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Honda Common Service Manual MOTORCYCLES

1. I z j ae z TOOL m l l D c b 3 olojaje a e c 3 oO nuMBFA S S 3 Z 2 8 amp 8 3 8 3 8 8 3 8 2 s JEg g S eS amp A u wo o ej N Orewa 4 3 A M T NI SS te o 3 3 pas gt el 3 eis slels slsls Saal 5 l 6 el2 e 3 3i 3 8 8 8 3 2 Ss 23lslz s 3 5 S88 amp 8S8 E SEAHING Fin ake 8 3 3 a 8 raa G E 99 amp 8 s 8 S S 2 amp 8 8 8 3 S 8 s 2 e sni i rie 8 g 1 P i s lt re Cs wm 4 D a woo o 2 wajo x i ga t 7 q 2 z F q s s s 9 293 9 a x siale 3 13 3 Ej Imm IT mi e m m sc Pie Re PRP epee Bm meme om e Finite r je e im iid re i gt a r ad ad ed ad ee ae er m Ajeji ml eel re rs a o o o a ad a o BIS oe S o gt aj o o 3 90 2 o c ola o e2 EEIE Date of Issue Sep 1988 1 1 7 HONDA MOTOR CO LTD eee 2 MAINTENANCE FUEL LINE 2 2 DRIVE CHAIN 2 21 FUEL STRAINER SCREEN 2 2 DRIVE CHAIN SLIDER CHAIN GUIDE inane JEENA NON 2 3 GUIDE SLIDER AND ROLLERS 2 24 OIL PUMP AND OIL LINE 2 stroke PE RER T eats separate oil supply motorcycles 2 4 BELT CASE AIR CLEANER 2 25 CARBURETOR CHOKE 2 5 FINAL DRIVE OIL LEVEL 2 25 AIR CLEANER 2 6 BATTERY 2 26 AIR CLEANER CASE DRAIN TUBE BRAKE FLUID 2 27 off road motorcycles and ATVs 2 7 BRAKE SHOE WEAR 2 28 CRANKCASE BREATHER Oe vena UFAR ae SPARE PLUG 28 BRAKE SYSTEM 2 28 VALVE CLEARANCE 2 9 BRAKE LIGHT SW
2. 4 Cone spring lock washer important points inside the Installing in the opposite direction prevents engine effective locking Always install cone CONE TYPE Clutch lock nut washers with their OUTSIDE mark facing LOCK WASHER Primary gear jock nut Drive sprocket center balt out No marked set cone spring washers as shown in the table at left Da not use if damaged or deformed j 7 When using a lock nut chamfered on one side install the nut with chamfered side fac ing the lock washer as shown below CK TEE X i CHAMFERED EDGE A a 11 P a The hearing surface presses on the cone spring washer and the spring raaction presses against the nut to prevent it from loosening Date of Issue Sep 1998 HONDA MOTOR CO LTD 1 GENERAL INFORMATION APPLICATIONS CAUTION TYPES OF FASTENERS 5 Tengued lack plate Important paints inside angine Ensure that a tongue ichawl has locked the J oe Clutch lock nut nut properly important safety points on the Sinca repeated bending straightening frarne damages the tongue replace the lock plate Steering head bearing top with a new one whenevar the lock plate is nut removed Driven sprocket nuts Align the tongue to the nut in such a manner that the nut aligns perfectly when proper nut j i torque is reached or so that the nut m
3. Faulty battery Date of Issue Sep 1988 D HONDA MOTOR CO LTD 22 3 BATTERIES CHARGING LIGHTING SYSTEM BATTERY DESCRIPTIONS There are two types of batteries used in Handa motorcycles scontors and ATVs the conventional battery and the Maintenance free battery THE STRUCTURE OF A CONVENTIONAL BATTERY TERMINAL BREATHER FILLER CAP p NEGATIVE PLATE SEPARATOR GLASS MAT POSITIVE PLATE Conventianal Battary This battery conducts electricity when the chemical action o electrolyta sulphuric acid takes place betwean the two plates tlead peroxide and laadi The sulfate in the electrolyte com bines with the plate materials forming lead suiphata battery discharge By passing an electric current back into the bat tery the plates revert to lead peroxide and lead battery charge Since the specific gravity af the electrolyte relative weight of sulphuric acid as compared with an equal volume of water varies the battery state of charge is detarmined by measuring the eloctrolyta s specific gravity The battery gives off explosive gases keep sparks flames and cigarettes away Provide adequate ventila tion when charging or using the batteries in an anclased i Space The battery contains sulfuric acid slectrelyte Contact with skin or eyes may cause severe burns Wear protas tive clothing and a face shield H alactrolyte gets on your skin flush with water if ale
