1992
 IMPORTANT NOTICE
OPERATOR ONLY.NO PASSENGER
* This scooter 1s designed and constructed as an operator-only model. The seating
configuration does not safely permit the carrying of a passenger. Do not exceed the
maximum weight capacity shown on the accessories and loading label.
* ON-ROAD USE ONLY
This scooter 15 not equipped with a spark arrester and is designed to be used only on
the road. Operation in forest, brush or grass covered areas may be illegal. Obey local
laws and regulations.
READ THIS OWNER’S MANUAL CAREFULLY
e Pay special attention to statements preceded by the following words:
A WARNING
Indicates a strong possibility of severe personal injury or death if
instructions are not followed.
CAUTION:
Indicates a possibility of personal injury or equipment damage if
instructions are not followed.
NOTE:
Gives helpful information.
This manual should be considered a permanent part of the scooter and should remain
with the scooter when resold.
HONDA SK50M Dio SR 1992
OWNER’S MANUAL
All information in this publication is based on the latest production
information available at the time of approval for printing. HONDA MOTOR
CO., LTD. reserves the right to make changes at any time without notice
and without incurring any obligation.
No part of this publication may be reproduced without written permission.
O Honda Motor Co., Ltd., 1991
WELCOME
Thank you for purchasing this Honda scooter, and welcome to the family of Honda
scooter riders. To enjoy safer and more pleasant riding, become thoroughly familiar with
this owner’s manual BEFORE YOU RIDE THE SCOOTER. Your safety depends not
only on your own alertness and familiarity with the scooter, but also the scooter’s
mechanical condition. A pre-ride inspection before every outing and regular maintenance
are essential.
When regular maintenance or repairs are required, remember that your authorized
Honda scooter dealer knows what it takes to keep your Honda going strong. If you have
the required mechanical “know-how” and tools, your Honda dealer can supply you with
an official Honda Service Manual to help you perform many maintenance and repair
tasks.
Pleasant riding, and thank you for choosing a Honda.
HONDA
IWNER”S MANUAL
BALI EX
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HONDA BALI EX 1995
OWNER’S MANUAL
All information in this publication is based on the latest production
information available at the time of approval for printing. HONDA MOTOR
CO., LTD. reserves the right to make changes at any time without notice
and without incurring any obligation.
No part of this publication may be reproduced without written permission.
© Honda Motor Co., Ltd., 1991
OPERATION
Page
1 SCOOTER SAFETY
3 Safe riding Rules
5 Modifications
6 Protective Apparel
7 Loading and Accessories
10 PARTS LOCATION
13 Parts Function
17 MAJOR COMPONENTS (Information
you need to operate this scooter)
17 Brakes
20 Fuel
23 Engine Oil
25 Tires
28 Battery
29 ESSENTIAL INDIVIDUAL
COMPONENTS
29 Ignition Switch
30 Right Handlebar Controls
31 Left Handlebar Controls
Page
32 FEATURES (Not required for
operation)
32 Steering Lock
32 Seat Lock
33 Helmet Holder
34 . Center Compartment
35 Hook and Inner Rack
36 OPERATION
36 Pre-ride Inspection
37 Starting the Engine
42 Break-in
43 Riding
50 Parking
51 Anti-theft Tips
52 High Altitude Riding
MAINTENANCE
Page
53 MAINTENANCE
54 Maintenance Schedule
58 Maintenance Record
59 Serial Numbers
60 Color Label
61 Maintenance Precautions
62 FILTERS/LUBRICATION
62 Air Cleaner
64 ENGINE
64 Spark Plug
66 Idle Speed
67 FRAME/BRAKES
67 Brake shoe wear
Page
68 ELECTRICAL
68 Fuse Replacement
70 TRANSPORTING
71 CLEANING
73 STORAGE GUIDE
73 Storage
74 Removal from storage
75 NOISE CONTROL SYSTEM
(AUSTRALIA ONLY)
76 SPECIFICATIONS
SCOOTER SAFETY
Read these WARNING LABELS before you ride.
REAR CARRIER WARNING
LABEL
ACCESSORIES AND LOADING
WARNING LABEL
ENGINE OIL CAUTION LABEL
LM UP т ООО
a
|
A
| OPERATOR WARNING LABEL
| TIRE INFORMATION LABEL
S
C
O
O
T
E
R
S
A
F
E
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Y
AWARNING
* Scooter riding requires special
efforts on your part to ensure
your safety. Know these
requirements before you ride:
SAFE RIDING RULES
1. Always make a pre-ride inspection
(page 36) and perform any needed
adjustments or repairs before you ride
the scooter. You may prevent an
accident or equipment damage.
2. This scooter has been designed and
constructed as an operator-only model.
There are no provisions for carrying
passengers safely. Vehicle stability and
control may be severely affected. Never
carry passengers.
NO PASSENGERS
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3. Many accidents involve inexperienced
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4
riders. Most states require a special
riding test or license. Make sure you are
qualified before you ride. NEVER lend
your scooter to an inexperienced rider.
4. Many automobile/scooter accidents
happen because the automobile driver
does not “see” the rider. Make
yourself conspicuous to help avoid the
accident that wasn’t your fault:
®* Wear bright or reflective clothing.
e Dont ride in another motorists
“blind spot.”
.Obey all federal, state and local laws
and regulations.
e Excessive speed is a factor in many
accidents. Obey the speed limits, and
NEVER travel faster than conditions
warrant.
® Signal before you make a turn or lane
change to alert other motorists of
your intentions.
.Don’t let other motorists surprise you.
Use extra caution at intersections,
parking lot entrances and exits, and
driveways.
7. This scooter is designed for speeds up to
38 mph. Check local and state laws
limiting operation. Riding on roads where
other vehicles are traveling at greater
rates of speed is not advisable. If you must
ride in these conditions, be especially
alert.
8. Keep both hands on the handlebars and
both feet on the floor boards while
riding.
9. Never leave your scooter unattended
with the engine running.
10.Moderate your speed when riding over
bumpy roads. Avoid hitting road
hazards, such as sharp bumps and holes,
in the road surface. These hazards can
cause loss of control or structural
damage to the vehicle.
MODIFICATIONS
A WARNING
* Modification of the scooter or
removal of original equipment
may render the vehicle unsafe or
illegal. Obey all federal, state and
local equipment regulations.
