing. ALTERNATIVE METHOD (5) 174 PULSER STATIC GENERATOR Remove the pulser generator cover. “£6 Rotate the crankshaft counterclockwise and align the “1‘4 87F“ mark with the index mark. “915",” , “we Either No.1 or Noll piston must be near T.D.C‘ of the compressian stroke at thistime. The timing Is correct if the narrow projection of the ”1.4" pulser generator aligns with the rotor tooth. INSPECTION AND ADJUSTM ENT SPARK ADVANCER Remove the pulser generator Covet Connect a lwming light ‘0 the No.4 high kension oord. Stan the engine. Bring engine speed to 2,725 rpm or above and check that the index mark is between the full advance marks. CA U TION Do not allow engine speed to exceed 9,500 mm or engine damage may result Hep‘aoe the advancer assembly if it is not functioning properly. Install the pulsar generator cover, 3-5 HONDA C3650 INSPECTION AND ADJUSTMENT VALVE CLEARANCE NOTE Inspect and adjust the valve clearance while the engine is cold (Below 35" C,95°Fl. Raise the seat. Turn the fuel valve OFF and remove the fuel tube and fuel tank. Remove the breather tube from the breather cover. Remove the right and left aidustment covers and breather cover. Remove the pulsar generator cover. Rotate the crankshaft clockwise and align the “1.4 T” mark with the index mark. Make sure the No.1 piston is at T,D.C. (Top Dead Center) of the compression stroke. Measure the valve clearance for the valves marked “0“ in the chart below, by inserting a feeler gauge between the camshaft and each rocker arm slipper. Cylinder No. No.1 Na. 2 No. 3 No.4 W o a a o EX 0 o o o VALVE CLEARANCES: IN: 0.05 mm (0.002 ini EX: 0,08 mm (0.003inl Adjust by loosening the lock nut and turning the adiusting screw until there is a slight drag on the feeler gauge. Hold the adjusting screw and tighten the lock nut. TORQUE: 12—16 M!“ (Ll—1.6kwm, 9—12 ft-lb) Recheck the valve clearance. Rotate the crankshaft one full turn (360°) clockwise and align the ”1A4T" mark with the index mark. Check and adjust the valve clearance for the valves marked “O" in the same chart. Install the pulser generator cover, right and left adjustment covers, breather cover, fuel tank and fuel tuba. INSPECTION AND ADJUSTMENT CAM CHAIN Remove the pulser generator cover. Loosen the cam chain tensioner lock nut. Tighten. the lock nut while rotating the crankshatt clockwise. TORQUE: 10—14N-m (1.0—1.4 kg-m, 7—10 It-Ihl tion itself to provide the correct ten» sion when the lock nut is loosened. Install the pulsar generator cover. THRIlTTLE flPERATIflN Make sure that there is no deterioration, damage, or kinks in the throttle cables, and that the throttle grip free play is 2—6 mm (1/8 — 1/4 in) on the outer edge of the throt- tle grip flange. Check for smooth throttle grip full opening and automatic full closing in all steering positions, NOTE The accelerator pump may flood the Major adjustments are made at the lower adjuster. To adjust, remove the fuel tank, loosen the grip free play adjuster lock nut and turn the adjuster. Tighten the lock nut. Minor adjustments are performed at the upper adjuster. Hecheck the throttle operation. Replace any damaged parts. HONDA C3650 2—6 mm (1/8—1/4 in.) ‘ _ NCREASE - ‘_ l1 ILOCK NUT HONDA C3650 INSPECTION AND ADJUSTMENT CHOKE MECHANISM Operate the ehoke knob and check for choke knob free play and smooth operation of the choke knob, choke lever and choke shaft. Make sure the shake lever does not move upward (closed side) when the choke knob is pulled all the way out. :(3) mesa/as: Adjust by loosening the choke cable clamp and moving the choke cable. Tighten the clamp, holding the choke lever fullv closed. Adjust the choke operating friction by turn- ing the adjuster. The choke knob must move smoothly and stav where positioned‘ HONDA C3650 INSPECTION AND ADJUSTMENT CARBIIRETDR SYNCHRflNlZATlflN NOTE Synchronize the carburetors with the engine atnormal operating temperature, transmission in neutral and motorcycle on the center stand‘ Remove both side covers and raise the seat. Tum the fuel valve OFF and remove the fuel line and fuel tank‘ Prepare a longer fuel line and reconnect it between the fuel tank and carburetor, Position the fuel tank higher than normal. Remove the plugs from the intake ports and install the vacuum gauge adaptors. Connect the vacuum gauge, HONDA C8650 INSPECTION AND ADJUSTMENT ADJUSTM E NT NOTE The No. 2 carburetor cannot be adjust- ed; it is she base. Start the engine and adjust the idle speed. IDLE SPEED: 1,050 i100 min" (1,050 i 100 rpm) check that the difference in vacuum readings is 60 mmHg (24 ianl or less. " l 2) ADJUSTING saw v Adjust by removlng the No.1, 3 and 4 car- buretov top covers, loosening the lock "ms and turnlng the adjustlng screws with the ”Carburetor Throttle Wrench" tool. Tighten the lock nuts and recheck the idle speed and synchronizatlonl Install the carburetor (0p covers. Install \he intake port plugs, fuel tank, fuel line and side covers. (1 )CAHB‘THHOTTLE WRENCH 07908—4220100 3-10 HONDA C3650 INSPECTION AND ADJUSTMENT IDLE SPEED NOTE“ _ inspect and adjust idle speed after all other engine adjustments are within specifications. The engine must be warm for accurate idle adjustment. Ten minutes of stoprandvgo driving is sufficient, a i2‘l’lN’C’REASE Warm up the engine, shift to NEUTRAL, and place the motorcycle on its center stand. Turn the throttle stop screw as required to obtain the specified idle speed. lDLE SPEED: 1,050 :10!) min" (1.050 t 100 rpm) CflMPRESSIflN TEST Warm up the engine. Remove all spark plugs. Insert the compression gauge. Open the choke and throttle valves fullyi Crank the engine with the starter motor. NOTE 7,. _.___,. ‘_ Crank the engine until the gauge res ng stops rising. The maximum reading is usually reached within 4A7 seconds. COMPRESSION PRESSURE: 1,176.2 $196.2 We (12 t 2 Ira/mi, 170 e 28 psi) If compression is low, check the following: — Leakv valves — Improper valve clearance 7 Leaking cylinder head gasket — Worn piston/ring/eylinder If compression is high, it indicates that carbon deposits have accumulated on the combustion chamber or the piston crown. 3-11 DRIVE CHAIN Place the vehicle on its center stand and shift the transmission in neutral, and turn the ignition switch OFF. Inspect drive chain free play midway between the sprockets on the lower chain run. FREE PLAY: 15—25 mm (5/8 — 1 in) CA U TlON . Excessive chain free play; 40 mm (6/8 in) or more, may damage the frme. Inspect the drive chain and sprockets for damage or wear. A drive chain with damaged rollers or loose pins must be replaced. Replace any sprocket which is damaged or excessively worn. CHAIN REPLACEMENT NOTE Never install a new drive chain on worn sprockets or a worn chain on new sprookets. Both Chain and sprockets must be in good condition or the replacement chain or sprockets wnl wear rapidlyt ADJUSTMENT Remove the rear axle cotter pin and loosen the axle nut. Loosen the adjuster bolt lock nuts, Turn the adjuster bolts an equal number of turns to obtain the specified free play, CA U T] 0N Be sure that the index mark on the chain adjuster aligns with the same graduation of the scale on both rides. Tighten the adiuster bolt lock nuts. Tighten the axle nut and install a new cotter pin. AXLE NUT TORQUE: 80—100 N-m (13.0—10.0 kg-m, 58—72 ft-lb) LUBR ICATION Lubricate the drive chain. NOTE m LUBRICANTS Commercial aerEsBl tvpe drive chain lubricant is recommended. _ 3-12 HONDA INSPECTION AND ADJUSTMENT C3650 9mm ‘ “m ' ”W Remove the right side cover, Inspect the fluid level. When the fluid level nears the lower level, remove the battery and refill with distilled water to the upper level. NOTE Add only distilled water. Tap water will shorten the service life of the hate teryt The battery electrolyte contains sulfuric acid, Protect your eyes, skin and cloth- ing. In case of Contact, fluxh thoroughly with water and call a doctor If electralyte gets in your eyes. Replace the battery, if sulfation forms or sediments accumulate on the bottom, BATTERY REMOVAL Disconnect the ground and positive cables at the battery terminals. Remove the battery holder plate bolts. Remove the battery BRAKE FLUID Check the front brake fluid reservoir level. It the level nears the lower level mark, fill the reservoir with SAE .11703 or DOT—3 BRAKE FLUID to the upper level mark. Check the entire system for leaks, if the level is low. CA UTION Do not remove the cover until the handlebar has been turned 0: that the reservoir is level. Avoid operating the brake lever with the cover removed. Brake fluid will squirt out if the lever is pulled. NOTE Use only SAE J1703 or DOT—3 brake fluid from a sealed container. 3-13 HONDA C3650 INSPECTION AND ADJUSTMENT BRAK PADS/SHBES WEAR BRAKE PAD WEAR Remove the cap from the caliper and check for brake pad wear. Replace the brake pads if the red line on the too of the pads reaches the edge of the brake disc {Refer to Section 15L CA UTION Always replace the brake pads in pairs to assure even disc pressure. (”BRAKE PADS BRAKE SHOE WEAR Replace the brake shoes if the arrow on the brake arm aligns with the reference mark “ V " on full application of the rear brake. BRAKE SYSTEM Check that there is no deterioration, damage or leaks in brake lines and fittings. Check the brake rod for loose connections, excessive play or damage. inspect the mounting of the rear brake arm to the brake cum to make sure the locking bolt is tight and the splines u'ndamaged. Check that the cotter pin is properly installed. Replace or repair if necessary. BRAKE PEDAL HEIGHT Loosen the lock nutl Adjust the pedal height so that the distance between the oedal and upper face of the foot- peg is 25.5 mm (1 in) by turning the adjust- ing bolt‘ (1 l LOCK NUT Tighten the lock nut. INSPECTION AND ADJUSTMENT BRAKE PEDAL FREE PLAY Check the brake pedal free play. FREE PLAY: 20—30 mm (3/4-1-1/4 in) Turn the rear brake adjusting nut, if neces- sary. BRAHELIGHT SWITCH Adjust the brakelight switch so that the brake- Iight will light when the brake pedal is dpres- sed and the brake begins engagement. NOTE Do not turn the switch body. The front brakelight switch does not require adjustment. Adjust by turning the switch adjusting nut as shown ‘ADJUSTING ' NUT HEADLIGHT AIM Adjust vertically hy loosening both headlight case mounting bolts. Adjust horizontally by turning the adjusting screw on the headlight rim. Turn the adjusting screw clockwise to direct the beam toward the right side of the ridert NOTE Adjust the headlight beam as specified by local laws and regulations An improperly adjusted headligh! may blind oncoming drivers, or it may full to HONDA C3650 3-15 HONDA C3650 INSPECTION AND ADJUSTMENT CLUTCH FREE PLAY _ / Inspect the clutch lever free play at the and of the lever, \‘6 l , FREE PLAY: 10—20 mm (313.314 in) 1 —2'om m (3/2? 3%; in) ADJUSTM E NT Loosen the upper adjusting bolt's lock nut and tum the adjusting bolt until the correct free play is obtained, Tighten the lock nutt (1JLOCK NUT l2) ADJUSTING BOLI (3} INCREASE NOTE Do not expose the adiusting bolt threads more than 8 mm (5/16 in). If adjustment cannot be made with the clutch lever adiusting bolt, screw the adjusting bolt all the way in. Adjustment must be made at the clutch hous- ing. Loosen the lower clutch cable adjusting lock nut and turn the adjusting nut all the way out to obtain maxlmum free play. 3-16 INSPECTION AND ADJUSTMENT Remove the clutch lifter cap, loosen the clutch lifter lock nut. Then turn the adiust ing screw clockwise until a slight resistance is felt. From this position, turn the clutch adjusting screw oounterclockwise 3/4 turn, and tighten the lock nut. lnstail the lifter cape Turn the clutch cable lower adjusting nut so that there is ‘iD—20 mm (3/8 ~ 3/4 in) of free play at the end of the clutch lever. Tighten the lock nut, Any minor adjustment can be obtained with the adjusting bolt and lock nut at the clutch lever. After adjustment, be sure all lock nuts are tightened securelyr Check to see that the clutch is not slipping and is properly disengaging‘ SIDE STAND Check the rubber pad for deterioration or wear. Replace if any wear excems to the wear line as shown Check the side stand spring for damage and loss of tension, and the side stand assembly for freedom of movement and bending, NOTE When replacing, use a rubber pad with the mark “OVER 260 lbs ONLY". Spring tension is correct if the measure ments fall within 15—25 kg (3.3-6.5 lb) when pulling the side stand lower end with a spring sealer [1] GOOD i2) REPLACE (3i WEAR LiNE 3-17 HONDA C3650 INSPECTION AND ADJUSTMENT SUSPENSIUN Do not ride a vehicle with faulty suspen- sion. Loose, worn or damaged suspension parts impair vehicle stability and control. FRONT Check the action of the front forks by com pressing them several times, Check the entire fork assembly for leaks or damage. RepIace damaged components which cannot be repaired, Tighten all nuts and bolts. REAR Place the motorcycle on its centev stand, Move the rear wheel sideways with force to see if the swing arm bushings are worn, Replace if excessively worn, Check the entire suspension assenhblv to see if It is securely mounted, and not damaged or distorted. Tighten all nuts and boks‘ Lubrlcate the swing arm bushings. 3-18 INSPECTION AND ADJUSTMENT WHEELS/SPOKES TlRE PRESSURE NOTE Tire pressure should be checked when tires are COLD. Check the tires for cutsl imbedded nails, or other sharp objects RECOMMENDED TlRE PRESSURE AND TIRE SIZE: Com m mm“; Front 200 (2.0, 23) m (kg/cm’, Dst) Rear 280 (2.8‘ 40) Drwer Dilv Front 200 (2.0, 28) law 200 (2,0, 28) Tire 5m Front 3.25H15—4PR Fleur 3.75Ht8—4PR Tm: brand From ansasmns 5103 “WWW” Rear BRlDGESTONESTlO Check the front and rear wheels for true- "853‘ Measure the tread depth at the center of the tires. Replace the tlres if the tread depth reaches the following limitt Minimum tread depth: ant: 1.5 mm (1/16 inl Rear: 2‘0 mm (3/32 in) STEERING HEllll BEllRlNGS NOTE Check that the control cables do not interfere with the handlebar rotation, Raise the front wheel off the ground. Check that the handlebar rotates freely. If the handlebar moves unsvenlv, binds, or has vertical movement, adjust the steering head bearing by turning the steerlng head adjusting nul wlth a pin spanner (Page 13—26)‘ NlllS, BllLTS, FASTENERS Check that all chassis nuts and bolts are tight- ened to correct torque values. Check all cotter pins and safety clips. 3-19 é HONDA C3650 FUEL SYSTEM 4-0 FU E L SYSTEM HONDA. C3650 0.64 ,2 N~m (0.06—0.12 kgm. 5711 inrlb) 4-0 HONDA C3650 FUEL SYSTEM SERVICE INFORMATION 4~1 CARBURETOR ASSEMBLY 4~8 TROUBLESHOOTING 4~2 ACCELERATOR PUMP ADJUSTMENT 4—13 CARBURETOR REMOVAL 4—3 PILOT SCREW ADJUSTMENT 4~13 FLOAT CHAMBER DISASSEMBLY 4—4 CARBURETOR INSTALLATION 4—14 ACCELERATOR PUMP DISASSEMBLY 4*5 FAST IDLE ADJUSTMENT 4—14 FLOAT LEVEL ADJUSTMENT 4—5 FUEL TANK 4—15 COMPONENT ASSEMBLY 4—6 AIR CLEANER CASE 4*15 CARBURETOR SEPARATION 4—6 SERVICE INFORMATION GENERAL INSTRUCTIONS Use caution when working with gasoline. Alwavs work in a well~ventilated area and away from sparks or flames, When disassembling fuel system parts] note the locations of the O-rings‘ Replace them during assembling. The float bowls have drain plugs that can be loosened to drain residual fuel, SPECIAL TOOLS Common Tool Float Gauge 07401—0010000 Special Tools Carburetor Throttle Wrench 07908—4220100 Carburetor Pilot Screw Wrench 07908—4220200 TORQUE VALUES Choke valve DIS-1.2 N-m (0.06—0.12 kgrm, 5~11 inrlbl SPECIFICATIONS Venturi dia. 26 mm (1,02 in) Setting mark PDBIA Main jet 92 Float level 12!: mm (0.49 in) Idle speed 1,050 1100 min" (1,050 i 100 rpml Throttle grip free play 2A6 mm (1/8 —1/4in) I Fast idle 2,000 1 700 min'1 (21000 i 700 rpm) Pilot screw opening 1-1/2 turns out FUEL SYSTEM TRIlllBlESHllllTING Engine cranks but won't start 1. No fuel in tank 2. No fuel to carburetor 34 Engine flooded with fuel 4. No spark at plug (ignition malfunction) 5, Air cleaner clogged 6 Intake air leak 7, Improper chokepperation 8, Improper throttle operation Hard starting or stalling after starting . Improper choke operation . Ignition malfunction . Fast idle speed incorrect , Carburetor malfunction , Fuel contaminated . Intake air leak , Idle speed incorrect vamwa—x Rough idle 1. Ignition malfunction 2r Idle speed incorrect 3. Incorrect Carburetor Synchronization 4. Carburetor malfunction 5, Fuel contaminated Misfiring during acceleration 'l. Ignition malfunction 2. Faultv accelerator pump Backfiring 'I. Ignition malfunction 2, Carburetor malfunction 3. Faulty accelerator pump Poor performance (driveabilityl and pour fuel economy 1. Fuel system clogged 2t Ignition malfunction 3, Faultv accelerator pump Lean mixture 1. Clogged fuel jets 2. Piston stuck open 3. Faulty float valve 4. Float level low 5. Fuel cap vent clogged 6. Fuel strainer screen clogged 7‘ Restricted fuel line 8‘ Air vent tube clogged 9. Intake air leak Rich mixture . Clogged air iets . Faulty float valve . Float leveltoo high . Choke stuck open . Dirty air cleaner mAmMa HONDA C8650 CARBURETOR REMOVAL Turn the fuel valve OFF and disconnect the fue! fine at the carburetor. Remove both side covers and raise the seat. Drain residua! fuel by loosening each drain screwr Loosen the air cleaner-to-chamber band‘ Laosen the air cleaner chamber-to-carburetor bands. Disconnect the