4. Date of Issue Sep 1988 HONDA MOTOR co LTD 1 9 1 1 REAR SUSPENSION Check the pivot collars dust seals bushings and or bearings for wear or damage and replace if necessary Refer to tha Madel Specific manual for thes replacement procedures Refer to the Mudel Specific manual if your motorcycle is equipped with needle roller or spherical bearings INSTALLATION Apply molybdenum disulfide grease to alt pivat paints Pack the grease fittings lif installed with graase Reassemble the suspension linkage with care to the proper in stallation directions and loosely tighten the pivot bolts Reinstall the suspension linkage assembly on to the frame and tighten each bolt to the specified torque Refer to the Model Specific manual for the proper torque spacifications 19 12 PIVOT COLLAR SHOCK ARM GREASE FITTING EO Sa DUST SEAL CUSHION ROD PIVOT BOLT Date of Issue Sep 1988 HONDA MOTOR CO LTD 20 FRAME BODY PANEL SERVICE INFORMATION 20 1 DESCRIPTION 20 2 TROUBLESHOOTING 20 1 INSPECTION 20 4 SERVICE INFORMATION Although it is possible to weld some cracked frames and straighten some frames that are slightly bent it is best to raplace the frama with a new ane when it is damaged Generally speaking plastic body panets cannot be repaired and therefore must be replaced it is possible that a front end collision will bend the steering head of tha frame but not th
5. Idle speed is erratic evan after warm up imperfect com bustion starter valve is not completely closed ton When the above mentioned symptoms occur inspect and overhaul the choke system accarding to the Procedures specified in the Model Specific manual If you find nothing wrong with it proceed with the overhaul of the other items on the breakdown diagnosis list Date of Issue Sap 1988 HONDA MOTOR CO iTD 2 5 MAINTENANCE AIR CLEANER fA LEANER AIR CLEANER COVER When the element becomes dirty the air fuel mixture will AIR CLEANER become too rich CASE Periodic cleaning or replacament is necessary CARBURETOR Vehicles used in dusty areas require more frequent inspections Whan replacing the air cleaner element be careful of tha fotlowing points NOTE If the alement joint has a rubber seal the joint will become mora airtight if a smatl amount of grease j ap plied to the seal Check to see that both tha air cleaner and tha holder are L property secured and da not contain any dust or dirt Oiled Urethane Foom Element Remove the air cleaner from the holder and wash away any ac cumutated dust or dirt by gantly squeezing it in non flammable or high flash point solvent Using gasoline or tow flash paint solvents for cleaning r Parts may result in a fire or explosion CAUTION E Cleaning the slement with gasoline or any a
6. Connect bieed hose to the bleed valve Loosen the bleed valve and pump the clutch lever Stop operating the fever when no fluid flows out of the bleed valve Refill with the same type of fluid from an unopened container Do not allow foreign material to enter the system when refill ing the reservoir Using the wrong efficiancy Contaminated fluid can clog the System Causing a logs of braking ability fluid will cause loss of braking SS aa a M j Connect the brake bleader to the blaed valye Pump the brake blaeder and loosen the bleed valve Add clutch fluid when the fluid ievel in the master cylinder BLEED HOSE BLEED VALVE reservoir is low Repeat above procedure until gir bubbles do not appear in the bleed hose NOTE Be sure the fluid reservoir ts parallel to the ground nate removing the cover and diaphragm i if air enters tha bleeder from around the bleed valve W threads seal the threads with teflon tape If the brake bleeder is not available perform the following Procedure Connect a bleed hose to the bleed valve Loosen the slave cylinder bleed valve and pump the clutch lever Stop operating the laver whan no fluid flows out of the bleed valve Close the bleed valve Fill the reservoir and install the diaphragm Pump up the systam pressure with the iever until thare are no air bubbles in the fluid flowing out of the reservoir s
