Honda SK50M Dio Service Manual 117 Pages

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Manual
Honda SK50M Dio Service Manual | Manualzz
Introduction Contents
This service manual describes the service procedures for General Information
the SKSOM.
This Model Specific Manual includes every service
procedure that is of a specific nature to this particular
model. Basic service procedures that are common to
Frame/Body Panels/Exhaust System
other Honda Motorcycles/Motor Scooters/ATVs are Maintenance
covered in the Common Service Manual. This Model
Specific Service Manual should be used together with Lubrication System
the Common Service Manual in order to provide
complete service information on all aspects of this
scooter.
Fuel System
Follow the Maintenance Schedule (Section 3) Engine Removal/Installation
recommendations to ensure that the vehicle is in peak
operating condition. Performing the first scheduled
maintenance is very important. It compensates for the
initial wear that occurs during the break-in period.
Cylinder Head/Cylinder/Piston
Kickstarter/Drive Pulley/Clutch/Driven Pulley
Sections 1 and 3 apply to the whole scooter. Section 2
illustrates procedures for removal/installation of
components that may be required to perform service
described in the following sections. Crankcase/Crankshaft |
While Sections 4 through 17 describe parts of the
Final Reduction
Engine and Drive Train
| | | -!-/-I | | I |
Nisk: EII |
scooter, grouped according to locations. . .
group 9 = | Front Wheel/Suspension/Steering/Brake
Find the section you want on this page, then turn to the E -
table of contents on the first page of the section. о Rear Wheel/Suspension/Brake
Most sections describe the service procedure through Charging System/Alternator
system illustration. Refer to the next page for details on
how to use this manual. _ Ignition System
| 5 |
If you don’t know the source of the trouble, go to 2 A
section 18 TROUBLESHOOTING. 8 | Electric Starter
| 2
LL . | .
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS Lights/Meters/Switches
AND SPECIFICATIONS INCLUDED IN THIS
PUBLICATION ARE BASED ON THE LATEST PRODUCT
INFORMATION AVAILABLE AT THE TIME OF APPROVAL
FOR PRINTING. HONDA MOTOR CO., LTD, RESERVES
THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT Troubleshooting
NOTICE AND WITHOUT INCURRING ANY OBLIGATION
WHATEVER. NO PART OF THIS PUBLICATION MAY BE |
REPRODUCED WITHOUT WRITTEN PERMISSION. THIS Index
MANUAL IS WRITTEN FOR PERSONS WHO HAVE
ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON
HONDA MOTORCYCLES.
HONDA MOTOR CO., LTD.
SERVICE PUBLICATIONS OFFICE
Wiring Diagram
PAS —
E
Date of Issue: Jan., 1992
© HONDA MOTOR CO., LTD.
Important Safety Notice
Indicates a strong possibility of severe personal injury or death if instructions are not followed.
CAUTION: Indicates a possibility of equipment damage if instructions are not followed.
NOTE: Gives helpful information.
Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is
important 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 recommended by Honda,
might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all
such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy himself
thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected.
How to Use This Manual
Finding Information You Need
This manual is divided into sections which cover each of
the major components of the motorcycle.
To quickly find the section you are interested in, the first
page of each section is marked with a black tab that lines
up with one of the thumb index tabs before this page.
The first page of each section lists the table of contents
within the section. |
Read the service information and troubleshooting related
to the section before you begin working.
An index of the entire book is provided in the last chapter
to directly locate the information you need.
Note on the Explanation Method of This Manual
The removal and installation of parts are for the most part illustrated by large and clear illustrations that should provide the
reader with visual aid in understanding the major point for servicing.
The system illustrations are augmented by callouts whose numbers or letters indicate the order in which the parts should
be removed or installed. |
The sequence of steps represented numerically are differentiated from the ones represented alphabetically to notify the
reader that they must perform these steps seperately.
For example, if the steps prior and up to camshaft removal are performed with the engine installed, but the subsequent
steps like cylinder head removal require engine removal, the callouts are grouped in numerical and alphabetical orders.
The illustrations may contain symbol marks to indicate necessary service procedures and precautions that need to be
taken. Refer to the next page for the meaning of each symbol mark.
Aiso in the illustration is a chart that lists information such as the order in which the part is removed/installed, the name of
the part, and some extra notes that may be needed.
Step by step instructions are provided to supplement the illustrations when detailed explanation of the procedure is neces-
sary or illustrations alone would not suffice.
Service procedures required before or after the procedure described on that particular page, or inspection/adjustment pro-
cedures required following the installation of parts, are described under the title Requisite Service.
Standard workshop procedures and knowledge covered in the Common Service Manual are abbreviated in this manual.
Detailed description
Symbol mark System illustration of the procedure
CYLINDER HEAD/CYUNDEN/ PISTON / CYLINDER HEAD/CYLINDER/PISTON
CYLINDER HEAD REMOVALANSTALLATION . . / CAMSHAFT IDLE GEAR CASE INSTALLATION ¡ vai CORRECT
install the camenah tle gens Cone dowel pins property
e 30 #30. 225 р nove | AR
ur ng gane | 5 come
и the camehatt wie geer cape onto the cre 10. ine 7
pe 2 2» a. ~~ pen. case shoud be Нед uo angry trom the cyander | GEAR
Metal a mew sesing washer and mounung bolis Tighten à
volts м э gaduel. аз shawn
Step Pr |!
sequence
{ numer al 5 и CYLINDER HEAD NUT/BOLT INSTALLATION _ PI SPECIAC NUT
Se o А
dequisive senvice T cl 5 e >.
Engene 'ernovelimateltation :page 7.21 * Caomanett removaumstensvon ipege 8 21 x . ve y _ }
PROCEDURE Ow REMARKS wot
REMOVAL ФАЕР | TT TT. Insteltstion D sm he reverse Order of сетов
11) Cylnater hand special nut 2 ineiatetion ¡pogo 6 $)
‘2 Cringe heed точь 2 insted the cybnge: head mounting bone
14) Genet 1 имей wih the UP mark feerg up end resta Tighten the specie nuts eng Meuntng DONS m © gradual.
(9) Qowet pa 2 Cesecrass portar
16) Comenen die gear coso 5
17) Comghah «dia pen: copo dows! on 2 inatetonan :pege 8-5: TORQUE:
18: Sesirg washer ‘ Special mat: 320 Nm (3.0 6-ю. 22 пы!
(9 Comansh ale gear cess ' Maunting beit: 12 М. (3.2 4g-w, D tub)
110) Cortverator поме a At meatedanan. ahen me manso: groove wah the engene
f A wa with mo + UP men tec vase icarburetos vase)
8-4 | \ 8-5
РА .
Part name Number of Extra notes or precaution
parts related to the service procedure
Symbols
The symbols used throughout this manual show specific service procedures. № supplementary information is required pertain-
ing to these symbols, it would be explained specifically in the text without the use of the symbols.
Replace the part(s) with new one(s) before assembly.
Use special tool
Use optional too!. Use the same procedure you use to order parts.
10%
Torque specification. 10 N-m (1.0 kg-m, 7.2 ft-Ib)
mb
о
=
©
N
.2)
Use recommended engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1 : 1).
Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote® BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent) |
Example: Molykote® G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited, U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone grease
Apply a locking agent. Use the agent of the middle Strength, unless otherwise specified.
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
Tat aie eee
Use Fork or Suspension Fluid.
1. General Information
General Safety 1-1 Tools 1-11
Model! Identification 1-2 Lubrication & Seal Points | 1-12
Specifications 1-3 Cable & Harness Routing | 1-14
Torque Values 1-9 |
General Safety
Carbon Monoxide Brake Dust
If the engine must be running to do some work, make sure
the area is well ventilated. Never run the engine in an
enclosed area.
- The exhaust contains poisonous carbon monoxide
gas that can cause loss of consciousness and may
lead to death.
Run the engine in an open area or with an exhaust
evacuation system in an enclosed area.
Gasoline _
Work in a well ventilated area. Keep cigarettes, flames or
sparks away from the work area or where gasoline is
stored.
- Gasoline is extremely flammable and is explosive
under certain conditions. KEEP OUT OF REACH
OF CHILDREN.
Hot Components
« Engine and exhaust system parts become very hot
and remain hot for some time after the engine is
run. Wear insulated gloves or wait until the engine
and exhaust system have cooled before handling
these parts.
Never use an air hose or dry brush to clean brake as-
semblies. Use a vacuum cleaner or alternate method
designed to minimize the hazard caused by airborne
asbestos fibers.
- Inhaled asbestos fibers have been found to cause
respiratory disease and cancer.
Battery Hydrogen Gas & Electrolyte
A WARNING
- The battery gives off explosive gases: keep sparks,
flames and cigarettes away. Provide adequate
ventilation when charging.
- The battery contains sulfuric acid (electrolyte).
Contact with skin or eyes may cause severe burns.
Wear protective clothing and a face shield.
— If electrolyte gets on your skin, flush with water.
— If electrolyte gets in your eyes, flush with water
for at least 15 minutes and call a physician.
- Electrolyte is poisonous.
— If swallowed, drink large quantities of water or
milk and follow with milk of magnesia or veget-
able oil and cail a physician. KEEP OUT OF
REACH OF CHILDREN.
1-1
General Information
Model Identification
(2)
(1) FRAME SERIAL NUMBER
The frame serial number is stamped on the left side of the
frame.
(2) ENGINE SERIAL NUMBER
The engine serial number is stamped on the left side of the
transmission cover.
(4) COLOR CODE LABEL — o nn
- The color code label is attached to the luggage box under
the seat. When ordering a color coded parts, always
specify its designated color.
(3) CARBURETOR IDENTIFICATION NUMBER
The carburetor identification number is stamped on the left
side of the carburetor body.
Y
O TES о
(5)
(5) SAFETY CERTIFICATION LABEL (CM type only) _
The safety certification label is attached to the right side of
the frame.
1-2
General Information
Specifications
— General
Unit: mm (in)
ltem
Specifications
Dimensions
Overall length
1,650 (65.0)
Displacement
Compression ratio
Port timing intake open
Port timing intake close
Port timing Exhaust open
Port timing Exhaust close
Port timing Scavenge open
Port timing Scavenge close
Firing order
Lubrication system
Oil pump type
Cooling system
Air filtration
Crankshaft type
Egnine weight (dry)
Overall width 645 (25.4)
Overall height 990 (39.0)
Wheelbase 1,145 (45.1)
Seat height 715 (28.1)
Footpeg height 360 (14.2)
Ground clearance 100 (3.9)
Dry weight 66 kg (146.6 Ibs)
Curb weight 71 kg (157.7 Ibs)
Maximum weight capacity 91 kg (200 lbs)
Frame Frame type Under bone
Front suspension Telescopic
Front wheel travel 53.7 (2.11)
Rear suspension Final drive unit/swingarm
Rear wheel travel 60.7 (2.39)
Front damper —
Rear damper —
Front tire size 3.00—10 42J
Rear tire size 3.00- 10 42J
Tire brand (Bridgestone) Front/Rear ML31/ML32.
Tire brand (Dunlop) Front/Rear K378F/K378
Tire brand (IRC) Front/Rear MB48/MB47
Front brake Internal expanding shoe
Rear brake Internal expanding shoe
Caster angle 26° 30’
Trail length 73 (2.9)
Fuel tank capacity 5.0 liters (1.32 US gal, 1.10 Imp gal)
Fuel tank reserve capacity —
Fork leg oil capacity —
Engine Bore and stroke 39.0 x 41.4 (1.54 x 1.63)
49.4 cm? (3.01 cu in)
| 7.1
Reed valve controlled
Reed valve controlled
84° BBDC
84° ABDC
62° BBDC
62° ABDC
Oil automatically mixed with gasoline
Plunger type
Forced air cooled
Urethane foam
Assembly type
16.1 kg (35.5 Ibs)
1-3
General Information
— General (cont'd)
Unit: mm (in)
Starting system
Charging system
Regulator/rectifier type
Item Specifications
Carburetor Carburetor type Piston valve
Venturi dia. 14.0 (0.55)
Drive train Clutch system Dry, automatic centrifugal clutch
Primary reduction —
Final reduction 12.115
Gear ratio 2.450-0.850
Electrical Ignition system CDI
Electric starter motor/kickstarter
Single phase alternator, 12 V-133 W
SCR switching regulator, AC regulator built in type/ single
phase, half-wave rectifier
General Information
Unit: mm (in)
— Lubrication
item
Standard
Service limit
Engine oil tank capacity
Recommended engine oil
1.2 liters (1.27 US qt, 1.06 Imp at)
Use Honda 2-stroke oil or equivalent
— Fuel System
Carburetor identification number ^^
Main jet
Slow jet
Jet needie clip position
| Air screw initial opening
Air screw high altitude adjustment
Float level |
Idle speed
Throttle grip free play
#75A
#35 _
3rd groove
1-1/4 turns out
8.0 (0.31)
1,800 + 100 min”! (rpm)
2—6 (0.08 —0.24 in)
TT
— Cylinder Head/Cylinder/Piston
Cylinder compression
Cylinder head warpage
Cylinder warpage |
Cylinder identification mark location
Cylinder I.D. A mark
No mark
out of round
taper
Piston mark direction
Piston O.D. (D) A mark
B mark
No mark
Piston O.D. measurement point (H)
Piston pin hole |.D. (9) A
E wo
798] С
ah o
Cylinder-to-piston clearance
Piston pin O.D.
Piston-to-piston pin clearance
Top ring-to-ring groove clearance
Second ring-to-ring groove clearance
Top ring end gap
Secend ring end gap
Top ring mark 5
Second ring mark
or no mark
“EX” mark
| 0.10-0.25 (0.004-0.010) |
981 kPa (10.0 kg/cm?, 142 psi)/600
min”! (rpm)
Lower surface of the cylinder
39.000 -39.005 (1.5354 — 1.5356)
39.005 -39.010 (1.5356 — 1:5358)
“EX” mark facing exhaust side
38.955 — 38.960 (1.5337 — 1.5339)
38.965 -38.970 (1.5341 —1.5342)
38.960-38.965 (1.5339- 1.5341)
6.5 (0.26) from the bottom
12.002- 12.008 (0.4725-0.4728)
0.035-—0.050 (0.0014 -0.,0020)
11.994 — 12.000 (0.4722-—0.2724)
0.002-0.014 (0.0001 - 0.0006)
0.10-0.25 (0.004 -0.010)
“N” mark
“ZT” mark
(0.0004)
0.01 (0.0004)
39.05 (1.537)
39.05 (1.537)
0.10 (0.004)
0.10 (0.004)
38.90 (1.531)
38.90 (1.531)
38.90 (1.531)
12.03 (0.474)
0.10 (0.004)
11.98 (0.4717)
0.03 (0.001)
0.40 (0.016)
0.40 (0.016)
General Information
Unit: mm {in)
— Crankshaft
Driven face spring free length
Driven face O.D.
Movable driven face I.D.
Final reduction gear case oil capacity at disassembly
at draining
Clutch outer I.D.
33.965-33.985 (1.3372 — 1.3380)
34.000 — 34.025 (1.3386 — 1.3397)
90 cc (3.04 US oz, 3.16 Imp oz)
107.0- 107.2 (4.21 —4.22)
item Standard Service limit
Connecting rod small end |.D. 17.005—17.017 (0.6695 -0.6700) | 17.03 (0.6705)
Connecting rod big end side clearance 0.15—0.55 (0.006-0.022) 0.60 (0.024)
radial clearance 0.007 -0.019 (0.0003 —0.0007) 0.04 (0.002)
Crankshaft runout at A _— 0.15 (0.006)
at В — 0.10 (0.004)
A |
Tou
70 40 !