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PROTECTIVE APPAREL
ALWAYS wear a helmet. Clothes should
You should also wear a face shield or goggles. close-fitting.
Wear gloves.
Shoes should be close-fitting, have low heels and
offer ankle protection.
be
LOADING AND ACCESSORIES
A WARNING
* A scooter is sensitive to changes
in weight distribution. Improper
loading of cargo and mounting of
accessories can impair the
scooters stability and
performance. To prevent an
accident, use extreme care when
mounting accessories and riding
with cargo.
These general guidelines may help you
decide whether or how to equip your
scooter, and how to load it safely.
1. The combined weight of the rider,
cargo, and all accessories must not
exceed the maximum weight capacity:
91 kg (200 165)
2. Do not install another fairing or modify
the existing one.
3.Do not carry items that protrude
through the rack or block the taillight.
4.Do not carry pets on either carrier.
<< | поп» 0 тп ООС
<- IMmIPO DM-40000
5, Keep cargo weight low and close to the
center of the scooter. As weight is
located farther from the center of
gravity, handling is proportionally
affected. Load weight equally to
minimize imbalance.
6. When the optional front basket is
installed, be sure that loaded parcels do
not protrude from the basket, since the
parcels may interfere with the steering
or headlight.
Overloading the scooter will adversely affect stability and handling.
Rear carrier;
never exceed the maximum
weight limit:
3 kg (6.6 Ibs)
Be sure all cargo is secure before
riding.
Center compartment;
never exceed the maximum
weight limit:
10 kg (22 165)
Hook and Inner Rack:
never exceed the maximum weight
limit:
1.5 kg (3 165)
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PARTS LOCATION
Instruments and Indicators
Rearview mirror O
ss
Rear brake lever
Rearview mirror
Z Front brake lever
he
Headlight dimmer = ON D Throttle eri
w A n° rottle grip
> 2 NI ==
By
Turn signal switch NS — A Engine stop switch
Horn button \ Starter button
Ignition switch
10
Rear brake lock lever
Helmet holder
Center stand
Battery
Kickstarter pedal
Fuse
11
12
Engine oil tank cap
Fuel tank cap
PARTS FUNCTION
Instruments and Indicators
The indicators are grouped between the
handlebars.
Their functions are described in the table
on the following page.
(1) High beam indicator
(2) Speedometer
(3) Turn signal indicator
(4) Oil level warning indicator
(5) Odometer
(6) Fuel gauge
This illustration is for Australia model.
13
(Ref. No.) Description
Function
| D High beam indicator
Lights when the headlight is on high beam.
(2) Speedometer
Shows riding speed.
(3) Turn signal indicator
Flashes when either turn signal is operated.
(4) Oil level warning light
Lights when oil level is low (see page 16).
(5) Odometer
Shows accumulated mileage.
(6) Fuel gauge
Shows the approximate fuel supply available.
14
Fuel Gauge
The fuel gauge (1) shows the approximate
fuel supply available. At F (Full), the fuel
tank capacity including reserve is: (2)
5.0 £ (1.32 US gal, 1.10 Imp gal)
When the gauge needle enters the red band
(2), fuel will below and you should refill the
tank as soon as possible. The amount of fuel
left in the tank when the needle enters the red
band is approximately:
1.2 # (0.32 US gal, 0.26 Imp gal)
This illustration is for Australia model.
(1) Fuel gauge (2) Red band (1)
15
Oil Level Warning Light
The oil level warning indicator (1) lights
when the 2-stroke engine oil level is below
approximately:
1.2 ¢ (1.2 US at, 1.0 imp qt)
AWARNING
* If the warning light comes on while
riding, stop riding and shut the
engine off. Fill the oil tank to the
UPPER LEVEL mark with the
recommended oil (see page 24).
Continuing to ride with a low oil
level may lead to engine failure that
could result in an accident.
his ill tion 1s for Australi del.
This illustration 1s for Australia mode (1) Oil level warning light (1)
16
MAJOR COMPONENTS (Information you need to operate this scooter)
(Refer to the maintenance precautions on
page 59).
BRAKE
Adjustment
1. Measure the distance the front brake
lever (1) and the rear brake lever (2)
move before each brake starts to take
hold. Free play at the tips of the brake
levers should be:
10—20 mm
(2) Rear brake lever (1) Front brake lever
17
2. Make free play adjustments by turning Make sure the cut-out on the adjusting
the adjusting nut (3) at the brake arm. nut is seated on the brake arm pin (4)
Front Rear after making final free play adjustment.
7
correct
a
) [3 incorrect
(3)
(3) Adjusting nut (A) Decrease free play
(B) Increase free play (3) Adjusting nut (4) Arm pin
18
3. Apply each brake several times and
check for free wheel rotation after the
brake lever is released.
NOTE:
* Tf proper adjustment cannot be obtained
by this method, see your authorized
Honda scooter dealer.
19
FUEL
Fuel Tank
The fuel tank is located under the step board.
Unlock and open the fuel tank lid (1) with the
ignition key, then remove the fuel cap (2) by
turning it counterclockwise. Fuel tank capaci-
ty is:
5.0 7 (1.32 US gal, 1.10 Imp gal)
Install the fuel tank cap by turning it
clockwise. Make sure to lock the fuel tank lid
securely after filling.
Your engine is designed to use any
gasoline that has a pump octane number
(R+M)/2 of 86 or higher, or that has a
research octane number of 91 or higher.
Gasoline pumps at service stations
normally display the pump octane number.
(1) Fuel tank lid (2) Fuelcap (3) Filler neck
20
We recommend that you use unleaded
fuel because it produces fewer engine and
spark plug deposits and extends the life of
exhaust system components.
Never use stale or contaminated gasoline
or an oil/gasoline mixture. Avoid getting
dirt, dust or water in the fuel tank. Use of
a lower octane gasoline can cause
persistent “pinging” or heavy “spark
knock” (a metallic rapping noise) which,
if severe, can lead to engine damage.
FOR AUSTRALIA ONLY:
Use unleaded petrol with a research octane
number of 91 or higher.
