Home
Honda NH80 1983 Service Manual
Contents
1. IGNITION SWITCH BK AP MINI tp o tn HEADLIGHT 11 i B 3 Br SPEEDOMETER LIGHT cs 12V 3 4W D OIL INDICATOR LIGHT 12V HIGH BEAM PILOT LAMP Jaw TURN SIGNAL PtLOTLAMP 12V 3 4W FUEL METER G VAN Bk REAR SRAKE SWITCH G v m L FRONT TURN SIGNAL 12V 32cp G L Ww A HL LoH TURN SIGNAL DIMMER HORN SWITCH SWITCH CONTINUITY TURN SIGNAL SWITCH IGNITION SWITCH ODAN BUTTON SWITCH DIMMER SWITCH STARTER SWITCH eons PUSH COLOR G Date of Issue November 1983 American Honda Motor Co Inc 1983 All Rights Reserved 16 WIRING DIAGRAM REGULATOR RECTEIFIER ALTERNATOR TURN SIGNAL RELAY GROUND FRAME RA REAA SIGNAL 12V dice SPARK PLUG dae BRAKE AND TAIL LIGHT 12V B 25W Br TUBE L REAR TURN SIGNAL 12V 32cp 1 FUSE 2 s YAN Oli LEVEL SWITCH ndi Bk BLACK 8r BROWN Y YELLOW MEE ORANGE FUEL UNIT ics BLUE L6 LIGHT BLUE GREEN BG ae _ LIGHT GREEN 1 RED s PINK WHITE GRAY ENGINE STOP SWITCH WIRING DIAGRAM 1984 STARTEH ENGINE STOP SWITCH A FRONT TURN SIGNAL 12v 22 GY FRONT SRAKE SWITCH Bk YIA 4 Bk N TURN SIGNAL
2. SERVICE INFORMATION ALTERNATOR REMOVAL 7 2 ALTERNATOR INSTALLATION SERVICE INFORMATION GENERAL Al alternator maintenance can b e made with the engine installed e Do not remove the pulse generator from the stator base See Section 15 for alternator inspection TORQUE VALUE Flywheel 35 40 N m 3 5 4 0 kg m 25 29 ft Ib TOOLS Common Rotor puller 07733 0010000 or 07933 0010000 Universal holder 07725 0030000 Date of Issue May 1983 67 1 1 HONDA MOTOR CO LTD ALTERNATOR E HONDA 80 ALTERNATOR REMOVAL Remove the frame center cover Section 11 Remove the muffler Remove the fan cover Remove the four boits attaching the cooling fan and remove the cooling fan Remove the right floor board Attach the universal holder to the flywheel Hold the flywheel and remove the flywheel 10 mm flange nut 68 FAN COVER mci RIGHT FLOOR BOARD UNIVERSAL HOLDER 077 25 0030000 EE 1 10 mm FLANGE NUT Date of Issue May 1983 HONDA MOTOR CO LTD ee ALTERNATOR ROTOR PULLER Remove the flywheel with the rotor puller 07733 001000 or 07 Remove the woodruff key ue 933 0010000 Disconnect the alternator wire connectors CONNECTORS Remove the two bolts attaching the stator and re PULSE GENERATOR move the stator ey NOTE Do not remove the pulse ge
3. i E GEN THROTTLE VALVE SPRING CARBURETOR TOP EE ES D 4 p TAE THROTTLE VALVE THROTTLE CABLE SEALING CAP CARBURETOR TOP ag 4 2 36 Date of Issue May 1983 HONDA MOTOR CO LTD Pry off the needle retainer and remove the jet needle JET NEEDLE THROTTLE VALVE INSPECTION Check the jet needle and throttle valve for wear or damage CARBURETOR REMOVAL Remove the right and left frame covers Loosen the drain screw to drain fuel from the carbu retor Remove the air cleaner element FUEL SYSTEM NEEDLE RETAINER CLIP JET NEEDLE A THROTTLE VALVE Date of Issue May 1983 HONDA MOTOR CO LTD 37 FUEL SYSTEM Remove the carburetor top and throttle valve CARBURETOR TOP p Disconnect the fuel tube from the carburetor CHOKE CONTROL BOX TUBE Remove the carburetor attaching bolts ee ene BYSTARTER TUBE TIE E oF fe meme Bs e j j Gimme z Remove the frame center cover for easy re LN 1 n Li 1 uc _ 8 gii moval of the attaching bolts if necessary Disconnect the control box and bystarter tubes from the carburetor 4 4 28 Date of Issue May 1983 HONDA MOTOR CO LTD FLOAT FLOAT VALVE JETS DISASSEMBLY Remove the float chamber from the carburetor body Remove the carbu
4. IGNITION SWITCH HEADLIGHT ELECTRONIC BUZZER lt LIGHT 12V 3 4W G OIL INDICATOR LIGHT 5 12 34 4 1 i HiG BEAM PILOT LAMP 12V 3 4W TURN SIGNAL PILOT LAMP Les 5 12V 34W uu REAR BRAKE SWITCH L FRONT TURN SIGNAL gt I HORN 12v 22 TURN SIGNAL DIMMER HORN SWITCH SWITCH CONTINUITY TURN SIGNAL SWITCH IGNITION SWITCH HORN BUTTON wiTCH DIMMER SWITCH STARTER SWITCH ENGINE ST ear 2 16 E ON 3 0 mooto 1 6 2 180 REGULATOR RE TIFIER ALTERNATOR STARTER MOTOR REAA TURN SIGNAL 12V 32cp SPARK PLUG UNIT AND TAIL LIGHT 7 Br TUBE L REAR TURN SIGNAL 12V 32 YW OIL LEVEL SWITCH BLACK BROWN 12 Y YELLOW ORANGE ae ees 8 BLUE L8 cee LIGHT BLUE GREEN 6 LIGHT GREEN Re REO PINK WHITE JPSWMTCIS Date of issue November 1983 American Honda Motor Co Inc 1983 Rights Reserved 17 TECHNICAL FEATURES ENGINE AUTOMATIC TRANSMISSION ENGINE The features of the NH80O engine described below all contribute to meet United States emissions standards and to provide better power and fuel economy than comparable engine
5. STEERING HEAD BEARINGS NOTE Check that the control cables do not interfere with handlebar rotation 1 Raise the front wheel off the ground and check that the handlebar rotates freely If the handlebar moves unevenly binds or has verti cal movement adjust the steering head bearing by turning the steering head adjusting nut Page 12 24 3 1 2 32 Date of Issue May 1983 HONDA MOTOR CO LTD FUEL SYSTEM FUEL TANK AUTO FUEL VALVE FUEL TUBE FUEL STRAINER VACUUM TUBE 4 0 34 Date of Issue May 1983 HONDA MOTOR LTD 4 FUEL SYSTEM SERVICE INFORMATION 4 1 FLOAT LEVEL INSPECTION 4 7 5 4 1 CARBURETOR INSTALLATION 4 7 THROTTLE VALVE DISASSEMBLY 4 2 THROTTLE VALVE INSTALLATION 4 9 CARBURETOR REMOVAL 4 3 AIR SCREW 4 10 FLOAT FLOAT VALVE JETS DISASSEMBL Y 4 5 HIGH ALTITUDE ADJUSTMENT 4 11 JETS FLOAT VALVE FLOAT REED VALVE 4 12 oe cme AUTO FUEL VALVE 4 13 GENERAL WARNING or allo w flames or sparks in the work area Gasoline is extremely flammable and is explosive under certain conditions Work in a well ventilated arca Do not smoke The fuel tank is equipped with an auto fuel valve that is turned OFF automatically when the engine is stopped Use caution when working with gasoline Always work in a well ventilated area and away from sparks or flames When disassem
6. 3 4 OIL INDICATOR Probable Cause Worn brake shoes Worn brake cam Worn cam contacting face of shoe Worn brake drum Worn brake shoes Foreign matter on brake lining Rough shoe contact face of brake drum Faulty or elongated brake cable Brake shoes partially contacting brake drum Mud or water in brake drum Brake linings fouled with grease or oil INDICATOR LAMP DOES NOT LIGHT WHEN IGNITION SWITCH IS TURNED ON Probable Cause 1 Check battery circuit by operating SIGNALS DIM REMAINED 1 turn signals ON OR NOT OPERATED 2 SIGNALS OPERATING CORRECTLY 3 60 120 flashings min 4 5 2 Remove lamp and check for broken LAMP NOT LIT 9 1 fifament LAMP LIT INCORRECT 1 2 3 3 Check for loose disconnected or improperly connected terminal CORRECT INCORRECT ED 1 2 4 Remove oil level sensor and check operation Float up Lamp off Float down Lamp on CORRECT Blown fuse Weak or dead battery Faulty ignition switch Disconnected wire connector Broken wire harness Blown bulb Loose or disconnected terminal Broken wire harness Incorrect wire connection Stuck float Broken or shorted balancing coils INDICATOR LAMP REMAINS ON WITH SUFFICIENT OIL IN OIL TANK IGNITION SWITCH ON Probable Cause 1 2 3 1 Check for loose disconnected or improperly connected terminals CORRECT 2 Remove oil level sen
7. BULB REPLACEMENT BULB SOCKETS Remove the sockets and replace the bulbs with new ones METER DISASSEMBLY METER ASSEMBLY Remove the four screws and remove the meter as sembly Remove the meter cover Remove the indicator panel by releasing the locking pawis Date of issue May 1983 123 m HONDA MOTOR CO LTD 1 2 5 STEERING FRONT WHEEL BRAKE SUSPENSION Remove the meter from the case by removing the three nuts and two screws METER ASSEMBL Y INSTALLATION The assembly and installation sequence is essentially the reverse order of disassembly and removal HANDLEBAR REMOVAL Remove the meter assembly Page 12 3 Remove the left handlebar switch by removing the two screws Remove the right handlebar switch by removing the two screws Disconnect the throttle cabie from the throttle grip and remove the throttle grip from the handlebar 12 6 THROTTLE GRIP Date of Issue May 1983 HONDA MOTOR CO LTD STEERING FRONT WHEEL BRAKE SUSPENSION Remove the steering stem cap STEM CAP m i EXTENSION 07716 0020500 OR Remove the steering stem nut COMMERCIALL Y AVAILABLE IN U S A T esito Remove the handlebar g LOCK NUT WRENCH 30 32 mm 07716 0020400 OR COMMERCIALLY AVAILABLE IN U S A INSTALLATION Install the handlebar aligning the tabs of the han dlebar
8. Date of Issue May 1983 HONDA MOTOR LTD FUEL SYSTEM Install the float valve float and float pin FLOAT PIN FLOAT LEVEL INSPECTION Measure the float level with the float tip just contact ing the float valve FLOAT LEVEL 8 5 mm 0 335 in Adjust by carefully bending the float arm until the float tip en Check operation of the float and install the float chamber a 7 38 Doe w E ut 4 FLOAT GAUGE 074010010000 CARBURETOR INSTALLATION CONTROL TUBE CAUTION Do not allow foreign particles to enter the car buretor Connect the control box and bystarter tubes to the carburetor install the carburetor and connect the fuel tube Install the frame center cover if it was removed BYSTARTER TUBE HN CARBURETOR FUEL TUBE Date of Issue May 1983 41 HONDA MOTOR CO LTD 4 47 FUEL SYSTEM install the throttle valve aligning the groove in the GROOVE throttle valve with the throttle stop screw ee Se 3 T ii 13 Install the carburetor top ur THROTTLE STOP SCREW Install the air cleaner element ins tall the right and left frame covers Perform the following adjustments and operation Throttle cable free play adjustment Page 3 4 Oil pump ad ustment Page 2 4 e Idle speed adjustment Page 3 7 4 8 E 42 Date of Issue May 1983 HONDA
9. HONDA MOTOR CO LTO 8 11 DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH KICK STARTER ASSEMBLY Assemble the kick starter idle shaft Install the special pin in the hole of the spindle and install the spring on the spindle KICK STARTER INSTALLATION Apply grease to the spring groove and spline of the idle gear install the kick starter idle gear aligning the dowel pin on the idle gear with the cutout of the case Align the idle gear friction spring with the groove in the left case as shown 8 12 DOWEL PIN STARTER IDLE GEAR FRICTION SPRING IDLE GEAR 84 SPRING IDLE GEAR SHAFT RETURN SPRING SPECIAL PIN CUTOUT KICK STARTER SPINDLE FRICTION SPRING Date of Issue May 1983 HONDA MOTOR CO LTO DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH 1 Sa SSIS 7 3 Ji T 1 m dum Install the starter driven gear STARTER DRIVEN GEAR rei 1 1 Install the kick starter spindle turning the idle gear to align the punch mark as shown Hook the long end of the spindle return spring on the spring stopper as shown Install the drive belt and movable drive face assem bly Page 8 6 Install the left case cover and kick starter pedal Page 8 7 Install the frame center cover Section 11 Date of Issue May 1983 OHONDA MOTOR LTO DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH CLUTCH DRIVE
10. TORQUE VALUES ENGINE THREAD DIA TORQUE 6 10 10 10 6 6 6 8 12 0 8 1 2 6 9 While the engine is cold below I c Cylinder head Flywheel 35 40 3 5 4 0 25 29 35 C 95 F Drive pulley 35 40 3 5 4 0 25 29 35 40 3 5 4 0 25 29 35 40 3 5 4 0 25 29 Clutch outer Driven face and clutch Intake pipe 8 12 0 8 1 2 6 9 Carburetor 9 12 0 9 1 2 7 9 Crankcase 8 12 0 8 1 2 6 9 FRAME THREAD DIA TORQUE N m kg m ft lb REMARKS Steering stem nut 8 0 12 0 58 87 Front axle nut 5 0 7 0 36 51 Self locking nut Engine hanger bolt 2 7 3 3 20 24 Self locking nut Rear axle nut 8 0 10 0 58 72 Self locking nut Rear shock absorber 3 0 4 0 22 29 Upper Rear shock absorber 2 0 3 0 14 22 Lower Rear shock absorber damper lock nut Rear brake arm 0 4 0 7 3 5 Kick starter pedal 0 8 1 0 6 7 Front brake arm 0 8 1 2 6 9 Front fork pivot arm 2 0 2 4 14 17 1 5 2 5 11 18 Apply a locking agent Muffler 4 0 5 0 29 36 Torque specifications listed above are for important fasteners Others should be tightened to the standard torque values below STANDARD TORQUE VALUES ITEM TORQUE N m kg m ft Ib TORQUE N m kg m ft Ib 5 mm bolt and nut 4 6 0 4 0 6 3 4 mm screw 3 5 0 3 0 5 3 4 6 mm b
11. Remove the journal bearing from the crankshaft CRANKSHAFT JOURNAL BEARING with the bearing puller Remove the right and teft oil seals NOTE Replace the oil seals with new ones whenever disassembled UNIVERSAL BEARING PULLER CRANKSHAFT 07631 0010000 NOT AVAILABLE IN U S A EQUIVALENT AVAILABLE IN U S A CRANKSHAFT INSPECTION mE Measure the connecting rod big end side clearance with a feeler gauge SERVICE LIMIT 0 5 mm 0 02 in Measure the connecting rod big end radial clearance at two points in the X and Y directions SERVICE LIMIT 0 04 mm 0 0016 in Date of Issue May 1983 107 HONDA MOTOR CO LTD 1 3 CRANKCASE CRANKSHAFT Set the crankshaft on a stand or in V blocks and read runout at points A and B using a dial gauge SERVICE LIMITS A 0 10 mm 0 004 in B 0 10 mm 0 004 in Spin the crankshaft bearing by hand and check for play The bearing must be replaced if it is noisy or has excessive play CRANKSHAFT INSTALLATION Wash the crankshaft in solvent and blow dry with compressed air Check for cracks or other faults NOTE Apply clean engine oil to all moving and sliding surfaces Remove all gasket materials from the crankcase mating surfaces Dress any roughness or irregularities with oil stone 10 4 108 m if 2 4 8 RADIAL Date of Issue May 1983 HONDA MOTOR CO LTO Drive a new journal b
12. SGHOP MANUAL NHS8SO aeroSgQ GC801 PC M A5009209E 61 O H O lt P 80 HOW TO USE THIS MANUAL Follow the Maintenance Schedule Section 3 re commendations to ensure that the vehicle is in peak operating condition and the emission levels are withir the standards set by the U S Environ mental Protection Agency Performing the first scheduled maintenance is very important It com pensates for the initial wear that occurs during the break in period Sections 1 through 3 apply to the whole motor scooter while sections 4 through 16 describe parts of the scooter grouped according to loca tion Find the section you want on this page then turn to the table of contents on page 1 of that section Most sections start with an assembly or system illustration service information and trouble shooting for the section The subsequent pages give detailed procedures If you are familiar with this scooter read the TECHNICAL FEATURES in section 16 If you don t know what the source of the trouble is refer to section 18 Troubleshooting ALL INFORMATION ILLUSTRATIONS DI RECTIONS AND SPECIFICATIONS INCLUD ED N 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 NO TICE AND WITHOUT INCURRIN
13. Battery Capacity 12V 1 270 1 290at 20 C 68 F Charging rate 0 5A max Alternator Charging rpm 2 000 rpm max 16 4V Capacity 0 9A min 4 000 rpm 17 7V 1 4A max 6 000 rpm 18 0 V IGNITION SYSTEM ITEM SPECIFICATIONS 1 5 For cold climate Below 5 C 41 F BP Ren For extended high BPR7HS W22FPR speed riding Spark plug gap 0 6 0 7 mm 0 024 0 028 in Ignition timing 14 BTDC at 1 800 rpm Spark plug Date of Issue May 1983 159 1 5 HONDA MOTOR CO LTD b ELECTRICAL EQUIPMENT TROUBLESHOOTING CHARGING SYSTEM No power 1 Dead battery Low fluid level Battery sulfation Internally shorted battery Charging system failure 2 Disconnected battery cable 3 Fuse burned out 4 Faulty ignition switch Low power 1 Weak battery 2 Loose battery connection 3 Charging system failure IGNITION SYSTEM No spark at ptug 1 Faulty spark plug 2 Poorly connected broken or shorted wire Between pulse generator and CDI unit Between CD unit and ignition coil Between CD unit and ignition switch Between ignition coil and spark plug Faulty ignition switch Faulty ignition coil Faulty CDI unit Faulty pulse generator LW Starter won t turn 1 Fuse burned out Weak battery Faulty ignition switch Faulty starter switch Faulty front or rear stop switch Faulty starter relay Poorly connected
14. SPARK PLUG INDEX MARK Ss a 15 8 Date of Issue May 1983 HONDA MOTOR CO LTO HON DA NH80 ELECTRICAL EQUIPMENT IGNITION COIL INSPECTION Remove the left frame cover Disconnect the plug cap from the high tension wire while rotating the plug cap Measure the resistances of the primary and second ary coiis RESISTANCES Primary coil 0 2 0 3 2 Secondary coil 3 4 4 2 PULSE GENERATOR INSPECTION PULSE GENERATOR CONNECTORS NOTE nun It is not necessary to remove the stator to make this test Remove the frame center cover Section 17 Disconnect the stator coupier Measure the resistances between the terminals with an ohmmeter Black red Engine ground 50 300 2 Blue yellow Body ground 10 100 82 m iini liz Measure the resistances in the x 1 range Alternator removal installation Page 7 2 7 4 Date of Issue May 1983 167 HONDA MOTOR 1 5 ELECTRICAL EQUIPMENT CDI UNIT INSPECTION Remove the left frame cover Section 11 Disconnect the COI coupler and remove the COI unit Measure the resistances between the terminals IGN EXT Replace the unit if the readings do not fall within the limits in the table NOTE For accurate testing it is necessary to use a specified tester Use of an improper tester or measurements in an improper range may give false readings Use Sanwa Electric Tester