(2.8) (1.6)
Kickstarter/Balancer
Kickstarter spindle O.D. —— ——
bushing 1.D. — —
Kickstarter idle gear I.D. — ——
bushing O.D. —— —
Kickstarter driven gear I.D. —— —
boss О.Б. —— —_
— Drive Train
Drive belt width 15.5 (0.61) 1 14.5 (0.57)
Movable drive face bushing I.D. 20.035-20.085 (0.7888-0.7907) | 20.60 (0.811)
boss O.D. 20.010-20.025 (0.7878-0.7884) | 19.97 (0.786)
weight roller O.D. 15.92-16.08 (0.627 —0.633) 15.40 (0.606)
Clutch lining thickness — 4.5 (0.18) 2.0 (0.08)
Engine brake clutch lining thickness |
1.0. —— ——
Drive chain slack ——
98.1 (3.86) | 92.8 (3.65)
33.94 (1.336)
34.06 (1.341)
107.5 (4.23)
— Cooling System
Coolant capacity (Radiator and engine)
(Reserve tank)
Radiator cap relief pressure
Thermostat begin to open
Thermostat fully open |
Thermostat valve lift
HTT
1-6
General Information ©
Unit: mm (in)
Wheels/Tires
u item
Standard
Service limit
Cold tire pressure (Front)
(Rear)
Front and rear axle runout
Front and rear wheel rim runout (Radial)
(Axial)
Drive chain slack
Drive chain size/link (DID)
(RK)
125 kPa (1.25 kg/cm’, 18 psi)
200 kPa (2.00 kg/cm?, 29 psi)
qT
0.2 (0.008)
2.0 (0.08)
2.0 (0.08)
Front Suspension
Fork spring free length
Fork spring free length A
B
Fork spring direction
Fork tube runout
Recommended fork oil
Fork oil level
Fork oil level (Right)
(Left)
Fork oil capacity
Fork oil capacity (Right)
(Left)
Fork air pressure
Steering bearing preload
133.5 (5.26)
Tightly wound coil facing up
129.5 (5.10)
ATTA
— Rear Suspension
Shock absorber spring free length
Shock absorber spring free length A
B
Shock absorber spring direction
Damper drilling point
ИИ
ATT
Brakes
Front brake fluid
brake fever free play
brake disc thickness
brake disc runout
master cylinder I.D.
master piston O.D.
caliper cylinder I.D.
caliper piston O.D.
brake drum |.D.
brake lining thickness
Rear brake fiuid
brake lever free play
brake pedal free play
brake disc thickness
brake disc runout
master cylinder !.D.
master piston O.D.
caliper cylinder I.D.
caliper piston O.D.
brake drum 1.0.
brake lining thickness
т
N
O
о
И
©
©
Al]
gr
= ©
© ©
о
О —
bh
N
т
№
O
o
1
O
9
Il
95.0 (3.74)
3.0 (0.12)
General Information
Unit: mm (in)
— Battery/Charging System
item
Standard
Service limit
Alternator charging coil resistance (at 20°C/68°F)
lighting coil resistance (at 20°/68°F)
Regulator/rectifier regulated voltage (Charging)
(Lighting)
Battery capacity
Battery specific gravity (Fully charged)
(Needs charging)
Battery charging rate (Normal)
(Quick)
Battery voltage (Fully charged, at 20°/68°F)
| (Needs charging, at 20°/68°F)
Auto bystarter resistor resistance (6.7 о 5 W)
0.4-1.00 (between W and ground)
0.2-0.8Q (between Y and ground)
14.0—15.0 V/5,000 min"! (rpm)
12.6—13.6 V/5,000 min"! (rpm)
12 V3 Ah
04Ax5h
4Ax0.5h
13.0-13.2 V
12.3 V
4.7-5.3 9
ИНН
— Ignition System
Spark plug (Standard)
(For cold climate/below 5°C/41°F)
(For extended high speed riding)
Spark plug gap
Ignition timing “F” mark
Peak voltage Ignition coil
Exciter coil
Pulse generator coil
BR6HSA (МСК)
W2OFR-L (NIPPONDENSO)
BR4HSA (NGK)
W14FR-L (NIPPONDENSO)
BR8HSA (МСК)
W24FR-L (NIPPONDENSO)
0.6-0.7 (0.024-0.028)
17° BTDC/1,800 min! (rpm)
100 V minimum
100 V minimum
0.7 V minimum
ИЕН
Alternator exciter coil resistance (at 20°C/68°F) 400-800 ©
ignition coil resistance (at 20°C/68°F)
Primary 0.1—0.4 Q
Secondary with plug cap 6.5—9.7 kQ
Secondary without plug cap 2.7—3.5 КЮ
Pulse generator resistance (at 20°C/68°F) 50—2002
— Lights/Meters/Switches
Fuse 10 A —
Headlight (high/low beam) U type 12 V 35/35 W ——
СМ туре | 12 V 25/25 W —
Brake/taillight U type 12 V 21/5 М —
| CM type | 12 V 32/3 cp ——
Front turn signal light U type 12V21Wx2 ——
| СМ type | 12 V 21 cpx2 ——
Rear turn signal light U type 12V21Wx2 —
CM type | 12 V 32 cpx 2 ——
Instrument light. 12V1.7Wx2 ——
High beam indicator 12V1.7W ——
Turn signal indicator 12 V3.4 М _—
Fuel level sensor resistance (at full position) | |
between G and Y/W 25—45 9 —
between G and Bu/W 400-700 Q —
between Y/W and Bu/W 450-750 Q —
(at empty position)
between G and Y/W 400—700 © ——
between С and Bu/W 125-45 Q © —_——
between Y/W and Bu/W —
450-750 Q
1-8
General Information |
Torque Values
— Standard
| Torque Torque
Fastener Type №-т (kg-m, ft-1b) Fastener Type N-m (kg-m, ft-lb)
5 mm bolt and nut 5 (0.5, 3.5) 5 mm screw | | 4 (0.4, 2.9)
6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5)
8 mm bolt and nut 22 (2.2, 16) 6 mm flange bolt (8 mm head) 9 (0.9, 6.5)
10 mm bolt and nut 35 (3.5, 25) 6 mm flange bolt (10 mm head) and nut 12 (1.2, 9)
12 mm bolt and nut 55 (5.5, 40) 8 mm flange bolt and nut 27 (2.7, 20)
| 10 mm flange bolt and nut 40 (4.0, 29)
« Torque specifications listed below are for important fasteners.
Others should be tightened to standard torque values listed above.
— Engine
. Thread Torque
Item Q'ty dia. (mm) N-m (kg-m, ft-lb) Remarks
Lubrication system:
Oil pump mounting bolt 1 | 6 10 (1.0, 7)
Fuel system:
Carburetor mounting bolt 2 6 10 (1.0, 7)
Left shroud mounting bolt 2 6 10 (1.0, 7)
Intake manifold mounting boit _ 4 6 10 (1.0, 7)
Air cleaner case mounting bolt 2 6 12 (1.2, 9)
Cylinder head/cylinder/piston:
Cylinder head bolt 4 6 10 (1.0, 7) Г Apply oil to the threads and
Spark plug 1 14 14 (1.4, 10) flange surface.
Kickstarter/drive pulley/clutch/
driven pulley:
Left crankcase rear cover bolt 5 6 10 (1.0, 7)
Left crankcase front cover bolt 5 6 10 (1.0, 7)
Drive pulley nut 1 12 60 (6.0, 43) TT АРРУ oil to the threads and
Clutch outer nut 1 10 40 (4.0, 29) seating surface.
Movable drive face seal bolt 3 4 4.5 (0.45, 3.3) |
Clutch drive plate nut 1 28 55 (5.5, 40)
Final reduction:
Transmission cover bolt 5 6 10 (1.0, 7)
Transmission oil level check bolt 1 8 13 (1.3, 9)
Crankcase/crankshaft:
Crankcase bolt 6 6 10 (1.0, 7)
Charging system/alternator:
Cooling fan cover bolt 2 ‚ 6 10 (1.0, 7)
Cooling fan bolt 4 6 8 (0.8, 5.8)
Flywheel nut 1 10 40 (4.0, 29)
Stator bolt 2 6 10 (1.0, 7)
Pulse generator bolt 2 6 10 (1.0, 7)
Electric starter: |
Starter motor mounting bolt 2 6 10 (1.0, 7)
1-9
General Information
- bolt
— Frame
, Thread Torque
item O'Y |dia. (mm) | Nem (kg-m, ft-lb) Romarks
Exhaust system: |
Exhaust pipe joint nut 2 6 12 (1.2, 9)
Muffler mounting bolt 2 8 27 (2.7, 20)
Exhaust pipe protector bolt 2 6 12 (1.2, 9)
Engine mount:
Engine mounting bolt 1 10 50 (5.0, 36)
Engine mounting bracket bolt 1 10 60 (6.0, 43)
Front wheel/suspension/
steering/brake: | |
Speedometer cable set screw 1 4. 2 (0.2, 1.4)
Front axle nut 1 10 45 (4.5, 33)
Front brake arm bolt 1 5 6 (0.6, 4.3)
Fork pinch bolt 4 8 27 (2.7, 20)
Handlebar pinch bolt 1 10 50 (5.0, 36)
Steering stem lock nut 1 25.4 70 {7.0, 51)
Rear wheel/suspension/brake:
Rear axie nut 1 14 120 (12.0, 87) Apply oil to the threads and
Rear brake arm bolt 1 5 _ 6 (0.6, 4.5) eating surface.
Shock absorber upper mounting 1 10 40 (4.0, 29)
bolt
Shock absorber lower mounting 1 8 27 (2.7, 20)
1-10
General Information
Flywheel puller
07733—0010000
Flywheel removal
Tools
¢ Refer to “Ball bearing replacement” in section 1 of the Common Service Manual.
Description Tool Number Application Section
Float level gauge 07401—0010000 Carburetor float level inspection 5
Clutch center holder 077240050001 Drive pulley face removal/installation
Universal holder 07725—0030000 Clutch outer removal/installation
Clutch spring compressor 07960—KM10000 -Clutch/driven pulley disassembly/assembly 8
Lock nut wrench, 39 x 41 mm 07GMA—KS40100
Bearing driver 07945—GC80000 Driven face outer bearing installation
Crankcase assembly collar 07965—GM00100 y Priveshaft installation
Crankcase assembly shaft 07965 —- GMO0300 9
| Shaft protector 07931 — 1870000 Driveshaft removal
Case puller 07935—GK80000 Crankcase separation
Case/driven gear puller 07935—KG80000 . Crankshaft removal
Universal bearing puller 07631-—0010000 Crankshaft bearing removal |
Shaft protector 07931 — 1870000 Crankcase separation, crankshaft removal 10
Crankcase assembly collar 07965—GM00100 pp Crankshaft installation |
Crankcase assembly shaft 07965— 1660200 |
Crankcase assembly collar 07965—GM00100 y crankcase assembly
Crankcase assembly shaft 07965 —GM00300
Lock nut wrench A 07916—KM10000 “Ty Steering stem lock nut removal/installation
Lock nut wrench B 07916—1870100
Ball race remover 07946—GA70000 Steering head ball race removal 11
Driver 07749—0010000 Ty Steering head ball race installation
Attachment, 42 x 47 mm 07746—0010300
Snap ring pliers 07914-3230001 Fork disassembly/Assembly
Universal holder 07725—0030000 Flywheel removal/installation 13
1-11
General Information
Tools
+ Refer to “Ball bearing replacement” in section 1 of the Common Service Manual.
Description Tool Number Application Section
Float level gauge 07401 -—-0010000 Carburetor float level inspection 5
Clutch center holder 07724—0050001 Drive pulley face removal/installation
Universal holder 07725—0030000 Clutch outer removal/installation
Clutch spring compressor 07960—KM10000 y Sluteh/driven pulley disassembly/assembly 8
Lock nut wrench, 39 x 41 mm 07GMA—KS40100
Bearing driver 07945—GC80000 Driven face outer bearing installation
Crankcase assembly collar 07965—GMO0100 y Priveshaft installation
Crankcase assembly shaft 07965—GM00300 9
Shaft protector 07931— 1870000 Driveshaft removal
Case puller 07935—GK80000 Crankcase separation
Case/driven gear puller 07935—KG80000 Crankshaft removal
Universal bearing puller 07631—0010000 Crankshaft bearing removal
Shaft protector 07931— 1870000 Crankcase separation, crankshaft removal 10
Crankcase assembly collar 07965—GM00100 “Tp Crankshaft installation
Crankcase assembly shaft 07965— 1660200 |
Crankcase assembly collar 07965—GM00100 y Crankease assembly
Crankcase assembly shaft 07965—GMOO300 -
Lock nut wrench A 07816—KM10000 Ty Steering stem lock nut removal/installation
Lock nut wrench B 07916—1870100
Ball race remover 07946—GA70000 Steering head ball race removal 11
Driver 07749—0010000 pr >teering head ball race installation
Attachment, 42 x 47 mm 07746—0010300
Snap ring pliers 07914—3230001 Fork disassembly/Assembly
Universal holder 07725—0030000 Flywheel removal/installation 13
Flywheel puller
07733—0010000
Flywheel removal
1-11
General Information
Lubrication & Seal Points
— Engine
Location
Material Remarks
Crankcase mating surfaces
Liquid sealant
Oil pump O-ring
Oil pump shaft bearing
Cylinder
Piston
Piston pin
Connecting rod small end bearing
Crankshaft oil seals
Crankshaft 12 mm threaded portion
Honda 2-stroke engine oil
Crankshaft bearings
Muntipurpose grease
Oil pump gear
Molybdenum disulfide grease
Driven face
Kickstarter driven gear
Kickstarter spindle bearing
Starter pinion bearing
Lithium based grease
— MITSUBISHI: HD-3
—NIPPON SEKIYU: LIPANOX
DELUX 3
—|DEMITSU: AUTOLEX В
Pack 5.0—5.5 а (0.18—
0.19 oz) of grease to the
inside.
Transmission (final reduction) case
Hypoid gear oil ¿90
90 cc (3.04 US oz, 3.16 Imp
oz) |
Transmission (final reduction) ой seal
Cylinder head bolts
4-stroke engine oil
— Frame
Location
Material
Remarks
Front wheel dust seal lip
Fork
Fork dust seal lip
Fork tube bushing sliding surface
Rebound spring
Fork spring tightly wound coils
Front brake cam
Front brake panel anchor pin
Front brake panel oil seal lip
Rear brake cam
Rear brake anchor pin
Steering stem bearings
Steering stem bearing races
Speedometer cable
Seat lock pivot
Center stand pivot
Speedometer gear
Speedometer pinion
Multipurpose grease
Pack 1.5—2 д (0.05—0.07
oz) of grease between the
bottom case and fork tube
(page 11-9).
Inside of the front brake cable boot
Inside of the rear brake cable boot
Silicone grease
1-12
General Information
u Frame -
| Location Material Remarks
Brake cam felt seals Engine oil
Brake cables
Inside surface of handle grip Honda Bond A or equivalent
Air cleaner connecting tube-to-case joint Semedain #540
Air cleaner element | Honda 2-stroke engine oil
Engine oil tank
1-13
General Information
Cable & Harness Routing
| (2) REAR BRAKE CABLE
(1) FRONT BRAKE CABLE
(3) SPEEDOMETER CABLE
(7) THROTTLE CABLE |
(4) CLAMP
(6) IGNITION SWITCH
(5) RESISTOR
(8) RESISTOR
(9) SPEEDOMETER CABLE
(10) FRONT BRAKE CABLE
1-14
General Information
(2) THROTTLE CABLE
(1) ALTERNATOR/STARTER MOTOR
WIRE HARNESS
WD E oy 4 LES
ST b |
Sa
SÍ |
— 7, Ka (3) OIL INLET TUBE
(6) REAR BRAKE CABLE (4) CARBURETOR DRAIN TUBE
(5) OIL PUMP CONTROL CABLE
(7) CDI UNIT
(8) BATTERY
(9) FUEL LEVEL SENSOR WIRE
(11) REGULATOR/RECTIFIER
(10) MAIN WIRE HARNESS
1-15
General Information
(1) TAILLIGHT/TURN SIGNAL LIGHT WIRE
T EN o
EAN
à y] o
Sr} 70 Е 7
© ©
\
7 — у
D
NS
A
ZNO
(2) CLAMP —
1-16
2. Frame/Body Panels/Exhaust System
Service Information | 2-1 Fuel Tank Removal /Installation 2-8
Troubleshooting 2-1 Muffler Removal/installation 2-9 |
Frame Cover Removal /Installation 2-2
Service Information
- Gasoline is extremely flammable and explosive under certain conditions.
« Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.
- Work in a well ventilated area. Smoking or allowing flames or sparks in the working area or where gasoline is stored can
cause a fire or explosion.
« This section covers removal and installation of the frame covers, fuel tank and exhaust system.
Frame cover installation is in the reverse order of removal, unless noted otherwise.