engine breather tube at the breather cover‘ Move the air cleaner chamber to the rear. Loosen the carburetor manifold bands. Remove the carburetor assembiy, Disconnect the throttle and choke cables, FUEL SYSTEM FLflAT CHAMBER DISASSEMBLY Remove the float chamber body. Pull out the float arm pin with a pair of pliers‘ Remove the float and float valve. Inspect the float valve and seat for grooves, nicks or deposits, Inspect the float valve operation, Remove the main jet. Remove the jet needle holder. Till the carburetor to remove the needle iet. NOTE The slow air jet cannot be removed‘ it is a press fit. Blow all jets and body passages with compres- sed air, NOTE If the needle iet is difficult to remove, carefully press the needle jet from the throttle valve side with a salt mamrial after senarating the carburetors Before removing the pilot screws, record the number of turns neces- sary to make them seat to ensure original assemblyl Do not damage the pilot screw threads when removing the plain washer and Orring FUEL SYSTEM {1 l MAIN JET “' (a) SLOW JET l4) PILOT SCREW 4-4 HONDA C8650 FUEL SYSTEM ABBELERATDR PUMP DISASSEMBLY Remove the accelerator pump cover and spring. Remove the diaphragm. Inspect the diaphragm for cracks and brit‘ tleness. NOTE Be sure the accelerator pump rod is not bent. FlllllT LEVEL ADlUSTMENT To adjust the float level, bend the float arm carefully until it iust contacts the float valve, FLOAT LEVEL: 12.5 mm 10.49 in) NOTE Before adiusting, remove the adjacent chambers. (3) FLOAT GAUGE {1 l FLOAT 07401—0010000 4-5 é HONDA FUEL SYSTEM C3650 CBMPONENT ASSEMBLY To assemble the accelerator pump and float chamber, reverse the disassembly procedure. NOTE Note the carburetor number on the float chamber bodvt (1J‘1'MARK (2)3 2" MARK ‘3)“3‘4 'W‘HKS CARBURETHR SEPARATION Unhook the choke relief spring from the choke shaft arm of the No.3 and No.4 carbu- retors. Remove the carburetor top covers. Remove the throttle link arm setting screws, (1) SET SCREWS 4-6 HONDA C3650 FUEL SYSTEM File the smked ends of the choke valve screws. Remove the choke valves and discard the screws. (1 ) CHOKE VALVE NOTE Do not allow the cut ends to enter the carburetors. Remove the rear bracket. Remove the front bracket. Carefully separate the No.1 and No.4 carbu- YECOI’S. CAUTION Separate the carburetars horizontally to prevent damue tn the file! and air joint pipes and choke link E (3INO‘4 CARBURETOR FUEL SYSTEM Loomn the throttle linkage set screw lock- nut and screw. (4) No.3 CARB Carefully separate the No.2 and N03 car- buremr, throttle linkage and throttle shaft, CA UTION Separate the carburetor han’znntally to prevent damage to the fiwl and air faint pipes and woke link. THROTTLE VALVE DISASSEMBLY Loosen the two screws and remove the throtr (2}THROTTLE VALVE tle valve and jet needle from the link arm‘ (1 ) L'NK ARM Inspect the is: needle and throttle valve for wear, damage or score. (31.151 NEEDLE CARBURETDR RSSEMBLY (2) THROTTLE VALVE Install the throttle valve to the link arm so that the cut-away is facing the choke valve. (a) LINK ARM l 1 ) CUT—AWAY 4-8 HONDA C3650 FUEL SYSTEM lnstall the throttle valves in the carburetor bodies. (sleJUSTING SCREW NOTE The 1ka arm which is not equipped with an adjusting screw should be installed in the No.2 carburetor. l2) N0l1,3,4 LINK ARM (1) No.2 LlNK ARM Insert the throttle shaft into the N03 car- buretor through the throttle spring. Install new O»rings an the fuel joint pipes. NOTE Apply a thin coating of oil to the O-rings. Insert new choke shaft into the No.2 and No.3 carburetors. Install the throttle linkage and nylon washer to the throttle shaft. Assemble the No.3 and No.2 carburetors, pressing them together carefully, Align the hole in the throttle shaft with the throttle linkage set screw and tighten the set screw and lock nut. Install the spring. HONDA C3650 FUEL SVSTEM Assemble the MM and 4 carburetors to the No.2 and No.3 carburetor assemblyl press- ing them together carefully. Install the from bracket loos’ely, Evenly tighten the screws in the sequence shown in two or more staps to prevent car- buretor misalignment. NOTE Check for smooth choke shaft operat ion. If it is not, recheck the carburetor alignments lnstall the rear bracket. mumml‘m‘ 1! 4-10 HONDA C3650 FUEL SYSTEM Align the holes in the throttle shaft with each throttle valve link arm set hole. Install and tighten the set screws. Hook the throttle return spring ends to the throttle shaft arm and No.3 carburetor body. (1 ) THROTTLE RETURN SPRING (2) THROTTLE SHAFT ARM Inspect throttle operation as described below: - Open the throttle slightly by pressing the throttle linkage. Then release the throttle. Make sure that it returns smoothly, Make sure there is no drag when opening and closing the throttle. 4-1 1 HONDA C 3650 FUEL SYSTEM Hook the choke relief spring to the choke shaft arm of the No.3,4 carburetors, Install the choke valves, but do not tighten the boltst Make sure that choke valve operation is smooth by moving the choke linkage. Close the choke valve by turning the choke linkage. Replace the choke linkage and make sure that it returns smoothly. Tighten the choke valve bolts. TORQUE: 0‘6—1.2N~m lo.os«o.12 kg-m, 0.4—0.9 ft-lb, 5—1 1 in-lb) Fold the tabs of the lock washer up. Reeheck the throttle and choke operation. (”BOLT 4-12 HONDA C3650 FUEL SYSTEM ACCELERATOR PUMP ADJUSTMENT ‘ Measure the clearance between the accelerator pump rod and adlusting arm with the lhrottle vaIve closed‘ CLEARANCE: 0.4—0‘6 mm (0015—0323 in) Adiust by bendIng the adjusting armv _\$'4 Measure the clearance between the adjusting arm and stopper on the carburetor body. CLEARANCE: 8—10 mm (5/16—3/8 in) Adjust by bending the adiusting arm. PILOT SCREW ADIUSTMENT Turn the pilot screw clockwIse until It seats llghtlv and back it out to the specifications, PILOT SCREW OPENING: 1-1/21urnsout CA UTIUN Damage to fire pilot screw seat will remit if the pilot s‘crew is tightened againxt the Seat, , W mm 5cm: 5 FU E L SYSTEM CARBURETDR INSTALLATIUN ' The installation sequenoe is essentially the reverse of removal. MANIFOLD BAND TORQUE: 3—5 mm (1/3—«1/4in) GAP NOTE Position the arrow on the carburetor manifoid to the engine side. Route the throttle and choke cables properly (Page 1—11 to 1—13). Perform the following inspections and adjust- ments. Throttle cable free play (Page 3—7) Choke mechanism (Page 3—8) Idle speed (Page 3—11) FAST IDLE AfliUSTMENT NOTE Inspection and adjustment must be performed while the engine is cold. Pull the choke knob out completely and check that fast idle is within specifications immediately atter engine starts. FAST (DLE: 2.000 1 700 min"I (2,000 i 700 rpm) (COLD ENGINH To adjust, stop the engine, turn the fuel valve OFF. disconnect the fuel line and remove the fuel tank. Pull the choke knob out complete ly and turn the adjusting screw untii it touch- es the cam surface. Push the choke knob in and turn the adjusting screw in 24 /2 turns. Instali the fuel tank and fuel line, Recheck the fast idle. 4-14 HONDA C3650 FUEL SYSTEM FUEL TANK Do not allow flames or sparks néEngEH—f line‘ Wipe up spilled gasoline at once. Check the vent hole of the filler cap for block- age. Check that fuel is flowing out of the fuel valve freelyl ll fuel flow is restricted, clean the fuel strainer, NOTE Do not overfiighten the fuel valve locknutl Make sure there are no fuel leaks, MR CLEANER USE AIR CLEANER CASE/CHAMBER check the air cleaner case for deterioration. CRANKCASE VENT] LATlON SYSTEM Check that (he breather tube is not restrict/adv (1) AIR CLEANER 4-15 é HONDA . ' C3650 ENGINE REMOVAL/INSTALLATION 5-0 HONDA C3650 ENGINE REMOVAL & INSTALLATION 8 mm BOLT 26—32 N'm 10 mm BOLT (2.6—3.2 kg~m, 30—40 N'm 19—23 Mb) {3.0-4.0 kQ-my 22—29 f-t-Ib) 8 mm BOLTS 26—32 N'm (2.6—3.2 kg-ml 19723 ft~|b) 8 mm BO LT 26—32 N-m (2.6—3.2 kg-m, 19—23 ft-Ib) 10 mm BOLT 30—40 N'm (3.0—4.0 kg-m, 22—«29 ((-lb) 10 mm BOLT 30—40 N'm (3.0—4.0 kgvm, 22—29 ft-lb) 12 mm BO LT 80—100 N‘m (813—10.!) kg-m, 58-42 ft<|b) ENGINE REMOVAL Bi INSTALLATION HONDA C3650 SERVICE INFORMATION 5—1 ENGINE REMOVAL 5‘2 ENGINE INSTALLATION 5—6 SERVICE INFBRMATIIJN GENERAL INSTRUCTIONS The following parts or components can be serviced with the engine instaiied in the frame. Clutch Shift linkage Camshaft - Carburuwv SPECIFICATIONS Engine dry weight Oil capacity TORQUE VALUES 8 mm bolt 10 mm bolt 12 mm bolt Rear axle nut Spark plug Swing arm pivot - A. c. generamv - Piston - Starlev momr ~ Cam chain tensions! ~ Cylinder head - Oil pump ‘ Cylinder 71 kg (156.6 lb) approx. 3.5 lit (3.7 US qL, 3,1 Imp at) at engine assembly 3.0 lit (32 US ql., 2.6 imp al) at change 26—32 N-m (2.6—3.2 mm, 19—23 mm) 30740 N‘m (3.0—4.0 k9~m, 22729 ft-ib) BO—IOON'm 03.0—10.0 kg-m, 58—72 {bib} 80—100 Nrm (SB—10.0 kg-m, 58—72 ft-lb) 12—16 N-m (1.271 .6 kgrm. 9712 fi-ib] 60—70 N-m (6.0—7.0 kg»m, 43—51 (Nb) HONDA C3650 ENGINE REMUVAL Drain 0” from the engine (See page 2—-2), ENGINE REMOVAL 8: INSTALLATION Turn the fuel valve OFF. Raise the seat and remove the fuel tank and bath side covers. Disconnect the starter cable at the starter relay switch. Disconnect the pulsar generator coupler. (2') PULSER GENERATOR / Remove the carburetor and air cleaner chamber (Page 4—3, 4—15). HONDA 63650 ENGINE REMOVAL 8: INSTALLATION Remove the spark plug caps. Disconnect the tachomemr cable, Disconnect the breather tube. Disconnect the clutch cable at the clutch arm. Remove the exhaust system. 5-3 HONDA C3650 ENGINE REMOVAL 8. INSTALLATION Disconnect the A. C, generator coupler. Disconnect the neutral and oil pressure switch coupier‘ Remove the cotter pin and loosen the rear axie nut. Loosen both chain adjusters and push the reav wheel forward Remove the gearshift arm {gearhish pedal: DK and DML Remove the left rear crankcase cover. HONDA C3650 ENGINE REMOVAL & INSTALLATION Remove the drive sprocket and dvive chain. Place a Back under the engine. Remove the engine hanger brackets and baits. Remove the engine toward the right. 5-5 HONDA C3650 ENGINE REMOVAL& INSTALLATION ENGINE INSTALLATIUN The mstallatmn sequence is the reverse of removal. NO TOR Route the wires and cables prupevly TE (Pages 1—1 1 to 1—13) Fill the crankcase to the proper level (Page 272). Perform me followlng inspections and adjustments: Throttle cable has play (Page 3—7} clutch lever free play (Page 3—16) Drive chain mnsion (Faun 3—12) Choke cable (Page 3—8) QUE VALUES: 8 mm flange bolt/nut 10 mm flange bolt/um 26—32 N‘m [2.6—3.2 kg-m, 19723 ft-lb) 30—40 N-m (SD—4.0 kg-ml 22—29 ft—Ib) 12 mm flange halt/nut 80—100 N‘m (8.0—104] kg-m, 58—72 ft-lbl Swing arm pivot nut 60—70 N-m (6.0—7.0 kg-m, 43—51 ft—Ib) (2)10mm sous é HONDA _ c3650 CYLINDER HEAD/ VALVE 6-0 HONDA. C3650 CYLINDER HEAD/VALVE 8~12 N‘m (0.8—1 2 kg-m, 6—9 “113) 10714 N‘m ., w 8~12N'm (1 .0—1.4 kg»m, 7—10 11-11:) ' ‘ ‘ (0.8—1.2 kg-m, 6‘9 ft-Ib) 24—30 N'm (2.4—3.0 kg-ml 17—22 fl-lb) 10—14 NW1 7 g g ‘ ' 14—15 N-m (1.0—1.4 kg-m, y 6 (1.44.8 k9,10—13h-lb) 740mb) % . Q 12—16 N‘m (1.24.6 kgrm, 942 ft-lb) 6-0 HONDA CVLINDER HEAD/VALVE C3650 SERVICE INFORMATION 6—1 VALVE GUIDE REPLACEMENT 6—12 TROUBLESHOOTING 6—2 VALVE SEAT INSPECTION/REFACING 6—13 CYLINDER HEAD COVER REMOVAL 6—3 CYLINDER HEAD ASSEMBLY 6—14 CVLINDER HEAD COVER DISASSEMBLY 6—4 CYLINDER HEAD INSTALLATION 6—15 CAMSHAFT REMOVAL 6—6 CAMSHAFT INSTALLATION 6—16 CVLINDER HEAD REMOVAL 6—9 CYLINDER HEAD COVER ASSEMBLY 6—17 CYLINDER HEAD DISASSEMBLY 6—9 CYLINDER HEAD COVER 6—18 INSTALLATION SERVICE INFIIRMIITIIIN GENERAL INSTRUCTIONS o All cylinder head maintenance and inspection can be accomplished without removing the engine. . During assembly, appiy molybdenum disulfide to the camshaft bearing to provide initial lubrication. SPECIAL TOOLS Special Tools Common Tools VaIVe Guide Reamer 07984—2000000 Valve Guide Ramover 15.5 mm) 07742—0010100 Cylinder Head Bolt Wrench 07906—3230000 Valve Guide Driver (3) 07742—0020200 Valve Seat Cutter (29 mm) 07780—0010300 Valve Spring Compressor 07757—0010000 Valve Seat Cutter (30 mm) 07780—0010400 Valve Sea! Flal Cutler I30 mm) 00780—0012200 Valve Seat Flat Cutter (35 mm) 00780—0012300 Valve Seat Interim Cutter I30 mm100780—0014000 Valve Seat Cutter Holder (5,5 mm) 00781—0010100 TORQUE VALUES Cvlinder head cover 8—12 N-m ((18—12 kg-m, 6—9 It-lb) Valve adiusting nut 12—16 NAm (1‘2—1.S kg-m, 9—12V!»lb) Rocker arm shaft cotter pin 10—14 Nvm (LO—1.4 kg-m, 7—10 ft—ib) Rocker arm shaft Cap bolI 8—12 N-m (OB—1.2 kg-rn, 6—9 fI-Ibl CyIinder head bolt: 8 mm 24—30 N-m {2.4—3.0 kg-m, 17—22 It-Ib) 6mm 10—14 N-m Ito—1,4 kgrm, 7—10ft-Ib) Spark plug 12—16 N-m (IQ—1‘6 kg-m, 9—12ft-Ib) Cam sprocket 14—16 Nam (1.4—1.8 kg~m,10—13ft—Ib] Cam chain tensioner 10—14 N‘m (1.0—1.4 kgrm, 7—10 ft-lb) HONDA C3650 CYLINDER HEAD/VALVE SPECI FlCATlONS STANDARD SERVICE LlMlT Compression pressure 1,176.8 1 196.2 kPa (12 t 2 kg/cm’, 170 t 28 psi) Camshaft Cam height lN 35527-435787 mm (1.4026~1.4089inl 35.6 mm (1.402 in) EX 35314—35474 mm (1.3903—1396611'11 35.3 mm (1.390in1 Run out 0.1 mm (0.004 in) Side clearance 0035—0050 mm (00013—013020 in) 0.1 mm (0.0041n) Oil Clearance 0.160v0202 mm (000637700080 in) 0.21 mm (0.008 m) Rocker arm Rocker arm I. D. 12000—12018 mm (011724704731 in) 12,05 mm (0.474 in) Shaft O. D. 11973711384 mm (0.4714—0.4718m] 11.94 mm (0.4701") Valve Valve stem 0. D. IN 5475—5490 mm (02156—412161 in) 5.47 mm (0,215 in) EX SASS—5.470 mm (0.2148—02154lnl 5.45 mm (0.2151n) Valve guide |. D. 5500—5515 mm (02165402171 in] 5.55 mm (0.219 in] Stemrtnguide clearance IN 0010—0.an mm (00004—013016 in) 0.08 mm (0.003 in) EX 11030—0050 mm (0.0012A0.0020 in) 0.10 mm (0.004 in) Valve stem ruhout 7 0.05 mm (0.002 in) Valve length IN 90.2 mm (3.551 in) 89.7 mm (3.531 in) EX 88.7 mm (3.492 in) 88.0 mm (3.465 in) Valve seat width 1.2 mm (0.047 in) 1.5 mm (0.06 in) Valve spring Free length Inner 39.2 mm (1.54 in) 37.9 mm (1.49 in) Outer 44.85 mm (1.77 in) 43.3 mm (1.70 in) Preload (length Inner 21.85—25.15 kg/25.9 mm (48.1774833 20.8 kg/25.9 mm lb/1.02 in] (45.9 lb/1.02 in) Outer 502247.78 kg/30.G mm (11074231) 472 kg/30.6 mrn Ib/1.201hl l1.401b/1.201nl Cylinder head Warpage —~—— 0.25 mm (0.010in1 TRllllBLESHllllTlllG Engine topend problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing noises to the toprend with a sounding rod or stethoscope. Low compression 1. Valves — Incorrect va(ve adiustment __ Burned or bent valves — Incorrect valve timing — Broken valve spring 2. Cylinder head — Leaking or damaged head gasket — Warped or cracked cylinder head 3. Cylinder and piston (Refer to Section 7.) Compression too high 1. Excessive carbon build-up on piston or combustion chamber Excessive noise . Incorrect valve adjustment . Sticking valve or broken valve spring . Darnaged or worn camshaft . Loose or worn cam chain . Worn or damaged cam chain tensioner . Worn cam sprocket teeth . Worn rocker arm and/or shaft ummsxmma CVLINDER HEAD/VALVE CYLINDER HEAD COVER REMOVAL Disconnect the tachometer cable. Disconnect the breather tube. Remove the spark plug caps. Remove the spark plugs‘ Remove the right and Ian adjus‘ment covers and breather cover Loosen the cylinder head cover bolts evenly and remove the cyiinder head cover. NOTE Remove the hairs in 2—3 steps in a crisscross pattern to prevent warpage. HONDA C3650 CYLINDER HEAD COVER DISASSEMBLY Remove the tachometer drive gear attaching bolt and drive gear‘ Remove the rocker arm shaft cotter pin nuts. Drive ‘he comer pins out. Remove the rocker arm shaft cap bolts. CYLINDER HEAD/VALVE ' ROCKER ARM SHAFT HOMETER DRIVE GEAR CAP BOLTS 6-4 HONDA. C3650 CYLINDER HEAD/VALVE Screw a 6 mm bolt in the rocker arm shaft ‘ . _ s __ -. , and pull the rocker arm shah out ‘ ‘ - {MROCKER ARM SPRDNGS 1 Remove the rocker arms and springs. ' , V ' ‘ \ ‘ _ - NOTE Mark a" disassembled parts to ensure correct assembly. ROCKER ARM BORE |. D. MEASUREMENT Measure rocker arm bore L D. SERVICE LIMIT: 12.05 mm (0.474 in) ROCKER ARM SHAFT O. D. MEASUREMENT Measure rocker arm shaft 0. D, SERVICE LIMIT: 11.94 mm (0.470 in) HONDA C3650 CYLINDER HEAD/VALVE EAMSHAFT REMllVAL Remove the pulsar generator cover. Remove the cam sprocket bolt. Turn the crankshaft clockwise and remove the other cam sprocket bolt. NOTE Do not allow bolts to fall into the crankcase. Remove the camshaft. NOTE Suspend the cam chain with a piece of wire to keep it from falling into the engine. Remove the cam sprocket. CAM BEARING SURFACE INSPECTION Inspect the cam beating surfaces for scoring, scratches, or evidence of insufficient lubrica- tion. Inspect the bearing surface of the camshaft holders. HONDA CYLINDER HEAD/VALVE CB650 CAMSHAFT RUNOUT check the camshafl runout with a dial indi- cator. Support both ends of the camshaft with V;b|ocks. SERVICE LIMIT: 0.1 mm (0.004311) CAM ISNPECTION Using a micrometer, measure each cam lobe. Check for wear or damage. SERVICE LIMITS: IN: 3515mm (1.402in) EX: 35.3mm (1.390in} CAMSHAFT END CLEARANCE Using a dial indicator, measure camshaft end clearance. SERVICE LIMIT: 0.1 mm (0.004 in) 6-7 HONDA C3650 CYLINDER HEAD/VALVE CAMSHAFT OIL CLEARANCE Lay a strip of plastigauge lengthwise on top of each camshaft journal. NOTE Wipe any oil from the journals before using plastigauge‘ Install the cylinder head cover, and tighten in a crisscorss pattern. NOTE Do not rotate the camshaft when us 9 plastigauge TORQUE: 8—12 N-m (OS—«1‘2 kg-m, 6~9 ft—lbl Remove the cylinder head cover and measure the width of each plastigauge. The widest thickness determines the oil clearance SERVICE LIMIT: 0.21 mm (0.008 in) when the service limits are exceeded, replace the camshaft and recheck the oil clearance. Replace the cylinder head and cylinder head cover if the clearance still exceeds service Ilmlu. II(31\II)I§ C3650 CVLINDER HEAD/VALVE BYLINDER HEAD REMOVAL Remove the carburetor [Page 4—Z)v Remove the exhaust system (Page 5—3) Remove the six rubber seals. Remove the cam chain tensioner set bolt. Remove the 74 cylinder head bolts. NOTE _ Remove the bolts ln 2»3 skeps in a criss» cross pattern to prevent warpege. Remove the cylinder head Remove the cylinder head gasket, dowel pins and Orings. CYLINDER HEAD DISflSSEMBLY (“VALVE SPRING Remove the valve spring comers, retainers, COMPRESSOR springs and valves‘ 07757 ~ 0010000 CAUTION To prevent 1033 of Iensirm» do not Com- prexs the valve springs mare than neces- sary to remove the comm NOTE Mark all disassembled parts to ensure original assembly. Remove the valve stem seals, HONDA c3650 CYLINDER HEAD/VALVE Remove the carbon deposits from the combustion chamber. Clean off the head gasket surfaces. NOTE Avoid damaging the gasket surfaces. Gasket will come off easier if soaked in solvent. CYLINDER HEAD INSPECTION Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with a straight edge and a feeler gauge. SERVICE LIMIT: 0.25 mm (0.010in) VALVE SPRING FREE LENGTH INSPECTION Measure me Ienght of the inner and outer vaIve springs. SERVICE LIMITS: If” :r: IN., EX. 37.9 mm (1.49 in) Outer: IN., EX. 43.3 mm (1.70 in) 6-10 HONDA CYLINDER HEAD/VALVE C3650 VALVE STEMvTO-GUIDE CLEARANCE Inspect each valve for bending, burning. scratches or abnormal stem wear. Check valve movement in the guide. Measure and record each valve stem 0‘ D. SERVICE LIMITS: IN: 5.47 mm (0,215 in) EX: 5.45 mm (0.214 in) Measure valve stem runout. SERVICE LIMIT: 0.05 mm (0.002in) Measure the valve length. SERVICE LIMITS: IN. 89.7 mm (3.531 in) EX. 88.0 mm (3.465 in) NOTE Ream the guides to remove any carbon build-up before checking clearance. l1 )VALVE GUIDE REAMER Measure and record each valve guide l. Dr 07984‘2000000 using a bail gauge or inside micrometer. SERVICE LIMITS: W. 5.55 mm (0.219in) EX. 5.55 mm (0.2mm) Subtract each valve stem 0. D, from the cerresponding guide I. D. to obtaimthe stem to guide clearance. SERVICE LIMITS: IN. 0.08 mm (0‘003in) EX. 0.10mm (0.004 in) NOTE If the stemrtorguide clearance exceeds the service limits, determine if a new guide with standard dimensions would bring the clearance within tolerance. if so, replace any guides as necessary and ream to fit. If the stem-to-guide clearance exceeds the service limits with new guide, replace the valve and guides. NOTE Reface the valve seats whenever the valve guides are replaced (Page 6712). 6-11 HONDA C3650 VALVE GUIDE REPLACEMENT Support the cylinder head and drive out the guide from the valve port. NOTE When driving out the valve guide, do not damage the head. Install an oversize valve guide form the top of the head. Ream the new valve guide after installation, NOTE Use cutting oil on the veamer during this operation. Rotate the reamer when inserting and remuing it, Hefaee the valve seat. Ciean the cylinder head thoroughly to remove any metal particles. CYLINDER HEAD/VALVE ALVE GUIDE EMOVER (5.5mm) (1 ) VALVE GUIDE REAMER 07984—2000000 6-12 HONDA C 3.6 5 O CYLINDER HEAD/VALVE VALVE SEAT INSPECTION/ REFAC ING Clean all intake and exhasut valves thoroughly to remove carbon deposits. Apply a light coating of valve lapping come pound to each valve face. Lap each valve and seat using a rubber hose or other handvlapping tool. NOTE Take care not to allovfihe compound to enter into between the valve stem and guide. After lapping, wash out the com» pound completely and apply a coat of engine oil to the valve face and seatr Remove the valve and inspect the fame. CA U TION The valves cannot be ground, If the valve face if mugh, worn unevenIy, or contacts the sear improperly, the valve must be replaced Insect the valve seat. (I) SEAT WIDTH: 1,2 mm (0.047 in) (2) SERVICE LIMIT: If the sear is too wide, too narrow, or has low spots, the seat must be ground. NOTE Follow the refacer manufacturer's ope- l rating instructions, 15 mm (0.06 in) After cutting the seat, apply lapping com- pound to valve lace, and lap the valve using light pressure. After lapping, wash any residual compound off the cylinder head and valve. (3) l4) (1) IN: CUTTER No. 077804012300 (35 (9) IN, EX: CUTTER lN: CUTTER No. 07780—0010400l30 a) EX: CUTTER No. 0778040012200 (30 ml Nor 07780—0014000 (30 9’) EX: CUTTER No. U7780—00’l0300 (29 w) (2) OLD SEAT WIDTH (2) OLD SEAT WIDTH 12 mm (0.047 in) \/ 6°“ (5) HOLDER no, 0778170010100 6-13 HONDA. C3650 CYLINDER HEAD/VALVE CYLINDER HEAD ASSEMBLY NOTE Install new valve slem seals when assembling. Lubrlcate each valve stem with molybdenum disulfide grease and insert the valve into the valve guide. NOTE To avoid damageTeitgsgnTsréal, turn Install the valve springs and retalners, (5)5PRING RETAINER ”’fl NOTE (73 VALVE COTTERS Install the valve springs wlth the tightly wound coils facing the cylinder head. (1) VALVE SPRING Install the valve cutters. COMPRESSOR 07 757 “ 0010000 CA U’I‘ION To prevent lam of tension, do not com- presx the valve spring mum than necessary to install the valve corlerx. Tap the valve stems gently with a soft ham V mer to firmly seat me cutters NOTE Support the cylinder head above the work bench surface to prevent possible valve damage. 6-14 CYUNDERHEAWVALVE CYLINDER HEAD INSTALLATIIJN Clean the cylinder head surfaces of any gasket material. Install the O-rings and dowl pins. lnstall new gasket. Laosen the cam chain tenionser lock nut and pull the tensicner up. Retighten the lock nutl Install the cylinder head assembly. Tighten the cylinder head bolts m the sequence shown. NOTE Tighten the tiling—3 steEé. Tighten the 6 mm bolt. TOROUES: 8 mm boll: 24430 N-m (Zed—3‘0 kg—m, 17—22 {Mb} 6 mm bolt: 10—14 N-m (1.0~1,4 kg-m, 7—10 ft-lb) lnstall the rubber seals. 6-15 HONDA C3650 CYLINDER HEAD/VALVE CAMSHAFT lNSTMLATIflN Lubricate the camshaft bearings with molyb- denum disulfide grease. Turn the crankshaft cloakwlse until the "1.4 T" mark aligns with the Index mark. P‘ace the cam chain over the cam sprocket and install the camshaft. NOTE Install the camshaft from the right side with the index mark end facing right. HONDA CVLlNDER HEAD/VALVE C3650 Align the center of the index mark on the camshaft right end with the cylinder head surface. Align the camshaft sprocket bolts with the camshaft holes. install the sprqcket bolts and tighten to the specified torque. TORQUE: 14-18N~m (14—13 kg—m, 10—13 ft-lb) CYLINDER HEAD COVER ASSEMBLY Install the rocker arms and springs and insert the rocker arm shaft. (MROCKER ARM SPRINGS NOTE Install the rocker arms and shafts in their original positiun. Install the rocker arm shaft with the thread hole end facing out. InStail the rocker arm shaft cotter pins and tighten the nuts. TORQUE: 10—14 N-m (1.0—1.4 kgrm, 7710 ft-Ibl 6-17 HONDA c3650 CYLINDER HEAD/VALVE Install the maker arm shaft cap bolts. TORQUE: 8—12 N-m (0.8»12 kwm, 6—9 fl—lb) Install lhe tachometer drive gear. TORQUE: 8—12 N-m (0.8—1.2 kg-m, 6—9 ft-lbl ROCKER ARM SHAFT CAP BOLTS CYLINDER HEAD COVER |NSTALLATIUN Inspect the cylinder head cover gasket for damage or deterioration. Install the dowel pins‘ “U wfi M m. J...“— ll :5. HONDA C3650 CYLINDER HEAD/VALVE Loosen the valve adiusting screws fully and installthe cylinder head cover. ( )SEALING WASHER Tighten the cylinder head bolts evenly in the sequence shown NOTE Tighten the belts in 5—6 stepsl TORQUE: 8—12 N-m (0.8—12 kgvm, 6—9 ft-Ib) Install the exhaust system. Install Ihe carburetor (Page 4—14), Install Ihe spark plugs. Install the spark plug caps, tachometer cable and engine breather tube. Install the pulsar generator cover. Adiust the cam chain tension (Page 3—7). Adjust valve clearance (Page 8—6), Adjust throttle cable free play (Page 377). 6-19 fléflbNDA ’ C3650 CYLINDER/PISTON 7-0 N O T w P / R E D m L Y C 7-0 HONDA C8650 CYLINDER/PISTON SERVICE INFORMATION TROUBLESHOOTING CYLINDER REMOVAL 7—1 PISTON REMOVAL 7—1 PISTON INSTALLATION 7~2 CYLINDER INSTALLATION SERVICE INFIIIIMATIIIN GENERAL INSTRUCTIONS All cylinder/piston maintenance and inspection can be accomplished without removing the engine, SPECIAL TOOLS Special Tools Piston Base 12 required) Piston Ring Compressor 12 required) 07958—2500001 07954~3740000 SPEC! FlCATIONS STANDARD SERVICE LIMIT Cylinder I. D. 59000—59310 mm (23543723547 in) 59.90 mm (2.358 in) Warpage mm 0.25 mm (0.0101nl Piston, Piston ringAtorring TOP 001570.045 mm (00006—00018 in) 0.15 mm 10.006 in) piston rings groove clearance SECOND 0015—0045 mm (0.0006—D.0018 in) 0.15 mm (0.006 in) and piston Ring end gap TOP 0.10—0.30 mm (0.004~0.012 in) 0.7 mm 10.028 in) pin SECOND 0.104330 mm (0004-43012 in) 0.7 mm 10.023 in) (OSIILDE RAlL) 0.3—0.9 mm (0,012—0335 in) 1.1 .mm 10.043 in) Piston O. D. 59.77~59.79 mm 12353—235400 59.65 mm (2.348 in) Piston pin bore 15002—15008 mm 10.5906—05909 in) 15.08 mm (0.594 in) Connecting rod small end l. D. 15016—15034 mm 105912435919 in) 15.07 mm 10.593 in) Piston pin 0. D. 14394715000 mm 105903415906 in) 14.98 mm 10.590 in) Piston‘topiston pin clearance - -—- 0.04 mm 10.002 in) Cylinder-m-piston clearance 0.10 mm (0.004 inl IROUBLESHBUTING Compression low 1. Worn cylinder or piston rings Excessive smoke 1. Worn cylinder or piston 2. Improper installation of piston rings 3. Scored or scratched piston or cylinder wall Overhaaflng 1. Excessive carbon build-up on pismn or combustion chamber wall Knocking or abnormal noise 1. Worn piston or cylinder 2. Excessive carbon buildup 7-1 HONDA. C3650 CYLINDER/PISTON CYLINDER REMOVAL Remove the cy‘inder head (Seciton 6). Remove the cam chain tensioner \ock nun Remove the cylinder. Remove the cam chain tensioner and chain guide, Remove the cylinder gasket, dowet pins and O-rings. Clean off the head gasket surface. NOTE Avoid damaging the gasket surface, Gasket will come off easiar if soaked in solvent HONDA C3650 CYLINDER/PISTON CYLINDER INSPECTION Inspect the cylinder bore for wear or damage. Measure the cvlinder I. D. at three Ievels in X and Y axis. SERVICE LIMIT: 59.50 mm (2.358 in) Inspect the top of the cylinders for warpage. Check in an X pattern as shown. SERVICE LIMIT: 0.25 mm (0.010 in) CAM CHAIN TENSIONER INSPECTION Inspect the slipper of the cam chain tensioner (1 ) CAM CHAIN for damage or excessive wear. TENSIONER Inspect the tension spring for weakness. IZICAM CHAIN GUIDE CYLINDER/PISTON PISTON REMIIVAL " . *1 Remove each piston pin clip with needle nose pliers; NOTE Do not allow clips to fall into (he crank» case. Press the piston pin out. NOTE Mark the pistons 10 indicate (he cyl- inder positions. "PISTON PISTON/PISTON RING iNSPEC- TION Inspect the piston ring‘to-groove clearance. SERVICE LIMITS: TOP: 0.15 mm (0.0mm) SECOND: 0.15 mm (0.006 in) NOTE Mark the rings so that they can be returned to meir originai locations. Inspect the pistons for damage and cracks; ring grooves for wear. Insert each pismn ring into the cylinder, and inspect the end gap. SERVICE LIMITS: TOP: 0.7mm (0.028 in) SECOND: 0.7 mm (0.025 in) OlL(Side 1.1mm (0.043 in) Rail) STANDARD END GAPS: TOP: 0.10—0.30 mm (01104—0312 in) SECOND: 0.10—0.30 mm (0304—0012 in) GI L (Side 0.3-0.9 mm Rail) (0.012-«0.035 in) CLIP HONDA c3650 CYLINDER/PISTON Measure the piston 0. D. at the skirt. SERVICE LIMIT: 59.65 mm (2.348 in) NOTE Measurements should be ‘aken 10 mm (0.04 in) from (he bottom. Calculate the cylinder-torpiston dearance. SERVICE LIMIT: 0.10 mm (0.004 in) Measure the piston pin hoie I. D. SERVICE LIMIT: 15.08 mm (0.594 in) Measure the connecting rod smaH end I. D. (See Section 12 for replacement promdure) SERVICE LIMIT: 15.07 mm (0.593 in) CYLINDER/PISTON HONDA C8650 Measure the piston pin 0. D. SERVICE LIMIT: 14.98 mm (0.590 In) Determine the piston-to-piston pin cIearance. SERVICE LIMIT: 0.04 mm (0.002 in) PISTON RING INSTALLATION InstalI the piston rings. NOTE Alt rings should be installed with the markings facing up. After installation, the rings should rotata freely. (1) TOP I (CHROME PLATED) I2) 7-6 HONDA C3650 CVLINDER/PISTON Space the piston ring and gaps 120 degrees apart. Do not align the gaps in the oil rings‘ )‘ (mop msscown \ (31$qu RAIL \ V j (MSPACER _ / (6)20mm OR MORE l3lSlDE RAIL W“ www— (6l20 mm OR MORE l5lGAP PISTflN INSTALLATION Apply molybdenum disulflde grease to the connecting rod small ends. install the pistans, piston pins and clipsi NOTE ‘ Position the mark "IN" on the piswn m the intake side. Install the pistons in their original positions. Do not allow piston pin clips to (all into the crankcase. CYLINDER/PISTON CYLINDER INSTALLATION Install the dowel pins, O-rings and cylinder gasket. Make sure the oil orifices in the dowel pins are not clogged. Install the cylinder. NOTE Before using the specim tools, position the No.2 and No.3 pistons at T. D. C. (Top Dead Center). HONDA C8650 CYLINDER/PISTON Install the cam chain tensioner and lock nut. Make sure the (ensioner lower end is properly seated in the crankcase groove as shown. (2)CAM CHAIN (1 ) CAM CHA|N TENSIONER H) TEN510NER (2) GROOVE 7-9 HONDA C3650 CLUTCH 8-0 HONDA. C3650 CLUTCH .5 C LUTCH SERVICE INFORMATION 8—1 CLUTCH REMOVAL 8—3 TROUBLESHOOTING 8—1 CLUTCH INSTALLATION 8—5 CLUTCH COVER REMOVAL 8—2 CLUTCH COVER INSTALLATION 8—8 SERVICE lNFllllMATlllN GENERAL INSTRUCTIONS This section covers remuval and installation of the clutch. This operation can be accomplished with the engine in the frame. SPECIAL TOOLS Common Tools Universal Holder 077254010101 Extension Ear 07716—0020500 Luck Nut Wrench 07716—0020202 TORQUE VALUES Clutch lock nul 47—53 N-m (4.7-5.3 kgm, 34—38 thI SPECIFICATIONS STANDARD SERVICE LIMIT clumh Lever free play (at lever end) 10—20 mm (3/8—3/4 in) Spring free length 36.6 mm (1.45 in) 35.4 mm (1.39 in) Spring preload/length 27.08—29.93 kg/24J mm (59.70—65.98 lb/Ol95 in) Disc thickness 3.42—3.58 mm (013540.141 in) 3.2 mm (0.13 in) 2.62—2.78 mm (u.1oa—a.109 in) 2,4 mm (0.09 in) Plate warpage fi 03 mm (0.012 in) Clutdl outer I. D. 39990—30005 mm 11.1807—1.1813inl 30.05 mm (1.183 in) Clutch outer guide 0. D. 29359—49830 mm ll.1795~—I.1803 in) 29.94 mm (1.179 in) TIIIllJIlLESIIlIllTING Clinch Faulty clutdl operation can usually be correaed by adjusting the free play. Clutch slips Mo‘orcyola map: with clutch disengaged 1. No free play 1. Too much free play 1 Discs worn 2. Plates warped 3. Springs weak clutch will not disengge I. Too much free play 2. Plates warped Excessive lever pressure 1. Clutch cable kinked, damaged or dirty 2. Lifter mechanism damaged Clutch operation feels rough 1. Outer drum slots rough HONDA C 3650 CLUTCH ELUTBH CIIVER REMOVAL Drain the engine oil thoroughly. Disconnect the clutch cable at the clutch arm. Remove the clutch cover. CLUTCH LIFTER REMOVAL Remove the adjusting screw, adjusting arm ; , (1 ) ADJUSTING and lifter shaft. ~ SCREW Remove the clmch litter guide, bearing and bearing retainer, CLUTCH HONDA C5650 CLMCH REMDVM. Use the universal ho|der if the drive chain is removed. Shift the transmission into gear to lock the countershaft and mainshaft. Block the drive sprocket to prevent it from turning. When servicing the clutch in the frame, shift the transmission into gear,and press the brake pedal to lock the transmission gear shafts. CLUTCH LIFTER PLATE REMOVAL Remove the bolts, lifter p‘ate and springs. NOTE Loosen the butts in a criss cross pattern in 2-3 steps. CLUTCH CENTER, PLATES AND DISCS REMOVAL Attach the rock nut wrench. (1) LOCK NU SOCKET(_ Remove the lock nut and rock washer 07715 .. O The clutch can then be removed as a unit, HONDA. 63650 CLUTCH Remove the dutch center, Remove the disc spring, discs A and B. and plates. Remove the pressure pIate and clumh outer guide. CLUTCH SPRING INSPECTION Check spring free length. SERVICE LIMIT: 35.4mm (1,39ifl) CLUTCH DISC INSPECTION Replace the clutch discs if they Show signs of scoring or discaloration. Measure disc thicknessI SERVICE LIMITS: DISC A: 3.2 mm (0.13 in) DISC B: 2.4 mm (0.09 in) (1 ) CLUTCH CENTER I3)PLATES AND DISCS AV E (2I PRESSURE PLATE 8—4 HONDA CLUTCH C3650 PLATE INSPECTION Check for plate warpage on a surface plate, using a feeler gauge, SERVICE LIMIT: 0.3 mm (0.012inl CLUTCH OUTER AND OUTER GUIDE INSPECTION Check xhe slots in the outer drum for hicks, cuts or indentations made by the friction discs. Measure the clutch outer I, D. and outer gmde 0. D. SERVICE LIMITS: I.D.: 30.05 mm (1.133 in) 0.0.: 29.94 mm (1.179inI CLUTCH INSTALLATION InstaII the thrust washer. HONDA C 5650 CLUTCH Install me following parts in the clutch cute! in (he order listed‘ Clutch enter guide Pressure plane DiscsA (7) and plates (7) alternately Disc B Disc spring Clutch center NOTE Before installing the clutch, coat the discs and plates with engine oil. (8) Install the judder spring with the l” CLUTCH OUTER (3) CLUTCH CENTER cupped side facing inside. (7) CLUTCH LlFTER PLATE (4) DISC A (7) l5) PLATE (7) (2) CLUTCH ‘ (a) msca m ; ”Human _ _ SPRING“ CLUTCH HONDA C3650 Align the splines by rotating the clutch center. Install the clutch assembiy‘ Install the lock washer and lock nut. NOTE Position m; mark "OUTSIDE" on the \ock washer facing sun 77 Tighten the lock nut. TO ROUE: 47—53 N-m (In—5.3 kg-m, 34—68 ft-lb) HONDA C B650 CLUTCH Install the clutch springs and lifter plane. Tighten the bolts. (2) NOTE OUTSIDE install the iifter plate with (he cupped side facing inside. instail the bearing retainer, lifter guide and bearing, CLUTCH COVER INSTALLATION Instaii the liner shaft, adjusting screw, adjusting arm and spring. Instaii the dowel pins and gasket, and then instal! the clutch cover. Connect m- clutch cabie. Adjust the clutch free play (Page 3—16). 