7. O RINGS Let the cylinder head cool to room temp rature then raam the new valve guides Fiangeless Type Guides VALVE GUIDE Measure and record the exposed height of the valye guide us ing a pair of vernier calipers EXPOSED HEIGHT Chili the valve guides in the freezer section of a refrigerator for about an hour Heat the cylindar head to 130 C 140 C 275 F 290 F Do nat heat the cylinder head beyand 150 C 300 F Use temperature indicator sticks available from walding supply Stores ta be sure the cylinder head is heated to the ptoper temperature VALVE GUIDE REMOVER or DRIVER VALVE GUIDE 5 rao CAUTION CU Using a torch to heat the cylindet head may cause _ warping ss a To avoid burns waar insulated gloves whan handling tha heated cylinder head a eee Support the cylinder head and drive the old guides out of tha combustion chamber side of the cylinder CAUTION s p Avoid damaging the haad when driving the valve guide out Date of Issue Sep 1958 9 10 HONDA MOTOR CO LTD CYLINDER HEAD While the cylinder head is still heatad drive a naw valve guide g q Fan in from valye spring side until tha exposed height is the same as was measured far the old guide Pi Fe Fan is Fi Sa 4 roo s VALVE GUIDE a REMOVER or DRIVER Let the cylinder head cool to roam t
8. FRONT SUSPENSION RACE REPLACEMENT Tiga BALL RACE Ei REMOVER NOTE Bearings should be replaced as a set inner and outer races If the motorcycle has been involved in an accident gx amine the area around the steering head for cracks Remove the racas from the steering head using the ball race ramover s roc BALL RACE REMOVER Refer to the Model Specific manual for specific tools Install new races inte the steering haad of the frame using the driver and attachment NOTE Drive the races in squarely making sure that they are ful ly seated a On aluminum frames replace the races using the Ball Race Remove Set as dascribed in the folowing procedure Ball race remover set includas 1 thru 6 07946 KM90001 it Driver shaft 07946 KM90300 2 Base 07946 KMS9G600 3 Attachment A 47 mm 07546 KM390100 i Attachment B 55 mm 07946 KM30200 5 Remover A 47 mm 67946 KM90401 6 Remover B 55 mm 07546 KMS0500 Top Race Removal Instali remover tool A into the steering head and place attach DRIVER ATTACHMENT A 47 mm mant A onte remover A and secure it with nut B UPPER OUTE Instalt attachment B onto the Driver shaft and install them RACE through attachment A BEARING gt x mee REMOVER A install the base noting the praper installing direction and screw 4 T A in nut A gE Set attachment B into the bottom of the steering head DRIVER Hold the
9. Pump the braka blaedar and loosen the bleed valva Add fluid when the fluid levet in the master cylinder is low Repeat the above procedures until no air bubbles appaar in the plastic hose NOTE Check the fluid levet often while bleeding the brakes to i pravent air fr m being pumped into the system Use only specified brake fluid from a sealed containar If airis entering the bleadar frorn around the blead valve If the brake bleeder is not available perform the following procedure Connect the transparant bleeder hose to the bleed valve and place the other end of the hose in a container Loasen tha blead valve 1 4 turn and pump the brake lever or pedal until there are no air bubbles in the bleed hose and lever or pedal resistance is feit Aftar filing the system close the bleed valve and inspect tha system for air bubbles by operating the brake lever or pedal if it feels spongy bleed the systam as follows BLEED VALVE BRAKE BLEEDER BLEED VALVE a Date of Issue Sap 1988 HONDA MOTOR CO LTD 17 9 BRAKES AIR BLEEDING 1 Squeeze the brake lever than open the blaed valva 1 4 turn and close the valve NOTE Do not release the brake lever or padal until the bleed valve has been closed Check the brake fluid iaval often while bleeding the system to prevent air from being pumped into the system 2 Release the brake lever slowly and wait several