« When romoving the cover, be careful not to damage any tab or groove of a cover.
- Always inspect the exhaust system for leaks after installation.
Troubleshooting
Excessive exhaust noise
+ Broken exhaust system
+ Exhaust gas leak
Poor performance
- Deformed exhaust system
+ Exhaust gas leak
- Clogged muffler
2-1
Frame/Body Panels/Exhaust System
Side Cover |
Remove the trim clip and two Screws.
Release the front tabs of the cover from the front fender
while sliding the cover rearward.
@Push the cover rearward and release the four front tabs
outward.
@Push the cover rearward and release the three tabs from
the frame body cover downward.
@Release the two rear tabs while pulling down the rear of
the cover.
NOTE
Attach the rear of the front fender with the side cover front
screw.
Frame Body Cover
Remove the luggage box (page 2-4).
Disconnect the turn signal light and taillight wire connectors.
Remove the three bolts and the rear carrier assembly.
Remove the side covers.
Remove the center cover (page 2-4).
Remove the two tapping screws and two trim clips.
(Release the front tabs upward.
@Remove the frame body cover rearward.
@Remove the two tapping screws and the body cover lid.
@Pull the left frame body cover back to release the two tabs
and separate the left and right frame body covers.
O |
5
D A
cy
(2) SIDE COVER
(1) SCREWS (3) TRIM CLIP
(1) BOLT (2) REAR CARRIER ASSEMBLY
(2) TAPPING
SCREW (3) BODY
| COVER
LID
‘4 y
Y “A
Y y
Y Sm
(6) TAPPING SCREW (5) TAB (4) TRIM CLIP
2-3
Frame/Body Panels/Exhaust System
Side Cover
Remove the trim clip and two screws.
(Release the front tabs of the cover from the front fender
while sliding the cover rearward.
(Push the cover rearward and release the four front tabs
outward.
@Push the cover rearward and release the three tabs from
the frame body cover downward.
@Release the two rear tabs while pulling down the rear of
the cover.
NOTE
Attach the rear of the front fender with the side cover front
screw.
Frame Body Cover
Remove the luggage box (page 2-4).
Disconnect the turn signal light and taillight wire connectors.
Remove the three bolts and the rear carrier assembly.
Remove the side covers.
Remove the center cover (page 2-4).
Remove the two tapping screws and two trim clips.
_ (Release the front tabs upward.
@Remove the frame body cover rearward.
@Remove the two tapping screws and the body cover lid.
@Pull the left frame body cover back to release the two tabs
and separate the left and right frame body covers.
(2) SIDE COVER
(1) SCREWS
(3) TRIM CLIP
(1) BOLT (2) REAR CARRIER ASSEMBLY
(3) WIRE CONNECTORS
(1) TAB (2) TAPPING
SCREW (3) BODY
(7) FRAME I
BODY =
cover (Е. IA
(6) TAPPING SCREW
(5) TAB (4) TRIM CLIP
2-3
Frame/Body Panels/Exhaust System
Luggage Box
NOTE |
| - The luggage box can be removed together with the seat.
Open the seat.
Remove the two screws and the battery cover.
Open the body cover lid.
Remove the oil tank cap and seal rubber.
Remove the five bolt and the luggage box.
NOTE
- After removing the luggage box, install the seal rubber
and oil tank cap to prevent dirt and dust from entering
the oil tank.
Center Cover
Remove the luggage box. |
Slide the center cover upward to release the two tabs from
the frame body cover and remove the center cover.
Open the fuel tank lid.
Remove the two screws and the fuel tank lid.
(2) BATTERY COVER
(1) SCREWS | (3) BOLTS
(4) OIL TANK
CAP
RUBBER
AG
\
<
MO
AÑ
(6) BODY COVER LID
(7) LUGGAGE BOX
(1) FUEL TANK LID
(2) CENTER COVER
(3) SCREW
_ (4) TABS |
2-4
Frame/Body Panels/Exhaust System
Seat
Open the seat.
Remove the two nuts and the seat.
Floor Board
Remove the frame body cover (page 2-3).
Remove the four bolts.
Raise the rear of the floor board slightly, pull the floor board
rearward to release the tabs and remove it.
Front Cover
Remove the four tapping screws.
Remove the two trim clips.
Remove the three screws.
Release the tabs while pushing both sides of the cover
inward and the remove cover.
NOTE
(1) BOLTS Lx
(3) TAB
¢ When installing, make sure that the tabs are aligned with
the slots properly before tightening the screws.
{4) TRIM CLIPS o -- (3) TAPPING SCREW.
(2) FRONT COVER
(1) SCREW
Frame/Body Panels/Exhaust System
Frame Cover Removal/Installation
Frame Cover Locations
D
© © O
(Side cover @Rear Fender
(Center cover @Front cover
@Frame body cover @Front inner cover
(Floor board ` (ОНапа!е front cover
®Battery cover (dDHandle rear cover
GLuggage box
Frame Cover Removal Chart
« This chart shows removal order of frame covers by means of arrow.
| OFront cover | | | DSide cover | | ОВацегу cover | | | @Handie rear cover |
— | OLuggage box | | @Handle front cover |
| |
| @Center cover |
| @Frame body cover | и
|
—_ — @Floor board po | DRear fender |
|
| @Front inner cover
2-2
Frame/Body Panels/Exhaust System
Front Inner Cover
Remove the floor board (page 2-5).
Remove the front cover (page 2-5).
Remove the four tapping screws attaching the inner cover to
the front fender.
Remove the screw attaching the inner cover to the frame.
Pull the upper portion of the cover back out of the frame.
Slide the cover upward along the frame and remove it.
Remove the six tapping screws and separate the upper and
lower inner covers.
NOTE
| * When installing, align the bosses of the inner cover with
the holes in the frame properly.
Rear Fender
Remove the oil tank (page 4-4).
Remove the ignition coil (page 14-6).
Remove the CDI unit, starter relay switch and fuse holder
from the rear fender.
Remove the rear fender from the frame.
(3) UPPER FRONT INNER COVER
(2) TAPPING SCREW
(4) SCREW
(1) TAPPING SCREW
(5) FRAME
(1) STARTER RELAY SWITCH
(2) CDI UNIT
(4) FUSE HOLDER
(3) REAR FENDER
Frame/Body Panels/Exhaust System
Handle Rear Cover
Remove the rearview mirrors.
Remove the two tapping screws and the screw.
Release the three hooks by pushing down the cover and
sliding it rearward.
Remove the cover from the handlebar.
NOTE
| ‚ When installing, be careful not to pinch the wires. |
Disconnect the speedometer cable from the speedometer.
Disconnect the five connectors from the handlebar
switches.
Remove the three screws and the cover from the instrument
case.
NOTE
(4) TAPPING SCREW
(1) REAR VIEW MIRROR
S
A
(3) HANDLE REAR COVER
- It is not necessary to remove the handle rear cover from
the instrument case to remove the handle front cover.
Handle Front Cover
Remove the handle rear cover from the handlebar.
Remove the two tapping screws and the screw.
Disconnect the headlight connector.
Disconnect the turn signal light wire connectors and remove
the handle front cover.
(1) HANDLE REAR COVER
(2) SCREW
(5) CONNECTOR
| (3) SPEEDOMETER CABLE
(4) INSTRUMENT CASE
(1) TAPPING SCREW
(2) HEADLIGHT CONNECTOR
(3) HANDLE FRONT
A
(5) TURN SIGNAL WIRE
(4) SCREW
2-1
Frame/Body Panels/Exhaust System.
Fuel Tank Removal/Installation
(3) (3)
(5) p< pS
O
(4)
(1)
(8)
(2)
AWARNING | |
| - Gasoline is extremely flammable and is explosive under certain condition. KEEP OUT OF REACH OF CHILDREN.
« Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can
cause a fire or explosion. | |
Requisite Service
* Front inner cover removal/installation (page 2-6)
Procedure O’ty Remarks
Removal Order Installation is in the reverse order of removal.
Fuel tank _ |
(1) | Fuel unit wire connector 1
(2) | Fuel line 1 NOTE
| - Plug or clamp the fuel line to prevent gasoline from
flowing out.
(3) | Fuel tank mounting boit 4
(4) | Floor plate 1
(5) | Fuel tank 1
Fuel level sensor
(6) | Retainer
(7) | Fuel level sensor 1
(8) | Seal rubber 1
2-8
Frame/Body Panels/Exhaust System
Muffler Removal/Installation
(3)
| - Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.
Requisite Service
- Center cover removal/installation (page 2-4)
Procedure : O'ty Remarks
Removal Order Installation is in the reverse order of removal.
(1) | Muffler mounting bolt 2
(2) | Exhaust pipe joint nut 2 Loosen.
(3) | Muffler 1 |
(4) | Exhaust pipe gasket 1
2-9
3. Maintenance
Service Information 3-1 Oil Pump and Oil Line 3-6
Service Access Guide 3-2 Headlight Aim 3-6
Maintenance Schedule 3-4
Service Information
« Refer to Common Service Manual for service procedures of items not included in this manual.
- Refer to Specifications (section 1) for maintenance service data.
Maintenance
Service Access Guide
- The following shows the locations of the parts that must be removed for the maintenance items listed below. Refer to the
Common Service Manual for items not included in this manual.
¢ Refer to section 2 (frame/Body Panels/Exhaust System), for the parts that must be removed for service.
For example: FUEL LINE (Damage, leakage) —— Maintenance part
| - Floor board —— The part that must be removed for service.
(3) THROTTLE GRIP (Operation, free play)
(2) SPARK PLUG (Wear, damage, color)
(4) FRONT BRAKE LEVER
(Operation, free play)
(1) TIRE (Wear, damage, pressure)
(5) HEADLIGHT ADJUSTING SCREW
(Aim: page 3-6)
A
=
(6) STEERING HEAD BEARING
(Damage)
es
oO
O)
of/
Pt]
—
(7) WHEEL
(Damage, runout)
(11) WHEEL (Damage, runout)
(8) SUSPENSION
(Loose, wear, damage)
(10) CYLINDER HEAD (Decarbonizing)
« Frame body cover
(9) TIRE (Wear, damage, pressure)
3-2
Maintenance
(3) OIL PUMP AND OIL LINE
(2) FUEL LINE (Damage, leakage, deterioration) (Adjustmnt: page 3-6)
FUEL FILTER (Clogging) damage, leakage, deterioration)
‚ Floor board » Frame body cover
(4) SUSPENSION
(1) REAR BRAKE LEVER (Loose, wear, damage)
(Operation, free play)
(5) AIR CLEANER (Contamination,
clogging, cleaning)
= we PTT TT
(6) REAR BRAKE
(Brake shoe wear)
|
| |
| |
| |
|
| |
| . |
| |
(9) FRONT BRAKE | |
(Brake shoe wear) | |
(7) CLUTCH (Clutch shoe wear)
À
(8) THROTTLE STOP SCREW
(Idle speed adjustment)
3-3
Maintenance
Maintenance Schedule
Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.
Г: inspect and clean, adjust, lubricate or replace if necessary.
C: Clean R: Replace A: Adjust L: Lubricate
The following items require some mechanical knowledge. Certain items (particularly those marked * and жж) may require
more technical information and tools. Consult your authorized Honda dealer.
U type |
Frequency | Whichever Odometer Reading (Note 1)
frat a> | x 1,000 km 1 4 8 12 Refer to
y x 1,000 mi | 0.6 2.5 5 7.5 page
Items Note - Months 6 12 18
* | Fuel Line I I I Note 3
* | Throttle Operation I I I Note 3
** | Oil Pump and Oil Line I I I 3-6
Air Cleaner Note 2 C C C Note 3
Spark Plug Every 1,600 km (1,000 mi) R Note 3
** | Decarbonizing Every 3,000 km (2,000 mi) C Note 3
* | Carburetor Idle Speed I I I I Note 3
Brake Shoe Wear I I I Note 3
Brake System I I I I Note 3
* | Brake Light Switch I I I Note 3
* | Headlight Aim | I I I 3-6
** | Clutch Shoe Wear | I Note 3
* | Suspension I I I Note 3
* | Nuts, Bolts, Fasteners I I Note 3
** | Wheels/Tires I I I Note 3
** | Steering Head Brearings I I Note 3
* Should be serviced by your 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 only by your authorized Honda dealer.
Notes:
1. At higher odometer reading, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Refer to Common Service Manual.
3-4
Maintenance
CM type
Frequency | Whichever Odometer Reading (Note 1)
Fret md | x 1,000 mi 0.6 2.5 5 7.5 Refer to
y x 1,000 km 1 4 8 12 page
Items Note Months 6 12 18
* | Fuel Line I I I Note 4
* | Throttle Operation I I I Note 4
** | Oil Pump and Oil Line I I I 3-6
Air Cleaner Note 2 C C _ С Моте 4
Spark Plug Note 3 Every 1,000 mi (1,600 km) R Note 4
** | Decarbonizing Note 3 Every 2,000 mi (3,200 km) C Note 4
* | Carburetor Idle Speed I . I I I Note 4
Brake Shoe Wear I I I Note 4
Brake System I I I I Note 4
* | Brake Light Switch I I I Note 4
* | Headlight Aim I I I 3-6
** | Clutch Shoe Wear I Note 4
* | Suspension I I I Note 4
* | Nuts, Bolts, Fasteners I I Note 4
** | Wheels/Tires I I I Note 4
** | Steering Head Brearings I I Note 4
* Should be serviced by your authorized Honda dealer, unless the owner has proper tools and service data and is
mechanically qualified.
жж п the interest of safety, we recommend these items be serviced only by your authorized Honda dealer.
Notes: 1.
At higher odometer reading, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. HONDA 2 STROKE MOTORCYCLE OIL has been specifically tested in 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.
4. Refer to Common Service Manual.
Maintenance
Oil Pump and Oil Line
Oil Pump Control Cable Adjustment
NOTE
- The oil pump control cable should be adjusted after the
throttle grip free play adjustment.
Remove the center cover (page 2-4).
Open the throttle fully and check that the aligning mark on
the oil pump control lever is aligned with the index mark on
the oil pump body.
Adjust by loosening the oil pump control cable lock nut and
turning the adjusting nut.
CAUTION
(1) CONTROL LEVER (2) OIL PUMP BODY
(3) ALIGNING
MARK AND
INDEX MARK
(5) LOCK NUT |
(4) ADJUSTING NUT
- Ап adjustment within 1 mm (0.04 in) of the index
mark on the open side is acceptable. However, the
aligning mark must never be on the closed side of the
index mark, otherwise engine damage will occur
because of insufficient lubrication.
Headlight Aim
‹ Ап improperly adjusted headlight may blind
on-coming drivers, or it may fail to light the road for a
safe distance.
Place the scooter on firm, level ground and suppott it with
the center stand. |
Start the engine and allow it to idle.
Make sure that the headlight and taillight are on.
Check the operation of the headlight dimmer (Lo-Hi) switch.
Adjust the headlight beam by turning the horizontal
adjusting screws.
CAUTION
(1) ADJUSTING SCREWS
- Adjust the headlight beam as specified by local laws
and regulations.
3-6
4. Lubrication System
Service Information | 4-1 Oil Pump Removal/Installation 4-3
Troubleshooting — 4-1 Oil Tank Removal/Installation 4-4
Lubrication System Diagram 4-2 | |
Service Information
CAUTION
- Air in oil system will block or restrict oil flow and may result in severe engine damage.
« Bleed air from the oil lines whenever the oil lines or pump have been removed or there is air in the oil lines
- Bleed air from the oil inlet line first, then bleed air from the oil outlet line.
« The oil pump servicing can be performed with the engine installed.
« When removing and installing the oil pump, be careful not to let any foreign material enter the engine.
« Do not attempt to disassemble the oil pump.
‚ Fill the oil outlet line with oil whenever the oil outlet line is disconnected.
« Refer to section 2 of the Common Service Manual for oil strainer screen cleaning.
‚ When disconnecting the oil inlet tube, clamp or plug the tube to prevent oil from flowing out.