9 g HONDA . ' C8650 GEARSHIFT LINKAGE 9-0 GEARSHIFT LINKAGE 9-0 GEARSHIFT LINKAGE SERVICE INFORMATION 9-1 TROUBLESHOOTING 9—1 GEARSHIFT PEDAL REMOVAL g_2 GEARSHIFT LINKAGE REMOVAL 9—2 GEARSHIFT LINKAGE INSTALLATION 9—3 GEARSHIFT PEDAL INSTALLATION 974 SERVICE IIIFIIIIMATIIJII GENERAL INSTRUCTIONS The gearshift spindle and stopper arm: can be serviced with the engine in the frame. If the shift forks, drum and transmission require servicing, remove the engme and separate the crankcase. TORQUE VALUES Gearshift pedal 842 N-m (0.8—1.2 kg-m, 6—9 ft-Ib) TIIIIIIBLESIIIIIITIIIE Hard to ski" I. Improper clutch adjustment; too much free play 2. Shift forks bent 3. Shift shaft bent 4. Shift claw bent 5. Shift drum cam grooves damaged Transmission jumps out of gear 1. Gear dogs worn 2. Shift shaft bent 3. Shift drum stopper broken 4. Shift forks bent 9-1 HONDA C3650 GEARSHIFT LINKAGE GEARSHIFT PEDAL REMflVM. Remove the gearshift arm locking bolt and arm. Remove the clrcllp and remove the gearshift pedal with linkage. (DK and DM Types) Remove the gearshift pedal locking bolt and gearshift pedal. BEARSHIFT LINKAGE REMflVAL Drain the engine all. Remove the clutch (Seciton 8). Remove the neutral and drum stopper arm bolts and both arms. Pull the gearshift spindle assembly out. Remove the positive plate bolts and plate, Remove the stopper cam plate bolt, cam plate, drum center and drum pins. GEARSHIFT lINKAh‘E INSTALLATlflN Install the drum pin‘ Align the hole in the drum center with the drum pin. Install the drum plate. Align the hole in the cam plate with the drum pin. Tighten the halt securely‘ Install the positive plate. GEARSHl FT LINKAGE HONDA C3650 9-3 HONDA C3650 GEARSHIFT LINKAGE Install the gearshift spindle. Install the drum and neutral Stopper arms. Install the stopper spring. Rotate the gearshift spindle and check the linkage for smooth operation. Instali the clutch assembly and cover Section 8). GEARSHIFT PEDAL INSTALLATION Instali the gearshift pedal as shown, TORQUE: 8—12 N-m (0.3—1.2 kg—m, 6~9 fl~lb) NOTE ~ Coat the dust seal with cii. Align the punch mark on the gear» shift arm with the punch mark on the gearshift spindle. Tighten the bolt and nut securely. Check pedal height from the foot peg. STANDARD: 33 mm (1-5/16 in) Adjust by loosening the lock nuts and turn- ing the adiusting rod. Tighten the lock nuts. 1 n g HONDA . ‘- C3650 CRANKBASE 10-0 HONDA é C3650 cRANKCASE 1 0-0 HONDA CRAN KCASE C 365° SERVICE INFORMATION 10—1 CRANKCASE DlSASSEMBLY 10—2 CRANKCASE ASSEMBLY 10—5 SERVICE lNFflRMATlflN GENERAL INSTRUCTIONS To repair the crankshaft, connecting rod, primary shaft and transmission including the shift fork and drum, it is necessary to separate the crankcase halves. The following parts must be removed before disassembling the crankcase. To service Remove Cran kshait and connecting rod Cylinder head, cylinder, piston, A. C. generator rotor, clutch, pulser generator, gearshift linkage and oil pump Transmission/primary shah Clutch, gearshift, oil pump and pulser generator TORQUE VALUE crankcase 8 mm bolt 22—26 N-m (22—26 kg-m. 16—19ft-lb) Crankcase 6 mm bolt 10—14 N-ml1.0A1.4 kgrm, 7—10 h-lb) 10-1 HONDA C3650 CRANKBASE DISASSEMBLY Remove the oil filter, oil pan and oil strainer (Section 2). Remove the cylinder head, cylinder and piston (Secticnfiand 7), Remove the clutch and gearshift linkage [Section 8 and 9). Remove the A. C. generator, pulser generator, spark advanoer and starting motor (Section 16,17 and18). Remove the oil pump. NOTE The crankcase can be separated without removing the A. C. generator, starting motor, oil filter, oil pump and oil strainer. However, we recommend removal of these parts, because the transmission gears may be dropped when separating the orankcases. Remove the upper crankcase bolts. Turn the engine upside down. Remove the lower crankcase bolts. NOTE Remove the bolts In two or more steps and in a crisscross pattern to prevent warpage. CRAN KCASE 1 0-2 HONDA C3650 CRAN KCASE PRIMARY SHAFT REMOVAL Remove the circlip. Remove the primary drive gear by using a gear puller‘ Remove the bearing stopper plate. Remove the primary chain tensianer spring. SPRING Remove the primary shaft thh special tools. (3) sum 019 10-3 HONDA C3650 CRAN KCASE CRANKCASE D ISASSEMB LY Separate the crankcase. 2) LOWER CA UTION ‘ ’ ~ ASE Do not pry between the upper and lower ‘ , CRANKC casein CRANKCASE ASSEMBLY Clean the crankcase mating surfaces. Apply liquid sealant to the mating surface of the lower crankcase, NOTE Do not apply sealant to the area near the main bearings and all passages, Apply molybdenum disulfide grease to the crankshaft main bearings. Make sure the transmission bearings and oil seal are properly seated in the upper crank~ case. Place the primary chain and damper assembly on the transmission. Assembly the crankcase halves, CRANKCASE Do not coat this area with sealant. z) LOWER CRANKCASE 1 0-5 HONDA C3650 CRANKCASE Insert the primary shaft and carefully drive it in with a plastic hammer, Install the bearing stopper plate. Install the clrclip. Install the primary drive gear and circlip. Install the tensianer spring as shown. (1 )YENSIONER SPRING HONDA C 3650 CRANKCASE Tighten the bois lo the specified torque values in the sequence shown, TORQUES: 8 mm bolt: 22—26 N-m (2.2~2.6 kg‘m, 18—19 fl-Ib) 6 mm boll: 10—1d N-m (1.0—1.4 kq-m, 7-10 hAlb) NOTE - Apply molybdenum disulfied grease to the threads and head of the 10 crankshaft holding bolts. If the oil gallery cap is removed, apply molybdenum disuliisd grease to the threads when installing. 10-7 kc: ‘12:? 11 PRIMARY SHAFT/ TRANSMISSION 11-0 HONDA PRIMARY SHAFT/TRANSMISSION c 3650 11-0 HONDA C 3650 PRIMARY SHAFT/TRANSMISSION SERVICE INFORMATION 11—1 TROUBLESHOOTING 11—2 PRIMARV SHAFT DISASSEMBLY 11—3 STARTOR CLUTCH OISASSEMBLV 11—4 STARTER IOLE GEAR REMOVAL 11—4 PRIMARY CHAIN TENSIONER REMOVAL 1145 PRIMARY NOZZLE REMOVAL 1st TRANSMISSION DISASSEMBLV I14 SHIFT FORK AND SHIFT DRUM REMOVAL 11—9 SHIFT ORUM AND SHIFT FORK INSTALLATION 11—11 TRANSMISSION ASSEMBLY 11—12 PRIMARY SHAFT ASSEMBLY 11—14 SERVICE IIIFIIRMIITIIIN GENERAL INSTRUCTIONS The gearshift linkage can be sarviced with the engine in the frame. For internal transmission repairs, the crankcase must be separated {Refer to Section 10). SPECIAL TOOLS Common TooIs Special Tunis Driver Handie IB) 07746—0020100 Torx Driver Bit 07703—0010200 Driver Handle (C) 07746—0030100 Outer Driver 07947—6710100 25 mm Inner Driver 0774641030200 Driver Handle (A) 07749—0010000 Driver Pilot (22 mm) 07746—0041000 TORQUE VALUES Neutral switch rotor 6—10 N-m (0.6—1.0 kgvm, 4—7 ft~lbi Primary chain tensioner 10714 Nrm (“I 071.4 kgrm. 7710 ftrib) Primary chain nozzie 8—1 2 N-m (0.84.2 kgm, 6~9 ft-Ib) Starting clutch 12—4 6 N'm (1.2—1.6 kg‘m, 9—1 2 be) SPECIFICATIONS STANDARD SERVICE LIMIT Transmission Backlash 15!, 2nd, 3rd 0,044-0.133 mm (00017—00052 in) 0.20 mm (0.008 in) 4th, Sth 0046—0140 mm (00018—00055 in) 0.20 mm (0.008 inI Gear I. D. M4 25.020~25.04I mm (03850—03859 W 25.06 mm (0.987 in) M5 23000721033 mm (03055-09068 in) 23.06 mm (0.908 in) CI 24.000—24.033 mm (09449—09462 in) 24.06 mm (0,947 in) CZ, C3 25020-45041 mm (03850—09359 in) 25.07 mm (0.987 in) Gear bushing M5 0. D. 22984—22993 mm I0.9849——0.9052 in) 22.96 mm “3.904 MI M5 I. D. 20010—20030 mm (08665—07836 In) 20.07 mm (0.790 in) C1 0. D. 21984—23393 mm (03443—09446 in) 23.95 mm (0.9431n) CI I. D. 20010720030 mm I0.8665~0,7886 in) 20.07 mm (0.790 in) 11-1 PRWIARY SHAFT/TRANSMISSION HONDA C3650 STANDARD SERVICE LIM1T Transmission Mainshafl CD. at M4 24959724980 mm (09826433835 in) 24.93 mm (0.981 in) at M5 19387—20000 mm (07869—07874 in) 19.93 mm (0.785 in) Countershaft 0. D. at C1 19.987 720.000 mm (07869—117874 in] 19.93 mm (0.785 in) at c2. ca 24359—24980 mm (09826—03835 in) 24.93 mm (0.951 in) Gear to bushing or M4 to shaft 0.10 mm (0.004 in) shaft clearance M5 to bushing — 0.10 mm (0,004 in) M5 bushing to 0.10 mm (0.004 in) shaft C1 to bushing ———~— 0.10 mm (0.004 in) C1 bushing to 0.10 mm (0.004 in) shaft (:2 to shaft ——~——— 0.10 mm (0.004 in) C3 to shaft 0.10 mm (0.004 in) Side clearance M5 0.3-0.5 mm (0012—0020 in) CI 0.1—0.3 mm ((1004—0012 in) --—~-— Shift fork Claw thickness 5.937600 mm (0233—0236 in) 5.6 mm (0.22 in) I. D. Center 38000-38025 mm (1.4961—1.4970 in) 38.075 mm (1.4991n) Left and right 13000—13018 mm (05118—05125 in) 1304 mm (0.513171) Fork shaft 0. D. 12966—11984 mm (05104-405112 in) 1290 mm (0.50801) Shift drum 0. D. 37850—37375 mm (1.4941—1.495'l in) 37.90 mm (1.4921n) E(ectric starter Drive gear 0. D. 41 BSD—42.200 mm (10516—1 .6614 in) 41.93 mm (1.5501n) ld1e gear I. D. 10.000—1 0.015 mm (03937—03943 1111 10.04 mm (0.395 in) Idle gear shaft 0. D, 997243.987 mm (0.39264039321n) 9.95 mm (0.392 in) Idle gear-to»shaft clearance 0.1 mm (0.004 in) TRUHBLESHUGTINE Had to shift 1. Improper clutch adjustment; too much free play 2. Shift fork bent 3. Shift shaft bent 4. $111“ claw be"! 5 . Shift drum cam grooves damaged Transmission Jumns out of near 1. Gear dogs worn 2. Shift shaft bent 3. Shift drum stopper broken 4. Shift forks bent 11-2 HONDA C3650 PRIMARY SHAFT/TRANSMISSION PRIMARY SHAFT DISASSEMBLY Remove the prrmary shaft and senarate the crankcase (see Section 10]. PRIMARY SHAFT INSPECTION Check for scoring, wear or other damage. DAMPER DISASSEMBLY (1 ) CIRCLIP Remove the circlip. Remove the collar andvcotters. (2) COLLAR (3) corneas Remove the primary driven sprocket and damper rubbers, DAMPER RUBBER INSPECTtoN Check for damage or deterioration. NOTE Replace rubbers as; set. 11-3 PRIMARY SHAFT/TRANSMISSION HONDA C3650 STARTER CLUTCH DISASSEMBLY Remove the "rorx” bolts: Remove the starter clutch outer. Remove the rollers, plungers and springs. STARTER CLUTCH INSPECTION Inspect the rolIers for smooth operation. Check the roHers for excessive wear. Inspect the drive gear for damage or excesV sive wear. V Measure the O. D. SERVICE LIMIT: 41.93 mm (L650 in) STARTER IDLE GEAR REMOVAL Straighten the luck washer tabs. Loosen the starter idle gear set bolt. Remove the We gear shaft and gear. (2) TORX DRIVER Bu 07703-00102‘00‘ (1 ) CLUTCH OUTER 11-4 HONDA C3650 PRIMARY SHAFT/TRANSMISSION STARTER IDLE GEAR AND SHAFT INSPECTION Inspect the idle gear for damage or excessive wear. Measure the gear I, D‘ SERVICE LIMIT: 10.04 mm (0395 in) Measure the shaft 0. D. SERVICE LIMIT: 9.95 mm (0.392 in) PRIMARY CHAIN TENSIUNEII REMIJVAI. Remove the tensioner huh and tensioner. HONDA C3650 PRIMARY SHAFT/TRANSMISSION TENSIONER INSPECTION Check the sliper for damage or excessive wear. PRIMARY NOZZLE REMOVAL Remove the primary nozzte. Check the nozzle for clogging 11-6 HONDA c 3650 PRIMARY SHAFT/TRANSMISSION For servicing of the gearshift linkage, see Section 9. TRANSMISSIDN DISASSEMBLY Separate the crankcase (Section 10]. Inspect each gear for backlash. SERVICE LIMIT: 0.2 mm (0008 in) Remove the mainshsft and countershaft‘ Remove the dowel pins and bearing set rings from the crankcase. 11-7 HONDA C3650 PRIMARV SHAFT/TRANSMISSION TRANSMISSION INSPECTION Check gaiar dogs, dog ham and teem for excessive or abnormal wear, or evidence of Insufficient lubriCation. Measure the |. D. of each gear. SERVICE LIMITS: M4 gear: 25.06 mm (0.987 in) M5 gear: 23.06 mm (0.908 in) C1 gear: 24.06 mm (0.947 in) (:3 gear: 25.07 mm (0.987 in) 02 gear: 25.07 mm (0.987 inI Measure the I. D. and O. D. of the gear bushings. SERVICE LIMITS: M5 0.0.: 22.96 mm (0.9041n) 20.07 mm (0.790 in) C1 0.D.: 23.95 mm (0.943in] C1 LD. 20.07 mmIOJQOilII Measure the O. D. of the mainshaft and couu» tershaft. SERVICE LIMITS: A: 24.93 mm (0.981 in) B: 19.93 mm (0.785 in) c: 19.93 mm (0.785 in) Calculate the cIearance between (he gear and gear shaft or bushing. SERVICE LIMIT: 0.10 mm (0.004in) 11-8 HONDA C 3650 PRIMARY SHAFT/TRANSM ISSION SHIFT FIIIIK AND SHIFT IIIIIIM REMIIVAL Remove the beefing stopper plate. Remove the cam plate and shift drum center, I3) DRUM ' IZICAM PL Remove the neutral switch. SWITCH Remove the shift fork shaft and forks. Remove the shift drum and bearing‘ HONDA C3650 PRIMARY SHAFT/TRANSMISSION Remove the shift fork set pin clip. Remove xhe shift fork set pin and fork. (1) CLIP (2) FORK SET PIN GEARSHIFT DRUM AND SHIFT FORK INSPECTION Inspect the shift drum end for scoring, scratches, or evidence of insufficient lub- rication. Check the shift drum groove for damage. Measure the shift drum 0. D. SERVICE LIMIT: 3730 mm (1.492 in) Measure the shift fork shaft 0. D. Check for scratches, scoring. or evidence of insufficient lubrication. SERVICE LIMIT: 12.90 mm (0.508 in) Inspect the shift drum hole and shift fork shaft hole for scoring or scratches. 11-10 HONDA C B650 PRIMARY SHAFT/TRANSMISSION Measure the shift fork LD. and claw Vhickness. SERVICE LIMITS: ID. IL AND RI: 13.04 mm (0‘513InI LD, (CENTER): 33.075 mm (1.499 inI CLAW THICKNESS: 5.6 mm [0.22 in) SHIFT DRUM AND SIIIFT FORK INSTALLATION Install the shift drum and shift forks by reversing the remova! procedure. Keep pains are shown here. Align the tab on the neutral swimh with the slot in the shift drum end. TORQUE: 6—10 N'm (0.6—1.0 kq—m, 4—7 beI 11-11 PRIMARY SHAFT/TRANSMISSION TRANSMISSIBN ASSEMBLY Assemble the mainshafl and muntershafl. NOTE Cheuk the gears for freedom of movement or rotatI’on on the shaft Check that the snap rings are seated in the grooves. NOTE Install the mainéhafc bearing with special tools. ('1 )DRIVER HANDLE (c) 07746- 0030100 INNER DRIVER (25mm) 07746— 003 0200 11-12 HONDA C 3650 PRIMARY SHAFT/TRANSMISSION Install the dowel pins and bearing set rings. (2) BEARING SET RINGS Align the hole in the needle bearings wilh the dowel pins by flashing the aligning marks with the crankcase surface. Align the ball bearing groove with file bearing set ring‘ NOTE Push the countershafl oil seal in until the oil se‘al lip is seated completely on the hearing before assembling the lower crankcase to prevent oil leakagei Assemble the crankcase (Refev to Section 10). 11-13 PRIMARY SHAFT/TRANSM ISSION HONDA C3650 PRlMARY SHAFT ASSEMBLY Install the pvimarv chain nozzle‘ TORQUE: 8—12 N-m (0.8~1.2 kg-m, 6—9 h-lb) lnstaH the tensioner and tighten the bolt. TORQUE: 10‘14 N-m (LO—1‘4 kg-m, 7—10 fl-Ib) DAMPER ASSEMBLY Instal! the damper rubbers. Instal! the primary sprocket. Install the comers and collar. Install the circiip. (1) CIRCLIP > (2) COLLAR 11-14 HONDA c 3650 PR1MARY SHAFT/TRANSMISSION STARTER IDLE GEAR INSTALLATION mm" the starter idle gear and shaft. Tighten the butt and fold the Iock washer tabs. STARTER CLUTCH ASSEMBLY Instail me starter clutch outer. TORQUE: 12—16 N'm (1.2—1.6 kg-m, 9—12 fflh) L(2) TORX DRIVER BIT 07703-0010200 (1 ) CLUTCH omen InstaH the starter ctu‘ch springs] plungers and roilers. (2) PLUNGER (1) ROLLER 11-15 PRIMARY SHAFT/TRANSMISSION instail the starter drive gear while rotating it counterclockwise, PRIMARY SHAFT ASSEMBLY Install the bearing into the primary shaft, J1)DRWERHANDm(m 0774650020100 ' Install the bearing into the primary shaft borei Assemble the crankcaye and instali the primary shaft (Section 10), 11-16 é HONDA ‘I 2 C3650 CRANKSHAFT 12-0 HONDA C3650 CHAN KSHA FT 12-0 HONDA C3650 CRANKSHAFT SERVICE INFORMATION 12—1 TROUBLESHOOTING 12—1 CONNECTING ROD REMOVAL 12—2 BEARING INSPECTION 12-3 BEARING SELECTION 12—5 CONNECTING ROD INSTALLATION 12—7 SERVICE IIIFIIIIMATIIIII GENERAL INSTRUCTIONS All bearing inserts are select fit and are identified by color code. Select replacement bearings from the code tablest After installing new bearings, recheck them with plastigauge to verify clearance. Applv molybdenum disulfide grease to the main journals and crankpins during assembly. TORQUE VALUES Connecting rod 24—28 N-m (2472.8 kg‘m, 17—20 ftelb) Crankshaft 22—26 N-m (2.2—2.6 kgvm, 16—19 flvlb) SPECIFICATIONS STANDARD SERVICE LIMIT Crankshaft Connecting rod big and side clearance 012—027 mm (ODDS—0.011 in) 0.35 mm (0.014 in) Runoul 005 mm (0.002 in) Crankpin oil Clearance 0018—0047 mm (0.00074.0019 in) 008 mm (0.003 in) Main journal Oil Clearance 0.02070‘048 mm (00008—013019 in) 0.08 mm (0.003 in) Cam chain Length 18437—18430 mm (7179—1280 in) 136A mm (734 in} Primary chain Length 11415—114‘40 mm MAM—4.504 in) 115.5 mm (4.55 in) TRUIIBLESIIIIIITING Excessive noise 1. Worn main journal bearing 2. Worn crankpin bearing 12-1 HONDA CRANKSHAFT C5650 CUNNEBTING RIID REMIIVAI Separate the crankcase (Section 10L Check the connecting rod side clearance. SERVICE LIMIT: 0.35 mm (0.014 in) Remove the bearing caps and rods. NOTE Mark the rods, bearings and bearing caps to indicate cylinder position. CRANKSHAFT INSPECTION Remove the cam chain and primary chain. Set the crankshaft on a stand or V Mocks. Set a dial indicator to the center main journal. Rotate the crankshaft two revolutions and read runout at the center journal. SERVICE LIMIT: 005 mm (0.002in) CAM CHAIN LENGTH MEASUREMENT Place the can chain over the cam and crank- shaft sprockets, Secure one sprocket. Appiy 13 kg (29 lb) (4) CRANKSHAFT m CAM SPROCKET of tension with a spring scale to the other SPROCKET sprocket, Measure the chain iength as shown SERVICE LIMIT: 186.4 mm (7.34in) (3) MEASURE 12-2 HONDA. C5650 CRANKSHAFT PRIMARY CHAIN LENGTH MEASUREMENT Place :he primary chain over the primary drive and driven gears. Secure one gear. (4) ggfigKSHAFT (1) PRIMARY GEAR $1152 (3) SEcyRE I (2) MEASURE Apply 32 kg (71 lb} of tension with a spring scale to the other gear. Measure the chain length as shown. SERVICE LIMIT: 115.5 mm (4.55 in) 32 kg (71 lb) BEARINE INSPECTIBN CONNECTING RODS Inspect the bearing inserts for damage or sepa- ration. t Clean ali ail (mm the bearing inserts and crankpins. Put a niece of piastigauge on each crankpin. Install the bearing caps and rods on the correct crankpins, and tighten them eveniy. TORQUE: 24—28 N-m (2.4—2.8 kgva 17—20 ft-ih) NOTE Do not relate the crankshaft during inspection. HONDA C3650 CRANKSHAFT Remove the caps and measure the compreswd plastigauge on each crankpin. OIL CLEARANCE SERVICE LIMIT: 0.08 mm ((1003 in) MAIN BEARINGS Inspect the bearing inserts for damage or separation, Clean all oil from the bearing inserts and journals. Put a piece of plastlgauge on each journal, avoiding the all holes. Install the main hearings on the correct journals on the upper crankcase and tlghten them evenly in the sequence shown and ln 2-3 stepst SPECIFIED TORQUES: 8 mm bolt (Crankshaft) 22—26 M!