CAUTION:
* If “spark knock” or “pinging” oc-
curs at a steady engine speed un-
der normal load, change brands of
gasoline. If spark knock or
pinging persists, consult your au-
thorized Honda dealer. Failure to
do so is considered misuse, and
damage caused by misuse is not
covered by Honda’s Limited
Warranty.
Occasionally you may experience light
spark knock while operating under heavy
loads. This is no cause for concern, it
simply means your engine is operating
efficiently.
AWARNING
* Gasoline is extremely flammable
and is explosive under certain con-
ditions. Refuel in a well-ventilated
area with the engine stopped. Do
not smoke or allow flames or sparks
in the area where gasoline is stored
or where the fuel tank is refueled.
* Do not overfill the tank (there
should be no fuel in the filler neck
(3). After refueling, make sure the
fuel cap is closed securely.
* Be careful not to spill fuel when
refueling. Spilled fuel or fuel vapor
may ignite. If any fuel is spilled,
make sure the area is dry before
starting the engine.
21
AWARNING
* Avoid repeated or prolonged
contact with skin or breathing of
vapor. KEEP OUT OF REACH OF
CHILDREN.
Gasolines Containing Alcohol
If vou decide to use a gasoline containing
alcohol ( “gasohol” ), be sure its octane
rating is at least as high as that
recommended by Honda. There are two
types of “gasohol” : one containing
ethanol, and the other containing
methanol. Do not use gasohol that
contains more than 10% ethanol. Do not
use gasoline containing methanol (methyl
or wood alcohol) that does not also contain
cosolvents and corrosion inhibitors for
methanol. Never use gasoline containing
more than 5% methanol, even if it has
cosolvents and corrosion inhibitors.
22
NOTE:
* Fuel system damage or engine
performance problems resulting from
the use of fuels that contain alcohol is
not covered under the warranty. Honda
cannot endorse the use of fuels
containing methanol since evidence of
their suitability is as yet incomplete.
* Before buying fuel from an unfamiliar
station, try to find out if the fuel
contains alcohol. If it does, confirm the
type and percentage of alcohol used. If
you notice any undesirable operating
symptoms while using a gasoline that
contains alcohol, or one that you think
contains alcohol, switch to a gasoline
that you know does not contain alcohol.
ENGINE OIL
Oil Level
When the oil level indicator lights, it
means the oil level in the oil tank is low;
stop the engine and fill the oil tank as soon
as possible.
AWARNING
* If the warning light comes on
while riding, stop riding and shut
the engine off, Fill the oil tank to
the UPPER LEVEL mark with
therecommended oil (see page
24 ). Continuing to ride with a
low oil level may lead to engine
failure that could result in an
accident.
CAUTION:
* If the engine has been run after
the oil indicator light has come on,
the scooter must be taken to an
authorized Honda scooter dealer
for inspection and bleeding of the
oil system, Failure to do this will
result in serious engine damage.
To fill, lift the seat, lift the oil tank lid (1), (2)
remove the cap (3) from the oil tank, and fill
with the recommended oil up to the UPPER
LEVEL mark (4).
Capacity:
1.2 £ (1.2 US qt, 1.0 Imp qt)
(1), (2) Oil tank lid
(3) Oil tank cap (4) UPPER LEVEL mark
23
Oil Recommendation:
USE HONDA 2-STROKE OIL OR AN
EQUIVALENT
CAUTION:
* The use of improper oils may
cause excessive and/or premature
carbon build-up in the engine and
exhaust system, resulting in loss
of power and possible engine
damage. Genuine Honda 2-Stroke
Oil has been specifically designed
and tested in Honda scooters and
is a proper oil.
NOTE:
* When filling, do not let dirt or other
foreign materials enter the tank.
24
TIRES
Maintaining proper tire pressure will
provide maximum traction, stability,
riding comfort and tire life.
See your authorized Honda scooter dealer
for repair or replacement of tires.
Tire Pressure Check
Check tire pressures frequently with a
tire pressure gauge and adjust if
necessary.
NOTE:
* Tire pressure should be checked before
you ride, while the tires are “cold.”
A WARNING
+ Improper tire inflation will cause
abnormal tread wear and create a
safety hazard. Underinflation
may result in the tire slipping on,
or coming off of the rim causing
tire deflation that may result in a
loss of vehicle control.
Tire Front | 125 kPa (1.25 kg/cm?, 18 psi)
Pressure | Rear | 200 kPa (2.00 kg/cm?, 29 psi)
MAXIMUM WEIGHT CAPACITY
91 kg (200 Ibs)
TIRE SIZE
Front: 3.00—10 42]
Rear: 3.00—10 42]
TIRE BRAND Front Rear
DUNLOP K378F K378
IRC MB48 MB47
BRIDGESTONE ML31 ML32
(2)
(2)Tire gauge
(1)Tire valve
25
Cracks and Damage Abnormal Wear
Check the tire tread and sidewalls for Check for abnormal wear (1) of the tire
conspicuous cracks (1) or other damage tread.
E
A WARNING * Abnormal wear will adversely
*Tires that are cracked or affect traction and handling.
damaged are a safety hazard.
They may lose pressure rapidly,
and a loss of vehicle control could
result.
(1) Abnormal wear
(1) Crack (2) Damage
26
Nails, Rocks and Other Sharp
Objects
Check the tire tread and sidewalls for
nails, rocks, or other sharp objects ( 1).
AWARNING
* Nails, rocks or other sharp objects
may cause a puncture that could
result in a loss of vehicle control.
(1) Nails, rocks or other sharp objects
Tread Depth
Inspect the wear indicator (1) to check for
insufficient tread depth. If the wear
indicator is visible, the tire should be
replaced.
AWARNING
* Operation with excessively worn
tires is hazardous and will ad-
versely affect traction and han-
dling.
(1) Wear indicator
(2) Wear indicator position mark
27
BATTERY
It is not necessary to check the battery
electrolyte level or add distilled water as
the battery is a maintenance-free (sealed)
type. If your battery seems weak and/or is
leaking electrolyte (causing hard starting
or other electrical troubles), contact your
authorized Honda scooter dealer.
A WARNING
* Even though the battery is sealed,
it still vents explosive gases.
Do not allow open flames or
sparks near the battery.
CAUTION:
* Removing the battery caps can
damage the caps and result in
leaks and eventual battery
damage.