Troubleshooting
Excessive smoke and/or carbon on spark plug
« Faulty oil pump (too much oil flow)
« Low quality engine oil
Overheating or seized piston
« No oil in tank or clogged oil line
‚ Air in oil lines or oil pump
« Faulty oil pump (too little oil flow)
« Clogged oil strainer
« Clogged oil tank cap breather hole
Lubrication System
Lubrication System Diagram
(1) OIL TANK
| (2) OIL INLET TUBE
(3) CARBURETOR
(5) OIL PUMP CONTROL CABLE
(6) OIL PUMP |
Lubrication System
Oil Pump Removal/Installation
NUT
NOTE
- It is not necessary to loosen the oil pump adjusting nut. If the nut is loosened, perform the oil pump control cable
adjustment (page 3-6) after installing the oil pump. | | |
- After installing the oil pump, perform the oil pump/oil line bleeding refering to page 4-11 of the Common Service
Manual. |
Requisite Service
‚ Frame body cover removal/installation (page 2-3)
Procedure | Oty Remarks
Removal Order Installation is in the reverse order of removal.
(1) | Oil inlet tube 1 NOTE
| - Before disconnecting, clamp or plug the tube to prevnt oil
from flowing out.
(2) | Oil outlet tube 1
(3) | Starter motor mounting bolt 1
(4) | Oil pump mounting bolt/harness clamp 1/1 NOTE
| - Be careful not to lose the nut at the oil pump side.
(5) | Clamp 1 Remove from oil pump control cable.
(6) | Oil pump control cable 1 |
(7) | Oil pump 1
(8) | Oil pump mounting collar 1
(9) | O-ring 1
Lubrication System
Oil Tank Removal/Installation
(4) (2)
NOTE
| - After installing the ой tank, perform the ой ритр/ой line bleeding refering to page 4-11 of the Common Service Manual.
Requisite Service
« Battery removal/installation (page 13-4) « Ignition coil removal/installation (page 14-6)
« Rear combination dummy removal/installation (page 16-4)
Procedure | Q'ty | Remarks
Removal Order | Installation is in the reverse order of removal.
(1) | Rear fender mounting bolt
(2) | Oil tank mounting bolt
(3) | Oil level switch connector
(4) | Oil tank
(5) | Oil inlet tube
Slide the rear fender down and remove the tank.
NOTE
+ Disconnect the tube at the oil pump and drain the oil into
the clean container.
— = № = =
(6) | Oil strainer
(7) | Oil level switch
4-4
5. Fuel System
Service Information | 5-1 Carburetor Disassembly/Assembly 5-5
Troubleshooting | 5-2 Reed Valve Removal/Installation 5-6
Carburetor Removal/Installation 5-3 Air Cleaner Case Removal/Installation 5-7
Throttle Valve Disassembly/Assembly 5-4 Fuel Pump Removal/Installation 5-8
Service Information
- Gasoline is extremely flammable and is explosive under certain conditions. |
- Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored
can cause a fire or explosion.
- Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind,
resulting in loss of vehicle control.
« When disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly.
- Before disassembling the carburetor, place a suitable container under the carburetor drain screw, loosen the screw and
drain the carburetor.
« After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with piece of tape to
prevent any foreign material from dropping into the engine.
NOTE
+ If vehicle is to be stored for more than one month, drain the float chamber. Fuel left in the float chamber may cause
clogged jets resulting in hard starting or poor driveability. | |
Fuel System
Troubleshooting
Engine won't start
¢ No fuel to carburetor
— No fuel in fuel tank
— Fuel filter clogged
— Fuel line clogged
— Float valve stuck
— Float level misadjusted
— Fuel tank breather hole clogged
— Fuel pump malfunction
« Too much fuel getting to the engine
— Air cleaner clogged
— Flooded carburetor
- Intake air leak
- Fuel contaminated/deteriorated
« Bystarter circuit clogged
Lean mixture
- Fuel jets clogged
‚ Float valve faulty
- Float level too low
- Fuel line restricted
- Carburetor air vent tube clogged
. Intake air leak
‚ Fuel pump malfunction
- Throttle valve operation faulty
Rich mixture
- Bystarter valve in ON position
- Float valve faulty
- Float level too high
- Air jets clogged
« Air cleaner element contaminated
¢ Flooded carburetor
Engine stalls, hard to start, rough idling
- Fuel line restricted
- Ignition malfunction
« Fuel mixture too lean/rich
- Fuel contaminated/deteriorated
- Intake air leak
- Idle speed misadjusted
- Fuel pump malfunction
- Air screw misadjusted
« Bystarter circuit clogged
+ Float level misadjusted
« Fuel tank breather hole clogged
Afterburn when engine braking is used
« Lean mixture in slow circuit
Backfiring or misfiring during acceleration
- Ignition system faulty
« Fuel mixture too lean
Poor performance (driveability) and poor fuel economy
« Fuel system clogged
« Ignition malfunction
5-2
Fuel System
Carburetor Removal/Installation
DRAIN TUBE
HOLE IN THE SHROUD
(1)
(5)
(10)
Requisite Service
« Center cover removal/installation (page 2-4)
- Air cleaner case removal/installation (page 5-7)
Procedure O'ty Remarks
Removal Order installation is in the reverse order of removal.
(1) | Carburetor top/throttle valve 1 Disassembly/assembly (page 5-4)
(2) | Drain tube 1 Disconnect from the carburetor.
NOTE
+ When installing, insert the other end of the tube into the
hole in the shroud.
(3) | Fuel line 1
(4) | Oil outlet tube 1 NOTE
- Bleed air from the tube when installing.
{5) | Auto bystarter wire connector 1
(6) | Carburetor mounting bolt 2
(7) | O-ring 1
(8) | Insulator 1
(9) | O-ring 1
(10)! Carburetor 1 Disassembly/assembly (page 5-5)
5-3
Fuel System
Throttle Valve Disassembly /Assembly
(3)
(6)
(7)
(CRE —
|
JT
(2)
(4)
(5)
(1)
CAUTION
- The carburetor top is an integral part of the throttle cable assembly. The top cannot be separated from the
assembly without causing damage to the cable.
Requisite Service
+ Carburetor top/throttle valve removal/installation (page 5-3)
Procedure
Q'ty
Remarks
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Disassembly Order
Throttle cable
Throttle vaive spring
Carburetor top gasket
Retainer
Jet needle _
Needle clip
Throttle valve
Assembly is in the reverse order of disassembly.
Remove from the jet needle.
Standard position: 3rd groove
Fuel System
Carburetor Disassembly/Assembly
(1)
(2)
(3)
(9)
(5)
_: Requisite Service
* Carburetor removal/installation (page 5-3)
Procedure
O'ty
Remarks
Disassembly Order
Auto bystarter
(1) | Auto bystarter cover
(2) | Screw
(3) | Auto bystarter set plate
(4) | Auto bystarter
ob eet NN) —
Assembly is.in the reverse order of disassembly.
Float chamber
(5) | Screw
(6) | Float chamber
(7) | O-ring
(8) | Float pin
(9) | Float/float valve
Carburetor body
(10)| Main jet
(11)| Main jet holder
(12)| Needle jet holder
(13)| Slow jet
(14)| Air screw
(15) | Throttle stop screw
(16) | Spring/O-ring |
NOTE
- After installing the carburetor, adjust the idle speed.
5-5
Fuel System
Reed Valve Removal /Installation
(2) EH: (1.0, 7)
(3)
10 (1.0, 7)
(7)
ay
CAUTION
- Do not disassemble or bend the reed stopper. To do so can cause loss of power and engine damage. If the stopper,
reed or valve seat is faulty, replace them as a unit. |
Requisite Service
- Luggage box removal/installation (page 2-4) Carburetor removal/installation (page 5-3)
Procedure Q'ty | Remarks
Removal Order Installation is in the reverse order of removal.
(1) | Left shroud mounting bolt 2
(2) | Left shroud 1
(3) | Intake manifold mounting bolt/clamp 4/1
(4) | Intake manifold 1
(5) | Gasket 1
(6) | Reed valve 1
(7) | Gasket 1
Fuel System
(4)
(3)
(6)
(2)
Air Cleaner Case Removal/Installation
(6)
(5)
(6) e) 12 (1.2, 9)
Procedure Q'ty Remarks.
Removal Order Installation is in the reverse order of removal.
(1) | Tapping screw 5
(2) | Air cleaner case cover 1
(3) | Air cleaner element 1
(4) | Connecting tube band screw 1 Loosen.
(5) | Breather tube 1 Disconnect from the air cleaner case.
(6) | Air cleaner case mounting bolt/nut 2/1 NOTE
« Do not lose the nut.
(7) | Air cleaner case 1
5-7
Fuel System
Fuel Pump Removal/Installation
(2)
(3)
(1)
a +
TT TE (5)
_ (4)
| (6)
NOTE
- Do not attempt to disassemble the fuel pump.
- After installing the fuel pump, bleed air from the fuel lines and pump.
Requisite Service
« Floor board removal/installation (page 2-5)
Procedure O’ty Remarks
Removal Order Installation is in the reverse order of removal.
(1) | Bolt 2
(2) | Fuel pump 1 Inspection (page 5-9)
-Air bleeding (page 5-9)
(3) | Fuel line (discharge side) 1
(4) | Fuel line (suction side) | 1
(5) | Vacuum tube 1 NOTE
« When installing, do not connect the vacuum tube to the
fuel suction pipe of the pump.
(6) | Fuel filter 1
5-8
Fuel System
Fuel Pump Inspection
NOTE
- Before inspecting the pump discharge volume, warm up
the engine and check that the idle speed is within the
specification.
Start the engine and allow it to idle.
Disconnect the fuel line from the carburetor, allow the fuel
to flow out of the fuel line for more than 5 seconds, then let
the fuel flow into the graduated beaker for 10 seconds. Stop
the engine and connect the fuel line.
There should be 20 cc (0.70 US oz, 0.67 Imp oz) in the
beaker.
№ the fuel pump discharge volume is less than specified
volume, check the fuel lines, vacuum tube and fuel filter for
clogging or damage. If they are OK, replace the fuel pump.
Air Bleeding
After replacing the fuel pump, bleed the air from the pump
and fuel lines as follows:
Disconnect the fuel line from the carburetor and feed the
gasoline from the other container through the suitable fuet
tube.
Start the engine and allow it to idle to operate the fue! pump
until the fuel flows out of the fuel line.
Stop the engine and connect the fuel line to the carburetor.
(1) FUEL LINE
(2) BEAKER
(1) FUEL LINE >
=—A
+
=) ee |
AV MAO =
ESAS (2) GASOLINE
ACS a CONTAINER
6. Engine Removal /Installation
Service Information | 6-1 Engine Removal/Installation 6-2
Service Information
- The following components require engine removal for service:
— Driveshaft and final gear shaft bearings (section 9)
— Crankcase (section 10)
— Crankshaft (section 10)
- After installing the engine, perform the following adjustments:
— Throttle cable
— Oil pump control cable (page 3-6)
— Rear brake cable
6-1
Engine Removal/Installation
Engine Removal/Installation
=,
ne
a
Engine Removal/Installation
Requisite Service
‚ Frame body cover removal/installation (page 2-3)
- Carburetor top/throttle valve removal/installation (page 5-3)
Procedure Q'ty Remarks
Removal Order Installation is in the reverse order of removal.
(1) | Alternator/starter motor wire connector 2
(2) | Auto bystarter wire cennector 1
(3) | Oil inlet tube 1 NOTE
- Before disconnecting, clamp or plug the tube to prevent
oil from flowing out.
(4) | Fuel line 1
(5) | Carburetor top 1
(6) | Fuel pump vacuum tube 1
(7) | Spark plug cap 1
(8) | Oil pump control cable 1 Disconnect from pump and remove from cable stay.
(9) | Rear brake cable 1 Remove from the rear brake arm, crankcase and clamp.
(10)| Rear shock absorber upper mounting bolt 1
(11) Engine mounting bolt/nut | 1/1
(12)| Engine 1 NOTE
- Support the frame securely.
(13)| Engine mounting bracket bolt/nut 1/1
(14): Engine mounting bracket 1
7. Cylinder Head/Cylinder/Piston
Service Information 7-1
Cylinder Head, Cylinder and Piston
Removal/Installation
7-2
Troubleshooting 7-1
Service Information
. Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before
inspection.
- Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike the
cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to the
cylinder fins.
« Take care not to damage the cylinder wall and piston.
Troubleshooting
Compression too low, hard starting or poor performance at low speed
- Cylinder head
— Leaking or damaged cylinder head gasket
— Warped or cracked cylinder head
« Loose spark plug
- Worn, stuck or broken piston rings
- Worn or damaged cylinder and piston
- Leaking crankcase primary compression
— Blown crankcase gasket
— Damaged crankshaft oil seal
Compression too high, overheating or knocking
« Excessive carbon build-up on piston or combustion chamber
Abnormal noise
- Worn cylinder, piston, piston ring
- Worn piston pin or piston pin hole
«Worn connecting rod small end bearing
7-1
Cylinder Head/Cylinder/Piston
_ Cylinder Head, Cylinder and Piston Removal/Installation
7-2
Cylinder Head/Cylinder/Piston
Requisite Service
- Muffler removal/installation (page 2-9)
« Fan cover removal/installation (page 13-8)
« Left shroud removal/installation (page 5-6)
Procedure Q'ty Remarks
Removal Order Installation is in the reverse order of removal.
Cylinder head
(1) | Spark plug 1
(2) | Cylinder head boit 4 Loosen the bolts in a crisscross pattern in 2 or 3 steps.
{3) | Cylinder head 1 |
(4) | Cylinder head gasket 1
Cylinder
(5) | Cylinder 1 CAUTION |
« Do not pry between the cylinder and crankcase or strike
the fins.
(6) | Cylinder gasket 1 NOTE
« Clean the gasket surfaces of the cylinder and crankcase
being careful not to damage them.
Piston
(7) | Piston pin clip 2
(8) | Piston pin 1
(9) | Piston 1
(10)| Piston ring 2
(11)| Expander 1 Install the expander behind the second ring.
1(12)| Connecting rod small end bearing 1
7-3
8. Kickstarter/Drive Pulley/Clutch/Driven Pulley
Service Information 8-1 Drive Pulley and Clutch/Driven Pulley
Troubleshooting 8-1 Removal/Installation | 8-5
Movable Drive Face Disassembly/
Left Crankcase Cover Removal/
Installation 8-2 Assembly 8-7
. . L Clutch/Driven Pulley Disassembly/
Kickstarter Removal /Installation 8-3 Assembly 8-8
Service Information
NOTE
| - Do not apply grease to the movable drive face and weight rollers. |
- Avoid getting grease and oil on the V-belt and pulley drive faces in order to prevent belt slippage.
- Never operate the starter motor with the left crankcase front cover removed.
Troubleshooting
Engine starts but scooter won't move
- Worn drive belt
‚ Damaged ramp plate
+ Worn or damaged clutch lining
- Broken driven face spring
Engine stalls or scooter creeps
« Broken clutch shoe spring
Poor performance at high speed or lack of power
‚ Worn drive belt
« Weak driven face spring
+ Worn weight rollers
- Contaminated pulley faces
8-1
Kickstarter/Drive Pulley/Clutch/Driven Pulley
Left Crankcase Cover Removal /Installation
(6)
oy
(5)
Procedure O'ty Remarks
Removal Order Installation is in the reverse order of removal.
(1) | 6 mm special bolt 5
(2) | Left crankcase rear cover 1 Push down the kickstarter pedal and remove the cover.
(3) | Rubber gasket 1 NOTE
- Replace with a new one if damaged.
(4) | 6 mm bolt 5 NOTE
- When installing, do not forget to install the cable clamps
in position.
(5) | Left crankcase front cover 1
(6) | Gasket 1
(7) | Dowel pin 2
8-2
Kickstarter/Drive Pulley/Clutch/Driven Pulley
Kickstarter Removal /Installation
(3)
Requisite Service
« Left crankcase cover removal/installation (page 8-2)
Procedure
Q'ty
Remarks
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Removal Order
Kickstarter driven gear
Thrust washer
Bolt
Kickstarter pedal
Snap ring
Washer
Copper washer
Kickstarter spindle
Kickstarter return spring
Spindle bushing
à
Installation is in the reverse order of removal.
Rmove while turning the kickstarter pedal.
Installation (page 8-4)
-Inspectin (page 8-4)
Uhook the return spring end first and remove.
8-3
Kickstarter/Drive Pulley/Clutch/Driven Pulley
Kickstarter Inspection
Check the kickstarter spindle for wear or damage.