“ (21—23 kg-m, 16—19‘Il-Ib) NOTE Do not rotate the crankshaft during inspection. 12-4 HONDA C3650 CRANKSHAF‘I Remove the lower crankcase and measure the campressed plastigauge on each iournalt OIL CLEARANCE SERVICE LIMIT: 0,08 mm (0.003inI BEARING SELECTIUN If rod bearing clearance is beyond tolerv ance, select repiacement bearings as follows: CONNECTING ROD BEARING INSERTS Determine and record the corresponding rod i, D. code number, (1) ID. CODE Determine and record the corresponding crankpin O. D. code (or maasure the crank- Din O, 0.). NOTE The letter A or B on each crankweight is the code for each crankpin 0. D, (1) 0,0. cone 12-5 HONDA C3650 CRAN KSHAFT Cross reference the crankpin and rud codes to determine the replacement hearing color, CRANKPIN 0. D. CODE A B 34.996— 3488va 35.006 mm 311996 mm m 38.000» gg 1 38.007 mm D (Yellow! C (Green) 5 d 2 38'007‘ 0 (Green) a (Brown) % __r 38.014 mm 2 ‘3 38.014— 8 E 3 38.021 mm B (Brown) A (Black) MAIN BEARING Determine and record crankcase l. D. codes. NOTE The letter A or B on the lower rear crankcase is the code for the main journal I. D. from left to right; I. D. code For the third main journal is A Determine and record the corresponding main journal 0‘ Dr code (or measure the main journal 0. 0.). NOTE 0. D, Number 1 or 2 on each crankweight is the code for the adjacent main journal (1 COLOR CODE ‘ ' m Lu CODE 12-6 HONDA c3650 CHAN KSHA FT MAIN JOURNAL o. u. coma ‘ _ 1 2 (JICOLOR cons 32.990w 32.88[l« ' 33.000 mm 32.990 mm CASE I. D. A 36.0007 m serous mm DIY°"°WI C(Green) n 8 36,008— 8 36.016 mm C‘Greem Brsrown) c same— 36024 mm BIB’OWM AIBlack) CONNECTING RBI] INSTALLATION InstaIl the main bearings into the upper crank~ 0859‘ Apply molybdenum disulfide grease to the upper and lower maIn bearingst Install the crankshaft with the cam chain and primary chain. Before installing the connecting rods, make sure that the weight code combination is properly made. Facmry set node Available code IIIWEIGH CODE ' 12-7 / HONDA CRANKSHAFT C3650 Install the connecting rod and cap bearing inserts. Apply mo‘ybdenum disulfide grease to the connecting rod bearings. Install the connecting rods and bearing caps. NOTE . Be sure connecting rods are installed in their correct position and L D. code to the front. Cross relerence the rod and can I. D. codes to insure otiginal assembly‘ Tighten the connecting rod bearing cap boits‘ TORQUE: 24—28 N-m (24—23 kg-m, 17—20fl»|h) NOTE - Tighten The rod bearing cap belts in two or mere steps. After tightening the bolts, check that the rod move: freely without bind» mg. 12-8 g HONDA. C3650 FRONT WHEEL/ SUSPENSION 13-0 ‘ ,. HONDA c3650 FRONT WHEEL/SUSPENSION 28732 N‘rn (2.8—3.2 kgm, . 5.. (OB—1.3kg-m, " 7-«9ft-Ib) 30—40 N~m (3,0—4.0 kg-m, 22729 (Mb) 30—40 N~m (3.0—4.0 kg~ml 22—29 ftrlb) HIP-2.5 kg-m‘13—1Bh-lb) 13-0 HONDA C3650 FRONT WHEEL/SUSPENSION SERVICE INFORMATION TROUBLESHOOTING HEADLIGHT INSTRUMENTS HANDLEBAR SWITCH/HANDLEBAR FRONT WHEEL FRONT FORK STEERING STEM 13—1 13—2 13—3 13—6 1 3—7 13—13 13—18 13—24 SERVICE INFURMAIIIIN .GENERAL INSTRUCTIONS The front wheel uses a tubeless tire. For tubeless lire repair, refer to the TUBELESS TIRE MANUAL. Do not remuve rivets, nuts and pins from the rims, spoke pIate and hub. Never ride on the rim or Irv to bend the wheel. Avoid damaging the alminum alon rim. SPECIAL TOOLS TORQUE VALUES Speci'aI TooIs Front brake disc Hex. Wrench (6 mm) 079174230000 BaIl Race Remover 079534330000 Front axle nut Bearing Driver Attachment 079464290000 Bearing Driver Attachment 0794745710100 Front caliper carrler Common Tools _ Pin Spanner 0770270010000 “0‘“ ”"99“ A Retainer Wrench (B) 07710—0010200 Retainer Wrench Body O77IO~0010400 PW“ ““9 “O'd” "l" Bearing Driver Outer (42 x 47 mm) 07746—0010300 Bearing Driver Pilot (15 mm) mus—0040300 F’Om fork “P b0“ Front Fork 0:! Seal Driver Body 07747-0010100 From Fork on SeaI Attachment (EI 07747—0010600 Hand‘ebar mowing b0" Bearing Driver HandIe (A) 07749—0010000 . Lack Nut Wrench Seeker 07716—0020400 Fm ”WW“ W199 Extension Bar 07716—0020500 Fork tap bridge Steering stem nut 27—33 N-m (2.7733 kg-m. 20—44 It-lb) 55—65 Nrm (5576.5 kgrm, 4043 ft-Ib) 30740 N-m (3.0~4.0 kg-m, 22—29 ft—Ib) 30—40 N-m (SD—4.0 kg~ml 22729 ftrIb) 1045 Nrm (1.8—2.5 kg«m, 13718 ftrlb) 30-»40 N‘m (3,0740 kg'm, 22—29 ft-Ib) 28—32 N~m (2.8—3.2 kg-m, 20—23 ft-Ib) 30—40 Nrm (GIL—4.0 kg-m, 22—29 ft-Ib) 9—13N-m (0.9—1.3 kgrm, 7—9 ft—Ib) 80—120 N-m (Ell—12.0 kg-ml 58~87 frlb) 13-1 HONDA. FRONT WHEEL/SUSPENSION C3650 SPECIFICATIONS STANDARD SERVICE LIMIT Axle shaft runout W'— 02 mm (0.01 in) , Radial 7 2.0 mm (0.08 in) | Front whee rim runout Axial ~_ 20 mm (0.08 in) Fork spring free length 501.7 mm (19.8 in) 492.7 mm(19,4 in) Tube bend ~—— 0.2 mm (0.008 in) slider l. D. 35042—33104 mm (13796713820 in) 35.15 mmi1.384 in) fork tube 0, D. 34930734350 mm (1.3752v13760 in) 34.90 mmi‘l.374 in) TRflUBLESHflflTINB Hard steering 1. Steering adjustment nut too tight 2, Faulty steering stem bearings 3, Damaged steering stem bearings 4. Insufficient tire pressure Steers to one side or does nut track straight 'l. Unevenly adjusted right and left shock absorbers 2. Bent front forks 3. Bent from axle;wheel installed incorrectiy Front wheel wobbling 1, Distorted rim 2, Worn front wheel bearing 3. Faulty fire 4, Axle not tightened properly Soft suspension 1. Weak fork spring 2. Insufficient fluid in front forks Hard suspension 1. Incorrect fluid weight in front forks Front suspension noise 1, .Slider binding 2. Insufficient fluid in forks 3. Loose front fork fasteners 4. Lack of grease in speedometer gear box 1 3-2 HONDA C3650 FRONT WHEEL/SUSPENSION HEADLIGHT HEADLIGHT CASE REMOVAL Remove the headiight and disconnect all wires at their couplers and connectors. To remove the headiight case, unscrew the headlight case mounts. HEADLIGHT DISASSEMBLY/ ASSEMBLY Remove the retaining screws and horizontai adjusting screw from the rim. Remove the two headiight unir retaining screws, and headiight unit, Assembly is essentially the reverse of disas- sembiy. After assembly, adjust the headlight beam {Page 3—15). FRONT WH EEL/SUSPENSIDN HEADLIGHT CASE INSTALLATION Align the index marks on the headlight case with the punch marks on the brackets. NOTE Check each component for operation after asseminng. WIRING CONNECTIONS IN HEAD- LIGHT CASE Route the wires into the headIight case through the headlight case hols, LOWER HOLE: Main wire harneu UPPER RIG HT HOLE: Instrument wires Right handlebar switch wires Right turn signal wins UPPER LEFT HOLE: Fuse holdet wives Left handlebar switch wires Left turn signal wires Connect the colorcoded wires and couplers‘ (II INSTRUMENT 9-P COUPLER W (3) LEFT HANDLEBAR SWITCH 94’ COUPLER 1 3-4 HONDA C3650 FRONT WHEEL/SUSPENSION HEADLIGHT CASE BRACKET DlSASSEMB LY/ASSEMBLY Remove the headlight and disconnect all wires and wire cuu piers inside the case. Disconnect the brake hose from the from brake masler cylinder. NOTE Avoid spilling fluid on painted surfaces. Place a rag over the fuel rank whenever ‘he brake hose is disconnected. Remove the instruments. Disconnect the throttle] clutch and choke cables at the handlebar. Remove the headlight case bracket FRONT WH EEL/SUSPENSION INSTRUMENTS INDICATOR LIGHT BULB REPLACEMENT Remove the indicator llght panel screws and panel‘ Replace the bulb‘ If a replacement bulb does not light, check the wiring for short or open circuit. or loose connections. W METER lLLUMINATION LIGHT BULB REPLACEMENT Remove the meter mounting nuts and meter. Remove the bulb socket, Replace the bulb. lNSTRUMENT REMOVAL Remove the headlight Disconnect the instrument wire connectors in the headlight case. Remove the speedometer and tachometer cables from the instruments. Remove the instrument mounting nuts and instruments. 13-6 HONDA C3650 FRONT WHEEL/SUSPENSION HANDLEBAR SWITCH/ HANDLEBAR RIGHT HANDLEBAR SWITCH REPLACEMENT Remove the fuel tank. Remove the screws holding the upper and lower switch housings. Remove the throttle cables. Disconnect the front brakeiight switch wires from the swnch. Remove the headlight from the headlight case and disconnect the right handlebar switch wire coupler. Remove the switch wires from the headlight case. NOTE Connect a string to the switch wires and then remove the wires leaving the string, This string is used as a draw cord when routing the wiring of a new switch, install a new switch aligning with the hole in the handlebar. Tighten the forward screw first, then tighten the rear screw, Check switch operation. After installing, adjust throttle cable free play (Page 377), LEFT HANDLEBAR SWITCH REPLACEMENT Refer to RIGHT HANDLEBAR SWlTCH REPLACEMENT. Loosen the clutch lever bracket bolt. Disconnect the left handlebar switch wires. HONDA C8650 FRONT WHEEL/SUSPENSlON HANDLEBAR REMOVAL Loosen the three screws attaching the throt- tle grip/switch housing. Remove the right handlebar switch wires from the handlebar. Remove the brake master cylinder, CAUTION Secure the brake cylinder in an upn’ght position to prevent the fluid from leaking ,, . and damaging the [mint and to prevent ‘ . . C ‘ L3; air from enlering the brake system. ' ‘ ' ‘9” NOTE Do not loosen the brake hose unless necessaty‘ Remove the left grlpt Remove the left handlebar switch assembly. Loosen the clutch lever bracket bolt. Remove the clutch lever assembly. Remove the handlebar upper holder. Remove the handlebarv Remove the throttle grip and switch housing. 1 3-8 HONDA C3650 FRONT WHEEL/SUSPENSION HANDLEBAR INSTALLATION NOTE Apply grease to the throttle grip area of the handlebar. Position the handlebar on the fork bridge with the punch marks on the handlebar in line with the tent Place the upper holder on the handlebar. Tighten the forward bolts first, then tighten the rear bolts. Coat the throttle grip area of the handlebar with grease Install the throttle grip switch housing and throttle cables, Check throttle operation iPage 3—7). Install the master cylinder on the handlebar with the lug of the holder aligned with the switch case mating surface and wire relief facing down. Tighten the upper bolt first, then tighten the lower bolt. Install the clutch lever assembly. Install the handle lever bracket with the split aligned with the punch mark on the handle bar, Install the left grip. Install the left switch housingl HONDA C 3650 FRONT WHEEL/SUSPENSION IGNITION SWITCH REPLACEMENT Remove the two bolts holding the instrument cluster. Remove the bolts holding the ignition switch and disconnect the wire harness coupler. FUSE HOLDER REPLACEMENT Remove the fuse cover. Remove the handlebar upper holder. Remove the headlight. Disconnect the wire coupler. Remove the fuse holder, NOTE Before disconnecting the holder wires, tie a string to them. This string can be used as a draw cord when Installing a new holder. I1) FUSE HOLDER COUPLER 13-10 HONDA C3650 FRONT WHEEL/SUSPENSION CHOKE CABLE REPLACEMENT Remove the fuel tank. Disconnect the ch‘oke cable from the lower choke cable bracket, Remove the cable end from the choke lever. Remove the choke cable from the choke cable bracket on the handlebar holder, NOTE Before removing the cable, tie a string to the cable end. This string can be used as a draw card when installing a new choke cable, Lubricate the choke cable. CLUTCH CABLE REPLACEMENT Remove the fuel tank‘ Remove the clutch cable from lhe lever. 13-11 FRONT WHEEL/SUSPENSION Loosen the clutch adjuster lock nuts and remove the clutch cable from the clutch lever. NOTE Before removing the clutch cable, con- nect a string to the end of the cable so that a new cable can be installed easily by using this string as a draw cord. Lubricate the clutch cable. Adjust the clutch cable after replacement (Page 3—16)‘ THROTTLE CABLE REPLACEMENT Remove the fuel tank. Remove the right handlebar switch/throttle housing‘ Remove the throttle cables from the throttle housing. Remove the throttle cables from the car- buretors. Lubricate the throttle cables‘ Adjust throttle cable free play (Page 3—7). 13-12 fl HONDA C3650 FRONT WHEEL/SUSPENSION FRflNT WHEEL FRONT WHEEL- REMOVAL Remove the speedometer cable set screw and the speedometer cable, Remove the right or left caliper mounting bolts and caliper assembly (E, ED, F, G, U types). Remove the right or left caliper assembly from the fork leg (E, ED, F, G, U types)‘ NOTE Do not operate the front brake lever after removing the from wheel. To do so will cause difficulty in fitting the brake disc betwem the yrake pads, Remove the right and left axle holders. Jack up the engine until the folks clear the from axle and remove the front wheel. FRONT WHEEL DISASSEMBLY Remove the axle nut, speedometer gearbox, axle and collar. Remove the five bolts and disc ls)‘ 13-13 HONDA. FRONT WHEEL/SUSPENSION C8650 Remove the retainer. Remove the hearings and the distance collar from the hub. NOTE be replaced with new on WHEEL BEARING INSPECTION Check wheel heaving play by placing the wheel in a (wing stand and spinning the ' #— (“PLAY wheel by hand. Replace the bearing with a new one if it is noisy or has excessive plav. (1 I PLAY WHEEL INSPECTION Check rim runout by placing the wheel in a [wing stand. Spin the wheel slowly and read 1he runoul using a dial indicator gauge. SERVICE LIMITS: RADIAL RUNOUT:2.0 mm (01min) AXIAL RUNOUT: 2.0 mm (0.05m) NOTE The COMSTAR WHEEL cannot be repaired and must be replaced with a new one if the service limits are excer eded. 13-14 HONDA. C3650 FRONT WHEEL/SUSPENSION AXLE INSPECTION Set the axle in V biocks and measure the runout, The actual runout \5 1/2 of TIR (Tom Indicator Reading). SERVICE LIMIT: 0.2 mm (001 in) FRONT WHEEL ASSEMBLY NOTE ‘ The COMSTAR WHEEL has no rim band. ~ The front whee| uses a tubeless tire, For xubeless tire repair, refer to the TUBE LESS TIH E MANUAL Do not get grease on the brake disc. fi (1) BEARING RETAINER O 7, (545765 kg~m, 40417 ftrlb) (2.7—33 kgvml 20—24 ft-Ib] HONDA. FRONT WHEEL/SUSPENSION C3650 Pack all bearing cavities with grease. m BEARING DRIVER HANDLE (A) Drive in the right bearing first, 077490010000 / _\ Press the distance collar into place. BEARING DRIVER OUTER (42 x 47 mm) 07746700i0300 « NOTE BEARING DRIVER PILOT (15 mml Be Certain the distance collar is in 0774670040300 position before installing the bearing. Drive in the left bearing, LOTS , Drive the bearing squarely. Drive the bearing into position, making sure that it is fully seated and that the sealed side is facing out. install the bearing retainer with the tool used to remove it. NOTE Inspect the vetainer, if the threads are damaged, it should be replaced. Install the seal and the bearing retainer and peen the edge of the retainer. NOTE The spoke plate bolts and nuts require install the disc (5) and disc bolts (and nuts). TORQUE: 27—33 N-m (21—13 kg—m, 20—24 ft-lhl 13-16 Install the speedometer gear retainer. Lubricate the inside of the oil seal and install it, Remove the speedometer drive gear from the gearbox Wipe old grease off, check the sliding surfaces for wear or damage. Replace the drive gear and/or gearbox if necessary. Fill the gearbox with grease and install the drive gear. Install the speedometer gear in the wheel hub, aligning the tangs with the slots. install the left side collar and axle. lnstall the axle nut. TORQUE: 5545 MM (5.5—6.5 kgm, 40~47 mb) Clean the brake disc is) with a high quality degreasing agent. FRONT WHEEL lNSTALLATION Fit the calipers over the discs, taking care not to damage the brake pads. install the caliper mnunting bolts lE, ED, F, G, U types). TORQUE: 30—40N~m (3.0—4.0 kg-m, 22—29 fl-lbl Install the axle holders with the "F” arrow forward. Tighten the forward axle holder nuts lightly. Tighten the axle holders nuts (right axle holder nuts: E, ED, F, G and U typesl to the specified torque, starting with the forward nurse TORQUE: 18—25 N~m (HZ—~25 kgvm, 13718 ft-lbl lE, ED, F, G and u types) Measure the outside surface of the left brake disc and the rear of the left caliper holder with a 0.7 mm (0.028 in) feeler gauge. If the gauge cannot be inserted, pull the left fork out until the gauge can be inserted, There should be at least 0.7 mm (0.028 in) clearance between the caliper holder and disc. CAUTIQN After inrlalling the wheel, apply the brakes reveal times and recheck the clearance on both sides. Failure [0 pmvide correct clearance will damage the brake disdsj and affect braking efficiency. Tighten the left axle holder nuts tn the specified torque, starting with forward nuts. 13-17 FRONT WHEEL/SUSPENSION FRONT FDRK FRONT FORK OIL CHANGE Remove the cap bolt. Place a pan below the fork, remove the drain plug and allow the fork oil to drain. Compress the suspension to completely drain the fork. Refill the fork, page 13—22. REFILL CAPACITY: 150 mu3 (5.1 015) Repeat this operation For the remaining fork leg. FORK REMOVAL Remove the from wheel, Remove the brake caliper (5). NOTE Do not loosen the brake hose unless necessary. Remove the front fender. 