28
CAUTION:
* When the scooter is to be stored
for an extended period of time,
remove the battery from the
scooter and charge it fully. Then
store it in a cool, dry place. If the
battery is to be left in the scooter,
disconnect the negative cable
from the battery terminal.
ESSENTIAL INDIVIDUAL COMPONENTS
IGNITION SWITCH
The ignition switch (1) is on the right
side below the steering stem.
operated. The engine can be started.
NOTE:
* The headlight and instrument light
operate whenever the engine is running.
(1) Ignition switch
Key Position Function Key Removal
LOCK The steering is locked. The engine and | Key can be
(Steering Lock) | lights cannot be operated. removed.
OFF Engine and lights cannot be operated. Key can be
removed.
ON Taillight will be on and other lights can be
Key cannot be
removed.
29
RIGHT HANDLEBAR CONTROLS
Engine Stop Switch
The engine stop switch (1) is next to the
throttle grip. When the switch is in the
RUN position, the engine will operate.
When the switch is in the OFF position,
the engine will not operate. This switch is
intended primarily as a safety or
emergency switch and should normally
remain in the RUN position.
CAUTION:
* Jf your scooter is stopped with the
ignition switch ON and the engine
stop switch OFF, the taillight will
still be on, resulting in battery
discharge.
30
Starter Button
The starter button (2) is below the engine
stop switch (1).
When the starter button is pressed, the
starter motor cranks the engine. See page
36 for the starting procedure.
(1)
(1) Engine stop switch
(2) Starter button
LEFT HANDLEBAR CONTROLS
The three controls next to the left
handlebar grip are:
Headlight Dimmer Switch (1)
Select HI for high beam, LO for low beam.
Turn Signal Switch (2)
Move to L to signal a left turn, R to signal
a right turn. Remember to return the switch
to the center (off) after completing your turn
or lane change.
Horn Button (3)
Press the button to sound the horn.
(1) Headlight dimmer switch
(2) Turn signal switch
(3) Horn button
31
STEERING LOCK
To Lock:
To lock the steering, turn the handlebars
all the way to the left, and turn the key
(1) to lock. Remove the key.
AWARNING
* Do not turn the key to LOCK
while riding the scooter; loss of
control will occur.
LOCK (1)
(1) Ignition key
32
SEAT LOCK
The seat lock (1) is on the left side below
the seat.
To lift the seat, insert the ignition key (2)
and turn it clockwise to unlock.
To lock the seat, lower and push down on
it until it locks. Make sure the seat is
secure before riding.
(2)
(2) Ignition key
(1) Seat lock
HELMET HOLDER
The helmet holder (1) eliminates the need
for carrying your helmet after parking.
Insert the ignition key into the seat lock,
and turn it clockwise to unlock.
Hang your helmet on the hook at the seat
hinge and lower the seat to lock. To
remove a helmet, unlock the seat. Lift the
helmet off the holder and lower the seat,
making sure it is securely locked before
riding.
AWARNING
* The helmet holder is designed for
helmet security while the scooter
is parked. Do not operate the
scooter with a helmet attached to
the holder; the helmet may
interfere with the safe operation
of the scooter.
(1) Helmet holder
33
CENTER COMPARTMENT
The center compartment is below the seat.
Opening and Closing:
See “SEAT LOCK(page 32).”
MAXIMUM WEIGHT LIMIT:
10 Ка (22 165)
Documents:
The owner's manual (2) should be stored
in the slots on the underside of the seat.
AWARNING
* Never exceed the maximum
weight limit; handling and
stability may be severely affected.
CAUTION:
* The center compartment may
become heated by the engine. Do
not store food and other articles
which are flammable or
susceptible to heat in this
compartment.
34
NOTE:
* Do not direct water under pressure
against the side compartment as water
will be forced into the compartment.
(1) Center compartment (2) Owner's manual
Hook and Inner rack
Hook and Inner rack are provided below the
handlebar.
MAXIMUM TOTAL LOAD OF HOOK
AND INNER RACK:
1.5 kg (3.0 ibs)
CAUTION:
* Do not attach large luggage to the
hook that would hang out from the
scooter and/or interfere with the
movement of your feet.
* Make sure cargo does not extrude
from the inner rack.
Oversized cargo may interfere with
the operation of the handlebars are
adversely affect handling.
(1) Hook (2) Inner rack
35
OPERATION
PRE-RIDE INSPECTION
AWARNING
* If the Pre-ride Inspection is not
performed, severe personal injury
or vehicle damage may result.
Inspect your scooter every day before you
ride it and perform any needed
adjustments or repairs. The items listed
here will only take a few minutes to check
and, in the long run, can save time,
expense, and possibly your life.
1.Oil level—check the level and if
necessary, add oil (page 23)
2.Fuel level — fill fuel tank when
necessary (page 20 ). Check for leaks
3.Front and rear brakes — check
operation and if necessary, adjust free
play (page 17).
4. Tires — check condition and pressure
(page 25).
5. Throttle — check for smooth opening
and full closing in all steering positions.
36
6.Lights and horn — check that the
headlight, tail/brake light, turn signals, in-
dicators and horn function properly.
7.Engine stop switch — check for proper
function (page 30)
Correct any discrepancy before you ride.
Contact your authorized Honda scooter
dealer for assistance if you cannot correct
the problem.
STARTING THE ENGINE
This scooter has an automatic fuel valve
and choke; there is no manual operation.
NOTE:
* Operate the kickstarter or starter
button for slightly longer than usual
without opening the throttle if the
scooter has been left standing for a long
time or when the fuel tank has just been
refilled.
1. Place the scooter on its center stand.
(1) Lock lever (2) Rear brake lever
2. Lock the rear wheel by squeezing the
brake lever and setting the lock lever
(1).
AWARNING
* The rear wheel will spin if not
restrained by the brake or
contact with the ground.
Accidental contact with the
spinning rear wheel could cause
personal injury.
NOTE:
* The electric starter will only work
when the rear brake lever (2) is
operated.