15. broken or shorted wire Faulty starter motor SP WN 15 2 Intermittent power 1 Loose battery cable 2 Loose charging system connection 3 Loose connection or short circuit in lighting system 4 Loose ignition system connection Charging system failure 1 Loose broken or shorted wire or connection 2 Faulty regulator rectifier 3 Faulty alternator Engine starts but turns poorly 1 Ignition primary circuit Faulty ignition coil Loose or bare wire or connector Poorly contacted ignition switch 2 ignition secondary circuit Faulty ignition coil Fauity spark plug Faulty high tension wire Poorly insulated plug cap 3 Improper ignition timing Faulty pulse generator Stator not installed properly Fauity CDI unit Lack of power 1 Weak battery 2 Loose or bare wire or connection 3 Foreign matter stuck in starter or starter gear Engine does not crank starter rotates 1 Faulty starter pinion 2 Low battery 160 Date of issue May 1983 HONDA MOTOR CO LTD ELECTRICAL EQUIPMENT BATTERY NEGATIVE CABLE POSITIVE CABLE REMOVAL INSTALLATION Remove the battery cover Remove the battery holder by removing the attach ing boit Disconnect the negative cable first Then disconnect the positive cable Remove the battery The installation sequence is essentially the reverse order of removal NOTE Connect the battery breather tube to the bat tery breather pipe
16. 0 01 in Rim runout Radial 2 0 mm 0 08 o O S omo Cushion spring free length 225 8 mm 8 89 in 219 0 mm 8 62 in Front brake drum I D 110 0 mm 4 33 in 111 0 mm 4 37 in 4 0 mm 0 156 in 2 0 mm 0 08 in ee Brake lining thickness TORQUE VALUES Steering stem nut Front axle nut Front shock mount bolt Front fork pivot arm Front brake arm TOOLS Common Rear shock absorber compressor Driver Attachment 32 x 35 mm Attachment 42 x 47 mm Pilot 12 mm Extension Lock nut wrench 30 x 32 mm Fork seal driver Fork seal driver attachment Pin spanner Date of Issue May 1983 HONDA MOTOR CO LTD 80 120 N m 8 0 12 0 kg m 58 87 ft lb 50 70 N m 5 0 7 0 36 51 ft lb 30 36 3 0 3 6 22 26 ft lb 20 24 N m 2 0 2 4 kg m 14 17 ft Ib 8 12 N m 0 8 1 2 kg m 6 9 ft lb 07959 3290001 07749 0010000 07746 0010100 07746 0010300 07746 0040200 07716 0020500 07716 0020400 0774 0010499 9 Fork seal driver 07947 3550000 07702 0020000 07702 0010000 or M9361 412 099788 U S A only Equivalent tools commercially available in U S A T 12 1 STEERING FRONT WHEEL BRAKE SUSPENSION TROUBLESHOOTING Hard steering 1 Steering stem nut too tight 2 Steering stem bearings damaged 3 Steering ball and cone races damaged 4 insufficient tire pressure Steers to one side or does not track st
17. 0040200 Pla mm Use with 07746 0010100 and 07749 0010000 e 2 install from wheel bearings 0933242 07743 0010000 SUSPENSION FRAME H C TOOLNUMBER DESCRIPTION APPLICABILITY Steering stem adjuster nut removal adjustment Top steering head race tnstallation Use with Pilot 25 mm 07746 0040600 and 07749 0010000 Bottom steering head race installation Use with Pilot 30 mm 07746 0040700 and 07749 0010000 0997882 9361 412 099788 Adiustable Pin Soanner Wrench 0753491 07746 0010200 Attachment 37 x 40 mm 0959817 07746 0010300 Attachment 42x47 _ 0959916 07746 0040600 Pilot 25 mm Use with 07746 0010200 to install top steering head race 1021252 07746 0040700 Pilot 30 mm Use with 07746 0010300 to install bottom steering head race 0933242 07749 0010060 0338699 07947 3550000 Fork Seal Driver Steering stem bottom race installation Use with old bearing race turned over for additional height OPTIONAL TOOLS The following tools are available from American Honda but are not required tools for this model H C TOOL NUMBER DESCRIPTION APPLICABILIT Y 0688168 07959 3290001 1277649 07967 GA70001 Rear Shock Absorber Compressor eaimetisiciwabsarber ti Attachment 0324210 07567 1180100 American Honda Motor Inc 1985 Rights Reserved
18. 1983 HONDA MOTOR CO LTD 14 3 FUEL TANK OIL TANK OIL TANK REMOVAL INSTALLATION Remove the frame center and rear covers Section 11 Drain oil from the oil tank Disconnect the oil level indicator switch coupler Remove the oil tank Clean the oil strainer Page 3 6 To install reverse the foregoing removal procedure Bleed the oil line after installing the oil pump Page 2 3 OIL TANK qni y MI Y ELM ue i 1 ES o zi 1 r itl La f 15 1 E L P OIL LEVEL INDICATOR SWITCH COUPLER 14 4 158 Date of Issue May 1983 HONDA MOTOR LTD 15 ELECTRICAL EQUIPMENT __ SERVICE INFORMATION 15 1 STARTING SYSTEM 15 11 TROUBLESHOOTING 15 2 SWITCHES HORN 15 15 BATTERY 15 3 FUEL GAUGE SENSOR 15 17 CHARGING SYSTEM 15 5 OIL LEVEL INDICATOR UNIT 15 18 IGNITION SYSTEM 15 8 FRONT TURN SIGNALS 15 19 SERVICE INFORMATION GENERAL Do not quick charge the battery Quick charging may damage the battery Remove the battery from the motorcycle for charging Remove the cell caps before charging the battery Do not smoke or have flames near a charging battery The gas produced by a battery is very flammable and can explode Ignition timing cannot be adjusted If the timing is incorrect inspect the unit and pulse generator and replace any faulty parts SPECIFICATIONS CHARGING SYSTEM ITEM SPECIFICATIONS
19. A 1 2 Probable cause Worn or slipping drive belt Broken ramp plate Broken drive face spring Separated clutch lining Damaged driven pulley shaft splines Faulty transmission Seized transmission Broken shoe spring Stuck clutch outer Weight Seized pivot Worn or slipping drive belt Worn weight roller Seized drive pulley bearing Weak driven face spring Worn or seized driven pulley bearing Worn or slipping drive belt Worn weight roller Worn driven pulley bearing Oily or greasy substances on drive belt pulley Worn drive belt Weak driven face spring Worn or seized driven pulley bearing Probable Cause Steering head adjuster too tight Damaged steering cones or steel balls Excessive wheel bearing play Bent rim Loose axle nut Misaligned front and rear wheels Bent front fork Probable Cause Weak shock spring Excessive load Leaky damper Bent fork or shock rod Stider binding Damaged shock stopper rubber 190 18 4 Date of Issue May 1983 HONDA MOTOR CO LTD TROUBLESHOOTIN POOR BRAKE PERFORMANCE Check brake adjustment 1 If wear indicator arrow aligns with index mark on brake panel 3 9 11 2l 3 4 2 If either brake is squealing l 1 2 3 If brake performance is poor 2
20. Clogged fuel line 3 Clogged fuel strainer 4 Stuck fuel valve diaphragm Mixture too lean 1 Clogged fuel tank cap breather hole 2 Clogged or collapsed fuel line 3 Clogged fuel strainer Date of Issue May 1983 155 HONDA MOTOR CO LTO 1 4 1 FUEt TANK OtL TANK FUEL TANK FUEL GAUGE SENSOR REMOVAL INSTALLATION Raise the seat Disconnect the fuel gauge sensor wire connectors Remove the fuel gauge sensor by turning it counter clock wise NOTE e Do not bend the float arm Install the fuel gauge sensor with the arrow on the sensor aligned with the arrow on the fuel tank FUEL TANK REMOVAL Remove the frame center and rear covers Section 11 Disconnect the resistor wire connector Remove the bolt and take out the battery 14 2 156 CONNECTORS ARROWS ie BATTERY BOX Date of Issue May 1983 HONDA MOTOR CO LTO Disconnect the fuel and vacuum tubes Remove the seat Disconnect the fue gauge sensor wire connectors Remove the fuel tank mount bolts and remove the fuel tank Remove and clean the fuel strainer Remove the fuel gauge sensor Page 14 2 Check the fuel gauge sensor s operation page 15 18 FUEL TANK INSTALLATION The installation sequence is essentially the reverse order of removal FUEL TANK OIL TANK FUEL TUBE oW i M iilii i TC RO ei WIRE CONNECTORS Date of Issue May
21. EQUIPMENT STARTER MOTOR REMOVAL Remove the engine Section 5 Remove the two bolts attaching the starter motor and remove the starter motor STARTER MOTOR DISASSEMBL Y Disconnect the starter wires SPRING NOTE The brush springs will pop out when re moving the brush holder plate e Record the number and location of the commutator thrust washers BRUSH INSPECTION Measure the length of each brush SERVICE LIMIT 3 0 mm 0 12 in 15 12 7 BRUSH Date of Issue May 1983 HONDA MOTOR LTD COMMUTATOR INSPECTION Check the commutator for discoloration and other visual faults Blackened adjacent segments are an indication of a shorted circuit NOTE Do not use sand paper to clean the commuta tor Check for continuity between segments and com mutator and shaft The commutator is normal if there is continuity between the segments There should be no continuity between the commutator and shaft STARTER MOTOR ASSEMBLY Install the brush springs and brushes in the holder plate Install the commutator and thrust washers while extending the brushes outward NOTE Note the number and location of the thrust washers CAUTION Check that there is no foreign material inside the starter bod y Install the commutator with the brush holder into the starter body ELECTRICAL EQUIPMENT BRUSH HOLDER COMMUTATOR Date of Issue May 198
22. INSTALLATION 5 1 5 4 5 1 ENGINE REMOVAL INSTALLATION ENGINE REMOVAL Remove the frame center cover Remove the right and left floor boards Section 11 Remove the battery cover and disconnect the bat tery ground cable from the battery negative termi nal Remove the spark plug cap from the spark plug Remove the alternator and starter coupler and con nectors Date of Issue May 1983 HONDA MOTOR LTD ENGINE REMOVAL INSTALLATION Remove the carburetor top CARBURETOR TOP Disconnect the vacuum tube and fuel line Gm i pod miu 4 TC jane T 1 s dme imc Tux a eee oer FUEL LINE d VACUUM TUBE Disconnect the rear brake cable P 1 E E uu CABLE CLAM BRAKE CABLE CABLE SET PLATE Remove the rear shock absorber REAR SHOCK ABSORBER 2 Date of Issue May 1983 51 5 3 HONDA MOTOR CO C TD ENGINE REMOVAL INSTALLATION Unscrew the nut and remove the engine mounting bolt Slide the engine toward the rear Disconnect the oil control cable Disconnect the oil tube Remove the engine ENGINE INSTALLATION The installation sequence is essentially the reverse S q ER order of removal TUBE Tighten the engine mounting bolt and rear shock absorber upper and lower bolts to the specified torque values TORQUE Engine mounting bolt
23. SP 10D 07308 0020000 Kowa Electric Tester TH 5H or Kowa Digital Multi Tester KS AHM 32 003 U S A only n the table Needle swings then returns indicates that there is a charging current applied to a condenser The needle will then remain at unless the condenser is discharged rhe FIIIT PC E SW NOTE Use the x range for Sanwa Tester Use the x 100 82 for Kowa Tester UNIT KQ PROBE _ IGN PROBE we oo then returns 1 5 1 O 168 Date of Issue May 1983 HONDA MOTOR CO LTD ELECTRICAL EQUIPMENT FUSE 7A gt LJ STARTER SWITCH IGNITION SWITCH STARTING SYSTEM STARTING CIRCUIT BATTERY i FRONT REAR STOP STOP SWITCH SWITCH R W STOP LAMP RED ab 12v 21 Y YELLOW W WHITE STARTER RELAY G GREEN STARTER MOTOR STARTER RELAY INSPECTION The primary coil is normal if you hear a click when the starter button is depressed Connect a 12V battery to the primary coil Check for continuity of the secondary terminals Replace the starter relay switch with a new one if there is no continuity STARTER RELAY REMOVAL Remove the frame center cover Section 11 Remove the battery box Page 15 4 Remove the starter relay switch Date of Issue May 1983 169 S HONDA MOTOR CO LTD 1 5 1 1 ELECTRICAL
24. bracket with the grooves in the steering stem Date of Issue May 1983 125 HONDA MOTOR CO LTO 1 2 7 STEERING FRONT WHEEL BRAKE SUSPENSION Torque the steering stem nut TORQUE 80 120 N m 8 0 12 0 kg m 58 87 ft Ib Apply grease to the throttle grip area of the handle bar Install the throttle grip onto the handlebar and con nect the throttle cable to the throttle grip Install the right and left handlebar switch housings on the handlebar NOTE Align the punch mark on the handlebar with the split in the housing e Tighten the forward screw first then tighten the rear screw After tightening the screws check that the throttle grip rotates freely in all steering positions Install all the removed parts Perform the following adjustments and operations Brakelever free play Page 3 9 Headlight aiming Page 3 1 0 Throttle grip free play 3 4 Check the operation of all electrical parts 12 8 EXTENSION 07716 0020500 OR COMMERCIALL Y AVAILABLE IN U S A m ONCE FRR LOCK NUT WRENCH 30 x 32 mm 07716 0020400 OR COMMERCIALL Y AVAILABLE IN U S A THROTTLE GRIP PUNCH MARKS 126 Date of ssue May 1983 HONDA MOTOR LTD FRONT WHEEL REMOVAL Remove the cushion covers Disconnect the speedometer cable from the speedo meter gearbox Disconnect the brake cabie from the brake arm Loosen the right and left pivot arm bolts R
25. crankcase Remove the engine Section 5 Remove the starter motor Page 15 13 Disconnect the oi outlet line from the intake pipe Remove the oil pump attaching bolt and remove the oil pump OIL PUMP INSPECTION LEVER MATING SURFACE Remove the oil pump and inspect the following items Damaged or weak O rings Damage to crankcase mating surface Damage to pump body Control lever operation Worn or damaged pump gears Oii leaks CAUTION Do not disassemble the oil pump OIL PUMP INSTALLATION Install the oil pump onto the crankcase CAUTION e Lubricate the pump gear and O ring with clean grease before installation e Make sure that the oil pump is inserted into the crankcase properly 2 2 16 Date of Issue May 1983 HONDA MOTOR LTD LUBRICATION Tighten the oil pump attaching boit securely OIL OUTLET LINE Connect the oil outiet line mma Install the starter motor Page 15 15 Install the engine Page 5 4 9822 After installation perform the following inspec tions and adjustment Control cable adjustment Page 2 4 Oil pump bleeding Check for oil leaks EEG our D NES mum OIL PUMP BLEEDING CAUTION e Air in the oil system will block or restrict oil flow and may result in severe engine dam age e Bleed air from the oil inlet line first then ble
26. more existing models additional or replacement tools that you may need can be ordered using normal ordering procedures You should have these special tools or their approved equivalents in your dealership as outlined in Service Tool News General 82 Minimum Tool and Equipment Requirements New special tools as they are developed will be shipped to you automatically ENGINE TOOLS INSPECTION ADJUSTMENT H C TOOL NUMBER DESCRIPTION APPLICABILITY 1230382 ST AH 260 MC7 Hand Vacuum Pump with Gauge Fuel valve inspection Pump A937X 041 XXXXX may also be used 0238923 07401 0010000 Float Level Gauge CLUTCH H C TOOL NUMBER DESCRIPTION APPLICABILITY 1049154 07725 0030000 Universat Holder Hoid flywheel to assist drive clutch nut removal and installation 1072974 07916 1870001 Lock Nut Wrench Remove and install the driven pulley nut 1505809 07960 K J90000 C utch Spring Compressor Compresses the driven pulley to disassemble and ve assemble ciuich unit uu tle TOOL NUMBER DESCRIPTION APPLICABILITY 1049154 07725 0030000 Universal Holder Hold flywheel assist flywheel nut removal tor quing 0060756 07933 001 0000 Flywheel Puller Flywheel removal TRANSMISSION CRANKSHAFT H C TOOL NUMBER DESCRIPTION APPLICABILITY 0753509 07746 0010100 To install transmission cover bearing 46202 and left crankcase bearing 86201 0753491 07746 0010200 Attachment 37 x 40 mm To install tra
27. oil seal after assembling the crankcase SPECIFICATIONS ITEM J STANDARD SERVICE LIMIT Connecting rod big end side clearance 0 5 mm 0 02 in Connecting rod big end radial clearance 0 04 mm 0 0016 in _ Crankshaft runout 0 10 mm 0 004 TOOLS Special Seal and case assembling tool 07965 GC70000 or Assembly collar 07965 GC70100 L Assembly tool 07965 1480001 Universal bearing puller 07631 0010000 not available in U S A Crankcase puller 07935 KG80000 Common Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Pilot 25 mm 07746 0040600 Date of Issue May 1983 105 1 O 1 HONDA MOTOR CO LTO CRANKCASE CRANKSHAFT CRANKCASE SEPARATION Remove the crankcase attaching bolts CRANKCASE PULLER 07935 KG80000 Attach the crankcase puller on the right crankcase as shown with the two special long bolts Separate the right crankcase half i i 1 1 k FL y i ERE oa 4 eee lt t i XI MU anm RIGHT CRANKCASE CRANKSHAFT REMOVAL CRANKSHAFT Attach the special tool on the left crankcase as shown with the three special short bolts mu ort j 6 Remove the crankshaft ib ii A CAUTION Do not drive the crankshaft out with ham mer of EL CRANKCASE PULLER 07935 KG80000 1 O 2 106 Date of Issue May 1983 HONDA MOTOR CO LTD CRANKCASE CRANKSHAFT
28. rings Flaw in cylinder orcylinder head Compression leak past crankcase g Blown cylinder head gasket Faulty control box Air leaking past intake pipe Improper ignition timing Carbon blocking exhaust system Carburetor flooded Faulty control box Throttle valve open excessively Date of Issue May 1983 HONDA MOTOR CO LTD 187 18 1 TROUBLESHOOTING ENGINE LACKS POWER 1 Lightly accelerate engine ENGINE SPEED INCREASES 2 Check ignition timing CORRECT 3 Test cylinder compression NORMAL Y 4 Check carburetor for clogging NOT CLOGGED 5 Remove spark plug NOT FOULED OR DISCOLORED 6 Check if engine overheats NOT OVERHEATED 7 Try rapid acceleration or run at high speed ENGINE DOES NOT KNOCK Probable Cause ENGINE SPEED DOES NOT 9 1 INCREASE SUFFICIENTL Y 2 3 4 INCORRECT 1 2 2 3 4 d i FOULED A 1 DISCOLORED 2 OV ER HE A T E D d 1 2 3 4 5 ENGINE KNOCKS 9 1 2 3 4 Clogged air cleaner Restricted fuel flow Clogged fuel tank cap breather hole Clogged muffler Faulty CDI unit Faulty pulse generator Worn cylinder or piston rings Blown cylinder head gasket Flaws in cylinder or cylinder head Faulty or deteriorated reed valve Carbon build up in combustion chamber Carburetor not serviced frequent ly enou