Check the kickstarter return spring for weakness or damage.
Check the spindle bushing for wear, scratches or scoring.
Check the kickstarter driven gear for wear or damage.
Check the friction spring for weakness or damage.
Check the spindle and driven gear bearings for wear or
damage.
Kickstarter Driven Gear Installation
Align the friction spring with the boss on the crankcase front
cover and install the driven gear while turning the kickstarter
pedal.
Engage the spindle gear and driven gear while returning the
kickstarter pedal.
(3) KICKSTARTER
(1) RETURN SPRING
SPINDLE (2) SPINDLE BUSHING
(1) FRICTION SPRING
(2) DRIVEN GEAR
(1) SPINDLE BEARING
(2) DRIVEN GEAR BEARING
(1) DRIVEN GEAR (2) FRICTION SPRING
Kickstarter/Drive Pulley/Clutch/Driven Pulley
Drive Pulley and Clutch/driven Pulley Removal /Installation
(2)
Requisite Service
« Left crankcase cover removal/installation (page 8-2)
Procedure Q'ty Remarks
Removal Order Installation is in the reverse order of removal.
(1) | Nut
(2) | Washer
(3) | Drive pulley face Removal/installation (page 8-6)
(4) | Starter pinion
(5) | Drive belt
(6) | Movable drive face
(7) | Movable drve face boss
(8) | Clutch outer nut
(9) | Clutch outer
(10)| Clutch/driven pulley
Disassembly/assembly (page 8-7)
Removal/installation (page 8-6)
ti А ed eu ee 3 => > —
Disassembly/assembly (page 8-8)
8-5
Kickstarter/Drive Pulley/Clutch/Driven Pulley
Drive Pulley Face Removal/installation
Hold the drive pulley face with the clutch center holder and
remove the nut.
Remove the washer and drive pulley face from the
crankshaft.
Clutch center holder | 07724 - 0050001
Installation is in the reverse order of removal.
NOTE
- Align the splines of the drive pulley face and crankshaft
(1) DRIVE PULLEY FACE (2) NUT
у
и
а
7
N
p>
y
K
NX
properly.
Clutch Outer Nut Removal/Installation
Hold the clutch outer with the universal holder and remove
the clutch outer nut.
|
Universal holder 07725 —0030000
Installation is in the reverse order of removal.
(3) UNIVERSAL HOLDER
8-6
Kickstarter/Drive Pulley/Clutch/Driven Pulley
Movable Drive Face Disassembly/Assembly
(6)
Requisite Service
‚ Movable drive face removal/installation (page 8-5) _
Procedure O'ty Remarks
Disassembly Order Assembly is in the reverse order of disassembly.
(1) | Вон 3
(2) | Face seal 1
(3) | Ramp plate 1
(4) | Slide piece 3
(5) | Weight roller 6 NOTE
(6) | Movable drive face 1 « Do not apply grease to the movable drive face and weight
rollers.
Kickstarter/Drive Pulley/Clutch/Driven Pulley
Clutch/Driven Pulley Disassembly/Assembly
LONG SHORT
(WHITE PAINT)
| Requisite Service
- Clutch/driven puley removal/installation (page 8-5)
Procedure Q'ty | Remarks
Disassembly Order |
(1) | 28 mm special nut
(2) | Clutch assembly
à à
(a) | Snap ring 3
(b) | Washer 3
(c) | Clutch shoe 3
(d) | Clutch shoe spring 3
(e) | Dampr rubber 3
(f) | Clutch drive plate 1
(3) | Spring collar 1
(4) | Driven face spring 1
(5) | Seal collar 1 NOTE
« When removing, be careful not to damage or deform.
(6) | Guide pin
(7) | Movable driven face
(8) | O-ring
(9) | Oil seal
(10) | Inner bearing
(11)| Snap ring
(12)| Outer bearing
(13)| Driven face _
NN N
8-8
Kickstarter/Drive Pulley/Clutch/Driven Pulley
Procedure
Q'ty
Remarks
(13)
(12)
(11)
(10)
(9)
(8)
(7)
(6)
‚ (5)
(4)
(3)
Assembly Order
Driven face
Outer bearing
Snap ring
Inner bearing
Oil seal
O-ring
Movable driven face
Guide pin
Seal collar
Driven face spring
Spring collar
NOTE
« Pack 5.0-5.5 g (0.18-0.19 oz) of specified grease to
the inside when installing.
Drive in with the sealed side facing down.
Press in with the sealed side facing up
(f)
(e)
(c)
(b)
(a)
(d)
Clutch drive plate
Damper rubber
Cluch shoe
Washer
Snap ring
Clutch shoe spring
0 Yu >
NOTE
‚ Note the installation direction.
(2)
(1)
Clutch assembly
28 mm special nut
aud à
28 mm Special Nut Removal/Installation
Align the holes in the clutch spring compressor with the
bosses on the clutch drive plate and install the compressor
on the clutch/driven pulley.
Clutch spring compressor
Hold the clutch spring compressor in a vise.
07960 - KM10000
Remove the 28 mm special nut with the socket wrench.
Socket wrench
Installation is in the reverse order of removal.
07GMA-KS40100
(2) CLUTCH SPRING
(1) CLUTCH/DRIVEN COMPRESSOR
PULLEY
(1) SOCKET WRENCH
(2) CLUTCH SPRING
COMPRESSOR
8-9
9. Final Reduction
Service Information 9-1 Final Reduction Disassembly/Assembly 9-2
Troubleshooting 9-1
Service Information
+ The final reduction servicing can be performed with the engine installed in the frame. However, it is necessary to remove
the engine from the frame and remove the rear brake from the left crankcase to prevent the crankcase from damage when
the bearings in the left crankcase are to be repiaced.
« When installing the driveshaft, be sure to use the special tool; position the special tool against the bearing inner race and
pull the driveshaft into the bearing.
Troubleshooting
Engine starts but scooter won L move
« Damaged transmission
« Seized transmission
Abnormal noise
« Worn, seized or chipped gears
+ Worn or damaged bearings
Oil leaks
« Oil level too high
« Worn or damaged oil seal
“ « Cracked crankcase
9-1
Final Reduction
Final Reduction Disassembly/Assembly
Requisite Service |
- Rear wheel removal/installation (page 12-2)
- Air cleaner case removal/installation (page 5-7)
- Clutch/driven pulley removal/installation (page 8-5)
Procedure Q'ty Remarks
Disassembly Order Assembly is in the reverse order of disassembly.
(1) | 6 mm bolt 5 |
(2) | Transmisson cover 1
(3) | Gasket 1
(4) | Dowel pin 2
(5) | Final gear shaft 1
(6) | Thrust washer 1
(7) | Countershaft/gear 1/1
(8) | Thrust washer 1
(9) | Driveshaft 1 Replacement (page 9-3)
9-2
Final Reduction
Driveshaft Replacement
Press the driveshaft out of the transmission cover.
NOTE
| « Be careful not to damage the cover mating surface. |
Shaft protector 07931 - 1870000
Remove the driveshaft oil seal and bearing from the
transmission cover. Ä
Drive a new bearing into the transmission cover with the
marking facing out.
|
Driver | 07749-0010000
Attachment, 37 x 40 mm 07746 —0010200
Pilot, 17 mm 07746 -0040400
Pull the driveshaft into the bearing in the transmission cover.
Crankcase assembly collar 07965 —- GMOO100
Crankcase assembly shaft 07965 — GMO0300
Install a new driveshaft oil seal.
(1) SHAFT
PROTECTOR
(2) DRIVESHAFT
(3) TRANSMISSION COVER
(1) OIL SEAL (2) BEARING
(3) ATTACHMENT, 37 x 40 mm
(1) CRANKCASE ASSEMBLY COLLAR
(2) CRANKCASE ASSEMBLY SHAFT
9-3
10. Crankcase/Crankshaft
Service Information | 10-1 Crankcase Separation/Assembly 10-2
Troubleshooting 10-1
Service Information
« This section covers the crankcase separation to service the crankshaft.
« The following parts must be removed before separating the crankcase:
— Oil pump (page 4-3)
— Carburetor (page 5-3)
— Reed valve (page 5-6)
— Engine (section 6)
— Cylinder head, cylinder, piston (page 7-2)
— Drive pulley (page 8-5)
— Alternator (page 13-8)
— Starter motor (page 15-4)
In addition to the parts listed above, remove the following parts when the left crankcase half must be removed:
— Driven pulley (page 8-5)
— Final reduction (page 9-2)
— Rear brake (page 12-3)
- The crankcase separation/assembly and the crankshaft removal/installation require special tools.
When assembling the crankcases, be sure to use the special tools; position the special tool against the bearing inner race
and pull the crankshaft into the bearing in the crankcase. Therefore, if the bearings stay on the crankshaft after removing
the crankshaft, remove them and drive new bearings into the crankcases. Also, be sure to install new oil seals.
Troubleshooting
Excessive noise
+ Worn connecting rod big end bearing
- Worn connecting rod small end bearing
« Worn crankshaft main journal bearing
10-1
Crankcase/Crankshaft
Crankcase Separation/Assembly
(8)
Es
(3)
(5)
Ed
VTT
(1)
©
О (1.0, 7)
Requisite Service
- Refer to page 10-1 for the parts that must be removed before separating the crankcase.
Procedure Q'ty
Remarks
Separation Order
Crankcase bolt
Right crankcase
Dowel pin
Crankshaft
Right oil seal
Left oil seal
(1)
(2)
(3)
(4)
(5)
|
Separation {page 10-3)
(6)
(7)
(8)
Right bearing
Left bearing
2 + — N = 0)
LI
Removal (page 10-3)
Assembly Order
Right bearing
Left bearing
Crankshaft
Left oil seal
Dowel pin
Right crankcase
Right oil seal
Crankcase bot
(7)
(8)
(4)
(6)
(3)
(2)
(5)
(1)
чан
© — — N - ss do
-Installation (раде 10-4)
-АззетЫу (раде 10-5)
10-2
Crankcase/Crankshaft
Crankcase Separation
Screw the case puller shaft onto the crankshaft end.
Attach the case puller by threading the bolts into the bolt
holes of the stator.
Separate the crankcase by turning the case puller shaft
clockwise.
Case puller
Shaft protector
07935 — GK80000
07931 — 1870000
Crankshaft Removal
Attach the case/driven gear puller on the left crankcase as
shown, and remove the crankshaft by turning the puller
shaft clockwise.
Case/driven gear puller
Shaft protector
07935 - KG80000
07931 - 1870000
NOTE
(1) CASE PULLER
(2) SHAFT
PROTECTOR
| - Do not remove the crankshaft by tapping it.
Remove the right and left oil seals from the crankcases.
Remove the right and left bearings from the crankcases.
When the bearing stays on the crankshaft, remove it with
the universal bearing puller.
Universal bearing puller
Shaft protector
07631 -0010000
07931 — 1870000
NOTE
(3) SHAFT
PROTECTOR
(4) LEFT CRANKCASE
- Replace the crankshaft bearings and oil seals with new
ones when the crankcase is separated. |
Crankshaft Installation
Wash the crankcase in solvent and blow dry with
compressed air.
Check the crankcases for cranks or other faults.
Apply clean 2-stroke engine oil to all moving and sliding
surfaces.
Remove all gasket material from the crankcase mating
surfaces.
Dress any roughness or irregularities with an oil stone.
(1) SHAFT PROTECTOR
(2) UNIVERSAL BEARING PULLER
10-3
Crankcase/Crankshaft
Drive a new crankshaft bearing into the right crankcase.
Driver 07749 —0010000
Attachment, 52 x 55 mm 07746 —0010400
Pilot, 20 mm 07746 —0040500
Drive a new crankshaft bearing into the left crankcase.
Driver 07749 —0010000
Attachment, 52 x 55 mm 07746 —0010400
Pilot, 20 mm 07746 —0040500
Pisition the assembly collar against the crankshaft bearing.
Thread the assembly shaft onto the crankshaft.
Hold the assembly shaft and turn the nut counterclockwise
to draw the crankshaft into the bearing inner race in the left
crankcase.
Crankcase assembly collar 07965 - GMO0100
Crankcase assembly shaft 07965 — 1660200
CAUTION
- Be careful not to let the connecting rod press against
the crankcase mating surface while drawing the
crankshaft.
Install a new left crankcase oil seal until it is 1.0 + 0.5 mm
(0.04 + 0.02 in) below the surface of the left crankcase as
shown.
(2) ATTACHMENT,
52 x 55 mm
(3) PILOT, 20 mm
7 DRIVER
El эл
(3) ATTACHMENT, SEE EE —_
52 x 55 mm (2) PILOT, 20 mm
(1) CRANKCASE ASSEMBLY COLLAR
(2) CONNECTING ROD
| S ый
JA DS SD SS
ое »
IS ES
DS
(3) CRANKCASE ASSEMBLY SHAFT
(1) OIL SEAL
ome
S Е
(2) LEFT CRANKCASE
1.0 + 0.5 mm
(0.04 + 0.02 in)
т
10-4
Crankcase/Crankshaft
Crankcase Assembly
Apply liquid sealant to the crankcase mating surfaces and
install the dowel pins.
Install the right crankcase over the left crankcase.
Place the crankcase assembly collar against the bearing
inner race in the right crankcase. Thread the assembly shaft
onto the crankshaft.
Hold the assembly shaft and turn the nut counterclockwise
to draw the crankcase halves together.
Crankcase assembly collar 07965-GM00100
Crankcase assembly shaft 07965-GM00300
Install a new right crankcase oil seal using the crankcase
assmbly collar and shaft until it is 5.0 + 0.5 тт (0.20 + O.
02 in) below the surface of the right crankcase as shown.
Crankcase assembly collar 07965-GM00100
Crankcase assembly shaft 07965-GM00300
(1) CRANKCASE ASSEMBLY
(1) CRANKCASE ASSEMBLY 5.0 + O.
SHAFT 20 +
| (2) OIL SEAL
(3) CRANKCASE ASSEMBLY COLLAR
10-5
11. Front Wheel/Suspension/Steering/Brake
Service Information 11-1 Throttle Housing Removal/Installation 11-5
Troubleshooting 11-1 Handlebar Removal/Installation 11-6
Front Wheel Removal/Installation 11-2 Steering Stem Removal /Installation 11-7
Front Wheel Disassembly/Assembly 11-3 Fork Disassembly/Assembly 11-9
Front Brake Panel Disassembly/
Assembly 11-4
Service Information
- Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry
brush to clean brake assemblies. Use a vacuum cleaner or alternate method to minimize the hazard caused by
airborne asbestos fibers.
- A contaminated brake drum or lining reduces stopping power. Discard contaminated linings and clean a
contaminated drum with a high quality brake degreasing agent. |
* Always check the brake operation before riding the scooter.
Troubleshooting
Hard steering Poor brake performance
« Steering top cone race too tight | - Improperly adjusted brake
« Worn or damaged steering stem bearings - Worn brake linings
- Worn or damaged steering stem bearing races «Worn brake drum
- Insufficient tire pressure - Worn brake cam
- Improperly installed brake linings
Steers to one side or does not track straight - Brake cable sticking/needs lubrication
‚ Bent fork . + Contaminated brake linings
« Bent front axle + Contaminated brake drum
- Faulty steering stem bearings «Worn brake shoes at cam contact areas
- Bent frame - Improper engagement between brake arm and cam
+ Worn or damaged wheel bearings serrations |
Front wheel wobbling Brake lever hard or slow to return
- Bent rim * Worn/broken return spring
« Worn front wheel bearings - Improperly adjusted brake |
+ Faulty tire | - Sticking brake drum due to contamination
| | - Worn brake shoes at cam contact areas
Wheel turns hard « Brake cable sticking/needs lubrication
‚ Misadjusted brake « Worn brake cam
« Faulty wheel bearings - Improperly installed brake linings
Soft suspension | | Brake squeaks
« Weak fork springs + Worn brake linings
- Worn brake drum
Front suspension noise « Contaminated brake linings
« Fork spring binding - Contaminated brake drum
« Loose fork fasteners
11-1
Front Wheel/Suspension/Steering/Brake
Front Wheel Removal/Installation
(7)
NOTE
| - After installing the front wheel, adjust the front brake.