(1)
(1) Lock lever (2) Rear brake lever
37
3. Make sure that the engine stop switch 5. With the throttle closed, push the
is at RUN. starter button (4). Release the starter
4. Turn the ignition switch (3) to ON. Quito as soon as the engine starts.
* Do not use the electric starter for more
* Never run the engine in an enclosed than 5 seconds at a time. Release the
area. The exhaust contains poiso- starter button for approximately 10
nous carbon monoxide gas that can seconds before pressing it again.
cause loss of consciousness and
lead to death. CLOSED
(3)
(3) Ignition switch (4) Starter button
38
6. Be sure to keep the throttle closed and
the rear brake (5) locked while starting AWARNING
and warming up the engine. * Do not “BLIP” the throttle (open
7. Allow the engine to warm up before and close rapidly) as the scooter
riding (See “RIDING,” page 43). will move forward suddenly,
causing possible loss of control.
*Do not leave the scooter
CLOSED unattended while the engine is
warming up.
à (5)
DA
(5) Rear brake lever
39
To start the engine without the
electric starter,
1. Follow steps 1 through 4.
2. With the throttle closed, operate the
kickstarter with a rapid, continuous
motion.
CAUTION:
* Do not allow the kickstarter to
snap back freely against the pedal
stop as engine case damage could
result.
* Raise up the kickstarter pedal
after the kickstarter lever is
returned to the stop.
3. Follow steps 6 through 7.
40
If you cannot restart a warm
engine:
1. Place the scooter on its center stand and
set the parking brake.
2.0pen the throttle (1) 1/8—1/4 turn
while starting the engine.
(1) Throttle
41
BREAK-IN
During the first 1,000 km (600 miles), do
not operate the scooter at more than 80%
of the maximum speed.
Avoid full throttle operation, and do not
operate for a long time at one speed.
During initial break-in, newly machined
surfaces will be in contact with each other
and these surfaces will wear in quickly.
Break-in maintenance at 1,000 km (600 miles)
is designed to compensate for this initial
minor wear. Timely performance of the
break-in maintenance will ensure optimum
service life and performance from the engine.
42
RIDING 2.Stand on the left side of the
1. Make sure the throttle is closed scooter and push it forward and off
and the rear brake is locked (page the center stand.
36) before moving the scooter off the
center stand.
AWARNING
* The rear wheel must be locked
when moving the scooter off the
center stand or loss of control
may result.
(1) Rear brake lever (2) Lock lever
43
3. Mount the scooter from the left 4. Unlock the rear wheel by squeezing and
side keeping at least one foot on the releasing the rear brake lever (1).
ground to steady the scooter.
(1) Rear brake lever (2) Lock lever
5. Before starting off, indicate your
direction with the turn signals, and
check for safe traffic conditions.
Grasp the handlebars firmly with both
hands.
A WARNING
*Never attempt one-handed
operation; loss of vehicle control
could result.
6. To accelerate, open the throttle (1)
gradually; the scooter will move
forward.
A WARNING
* Donot “BLIP” the throttle (open
and close rapidly) as the scooter
will move forward suddenly,
causing possible loss of control.
7. To decelerate, close throttle.
Y
OPEN
NA
(1)
(1) Throttle
45
8. When slowing down the scooter,
coordination of the throttle (1) and
front and rear brakes (2)is most
important.
AWARNING
* Both front and rear brakes
should be applied together.
Independent use of only the front
or rear brake reduces stopping
performance.
Excessive brake application may
cause either wheel to lock,
reducing control of the scooter.
A
DE
(1) Throttle (1)
46
(2) Front and rear brakes
9. When approaching a corner or 10. After completing the turn, open the
turn, close the throttle (1) fully, and throttle gradually to accelerate the
slow the scooter down by applying both scooter.
front (2) and rear (3) brakes at the
same time.
(1) Throttle (2) Front brake (3) Rear brake
47
11. When descending a steep grade, CAUTION:
close the throttle (1) fully and apply * Avoid continuous use of the
both brakes (2) to slow the scooter. brakes, which may result in
overheating and reduction of
braking efficiency.
(1) Throttle (2) Front and rear brakes
48
12. When riding on wet or loose
surfaces, be especially cautious.
A WARNING
* When riding in wet or rainy
conditions or on loose surfaces,
the ability to maneuver and stop
will be reduced. For your safety:
* Exercise extreme caution when
braking, accelerating or
turning.
* Ride at slower speeds and allow
for extra stopping distance.
* Keep the scooter as upright as
possible.
* Use extreme caution when
riding over slippery surfaces
such as railroad tracks, iron
plates, manhole covers, painted
lines, etc.
49
PARKING
1. After stopping the scooter, turn the
ignition switch to the “OFF” position
and remove the key.
2.Use the center stand to support the
scooter while parked.
CAUTION:
* Park the scooter on firm, level
ground to prevent it from falling
over.
50
3. Lock the steering to help prevent theft
(page 32).
A WARNING
* The exhaust pipe and muffler
become very hot during operation
and remain sufficiently hot to
inflict burns if touched, even
after shutting off the engine.
HOW TO USE
CENTER STAND
ANTI-THEFT TIPS
1. Always lock the steering and never
leave the key in the ignition switch.
This sounds simple but people do forget.
2. Be sure the registration information for
your scooter is accurate and current.
3. Park your scooter in a locked garage
whenever possible.
4.Use an additional anti-theft device of
good quality.
5.Put your name, address and phone
number in this Owner’s Manual and
keep it on your scooter at all times.
Many times stolen scooters are
identified by information in the Owner's
Manuals that are still with them.
NAME:
ADDRESS:
PHONE NO:
51
HIGH ALTITUDE RIDING
When operating this scooter at high
altitude, the air-fuel mixture becomes
overly rich. Above 2,000 m (6,500 feet)
driveability and performance may be
reduced and fuel consumption increased.
The carburetor can be modified to
compensate for this high altitude richness.
However, the carburetor must be
returned to standard factory
specifications when lower altitude riding
is desired. See your authorized Honda
scooter dealer for high altitude
modification.
CAUTION:
* Sustained operation at altitudes
below 1,500 m (5,000 feet) with
high altitude carburetor modifica-
tions may cause engine overheating
and damage.
52
MAINTENANCE
* When service is required, remember that your authorized Honda scooter dealer knows
your scooter best and is fully equipped to maintain and repair it. The scheduled
maintenance may also be performed by a qualified service facility that normally does
this kind of work; or you may perform most of the work yourself if you are
mechanically qualified.