29. rotation and prevents clock wise rotation NOTE An air screw limiter cap must be installed It prevents misadjustment that could cause poor performance and increase emissions HIGH ALTITUDE ADJUSTMENT For sustained high altitude operation above 2 000 m 6 500 ft install a 82 main jet and readjust idle speed Remove the carburetor from the engine and remove the float chamber Replace the standard main jet with the high altitude 82 main jet Assemble and install the carburetor Adjust idle speed to 1 800 100 rpm using the throttle stop screw CAUTION Sustained operation at altitudes lower than 1500 m 5 000 ft with the high altitude main jet installed may cause engine overheat ing and damage For sustained operation below 1 500 5 000 ft reinstall the stand ard main jet and readjust idle speed type 1 500 m Standard 2 000 m 6 500 ft max 5 000 ft min s Idle speed 1 800 100 rpm Air screw initial Factory pre set 1 opening Attach the vehicle m ssion Control Information Update Label as shown NOTE Do not attach the label to any part that can be easily removed from the vehicle High altitude Main jet FUEL SYSTEM LIMITER CAP _ VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL Date of issue May 1983 HONDA MOTOR CO LTD a 4 11 FUEL SYSTEM REED VALVE REMOVAL Remove
30. the frame center cover Remove the carburetor Page 4 3 Remove the engine shrouds Page 6 2 Remove the intake pipe Remove the reed valve REED VALVE INSPECTION REED VALVE REED STOPPER Check the reed valve for damaged or weak reeds Check the valve seat for cracks damage or clearance between the seat and reed Replace the valve if necessary CAUTION Do not disassemble or bend the reed stopper To do so can cause loss of power and engine damage f the stopper reed or valve seat is fault y replace them as a unit INSTALLATION This installation sequence is essentially the reverse order of removal After installation check for secondary leaks REED VALVE SEAT 4 1 2 46 Date of issue May 1983 HONDA MOTOR CO LTD HONDA 80 FUEL SYSTEM AUTO FUEL VALVE INSPECTION INSPECTION Gasoline is extremely flammable is ex plosive under certain conditions Perform this operation in a well ventilated area and do not smoke or allow sparks the area 1 With the engine stopped disconnect the fuel line from the carburetor and check if fuel is flowing out of the fuel line The fuel valve is normal if fuel ceases to flow out HAND VACUUM PUMP of the fuel line after the remaining fuel 5 10 ST AH 260 MC7 cc has been drained out of the fuel valve and U S A ONLY fuel line thoroughly Should fuel fail to stop flowing out of the fuel line check the v
31. the top cone race Install the following Front wheel Page 12 12 Handlebar Page 12 7 Meter assembly Page 12 6 Glovebox Section 11 J SPANNER D7702 0020000 07702 0010000 or 9361 412 099788 U S A only 1 2 a 2 4 142 Date of Issue May 1983 HONDA MOTOR CO LTD REAR WHEEL BRAKE SUSPENSION 30 40 N m 3 0 4 0 kg m 22 29 ft lb 20 30 N m 2 0 3 0 14 22 ft lb 80 100 N m 8 0 10 0 kg m 58 72 ft lb 1 3 s O 144 Date of Issue May 1983 HONDA MOTOR CO LTO 13 REAR WHEEL BRAKE SUSPENSION SERVICE INFORMATION 13 1 TROUBLESHOOTING 13 1 REAR WHEEL 13 2 REAR BRAKE 13 3 REAR SHOCK ABSORBER 13 6 SERVICE INFORMATION GENERAL Brake dust contains esbestos which can be harmful to your health Do not use compressed air to clean brake drums or brake pads Use a vacuum with a sealed dust collector Wear a protective face mask and thoroughly wash your hands when finish ed SPECIFICATIONS ITEM STANDARD E SERVICE LIMIT Rear wheel rim runout 2 0 mm 0 08 Brake drum 1 0 95 0 mm 3 74 in 95 5 mm 3 76 in Brake lining thickness 5 0 mm 0 20 in Rear shock absorber spring free length 228 6 mm 9 00 in TORQUE VALUES Rear shock upper mount bolt 30 40 N m 3 0 4 0 kg m 22 29 ft lb Rear shock lower mount bolt 20 30 N m 2 0 3 0 kg m 14 22 ft lb Rear axle nut 80 100 N m 8 0 10 0
32. too high overheating or knocking 1 Excessive carbon build up in cylinder or on pis ton top Date of Issue 1983 55 6 1 HONDA MOTOR CO LTD CYLINDER HEAD CY LINDER PISTON CYLINDER HEAD CYLINDER HEAD REMOVAL Remove the right floor board Section 11 Remove the exhaust muffler Page 13 2 Remove the cooling fan cover uA Lae EARUM Remove the spark plug cap and spark plug Sasa FAN COVER Remove the rear shock absorber SHOCK ABSORBER Remove the air cleaner case rear fender SS e E iS 25 AIR CLEANER CASE REAR FENDER Remove engine shroud A SHROUDA 6 2 56 Date of Issue 1983 HONDA MOTOR CO L TD CYLINDER HEAD CYLINDER PISTON Remove the bolts attaching the control box and re SHROUD B move the control box rein Remove engine shroud B E La i EG CONTRO L BOX Remove the four cylinder head attaching bolts and remove the cylinder head NOTE Loosen the bolts in a criss cross pattern in 2 3 steps to prevent distorted head a CYLINDER HEAD CYLINDER HEAD INSPECTION Check the cylinder head for warpage with a straight edge and a feeler gauge n the directions shown SERVICE LIMIT 0 10 mm 0 004 in MU MT eer n Date of Issue May 1983 57 6 3 HONDA MOTOR CO LTD CYLINDER HEA
33. 1983 111 HONDA MOTOR CO LTD 1 7 FRAME COVERS Date of Issue May 1983 HONDA MOTOR CO LTD 11 FRAME COVERS FRAME COVER REMOVAL 11 2 FRAME COVER INSTALLATION 11 4 Date of Issue May 1983 113 1 1 1 HONDA MOTOR LTD FRAME COVERS FRAME COVER REMOVAL GLOVEBOX FLOOR PLATE REMOVAL Remove the floor mats Open the glovebox lid and remove the glovebox by GLOVEBOX NUT unscrewing the nut two bolts and ten screws T Remove the two boits attaching the floor plate and FLOOR PLATE remove the floor plate mess 1 1 2 114 Date of Issue May 1983 z HONDA MOTOR CO LTD FRAME COVERS FRAME CENTER COVER REMOVAL Remove the right and left frame covers Remove the floor mats Remove the four bolts and cap nut and remove the frame center cover RIGHT AND LEFT FLOOR BOARD REMOVAL Remove the glovebox and floor plate Page 11 2 Remove the frame center cover Remove the right and left floor boards CAP NUT CENTER COVER LEFT FLOOR BOARD s SEA Date of Issue May 1983 HONDA MOTOR CO LTO T 11 3 HONDA 12 STEERING FRONT WHEEL NH80 BRAKE SUSPENSION SERVICE INFORMATION 12 1 TROUBLESHOOTING 12 2 SPEEDOMETER 12 3 HANDLEBAR 12 6 FRONT WHEEL 12 9 FRONT BRAKE 12 13 FRONT SHOCK 12 16 FRONT FORK 12 20 SERVICE INFORMATION SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Axle shaft runout 0 2 mm
34. 27 33 N m 2 7 3 3 kg m 20 24 ft lb Rear shock absorber upper mounting bolt 30 40 N m 3 0 4 0 22 29 ft lb Rear shock absorber lower mounting bolt 20 30 2 0 3 0 kg m 14 22 ft Ib Perform the following inspections and adjustments after installation e Wire and cable routing Page 1 8 1 9 Throttle cable Page 3 4 Oil control cable Page 2 4 Oil pump bleeding priming Page 2 3 o LTD Rear brake adjustment Page 3 9 5 4 52 Date of Issue May 1983 j HONDA MOTOR CO CYLINDER HEAD CYLINDER PISTON 8 12 N m 0 8 1 2 kg m 6 9 ft lb 6 0 54 Date of Issue May 1983 HONDA MOTOR CO LTD HONDA NH80 6 CYLINDER HEAD CYLINDER PISTON SERVICE INFORMATION 6 1 TROUBLESHOOTING 6 1 CYLINDER HEAD 6 2 CYLINDER PISTON 6 4 SERVICE INFORMATION GENERAL All cylinder head cylinder and piston maintenance and inspection be done with the engine installed Before disassembly clean the engine to prevent dirt and dust from entering the cylinder and crankcase Remove all gasket material from the mating surfaces of the cylinder head cylinder and crankcase Use caution when disassembling and assembling the cylinder head cylinder and piston to avoid damaging them Ciean all disassembled parts thoroughly before inspection Coat all sliding surfaces with clean motor oil before assembly SPECIFICATIONS ITEM STAN
35. 3 HONDA MOTOR CO LTD ELECTRICAL EQUIPMENT HONDA NH80O Lubricate the starter pinion with clean grease Install the pinion and starter cover Lubricate the gear on the starter body and install the starter motor cover on the body Connect the starter wires STARTER MOTOR INSTALLATION NOTE Before installing the starter test for operation by connecting the starter coupler to the wire harness Install the starter motor in the reverse order of re moval Secure the wires with the wire clamps Install the engine Section 5 15 14 172 STARTER COVER PINION GEAR i STARTER BODY STARTER COVER STARTER WIRES Date of Issue May 1983 HONDA MOTOR LTO SWITCHES HORN Remove the handlebar lower cover and glovebox Check the continuity of each switch Continuity should exist between color coded wires indicated by interconnected circles on each chart IGNITION SWITCH BLACK GREEN ic HORN SWITCH COLOR LIGHT d n __ up E HEADLIGHT HI LOW SWITCH ELECTRICAL EQUIPMENT IGNITIDN SWITCH HEADLIGHT HI LDW SWITCH i Eqs a 8 le ls TURN SIGNAL SWITCH HORN SWITCH Date of Issue May 1983 HONDA MOTOR CO L TO 15 15 ELECTRICAL EQUIPMENT ENGINE STOP SWITCH COLOR BLACK CODE WHITE IG e STARTER SWITCH COLOR CODE RED eE 9 FR
36. 36 1660100 and REMOVER WEIGHT 07936 3710200 9 4 100 Date of Issue May 1983 HONDA MOTOR CO LTD FINAL REDUCTION DRIVER FINAL GEAR FINAL REDUCTION INSTALLATION SHAFT BEARING Install the drive shaft bearing in the transmission cover Install the final gear shaft bearing in the transmis sion cover using the following tools Driver 07749 0010000 Attachment 32 x 35 mm 07746 0010100 Pilot 15 mm 07746 0040300 ATTACHMENT 37 x 40mm DRIVE SHAF PILOT 17 mm 07746 0010200 BEARING 07746 0040400 Install a new oil seal in the transmission cover OIL SEAL DRIVER Drive the final shaft bearing into the left case 07749 001 0000 id i it NOUS BERE 2s EE M mgri au WB LZ ATTACHMENT 37 x 40 mm PILOT 17 mm 07746 0010200 07746 0040400 Date of Issue May 1983 101 9 5 HONDA MOTOR LTD FINAL REDUCTION Install a new final shaft oil seal E T CREER alea c dac v DRIVER Install the drive shaft bearing into the left case 07749 0010000 ATTACHMENT 32 x 35 mm PILOT 12 mm 07746 0010100 07746 0040200 Slide the drive shaft through the bearing from the inside DRIVE SHAFT Q 6 102 Date of Issue May 1983 HONDA MOTOR LTD FINAL REDUCTION Install the countershaft final gear and thrust wash COUNTERSHAFT FINAL GEAR er acd ie THRUST WASHER
37. 965 1480200 onto the crankshaft Hold the boit and turn the nut clockwise to draw the crankcase halves together Install the right oil seal place the collar 07965 GC70100 so its stepped end is against the crank case and oil seal Thread the bolt from assembly tool 07965 1480200 onto the crankshaft Hold the bolt and turn the nut clockwise to install the oil seal into place 10 6 DOWEL PINS ASSEMBLY TOOL COLLAR 07965 GC70100 INC IN 07965 GC70000 ITE ASSEMBLING TOOL 07965 1480200 INC IN 07965 GC70000 ASSEMBLING TOOL COLLAR 07965 GC70100 INC IN 07965 GC70000 Im P iim T ASSEMBLY TOOL 07965 1480200 INC IN 07965 GC70000 Date of Issue May 1983 HONDA MOTOR CO LTD 110 CRANKCASE CRANKSHAFT Drive the oil seal into the left crankcase until it is flush with the case gt T a E gt Sae u 1 T B t3 9t Mus 1 i E 1 MU LEFT OIL SEAL Instali and tighten the crankcase bolts NOTE Make sure that the crankshaft rotates freely after tightening the bolts Install the following Final reduction Page 9 5 Alternator Page 7 4 Piston cylinder and cylinder head Page 6 7 Drive and driven pulleys Page 8 6 8 22 Oil pump Page 2 2 Reed valve and carburetor Page 4 12 4 7 Engine Page 5 4 Date of Issue May
38. BRAKE SUSPENSION SPRING FREE LENGTH Measure the spring free length SERVICE LIMIT 221 7 mm 8 73 in ABSORBER ATTACHMENT A ATTACHMENT HOLDER ASSEMBLY 07967 GA70101 07967 GC80000 NOTE Install the spring with the tightly wound coit on the upper metal side Apply locking agent to the lock nut before installation TORQUE 15 25 N m 1 5 2 5 kg m 11 18 ft ib SHOCK ABSORBER LOCK LOWER COMPRESSOR NUT JOINT 07959 3290001 INSTALLATION UPPER MOUNT BOLT Install the rear shock absorber Po USE Tighten the upper and lower mount bolts to the ow er p specified torques 3 TORQUES a EM M 0I ee Upper bolt 30 40 N m 3 0 4 0 kg m 22 29 ft Ib Lower bolt 20 30 2 0 3 0 kg m 14 22 ft Ib Check the operation of the shock absorber by press ing down on the end of the frame several times I Mu 78 LOWER MOUNT BOLT 1 3 8 152 Date of Issue May 1983 x HONDA MOTOR LTO FUEL TANK OIL TANK Date of Issue May 1983 HONDA MOTOR CO LTD 154 14 0 2 HONDA SERVICE INFORMATION TROUBLESHOOTING FUEL TANK OIL TANK SERVICE INFORMATION GENERAL W WARNING Gasoline is extremel y flammable and is explosive under certain conditions Work in a well ventilated area Do not smoke or allow flames or sparks in the work area TROUBLESHOOTING Engine failsto start 1 No fuel in tank 2
39. D CYLINDER PISTON DECARBONIZING COMBUSTION CHAMBER Remove the carbon build up from the combustion chamber using a scraper as shown NOTE Do not scratch the combustion chamber wall and cylinder mating surface CYLINDER PISTON CYLINDER CYLINDER REMOVAL E Wi n m 23 1 4 Pull the cylinder up and off being careful not to tet the piston get damaged CAUTION Do not pn between the cylinder und crank case or strike the fins Place a shop towel into the crankcase around the PISTON piston Remove one piston pin clip and press the piston pin out of the piston NOTE Do not damage or scratch the piston Do not apply side force to the connecting rod Do not let the clip fall into the crankcase PISTON PIN CLIP PISTON PIN 6 4 58 Date of Issue May 1983 HONDA MOTOR CO LTD CYLINDER HEAD CYLINDER PISTON Remove the piston rings NOTE Spread each piston ring and remove by lifting it up at a point just opposite the gap Remove the expander CYLINDER PISTON INSPECTION Check the cylinder and ptston for wear or damage Clean carbon deposits from the cylinder exhaust port area and piston as shown CAUTION Do nort scratch or score the cylinder and pis ton DS Inspect the cylinder bore for wear at three levels in X and Y directions Use the largest measurement to determine the cylinder wear SERVIC
40. DARD SERVICE LIMIT Cylinder head 0 10 mm 0 004 Piston Piston O D 47 965 47 975 mm 1 8884 1 8888 in 47 900 mm 1 8858 in 0 035 0 050 mm n 0 001 3 0 0020 020 in 0 100 mm 0 0039 in 12 002 12 008 mm 0 4725 0 4728 12 025 mm 0 4734 in Piston ring end gap top second 0 15 0 35 mm 0 006 0 014 in 0 60m mm 0 0 024 in 17 005 17 017 mm 0 6695 0 6700 in 17 025 mm 0 6703 in 11 994 12 000 mm 0 47 22 0 4724 L 11 980 mm 0 4717 48 000 48 010 1 8898 1 8902 in 48 050 mm 1 8917 Warpage Cylinder to piston clearance Piston pin bore I d e Piston pin D Piston to piston pin clearance 0 002 0 012 mm 0 0001 0 0005 0 030 mm 0 0012 in Connecting rod small end t D TORQUE VALUE Cylinder head 8 12 0 8 1 2 kg m 6 9 ft lb TROUBLESHOOTING Compression too low hard starting or poor Abnormal noise piston performance at low speed 1 Worn cylinder and piston 1 Leaking cylinder head gasket 2 Worn piston pin or piston pin hole 2 Loose spark plug 3 Worn connecting rod small end bearing 3 Worn stuck or broken piston rings 4 Worn or damaged cylinder and piston Abnormal noise piston rings Faulty reed valve 1 Worn stuck or broken piston rings 2 Worn or damaged cylinder Compression
41. E LIMIT 48 050 mm 1 8917 in Date of Issue May 1983 HONDA MOTOR CO LTO SECOND RING TOP RING EXPANDER CYLINDER HEAD CYLINDER PISTON CAUTION The cylinder may or may not have an A mark on its crankcase mating surface as shown When the cylinder is replaced replace it with a similar one to match the crankcase Measure the piston O D at a point 4 mm from the bottomof the skirt SERVICE LIMIT 47 900 mm 1 8858 in Calculate the piston to cylinder clearance SERVICE LIMIT 0 100 mm 0 0039 in Measure the piston pin hole D PISTON PIN HOLE I D SERVICE LIMIT 12 025 mm 0 4734 in PISTON PIN O D Measure the piston pin O D SERVICE LIMIT 11 980 mm 0 4717 in 6 6 60 Date of Issue May 1983 HONDA MOTOR CO LTD CYLINDER HEAD CYLINDER PISTON PISTON RING INSPECTION Measure each piston ring end gap SERVICE LIMIT 0 60 mm 0 024 in NOTE Use the piston to set each ring squarely in the cylinder CONNECTING ROO INSPECTION Install the bearing and piston pin in the connecting rod small end and check for excessive play Measure the connecting rod small end I D SERVICE LIMIT 17 025 mm 0 6703 in PISTON CYLINDER INSTALLATION Install the expander in the second ring groove Align the ring ends with the locating pins in the ring grooves and install the top and second rings in their respective ring grooves NOTE The top ring is a keystone ring
42. E mr DRIVER 077490010000 2 DRIVER Drive in a new top ball race unti it bottoms 07749 001 0000 NOTE Do not allow the ball race to tilt during instal lation ATTACHMENT 42 x 47 mm 07746 0010300 BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race with a cold chisel be ing careful not to damage the steering stem BOTTOM CONE RACE 1 2 2 2 140 Date of Issue May 1983 HONDA MOTOR CO LTD Install a new bottom cone race over the steering stem Install the old bottom cone race over the new bot tom cone race upside down Drive the bottom cone race with special tools until it seats in place then remove the old bottom cone race FRONT FORK INSTALLAT ON Install the front fender on the front fork Coat the ball races with grease and install 26 steel balls on the top ball race and 29 steel balls on the bottom ball race Lubricate the top cone race with grease Screw in the race until snug against the top ball race then back it out 1 8 turn NOTE Check that the steering stem rotates freely and there is no vertical play Date of Issue May 1983 HONDA MOTOR CO LTD FORK SEAL DRIVER 07747 001 0700 and FORK SEAL DRIVER ATTACHMENT 07747 0010400 OR FORKSEAL DRIVER 07947 3550000 141 STEERING FRONT WHEEL BRAKE SUSPENSION STEERING FRONT WHEEL BRAKE SUSPENSION Install the head top thread nut and tighten it while holding