13-18 HONDA C3650 FRONT WHEEL/SUSPENSION NOTE Loosen the fork cap bolt to faciIitate disassembly later. Loosen the clamp bolts on the fork upper and lower bridges‘ Pul! the assembly down and out while turning the fork tuba‘ FORK DISASSEMBLY Remove the lack from the bottom of the fork leg‘ Remove the fork tube and components. NOTE Hoid the 60er slider in a vise. being careful not to overtighten it. (2)HEX. WRENCH (6 mm) 07917—323000!) / OIL SEAL REMOVAL Carefuflv remove the oil seal with a screw- driver. CAUTION Avoid damaging the inner md outer surfaces of the Slider when removing the meal (SDSCREWDRIVER {UOIL SEAL (MSHOP TOWELS OR OTHER PADDING (2}FORK SLIDER 13-19 FRONT WHEEL/SUSPENSION HONDA C3650 SPRING FREE LENGTH INSPECTION Check the free length of the fork spring. RepIacs if it does not meet the specifications‘ SERVICE LIMIT: 492.7 mm (19.4 in) FORK TUBE/FORK SLIDER/ PISTON INSPECTION Check the fork tubes, fork sliders and pistons for score marks, scratches, or excessive or abnormal wear, replacing those which cannot be reused. Remove the fork seaL Measure the inside diameter of the sliderl Measure the outside diameter of the fork tube and check the condition of the tube piston and rings‘ FRONT FORK SLIDER l. D SERVICE LIMIT: 35.15 mm (1.384 in) FRONT FORK TUBE O. D‘ SERVICE LIMIT: 34,90 mm (1.374 in) EORK TUBE INSPECTION Set the fork tube in V blocks and read the runout. Take 1/2 TIR to determine the actual runout. SERVICE LIMIT: 0.2 mm (0.01m) WNW (“FORK SLIDER 1 3-20 HONDA c B650 FRONT WHEE L/SUSPENSION FORK ASSEMBLY (5) FORK PIPE (1) CAP BOLT 20—30 N~m (IO—3.0 kg-ml 15—22 ft-lb) (6) DUST SEAL [7] OIL LOCK (8) OILSEAL (2) SPRING (9) SLIDER (3) PISTON ——® RING % \ (4) PISTON § (10) AXLE HOLDER 0”- SEAL INSTALL/“‘0“ FRONT FORK OILSEAL DRIVER BODY: cap the new fork sea‘ in ATP and instail n in 07747—0010100 the slider using the fork leg as a guide for the FRONT FORK OIL SEAL ATTACI'WIENT (E): seal driver. r \07747~0010600 Drive the oil seal into position until the snap ring groove appears. Install the snap ring and dust cover. .71,“ 13-21 FRONT WHEEL/SUSPENSION Install the piston and fork tube‘ Apply a locking agent to the bolt threads and underside of the bolt and tighten. TORQUE: 8—12 N-m l0.8~1.2 kgvml 6—9 it-lh) CA UTION Do not overlighten the fork slider in a vice. FILLING WlTH OIL Use ATF (Automatic Transmission Fluid) to fill the front fork‘ OIL CAPACITY: 170 cm“ (5.7 on) at assembly NOTE Pour the specified amount of ATF. Do not overfllll Slide the fork spring and spring seat into position and tlghten with the cap bolt, TORQUE: 30—40 N‘m (340—4.!) kg-m, 22—29 ft-Ib) NOTE Place the fork tube in a vise with shop towel, avoiding the sliding sur~ face. Note the spring direction g HONDA C3650 (ZlHEX. WRENCH (6 mm) 0791743230000 (1) SHOP TOWEL OR SOFT JAWS (2) SHOP TOWEL OR SOFT JAWS 13-22 HONDA C3650 FRONT WHEEL/SUSPENSION FORK INSTALLATlON Install the fork tubes in the fork top bridge and steering stem, while rotating them by hand. Position the fork tubes so that the fork tube upper and lines are even with the fork top bridge as shown, Tighten the fork tube pinch belts at the steering stemr TORQUE: 30—40 N-m (3‘0—40 kg»m, 22—29 ft-lb) Tighten the fork tube pinch bolts at the top bridge. TORQUE: 9—13 N-m (0.9—1.3kg-m, 7—9 ft-lh) Install the fender. Install the brake caliper. Secure the brake hose. Install the front wheel. FRONT WHEEL/SUSPENSION STEERING STEM STEM REMOVAL 30 x 32mm WRENC Remove the handlebar. 7715.- 0020400 Remove the instruments (Page 13-45). , Remove the headlight assembly and discon- ,TENSIOZOBGR' neat the wiring (Page 13—4). I 715.00 5 0 Remove the sieering stem nut, Remove the headlight case bracket, Remove the whee! and forks. Remove me fork [op bridge. Remove the bearing adjustment nut. Remove the steering stem, upper cone race and steei balis, Remove the lower cone race, dust seal and washev. HONDA C B650 : (1) LOWER CONE RACE 13-24 HONDA C3650 FRONT WHEEL/SUSPENSION Install a dust sea‘ and washer on the sxeering stem and drive the ‘ower cone race over the stern. Remove the upper baH race with the speciak tool. (1 )BALL RACE nemovzn Remove the lower ball race wwth the specia} tool. NOTE |f the motorcycle has been ‘mvoIved in an accident, examine the area around the steering head for cracks HONDA FRONT WHEEL/SUSPENSION C 3650 Drive the upper bell race into the steering head with the special tools. Drive the lower ball race into the steering head with the special tool. Grease the upper ball race and install 18 steel balls. Grease the lower cone race and install 19 steel balls Insert the steering stem into the steering head and install the upper cone race and bearing adjustment nuL Tighten the adjustment nut until snug against the upper cone race. L’ L P Then, loosen it 1/8 turn. t 2 (1 ) PW SPANNER F 07702-0010000 Make sure that there is no vertical movement and the stem rotates freely. 13-26 HONDA C3650 FRONT WHEEL/SUSPENSION TOP BRIDGE INSTALLATION Install the front fork legs. 30 X32 mm WRENCH I Temporarily hold me front fork lags by 07715—0020400 tlghlening the steering stem fork pinch bolts. EXTENSION BAR: 07716'0020500 Tighten the steering stem nut. TORQUE: 80—120 Nvm (an—12,0 kg-m, 58—87 ft—Ib) Tighten the bottom bridge fork bolts. TORQUE: 30—40 N~m (311—10 kg«m, 22-«29 be) Tighten the top bridge fork bolts, TORQUE: 9—13 N‘ m (0.9-1.3 kgAm, 7—9 ft-lb) Install the lollowing: Handlebar Instruments Headllght Front fender Front wheel 1 3-27 14. .1221?" REAR WHEEL/ SUSPENSION 14-0 HONDA c3650 REAR WHEEL/SUSPENSION (SD—4.0 kg-m. 2249 ft-Ib) 80—100 N-m (3,0400 kg-m, 53—72 mm 18—25 N‘m , (1.84.5 kg-m, , A. 1371amb) “ v E, ED, F, G, U (GD—7.0 kgvm, 43—51 ft~lb) 1 4-0 HONDA REAR WHEEL/SUSPENSION / C 3650 (3.041.!) kg-m, 22~29 ft-lb) 80—100 N»m (8.07101) kg-m, 58772 ft-lb) 18—25 N-m (1.8w2.5 kgrm,13718 h-Ib) DK, DM 14-0 HONDA C 3650 MEMO HONDA REAR WHEEL/SUSPENSION C5650 SERVICE INFORMATION 14—1 TROUBLESHOOTING 14—2 REAR WHEEL 14—3 SHOCK ABSORBER 14—9 SWING ARM 14—1 2 GENERAL INSTRUCTIONS The rear wheel uses a (ubeless tire. For (ubeless (ire repalrsl refer to the TUBE LESS TIRE MANUA L, Do not remove rivets, nuts and pins from the rim, spoke plate and hub, Never ride on the rim or try to bend the wheel. Avoid damaging the alminum allov rim. SPECIAL TOOLS Special Tools Bearing driver attachment 07946—329000!) Common Tools Bearing Driver Handle (A) 0774970010000 Bearing Driver Outer (62 x 65 mm) 07746—001050!) Bearing Driver Pilot (20 mm) 07745—0040500 Bearing Driver Pilot (25 mm) 07746—0040600 Rear Shock Absorber Compressor 07959—3290001 Retainer Wrench Body O7710~0010400 Retainer Wrench (A) 07710—001010!) Retainer Wrench (CI OHIO—0010300 TORQUE VALUES Rear Shock absorber 30740 N-m (3.0—4.0 kg-m, 22-29 ft-lb) Driven sprocket 80~100 N~m (ED—10.0 kg-m, 58772 beI Hear axle 807100 N-m (SD—10.0 kg-m, 58—72 ft—Ib) Swing arm pivot bolt 60—70 N-m (5.0v7fl kg-ml 43—51 ft-lbl Rear brake torque llnk 18-45 N-m (1.8—2.5 kg-m, 13—18 ft-Ib) SPECIFICATIONS STANDARD SERVICE LIMIT Axle runout —““" 0.2 mm (0-01 in) Rear wheel rim runout Radial 2.0 mm (0,031,” Axial _.___ 2.0 mm (0.08 in) Shock absorber spring free length 224.7 mm (8.8 in) 220.6 mm (8.7 in) Swing arm bushing I. D. 21500—21552 mm (0.8465v—0fi485 in) 21.7 mm (0.854 in) Swing arm COUEr O. D. 213127—2146!) mm (03436—03449 in) 21.4 mm (01mm) Rear brake lining thickness 5.0 mm (0,197 in) 2.0 mm (0.08 in) Rear brake drum LD, 180‘1803 mm (7.09—7.10in) 181 mm (7.1 in) 14-1 HONDA C3650 REAR WHEEL/SUSPENSION TROUBLESHUDTING Wobble or vibralion Suspension nuisa . Distorted rim 1. Shock case binding ‘ Loose whee‘ bearing 2, Loose fasteners ‘ Loose or distorted spokes ‘ Faulty tire . Loose axle . Tire pressure incorrec‘ ‘ Swing arm bushing worn ummbmm—x So" suspension 1. Weak spring 2. Shock absorbers improperly adjusted Hard suspension 1. Shock absorbers improperly adlusted 2r Bent shock absorber 14~2 HONDA REAR WHEEL/SUSPENSION C3650 REAR WHEEL REAR WHEEL REMOVAL Face the motorcycle on its center stand‘ Loosen the drive chain adjuster iock nuts and bolts. Disconnect the rear brake torque link by removing the cotter pin and nut. Remove the rear brake adjusting nut and disconnect the brake rode Remove the cotter pin from the rear axle and loosen the nut‘ Pull the adiusters down, push the whee! forward and remove the drwe chain from the drive sprocket. Remove the rear wheel, Remove the rear axle. REAR WHEEL DISASSEMBLY Loosen the driven sprocket nuts. Remove the driven flange from the whee‘ hub. Remove the driven sprocket. 14-3 HONDA c3650 REAR WHEEL/SUSPENSION Remove the bearing retainer. Remove the bearings and distance collar from the rear wheel hub‘ Remove the hearing from the final driven flange‘ 1) .y . W‘ER WRENCH glam 7‘10-0010400 , » AXLE INSPECTION Set the alxe in V blocks and read the axle runout‘ The actual runout is 1/2 of TlR (Total Indicator Reading). SERVICE LIMIT: 0.2 mm (0.01 in) REAR WHEEL BEARING PLAY INSPECTION Check wheel bearing play by rotating the “IIIPLAV wheel by hand. Replace the bearings with new ones if they are noisy or have excessive play. (llPLAY 1 4-4 REAR WHEEL/SUSPENSION REAR WHEEL FllM RUNOUT INSPECTION Check the rim for runour by placing the wheel in a trulng stand. Spin the wheel slowly. and read the-runaul using a dial indicator. SERVICE LIMITS: RADIAL RUNOUT:2.0 mm (01min) AXIAL RUNOUT: 2.0 mm (0.03m) FINAL DRIVEN SPROCKET INSPECTION Check the wndltion of the final driven sprack~ el teeth. Replace the sprocket If worn or damaged NOTE If the final driven sprocket requires re- placement, inspect the drive chain and driven sprocket (Page 3712]. DAMPER RUBBER INSPECTION Replace ms damper rubbbvs if they are damaged or deteriorated. HONDA C3650 (”GOOD IZIREPLACE (1 l mail/mam _ 14-5 HONDA C3650 REAR WHEEL/SUSPENSION BRAKE LINING THICKNESS INSPECTION Measure ‘he brake lining thickness. SERVICE LIMIT: 2.0 mm (0.03 in) BRAKE DRUM |. D. INSPECTION Measure the brake drum inside diameter, SERVICE LIMIT: 181 mm (7,1in) BRAKE SHOE REPLACEMENT Remove the brake arm. Remove the cotter pins. Replace (he brake shoes whh new ones. Appiy a iight coat of grease to the faces of the anchor pins and brake cam and groove in the brake cam. Contaminated brake linings reduce stop- ping power, Keep grease off the brake liningx. Wipe ext-em grease off the cam and anther pins» HONDA C3650 REAR WHEEL/SUSPENSION Align the punch marks on the brake cam and brake arm‘ Ttghten the brake arm boIL TORQUE: 24—30 N-m (2.4—3.0 kg-m, 17—22 fl-Ib) REAR WHEEL ASSEMBLY @@( III 0|L SEAL (2) BEARING RETAINER Q (3) FINAL DRIVEN SPROCKET 80—400 N‘m ‘ / (8.07101) kg-m, - ' 58772 mm 0 1- I .g _ I (5) ' ’ BEARING (6) BEARING (4) DAMPER I7) DISTANCE COLLAR RETAINER RUBBER .E (12) BRAKE CAM I9) INDICATOR PLATE (8) BRAKE ARM III) BRAKE SHOES I14) BRAKE PANEL COLLAR I13) BRAKE TORQUE LINK BOLT Q Q (10) BRAKE PANEL 80—100 N‘m I (ac—10.0 kg~m, ER 5342mm 19725 N‘m (1.9—2.5 kg-m, 14—18ft-Ib) HONDA C3650 REAR WHEEL/SUSPENSION Pack all bearing cavities with grease. Press the distance collar into place from the left side. Drive the right bearing first, then the left bearing. CA UT [0N - Drive the bearing squarely. Install the bearings with the sealed end facing aut, making sure they are filIly seated. Install the bearing retainer with the same tool used to remove It. Peen it to the hub. NOTVE__777 7777777; C ck the condition of the bearing retainer. Replace the retainer if the threads are damaged. InstaH the final driven sprocket. TORQUE: 80—100 N-m I8.0—-10.0 kgrm, 58—72 {MM (1) BEARING DRIVER HANDLE (A) 0774941010000 I (2) BEARING DRIVER (62 x 68 mm) 07746—0010500 (3) BEARING DRIVER ATTACHMENT 07746—329000!) (4) DRIVER PILOT (20 mm) 07746v—0040500 I5) DRIVER PILOT (25 mm) 07746-0040600 HONDA. REAR WHEEL/SUSPENSION C3650 REAR WHEEL lNSTALLATION Install the rear wheel in the reverse order of removal. NOTE W brakes several times, and then check to be sure that the wheel rotates freelv. Recheck me installation if the brake drags or wheel does not rotate freely. Use a new cotter pin for securing the axle nut. TORQUE: 80—100 N.m (8,0—10‘0 kg~m, 58—72 ft-Ibl Use a new cotter pin for securing the rear brake torque linkv TORQUE: 19725 NW!» (1,972.5 kg-m, 14~18 fl—Ih) Adiust drlve chaln free play (Page 3,12), Adjust the rear brake (Pagea—m)‘ SHOCK ABSBRBER SHOCK ABSORBER REMOVAL Remove the mufflers, Remove the rear carrier pipe attaching bollsr Remove the upper and lower shock absorber mounting bolts and nuts, and remove the shock absorbers. 14-9 HONDA. C3650 SHOCK ABSORBER DISASSEMBLY Compress the spring lust enough to remove the lock nut. Loosen the lock nus and remove the upper mount. SHOCK ABSORBER SPRING FREE LENGTH Disassemble the unit. Measure the free length of the springs Inspect the shack body for oil leaks‘ SERVICE LIMIT: 220.6 mm [8.7 in) SHOCK ABSORBER ASSEMBLY NOTE Install the spring with the tight coils at the bottom. REAR WHEEL/SUSPENSION REAR SHOCK ABSORBER COMPRESSOR 07959—3290001 “Elm (2) Q LOCK NUT @ 20—35 N‘m .\.0—-3.5 kg-m, 15—25 ft-lb) (3)5TOPPER RUBBER (4) . SPRING ADJUSTER l1) UPPER MOUNT 14-10 NOTE Apply a locking agent to the look nut at time of assembly. SHOCK ABSORBER lNSTALLATlON Tighten the shock absorber bolts and nutst TORQUE: 304D N‘m (3.0—4.0 kw", 22—29 fltlh) Install the mufflers. Adjust the right and left absorbers equally with the spring adjuster. Check shock absorber operation after instal- lation. REAR WHEEL/SUSPENSION HONDA C 3650 (1 ) REAR SHOCK ABSOREER COMP RESSOR 0795943290001 Ill [ll IV V (1) STANDARD :X 14-11 HONDA C3650 REAR WHEEL/SUSPENSION SWING ARM SWING ARM REMOVAL Remove the mufflers, Remove the left crankcase rear cover. Remove the rear wheel (Page 14—3), Remove the drive chain guard. Remove the right and left shock absorber; Remove the swing arm, l2) SWING ARM SWING ARM DISASSEMBLY/ ASSEMBLY NOTE fifflmw—v Drive the bushings into place, with a soft hammer, making sure that they are not damaged. Lubricate with grease after installation. SERVICE LIMITS: BUSHING I. D.: 2L7 mm (0.854 in) COLLAR 0. D.: 21.4 mm (0,843 in) SWING ARM INSTALLATION Place the drive chain over the swing arm, Tighten the swing arm pivot bolt. TORQUE: 60—70 N~m (6.0—7.0 kg-m, 43—51 fl-Ih) Install the shock absorbers. TORQUE: 30—40 N-m (3.0—4.0 kg-m, 22—29 folk) Install the mufflers‘ Install the rear wheel. 15. 0132;?