* The maintenance intervals shown in the following schedule are based upon average
riding conditions. Scooters subjected to severe use, or ridden in unusually muddy or
dusty areas, require more frequent servicing.
* Consult your authorized Honda scooter dealer for recommendations applicable to your
individual needs and use.
53
MAINTENANCE SCHEDULE for CANADA model
The following items require some mechanical knowledge. Certain items (particularly those marked * and * * )
may require more technical information and tools. Consuit your authorized Honda Scooter Dealer.
Perform the Pre-ride Inspection (page 36) at each scheduled maintenance period.
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C:CLEAN R:REPLACE A:ADJUST L:LUBRICATE
FREQUENCY WHICHEVER — | ODOMETER READING (NOTE 2)
COMES
FIRST! | xi090mi | 06 | 25 | 5 | 75
Refer
ITEM NOTE |x1000km| 1 | 4 | 8 | 12 | topages
* | FUEL LINE — I I I
* |THROTTLE OPERATION — I I I
** TOIL PUMP AND OIL LINE — I I I
AIR CLEANER NOTE 1 — | Сс С С 60—61
SPARK PLUG NOTE 3 EVERY 1,000 mi 62—63
(1,600 km) R |
++ | DECARBONIZING NOTE 3 EVERY 2,000 mi |
(3,200 km) C
* | CARBURETOR-IDLE SPEED LL II IT | #64
54
FREQUENCY
WHICHEVER — | ODOMETER READING (NOTE 2)
COMES
FIRST | | x1,000mi | 06 | 25 | 5 75
Refer
NOTE |x1,000km| 1 4 8 to pages
65
* SHOULD BE SERVICED BY YOUR AUTHORIZED HONDA SCOOTER DEALER UNLESS THE
OWNER HAS PROPER TOOLS AND SERVICE DATA, AND IS MECHANICALLY QUALIFIED. REFER
TO THE OFFICIAL HONDA SCOOTER SERVICE MANUAL.
** IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY YOUR
AUTHORIZED HONDA SCOOTER DEALER.
NOTES: (1) Service more frequently when riding in unusually wet or dusty areas.
(2) At higher odometer readings, repeat at the frequency interval established here.
(3) HONDA 2 STROKE MOTORCYCLE OIL has been specifically tested and is recommended for this
engine. The use of other oils may cause excessive carbon build-up in the engine and exhaust system,
resulting in loss of power and possible engine damage.
55
MAINTENANCE SCHEDULE for AUSTRALIA model
The following items require some mechanical knowledge. Certain items (particularly those marked * and * *) may
require more technical information and tools. Consult your authorized Honda Scooter Dealer.
Perform the Pre-ride Inspection (page 36) at each scheduled maintenance period.
I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE
FREQUENCY | WHICHEVER = ODOMETER READING (NOTE 2)
RT x1,000km | 1 4 8 12 Re
} x1,000mi | 06 | 25 | 5 | 75 to pages
ITEM NOTE |MONTHS 6 12 | 18
* | FUEL LINE — I I I
* | THROTTLE OPERATION — 1 I I
* * | OIL PUMP AND OIL LINE — I I I
AIR CLEANER NOTE 1 — | € C С 60—61
SPARK PLUG 00 TR 62—63
* * | DECARBONIZING Eee me
* | CARBURETOR-IDLE SPEED 1 | 1 j 1 [1 64
56
FREQUENCY | WHICHEVER = ODOMETER READING (NOTE 2)
COMES [1 000km | 1 4 8 | 12
FIRST - Refer
+ x1,000mi | 0.6 2.5 5 7.5 to pages
ITEM NOTE |MONTHS 6 | 12 | 18
BRAKE SHOE WEAR — I I I 65
BRAKE SYSTEM I I I I 17, 65
* | BRAKE LIGHT SWITCH — I I I
* | HEADLIGHT AIM — I I I
* | SUSPENSION — I I I
* | NUTS, BOLTS, FASTENERS I — I —
* * | CLUTCH SHOE WEAR — — I —
* * | WHEELS/TIRES — I I I
* * | STEERING HEAD BEARINGS I — — I
* SHOULD BE SERVICED BY YOUR AUTHORIZED HONDA SCOOTER DEALER UNLESS THE OWNER
HAS PROPER TOOLS AND SERVICE DATA, AND IS MECHANICALLY QUALIFIED. REFER TO THE
OFFICIAL HONDA SCOOTER SERVICE MANUAL.
* * IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY YOUR
AUTHORIZED HONDA SCOOTER DEALER.
NOTES: (1) Service more frequently when riding in unusually wet or dusty areas.
(2) At higher odometer readings, repeat at the frequency interval established here,
57
MAINTENANCE RECORD (For CANADA)
Mileage (km) Performed by Odometer Date
600
(1,000 km)
2,500 mi
(4,000 km)
5,000 mi
(8,000 km)
7,500 mi
(12,000 km)
® Make sure that whoever performs the maintenance completes this record. All scheduled
maintenance including the 600 mile (1,000 km) break-in maintenance, is considered a normal owner
operating cost and will be charged for by your authorized Honda Scooter Dealer.
® Detailed receipts verifying the performance of required maintenance should be retained. These
receipts should be transferred with the scooter to the new owner if the scooter is sold.
58
SERIAL NUMBERS
The frame and engine serial numbers are
required when registering your scooter.
They may also be required by your
authorized Honda scooter dealer when
ordering replacement parts. Record the
numbers here for your reference.
The VIN, Vehicle Identification Number
(1), 1s on the Safety Certification label,
which is attached to the frame pipe under
the floor panel.
The frame serial number (2) is stamped on
the left side of the frame body.
FRAME NO.
(1) VIN
(2) Frame serial number
59
The engine serial number (3) is stamped COLOR LABEL
on the back of the crankcase near the rear The color label (1) is attached to the
wheel. center compartment.
It is helpful when ordering replacement
parts. Record the color and code here for
your reference.
COLOR
ENGINE NO. CODE
3)
N | x
(3) Engine serial number (1) Color label
60
MAINTENANCE PRECAUTIONS
AWARNING
* If your scooter is overturned or
involved in a collision, inspect
control levers and cables,
switches and other vital parts for
damage. Do not ride the scooter if
damage impairs safe operation.