43. EDOMETER SPEEDOMETER CABLE THROTTLE CABLE FRONT BRAKE CABLE JUNCTION BOX MAIN HARNESS ANT SPEEDOMETER me ia SOME CABLE eC T THROTTLE bus CABLES CLAMP FRONT BRAKE REAR BRAKE SPEEDOMETER CABLE CABLE CABLE FRONT BRAKE CABLE 1 8 10 Date of ssue May 1983 HONDA MOTOR LTD GENERAL INFORMATION IGNITION SWITCH THROTTLE OL CONTROL CABLES 2 THROTTLE CABLE HORN MAIN HARNESS FUEL GAUGE SENSOR RESISTOR OIL LEVEL STARTER RELAY INDICATOR SWITCH CDI UNIT OIL CONTROL CABLE IGNITION COIL TURN SIGNAL a d THROTTLE CABLE RELAY REAR BRAKE CABLE Date of Issue May 1983 HONDA MOTOR CO LTD d 1 9 NH80 LUBRICATION OIL TANK OIL INDICATOR SWITCH OIL TUBE OIL PUMP OIL STRAINER OIL CONTROL CABLE OIL OUTLET TUBE CARBURETOR INTAKE PIPE 2 O 14 Date of Issue May 1983 HONDA MOTOR CO LTD SERVICE INFORMATION 2 1 TROUBLESHOOTING 2 1 OIL PUMP REMOVAL 2 2 OIL PUMP INSPECTION 2 2 OIL PUMP INSTALLATION 2 2 SERVICE INFORMATION GENERAL 2 LUBRICATION SS SCO E 25 occ NEL EE _ A OIL PUMP BLEEDING OIL PUMP CONTROL CABLE ADJUSTMENT FINAL REDUCTION OIL CONTROL CABLE LUBRICATION LUBRICATION POINTS HL M c e The engine must be removed from the frame when removing an
44. ESHOOTING DRIVE PULLEY KICK STARTER CLUTCH DRIVEN PULLEY SERVICE INFORMATION GENERAL Avoid getting grease and oil on the drive belt and pulley faces SPECIFICATIONS Movable drive face bushing 1 0 24 000 24 021 mm 0 9449 0 9457 in Drive face boss O D mE Weight roller O D Clutch outer 1 0 SERVICE LIMIT 24 070 mm 0 9476 in 23 940 mm 0 9425 in 17 92 18 08 mm 0 7055 0 7118 in 17 40 mm 0 685 in 112 0 112 2 mm 4 41 4 42 in 112 5 mm 4 43 in 59 1 mm 2 33 in 64 5 mm 2 54 in 33 950 33 975 mm 1 3366 1 3376 33 930 mm 1 3358 in Driven spring free length Driven face O D Movable driven face 1 0 34 000 34 025 mm 1 3386 1 3396 34 060 mm 1 3409 in TORQUE VALUES Movable drive face Movable driven face Clutch outer TOOLS Special Clutch spring compressor Bearing driver Lock nut wrench 39 mm Crankcase puller Bearingdriver attachment 28 x 30 mm Common Universal holder Bearing remover shaft Bearing remover head 12 mm Bearing remover head 15 mm Pilot 15 mm Driver TROUBLESHOOTING 35 40 N m 3 5 4 0 kg m 25 29 ft lb 35 40 N m 3 5 4 0 kg m 25 29 ft Ib 35 40 3 5 4 0 kg m 25 29 ft Ib 07960 K J90000 07945 GC80000 07916 1870001 07935 KG80000 07946 1870100 07725 0030000 07746 0050100 07746 0050300 07746 0050400 07746 0040300 07749 0010000 Poor performance at high spe
45. G ANY OBLIGATION WHATEVER PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN 44 MISSION HONDA MOTOR CO LTD Service Publications Office Date of Issue May 1983 HONDA MOTOR CO LTO LI AA el O O U ELECTRICAL EQUIPMENT 15 ENGINE CHASSIS FUEL SYSTEM CONTENTS i mu GENERAL INFORMATION LUBRICATION MAINTENANCE n s M r ENGINE REMOVAL INSTALLATION CYLINDER HEAD CYLINDER PISTON ALTERNATOR DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH 00 IM c ume ess EE FINAL REDUCTION CRANKCASE CRANKSHAFT FRAME COVERS STEERING FRONT WHEEL BRAKE SUSPENSION irae REAR WHEEL BRAKE SUSPENSION n _ FUEL TANK OIL TANK __ _ _ WIRING DIAGRAM TECHNICAL FEATURES TROUBLESHOOTING 1 GENERAL INFORMATION GENERAL SAFETY 1 1 TOOLS 1 6 SERVICE RULES 1 1 CABLE amp HARNESS ROUTING 1 7 MODEL IDENTIFICATION 1 2 EXHAUST AND NOISE EMISSION CONTROL SYSTEMS U S A ONLY 1 10 SPECIFICATIONS 1 3 EMISSION CONTROL TORQUE VALUES 1 5 INFORMATION LABEL 1 10 GENERAL SAFETY If the en
46. H SPRING COMPRESSOR 07960 K J90000 CLUTCH DRIVEN PULLEY INSTALLATION instal the driven pulley on the drive shaft HEE CLUTCH DRIVEN PULLEY Install the clutch outer and torque the nut while holding the clutch outer with the universal holder TORQUE 35 40 N m 3 5 4 0 kg m 25 29 ft tb Install the driven face Page 8 6 Install the left case cover Page 8 7 UNIVERSAL HOLDER 077250030000 8 2 2 94 Date of Issue May 1983 5 HONDA MOTOR CO LTD CLUTCH OUTER FINAL REDUCTION Q O 96 Date of ssue May 1983 HONDA MOTOR CO LTD HONDA ss NH8O 9 FINAL REDUCTION SERVICE INFORMATION 9 1 TROUBLESHOOTING 9 1 FINAL REDUCTION DISASSEMBL Y 9 2 FINAL REDUCTION INSPECTION 9 3 FINAL REDUCTION INSTALLATION 9 5 SERVICE INFORMATION GENERAL Specified oil Honda 4 stroke oil SAE 10W 40 or equivalent Oil quantity 90 cc 0 09 US qt TOOLS Special Bearing remover set 12 mm 07936 1660001 not available in U S A GET 07936 1660100 Bearing remover 15 mm 07936 KC10000 not available in U S A 07936 3710200 Common Attachment 32 x 35 mm 07746 0010100 Attachment 37 x 40 mm 07746 0010200 Pilot 12 mm 07746 0040200 Pilot 15 mm 07746 0040300 Pilot 17 mm 07746 0040400 Driver 07749 0010000 Engine starts but scooter won t move 1 Da naged transmission 2 Seized or burnt transmission Abnormal noise 1 Worn seized or chipped gears 2 Worn bearing
47. Install a new gasket and dowel pins DOWEL PINS Install the transmission cover Install the movable driven face clutch assembly Page 8 22 Install the drive pulley drive belt and left case cover Page 8 7 install the frame center cover Section 11 Install the rear wheel Page 13 3 Pour the specified amount of oil through the filler opening Page 2 4 Date of Issue May 1983 103 e 44 7 HONDA MOTOR CO LTD CRANKCASE CRANKSHAFT HONDA MOTOR CO L TD 10 CRANKCASE CRANKSHAFT SERVICE INFORMATION 10 1 CRANKSHAFT INSPECTION CRANKCASE SEPARATION 10 2 CRANKSHAFT INSTALLATION CRANKSHAFT REMOVAL 10 2 CRANKCASE ASSEMBLY SERVICE INFORMATION GENERAL This section covers crankcase separation to service the crankshaft The following parts must be removed before separating the crankcase Engine Page 5 2 Carburetor Page 4 3 Oil pump Page 2 2 Reed valve Page 4 12 Drive pulley Page 8 2 Alternator Page 7 2 Cylinder head cylinder Page 6 2 e In addition to the above remove the following parts when the left crankcase half must be replaced Final reduction Page 9 2 e When assembling the crankcase and crankshaft force the crankshaft into the case bore with the special tool rested against the crankshaft bearing inner race To do this it is necessary to remove the old bearing from the crankshaft and drive a new bearing onto the crankshaft on the case side Use a new
48. KE CABLE Install the cushion arm covers with the bolts CUSHION ARM COVER AE 1 2 1 2 130 Date of Issue May 1983 HONDA MOTOR CO LTD STEERING FRONT WHEEL BRAKE SUSPENSION 8 12 0 8 1 2 kg m 6 9 ft lb FRONT BRAKE DRUM INSPECTION Remove the front wheel Page 12 9 Remove the brake panel Measure the brake drum L D SERVICE LIMIT 111 0 mm 4 37 in Date of Issue May 1983 131 HONDA MOTOR CO LTD 1 2 1 3 STEERING FRONT WHEEL BRAKE SUSPENSION BRAKE LINING INSPECTION Measure the brake lining thickness SERVICE LiMIT 2 0 mm 0 08 in WV WARNING e Contaminated brake linings reduce stop ping power Keep grease off the linings e Brake dust contains asbestos which can be harmful to your health Do not use corn pressed air to clean brake parts Use a vacu um with a sealed dust collector Wear a protective face mask and wash your hands when finished BRAKE PANEL DISASSEMBL Y BRAKE ARM BRAKE SHOES at Remove the brake shoes Remove the brake arm and the brake cam Remove the speedometer drive gear SPEEDOMETER DRIVE GEAR BRAKE BRAKE PANEL ASSEMBL Y GREASE LIT n iE ji Lubricate the speedometer drive gear with grease and install the drive gear in the brake panel ZU mu 72 1 2 1 4 132 Date of issue May 1983 E HONDA MOTOR CO LTD STEERING FRONT WHEEL B
49. LINDER HEAD CYLINDER PISTON Remove all gasket material from the cylinder and crankcase mating surfaces Place a new cylinder gasket on the crankcase Lubricate the cylinder and piston with 2 stroke and install the cylinder over the piston while com pressing the piston rings CAUTION Avoid damaging the sliding surface of the pis ton Date of Issue May 1983 HONDA MOTOR CO LTD 63 LL di ek CY LINDER GASKET CYLINDER HEAD CYLINDER PISTON CYLINDER HEAD INSTALLATION Instail the cylinder head on the cylinder using a new cylinder head gasket Install and tighten the four cylinder head bolts in a criss cross pattern TORQUE 8 12 N m 0 8 1 2 kg m 6 9ft Ib Install engine shroud B SHROUD B Clean the cylinder head mating face of the control M box and install the control box n W i ng ui L T X g J CONTROL BOX Install engine shroud A Install all removed parts in the reverse order of re moval Perform the following inspections Compression test Page 3 8 Check for any abnormal engine noise Check for cylinder air leaks 6 1 O 64 Date of Issue May 1983 HONDA MOTOR LTD ALTERNATOR HONDA S NH8O 7 0 35 40 3 5 4 0 kg m 25 29 ft Ib 66 Date of Issue May 1983 HONDA MOTOR CO LTO 7 ALTERNATOR
50. MOTOR CO LTD FUEL SYSTEM THROTTLE VALVE INSTALLATION _ NEEDLE RETAINER CLIP JET NEEDLE Install the needle on the throttle valve and secure with the needle retainer Assemble the seal cap carburetor top and throttle spring Connect the throttie cable to the throttle valve THROTTLE VAL VEGROOVE Slide the throttle valve into the carburetor body FEL NOTE 5 2 r Align the groove in the valve with the throttle c een punte stop screw on the carburetor body mI THROTTLE STOP SCREW Tighten the carburetor top Install the teft frame cover Adjust the throttle cable free play Page 3 4 Date of Issue May 1983 43 4 E 9 HONDA MOTOR CO LTO FUEL SYSTEM AIR SCREW REMOVAL INSTALLATION NOTE The air screw is factory pre set and should not be removed unless the carburetor is over hauled Break the tab of the limiter cap with pliers Groove the end of the limiter cap with a hacksaw blade Turn the air screw in and carefully count the num ber of turns so it can be reinstalled in it original position Then remove the air screw CAUTION Damage to air screw and seat can occur if the air screw is tightened against the seat Inspect the air screw and replace it if it is worn or damaged Instal the air screw and return it to its origina posi tion as noted dur ing removal Perform air screw adjustment if
51. Measure the movable driven face SERVICE LIMIT 34 060 mm 1 3409 in Check the guide groove for wear Check the oil seal for wear damage or other faults DRIVEN FACE ASSEMBLY Using Bearing Driver 07945 GC80000 install the outer bearing in the movable driven face with the sealed end facing out Seat the snap ring in its groove Pack all bearing cavities with 5 0 5 5 g of grease NOTE Specified grease Nippon Sekiyu _ LIPANOX DELUXE 3 8 2 O 92 Date of Issue May 1983 j HONDA MOTOR CO LTO Using Driver 07749 0010000 28 x 30 mm Attachment 07946 1870100 not available in U S A and 15 mm Pilot 07746 0040300 install the inner bearing in the movable driven face with the sealed end facingout Install the snap ring install the movable driven face guide roller and roller pin Install the seal collar Date of Issue May 1983 HONDA MOTOR CO LTD DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH 93 GUIDE ROLLER INNER BEARING SNAP RING GUIDE ROLLER PIN DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH Position the driven face assembly spring and guide plate assembly on the clutch spring compressor Compress the spring by turning the handle LOCK NUT WRENCH 39 mm Install and tighten the 28 mm special nut 07916 1870001 Use a beam type torque wrench 12 14 inches long TORQUE 35 40 N m 3 5 4 0 kg m 25 29 ft ib VON CLUTC
52. N PULLEY 35 40 N m 3 5 4 0 kg m 25 29 ft lb 3 5 4 0 kg m 25 29 ft Ib 8 1 4 86 Date of Issue May 1983 7 HONDA MOTOR CO LTD DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH CLUTCH REMOVAL CLUTCH OUTER Remove the left case cover Page 8 2 Remove the movable drive face and drive belt Remove the 10 mm flange nut holding the clutch outer with the universal holder and remove the clutch outer UNIVERSAL HOLDER 07725 0030000 10 mm FLANGE NUT Remove the movable driven face and clutch from MOVABLE DRIVEN FACE C LUTCH the drive shaft bled Ib f DRIVEN FACE DISASSEMBLY Position the driven pulley in the clutch spring com LOCK NUT WRENCH 39mm pressor tool Turn the compressor handle compress the spring 9720 1979 ET C Be sure the drive bolt is centered on the pulley Place the compressor in a vise and remove the 28 mm special nut Remove the compressor from the vise and back out the drive bolt CLUTCH SPRING COMPRESSOR 07960 K J90000 Date of Issue May 1983 87 M HONDA MOTOR LTO 8 1 5 HONDA 80 DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH SPRING DRIVE PLATE CLUTCH OUTER CLUTCH SPRING CLUTCH WEIGHT 28mm SPECIAL NUT Remove the seal collar SEAL COLLAR 8 1 6 88 Date of Issue May 1983 HONDA MOTOR CO LTD DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH Withdraw the
53. NICAL DATA Charging rpm Initial 4 000 rpm 2 000 max 0 9A min If the readings are not within specifications check the stator and regulator rectifier Date of Issue May 1983 163 HONDA MOTOR LTD 1 5 5 ELECTRICAL EQUIPMENT ALTERNATOR INSPECTION NOTE This test can be made without removing the stator from the engine Remove the frame center cover Section 11 Disconnect the stator wire coupler Measure the resistances between the terminals as follows Y ellow and engine ground 0 1 1 0 2 NOTE Measure the resistances in the x 1 range Alternator removal installation Page 7 2 7 4 RESISTOR INSPECTION Remove the frame center cover Section 11 Measure the resistance between the resistor wire lead and any body ground RESISTANCE 6 7 2 NOTE faulty or poorly grounded resistor can bea frequent cause of a blown headlight REGULATOR RECTIFIER INSPECTION REGULATOR R ECTIF IER Remove the frame center cover Section 11 Disconnect the regulator rectifier coupler Remove the regulator rectifier by removing the attaching bolt p T iei inem I zm E z gpn pass m ee TT E imt dE SS COUPLER 1 5 6 EE 164 Date of Issue May 1983 HONDA MOTOR CO LTD HONDA 80 Measure the resistances between the terminals Replace the regulator rectifier with a new one if the readings do not fall within the l
54. ONT REAR STOPLIGHT SWITCH EE pen The switch is normai if there is continuity when the brake lever is applied The switches are not adjustable HORN horn is normal if it sounds when a 12V battery is connected across the terminals 15 16 Date of Issue May 1983 HONDA MOTOR CO LTD HONDA 80 ELECTRICAL EQUIPMENT FUEL GAUGE SENSOR UPPER LIMIT FUEL GAUGE SENSOR INSPECTION Remove the sensor from the fue tank Page 14 2 Measure the resistances between the terminals with the float at the UPPER FULL and LOWER EMPT Y positions Resistance 4109 97 5 107 5 Float position UPPER FULL LOWER FUEL GAUGE INSPECTION Connect the wire connectors and turn the ignition switch ON NOTE zem Before performing the following test operate the turn signals to determine that the battery circuit is normal Check the gauge needle for correct indication by moving the float up and down Float position Needle Position FLOAT AT UPPER LIMIT F FULL FLOAT AT LOWER LIMIT E EMPTY LOWER LIMIT Date of Issue May 1983 175 HONDA MOTOR CO LTD 1 5 1 7 ELECTRICAL EQUIPMENT OIL LEVEL INDICATOR UNIT OIL LEVEL SENSOR OIL LEVEL SENSOR INSPECTION GREEN RED GREEN Disconnect the coupler and remove the sensor Lower the float fully until it will no longer go Measure the resistances between the terminals as shown
55. OWER JOINT Compress the spring by hand and loosen the lock nut and joint Remove the joint and lock nut Remove the spring lower case and spring seat zu LOCK NUT Date of Issue May 1983 135 _ HONDA MOTOR CO LTD 1 2 1 7 STEERING FRONT WHEEL BRAKE SUSPENSION Disassemble the shock SPRING INSPECTION Measure the spring free length SERVICE LIMIT 219 0 mm 8 62 in FRONT SHOCK ASSEMBL Y INSTALLATION Place the front shock upper joint in a vise Extend the damper rod fully Install the upper spring seat spring lower case and lower spring seat Apply a thread lock to the lock nut and screw the lock nut onto the damper shaft completely Install the lower joint and tighten the fock nut 12 18 UPPER SPRING SEAT SHOCK ABSORBER SPRING ay LOWER CASE LOWER LOCK NUT LOWER SPRING SEAT JOINT N 219 0 mm 8 62 in LOWER JOINT DAMPER ROD Date of Issue May 1983 136 HONDA MOTOR CO LTD STEERING FRONT WHEEL BRAKE SUSPENSION Slide the front shock into the front fork and secure UPPER MOUNTING BOLT with the upper mounting bolt TORQUE 30 36 N m 3 0 3 6 kg m 22 26 ft Ib Lubricate and loosely install the front fork pivot arms with the attaching bolts and nuts Install the front wheel Page 12 12 FRONT FORK PIVOT ARM Date of Issue May 1983 137 HONDA MOTOR CO LTD 1 2 1 9
