Honda SK50M Dio Service Manual 117 Pages
Honda SK50M Dio Service Manual
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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 L-ZL 0059—HY9—Z0€00 MATT ЕЮ] *] [oO | | | AA aan tenth ano ОЮЮ] "|| DECOR [ми | [OLOT нем OrO} нем эта ней [п] эта I010| |“ |0 | 1|1 [OÙ | xn] [OO вю | | us | za Re seat [+ [мн On мм fetal | [3[5 | ме] on —— HOLIMSWENWIG HOUMS TWNOIS NUL _HOLMSNOLINDE == = №08 MHOMMSHEUVIS и 9013 ANIONa HOLIMS HOJIMS HOLIMS _ | HOLVNUALTV se UINWIC TYNOISNUNL NHOH Y mim т LL M 53 ||r2$|138 y vias y oun 1 вю O 911 999 | | oo 2 НО HAN A ualuVis | == = i а ГЕ 2 | de o mo ГЕ] а © <= [1 11 © ] rw ( ) 1109 NOLLINDI La AT | JO) — нов MAL ANDE Ln <5 Ang pr Ш : 8 =, (Miz ACL) LHOM TWNOIS NUNL UVAU 1331 (Mb'€ AZL) VOLVINONI TYN9IS TT) МУП (ML'LASL) 0 . 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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) To print chapters, click on the printer icon and fill in the page range. 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 Note: Make sure to select Y Shrink to fit in the printer dialog box when printing wiring diagrams.
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