Have your authorized Honda
scooter dealer inspect the major
components including frame,
suspension, and steering parts for
misalignment and damage that
you may not be able to detect.
Before performing any
maintenance, stop the engine and
support the scooter on a firm,
level surface.
Use new, genuine Honda scooter
parts or their equivalent for
maintenance and repair.
Parts which are not of equivalent
quality may impair the safety of
your scooter.
61
AIR CLEANER
(Refer to the maintenance precautions on
page 61).
The air cleaner should be serviced at
regular intervals (page 54). Service more fre-
quently when riding in unusually wet or dusty
areas.
1. Remove the five screws (1).
2. Remove the air cleaner cover (2).
3. Remove the air cleaner element (3)
ZO- 4DPOQ-FWC-NIMIC-A
62
(1) Screws
(2) Air cleaner cover (3) Air cleaner element
4. Wash the element in clean, nonflam-
mable or high flash point solvent and let
it dry thoroughly.
AWARNING
* Never use gasoline or low flash
point solvents for cleaning the air
cleaner element. A fire or explo-
sion could result.
(4) Air cleaner elment
5.Soak the element in gear oil (SAE 80—90)
until saturated, then squeeze out the ex-
cess oll.
6. For installation, reverse the removal
procedure.
63
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SPARK PLUG
(Refer to the maintenance precautions on
page 61).
Recommended plugs:
Standard:
BR6HSA (NGK) W20FR—L (NIPPONDENSO)
For cold climate: (Below 5°C/41°F)
BR4HSA (NGK) W14FR—L (NIPPONDENSO)
For extended high speed riding:
BR8HSA (NGK) W24FR—L (NIPPONDENSO)
1. Disconnect the spark plug cap (1).
(1)
(1) Spark plug cap
64
2. Clean any dirt from around the spark
plug base. Remove and discard the
spark plug.
3. Check the new spark plug gap (2) using
a wire-type feeler gauge. If adjustment
is necessary, bend the side electrode (3)
carefully.
The gap should be:
0.6—0.7 mm (0.02—0.03 in)
(2) (3)
A A
(2) Spark plug gap (3) Side electrode
4. With the plug washer attached, thread
the new spark plug in by hand to
prevent cross-threading.
5. Tighten the spark plug 1/2 turn with a
spark plug wrench to compress the
washer.
6. Connect the plug cap.
AWARNING
* Never leave shop towels in the
engine area after cleaning the
spark plug base. They may cause
the engine to overheat and
become damaged.
CAUTION:
* The spark plug must be securely
tightened. An improperly tight-
ened plug can become very hot
and possibly damage the engine.
* Never use a spark plug with an im-
proper heat range. Severe engine
damage could result.
65
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IDLE SPEED
(Refer to the maintenance precautions on
page 61).
The engine must be at normal operating
temperature for accurate idle speed
adjustment. Ten minutes of stop-and-go
riding is sufficient.
NOTE:
* Do not attempt to compensate for faults
in other systems by adjusting idle speed.
See your authorized Honda scooter
dealer for regularly scheduled
carburetor adjustments.
1.Warm up the engine and place the
scooter on its center stand.
1. Connect a tachomenter to the engine.
2. Adjust idle speed with the throttle stop
screw (1).
IDLE SPEED:
AWARNING
The rear wheel will spin if not
restrained by the brake or
contact with the ground.
Accidental contact with the
66
1,800 + 100 rpm
spinning rear wheel could cause
personal injury.
(1) Throttle stop screw
BRAKE SHOE WEAR
(Refer to the maintenance precautions on
page 61).
Wear Indicator
When the brake is applied, an arrow (1)
attached to the brake arm (2) moves
toward a reference mark (3) on the brake
panel.
If the arrow aligns with the reference
mark on full application of the brake, the
brake shoes must be replaced. See your
authorized Honda scooter dealer for this
service.
(1) Arrow (2) Brake arm (3) Reference mark
Other Checks
Check the brake cable for kinks or signs
of wear that could cause sticking or
failure.
Lubricate the brake cable with a
commercially available cable lubricant to
prevent premature wear and corrosion.
Make sure the brake arm, spring and
fasteners are in good condition.
(2)
(1) Arrow (2) Brake arm (3) Reference mark
67
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FUSE REPLACEMENT
(Refer to the maintenance precautions on
page 61).
The fuse holder (1) is near the battery.
When frequent fuse failure occurs, it
usually indicates a short circuit or an
overload in the electrical system. If this
happens, the electrical system should be
checked visually for damaged insulation
or other possible malfunctions. If the
problem cannot be located visually, the
scooter should be examined by an
authorized Honda scooter dealer.
The specified fuse is: 10 A
A WARNING
* Never use a fuse with a different
rating from that specified.
Serious damage to the electrical
system or a fire may result,
causing a dangerous loss of lights
or engine power.
68
CAUTION:
* Turn the ignition switch OFF
before checking or replacing the
fuses to prevent accidental short-
circuiting.
(1) Fuse holder (2) Spare fuse
AWARNING
* Do not pry the clips open to get a
fuse out; you could bend them and
cause poor contact with the new
fuse. A loose fuse could cause
damage to the electrical system
and even start a fire.
To replace the fuse, open the fuse holder
and lift out the fuse with the clips. Slide
the old fuse out of the clips and discard it.
Slide the clips onto the ends of the new
fuse, push them back into the fuse holder,
and close the fuse holder.
CAUTION:
+ After replacing the fuse, be sure
to return the fuse holder to its
original location.
REMOVAL
FUSE
69
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DZ2-ADODWNWZEPIœ
TRANSPORTING
A WARNING
*
To prevent the possibility of a fire
or explosion when transporting
the scooter, always:
—Drain the fuel tank and
carburetor.
—Carry the scooter upright in its
(1)
70
normal riding position to prevent
oil and battery electrolyte from
leaking.
Drain screw
Draining Fuel
Perform this operation only in a well-
ventilated area.
AWARNING
* Gasoline is extremely flammable
and is explosive under certain con-
ditions. Perform this operation in a
well-ventilated area with the engine
stopped. Do not smoke or allow
flames or sparks in the area where
gasoline is drained or stored and
where the fuel tank is refueled.