56. Oil leaks 1 Oil level too high 2 Worn or damaged oil seal Date of Issue May 1983 97 Q _ 1 HONDA MOTOR CO LTD FINAL REDUCTION FINAL REDUCTION DISASSEMBLY Remove the driven pulley Page 8 2 Drain the oil from the transmission case Page 2 4 Hemove the rear wheel Page 13 2 Hemove the transmission case cover bolts and re move the transmission cover TRANSMISSION COVER Remove the final gear and countershaft FINAL GEAR Remove the drive shaft from the transmission cover DRIVE SHAFT E Q 2 98 Date of Issue May 1983 B HONDA MOTOR CO LTD FINAL REDUCTION FINAL REDUCTION INSPECTION Inspect the drive shaft and gear for wear or damage Inspect the countershaft and gear for wear or dam age Inspect the final gear for wear or damage Date of Issue May 1983 HONDA MOTOR CO LTD FINAL REDUCTION Inspect the transmission cover bearings oil seal and countershaft bore for wear or damage If the final gear shaft bearing must be replaced use 15mm Bearing Remover 07936 KC10000 not available U S A J Inspect the left crankcase bearings oil sea and countershaft bore for wear or damage Use the bearing remover if drive shaft bearing re placement is necessary FINAL GEAR SHAFT BEARING DRIVE SHAFT BEARING COUNTERSHAFT BORE BEARING REMOVER SET 12 mm 07936 1660000 Not available in U S A or BEARING REMOVER 12 mm 079
57. RAKE SUSPENSION Apply silicone grease to the anchor contacting area e BRAKE CAM of each shoe and to the brake shoe contacting area 4 memes of the brake cam Install the brake cam Avoid getting grease on the inside of the brake drum or braking power will be reduced Clean the inside of the brake panel thoroughly Install the brake shoes Install the felt oil seai ALIGN Install the wear indicator plate on the brake cam Uu En t shaft An e uS NOTE Align the wide tooth on the plate with the widegroove on the camshaft lastall the brake arm PUNCH MARKS prp una l Align the punch marks on the brake arm and camshaft Torque the brake arm bolt TORQUE 8 12 0 81 2 kg m 6 9 ft lb Date of Issue 1983 133 E HONDA MOTOR CO LTO 1 2 1 5 STEERING FRONT WHEEL BRAKE SUSPENSION FRONT SHOCK FRONT SHOCK REMOVAL Remove the front wheel Page 12 9 Remove the pivot arm boltand the pivot arm PIVOT ARM 1 2 E 1 6 134 Date of Issue May 1983 HONDA MOTOR CO LTD HONDA 80 STEERING FRONT WHEEL BRAKE SUSPENSION Check the pivot arm bushing A for wear or damage PIVOT ARM BUSHING A If bushing replacement is necessary remove the front fork Page 12 20 Remove the front shock by removing the upper UPPER MOUNT BOLT mount bolts FRONT SHOCK DISASSEMBLY id Place the front shock upper ioint in a vise L
58. Rear Front brake lining swept area Rear brake lining swept area Fue capacity Fuel reserve capacity Caster Trail ENGINE Type Cylinder arrangement Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Transmission oil capacity Oil tank capacity Lubrication system Air filtration Cylinder compression Port timing Intake Open Close Exhaust Open Close Scavenge Open Close Engine dry weight Idle speed GENERAL INFORMATION 1 685 mm 66 3 in 665 mm 26 2 in 1 070 mm 42 1 in 1 170 mm 46 1 in 730 mm 28 7 in 256 mm 10 1 in 110 mm 4 3 in 75 kg 165 Ib 80 kg 176 Ib Back bone Bottom link 81 mm 3 19 in Engine Final drive unit swingarm 78 mm 3 07 in 222 kg 490 Ib 232 kg 505 Ib 145 kg 320 Ib 150 kg 330 Ib 3 50 10 4PR 3 50 10 4PR 21 psi 150 kPa 1 5 kg cm 24 psi 175 kPa 1 75 kg cm 21 psi 150 kPa 1 5 kg cm 86 psi 250 kPa 2 5 kg cm Internal expanding shoe 86 cm 13 4 sq in Internal expanding shoe 60 cm 9 3 sq in 5 3 liters 1 4 US gal 0 9 liters 0 25 US gal 63 70 mm 2 8 in Air cooled 2 stroke Single cylinder 15 inclined from vertical 48 x 44 mm 1 89 x 1 73 in 80 cm 4 88 cu in 6 8 1 5 BHP 5 000 rpm 0 82 kg m 5 9 ft Ib 3 500 rpm 90 cc 0 09 US qt 1 3 liters 1 4 US qt Lubricated by mixing oi with fuel Oiled urethane foam 10 0 14 0 kg cm 142 200 psi Reed valve controll
59. Remove the movable drive face assembly Remove the drive face boss Remove the three bolts attaching the movable drive face cover and remove the cover Remove the ramp plate RAMP PLATE Date of Issue May 1983 75 8 E 3 HONDA MOTOR CO LTD DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH Remove the weight rollers MOVABLE DRIVE FACE INSPECTION Check each roller for wear or damage Measure each roller O D SERVICE LIMIT 17 40 mm 0 685 in Measure movable drive face bushing 1 D SERVICE LIMIT 24 070 mm 0 9476 in 8 4 76 Date of Issue May 1983 HONDA MOTOR CO LTD Inspect the drive face boss for wear or damage Measure the O D at the drive face contacting face SERVICE LIMIT 23 940 mm 0 9425 in Replace if smaller than the service limit Check the face seal for wear or damage MOVABLE DRIVE FACE ASSEMBLY Use 10 15g of grease and apply evenly to the in side of the drive face Then install the weight rollers NOTE Specified grease Lithium based Mitsubishi HD 3 Nippon Sekiyu Lipanox Deluxe 3 Idemitsu Coronex Date of Issue May 1983 HONDA MOTOR CO LTD 77 FACE SEAL DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH DRIVE AND DRIVEN PULLEYS KICK STARTER CLUT CH Instal the ramp plate and movable face cover Tighten the seal attaching bolts to the specified tor que TORQUE 2 5 4 0 N m 0 25 0 40
60. Resistance 5 15 Q Terminal Green Red 4 to Black Green to Black OIL LEVEL INDICATOR SWITCH INSPECTION Connect the coupler and turn the ignition switch ON With the float raised fully measure the resist ance between the terminals Green Red 4 to Black 340 2 approx NOTE Operate the turn signals to see that the bat tery circuit is normal then perform the fol lowing inspection 0 18 0 04 in Raise and lower the float to make sure that the oil level indicator lamp blinks NOTE Should the lamp fai to go on and go out as the float is moved up and down check for loose connections and repeat the above proce dure 1 5 1 c 176 Date of Issue May 1983 HONDA MOTOR CO LTD ELECTRICAL EQUIPMENT TURN SIGNAL LENS TURN SIGNAL BULB REPLACEMENT Remove the turn signal lenses by removing the Screws 4 d E EM LE TI ir FH mii the papa Dai 5 gc 2 E de dw D Ene pi Replace the bulb with a new one BULB Install the lens being careful not to overtighten the screws ormai ok M d i i NI H Date of Issue May 1983 177 HONDA MOTOR LTD 1 5 1 9 STARTER ENGINE STOP SWITCH R FRONT TURN SIGNAL 2 32 o vin Bk w FRONT BRAKE SWITCH t
61. STEERING FRONT WHEEL BRAKE SUSPENSION FRONT FORK FRONT FORK REMOVAL LOCK NUT Remove the following Meter assembly Page 12 3 Handlebar Page 12 6 Front wheel Page 12 9 Glovebox Section 11 Steering stem nut 11 Z ILLE i EE am LR cA EE ip a o i m thee bie E PIN SPANNER 07702 0020000 07702 0010000 or M9361 412 099788 U S A oniy 1 2 2 O m 138 Date of Issue May 1983 HONDA MOTOR CO LTD STEERING FRONT WHEEL BRAKE SUSPENSION Remove the top cone race and remove the front TOP CONE RACE FRONT FORK fork e se i Place the steel balls in a parts tray so they are amp ur not lost FRONT FENDER REMOVAL FRONT FENDER Remove the two bolts attaching the front fender and remove the front fender ELM 0 357 13 Et qc PT FES life 1 5 Fi eka 7 nic hs ee 0 4 BALL RACE REPLACEMENT Remove the upper and lower ball races by tapping their flanges with a plastic hammer Date of Issue May 1983 139 HONDA MOTOR CO LTD 1 2 E 2 1 STEERING FRONT WHEEL BRAKE SUSPENSION ATTACHMENT 42 x 47 mm Drive in a new bottom ball race until it bottoms 07746001 LX 199 1 Do not allow the ballrace to tilt during instal EIU E 245 A gt lation t E
62. VABLE DRIVE FACE DRIVE FACE The drive pulley consists of a fixed face and a movable face The movable face is capable of sliding axially on the boss of the fixed face The ramp plate which pushes in the weight roilers against the drive face is attached to the boss of the drive face with a nut DRIVE BELT MOVABLE FACE ASSPEED INCREASES RAMP PLATE WEIGHT ROLLER As the speed of the engine increases centrifugal force on the weight rollers is also increased This pushes the movable drive face inward The unit then acts with a reduced drive ratio by allowing the drive belt to run on a pulley of greater diameter 1 1 4 184 Date of Issue May 1983 E HONDA MOTOR CO LTD TECHNICAL FEATURES DRIVEN PULLEY BALL BEARING NEEDLE BEARING CLUTCH WEIGHT DRIVE SHAFT GUIDE ROLLER CLUTCH OUTER MOVABLE DRIVEN DRIVEN FACE FACE SPRING GUIDE PIN AND ROLLER The driven pulley and clutch weights are attached over the drive shaft The clutch outer is attached to the drive shaft with a nut The force of the driven face spring is always exerted the movable face to push it against the driven face Therefore when engine speed is increased the driven pulley turns and the clutch connects automatically The effective diameter of the drive pulley is increased The movable face is forced outward by meansof the belt until an equilibrium is reached between the torque tension of the belt and force of the spring When this o
63. a new screw is in stalled Install a new limiter cap Page 4 11 ADJUSTMENT NOTE The air screw is factory pre set and no adjust ment is necessary unless the air screw is re placed z e z o Turn the air screw clockwise until it seats lightly and back it out to the specification given This is an in tial setting prior to the final air screw adjust ment INITIAL OPENING 1 1 2 turns out CAUTION J Damage to the air screw and seat will occur if the air screw is tightened against the Seat Warm the engine up to operating temperature Stop and go riding for 10 minutes is sufficient Connect a tachometer and adjust the idle speed with the throttle stop screw IDLE SPEED 1 800 100 rpm 4 10 LI JF z E AIR SCREW 44 E MITER CAP THROTTLE STOP SCREW Date of Issue May 1983 O HONDA MOTOR CO LTD Turn the air screw in or out to obtain the highest engine speed Readjust the idle speed to 1 800 100 rpm using the throttle stop screw LIMITER CAP INSTALLATION If the air screw has been removed anew limiter cap must be installed after air screw adjustment is com pleted After adjustment cement the limiter cap over the air screw using LOCTITE 601 or equivalent The limiter cap should be placed against its stop preventing further adjustment that woutd enr ich the fuel mixture limiter cap position permits counter clockwise
64. acuum tube for biockage 2 Disconnect the vacuum tube from the intake pipe and apply vacuum to the vacuum tube The fue valve is normal if fuel flows out of the fuel line when vacuum is applied f fuel does not flow out of the fuel line when negative pressure is applied do the following Clean the vacuum tube with compressed air Date of Issue May 1983 47 x HONDA MOTOR CO LTD 4 1 3 ENGINE REMOVAL INSTALLATION 7 22 29 ft Ib 20 30 N m 2 0 3 0 kg m 14 22 ft lb 30 40 N m z 3 0 4 0 kg m GANE f A a ath F j j _ T f J p 5 J i T f Rete i 3 E 4 JI Wi i E 1 27 33 N m 2 7 3 3 kg m 20 24 ft lb T Date of Issue May 1983 HONDA MOTOR CO LTD 48 5 0 SERVICE INFORMATION ENGINE REMOVAL ENGINE INSTALLATION SERVICE INFORMATION GENERAL Parts requiring engine removal for servicing Oil pump Starter motor Crankshaft SPECIFICATIONS Engine weight 18 kg 40 Ibs TORQUE VALUES Engine mounting bolt 27 33 N m 2 7 3 3 kg m 20 24 ft Ib Rear shock absorber upper mounting bolt 30 40 N m 3 0 4 0 kg m 22 29 ft Ib Rear shock absorber lower mounting bolt 20 30 Nm 2 0 3 0 kg m 14 22 ft lb Date of Issue May 1983 49 HONDA MOTOR CO LTD 9 ENGINE REMOVAL
65. and is not in terchangeable with the square second ring Check the fit of each ring in its groove by pressing the ring into the groove to make sure that it is flush with the piston at several points around the ring A ring that will not compress means that the ring groove is dirty or that the ring is in the wrong groove Date of Issue May 1983 HONDA MOTOR LTD 61 EXPANDER PISTON TOP RING 6 7 CYLINDER HEAD CYLINDER PISTON NOTE Install the piston rings with the marks fac ing up Do not replace one ring without replacing the other e Do not mix different brands of rings in one engine PISTON RING MARKINGS 1T TOP 2T SECOND Make sure that the ring ends align with the locating LOCATING PINS pins in the ring grooves CAUTION Be sure the rings do not rotate their grooves over the locating pins to prevent ring breakage and piston and cylinder damage Place a shop towel over the crankcase opening to PISTON prevent piston pin clips from falling into the crank xs it iti case EX MARK EE Em ES Coat the needle bearing and piston pin with 2 stroke oil Install the needle bearing in the connecting rod and install the piston EX mark facing the exhaust side E STILE Install new piston pin clips nt I gt EH TEE PISTON PIN CLIP PISTON PIN 6 8 62 Date of Issue May 1983 7 HONDA MOTOR CO LTD CY
66. any dirt from around the spark plug base Remove and discard the spark plug Measure the new spark plug gap using a wire type feeler gauge SPARK PLUG GAP 0 6 0 7 mm 0 024 0 028 Adjust by bending the side electrode carefully With the plug washer attached thread the spark plug in by hand to prevent crossthreading Tighten the spark plug another 1 2 turn with a spark plug wrench to compress the plug washer Then connect the spark plug cap ENGINE OIL LINE LU Remove the frame center cover Section 11 Check the engine oil lines and replace any parts which show deterioration damage or leakage Bleed the oil pump and line if they have air bub bles in them Page 2 3 install the frame center cover ENGINE OIL STRAINER SCREEN Remove the frame center cover Page 11 3 Disconnect the oii inlet line at the oil pump and allow the oil to drain into a clean container OIL INLET LINE 3 6 26 Date of Issue May 1983 7 HONDA MOTOR CO LTD MAINTENANCE Disconnect the oil line at the bottom of the oil tank OIL LINE by loosening the clip Remove the oil strainer Clean the oil strainer with compressed air Replace the oil strainer if necessary The installation sequence is essentially the reverse order of removal Fill the tank with the recommended oil up to the proper level and bleed air from the oi pump and oil line Page 2 3 AIR GUN NOTE Connect the oil l
67. bling fuel system parts note the locations of the O rings Replace them with new ones during assembly Bleed air from the oil outlet line whenever it is disconnected TOOLS Special Hand vacuum pump ST AH 260 MC7 U S A only Common Float level gauge 07401 001 0000 SPECIFICATIONS Venturi dia 246 mm 0 63 Identification number PB54D m Float level 8 5 mm 0 335 in Air screw opening See page 4 10 Idle speed 1 800 100 rpm a Throttle grip free play 2 6 mm 1 8 1 4 inj MM Enginecranks but won t start Engine idles roughly stalls or runs poorly Lean mixture 1 No fuel in tank 1 Idle speed incorrect 1 Carburetor fuel jets clogged 2 Fuel not reaching carburetor 2 No spark at plug 2 Fuel cap vent clogged 3 Too much fuel getting to cylinder 3 Loss of compression 3 Clogged fuel filter 4 Clogged air cleaner 4 Rich mixture 4 Fuel line kinked or restricted 5 Lean mixture Faulty float valve Rich mixture 6 Clogged air cleaner 6 Float level too low gt m Wake pipe leaking arem c 2 Float level too high 5 aupl sentarmire Clogg 3 Carburetor jets clogged Date of Issue May 1983 35 HONDA MOTOR CO LTD 4 1 FUEL SYSTEM THROTTLE VALVE DISASSEMBLY Remove the left frame cover Remove the carburetor top Disconnect the throttle cable from the throttle valve Remove the throttle valve spring carburetor top and sealing cap
68. ccurs the drive ratio decreases and less torque is delivered to the final reduction Date of Issue May 1983 185 HONDA MOTOR CO LTO 1 7 5 18 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START ENGINE LACKS POWER POOR PERFORMANCE AT LOW AND IDLE SPEEDS POOR PERFORMANCE AT HIGH SPEED POOR HANDLING OIL INDICATOR FUEL GAUGE STARTER MOTOR ENGINE DOES NOT START OR IS HARD TO START 1 Check if fuel is getting to carburetor by loosening drain screw GETTING TO CARBURETOR 2 Try spark test SPARK JUMPS 3 Test cylinder compression NORMAL COMPRESSION 4 Start by following normal starting procedure ENGINE DOES NOT FIRE 5 Remove spark plug DRY Probable Cause NOT GETTING TO 1 CARBURETOR 2 3 4 5 WEAKORNOSPARK t 2 3 4 5 6 7 LOW 5 1 2 3 4 5 6 ENGINE FIRES BUT 9 1 SOON STOPS 2 3 4 2 3 No fuel in fuel tank Clogged fuel tube up to carbu retos vacuum tube up to inlet pipe Clogged float valve Clogged fuel tank cap breather hole Clogged fuel strainer Faulty spark plug Fouled spark plug Faulty CDI unit Faulty pulse generator Broken or shorted high tension wire Broken or shorted ignition coil Faulty ignition switch Stuck piston rings Faulty or deteriorated reed valve Worn cylinder and piston
69. d Refer to the alternative column COMMON DESCRIPTION Float leve gauge Universal holder Sy Pin spanner Attachment 32 x 35 mm Attachment 37 x 40 mm Attachment 42 x 47 mm Pilot 12 mm Pilot 15 mm Pilot 17 mm Pilot 25 mm Driver Bearing remover shaft Rear shock absorber compressor Rotor puller Extension bar Fork seal driver Fork seal driver attachment Bearing remover head 12 mm Bearing remover head 15 mm Lock nut wrench 30 x 32 mm NUMBER 07401 001 0000 07725 0030000 07702 0020000 07746 0010100 07746 0010200 07746 001 0300 077 46 0040200 07746 0040300 07746 0040400 07746 0040600 07749 0010000 07746 0050100 07746 0050300 07746 0050400 07959 3290001 07733 001 0000 07716 0020400 077 16 0020500 07747 0010100 07747 0010400 ALTERNATIVE Pin spanner Driver May be used when pilot not used Rotor puller Equivalent tools commer cially available in U S A Fork seal driver NUMBER REF SECT 07702 0010000 07949 6110000 07933 00 10000 07947 3550000 4 7 7 2 7 5 8 2 8 7 8 15 8 22 12 20 12 23 9 5 9 6 12 11 9 5 10 5 12 22 9 6 12 11 8 21 9 5 9 5 10 5 13 7 13 8 7 3 12 7 12 8 12 7 12 8 12 23 12 23 Date of Issue 1983 HONDA MOTOR LTO CABLE amp HARNESS ROUTING Note the following when routing cables and wire harnesses A loose wire harness or cable can be a safet