Requisite Service
When removing the front fender:
« Front inner cover (page 2-6)
« Side cover removal/installation (page 2-3)
Procedure
Q
3
Remarks
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Removal Order
Speedometer cable set screw
Speedometer cable
Front brake adjusting nut
Front brake cable
Brake arm joint
Front axle nut
Front axle
Front wheel
Side collar
Front brake panel
Front fender
— >= 3 er nd ee el E ouh u EN
Installation is in the reverse order of removal.
Disassembly/Assembly (page 11-3)
Disassemly/assembly (page 11-4)
11-2
Front Wheel/Suspension/Steering/Brake
Front Wheel Disassembly/Assembly
(4)
(2) (1)
Requisite Service
+ Front wheel removal/installation (page 11-2) |
Procedure Q'ty Remarks
Disassembly Order Assembly is in the reverse order of disassembly.
(1) | Dust seal 1
(2) | Right wheel bearing (6200U) 1
(3) | Distance collar 1
(4) | Left wheel bearing (6200U) 1
11-3
Front Wheel /Suspension/Steering/Brake
Front Brake Panel Disassembly/Assembly
:
Е
=
©
Requisite Service
« Front wheel removal/instalation (page 11-2)
Procedure Q'ty Remarks
Disassembly Order Assembly is in the reverse order of disassembly.
(1) | Brake shoe/shoe spring 2/2
(2) | Brake arm bolt/nut 1/1 .
(3) | Brake arm 1 When installing, align the punch mark on the arm with the
index mark on the brake cam.
(4) | Wear indicator 1 .
(5) | Return spring 1
(6) | Brake cam 1
(7) | Felt seal 1
(8) | Dust seal 1
(9) | Speedometer drive gear 1
(10) | Brake panel 1
11-4
Front Wheel /Suspension/Steering/ Brake
Throttle Housing Removal/Installation
(9)
~ (4)
Requisite Service
« Handle cover removal/installation (page 2-7)
Procedure Q'ty | | Remarks
Removal Order Installation is in the reverse order of removal.
Front brake lever
(1) | Nut 1
(2) | Front brake lever pivot screw 1
(3) | Front brake lever 1
(4) | Front brake cable 1
Throttle housing
(5) | Bolt 1
(6) | Upper throttle housing 1 When installing, hook the slot in the upper housing to the
tab of the lower housing. .
(7) | Lower throttle housing 1 When installing, align the boss on the housing with the hole
in the handlebar.
| (8) | Throttle cable 1
(9) | Throttle grip | 1
11-5
Front Wheel/Suspension/Steering/Brake
Handlebar Removal /Installation
(9)
BOSS
(11)
(12)
Requisite Service
- Throttle housing removal/installation (page 11-5)
(12)| Handle grip
Procedure Q'ty Remarks
Removal Order installation is in the reverse order of removal.
Rear brake lever
(1) | Nut 1
(2) | Rear brake lever pivot screw 1
(3) | Rear brake lever 1
(4) | Rear brake cable 1
Rear brake lever bracket
(5) | Bolt 1 |
(6) | Lever bracket band 1 When installing, hook the slot in the band to the tab of thé
lever bracket.
(7) | Rear brake lever bracket 1 Whn installing, align the boss on the bracket with the hole
in the handlebar.
(8) | Nut 1
(9) | Handlebar pinch bolt 1
(10) | Washer 2
(11) | Handlebar 1 When installing, align the boss of the handlebar with the
groove in the steering stem.
11-6
Front Wheel/Suspension/Steering/Brake
Steering Stem Removal/Installation
o (1)
27 (2.7, 20) (4) 70 (7.0, 51)
(9) e
(2)
(8)
(6)
(page 1-11)
(5)
Requisite Service |
« Front wheel removal/installation (page 11-2) « Handlebar removal/installation (page 11-6)
- Procedure | Q'ty Remarks
Removal Order Installation is in the reverse order of removal.
Steering stem
(1) | Steering stem lock nut 1 Typ installation (page 11-8)
(2) | Top cone race 1
(3) | Steering stem 1
Steering stem bearings/races
(4) | Steering stem bearing 2
(5) | Bottom cone race 1
(6) | Ball race | 2
Front inner fender
(7) | Attaching bolt 2
(8) | Front inner fender 1
Fork
(9) | Fork pinch bolt 4 NOTE
| « The upper pinch bolts are the locating bolts.
(10)| Fork 2 Disassembly/Assembly (page 11-9)
11-7
Front Wheel/Suspension/Steering/Brake
| Top Cone Race/Stem Lock Nut Installation
Install the top cone race and hand-tighten it.
Rotate the steering stem lock-to-lock several times to seat AX
the bearings.
_ Make sure that the steering stem rotates smoothly without
vertical play.
(1) LOCK NUT WRENCH A
Cm
Hold the top cone race and tighten the steering stem lock
nut. | Ps Dd CA
> 7
Torque: 70 N-m (7.0 kg-m, 51 Я-№)
(2) LOCK NUT WRENCH B
Lock nut wrench A 07916—KM10000
Lock nut wrench B 07916 — 1870100
11-3
Front Wheel/Suspension/Steering/Brake
Fork Disassembly/Assembly
1
и
\ |
QS -==
15_2
| \ a a (0.05-0.07 oz)
aa
(4) | (page 1-11) / /
page 7
„ Susi — ISSO
|
Requisite Service
‚ Fork removal/installation (page 11-7)
Procedure
Оу
Remarks
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
‘Disassembly Order
Fork tube cap
Dust seal
Snap ring
Bushing
Rebound spring
Fork tube
Fork spring
Stopper rubber
Bottom case
md nd = ot at à
Assembly is in the reverse order of disassembly.
NOTE
- After installation, pack 1.5—2 д (0.05-0.07 oz) of
grease between the bottom case and fork tube as shown.
11-9
12. Rear Wheel/Suspension/Brake
Service Information | 12-1 Rear Brake Disassembly/Assembly 12-3
Troubleshooting 12-1 Shock Absorber Removal /Installation 12-4
Rear Wheel Removal/installation 12-2
Service Information
- Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry
brush to clean brake assemblies. Use a vacuum cleaner or alternate method to minimize the hazard caused by
airborne asbestos fibers. . | u
- А contaminated brake drum or lining reduces stopping power. Discard contaminated linings and clean a
contaminated drum with a high quality brake degreasing agent.
- Always check the brake operation before riding the scooter.
Troubleshooting
Rear wheel wobbling Poor brake performance
‚ Bent rim | - Improperly adjusted brake
- Axle nut not tightened properly - Worn brake linings
‚ Faulty tire - Worn brake drum
- Insufficient tire pressure - Worn brake cam
+ Improperly installed brake linings
Wheel turns hard - Brake cable sticking/needs lubrication
« Misadjusted brake
* Faulty wheel bearings
Soft suspension
- Weak shock absorber spring
- Oil leakage from damper unit
Hard suspension
- Bent damper rod
Rear suspension noise
« Shock absorber spring binding
- Contaminated brake linings
- Contaminated brake drum
- Worn brake shoes at cam contact areas
-Improper engagement between brake arm and cam
serrations
Brake lever hard or slow to return
« Worn/broken return spring
- Irproperly adjusted brake
* Sticking brake drum due to contamination
+ Worn brake shoes at cam contact areas
« Brake cable sticking/needs lubrication
- Worn brake cam
- Improperly installed brake linings
Brake squeaks
« Worn brake linings
- Worn brake drum
- Contaminated brake linings
+ Contaminated brake drum
12-1
Rear Wheel/Suspension/Brake
Rear Wheel Removal /Installation
\ (2)
Requisite Service
« Muffler removal/installation (page 2-9)
Procedure
Q'ty
Remarks
Removal Order
(1) | Rear axle nut
(2) | Washer
(3) | Rear wheel
Installation is in the reverse order of removal.
12-2
Rear Wheel/Suspension/Brake
Rear Brake Disassembly/Assembly
(8)
NOTE
| - After installing the rear wheel, adjust the rear brake.
Requisite Service
- Rear wheel removal/installation (page 12-2)
Procedure
Q'ty
Remarks
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Disassembly Order
Rear brake adjusting nut
Rear brake cable
Brake arm joint
Brake shoe/shoe spring
Return spring
Brake arm bolt
Brake arm
Wear indicator
Felt seal
Brake cam
Assembly is in the reverse order of disassembly.
When installing, align the punch mark with the wide groove
in the brake cam.
12-3
Rear Wheel/Suspension/Brake
Shock Absorber Removal /Installation
(2)
©
40 (4.0, 29)
27 (2.7, 20)
NOTE
| « Do not attempt to disassemble the shock absorber. Replace it as an assembly.
Requisite Service
« Frame body cover removal/installation (page 2-3)
Procedure
O'ty |
Remarks
(1)
(2)
(3)
Removal Order
Lower mounting bolt
Upper mounting bolt :
Shock absorber
Installation is in the reverse order of removal.
12-4
13. Charging System/Alternator
Service Information 13-1 Lighting Voltage Inspection 13-6
System Location 13-2 Regulator/Rectifier Inspection 13-6
_ Troubleshooting 13-3 Alternator Removal/Installation 13-8
Battery Removal/Installation 13-4 Alternator Inspection 13-9
Charging System Inspection 13-5 Resistor Inspection 13-9
Service Information
A WARRING
° The battery gives off explosive gases; keep sparks, flames, and cigarettes away. Provide adequate ventilation
when charging or using the battery in an enclosed space.
« The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective
clothing and a face shield.
— If electrolyte gets on your skin, flush with water.
— If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
+ Electrolyte is poisonous. If swallowed, drink large quantities of water or milk and follow with milk of magnesia
or vegetable oil and call a physician.
- KEEP OUT OF REACH OF CHILDREN.
- Always turn off the ignition switch before disconnecting any electrical component.
CAUTION
- Some electrical components may be damaged if terminals or connectors are connected or disconnected while the
ignition switch is ON and current is present.
« For extended storage, remove the battery, give it a full charge, and store it in a cool, dry place.
« For battery remaining in a stored scooter, disconnect the negative battery cable from the battery terminal.
NOTE |
| ‚ The maintenance free battery must be replaced when it reaches the end of its service life. |
CAUTION
- The battery caps should not be removed. Attempting to remove the sealing caps from the cells may damage the
battery.
- Battery can be damaged if overcharged or undercharged, or if left to discharge for long periods. These same conditions
contribute to shortening the “life span” of the battery. Even under mormal use, the performance of battery deteriorates
after 2-3 years.
- Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventually
die out. For this reason, the charging system is often suspected to be the problem. Battery overcharge often results from
problems in the battery itself, which may appear to be an overcharge symptom. If one of the battery cells is shorted and
battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions,
the electrolyte level goes down quickly.
- Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery
is frequently under heavy load.
+ The battery will self-discharge when the scooter is not in use. For this reason, charge the battery every two weeks to
prevent sulfation from forming.
* Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance, always
charge the battery. Also, the battery life is lengthened when it is initial-charged.
« When checking the charging system, always follow the steps in the troubleshooting flow chart (page 13-3).
- For battery testing/charging, refer to section 22 of the Common Service Manual.
‚ For charging system location, see page 13-2.
13-1
Charging System/Alternator
System Location
(1) BATTERY
(3) RESISTOR
(4) ALTERNATOR
| | | (8) FUSE (10A)
1 G
Y Ww G R
| 4 J i
(5) ALTERNATOR (7) REGULATOR/
RECTIFIER
(9) BATTERY
Y-@ |
(6) AUTO | (10)
BYSTARTER DIMMER
SWITCH
— = 4
o (12) HEADLIGHT (11) INSTRUMENT
LIGHT
| | | Bu vf Y Y
G/BI
: (13) RESISTOR Hi
Charging System/Alternator
Troubleshooting
Battery Overcharging
« Faulty regulator/rectifier
+ Broken regulator/rectifier ground wire or faulty cnnection.
Battery undercharging
NOTE
- In order to obtain accurate test readings for charging system, the battery must be fully charged and in good condition.
See Common Service Manual section 22 for check the battery condition.
Check the regulator/rectifier unit inspection
| (page 13-7)
| |
Incorrect | Correct
‚ Shorted wire harness
- Faulty ignition switch
-» + Faulty regulator/rectifier
— Check the battery using a Honda Battery Tester |
Incorrect Correct
« Electric system overloading
‚ Faulty battery
Y
‚ ° Open circuit in wire harness
« Poorly connected connectors
Check the charging coil at alternator (page
13-9)
| |
Abnormal Normal
« Poorly connected alternator
connector
> + Faulty alternator
Measure the battery current leakage ampere Incorrect
(Leak test) (page 13-5)
Correct
- Correct
| Inspect the regulated voltage (page 13-5)
Not Charging
Check the voltages of the regulator/rectifier Abnormal
battery charging line and ground line (page >
13-6)
Г
Normal
|
Check the alternator (charging coil) resistance at Abnormal
the regulator/rectifier connector (page 13-6)
Normal
Check the regulator/rectifier unit inspection Abnormal
(page 13-7)
= + Faulty regulator/rectifier
13-3
Charging System /Alternator
Battery Removal/Installation
(4)
Requisite Service
- Luggage box removal/installation (page 2-4)
Remarks
(1)
(2)
(3)
(4)
Procedure Q'ty
Removal Order
Battery negative © wire terminal 1
Battery positive @ wire terminal 1
Battery holder 1
Battery 1
Installation is in the reverse order of removal.
CAUTION
- With the ignition switch OFF, remove the negative ©
terminal first, then the positive ® terminal.
CAUTION
‚ When installing, install the posiive ® terminal first,
then the negative © terminal.
13-4
Charging System/Alternator
Charging System Inspection
Leak Test
Remove the battery cover (page 2-4).
Turn the ignition switch off and disconnect the ground ©
wire from the battery.
Connect the ammeter @ probe to the ground wire and the
ammeter © probe to the battery © terminal. |
With the ignition switch off, check for current leakage.
NOTE
« When measuring current using a tester, set it to a high
range, and then bring the range down to an appropriate
level. Current flow larger than the range selected may
‘blow out the fuse in the tester.
- While measuring current, do not turn the ignition on. A
sudden surge of current may blow out the fuse in the
tester.
Specified Current Leakage: 1 mA max.
If current leakage exceeds the specified value, a shorted
circuit is likely.
Locate the short by disconnecting connections one by one
and measuring the current.
Regulated Voltage/Ampere Inspection
NOTE
« Before performing this test, be sure that the battery is
fully charged and that the voltage between its terminals
is greater than 13.0 V.
Start the engine and warm it up to operating temperature,
then turn the ignition switch OFF.
- If the engine must be running to do some work, make
sure the area is well-ventilated. Never run the engine
in an enclosed area.
* The exhaust contains poisonous carbon monoxide gas
that may cause loss of consciousness and lead to
death.
Remove the battery cover (page 2-4)
Connect the tachometer.
oO
Connect a multitester betwen the battery terminals. mA
Digital Multitester 07411 —0020000
(1) FUSE
TERMINALS
Open the fuse holder and remove the fuse.
Connect the ammeter between the fuse terminals as shown. (2) FUSE — DD)
13-5
Charging System/Alternator
CAUTION
- Be careful not to short any tester probes.
- Although the current could be measured when the
ammeter is connected between the battery positive
terminal and the positive cable, a sudden surge of
current to the starter motor could damage the
ammeter.
+ Always turn the ignition off when conducting the test.
Disconnecting the ammeter or wires when current is
flowing may damage the ammeter.
Start the engine and increase the engine speed gradually.
Regulated voltage: 14.0—15.0 V/5,000 min”! (rpm)
Charging current: O—0.5 A/5,000 min”* (rpm)
Lighting Voltage Inspection
CAUTION
- Failure to measure the lighting voltage may lead to
electrical damage of lighting components.
Remove the handle front cover (page 2-7).
Connect the tachometer. |
Start the engine and turn the headlight dimmer switch to
“Hi” position.
With the headlight connector connected, connect the
ammeter @ probe to the blue wire terminal, and © probe to
the green wire terminal.
NOTE
(1) HEADLIGHT
(2) HEADLIGHT CONNECTOR
| - Select the AC range on the multitester. -
Gradually increase the engine speed and read the lighting
regulated voltage.
Regulated voltage: 12.6—13.6 V/5,000 min” (rpm)
Regulator/Rectifier
Wire Harness Inspection
NOTE
- № the engine has been running, after stopping the
engine, wait for 10 minutes or more and perform the
inspection.