“ HYDRAULIC BRAKE 15-0 HYDRAULIC BRAKE (2.5735 kgrm, 18—25 ftlb) (3.0—4.0 kgAm, 22—29 ft-\b) 30~40 N-m (30—40 kg-m,22~291tvlb) 15-0 HONDA. HYDRAULIC BRAKE ‘ ‘3650 SERVICE INFORMATION 15—1 TROUBLESHOOTING 15—2 BRAKE FLUID REPALCEMENT/AIR BLEEDING 15—3 BRAKE PAD/DISC 15—4 BRAKE MASTER CYLINDER 15—6 BRAKE CALIPER 15—3 SERVICE INFDRMATION GENERAL INFORMATION - The “out brake can be removed without disconnecting the hydraulic system. Once the hydraulic systems have been opened, or if the brakes feel spongy, the system must be bled. Do not allow foreign material to enter the system when filling the reservmr. v Avoid spilling brake fluid on painted surfaces or instrument lenses, as severe damage will result. ~ Always check brake operation before riding the motorcycle. SPEC|AL TOOLS Snap Ring Pllers SPECI F(CATlONS 0791473230001 TORQUE VALUES Brake hose bolt Front brake caliper carrier Front brake caliper A 25735 N‘m (ZS—3,5 kg-m, 18—25 ft-Ib) 30—40 N~m (3.04,!) (gm, 22—29 ft-Ib) 30—40 N-m (3.04.0 kgrm, 22—29 ftrlb) STANDARD SERVICE LIMIT 0' th‘ k DK, DM 6,947.1 mm (0.27—0.28 in) 6.0 mm (0.24 in) lSC IC ness E, ED, F, G, U 4.9—5.1 mm (0.19—0.20 in) 4.0 mm (0.16 in) Dis runout 0.3 mm (0.01 in) ‘ DK, DM 14000—14043 mm (05512705529 in) 14.055 mm (0.5533 in) Front master cylmder ID. E, ED, F, G, U 15370715313 mm (052487015265 in) 15.925 mm (0.5270 in) _ DK, DM 1195743984 mm (0.5495v05506 in) 13.945 mm (0.5490 in) Front master piston OD. E, ED, F, G, U 15.327w15.854 mm (05231—05242 in) 15.815 mm (0.6226 in) ‘ . DK, DM 42822—41772 mm (13859—115939 in) 42.765 mm (1.6837 in) Front calmer pIstOn O.D. E, ED, F, G, U 38.098—38J48 mm (14999—15019 in) 38.090 mm (1.4996 in) . , . DK, DM 42350—42350 mm (16870—115909 in) 42.915 mm (1.6896 in) Front cellper cylmder |.D. E, ED, F, G, U 38.180—38.230 mm (15032—15051 in) 38,240 mm (1.5055 in) 15-1 HONDA C 3650 TRUIJBLESHUIITING Brake layer so“ or spongy 1. Air bubbles in hydraulicsystem 2‘ Law fluid level 3. Hydraulic system leaking Brake level too hard 1. Sticking pistol’lls) 2, Clogged hydraulic system 3. Pads glaled or worn excessively Brakes drug 1. Hydraulic system sticking 2. Incorrect adjustment of lever 3. Sticking plstoMs) HYDRAULIC BRAKE Bakes grab or pull to one side 1. Pads contaminated 2. Disc or wheel mlsaligned Brakes charter or squeal 1. Pads contaminaled 2. Excesswe disc runout 3‘ Caliper installed lncorreclly 4‘ Disc or wheel misaligned 15-2 HONDA C 3650 HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/ AIR BLEEDING Check the fluid level with the fluid reservoir parallel to the ground. CA UTION > Install the diaphragm on the reservair when operating the brake lever. Failure to do so will allow brake [had to squirt out of the reservoir dunng brake operation, ~ Avoai the spilling fluid on painted surfaces. Place a rag over the fuel tank whenever the system is serviced. BRAKE FLUID DRAINING Connem a bleed hose to the bleeder valve. Loosen the caliper bleeder valve and pump the brake levert , Stop operating the lever when on fluid flows ’ out of the bleeder valve. ll NING A contaminated brake disc or pad reduces stopping power. Discard curtmml'mlted pads and dean a contaminated disc with a high quality brake degreast'ng agent. BRAKE FLUID FILLING NOTE Use only SAE J1703 or DOT 3 brake fluid from a sealed container, Close the bleeder valve, fill the reservoir, and install the diaphragm. AIR BLEEDING To prevent piston overtravel and brake fluid seepage, keep a 20 mm (3/4 inl space to the handlebar grip when bleeding the front brake system‘ Pump up the system pressure with the lever until there am no air bubbles in the fluid flowing out of the reservoir small hole and lever resistance is felt. NOTE Check the fluid level often while bleed- ing the brake to prevent air from being pumped into the system. 15-3 HONDA. C 3650 NOTE Never re-use the contaminated fluid which has been pumped out during brake bleeding, because this will impair the efficiency of the brake system. Squeeze the brake lever, open bleeder valve 1/2 turn and close the bleeder valve. Release the brake lever slowly and wait several seconds after it reaches the end of its travel. NOTE Do not release the brake lever until the bleeder valve has been closed again. Repeat the above stflps untll bubbles cease to appear in the fluid at the end of the hose. Fill the fluid reservoir to the upper level mark. A contaminated brake disc or pad reduce: slapping power. Discard can ramlnaled pads and clean a contaminated disc with a high quality brake degreasing agent, BRAKE PAD/DISC BRAKE PAD WEAR CHECK Replace the front brake pads ii the red llne on the top of the pads reaches the edge of the brake disc. HYDRAULIC BRAKE (ZlDISC 1 5-4 HYDRAULIC BRAKE BRAKE PAD REPLACEMENT Remove the caliper cover. Remove the clip. Push the caliper toward the right and push the piston all the way in to allow installation of new brake pads. Remove the pins, brake pads and shim. Apply a coat of silicon grease to the both side of the shimr Install new brake pads with the shim on the piston side of the pad. Install the pins and clip. Install the caliper cover. NOTE ‘ Always replace the brake pads in pairs to assure even disc pressure ~ Push the piston all the way in. ' Check the brake fluid level in the brake master cylinder reservoir as this causes the level to raise. DISC THlCKNESS Measure the disc thickness SERVICE LIMIT: DK, DM: 6.0 mm (0.24 in) E, ED, F, G, U: 4.0 mm (0.16311) 15-5 HONDA C3650 HVDRAULIC BRAKE BRAKE DISC WARPAGE Measure brake disc warpagel SERVICE LIMIT: 0.3 mm (0.01 in) BRAKE MASTER CYLINDER BRAKE MASTER CYLINDER D'SASSEMB LY (1 )BRAKE HOSE BOLT Drain brake fluid from the hydrautic system. Remove the brake lever and rear view mirror from the master cylinder. Disconnect the x brake hose, CAUTION - Avoid spilling brake fluid on painted surfaces, - Place a mgover thefuel rank whenever the brake system is serviced. NOTE When removing the brake hose bolt. cover the end Of the hose to prevent contamination and secure the hose. Remove the two master cylinder attaching bolts. (1 lSNAP RING PLIERS 07914*3230001 Remove the boot. Remove the circlip form the masIer cylinder body. 1 5-6 HONDA HYDRAULIC BRAKE C3650 Remove the stop plate‘ secondary cup and master pismn‘ Then remove the primary cup and spring. Remove the brake fluid reservoir from the (4) 1, (1) master cylinder bodv‘ % SPRING . DIAPHRAGM Clean the inside of the master cylinder and (2) reservoir with brake fluid ISIMASTER PISTON% RESERVOIR ISISECDNDARY CUP , I7) PRIMARY CUP fl § " MASTER CYLINDER I.D. INSPECTION Measure the master cylinder I.D. Check the master cviinder for scores, scratches or nicks. SERVICE LIMIT: DK. DM: 14.055 mm (0.5533 in) E, El), F, 64 U: 15.925 mm (0.6270 in) MASTER PISTON OD, INSPECTION Measure the master piston 0.D, SERVICE LIMIT: DK4 DM: 13.945 mm (0.5490 in) E, ED4 F, G, U: 15.815 mm (0.6226 in) Check the primary Cup and secondary cup for damage before assemblyr FRONT MASTER CVLINDER BODV 15-7 HONDA C3650 HYDRAULIC BRAKE MASTER CYLINDER ASSEMBLY CA U TION - Handle the master cylinder piston. cylinder and spring as a set. When mxtallr‘ng the cups, do not allow the Iipx to tum inside our, - Be certain the circlips is seated firmly in the groove. Assemble the master cylinder, Coat all parts with clean brake fluid before assembly. Place the spring on the check valve. Install the spring and valve together, Dip the piston cup in brake fluid before assembly. Install the boot, washer and clip. Install the reservoir on the master cylinder making sure that the O-ring is in good cor» dition, Place the master cylinder on the handlebar and install the holder and the two mounting bolts. Torque the (OP bolt first. Install the oil hose with the bolt and its two sealing washers. Install the brake lever. Fill the reservoir to the upper level and bleed the brake system according to page 15—3. BRAKE CALIPER CALIPER A DISASSEMBLY Place a container under the caliper and dis- connect the brake hose boltt NOTE Avoid spilling brake fluid on painted surfaces. Loosen the two caliper shafts gradually in several steps while pressing them against the caliper. Remove caliper A. (5) MASTER PISTON I6) SECONDARY CUP I7) PRIMARY CUP IllDIAPHRAGM I2)RESERVO|R (SIMASTER CYLINDER BODY (4) FRONT BRAKE- LIGHT SWITCH (1 IBRAKE HOSE BOLT 1 5-8 HONDA HVDRAULlC BRAKE C3650 Remove the piston boot. inspect the piston boot for damage or deterio- ration. (Zimsrom (1) BOOT Place the shop towel ever the pistun to contra! piston removal, and position the caliper with the piston down. CA IF Remove the piston by applying a small amount [2, L ER A of Bi! pressure to the fluid inlet i1) FLUlD INLET Do nut use high pressure air or bring the nozzle too close to the inlet. Examine the piston and cylinder for scoring or scratches and replace if necessary. (3) Slice Gwen. Remove the oil seal by firs! pushing it into the cylinder as shown. Clean the caliper grooves with brake fluid‘ (1 } OIL SEAL 15-9 HONDA C3650 HYDRAULIC BRAKE FRONT CALIPER PISTON 0.0. INSPECTION Check the piston for scoring or scratches. Measure the outside diameter of the piston with a micrometer, SERVICE LlMIT: DK, DM 42165 mm (15837 in) E, ED, F, G. U: 38.090 mm (1.4998 in) FRONT CALIPEFI CYLINDER LD. INSPECTION Check the caliper cylinder for scoring or scratches‘ Measure the inside diameter of the caliper cylinder bore. SERVICE LIMIT: DK, DM: 42.915 mm (1.6896 in) E, ED, F, G, U: 38.240 mm {1.5055 in) FRONT BRAKE CALIPER ASSEMBLY A cantaminured brake dixc or pad miuces stopping power. Replace cantaminated pads, and clean a contaminated disc with a good quality degreasing age): r. Assemble the caliper in the reverse order of disassembly. The oil seal must be replaced with a new one whenever removed. Lubricate the piston and seal with a medium grade of iii-Temperature Silicone grease or brake fluid before assembly. V (2) PISTON Be certain the piston seal is seated in the caliper groove. Place the piston in the caliper with the boat lip facing out. Install the boot on the piston. 15-10 HONDA HYDRAULIC BRAKE C3650 CALIPER CARRIER/CALIPERB \\ DISASSEMBLY Remove the speedometer cable clamp. Remove the carrier with caliper B by removing the two boltsv Remove the carrier shafts from the carrier and caliper B while rotating them by hand. Avoid damaging the boots. CALlPER CARRIER/CAMPER B ASSEMBLY Wash all remnved parts. Coat the Ovrings with silicon grease or brake fluid and install in the shaft grooves. NOTE Replace the O-rings with new ones whenever disassembled. Replace the boots with new ones if damaged. Install the boots on the carrier. Assemble the caliper B and caliper carrier together, makng sure that the boots are sealed In the caliper shalt grooves properly. install the carrier on the front fork. TORQUE: 30-40 N'm (3.0—4.0 kg»m, 22—29 ft-lh) 15-11 HONDA C3650 HVDRAULIC BRAKE I15) CALIPER SHAFT (2) SHIM (3) PIN CLIP (4} PISTON BOOT I5I OIL SEAR (6) BLEEDER VALVE (7) CALIPER PISTON I8) CALIPER B ‘1‘» x (10) SILICON GREASE 0R BRAKE FLUID (16) RING I13) CALIPER B (I) CALIPER COVER (12) SHAFT BOOT %-19) RETAINING PIN W9 (III CALIPER CARRIER % CALIPER A INSTALLATION Tighten the caliper shafts evenly while pushing them against caliper B. (1) NOTE TIghten the shafts carefully] noting the mating surfaces of caliper A and BI TORQUE: 30—40 N-m (3‘0—4‘0 kg-m. 22—29 be) Connect the brake hose. Install the caIIper cover, Fill Ihe brake mud reservoir and Need the front brake system. (See page 1543‘). 15-12 16. HONDA. C3650 BATTERY/ CHARGING SYSTEM (3) BATTIERIE (4) GENERATRICE DE COURANT ALTERNATIF (5) BATTERH;/CIRCUIT DE CHARGE [1) (2) (3| (4! [5] GLEKSHHICHTER REGLER BATTEFHE LICHTMASCHINE BATTEHlE/LADESVSTEM (1) (2) (3) (4) 15) RECTLFICADOR REGULADOR BATERIA GENERADOR DECA. EATERUVSISTEMA DE CARGA 16-0 HONDA (365° BATTERY/CHARGING SYSTEM H) RECTIFIRE (2) R EGU LATOH (5) BATI'ERY/CHARGING SYSTEM 80—100 N-m (80710.0 kg~m,58~70f1>|b) BATTE RY/CHARG I NG SYSTEM HONDA C3650 SERVICE INFORMATION TROUBLESHOOTING BATTE RY CHARGING SYSTEM A. C. GENERATOR REMOVAL/ INSTALLATION VOLTAGE REGULATOR 16—1 16—2 16—3 164 16-5 1 6—8 SERVICE INFHRMATIDN GENERAL INSTRUCTIONS ~ Battery flurd ievel should be checked regulariy, Fill with distiiled water when necessary. - Quick charge a battery, only in an emargency, Slow-charge Is preferred. Hemove the battery from the motorcycie for charging, It the battery must be charged on the motorcycle, disconnect the battery cables. Do not smoke, and keep flames army from a charging battery. The gas produced by a battery will explade rfa flame or spark It brought near. . AH chargingsystem components can be tested on the motorcycle. SPECIAL TOOLS Common toois Rotor puller SPECIFICATIONS 07733—0020001 Battery Capacrty 12V12AH Specific gravity 1.280/20°C (68°F) Charging rate 1.4 amperes maximum AC. generator Capacity 1,500 miri‘l 5,000 min" (1 ,500 rpm) 15,000 rpm} 65A min. 18A min. Voltage regulator Transistorized non-adiustabie regulator 16-1 é HONDA C 36 5 0 TROUBLESHBUTING No power - key turned on: 1, Dead batterv 7 Low fluid level — Low specificgravlty » Charging system failure 2 Disconnected battery cable 3, Main fuse burned cm. 4_ Faulty ignition switch ow 'l. L pawer — key turned on: Weak battery 7 Low fluid level —— Low specific gravity 7 Charging system failure 2. Loose battery connection Low power —— engine running: 1. Battery undercharged — Low flwd level ~ One or more dead cells 2. Charging system rarlure BATTERY/CHARGING SYSTEM Intermittent power: 1 2t 3. 4 Loose battery connection Loose charging system connection Loose starting system connection Loose connection or short circuit in ignition system Loose connection or short Circuit in lighting system Charging system failure: 1. 2 3. 4 Lease, broken, or shorted wire or cannection Faulty voltage regulator Faulty silicon rectifier Faulty A.Ct generator 16-2 BATTERV/CHARGI NG SYSTEM BATTERY REMOVAL Remove the right and left side coversr Disconnect the ground cable at the battery terminai. Disconnect the positive cabie at the starter relay switch terminal. Remove the battery holder. (2) PQSITWE CABLE (1}NEGATIVE6ABLE / TESTING SPECIFiC GRAVITY Test each celi with a hydrometer. (”ELECTROLYTE TEMPERATURE VS. SPECIFIC GRAVITY: SPECIFIC GRAVITY {20%; 68°F) 126071280 Fully charged Eelow1.250 Undercharged m L230 NOTE ‘ L280 ( i . The battery must be recharged if the FULLY CHARGED W“ specific gravitv is below 1,220. The specific gravity varies with the temperature as shown in tha accom- panying table. _ . ~ _ V _,_t.¥,,,,. Replace the batmry if suifation is ° (32” (4‘)”150)15t59)2° 166)15'177)3Di .86, evident or if the space below the cell (MELECTROLVTE TEMPERATURE 'c ('F) piates is filied with sediment. The battery contains sulfuric acid. Avoid canmct with skin, eyes, or cloth mg. Antidote: flush with mm and get (siSPECiFic GRAVITY AND CAPACITY prompt medical attention. I 253 (2) SPECIFIC GRAVI‘IY I 280 3 mm 3 a: 1,200 a: 0 1‘6“ E o 1.120 m n- J 5/1 1.039 “7, m mosaxomsosawzozomo (7) CAPACITY % 1 6-3 HONDA C 3650 BATTERY CHARGING Connect the charger positive (H cable to the battery positive (+) terminal. Connect the charger negative (—i cable to the battery negative (~) terminal. Charging currem: 1.4 amperes max. Charging: Charge the battery until specific gravity is 1.26071 .280 at 20°C (68°F). , Before charging a battery, remove the cap from each cell Keep flames and sparks away from a charging battery. - Turn power ON/OFF at the charger. not at the battery terminals ~ Discontinue charging if the electralyte temperature exceed: 45°C (1 13°F). BATTERY/CHARGI NG SVST EM CA UT ION Quick-charging should only be done in an emergency; slow-charging is preferred, BATTERY with clean grease. CA UTION After installing the battery, coat the terminals Route the breather tube as shown on the battery caution label. BREATHER l4i L _ swam _ CHARGINE SYSTEM CHARGING OUTPUT TEST Warm up the engine before taking readings. Connect a vokmetar and an ammster to check charging system output. NOTE Use a fully charged battery to check the charging system output. TANK DRAIN /\_... now , m‘CAUTION (5) 9 TI] CYLN. HEAD CARB.0VER TECHNICAL DATA MAIN SWITCH LIGHTING SWITCH |NIT|AL CHARGING AT 5,000 min" (5,000 rpm) ON ON (High beam) 1,650 min" (1 ,650 rpm) 0 amperes minimum/14 voits 1 6-4 BATTERY/CHARGING SYSTEM LC. GENERATOR REMflVAL/ INSTALLATIDN Remove the ieft side cover, raise the seat and disconneci the AC, generator coupier. Remove xhe A.C, generator cover by loosening four bolts. Remove the generator stator wixh the brush hoider by loosening five screwsv Shift the transmission into gear and appiv the rear brake. Remove the generator rotor boil, (1) GENERATOR ROTOR BO (1| GENERATOR COUPLER 9| 1 6-5 HONDA C3650 BATTERY/CHARGING SYSTEM Remove the generator rotor while applying the rear brake. INSPECTION Inspect the length of each brush as shown. if itshows wear to the scribed service limit iine, replace the brush, SERVICE LIMIT: Scribed line (1) SCRIBED LINES Remove and replace the brush by removmg the mounting screws i1 ) HOLDER iziBRUSHES 1 6-6 HON DA. BATTERV/CHARGING SYSTEM C3650 STATOR COIL CONTINUITY TEST NOTE It is not necessary to remove the stator to make this test. Check the yellow leads to the AC. generator stator for continuity with each other. Replace the stator if any velIow Iead is not continuous with the othars, or if any load has continuity to ground. SPECIFIED RESISTANCE: DV41~0.51Q INSTALLATION Install the generator rotor. TORQUE: 80—100 N~m (13.0—10.0 kg-m, 58—70 ft-lb) Route the generator leads properly‘ 16-7 HONDA C3650 BATTERY/CHARGING SVSTEM VOLTAGE REGULATIJR VO LTAG E R EGULATO R PERFORMANCE TEST (1]RECTIFIER SE? at Testing with a voltmeter Connect a voltmeter across the battery. Check regulator performance with the engine running. Regulator must cut off the field coll current when battery voltage reaches 14—15V‘ l2) REGULATOR bt Testing with a variable resistor \ ____________ J (3) BATTERY Connect two 12v batteries in series, (6)3ATTERY/CHARGING SYSTEM Connect a variable resistor (0—1009) across the battery with a50§l resrstor in between. Test lamp must go out when voltage reaches 14—15v on the voltmeter by adjusting the variable resistor. \ l 1 _ 1 Y I A. or "I ‘, ' (ElGENERATOR : r —L l4)VOLT ITm : “ METER : l r l2),BLACK (”REGULATOR (1o) RESISTOR son (9) TWO FULLY | ‘ - CHARGED “(SNARIABLE 12v BATTERIES RES'STOR VOLTMETER l7) (5) WHITE 1 6—8 VOLTAGE REGULATOR/ RECTIFIER TEST BATTERV/CHARGING SYSTEM Check the resistance between (he leads with an chmmeter. RESISTANCE IN NORMAL DIRECTION: Green and any veIIow: Red/white and any yellow: 5—403 5—409 RESISTANCE IN REVERSE DIRECTION: Red/white and any yellow: Green and any yellow: ZOOOQminV ZOOOSZmin. HONDA C3650 (3)YELLOW (4IGREEN (”NORMAL DIRECTION —————-———-> (ZIREVEHSE DIRECTION (5) RED/WHITE 1 6-9 gg? II()DIIJIL C3650 7 IGNITION SYSTEM BOEINE D'ALLUMAGE BOUGIE D'ALLUMAGE GENERATRICE D’IMPULSIONS ALLUMEUR A CONTACTS COMMANDE A TRANSlSTORS (1) (2) (3) (4) (5) ZUNDSPULE ZUNDKEHZE IMPULSGEBEH ZENTHIFUGAL ZUNDVERSTELLER