70. d installing the oil pump e When removing and installing the oil pump use care not to allow dust and dirt to enter the engine and oil line Bleed air from the oil pump if there is air in the oil inlet line from the oil tank to the oil pump or if the oil line is disconnected Bleed air from the oil outlet line from the oil pump to the carburetor if the line is disconnected SPECIFICATIONS Engine oil recommendation Honda 2 stroke oil or equivalent Final reduction oil capacity 90 cc 0 09 US qt Final reduction oil recommendation Honda 4 stroke oil or equivalent Viscosity SAE 10W 40 API Service classification SE or SF TORQUE VALUE Final reduction oil drain bolt TROUBLESHOOTING Excessive smoke and or carbon on spark plug 1 Pumpnot properly adjusted excessive oil 2 Low quality engine oil 3 Incorrect engine oil Overheating 1 Oil pump not adjusted properly insufficient oiling 2 Low quality oil 3 Incorrect engine oil Seized piston 1 No oil in tank or clogged oil line 2 Pump not properly adjusted insufficient oiling 3 Air in oil lines 4 Faulty oil pump Oil notflowing out of tank 1 Clogged oil tank cap breather hole 2 Clogged oi strainer Date of Issue May 1983 1 HONDA MOTOR CO LTD 10 14 N m 1 0 1 4 kg m 7 10 ft Ib 2 4 2 5 2 5 2 6 2 1 LUBRICATION OIL PUMP REMOVAL NOTE Before removing the oil pump clean the oil pump and
71. e lower level mark refill with distilled water to the upper levet Check the specific gravity of the battery electro lyte in each cell Page 15 3 Recharge the battery if necessary Page 15 4 QIE Add only distilled water Tap water will shorten the service life of the battery V WARNING The battery electrolyte contains sulfuric acid Protect your eyes skin and clothing In case of contact flush thoroughly with water and call a doctor if electrolyte gets in your eyes ARROW BRAKE SHOE WEAR aa ha Replace the brake shoes if the arrow on the brake arm aligns with the reference mark A when the brake is fully applied ae 4 ENCE ARROW MARK 3 8 28 Date of Issue May 1983 HONDA MOTOR LTO MAINTENANCE BRAKE SYSTEM FRONT BRAKE Measure the front brake lever free play at the tip of p the brake lever 10 20 mm Dung 3 8 3 4 in FREE PLA Y 10 20 mm 3 8 3 4 pe If adjustment is necessary turn the front brake ad justing nut x im Hi i hd tr em PLAY gj ADJUSTING NUT REAR BRAKE Measure the rear brake fever free play atthe tipof the brake lever FREE PLA Y 10 20 mm 3 8 3 4 10 20 mm __ 3 8 3 4 in Lj i i r 1 41 cr fu E 77 115 TS LIGH i Date of Issue May 1983 29 3 E 9 HONDA MOTOR CO LTD MAINTENANCE If adj
72. e nut TORQUE 80 100 N m 8 0 10 0 kg m 58 72 ft lb Install the muffler TORQUE 8 mm bolts 40 50 4 0 5 0 kg m 29 36 ft Ib Install the frame center cover REAR BRAKE REAR BRAKE CAM 4 7 0 4 0 7 kg m 3 5 ft b REAR BRAKE ARM Date of Issue May 1983 147 HONDA MOTOR L TD 1 3 3 REAR WHEEL BRAKE SUSPENSION Remove the rear wheel Page 13 2 DRUM INSPECTION Measure the rear brake drum I D SERVICE LIMIT 95 5 mm 3 76 in m 3 LINING INSPECTION Measure the rear brake lining thickness SERVICE LIMIT 2 0 mm 0 08 in V WARNING Keep grease off the brake linings Wipe off excess grease DISASSEMBL Y BRAKE CAM BRAKE SHOES Disconnect the brake cable from the brake arm E Remove the brake shoes e E Remove the brake arm and the brake cam BRAKE ARM BRAKE CABLE 1 3 4 148 Date of Issue May 1983 HONDA MOTOR CO LTD REAR WHEEL BRAKE SUSPENSION ASSEMBLY Apply grease to the anchor contacting area of the brake cam Apply grease to the brake cam and install Install the brake shoes Install the wear indicator plate SCRIBED LINES Instail the brake arm NOTE 1 ouo EE m 1 E dXX m 0 2 ar Tr EE E Align the wide groove on the cam with the Hd OX aa A O wide tooth on the indicator plate ua A 4 Align th
73. e scribed lines on the brake cam and brake arm Tighten the brake arm bolt to the specified torque TORQUE 4 7 N m 0 4 0 7 kg m 3 5 ft lb BRAKE CAM BRAKE ARM Install the brake arm spring BRAKE ARM SPRING Date of Issue May 1983 149 E HONDA MOTOR CO LTD 1 3 5 REAR WHEEL BRAKE SUSPENSION Connect therear brake cable to the brake arm NOTE insert the brake cable into the groove in the left crankcase and instali the plate as shown T d REAR BRAKE CABLE PLATE REAR SHOCK ABSORBER 30 40 3 0 4 0 kg m 22 29 ft Ib 20 530 2 0 3 0 kg m 14 22 ft lb 15 25 1 5 2 5 11 18 ft lb 1 3 G6 150 Date of Issue May 1983 HONDA MOTOR LTD REAR WHEEL BRAKE SUSPENSION REMOVAL REAR SHOCK ABSORBER a a on i EI Ju L IE 4 X Ld rH m 4 til n ti Remove the rear shock absorber upper and lower bolts Remove the rear shock absorber ABSORBER ATTACHMENT A ATTACHMENT HOLDER DISASSEMBLY 07967 GA70101 07967 GC80000 Remove the rear shock absorber lower joint by pressing it with the compressor SHOCK ABSORBER COMPRESSOR LOCK LOWER 07959 3290001 NUT JOINT REAR SHOCK ABSORBER SPRING REAR DAMPER LOWER JOINT STOPPER RUBBER LOCK NUT Date of Issue May 1983 151 HONDA MOTOR CO LTD 1 3 7 REAR WHEEL
74. ear the batter y cells e Discontinue charging if the electrolyte temperature exceeds 45 C 117 F CAUTION uick charging should erly be done in an 1 SPECIFIC GRAVITY VS CHARGING TIME emer genc y slow charging is pref erred Charging time 3 15 hours Charging Charge the battery at 0 5A until specific gravity is 1 270 1 290 20 C 68 F Bie gt 4 O o C a 2 10 12 14 CHARGING TIME CAUTION Check routing of the breather tube as shown on the battery caution label INSERT THE BATTERY BREATHER TUBE SECURELY Reon x Nr ERA LP ee 9 ete WORST Adi P PL ES m 1 5 4 162 Date of Issue May 1983 x HONDA MOTOR CO LTD HONDA NH8O ELECTRICAL EQUIPMENT CHARGING SYSTEM CHARGING CIRCUIT REGULATOR RECTIFIER 4L 151 x u R W ALTERNATOR MAIN SWITCH l di BL FUSE L BATTERY HEADLIGHT 25W c i HEAD LIGHT RESISTOR HIGH BEAM INDICATOR W WHITE R RED BL BLACK PINK Y YELLOW PERFORMANCE TEST Warm up the engine NOTE Use a fully charged battery to check the charging system output Disconnect the black wire lead from the regulator rectifier coupler Open the fuse holder and disconnect the red wire from the holder Connect an ammeter and voitmeter as shown Start the engine and take meter readings The readings should match the chart TECH
75. earing into the right crankcase Drive a new journal bearing into the left crankcase Install the crankshaft into the jeft crankcase Position Collar 07965 GC70100 with the small O D against the crankshaft bearing Thread the bolt from Assembiy Tool 07965 1480200 onto the crankshaft Hold the bolt and turn the nut clockwise to fully install the crankshaft Lubricate the crankshaft main and journal bearings with Honda 2 stroke oil or equivatent Date of Issue May 1983 HONDA MOTOR CO LTD CRANKCASE CRANKSHAFT DRIVER 07749 0010000 i X ATTACHMENT 42 x 47 mm 07746 0010300 PILOT 25 mm 07746 0040600 DRIVER 07749 0010000 52 1 E RE MEN 4 4 b i St HL a E pt 2 Als n CFR iD ls hele ra A LS 4 E hie pet pi ATTACHMENT 42 x 47 mm PILOT 25 mm 07746 0010300 07746 0040600 ASSEMBLY TOOL 07965 1480200 INC IN 07965 GC70000 E aa cg Hh i ot WEN CPI M P m 07965 70100 INC IN 07965 GC70000 109 10 5 CRANKCASE CRANKSHAFT CRANKCASE ASSEMBLY Install a new gasket and dowel pins on the crank case mating surface Assemble the crankcase halves place the collar 07965 GC70100 with the small O D against the right crankshaft bearing Thread the bolt from as sembly tool 07
76. ease Drive in the left bearing and install the distance colar Then drive in the right bearing NOTE Drive the bearings squarely Install the bearings with the sealed ends facing out e Contaminared brake linings reduce stop ping power Keep grease off the linings and brake drum Apply grease to the inside of the dust seal Install the dust seal and axle collar Date of ssue May 1983 HONDA MOTOR CO LTO STEERING FRONT WHEEL BRAKE SUSPENSION FLANGE NUTS Mit m SPOKE PLATE DRIVER 077 49 0010000 M 1 i L H bu ATTACHMENT 32 35 mm PI LOT 12 mm 07746 0010100 07746 0040200 DUST SEAL COLLAR ie emen dur dm 12 11 STEERING FRONT WHEEL BRAKE SUSPENSION INSTALLATION Position the front wheel between the fork legs NOTE Align the brake pane groove with the pivot arm stopper Insert the axle shaft through the wheel hub from the right side and install the axle nut Tighten the right and left pivot arm bolts TORQUE 20 24 N m 2 0 2 4 kg m 14 17 ft lb Tighten the axle nut to the specified torque AXLE NUT Connect the speedometer cable to the speedometer m i gearbox Connect the brake cable to the front brake arm 52 2 Adjust the front brake lever free play Page 3 9j i iir SPEEDOMETER CABLE BRA
77. eassem bly 7 After reassembly check all parts for proper installation and operation 8 Route all electrical wires as shown on page 1 7 Cable and Harness Routing and always away from sharp edges and areas where they might be pinched between moving parts Date of Issue May 1983 HONDA MOTOR CO LTD GENERAL INFORMATION The vehicle identification number is on the frame pipe of MODEL IDENTIFICATION the center of the front cover s DE NR e Beginning Frame Number HF010 DS000001 The frame seriai number is stamped on the left side of the The carburetor identification number is on the left side of frame body y The engine serial number is stamped on the back of the The color label is attached to the left side of the fuel tank crankcase near the rear wheel under the seat i dmi E linia cad n 7 1 2 4 Date of Issue May 1983 HONDA MOTOR CO LTO SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS Overall length Overall width Overall height Wheelbase Seat height Foot peg height Ground clearance Dry weight Curb weight FRAME Front suspension travel Rear suspension trave Gross vehicle weight rating 83 84 Vehicle capacity load 83 84 Front tire size Rear tire size Cold tire Up to 90 kg pressure 200 lbs load Rer Up to vehicle Front capacity load
78. ed lack of power 1 Worn drive belt 2 Weak driven face spring 3 Worn weight roller 4 Faulty driven face Date of Issue May 1983 73 8 Bd 1 HONDA MOTOR CO LTD Engine starts but scooter won t move Engine stalls or scooter creeps i Worn drive belt 1 Broken clutch weight spring 2 Damaged ramp plate 3 Worn or damaged clutch lining DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH DRIVE PULLEY LEFT CRANKCASE COVER REMOVAL LEFT CRANKCASE COVER E Remove the frame center cover and left floor board Section 11 Remove the kick starter pedal Remove the bolts and left case cover install the universal holder to hold the flywheel and remove the 10 mm flange nut and drive face Remove the drive belt Remove the gasket and dowel pins iue DRIVE BELT REMOVAL DRIVE FACE CAUTION Do not bend the drive belt UNIVERSAL HOLDER 10 mm NUT DRIVE BELT 07725 0030000 DRIVE BELT INSPECTION Check the drive belt for cracks separation or ab normal or excessive wear Measure the drive belt width NOTE Use a genuine Honda Drive Belt SERVICE LIMITS 13 5 mm 0 531 in t 74 Date of ssue May 1983 HONDA MOTOR CO LTD DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH MOVABLE DRIVE FACE REMOVAL MOVABLE DRIVE FACE DISASSEMBLY ee CHEM EE T fr E H isl Tee HE himm EC p 1 liu irn i EL TH 4
79. ed Reed valve controlled 809 BBDC 809 ABDC 55 BBDC 55 ABDC 18 kg 39 7 Ib 1 800 100 rpm Date of Issue November 1983 American Honda Motor Co Inc 1983 All Rights Reserved GENERAL INFORMATION ITEM SPECIFICATION CARBURETION Carburetor type size Piston valve 16 mm 0 63 in venturi dia Identificatton number 54 0 Air screw Refer to page 4 10 Float level 8 5 mm 0 33 in DRIVE TRAIN Clutch type Automatic dr y centrifugal clutch Primary reduction V belt Gear ratio 2 3 12 1 Final reduction 6 914 1 ELECTRICAL Ignition type Ignition timing F mark 14 BTDC at idle Starting system Starting motor and kickstarter Alternator 12V 110W 5 000 rpm Battery capacity 12V 5AH Spark pl Spark plug ND i Standard BPR6HS W20FPR For cold climate ieee Below 5 C 41 F Bis iudi For extended highispediriding BPR7HS W22FPR Spark plug gap 0 6 0 7 mm 0 024 0 028 in Fuse capacity 7A LIGHTS Headlight High Low 12V 25 25W Taif brake light 12V 3 32 cp SAE No 1157 Turn signals Front 12V 32 cp SAE No 1156 Rear 12V 32 cp SAE No 1156 Speedometer light 12V 2 cp SAE No 57 Oil indicator light 12V 2 SAE No 57 Turn signal indicator 12V 2 cp SAE No 57 High beam indicator 12V 2 cp SAE No 57 1 4 6 Date of Issue May 1983 HONDA MOTOR CO LTD GENERAL INFORMATION
80. ed air from the oil outlet line OIL INLET LINE OIL PUMP CAUTION Bleed air from the lines whenever the oil dines or pump have been removed or there is dir in the oi lines Fill the oil tank with recommended oil OIL INLET LINE Place a shop towel around the oil pump Disconnect the oil inlet line from the oil pump Fill the oil pump with oil by squirting clean oil through the joint about 3 cc Fill the oil line with oil and connect it to the joint of the oil pump After installation make sure there is no air in the oil inlet line CAUTION Bleed air from the oil outlet line after bleeding the inlet line and pump Date of Issue May 1983 17 2 3 HONDA MOTOR CO LTD LUBRICATION OIL OUTLET LINE OIL PUMP 1 Disconnect the oil outlet lineat the carburetor and force air out of the tube by filling it with oil using an squirt can Connect the oil outiet line to the carburetor Start the engine and allow it to idle with the oil control lever in the fully open position making sure that there are no air bubbles in the oil from the oil pump 4 If there are air bubbles repeat steps 1 through until the oil line is free of air bubbles HE WN Q WARNING e Perform this operation in well ventilated oom MM e CAUTION n TR dis a e Do not race the engine un
81. emove the axle nut withdraw the axle shaft and remove the front wheel INSPECTION e AXLE SHAFT Set the axle in V blocks and measure the runout The actual runout is 1 2 of the total indicator read ing SERVICE LIMIT 0 2 mm 0 01 in Date of Issue May 1983 HONDA MOTOR CO LTO STEERING FRONT WHEEL BRAKE SUSPENSION CUSHION ARM COVER ipud ant T m EN F s E 1 E 1 Ej i m lux ultr s i27 My im E EUN F 4 bu Em s AXLE NUT T 12 9 STEERING FRONT WHEEL BRAKE SUSPENSION e WHEEL BEARING Check the wheel bearing play by placing the wheel in a truing stand and spinning the wheel by hand Replace the bearings if they are noisy or have exces sive play e WHEEL RIM Check the rim runout by placing the wheel in a truing stand Then spin the wheel by hand and read the runout using a dial gauge SERVICE LIMITS Radial 2 0 mm 0 08 in Axial 2 0 mm 0 08 in DISASSEMBLY Remove the dust seal bearings and distance collar RADIAL Date of Issue May 1983 12 10 128 HONDA MOTOR CO LTD HONDA NH80 Remove the three flange nuts and remove the spoke plate from the rim ASSEMBLY Install the spoke plate onto the rim and tighten the flange nut TORQUE 22 28 2 2 2 8 kgm 16 20 ft Ib Pack all bearing cavities with gr
82. gh Plug not serviced frequently enough Use of plug with improper heat range Worn cylinder or piston Fuel air mixture too lean Use of improper grade of fuel Excessive carbon build up in combustion chamber Ignition timing too advanced Excessive carbon build up in combustion chamber Use of improper grade of fuel Clutch slipping Fuel air mixturetoo lean 18 2 188 Date of Issue May 1983 HONDA MOTOR CO LTD POOR PERFORMANCE AT LOW AND IDLE SPEEDS 1 Check ignition timing CORRECT 2 Check carburetor air screw for proper adjustment CORRECT 3 Check if air is leaking past intake pipe NOT LEAKING 4 Try spark test GOOD SPARK TROUBLESHOOTING Probable Cause INCORRECT amaumf 1 2 INCORRECT 1 2 LEAKING 2 3 WEAK OR 1 INTERMITTENT SPARK 2 3 4 5 6 POOR PERFORMANCE AT HIGH SPEED 1 Check ignition timing CORRECT 2 Disconnect fuel tube at fuel valve FUEL FLOWS FREEL Y 3 Remove carburetor and check for a clogged jet NOT CLOGGED INCORREGT 1 2 FUEL FLOW RESTRICTED 1 2 3 CLOGGED E Faulty CDI unit Faulty pulse generator Fuel air mixture too rich Perform idle drop Fuel air mixture too lean Perform idle drop Loose carburetor Deteriorated inlet pipe gasket Deteriorated insulator O ring Faulty carbon or wet fouled spar
83. gine must be running 10 do some work make sure the area is well ventilated Never run the engine in a closed area The exhaust contains poisonous carbon monoxide gas Gasoline is extremely flammable and is explosive under certain conditions Do not smoke or allow flames or sparks in your working area The battery electrolyte contains sulfuric acid Protect your eyes skin and clothing In case of contact flush thoroughly with water and call a doctor if electrolyte gets in your eyes The battery generates hydrogen gas which be highly explosive Do not smoke or allow flames or sparks near the battery especially while charging it SERVICE RULES 1 Use genuine HONDA or HONDA recommended parts and liubricants or their equivalents Parts that do not meet HONDA s design specifications may damage the scooter 2 Use the special tools designed for this product 3 Use only metric tools when servicing this scooter Metric bolts nuts and screws are not interchangeable with English fasteners The use of incorrect tools and fasteners may damage the scooter 4 Install new gaskets O rings cotter pins lock plates etc when reassembling 5 When tightening bolts or nuts begin with larger diameter or inner bolts first and tighten to the specified torque diagonally in 2 3 steps unless a particular sequence is specified 6 Clean parts in non flammable or high flash point solvent upon disassembly Lubricate any sliding surfaces before r