. Stop the engine.
Empty the fuel
tank using a
commercially available hand siphon or
an equivalent method.
3. Place the free end of the carburetor
drain tube in a suitable container.
4.0pen the carburetor drain by turning
the drain screw (1 ) counterclockwise.
When all the fuel has drained, turn the
screw clockwise until tight.
CLEANING
Clean your scooter regularly to protect
the surface finishes and inspect it for
damage, wear and oil seepage.
CAUTION:
* Avoid spraying high pressure
water (typical in coin-operated
car washes) at the following
areas:
Wheel Hubs
Muffler Outlet
Under Seat
Ignition Switch
Handlebar Switches
1. After cleaning, rinse the scooter
thoroughly with plenty of clean water.
Strong detergent residue can corrode
alloy parts.
NOTE:
* Clean the plastic parts using a cloth or
sponge soaked with a solution of mild
detergent and water. Rub the soild areas
gently rinsing it frequently with fresh
water.
2. Dry the scooter thoroughly.
3.Start the engine and let it run for
several minutes.
71
OZ~2Z2pmr CO
QZ—=2Z2pmrd
4. Test the brakes before riding the
scooter in traffic. Several applications
may be necessary to restore normal
braking performance.
AWARNING
* Braking performance may be
impaired immediately after
washing the scooter.
72
TEST BRAKES
STORAGE GUIDE
STORAGE
Extended storage, such as for winter,
requires that you take certain steps to
reduce the effects of deterioration from
non-use of the scooter. In addition,
necessary repairs should be made
BEFORE storing the scooter; otherwise,
these repairs may be forgotten by the time
the scooter is removed from storage.
1. Drain the fuel tank and carburetors into
an approved gasoline container. Spray
the inside of the tank with an aerosol
rust-inhibiting oil.
Reinstall the fuel cap on the tank.
NOTE:
* Tf storage will last more than one month,
carburetor draining is very important,
to assure proper performance after
storage.
AWARNING
* Gasoline is extremely flammable
andis explosive under certain con-
ditions. Perform this operation in a
well-ventilated area with the engine
stopped. Do not smoke or allow
flames or sparks in the area where
gasoline is drained or stored and
where the fuel tank is refueled.
2. Remove the spark plug and pour a
tablespoon (15—20 cc) of clean 2-stroke
oil into the cylinder. Operate the
kickstarter several times to distribute
the oil, then reinstall the spark plug.
NOTE:
* When turning the engine over, the
Engine Stop Switch should be OFF.
3. Remove the battery. Store in an area
protected from freezing temperatures
and direct sunlight.
4. Wash and dry the scooter. Wax all
painted surfaces.
73
mo-CO) MOPIO-0
MOU-Co MAPIO-40A
5.
74
Inflate the tires to their recommended
pressures. Place the scooter on blocks to
raise both tires off the ground.
.Cover the scooter (don’t use plastic or
other coated materials) and store in an
unheated area, free of dampness and
with a minimum of daily temperature
variation. Do not store the scooter in
direct sunlight.
REMOVAL FROM STORAGE
1. Uncover and clean the scooter.
2.Check the voltage and slow charge the
battery if it is below 12.3 V.
3. Drain any excess aerosol rust-inhibiting
oil from the fuel tank. Fill the fuel tank
with fresh gasoline.
4. Perform all Pre-ride Inspection checks
(page 36).
Test ride the scooter at low speeds in a
safe riding area away from traffic.
NOISE CONTROL SYSTEM (AUSTRALIA ONLY)
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Owners are warn-
ed that the law may prohibit: (a) The removal or rendering inoperative by any person other than
for purposes of maintenance, repair, or replacement, of any device or element of design incor-
porated into any new vehicle for the purpose of noise control prior to its sale or delivery to the
ultimate purchaser or while it is in use; and (b) the use of the vehicle after such device or element
of design has been removed or rendered inoperative by any person.
75
NZ0-1DO-T-OMDN
SPECIFICATIONS
DIMENSIONS
Overall length
Overall width
Overall height
Wheelbase
Ground clearance
WEIGHT
Dry weight
CAPACITIES
2 stroke engine oil
Transmission oil
Fuel tank
Passenger capacity
Maximum weight capacity
76
1,650 mm (65 in)
645 mm (25.4 in)
990 mm (39 in)
1,145 mm (45 in)
100 mm (3.9 in)
60 kg (145.6 Ibs)
1.2 € (1.2 US gt, 1.0 Imp qt)
0.09 2 (0.10 US gt , 0.08 Imp qt) After draining
5.0 £ (1.32 US gal, 1.10 Imp gal)
Operator only. No passengers.
91 kg (200 Ibs)
ENGINE
Bore and stroke
Compression ratio
Displacement
Spark plug
Standard
For cold climate
(Below5C. 41°F)
For extended
high speed riding
Spark plug gap
Idle speed
39.0 x 41.1 mm (1.54 in x 1.63)
71:1
49 cm? (3.0 cu-in)
W20FR-L (NIPPONDENSO)
BR6HSA (NGK)
W14FR-L (NIPPONDENSO)
BR4HSA (NGK)
W24FR-L (NIPPONDENSO)
BR8HSA (NGK)
0.6—0.7 mm (0.02—0.03 in)
1,800 + 100 rpm
77
NZO- > © = "п = С) то о
ог Он» С — тп - Ото т
CHASSIS AND SUSPENSION
Caster
Trail
Tire size, front
Tire size, rear
ELECTRICAL
Battery
Alternator
POWER TRANSMISSION
Primary reduction
Final reduction
LIGHTS
Headlight
Tail/break light
Front turn signal lights
Rear turn signal lights
Instrument lights
Turn signal indicator light
High beam indicator light
FUSE
78
26° 30°
73 mm (2.9 in)
3.00—10 42]
3.00—10 42]
12 V—3 AH
12 V 135 W/5,000 rpm
V — Belt
12.115 : 1
12 V—25/25 W <12 V—35/35 W>
12 V—8/25 W <12 V—21/5 W>
12 V—17 W <12 V—21 W>
12 V—23 W <12 V—21 W>
12 V— 1.7 Wx2
12 V—3.4 W
12 V—1.7 W
10 À
< >: AUSTRALIA model
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