ZUNDEINHEIT BOEINA DE ENCENDIDO EUIIA GENERADOR DE IMPULSOS AVANZADOR CENTRIFUGO UNIDAD DE CHISPAS 17~0 IGNITION SYSTEM C3650 (1) IGNITION COIL (5) SPARK UN IT (4) CENTRIFUGAL ADVANCEH 17-0 HONDA. C3650 IGNITION SYSTEM SERVICE INFORMATION 17—1 TROUBLESHOOTING 17—1 IGNITION COIL 17—s2 TRANSlSTORlZED IGNITION SYSTEM 17~a (Pulsar Generator, Spark Unit) SPARK UNIT 17—5 SERVICE lNFflRMATlDN GENE HAL INSTRUCTIONS A TRANSISTORlZED IGNITION SYSTEM is used and no adjustments are to be made unless the pulser generator screws are loosened. if these screws are loosened, ignition timing for either the No. i or No.4 cylinder must be adjustr ed, Fro spark piug information, see pageS-a. SPECIFICATIONS Model E, G, F, ED U DK, DM Spark plug ND X24ESR-U X24ES>U X22ES-U NGK DFiBES-L DBEA D7EA Spark piug gap 05—07 mm (0024—0028 in) Ignition timing At idle speed 10" (BTDCI Fuil advance 28°30’ BTDC/2,725 min“ (2,725 rpm Ignition coii 3-point spark test 6 mm (1/4 in) minimum iRflUBlESHllllTlllG NOTE Engine cranks but will not start — Engine stop switch OFF. — No spark at plugs w Faulty transistorized spark unit 7 Faulty pulser generator No spark at plug - Engine stop switch OF F The ignition system has two sub-systems; one for the NO. ‘i and No. 4 cviinders and one for No. 2 and No. 3 cviindersr Determine which sub-system is faulty, then proceed to the detailed tests below 7 Fauity ignition coil — Fauity ignition switch ‘ Faulty spark unit 7 Faulty pulser generator Engine starts but runs poorly — Ignition primary circuit Faulty ignition coil Loose or bare wire intermittent short circuit — Secondary circuit Faulty plug Faulty high tension cord — Poorly connected, broken or shorted wires Timing advance incorrect Between ignition switch and engine step switch — Centrifugai advancer faulty Between spark unit and engine stop switch Between spark unit and ignition coil Between ignition coil and plug Between spark unit and puiser generator 17-1 HONDA C 3650 IGNITION SYSTEM (3)2ENER DIODE (4)IGNITION COIL (”TRANSISTOR E _,7mswuw_____ / ) (5 '1 IGNITION SWITCH . ' o~ . ..._... (6) . - , “EATTERV ' I g :4;- ’ 7F F /_ T T ‘ > 7 I , /, * I (7ISPARK PLUG (12) (13) {© (11) TRANSISTOR® TRANSISTOR @ I10) DIODE gIQICONDENSER (8IPULSER GENERATOR IGNITIIIN COIL REMOVAL Remove the fueI Xank. Disconnect the wire leads Remove the coils by removing the attaching bolts. PERFORMANCE TEST Perform the 3-point spark lest with a coil [ESKCL SERVICE LIMIT: 6 mm (1/4 in) min NOTE urers Instructions‘ TRANSISTOR (1) (1) 6 mm (1/4 In) MINIMUM (3) PRIMARY ELECTRODE I2} SECONDARY ELECTRODE I5) SPARK (4) THIRD ELECTRODE 17-2 HONDA C5650 IGNITION SYSTEM TRANSISTDRIZED IGNITION SYSTEM INSPECTION System Disconnect the 1 and 2 plugs. Hold each plug against any convenient engine ground. Turn the ignition switch on. Remove the pulser generator cover. Touch the end or a screwdriver to one pulser generator steel core A good spark to the plug means that (he Ignition sysrem for that cylinder ‘Is in good shape Repeal the above for the other pulsar. (GIHIGH TENSION CORD NOIEIIGNITION COIL (3)ENGINE STOP SWITCH (ZIIGNITION SWITCH @gngj m0” flow WW W G) 1’ OFF OFF ® . §Il§ (i) T (il —-—- BATTERY 8 -I- CVLINDER NO. 6) (2) ® ; _J_ (4) SPARK UNIT (QISPARK PLUG -: Pulsar gsnemor Measure the coil resistance. COIL RESISTANCE: 53o 1: 50:2 (20°C, 68°F) Between yellow leads (2.3 cylinders) Between blue leads (1.4 cylinders) - (1) PULSER COIL ‘ ‘ COUPLER 17—3 lGNlTION SYSTEM HONDA C3650 SPARK UNIT Disconnect the wirings at the pulser generator coupler. Attach the positive lead of a voltmeter to the blue with yellow tube wire terminal (1.4) or yellow wire terminal of the 6-pole coupler. Attach the negative lead to any convenient groudr Turn the ignition switch on. Ground each carrespondlng terminal (1.4: blue with white tube wire terminal, 2.3: yel- low with white lube wire terminal) of the 6- pole coupler lntermltl‘el’llly, The transistor unit is normal if the voltage indicated by the voltmeter changes from 12V to 0V in each test. ZJVELLOW wrm‘ wluTE TUBE 17-4 HONDA C3650 IGNITION SYSTEM PULSER REPLACEMENT If pulser replacement is necessary, iaosen the three pniser base plate screws‘ Replace the puiser generator assembiy‘ Adjust the ignition (iming (Section 3)‘ SPARK ADVANCER For advancer function test, see Page 3—5. Remove the pulser generatur cover‘ Remove the pulsar generator. ADVANCER VISUAL INSPECTION Check the mechanical advancer cam for sticking. Lubricate the sliding surfaces, and check the spring for loss of tension and advancer pin for excessive werar if the advancer fails to return. ADVANCER REPLACEMENT Remove the advancer bolt by holding the suaoer. Remove the advancer. IGNITION SYSTEM Align the rotor tooth with the “0" mark on the advancerv \nstaH the advancer. Align the pm on the advancer with the hole in the crankshafL nghten the bolt. TORQUE: 25~29 N~m (25—23 kg-m, 18—21 h-Ib) Install the pulsar generawn Adjust Ignition timing (Page 374). 17-6 "312? ELECTRIC STARTER 18 SERVICE INFORMATION 18—1 TROUBLESHOOTING 18—1 STARTER MOTOR 18—2 STARTER RELAY 18-5 SERVICE INHIRMAIIDN GENERAL INSTRUCTIONS The starter motor can be removed with the engine in the frame. SPECIFICATIONS STANDARD SERVICE LIMIT Starter motor Brush spring tension 560 9—6809i19.75—23.89 oz) 560 g (19.75 oz) Brush Isngth 11043.0 mm (0.47—0.51 in) 7.5 mm (0.3 in) STARTE R MOTOR {Hm RED BRUSHES STARTER RELAY O SWITCH " GREEN/RED FUSE 30A DIODE GREEN/"ED YELLOW/ ~— 5 I FED ‘A. 54 Q/i : '13 STARTER o m g _ FIELD COIL ”MATURE SWITCH RELAY COIL g ._ S ‘3 a m < a: z t MAIN SWITCH 5g E E g a: La " 0 B 3 '-“ e 63 NEUTRAL z o ‘9 FIELD MAGNET INDICATOR i BATTERY 7 ? Starter motor will not turn Starter motor turns, but engine does not mm — Battery discharged — Faulty starter eiutch — Fauity ignition switch — Faulty stater motor gears 7 Fauity starter switch A Faulty starter motor or idle gear — Fauity neutral switch — Faulty starter relay switch Starter motor and engine turns, but engine e Loosen or disconnected wire or cable does not start — Neutral diode open —~ Faulty ignition system — Engine problems Starter motor turns engine slowly a Low specific gravity 7 Excessive resistance in circuit — Binding in starter motor 18-1 ELECTRIC STARTER STARTER MOTOR REMOVAL With lhc ignitivn switch OFF, remo‘ the negative cable at the battery before servicing the starter motor. Remove the right side cover and disconnect the startev cable at the starter relay swwtch. Remove the starter motor cover and starter motor. {2 ) ARMATURE (8] O‘RING {3 ) TONGUED WASHER (1 )REAR covER (5) FRONT BRACKET (12) SH' MS (S ) BRUSH HOLDER W53; (“CASE AND FIELD COIL ("BRUSH (10)BRUSH SPRING _ (8)0—RING 18-2 HONDA C 3650 ELECTRIC STARTER BRUSH INSPECTION Remove the starter motor case screws. inspect the brushes and measure the brush length. Measure brush spring tension with a spring scale. SERVICE LIMITS: Brush length; Brush spring tension: 7.5 mm (0.30 in) 5609(19.75 nz) COMMUTATOR INSPECTION Remove the starter motor case. NOTE Record the location and number of thrust washers. Inspect the commutator bars for discolora- tion. Bars discoiored in pairs indicate grounded armaturecails‘ NOTE Do not use emerbv or sand paper on the commutator. Check for continuity between pairs of corn- mumtor bars, and also between commutator bars and armature shaft. i1) BRUSH LENGTH (1) COMMUTATOR (“COMMUTATOR BAR PAIRS CONTiNUiTY: NORMAL (2) ARMATURE ~ SHAFT No—communv: NORMAL (1) BRUSH LENGTH HONDA. C3650 ELECTRIC STARTER FIELDCOILINSPECTION _ __ - _ ‘ ‘ ‘ _ ("CABLE TERMINAL- MOTOR CASE Check for continuity from the cable terminal O—CONTINUIT NORMAL 3 4 ta the brush wire. ‘ H _ - - : Replace the starter motor if the field coil is npt continuous or ii it is shorted to the motor ease. (NCABLE TERMINAL- , t CONTINUITY: NORMAL ASSEMBLY/INSTALLATION Assemble the starter motor. Align the case notch with the brush holder pin. (3) CASE (4) BRUSH HOLDER Instail the [ear cover aligning its slot with the brush hoider pin‘ (3) SLOT (1) PIN (2i BRUSH - HOLDER 1 8-4 HONDA C3650 ELECTRIC STARTER STARTER RELAY SWITCH INSPECTION Depress the starter switch button with the ignitign ON, The (mil is normal if the starter relay switch clicks. Connect an ohmmeter to the starter relay switch terminals. Connect a 12 V battery to the switch cable terminals. The switch is normal it there is continuity. .18-5 19. SWITCHES Iicmurua C3650 SERVICE INFORMATION 19—1 HANDLEBAR SWITCHES 19—3 OIL PRESSURE WARNING SWITCH 19—2 IGNITION SWITCH 19—5 BRAKE SWITCH 19—2 CLUTCH SWITCH 19—5 NEUTRAL SWITCH 19—2 SERVICE INFORMATION GENERAL INFORMATIONS - Some wires have different colored bands around them near the connector. These are connected to other wires which wr- respond with the band color. B Bk Br G Gr LB Blue Black Brown Green Gray Light Blue LG 0 P n w v All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnecting. The following color codes used are indicated throughout this section and on the wiring diagram. Light Green = Orange Pink = Red ll ll White Yellow ‘ To isolate an lectrical lailure, check the continuity of the electrical path through the part. A continuitv check can usually be made without removing the part from the motorcycle Simply disconnect the wires and connect a continuity tester or volt- ohmmemr to the terminals or connections. - A oontinuity tester is useful when checking to find out whether or not there is an electrical connection between the two points, An ohmmeter is needed to measure the resistance of a circuit, as when there is a specific coil resistance involved] or when checking for high resistance caused by corroded connection; 19-1 HONDA. C3650 IJIL PRESSURE WARNING SWITCH Check for continuitv while applying pressure to the switch. Replace the switch if necessary‘ Apply a liquid sealant to the switch threads. BRAKE SWITCHES Check the rear brakelight switch for continui~ ty with the rear brake applied‘ Check the front brakelight switch for contl~ nultv with the front brake applied. Replace the switches if necessary. NEUTRAL SWITCH Remove the foot pegs, gearshift pedal and left rear crankcase cover. Check the switch for continhitv between the switch terminal {wire removed) and ground with the transmission in neutral and with the transmission in any gear. Replace the neutral switch if necessary. SWlTCHES t1) CONTlNUlTY: BELOW 20 We (02 kg/cmz, 2.8 psil ’ / (2) NO CONTINUITY‘ ABOVE 20—40 We {02—04 Kg/cmz, 2.8—5.6 psi) (ZIHEAR (“FRONT e l3)BRAKE APPLIED: CONTlNUlTY BRAKE NOT APPLIED: NO CONTINUITY 19-2 SWITCHES HONDA C3650 HANDLEBAR SWITCHES The handlebar cluster switches llighxs, tum signals, horn, passing, dimmer, “an and stop) must be replaced as assemblies, Continuity tests for the components of the handlebar cluster switches follow: Continuity should exist between the color coded wires on each Chart, HEADLIGHT HI—LOW SWITCH HI: B/W toB MIDDLE IN): B/WthoB LO: B/onw TURN SIGNAL SWITCH LEFT: G! to O, Br/W to LB/W OFF: No mnfinuity RIGHT: Gr to LB, Br/W to GM HORN BUTTON L6 to G wish bunon depressed No continuky with button released I1) DIMMER SWITCH (2) HORN SWITCH Headlight Hi——Low Switch HL HE LB Hi Turn Signal Switch LEFT OFF RIGHT Code Dolor Horn Bunon H0 E Code color LG I4} PASSING SWITCH (3) TURN SIGNAL K SWITCH q 19-3 HONDA c3650 SWITCHES PASSING SWITCH W/G to B with button depressed No conr flnuitv with button released. FREE: No continuity PUSH: WIG to B BAT; Hi FREE PUSH o——-o Codecolor WIG a STARTER BUTTON amat’hgfis' . ’ ”E J (1) STOP Bk to V/R with button depressed SWITCH Starter Button EAT; ST FREE START O——O Code color Bk Y/R ENGINE STOP SWITCH RUN: Bk to Bk/w OFF: No continuity (3) LIGHTING SWITCH BUTTON Engina Stop Switch BAT; IG OFF RUN O——O OFF Code color Bk BkM LIGHTING SWITCH BAT“ n. was ”L OFF: No continuity 0 (OFF) P: Br/B to Br/W HL: Br/B to Br/W. Br/R m BIW P Ow—O HL O—-—O O——-O Code color BrIB Er/W Bk/R B/W 1 9-4 HONDA SWITCHES C3650 IGNITION SWITCH Remove the instrument cluster and discon- nect the plug. Remove the ignition switch. ‘I1) IGNITION =1 ITCH NOTE Identify the wire colors at the cor» hector. There are no colors on the switch. Check continuity of terminals on the ignition switch in each switch position. SWITCH POSITION LOCK: No continuity OFF: No continuity 0N: BAT, to IG, TL, to TL; PARK: P to BAT, $23" P BATi IG TL. TL; 9 O--O 0“ O--O O~‘O OFF P LOCK ’tslc‘LUTcH APPLIED: CONTINUITY “0N . m EAT) CLUTCH RELEASED. NO CONTINUITV CLUTCH SWITCH Check continuity of the clutch lever (safety) switch with the clutch released and applied. Replace if necessary. IIICLUTCH SWITCH REMOVAL Unplug the wires. Remove the clutch lever and cabiev Remove the switch, NOTE The switch case has a 5m 'Brotrusicn that must point toward the handlebar when installed. 19-5 HONDA C 3650 TRUUBLESHDUTING 20 ENGINE DOES NOT START OR IS HARD TO START 1. 5. Remove and inspect spark pulg Check fuel flow to carburetor REACHING CAREURETOR V . Perform spark test GOOD SPARK V . Test cylinder compression COMPRESSION NORMAL l . Start by following normal procedure ENGINE DOES NOT FIRE NOT REACHING CARBUHETOR "‘—‘> (1) I2) (3) (4) WEAK OR NO SPARK——---——~> (‘il (2l (3) (4) (5) l6) (7) (8) LOW COMPRESSION —————~——> (1) l2) l3) l4) (5 l6) l7) ENGINE FIRES BUT STOPS—-—> (i) (2) (3) (4) l5) (6) WET PLUG ~—————-—> (1) (2) (3) (4i POSSIBLE CAUSE Fuel tank empty Clogged fuel tube or fuel filter Sticking float valve Clogged fuel tank cap breather hole Faulty spark plugs Fouled spark plugs Faulty spark unit Broken or shorted high tension wires Faulty A,C. generator Broken or shorted ignition coil Faulty ignition switch Faulty pulser generator Low battery charge Improper valve clearance Valve stuck open Worn cylinder and piston rings Damaged cylinder head gasket Seized valve Improper v'alve timing improper choke operation Carburetor incorrectly adiusted Manifold leaking Improper ignition timing (Spark unit or pulser generator) Incorrect last idle Fuel contaminated Carburetor flooded Choke closed Throttle valve open Air cleaner dirty 20-1 TROUBLESHOOTING ENGINE LACKS POWER I, Raiw wheel: a" ground and spin by hand WHEEL SPINS FREELY m . Check me pressure PRESSURE NORMAL 5.: Accelerate ripid from low lo second ENGINE SPEED LOWERED WHEN CLUTCH IS RELEASED a . Acmleréte lightly ENGINE SPEED INCREASES 9‘ Check ignition timing CORRECT .57 Check valve clearance CORRECT \r . Test cyllndsr compression NORMAL 8‘ Check Carburetor Iar clogging NOT CLOGGED 9. Rumors spark plug NOT FOULED OR DISCOLORED 104Check oiI Imml and condllion CORRECT H. Remove wlindev head caller and inspen lubrication VALVE TRAIN LUBRICATED PROPERLY 12. Check var engine overheatlug NOT OVER HEATING I3. Accelerate or run al nign speed ENGINE DOES NOT KNOCK WHEELS DO NOT SPIN FREELY-—->H) (2) (3) (4) PRESSURE LOW ————-—> (I) I?) ENGINE SPEED CHANGED—*‘(U WHEN CLUTCH IS RELEASED (2) (a) ENGINE SPEED NOT INCREASED—>0) l2) (3) (4) I5 INCORRECT -—-——-—-v—>(I) (2) T00 LOW ————-—>Il) (2) (3) (4) CLOGGED —_.__._.~_.._'(1) FOULED OR DISCOLDRED Mb“) I2 INCORRECT ————-—-—-——-—-—-——-D(ll (2) (3) VALVE TRAIN NOT LUBRICATED—>(l) PROPERLY (2) OVERHEATING————-—-~>ll) I2) (3) ENGINE KNOCKS -————-—-————-> III I2I (3} I4) POSSIBLE CAUSE Brake dragging Worn or damaged wheel bearluq thal bearing needs lubrication DrIve chain too tight Punmured tire FauIly (ire valve Clutch slipping Worn clutch disc/plate Warped clutch disc/plate Carburetor choke closed Clcgged air cleaner Resivicted fuel Ilow Cloggsd Ina] tank breather lube Clogged murrlnr Faulty summit Faully pulse! generator Faullv ignition advancer Improper valve adjustment Worn valve seal Valve stuck open Wom cylinder and piflon rings Leaking head gasket Improper ualv: timing Carburetor no! serviced Irequenfly mongh Plugs not serviced frequently enougn Spark plug with incorrect heal range Oil level mo high OII level (00 low Contaminated oil clogged oil passage CIowed ail conlrol oniice Excessive carbon build-up in combustion chamber Use cl poor quality fuel Clutch sllpoing Warn piston and clender Wrong typs av Iuel Excessive carbon buIIt~ua in combustion chamber Ignition timlng ton advanced (Faulty spark unit or advaner) 20-2 HONDA C3650 TROUBLESHOOTING POOR PERFORMANCE AT LOW AND IDLE SPEEDS V Check lgnlliorl liming and valve ctealmu [Ncogfigc7—_..._.m (2) CORRECT , Check carbumor pllol screw adiuument INCOR RECT—> 523 Fuel System Senion CORfiECT m . Check lorleakinq manilold LEAKING —>(Il NO LEAK (2 » Pevlounspzrktesl WEAK DR INTERMITTENT SPARK—bu) GOOD SPARK (2) (3) (A) (5) POOR PERFORMANCE AT HIGH SPEED . Check igmuon tlmlnq and valve clearance INconnEc‘r————————> (ll (2) (al CORRECT (4) . Dlsuoilnzcl Iuel lube aI cmburelol FUEL FLOW RESTRICTED —-——> (1) (2) FUEL FLcws FREELY (3| (4) 3. Rermve carburelov and check lor CLOGGEDWM (ll cluwedie! NO CLOG ‘ Check valve xlmlnp INCORRECT —————-—> (I) CORRECY . Check valve spring tension WEAK—p (I) NOT WEAKENED POOR HANDLING —> checkxivepressuve I. II murinu is heavy . (1) 41) 2. If tithvl whccl It wobbllnn -——-—-—-———-————————————————->H) (2) [3) (A (5) (8) GI If tho motorcycle pull! «a on! side W'_——> I” (2} (3) (4) POSSIBLE CAUSE Improper um clam-nee Implcpel Ignition (Iming (Faulty 59th unit oI spark advanced umriomeu insulalov Drrlng Lnosa carburelor Flukv, Cuban 0! wel fouled spark plug Faulxy spark uni! 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