84. guide roller pin and guide roller GUIDE ROLLER GUIDE ROLLER PIN DRIVEN FACE MOVABLE DRIVEN FACE SEAL COLLAR GUIDE ROLLER PIN GUIDE ROLLER Date of Issue May 1983 89 4 HONDA MOTOR CO LTO 8 1 7 DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH Remove the snap ring and remove the inner bearing with Bearing Remover Shaft 07746 00501 00 and Bearing Remover Head 15 mm 07746 0050400 INNER BEARING Remove the snap ring and remove the outer bearing SNAP RING with Bearing Remover Shaft 07746 0050100 and Bearing Remover Head 12 mm 07746 0050300 INNER BEARING OUTER BEARING 8 1 8 90 Date of Issue May 1983 a HONDA MOTOR CO LTO DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH CLUTCH DRIVEN FACE INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer 1 0 SERVICE LIMIT 112 5 mm 4 43 in Inspect the clutch shoes for wear or damage Measure the thickness of each shoe SERVICE LIMIT 2 0 mm 0 08 in Measure the driven face spring free length SERVICE LIMIT 59 1 mm 2 33 Date of Issue May 1983 91 E HONDA MOTOR CO LTD 8 1 DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH Inspect the driven face assembly for wear or dam age Measure the driven face O D SERVICE LIMIT 33 930 mm 1 3358 in Inspect the movable driven face for wear or damage
85. imits shown in the table NOTE For accurate testing it is necessary to use a specified tester Use of an improper tester or measurements the improper range may give false readings Use Sanwa Electric Tester SP 10D 07308 0020000 Kowa Electric Tester TH 5H or Kowa Digital Multi Tester KS AHM 32 003 U S A only Measuring range SANWA ELECTRIC TESTER xKQ KOWA ELECTRIC TESTER x 1009 1 UNIT 4 PROBE PINK WHITE BLACK PROBE Date of Issue May 1983 HONDA MOTOR ELECTRICAL EQUIPMENT PINK WHITE BLACK RED 15 7 ELECTRICAL EQUIPMENT IGNITION SYSTEM IGNITION SYSTEM CIRCUIT ALTERNATOR OFF BL R 00000000 r IGNITION COIL PULSE COIL 2000 SPARK PLUG For spark plug gap inspection and adjustment see Page 3 6 IGNITION TIMING NOTE The ignition timing is not adjustable 1 the ignition timing is not correct check the CD unit and alternator and replace any faulty parts Remove the fan cover and check the ignition timing with a timing light Timing is correct if the index mark aligns with the F mark within 3 at 1 800 rpm IGNITION TIMING 14 3 BTDC at 1 800 rpm sn m i s3a IGCONDENSER SCR GATE C BL BLACK Y YELLOW BU BLUE G GREEN R RED W WHITE IGNITION COIL
86. ine securely Check for leaks MUFFLER DECARBONIZATION Remove the muffler Page 13 2 Remove the carbon fromthe muffler Reinstall the muffler Page 13 3 CARBURETOR IDLE SPEED NOT E e Inspect and adjust idle speed after all other engine adjustments are within specifications The engine must be warm for accurate ad justment en minutes of stop and go riding 15 sufficient DECREASE Remove the left side cover Warm up the engine and place the scooter on its center stand Turn the throttle stop screw as required to obtain the specified idle speed EF THROTTLE STOP SCREW IDLE SPEED 1 800 100 rpm Date of Issue May 1983 27 e HONDA MOTOR CO LTD 3 7 O po MAINTENANCE COMPRESSION TEST Remove the left frame cover and warm up the engine Stop the engine and remove the spark plug Insert a compression gauge Open the throttle grip fully and operate the kick starter several times COMPRESSION 10 0 14 0 kg cm 142 200 psi Low compression can be caused by e Blown cylinder head gasket Worn piston rings e Worn cylinder High compression can be caused by e Carbon deposits in combustion chamber or on pis ton head i 4 lg COMPRESSION GAUGE BATTERY UPPER LEVEL Remove the battery cover Inspect the battery fluid level When the fluid level nears th
87. isconnect the fuel lines from the fuel filter Replace the fuel filter with a new one Gasoline is flammable and is explosive under certain conditions Do smoke or allow flames or sparks in your working area Install the fuel filter with the arrow in the normal direction of fuel flow After installing check that there are no fuel leaks ARROW Date of Issue May 1983 HONDA MOTOR CO LTD 23 3 3 MAINTENANCE THROTTLE OPERATION Check for smooth throttle grip full opening and auto matic full closing in all steering positions Check the throttle cable and replace it if it is deterio rated kinked or damaged Lubricate the throttie cable page 2 5 if throttle operation is not smooth Measure the throttle grip free play at the throttle grip flange FREE PLAY 2 6 mm 1 8 1 4 in Adjustments can be made by loosening the lock nut and turning the throttle grip free play adjuster Replace the throttle cable when the above procedure is no longer effective AIR CLEANER Remove the left frame cover Remove the spring clip and remove the air cleaner case cover 3 4 AIR CLEANER CASE COVER 24 ADJUSTER 2 8234 4 im wir LOCK NUT SPRING CLIP Date of Issue 1983 HONDA MOTOR CO LTD MAINTENANCE Remove the air cleaner element Wash the element in non flammable or high fiash point
88. k plug Faulty CDI unit Faulty pu se generator Fauity ignition coil Broken or shorted high tension wire Faulty ignition switch Faulty unit Faulty pulse generator No fuel in fuel tank Clogged fue tube or fuel filter Clogged fuel tank cap breather hole Clean Date of Issue May 1983 HONDA MOTOR CO LTO 189 18 3 TROUBLESHOOTING POOR HANDLING CLUTCH AND DRIVE DRIVEN PULLEYS 1 if engine fires but motorcycle does not start 2 3 4 5 6 7 2 if motorcycle creeps or engine Starts but soon stops 1 2 3 if engine lacks power at start of a grade 1 2 3 4 5 4 If engine lacks power at high speed 1 2 3 5 If there is abnormal noise or smell mm 1 2 3 4 LOSS OF CONTROL 1 If steering is heavy pil 2 Check tire pressure 2 If either wheel is wobbling J 1 2 3 3 If the motorcycle pulls to one side 1 2 POOR FRONT REAR SUSPENSION PERFORMANCE Check tire pressure 1 If suspension is too soft 1 2 3 1 2 f suspension is too hard If suspension is noisy A A
89. kg m 2 3 ft lb NOTE Make sure that the O ring is in position uM MOVABLE FACE SEAL Install the drive face boss in the movable drive face DRIVE MOVABLE DRIVE FACE INSTALLATION MOVABLE DRIVE FACE Clean the hole in the movable drive face drive face boss and crankshaft Install the movabie drive face assembly onto the crankshaft CRANKSHAFT RAMP PLATE FACE BOSS 8 6 Date of Issue May 1983 HONDA MOTOR CO LTD DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH DRIVE FACE AND LEFT CASE COVER INSTALLATION Install the gasket and dowel pins Install the plain washer onto the kick spindle Install the drive belt Install the universal hoider Install the movable drive face and tighten the 10 mm flange nut TORQUE 35 40 3 5 4 0 kg m 25 29 ft lb NOTE Do not get oil or grease on the drive beitor pulleys Install the left case cover and kick starter pedal Install the left floor board and frame center cover T NE Mee MES i zd alia T GASKET DOWEL PIN ppr EUNT DOWELPIN PLAIN WASHER DRIVE FACE DRIVE BELT Date of Issue May 1983 HONDA MOTOR CO LTD DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH KICK STARTER 8 8 80 Date of Issue May 1983 5 HONDA MOTOR LTD DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH KICK STARTER REMOVAL GASKET DOWEL PINS Remove the left case co
90. kg m 58 72 ft Ib TOOLS Special Rear shock absorber attachment A 07967 GA70101 Spring attachment holder 07967 07967 GC80000 or 07967 1180100 Common Rear shock absorber compressor 07959 3290001 Rear wheel wobbling Poor brake performance 1 Bent rim 1 Brake not adjusted properly 2 Faulty tire 2 Contaminated brake linings 3 Axle not tightened Worn brake linings 4 Worn brake shoes at cam contacting area Soft suspension 5 Worn brake cam 1 Weak shock absorber spring 6 Worn brake drum 7 Improper engagement between brake arm and Brake squeaks camshaft serrations 1 Worn brake linings 2 Foreign matter on linings 3 Rough brake drum shoe contacting face Date of Issue May 1983 145 HONDA MOTOR CO LTD 1 3 A 1 REAR WHEEL BRAKE SUSPENSION REAR WHEEL REMOVAL Remove the frame center cover Section 11 Remove the exhaust muffler Remove the axle nut and the rear wheel REAR WHEEL RIM RUNOUT INSPECTION Check the rim for runout using a dial gauge as shown SERVICE LIMITS Radial 2 0 mm 0 08 Axial 2 0 mm 0 08 in 1 3 es 2 146 Date of Issue May 1983 HONDA MOTOR CO LTO REAR WHEEL SPOKE Remove the three flange nuts attaching the spoke plate to the wheel rim and remove the spoke plate Reinstall the spoke plate and tighten the flange nut TORQUE 22 28 2 2 2 8 kg m 16 20 ft lb INSTALLATION Instatl the rear wheel and tighten the axl
91. m 8 page FUEL FILTER gt THROTTLE OPERATION O AIR CLEANER NOTE 1 CARBURETORCHOKE CLEANER NOTET 3 SPARK PLUG OIL PUMP ENGINE OIL LINES 2 2 ENGINE OIL STRAINER SCREEN MUFFLER DECARBONIZATION TRANSMISSION OIL 2 YEARS R _ BATTERY MONTH SS vee eee 38 BRAKE SHOE WEAR BRAKESYSTEM E PARKING BRAKE od 7 BRAKE LIGHT SWITCH 1 HEADLIGHT AIM 5 SUSPENSION ab EN gt NUTS BOLTS FASTENERS gt CLUTCH SHOE WEAR 2 WHEELS e STEERING HEAD BEARINGS SHOULD SERVICED BY AN AUTHORIZED HONDA SCOOTER DEALER UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALL Y QUALIFIED IN THE INTEREST OF SAFETY WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED HONDA SCOOTER DEALER NOTES 1 Service more frequently when riding in dusty areas 2 For higher odometer readings repeat at the frequency interval established here 3 2 22 Date of Issue 1983 HONDA MOTOR CO LTO MAINTENANCE FUEL LINES Remove the frame center cover Section 11 Check the fuel lines and replace any parts which show deterioration damage or leakage Install the frame center cover FUEL FILTER Replace the fuel filter with a new one when indicated by the maintenance schedule page 3 2 Remove the frame center cover and battery box Sec tion 11 D
92. mission oil Clutch shoe wear SPECIFICATIONS Engine Spark plug 3 MAINTENANCE COMPRESSION TEST BATTERY BRAKE SHOE WEAR BRAKE SYSTEM PARKING BRAKE BRAKE LIGHT SWITCH HEADLIGHT AIM SUSPENSION NUTS BOLTS FASTENERS WHEELS STEERING HEAD BEARINGS Standard For cold climate below 5 C 41 F For extended high speed riding NGK ND NGK ND NGK ND BPR6HS W20FPR BPR5HS WIGFPR BPR7HS W22FPR Spark plug gap 0 6 0 7 mm 0 024 0 028 in Throttle grip free play 2 6 mm 1 8 1 4 in Idle speed 1 800 100 rpm Cylinder compression 10 0 14 0 kg cm 142 200 psi lt Chassis gt Front brake free play Rear brake free play 10 20 mm 3 8 3 4 in 10 20 mm 3 8 3 4 in Tire Front Rear Tire size 3 50 10 4PR 3 50 10 Up to 90 kg 200 165 load 21 150 1 5 24 175 1 75 Cold tire pressure psi kPa kg cm 90 kg 200 165 load and up to vehicle capacity load 21 150 1 5 36 250 2 5 Date of Issue May 1983 HONDA MOTOR CO LTD 2 3 1 MAINTENANCE MAINTENANCE SCHEDULE Perform the Pre ride Inspection in the Owner s Manual at each scheduled maintenance period INSPECT AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY 4 C CLEAN R REPLACE A ADJUST L LUBRICATE FREQUENCY WHICHEVER COMES ODOMETER READING NOTE 2 FIRST 600mi 2500mi 5 i 7 i Refer to EVERY 1 000 4 000 k
93. necessarily INTAKE PIPE OIL PUMP CONTROL CABLE ADJUSTMENT LOCK NUT Fa ADJUSTING NUT rr as X uA amp s 1 1 NOTE The oi pump control cable should be adjusted after the throttle grip free play adjustment Remove the frame center cover Page 11 3 Loosen the oil pump control cable lock nut and open the throttle fully Check that the aligning mark on the oil pump control lever is aligned with the index mark projection on the pump body Adjust if necessary by turning the adjusting nut CAUTION Reference tip adjustment within 0 04 in of index mark on the open side is accept able However the aligning mark must never be on the closed side of the index mark other wise engine damage will occur because of insufft cient lubrication Excessive white smoke or hard starting Pump control iever excessively open Seized piston Pump control lever not properly adjusted iw INDEX MARK PROJECTION 2 4 18 Date of Issue May 1983 HONDA MOTOR CO LTD LUBRICATION FINAL REDUCTION OIL CHECK NOTE Place the scooter on a level ground and support with the center stand Remove the oil level check bolt and check that the oil level is at the oil level check bolt hole CHANGE Remove the level check bolt Remove the drain bolt to allow the oil to drain thoroughly Reinstall the d
94. nerator from the stator base Avoid damaging the stator coils Date of Issue May 1983 69 T 3 HONDA MOTOR CO LTD ALTERNATOR ALTERNATOR INSTALLATION Install the alternator wire grommet in the case Install the stator install the woodruff key in the keyway in the crank shaft Connect the alternator wire connectors NOTE Route the alternator wires properly and se cure with the wire clamp ai UNT C GROMMET BE ceed i il lk I it s ONNECTORS Fu 70 Date of Issue 1983 HONDA MOTOR LTD ALTERNATOR NOTE Clean the tapered hole in the flywheel of any burrs Install the flywheel onto the crankshaft 5 P wu p e up f NOTE Make sure that there are no foreign particles inside the flywheel Torque the flywheel 10 mm flange nut TORQUE 35 40 3 5 4 0 kg m 25 29 ft Ib Install all removed parts in the reverse order of re me UNIVERSAL HOLDER 07725 0030000 Start the engine and check the ignition timing Page 15 8 Date of Issue May 1983 71 7 E 5 HONDA MOTOR CO LTO DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH 8 O E 72 Date of Issue May 1983 HONDA MOTOR CO HONDA 8 DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH SERVICE NFORMATION TROUBL
95. nsmission cover and left crankcase ioe 0959817 107746 0010300 Attachment 42 x 47 mm To install crankshaft bearings 46004 0959874 07746 0040200 Pilot 12 mm Use with attachment 07746 0010100 to instat lefi transmission cover bearing 36202 0959890 07746 0040400 Pilot 17 mm Use with attachment 07746 0010200 to instail wd transmission cover and left crankcase bearing 6203 959916 07746 0040600 Pilot 25 mm Use with attachment 07746 0010300 to install ree hm srantatteanng 008 _ anas 0933242 07749 0010000 Driver Use with all attachments m pilots over MSY 5523 8819 8505 ROUTING Copy 1 O GENERAL MANAGER PARTS MANAGER TOOL CATALOG BINDER Copy 2 SERVICE MANAGER O SERVICE TECHNICIANS D SERVICE MANUAL BINDER AMERICAN HONDA MOTOR CO ALL RIGHTS RESERVED NH80 1 REVISEO MAY 1985 ENGINE TOOLS CONTINUED TRANSMISSION CRANKSHAFT continued H C TOOLNUMBER DESCRIPTION APPLICABILITY 1490978 07935 KG80000 Case Puller e Kick starter driven gear removal Use with special bolts e Crankcase separation 1503267 07965 GC70100 Use together for assembling the and 1503275 07965 1480200 Assembly Bolt crankcases CHASSIS TOOLS WHEEL BRAKE C TOOL NUMBER DESCRIPTION APPLICABILIT Y 0753509 07746 0010100 Front wheel bearings 6201 installation Use with 07746 0040200 and 07749 0010000 0959874 07746
96. olt and nut 8 12 0 8 1 2 6 9 6 mm screw 7 11 0 7 1 1 5 8 8 mm bolt and nut 18 25 1 8 2 5 13 18 6 mm bolt and nut 10 14 1 0 1 4 7 10 10 mm bolt and nut 30 40 3 0 4 0 22 29 8 mm bolt and nut 20 30 2 0 3 0 14 22 12 mm bolt and nut 50 60 5 0 6 0 36 43 10 mm flange bolt and nut 30 40 3 0 4 0 22 29 Date of Issue 1983 7 1 5 HONDA MOTOR CO LTD GENERAL INFORMATION TOOLS SPECIAL Clutch spring compressor Seal and case assembling tool Bearing driver Spring attachment holder Lock nut wrench 39 mm Universal bearing puller Crankcase pulter Bearing remover set 12 mm Bearing remover 15 mm Hand vacuum pump Rear shock absorber atwchment Bearing driver attachment 28 x 30mm 07960 K J90000 07965 GC70000 07945 GC80000 07967 GC80000 07916 1870001 07631 0010000 07935 KG80000 07936 1660001 07936 KC10000 ST AH 260 MC7 07967 GA70101 07946 1870100 Assembly collar Assembly tool bolt only Spring attachment holder Bearing remover 12 mm Remover weight U S A only 07965 GC70100 07965 1480200 07967 1180100 07936 1660100 07936 37 10200 8 15 8 22 10 5 10 6 8 20 13 7 13 8 8 15 8 22 10 3 8 9 10 2 9 4 9 4 4 13 13 7 13 8 8 21 These tools are not available in the U S A Equivalent tools or commercially available in U S A or other methods recom mende
97. on of the front fork shocks by com pressing them several times Check the entire fork assembly for damage Repiace damaged components which cannot be re paired Tighten all nuts and bolts REAR Place the scooter on its center stand Move the rear wheel sideways with force to see if the engine hanger bushings are worn Replace the hanger bushings if there is any looseness Check the shock absorber for damage Tighten all rear suspension nuts and boits NUTS BOLTS FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values Section 1 at the intervals shown in the Maintenance Schedule Page 3 2 Check all cotter pins safety clips hose clamps and cable stays WHEELS NOTE Tire pressure should be checked when tires are COLD Check the tires for cuts imbedded nails or other sharp objects RECOMMENDED TIRES AND PRESSURES Tire size Up to 90 kg 21 Cold tire 200103 load 150 7 5 pressure 9 psi kPa 90 kg 200 ibs 21 kg cm and upto vehicle 1150 1 5 capacity load Date asue May 1983 1 P HONDA MOTOR CO LTD 3 11 HONDA 80 MAINTENANCE Check the frontand rear wheels for trueness Measure the tread depth at the center of the tires Replace the tires if the tread depth reaches the fol lowing limits Minimum tread depth Front 0 8 mm 0 03 in Rear 0 8 0 03 in