Disconnect the regulator/rectifier connector and check the
connector for loose or corroded terminals.
13-6
Charging System/Alternator
Measure the following between connector terminals of the
wire harness side.
Item Terminals Specification
Battery chrging | Red (+) and Battery voitage
line ground should be measured
Ground line Green and Continuity
ground
Charging line White and 0.4-—1.0 9
ground (20°C/68°F)
Lighting line Yellow and 0.2-0.8 Q*
ground (20°C/68°F)
* Disconnect the auto bystarter connector, taillight yellow
connector and 9P connector located at the steering head
and measure.
Unit Inspection
Provided the circuit on the wire harness side are normal and
there are no loose connections at the connector, inspect the
regulator/rectifier unit by measuring the resistance between
the terminals.
Unit: kQ
& Probe
© Probe A L B E
A 00 3-50 со
L со со | 5-100
В oo | CO oO
E со 5—100 со
МОТЕ
- You'll get false readings № the probes touch your fingers.
« Use the specified multitesters. Using other equipment
may not allow you to obtain the correct results.
This is due to the characteristic of semiconductors,
which have different resistance values depending on the
applied voltage.
Specific Multitester:
—07411—0020000 (KOWA Digital type)
— 07308 —0020001 (SANWA Analogue type)
—-TH-5H — (KOWA Analogue type)
- Select the following range:
SANWA: kQ
KOWA: x100 |
‚ An old battery stored in the multitester could cause
inaccurate readings. Check the battery if the multitester
registers tncorrectly.
- When using the KOWA multitester, remember that all
(2) REGULATOR/RECTIFIER
(1) HARNESS SIDE CONNECTOR
readings should be multiplied by 100.
Replace the regulator/rectifier unit if the resistance value
between the terminals is abnormal... |
13-7
Charging System/Alternator
Alternator Removal /Installation
6} 10 (1.0, 7)
(14)
(1)
(16)
(9)
(3)
(2)
Or
10 (1.0, 7)
y | (page 1-11)
de 40 (4.0, 29)
(4) (5)
Requisite Service
- Frame body cover removal/installation (page 2-3)
Procedure O'ty Remarks
Removal Order Installation is in the reverse order of removal.
(1) | Spark plug cap |
(2) | Bolt
(3) | Fan cover
(4) | Bolt
(5) | Cooling fan
(6) | Flywheel nut
(7) | Flywheel
(8) | Woodruff key
(9) | Alternator wire connector
(10)| Starter motor connector
(11)| Starter motor lower mounting bolt
(12)| Pulse generator bolt
(13)| Pulse generator
(14)| Stator bolt
(15) | Stator
(16)! Grommet
Removal/installation (page 13-9)
Remove the starter motor ground wire.
NN NN 2. BP | N om
13-8
Charging System/Alternator
Fiywhel Nut Removal /Installation
Hold the flywheel with the universal holder and remove the
flywheel nut.
—
Universal holder 07725 —0030000
install the nut in the reverse order of removal.
Alternator Inspection
NOTE
(1) FLYWHEEL NUT
(2) UNIVERSAL HOLDER
« This inspection can be performed with the stator
installed.
Remove the frame body cover (page 2-5).
Disconnect the alternator 6P connector.
Measure the charging coil resistance between the white wire
terminal and ground.
Standard: 0.4—1.0 о (20°C/68°F)
Measure the lighting coil resistance between the yellow wire
terminal and ground.
Standard: 0.2-0.8 © (20°C/68°F)
Resistor Inspection
Remove the front cover (page 2-5).
Disconnect the resistor wire connector and measure the
` resistance between the wire terminal and body ground.
Standard: 4.7—5.3 о (20°C/68'F)
. | _ ms
JE NR
an
(1) ATERNATOR GP CONNECTOR
(1) RESISTOR WIRE
WAN
(3) GROUND (2) RESISTOR
13-9
14. Ignition System
Service Information 14-1 Ignition Coil 14-6
System Location 14-2 Alternator Inspection 14-7
Troubleshooting 14-3 Ignition Timing 14-7
Ignition System Inspection 14-4
Service Information
* If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine т an
enclosed area.
* The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
- When checking the ignition system, always follow the steps in the troubleshooting flow chart (page 14-3).
« The CDI ignition system uses an electrically controlled ignition timing system. No adjustment can be made to the ignition
timing.
« The CDI unit may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive
voltage may damage the unit. Always turn off the ignition switch before servicing.
« A faulty ignition system is often related to poorly connected connectors. Check those connections before proceeding.
« Make sure the battery is adequately charged. A weak battery may be unable to turn the starter motor quickly enough, or
adequate ignition current may not be supplied.
- Use a spark plug of the correct heat range. Using a spark plug with an incorrect heat range can damage the engine. Refer
to section 23 of the Common Service Manual.
- For ignition switch inspection, check for continuity on the continuity chart of the Wiring Diagram (section 17).
14-1
Ignition System
System Location
(1) CDI UNIT
(2) SPARK PLUG
(3) IGNITION SWITCH
(4) PULSE GENERATOR
(6) IGNITION COIL
(5) ALTERNATOR
(9) IGNITION SWITCH
(11) IGNITION COIL
(7) PULSE GENERATOR
_ (8) ALTERNATOR | _ (12) SPARK PLUG
14-2
Ignition System
Troubleshooting
« Before troubleshooting, check that no spark jumps at the spark plug using a known good spark plug (to ensure that the
plug does not cause the problem).
Moreover, check for proper spark plug gap and loose spark plug wire as well as for leakage of the ignition coil secondary
current caused by moisture.
No spark at plug
Unusual condition Probable cause (Check in numerical order)
Ignition coil Low peak voltage. The multitester impedance is too low.
primary @Cranking speed is too low.
voltage - Battery is undercharged or operating force of the
kickstarter is weak.
@The sampling timing of the tester and measured pulse
were not synchronized. (System is normal if measured
voltage is over the standard voltage at least once).
@Poorly connected connectors or an open circuit in
_ ignition system.
G'Faulty exciter coil. (Measure the peak voltage.)
© Faulty ignition coil.
@Faulty CDI unit (in case when above No. @-© are
normal).
No peak voltage. (Dincorrect peak voltage adaptor connections.
@Faulty ignition switch.
@Loose or poorly connected: CDI unit connector.
(Open circuit or poor connection in ground wire of the
CDI unit.
Faulty peak voltage adaptor.
&Faulty exciter coil. (Measure the peak voltage.)
@Faulty pulse generator. (Measure the peak voltage.)
@®Faulty СО! unit (in case when above No. D-Ü@ are
normal).
Peak voltage is normal, but no spark jumps at | (Faulty spark plug or leaking ignition coil secondary
plug. current.
@Faulty ignition coil.
Exciter coil Low peak voltage. (DThe multitester impedance is too low.
@Cranking speed is too low.
- Battery is undercharged or operating force of the
kickstarter is weak.
@The sampling timing of the tester and measured pulse
were not synchronized. (System is normal if measured
voltage is over the standard voltage at least once).
@Faulty exciter coil (in case when above No. D-@® are
| - normal).
No peak voltage. @Faulty peak voltage adaptor.
@Faulty exciter coil.
Pulse Low peak voltage. The multitester impedance is too low.
generator @Cranking speed is too low.
- Battery is undercharged or operating force of the
kickstarter is weak.
@The sampling timing of the tester and measured pulse
were not synchronized. (System is normal if measured
voltage is over the standard voltage at least once).
@Faulty pulse generator (in case when above No. D-®
are normal).
No peak voltage. @Faulty peak voltage adaptor.
@Faulty pulse generator.
14-3
ignition System
Ignition System Inspection
NOTE
- If no spark jumps at the plug, check all connections for
loose or poor contact before measuring peak voltage.
«The reading differs depending on the multitester input
impedance. Therefore, use only Honda genuine digital
multitester or commercially available multitesters with
the input impedance higher than 10 MQ/DCV.
- If using imrie diagnostic tester (model 625), follow the
munufacturer’s instructions.
Connect the peak voltage adaptor to the digital multitester.
Imrie diagnostic tester (model 625) made in Australia or
Peak voltage adaptor 07HGJ — 0020100 with
Digital multitester 07411 —0020000
ignition Coil Primary Peak Voltage
NOTE
« Check all system connections before inspection. Poor
connected connectors can cause incorrect readings.
« Check that the cylinder compression is normal and the
(1) DIGITAL MULTITESTER
spark plug is installed correctly into the cylinder head.
Place the scooter on its center stand.
Remove the frame body cover (page 2-3).
Remove the spark plug cap from the plug, install a known
good spark plug to the plug cap and ground it to the engine
as shown. | |
Connect the peak voltage adaptor @ probe to the ignition
coil primary (black/yellow) wire terminal and the © probe to
the body ground.
Turn the ignition switch ON.
Crank the engine with the kickstarter or starter motor and
read the ignition coil primary peak voltage.
Connection:
Black/yellow wire terminal Ф — Body ground ©
Peak voltage: 100 V minimum
- То avoid possible electrical shock during voltage
measurements, do not touch test probe metal parts.
If the peak voltage is abnormal, check an open circuit or
poorly connected connectors in black/yellow wire.
If no defects are found in the harness, refer to the
troubleshooting chart (page 14-3).
(1) KNOWN GOOD SPARK PLUG
(1) IGNITION COIL (2) © PROBE
7 ax
IN А
I]
Pe DO
(3) © PROBE
14-4
ignition System
Exciter Coil Peak Voltage
NOTE
« Install the spark plug into the cylinder head and measure
the peak voltage under normal cylinder compression.
. Remove the frame body cover (page 2-3).
Remove the CDI unit from the rear fender and disconnect 6P
connector from the CDI unit.
Connect the peak voltage adaptor Y probe to the exciter coil
(black/red) wire terminal and the © probe to the ground
(green) wire terminal.
Crank the engine with the kickstarter or starter motor and
read the exciter coil peak voltage.
Connection:
Black/red wire terminal $ — Green wire terminal ©
Peak voltage: 100 V minimum
« To avoid possible electrical shock during voltage
measurements, do not touch test probe metal parts.
If the peak voltage measured at the CDI unit connector is
abnormal, disconnect the alternator wire connector and
connect the adaptor probes to the exciter coil terminal and
engine ground.
In the same manner as at the CDI unit connector, measure
the peak voltage and compare it to the voltage measured at
the CDI unit connector.
- If the peak voltage measured at the CDI unit is abnormal
and the one measured at the exciter coil is normal, the wire
harness has an open circuit or loose connections.
+ If both peak voltages measured are abnormal, check each
item in the troubleshooting chart. If all items are normal,
the exciter coil is faulty. |
Pulse Generator Peak Voltage
NOTE |
« Install the spark plug into the cylinder head and measure
the peak voltage under normal cylinder compression.
Remove the frame body cover (page 2-3)
Remove the CDI unit from the rear fender and disconnect 6P
connector from the CDI unit.
Connect the peak voltage adaptor @ probe to the pulse
generator (blue/yellow) wire terminal and the © probe to the
ground (green) wire terminal.
Crank the engine with the kickstarter or starter motor and
read the pulse generator peak voltage.
Connection:
Blue/yellow wire terminal Ф— Green wire terminal ©
Peak voltage: 0.7 V minimum |
(1) CDI UNIT CONNECTOR (2) CDI UNIT
No (3) © PROBE
cE
И IN
(4) © PROBE
(1) EXCITER COIL (BLACK/RED)
WIRE TERMINAL
(3) © PROBE
(1) CDI UNIT CONNECTOR (2) CD! UNIT |
\ X (3) Ф PROBE
_ _ \ ” EN
al] DS NN
/ =
(4) © PROBE
14-5
ignition System
° То avoid possible electrical shock during voltage
measurements, do not touch test probe metal parts.
If the peak voltage measured at the CDI unit connector is
abnormal, disconnect the alternator wire GP connector and
connect the adaptor probes to the pulse generator terminal
and engine ground.
in the same manner as at the CDI unit connector, measure
the peak voltage and compare it to the voltage measured at
the CDI unit connector.
«If the peak voltage measured at the CDI unit is abnormal!
and the one measured at the pulse generator is normal, the
wire harness has an open circuit or loose connections.
- И both peak voltages measured are abnormal, check each
item in the troubleshooting chart. If all items are normal,
the pulse generator is faulty.
Ignition Coil
Removal
Remove the frame body cover (page 2-3).
Remove the spark plug cap from the spark plug.
Remove the mounting bolt and the ignition coil.
Disconnect the ignition coil primary wires from the coil.
Continuity Test
Measure the primary coil resistance between the primary
wire terminals.
Standard: 0.1—0.4Q (20°C/68°F)
Measure the secondary coil resistance between the spark
plug cap and primary wire © terminal.
Standard (with plug cap): 6.5—9.7 kQ (20°C/68°C)
Remove the spark plug cap from the spark plug wire.
Measure the secondary coil resistance between the spark -
plug wire and primary wire © terminal.
Standard (without plug cap): 2.7—3.5 КО (20°C/68°F)
install the removed parts in the reverse order of removal.
(1) ALTERNATOR 6P CONNECTOR
ES
(3) © PROBE (2) © PROBE
(1) BOLT
A
tA
2 la] | |
[С
PE A
à"
С;
14-6
(2) SPARK PLUG САР
Ignition System
Alternator Inspection
NOTE
- This inspection can be performed with the alternator
installed into the engine.
Remove the frame body cover (page 2-3).
Exciter Coil
Disconnect the alternator black/red wire connector. |
Measure the exciter coil resistance between the black/red
wire terminal and engine ground.
Standard: 400-8002 (20°C/68°F)
Pulse Generator
Disconnect the alternator wire 6P connector.
Measure the pulse generator resistance between the blue/
yellow wire terminal and engine ground.
Standard: 50-2000 (20°C/68'F)
Ignition Timing
NOTE
(1) BLACK/RED WIRE CONNECTOR
LL - 1
> 1
C7 wo
(2) 6P CONNECTOR
« The CDI ignition timing is not adjustable. If the timing is
not correct, check the CDI unit, exciter coil and pulse
generator, and replace any faulty parts.
Remove the cooling fan cover (page 13-8).
Warm up the engine and connect the timing light and
tachometer.
NOTE
« Follow the timing light and tachometer manufacturer's
(1) INDEX MARK fr
Os,
\ (2) “F” MARK
instructions before operating.
Start the engine and check the ignition timing.
The ignition timing is. correct if the “F” mark on the flywheel
aligns with the index mark of the crankcase at 1,800 min”*
(rom).
ignition timing: 17°BTDC at 1,800 min”' (rpm)
14-7
15. Electric Starter
Service Information 15-1 Starter Motor Romoval/Installation 15-4
System Location | 15-2 Starter Motor Disassembly/Assembly 15-5
Troubleshooting 15-3
Service Information
« Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing
serious injury.
- A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
+ If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor
may be damaged.
15-1
Electric Starter
System Location _ (4) STARTER SWITCH
| =
— ÉS
(1) STARTER RELAY SWITCH “AN |
(2) BATTERY | | 6A >
AE
< X Хх»
(3) IGNITION SWITCH RO» с
(5) STARTER MOTOR
8) FUSE (10A
(8) | (9) IGNITION SWITCH
| R/W : /
LIGHT SWITCH |
(6) STARTER MOTOR (7) STARTER | |
| SWITCH д O rl] f G
| C2
| + r bso
G | + A
o | (11) BATTERY
(13) STARTER РИ |
RELAY | L
= —- = LIGHT SWITCH =
G/Y
15-2
Electric Starter
Troubleshooting
Starter motor will not turn
‚ Check for blown fuse before checking.
With the ignition switch ON and the brake lever
sqeezed, push the starter switch and check for a
click” sound from the starter relay switch.
Clicks
No click
\
Disconnect the starter relay switch connector
and check the ground circuit for continuity.
No continuity
JJ
Connect the starter motor terminal to the battery
positive terminal directly (do not use thin wire
because of a large current flows).
Continuity
Y
Connect the starter relay switch connector.
With the ignition switch ON and brake lever
squeezed, measure the starter relay voltage at
the starter relay switch (between the green/
yellow wire terminal and body ground).
No voltage
Battery voltage
|
| Check the starter relay switch operation.