98. raight 1 Uneven front shocks 2 Bent front fork 3 Bent front axle Front wheel wobbling Bent rim Axle nut tightened improperly Bent spoke plate Faulty or unevenly worn tire Excessive wheel bearing play So ft suspension 1 Weak fork springs Front suspension noise 1 Fork link binding 2 Loose front fork fasteners 1 2 2 120 Date of Issue May 1983 HONDA MOTOR LTO STEERING FRONT WHEE L BRAKE SUSPENSION SPEEDOMETER METER LOWER COVER 1 1 T SPEEDOMETER REMOVAL Remove the meter lower cover by backing off the one bolt and two screws Remove the right and left headlight covers by re HEADLIGHT COVERS moving the screws 1 AN xir mia eig Bad Hee Disconnect the front turn signal wires Remove the two bolts attaching the handlebar front cover and remove the front cover with the right and left front turn signals Date of issue 1983 121 HONDA MOTOR CO LTD 1 2 3 STEERING FRONT WHEEL BRAKE SUSPENSION Disconnect the headlight wires Remove the two bolts and headlight Remove the windshield by removing the three WINDSHIELD screws and two nuts Disconnect the meter wires and the speedometer REAR VIEW MIRRORS cable Remove the rear view mirrors and meter cluster assembly SPEEDOMETER CABLE 1 2 4 122 Date of Issue May 1983 HONDA MOTOR CO LTD _ STEERING FRONT WHEEL BRAKE SUSPENSION
99. rain bolt TORQUE 10 14 N m 1 0 1 4 kg m 7 10 ft lb NOTE Check that the sealing washer is in good condi tion Fill the final reduction case up to the proper level with recommended oil OIL CAPACITY 90cc 0 09 US qt EB wc SPECIFIED OIL HONDA 4 STROKE OIL or Pp equivalent 10W 40 DRAIN BOLT CONTROL CABLE LUBRICATION Periodically disconnect the throttle oil control and brake cables at their upper ends Thoroughly lubri cate the cables and their pivot points with a commer cially available cable lubricant Date of Issue May 1983 HONDA MOTOR CO LTD 2 5 NH80 MAINTENANCE LUBRICATION POINTS A or CABLE LUBRICANT M THROTTLE AND BRAKE LEVER BRAKE CABLES PIVOTS Ls ik or CABLE LUBRICANT N SPEEDOMETER CABLE _ Sum THROTTLE GRIP STEERING x77 HEAD Sie BEARING FINAL REDUCTION GEAR HONDA 4 STROKE OIL 1 FOOT PEG OR EQUIVALENT 10W 40 WHEEL PIVOT Cun bonus FIANAL SHAFT Sm BEARINGS DRIVE GEAR CENTER STAND PIVOT 2 6 20 Date of Issue May 1983 HONDA MOTOR CO LTD SERVICE INFORMATION MAINTENANCE SCHEDULE FUEL LINES FUEt FILTER THROTTLE OPERATION AIR CLEANER CARBURETORCHOKE CLEANER SPARK PLUG ENGINE OIL LINE ENGINE O L STRAINER SCREEN MUFFLER DECARBONIZATION CARBURETOR IDLE SPEED SERVICE INFORMATION GENERAL Oil pump Trans
100. retor float and float valve by re moving the pin FLOAT FLOAT VALVE INSPECTION Check the valve seat for wear or damage Check the float for deformation or fuel inside the float Date of Issue May 1983 HONDA MOTOR CO LTD 39 FUEL SYSTEM FLOAT PIN FLOAT FLOAT VALVE SEAT FLOAT VALVE FUEL SYSTEM NOTE e The air screw is factory pre set and should not be removed unless the carburetor is over hauled The air screw limiter cap is factory installed to prevent air screw misadjustment Remove the throttle stop and air screws Record the number of rotations until it seats so it can be return ed to its original positions CAUTION Do not force the screw against its seat to pre vent damage to the seat Remove the main jet needle jet holder and slow jet Blow open all jets and body opening with compressed air JETS FLOAT VALVE FLOAT ASSEMBLY Install the slow jet needle jet holder and main jet Install the throttle stop and air screws and return them to their original position as noted during re moval Perform air screw adjustment if new air screw is in stalled Page 4 10 NOTE Do not install a new limiter cap on a new air screw head until after adjustment has been made THROTTLE STOP SC REW AIR SCREW THROTTLE STOP SCREW NEEDLE JET HOLDER HOLDER SLOW JET AIR SCREW SLOW JET MAIN JET 4 6 40
101. s in its displacement category 5 SCAVENGE PORTS The 80 engine has 5 scavenge ports These ports are especially designed to swirl the incoming fuel air mixture into the com bustion chamber This swirl effect causes turbulence that will give the most efficient combustion This works with the special designs of the nozzle type exhaust port piston and combustion chamber PISTON COMBUSTION CHAMBER The piston top has a rim around it to help maintain turbulence during the engine compression stroke The turbulence is also aided by the semi spherical shape of the combustion chamber The chamber s shape and centrally located spark plug provide a fast smooth combustion process under all loads and engine speeds SQUASH ZONE Date of Issue May 1983 181 1 7 _ 1 HONDA MOTOR LTD TECHNICAL FEATURES VENTURI EXHAUST PORT The exhaust port on this engine has been designed with a slight venturi shape to create just enough back pressure to momen tarily restrict the exit of the exhaust gases for a more complete combustion cycle The exhaust quickly exits the cylinder after passing the venturi of the exhaust port This is a way that emission standards met by the NH80 engine that also help im prove fuel mileage HIGH SPEED 2 NOZZLE TYPE EXHAUST PORT 1 1 2 182 Date of Issue May 1983 ES OHONDA MOTOR CO LTD TECHNICAL FEATURES AUTOMATIC TRANSMISSION The automatic transmission provides vario
102. securely BATTERY HOLDER SPECIFIC GRAVIT Y TEST Test each cell by drawing electrolyte into a hydro meter SPECIFIC GRAVIT Y 20 68 1 270 1 290 Fully charged 1 230 or below Undercharged The battery must be charged if the specific gravity falls below 1 230 ELECTROLYTE NOTE e The specific gravity varies with the temper ature as shown Specific gravity changes by 0 007 for every 10 C Replace the battery if sulfation has form ed or if the space below the cell plates is filled with sediment The battery contains sulfuric acid Avoid contact with skin eves or clothing Antidote Flush with water and get prompt medical attention gt Ea 2 qd O O Lu a uU Lu ELECTROLYTE TEMP VS SPECIFIC GRAVITY 10 19 20 257 30 35 Ei gs TEMPERATURE C Date of Issue May 1983 161 HONDA MOTOR LTD 1 5 ELECTRICAL EQUIPMENT BATTERY CHARGING Remove the battery Remove the cell cap from the battery Connect the charger positive 4 cable to the battery positive 4 terminal Connect the charger negative cable to the bat tery negative terminal Charging current 0 5 amperes maximum l5 e Keep flames and sparks away from a charg ing battery to prevent igniting the hydro gen gas produced by the batter y e Turn power ON OFF at the charger not at the battery terminals to prevent sparks n
103. solvent squeeze out and allow todry Never use gasoline or low flash point solvents for cleaning the air cleaner element A fire or explosion could result Soak the element in clean motor oil SAE 10W 40 or gear oil 280 90 and squeeze out the excess Reinstal the element element holder air cleaner case cover and carburetor cover CARBURETORCHOKE CLEANER Remove the left frame cover Remove the carburetorchoke cleaner chamber and re move the element Wash the element in non flammable or high flash point solvent squeeze out the excess and allow it to dry V WARNING Never use gasoline or low flash point solvents for cleaning the cleaner element A fiie or ex plosion could result Soak the element in clean motor oil SAE 10W 40 or gear oil 80 90 and squeeze out excess Reinstall the carburetorchoke cleaner element and chamber and clamp the chamber in position Date of Issue May 1983 HONDA MOTOR CO LTD 25 SQUEEZE OUT AND DRY ELEMENT Ens T aiia gei T Di CHAMBER CARBURETORCHOKE CLEANER SQUEEZE OUT EXCESS OIL 3 5 MAINTENANCE SPARK PLUG CENTER ELECTRODE SIDE ELECTRODE RECOMMENDED SPARK PLUG NGK ND Standard BPR6HS W20FPR For cold climate Below 5 C 41 F BPR5HS W16FPR For extended high speed riding 0 6 0 7 mm BPR7HS W22FPR Disconnect the spark plug cap Clean
104. sor and check operation Float Lamp off Float down Lamp on CORRECT 2 2 Loose or disconnected terminal Broken wire harness Incorrect wire connection INCORRECT X X P 1 Jammed or stuck float Broken or shorted indicator sensor Deformed oil tank Foreign matter in tank Date of Issue May 1983 OHONDA MOTOR CO LTO 191 18 5 E M L1 oA Ee TROUBLESHOOTING FUEL GAUGE POINTER DOES NOT REGISTER CORRECTLY IGNITION SWITCH Check battery circuit by operating turn signals SIGNALS OPERATED PROPERLY Remove fuel level sensor and check for operation by moving float Float up Pointer at FULL Float down Pointer at EMPTY POINTER DOES NOT MOVE Short and opentank unit terminals on wire harness side POINTER DOES NOT MOVE Check for loose disconnected or incorrectly connected terminals CORRECT Probable Cause SIGNALS DIM REMAINED 1 ON OR NOT OPERATED 2 AT ALL 3 4 5 POINTER MOVES _ gt 1 POINTER MOVES _ __ 1 INGCORRECI _ i rr 2 Check battery circuit by operating turn signals SIGNALS OPERATED PROPERLY Remove tank unit and check for operation by moving float POINTER MOVES Move float up and down rapidly up and down stroke sec POINTER MOVES Check each connector CORRECT Blown fuse Weak or dead bat
105. tarter switch 2 Broken or shorted starter relay NORMAL 3 Loose connector or terminal 4 Test starter by connecting it to NOT ROTATED 9 1 Worn brushes battery 2 Broken or shorted rotor windings 3 Broken starter motor sub wire 4 Loose terminal ROTATED Broken wire harness STARTER MOTOR ROTATES BUT SLUGGISHLY OR FAILS TO CRANK ENGINE Probable Cause 1 Check battery circuit b y operating SIGNALS DIM REMAINED 4 1 Dead battery turn signals ON OR NOT OPERATED SIGNALS OPERATED PROPERLY v 4 2 Connect starter motor sub wires TURNED PROPERLY 1 Loose connector terminal across battery terminals 2 Poorly contacted starter relay TURNED BUT SLOWLY SPEED NOT CHANGED 3 Operate kickstarter HE A V Y 1 Seized engine LIGHT 1 Broken or shorted starter motor windings STARTER WON T STOP ROTATING Probable Cause 1 Turn ignition switch OFF STOPPED 1 Pinion stuck out NOT STOPPED A oe gt 1 Starter relay shorted or stuck closed Date of Issue May 1983 193 1 8 7 HONDA MOTOR CO LTD SERVICE TOOL NEWS NH80 1 REVISED MAY 1985 NHS80O 1983 AND AFTER REQUIRED SPECIAL TOOLS This STN supersedes NH8O 81 dated November 1983 The tools listed below are necessary to service and maintain this model However these tools should already bc in your inventory as they are necessary for servicing one or
106. tery Faulty ignition switch Disconnected terminal Broken wire harness Faulty float Broken or shorted balancing coil Disconnected terminal Incorrectly connected terminals Shorted or broken balancing coil lead POINTER FLUCTUATES OR SWINGS VIOLENTLY IGNITION SWITCH Probable Cause SIGNALS DIM REMAINED 11 ON OR NOT OPERATED 2 AT ALL 3 4 5 POINTER DOES NOT MOVE 1 POINTER DOES NOT MOVE t1 INCORRECT _ 1 Py 18 6 192 Blown fuse Weak or dead battery Broken or shorted ignition switch Loose or disconnected terminal Broken wire harness Loose or poor connection in fuel level sensor Lack of damper oil in meter Loose or disconnected terminal Shorted or broken balancing coil lead Date of Issue May 1983 OHONDA MOTOR CO LTD TROUBLESHOOTING STARTER MOTOR STARTER MOTOR DOES NOT ROTATE Probable Cause 1 Check operation of brake light DID NOT GO ON 1 Blown fuse by operating brakes 2 Weak or dead battery WENTON 3 Faulty stop light switch 4 Disconnected terminal 5 Broken or shorted ignition switch 2 Check battery circuit by operating SIGNALS DIM REMAINED 1 Dead battery turn signals ON OR NOT OPERATED SIGNALS OPERATED PROPERLY ATALL 60 120 flashings min 3 Check starter relay for operation ABNORMAL J 1 Poorly contacted starter switch by depressing s
107. us drive ratios between the engine and rear wheel according to the engine speed and load It accomplishes this by two sets of pulleys drive and driven and by the use of a drive belt between the pulleys The drive pulley is attached to the engine crankshaft The driven pulley is attached to a shaft and also incorporates a centrifugal clutch There is a final gear reduction between the driven pulley and rear wheel providing an additional increase in torque CLUTCH WEIGHT BALL BEARING NEEDLE BEARING DRIVE SHAFT WEIGHT SN ROLLER N GUIDE PIN GLUTEN AND ROLLER OUTER RAMP PLATE MOVABLE DRIVEN FACE DRIVEN SPRING FACE MOVABLE DRIVE FACE DRIVE FACE DRIVEN PULLEY DRIVE PULLEY DRIVEN PULLEY DRIVE PULLEY When the engine is running at low speed the unit As the speed of the engine increases or load on the can increase or multiply torque so that more torque rear wheel decreases centrifugal force on the weight is delivered than at high engine speed through a rollers throws the rollers radially outward When the greater drive ratio rollers are forced outward they press in the mov able face of the drive pulley closer to the drive face REDUCTION RATIO 2 1 which will result in a reduced drive ratio between the driven and drive pulleys REDUCTION RATIO 1 1 Date of Issue May 1983 HONDA MOTOR LTD iun 1 47 3 TECHNICAL FEATURES DRIVE PULLEY WEIGHT ROLLER RAMP PLATE MO
108. ustment is necessary turn the rear brake adiust ing nut PARKING BRAKE NOTE Parking brake inspection must be made after the rear brake is adjusted properly Apply the parking brake and check that the rear wheel is locked securely Squeeze the rear brake lever The parking brake should release automatically BRAKE LIGHT SWITCH Check that the brake light comes on when brake engagement begins Replace the switch if the brake light does not come on at the proper time NOTE The brake light switches cannot be adjusted HEADLIGHT AIM Adjust the headlight beam vertically by turning the vertical adjusting scew Turn the adjusting saew clockwise to direct the beam down Adjust the headlight beam horizontally by turning the horizontal adjusting saew Turn the adjusting screw clockwise to direct the beam toward the left side of the rider NOTE Adjust the headlight beam as specified by local laws and regulations An improperly adjusted headlight may blind oncoming drivers or it may fail to light the road for a safe distance HORIZONTAL M i ila DJUSTING SCREW 3 1 O 30 Date of Issue May 1983 j HONDA MOTOR CO LTD MAINTENANCE SUSPENSION MN Do not ride a scooter with faulty suspension Loose worn or damaged suspension paris im pair vehicle stability and control FRONT Check the acti
109. ver movable drive face Page 8 3 and drive belt Page 8 2 Remove the gasket and dowel pins Remove the plain washer from the kick starter spindle Es HER PLAIN WAS Remove the kick starter spring from the kick return KICK STARTER SPRING stopper Remove the kick starter spindle ILE NP ho EE KICK STARTER SPINDLE Attach the crankcase puller as shown with the two CRANK CASE PULLER 07935 KG80000 long special bolts eae 3 m Remove the kick starter driven gear with the case puller ELIT IT t SIDE ivi Hn Fi m 1 TES F 5 4 il Am i oe Date of issue 1983 81 HONDA MOTOR CO LTD 8 NH80 DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH Remove the kick starter idle shaft KICK STARTER IDLE SHAFT KICK STARTER DISASSEMBL Y KICK STARTER SPINDLE Disassembie the kick starter spindle SPECIAL PIN KICK RETURN SPRING Disassemble the kick starter idle shaft DOWEL PIN STARTER IDLE GEAR FRICTION SPRING SPRING IDLE GEAR SHAFT 8 1 O 82 Date of Issue May 1983 HONDA MOTOR CO LTD DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH KICK STARTER INSPECTION Inspect the kick starter spindle for wear or damage Inspect the kick starter spindle bushings and idle BUSHINGS gear shaft bearings for wear or damage Ve Inspect the gear and shaft for wear or damage Date of Issue May 1983
110. y hazard After clamping check each wire to be sure it is se cure Do not squeeze wires against the weld or end of its clamp when a weld on clamp is used Secure wires and wire harnesses to the frame with their respective wire bands at the designated loca tions Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses Route harnesses so they are not pulled tight or have excessive slack Protect wires and harnesses with electrical tape or tubing if they are contact a sharp edge or corner Clean the attaching surface thoroughly before applying tape Do not use wires or harnesses with a broken insula tor Repair by wrapping them with a protective tape or replace them Route wire harnesses to avoid sharp edges or corners Also avoid the projected ends of bolts and screws Keep wire harnesses away from the exhaust pipes and other hot parts Be sure grommets are seated in their grooves pro perly After clamping check each harness to be certain that it is not interfering with any moving or stid ing parts After routing check that the wire harnesses are not twisted or kinked Wire harnesses routed along the handlebars should not be pulled tight have excessive slack be pinch ed or interfere with adjacent or surrounding parts in all steering positions Date of Issue May 1983 HONDA MOTOR CO LTD GENERAL INFORMATION 1 7 GENERAL INFORMATION SPE
Download Pdf Manuals
Related Search
Related Contents
Sanitaire SC6070 User's Manual Plantronics Conferentietelefoon Konftel 100 MICRO SCT KitchenAid KSRF42DT Refrigerator User Manual 000 INTRO._1(Fr) sla-anlagen, die den unter dieser vereinbarung Stovax (P)8119**UC User's Manual EZ Crane Instructions and Safety workflow von mega erm Copyright © All rights reserved.
Failed to retrieve file