Normal
|
__]
Abnormal
Starter motor turns slowly
- Weak battery
« Poorly connected battery wire terminals
« Poorly connected starter motor wire
‚ Faulty starter motor
Starter motor turns, but engine does not turn
‚ Faulty starter pinion |
Starter motor and engine turn, but engine does not start
¢ Faulty ignition system
« Engine problem
— Low compression
— Fouled spark plug
Starter Starter
motor motor does
not turn
turns
Y
у - Faulty starter motor
« Loose or disconnected starter motor wire
« Faulty starter relay switch
- Faulty starter switch
« Loose or poor contact of connectors
‚ Open circuit in wire harness
‚ Faulty ignition switch
« Faulty brake light switch
« Loose or poor contact of connectors
- Open circuit in wire harness :
« Loose or poor contact of the starter relay
. switch connector
- Faulty starter relay switch
15-3
Electric Starter
Starter Motor Removal/Installation
GROUND WIRE (3)
Requisite Service
+ Frame body cover removal/installation (page 2-3)
Procedure O'ty | Remarks
Removal Order | Installation is in the reverse order of removal.
(1) | Oil pump mounting bolt 1
(2) | Starter motor mounting bolt 2 When installing, do not forget to install the ground wire
| with the lower mounting bolt.
(3) | Oil pump control cable stay 1 NOTE
« Do not loosen the oil pump control cable lock nut and
adjusting nut. If they are loosened, perform the oil pump
control cable adjustment (page 3-6)
(4) | Starter motor 1 | Disassembly/assembly (page 15-5)
(5) | Starter motor wire connector 1
(6) | O-ring 1
15-4
Electric Starter
Starter Motor Disassembly/Assembly
(2)
(4)
(5)
(7)
Requisite Service
- Starter motor removal/installation (page 15-4)
Procedure
O'ty
Remarks
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Disassembly Order
Motor case screw
Motor case
Armature
Brush holder
Spring
O-ring
Front bracket
aa AQ AQ =
Assembly is in the reverse order of disassembly.
NOTE
« When installing, make sure that there are no metal particle
inside the case.
15-5
16. Lights/Meters/Switches
Service Information | 16-1 ‘Ignition Switch Replacement 16-2
Fuel Level Sensor Inspection 16-2 Bulb Replacement | 16-2
Oil Level Switch inspection 16-2 Rear Combination Dummy Removal/
Installation | 16-4
Service Information
- A continuity test can be made with the switches installed on the scooter. Refer to the continuity chart of the wiring
diagram (section 17) for switch continuity. |
. Check the battery condition before performing any inspection that requires proper battery voltage.
. Refer to page 25-2 of the Common Service Manual for oil level indicator inspection.
- Refer to page 25-7 of the Common Service Manual for fuel gauge inspection.
16-1
Lights/Meters/Switches
Fuel Level Sensor Inspection
Remove the fuel level sensor (page 2-8).
Move the float with your hand and measure the resistances
between the terminals with the float at the FULL (upper) and
EMPTY (lower) positions. | |
Wire color of terminal FULL EMPTY
Green and yellow/white 25-450 400-7009
Green and blue/white 400 - 7002 25-450
Yellow/white and blue/white | 450-7500 | 450-7500
Oil Level Switch Inspection
Remove the oil level switch (page 4-4).
Check for continuity between the terminals.
There should be continuity with the float at upper position
and no continuity with the float at lower position.
Ignition Switch Replacement
Remove the front cover (page 2-5).
Disconnect the ignition switch wire connector.
Remove the two screws and the ignition switch.
Install the ignition switch in the reverse order of removal.
Bulb Replacement
Headlight
NOTE
-
2c
-
A
3 7
>
=
“a7
+ (1) FLOAT
(1) FLOAT
(1) SCREWS
| >
(3) IGNITION |
SWITCH
«If the headlight bulb has been blown, replace the
headlight unit.
Remove the handle front cover (page 2-7).
Remove the four screws and the headlight with the bracket
from the handle front cover.
Remove the two adjusting screws, attaching screw and the
headlight from the bracket.
Install a new headlight in the reverse order of removal.
After installing, adjust the headlight aim (page 3-6).
(1) HEADLIGHT
(3) BRACKET
16-2
Lights/Meters/Switches
Front Turn Signal Light
Remove the handle front cover (page 2-7).
Remove the bulb socket from the turn signal light by turning
it counterclockwise.
Pull the bulb out of the socket.
Install a new bulb and removed parts in the reverse order of
removal.
Instrument/Indicator light
Remove the handle rear cover (page 2-7).
Remove the bulb socket from the instrument case.
Pull the bulb out of the socket.
Install a new bulb and removed parts in the reverse order of
removal.
Taillight
Remove the two screws, taillight lens and packing.
Turn the bulb counterclockwise while pushing it in, and
remove it.
Install a new bulb and removed parts in the reverse order of
removal.
Rear Turn Signal Light
Remove the screw, turn signal light lens and packing.
Turn the bulb counterclockwise while pushing it in, and
remove it.
Install a new bulb and removed parts in the reverse order of
removal.
. Align the lug on the lens with the slot in the light case
properly.
(1) TURN SIGNAL LIGHT
a SOCKET
ST
a = А.
(3) BULB
(1) INSTRUMENT CASE
(2) BULB x 2
Pi
ù ©
\ NE
(3) SOC
(1) BULB
| (2) PACKING
(3) SCREWS
(4) LENS
(1) BULB
(2) LENS
(3) SCREW
te,
wee,
re
(4) PACKING
16-3
Lights/Meters/Switches
Rear Combination Dummy
Removal/Installation
Remove the frame body cover (page 2-3).
Remove the two bolts and the rear combination dummy.
Remove the taillight/turn signal light wires and wire clamp
from the rear combination dummy.
Install in the reverse order of removal.
NOTE
(1) CLAMP
(3) BOLTS
(2) REAR COMBINATION DUMMY
(4) WIRES
| « Route the taillight/turn signal light wires properly.
16-4
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18. Troubleshooting
Engine Does Not Start or is Hard to Start 18-1 Poor Performance at Low and Idle Speeds 18-3
Engine Lacks Power 18-2 Poor Performance at High Speed 18-3
Engine Does Not Start or is Hard to Start
1. Check if fuel is getting to NOT GETTING TO ~ + № fuel in fuel tank
carburetor by loosening drain CARBURETOR ‚ Clogged fuel tube to carburetor
screw - Clogged fuel filter
‚ Clogged float valve
GETTING TO CARBURETOR ‚ Clogged fuel tank cap breather
у hole
- Faulty fuel pump
2. Try spark test _ WEAK OR NO SPARK — - Faulty spark plug
‚ Fouled spark plug
SPARK . Fauty CDI unit
- Fauty alternator
« Broken or shorted spark plug wire
- Broken or shorted ignition coil
- Faulty ignition switch
Y
3. Test cylinder compression LOW COMPRESSION = +. Stuck piston rings
‚ Faulty or deteriorated reed valve
NORMAL COMPRESSION + Worn cylinder and piston rings
- Compression leak past crankcase
- Leaking cylinder head gasket
4. Start by following normal ENGINE FIRES BUT. > + Faulty auto bystarter
starting procedure SOON STOPS - Air leaking past intake pipe
- Improper ignition timing
ENGINE DOES NOT FIRE - Misadjusted idle speed
5. Remove spark plug WET PLUG > + Carburetor flooded
- Faulty auto bystarter
DRY . Throttle valve excessively open
« Clogged air cleaner element
18-1
Troubleshooting
Engine Lacks Power
Probable cause
1. Lightly accelerate engine ENGINE SPEED DOES NOT. =. Clogged air cleaner element
INCREASE SUFFICIENTLY ‚ Restricted fuel flow
ENGINE SPEED INCREASES | - Clogged fuel tank cap breather hole
| | + Clogged muffler
2. Check ignition timing INCORRECT— >. Faulty CDI unit
| - Faulty alternator
CORRECT
3. Test cylinder compression TOO LOW — Worn cylinder or piston rings
| « Blown cylinder head gasket
NORMAL - Compression leak past crankcase
- Faulty or deteriorated reed valve
4. Check carburetor for clogging CLOGGED »-Carburetor not serviced frequently
enough
NOT CLOGGED
5. Remove spark plug = FOULED OR DISCOLORED—————=-+ Plug not serviced frequently enough
« Use of plug with improper heat range
NOT FOULED OR DISCOLORED
6. Check if engine overheats | OVERHEATED »-- Worn cylinder or piston
| - Fuel-air mixture too lean
NOT OVERHEATED | o ‚ Use of improper grade of fuel
+ Excessive carbon build-up in
combustion chamber
- Ignition timing too advanced
у
7. Try rapid acceleration or run at high ENGINE KNOCKS >» Excessive carbon build-up in
speed combustion chamber
- Use of improper grade of fuel
ENGINE DOES NOT KNOCK - Ignition timing too advance
- Fuel-air mixture too lean
18-2
Troubleshooting
Poor Performance at Low and Idle Speeds
Probable cause
1. Check ignition timing INCORRECT
CORRECT
=: Faulty CDI unit
- Faulty alternator
=« Fuel air mixture too rich
2. Check carburetor air screw for proper INCORRECT.
adjustment
CORRECT
(Screw out to correct)
- Fuel air mixture too lean
(Screw in to correct)
3. Check if air is leaking past intake pipe LEAKING
x-- Loose carburetor
« Deteriorated intake pipe gasket
+ Deteriorated insulator O-ring
=. Faulty, carbon or wet fouled spark plug
- Faulty CDI unit
‚ Faulty alternator
‚ Faulty ignition coil
- Broken or shorted spark plug wire
« Faulty ignition switch
»=-Faulty auto bystarter
NOT LEAKING
4. Try spark test | WEAK OR INTERMITTENT:
SPARK
GOOD SPARK
y
5. Check auto bystarter ABNORMAL
NORMAL
Poor Performance at High Speed
Probable cause
1. Check ignition timing INCORRECT.
CORRECT
2. Disconnect fuel tube at carburetor FUEL FLOW RESTRICTED
—. Faulty CDI unit
- Faulty alternator
—. No fuel in fuel tank
FUEL FLOWS FREELY
|
« Clogged fuel tube or fuel filter
- Clogged fuel tank cap breather hole
- Faulty fuel pump
—. Clean
3. Remove carburetor and check for CLOGGED
clooged jet | |
NOT CLOGGED
4. Check auto bystarter ABNORMAL
NORMAL
>. Faulty auto bystarter
Air Cleaner Case Removal/Installation ............... 5-7
Alternator Inspection ........................... 13-9, 14-7
Removal/Installation ....................... 13-8
Battery Removal/Installation .......................... 13-4
Bulb Replacement 4. 16-2
Cable & Harness Routing............................... 1-14
Carburetor Disassembly/Assembly ................. 5-5
Removal/Installation .................... 5-3
Charging System Inspection.........................:- 13-5
Clutch/Driven Pulley Disassembly/Assembly ...... 8-8
Crankcase Separation/Assembly ..................... 10-2
Cylinder Head, Cylinder and Piston
Removal/Installation ..................................., 7-2
Drive Pulley and Clutch/Driven Pulley
Removal/installation......................... 8-5
Engine Does Not Start or is Hard to Start........ 18-1
Engine Lacks Power ..................................... 18-2
Engine Removal/Installation ............................. 6-2
Final Reduction Disassembly/Assembly ............. 9-2
Fork Disassembly/Assembly ........................... 11-9
Frame Cover Removal/Installation..................... 2-2
Front Brake Panel Disassembly/Assembly ........ 11-4
Front Wheel Disassembly/Assembly.............. 11-3
Removal/Installation ................ 11-2
Fuel Level Sensor Inspection .......................... 16-2
Fuel Pump Removal/Installation .................... ...5-8
Fuel Tank Removal/Installation......................... 2-8
General Safety ........................,................... 1-1
Handlebar Removal/Installation ...................... 11-6
Headlight Aim ses. 3-6
Ygnition Coil .................................. eeeceeeenenees 14-6
Ignition Switch Аерасетепт.......................... 16-2
Ignition System Inspection ............................. 14-4
Ignition Timing ........................,..... e eee eee nen 14-7
Kickstarter Removal/Installation........................ 8-3
Left Crankcase Cover Removal/Installation......... 8-2
Lighting Voltage Inspection ..........................…. 13-6
Lubrication & Seal Points............................... 1.-12
* Lubrication System Diagram ......................,...,, 4-2
Maintenance Schedule ......................,............. 3-4
Model Identification ...............................,,,.,0 1-2
Movable Drive Face Disassembly/Assembly ....... 8-7
Muffler Removal/Installation ............................ 2-9
Oil Level Switch Inspection ............................ 16-2
Oil Pump Removal/Installation ......................... 4-3
Oil Pump and Oil Line .................................. 3-6
Oil Tank Removal/Installation ........................... 4-4
Poor Performance at High Speed.................... 18-3
Poor Performance at Low and Idie Speeds....... 18-3
Rear Brake Disassembly/Assembly .............. 12-3
Rear Combination Dummy Removal/
Installation ................................... 16-4
Rear Wheel Removal/Installation .................... 12-2
Rear Valve Removal/installation ....................... 5-6
Regulator/Rectifier inspection ........................ 13-6
Resistor Inspection ............. ие: 13-9
3-2
Service Access Guide 4
Service Information
Charging System/Alternator............. 13-1
Crankcase/Crankshaft ..................... 10-1
Cylinder Head/Cylinder/Piston ........... 7-1
Electric Starter .............,...,......,...... 15-1
Engine Removal/Installation ............... 6-1
Final Reduction ................................ 9-1
Frame/Body Panels/Exhaust System ...2-1
Front Wheel/Suspension/Steering/
Brake ...................,........,...,.... 11-1
Fuel System................................... 5-1
Ignition System ................,............ 14-1
Kickstarter/Drive Pulley/Clutch/
Driven Pulley.............,................. 8-1
Lights/Meters/Switches................... 16-1
Lubrication System ...................... 4-1
Maintenance .................................... 3-1
Rear Wheel/Suspension/Brake ......... 12-1
Shock Absorber Removal/Installation .............. 12-4
Specifications......................... sise... 1-3
Starter Motor Disassembly/Assembly............ 15-5
Removal/installation .............. 15-4
Steering Stem Removal/Installation....... PR 11-7
System Location Charging System/Alternator...13-2
Electric Starter.................. 15-2
ignition System................. 14-2
Throttle Housing Removal/Installation ............. 11-5
Throttle Valve Disassembly/Assembly................ 5-4
Bo 0) [a 1-11
Torque Values ............................... еннинние 1-9
Troubleshooting
Charging System/Alternator............. 13-3
Crankcase/Crankshaft ..................... 10-1
Cylinder Head/Cylinder/Piston ........... 7-1
Electric Starter ............................... 15-3
Final Reduction ............................,... 9-1
Frame/Body Panels/Exhaust System ...2-1
Front Wheel/Suspension/Steering/
Brake ........ccccceccacceceeescceccetsveceaes 11-1
Fuel System...................,.......,........ 5-2
Ignition System .............................. 14-3
Kickstarter/Drive Pulley/Clutch/
Driven Pulley ............ooooococnccconcaronos 8-1
Lubrication System .............,............ 4-1
Rear Wheel/Suspension/Brake......... 12-1
Wiring Diagram ....................,,.. LS. 17-1
(130)
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1. | General Information .. 5-20
2. | Frame/Body panels/Exhaust 21 - 29
3. Maintenance 30 -35
4. Lubrication system 36 - 39
5. Fuel system 40 - 48
6. | Engine removal/Installation 49 - 51
7. | Cylinder head/Cylinder/ 52 - 54
Piston |
8. Kickstarter/Drive Pulley 55 - 63
Clutch/Driven Pulley
9. Final reduction 64 - 66
10. | Crankcase/Crankshaft 67 - 71
11. | Frontwheel/Suspension 72 - 80
/Steering/Brake
12. | Rear wheel/Suspension 81 - 84
/Steering/Brake
13. | Charging system/Alternator 85 - 93
14. | Ignition system 94 - 100
15. | Electric starter 101 - 105
16. | Lights/Meters/Switches 106 - 109
17. | Wiring diagrams 110
18. | Troubleshooting 111 - 113
Index
1
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printer dialog box when printing wiring diagrams.

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