10. clutch plates Install the pressure plate PRESSURE PLATE Install the washers clutch spring and set plate NOTE Install the clutch Spring with concave side toward the inside CLUTCH SPRING Instal the lack washer and lock nut see Page 11 20 Put the transmission in tap gear and apply the rear brake Then tighten the lock nut to the specified torque NOTE ae If the engine is notin the frame shift the transmission in to tap gear hold tha drive sprocket with the universal holder and tighten the lock nut es i Date of Issue Sap 1982 HONDA MOTOR CO LTD 1 1 23 CLUTCH Coat the push rod with grease and install it in the mainshaft Install the lifter rod Untie the clutch laver from the handlebar Install the bearing onto the iiiter plate Install the lifter plate and secure it with the sat ring LIFTER PLATE BEARING Type D install tha clutch springs on tha clutch outer CLUTCH SPRINGS DRIVE PLATE CLUTCH PLATE DANE cE in Assemble the drive plate in the clutch outer Install the clutch disc clutch plate and Primary drive gear Compress the clutch springs with the clutch spring com pressor then install the set spring in the groove of the clutch auter Aemove the tool 5 Tac CLUTCH SPRING COMPRESSOR 07960 0110000 PRIMARY SET RING DRIVE GEAR 1124 T 1 24 HONDA MOTOR
11. 1 2 Date of Issue Sep 1988 HONDA MOTOR CO LTD V MATIC BELT DRIVE SYSTEM ee L DRIVE BELT REMOVAL Remove the left crankcase cover isea Model Specific manual Hold the clutch outer using the universal holder and remove the nut and clutch outer Gest UNIVERSAL HOLDER 07725 0030000 CAUTION Use tha special tool when loosening the lock nut Holding the rear wheel or raar brake will damage the final reduction system s Squeeze the drive belt into the pulley groove as shown So that it slackens enough to remove the driven pulley fram the drive shaft Remove the driven pulley clutch with the drive belt in place Remove the drive balt fram the drivan pullay groove and drive pulley groove INSPECTION Check the drive belt for cracks Pry separation and wear replace as necessary Measure tha width of the drive delt as shown Replace the belt if the service limit is exceeded NOTE Use only a genuine HONDA replacement drive belt Do not get ail or grease on tha drive belt or pulley faces Clean off any grease or oil before reinstalling INSTALLATION Temporarily install the driven puley clutch assembly on the drive shaft Turn the pulley clockwise and spread the faces apart while in stalling the drive belt Dats of Issue Sep 1988 HONDA MOTOR CO LTD CLUTCH DRIVEN PULLEY MOVABLE DRIVEN PULLEY FACE V MATIC BELT DRIVE SYSTEM Remove the pulle
12. CLUTCH CENTER B AND ONE WAY CLUTCH Remove clutch center A the washer and the clutch outer WASHER CLUTCH OUTER f ty GUIDE i R A i R i 2 pal z2 yi A g B Lt VA He CLUTCH CLUTCH CENTER A OUTER Type D i Remove the lifter spring and oi through guide eII Li Remove the screws clutch outer cover and gasket A f Remove the clutch outer guida K GASKET LIFTER Date of Issue Sep 1988 HONDA MOTOR Co LTD 1 1 1 CLUTCH Straighten the lock washer tab zi 5 _ Hold the clutch outer using tha clutch outer holder Remove tha lock nut Using the lock nut wranch Remove lock washers A and A discard washer B NTE l Replace lock washer B whenever it is removed E EE LOCK WASHER 8 i k Replace Remove the clutch assembly from the crankshaft LOCK NUT WRENCH Remove the snap ring and primary drivan gear ftom tha COLLAR mainshaft Remove the ctutch center guide and colar from the crankshaft Remove the damper springs from the clutch outer DAMPER SPRINGS Date of Sep 1988 11 14 HONDA MOTOR CO LTO CLUTCH Install the primary drive gear onto the clutch assembly and Gao CLUTCH SPRING COMPRESSOR compress the clutch springs using the clutch spring cam pressor then remove the set ring rooL J CLUTCH SPRING COMPRESSOR 87960 0110000 Loosen and remove the tool then disassem
13. Date of issue Sep 1982 HONDA MOTOR CO LTD FUEL SYSTEM 1 Disconnect the fuel line and place it in clean container as shown NOTE j Placa a clean container under the fuel tube i i i u Pa as 2 Refer to the Model Specific manual for repiacament CE fine LAS Sr a 2 Connect the fuel auto valva vacuum tube to the vacuum pump and apply vacuum Ba sure that the fuel flows out smoothly f tha vacuum dogs nat remaln steady it indicates the diaphragm is incorrectly installed or damaged f If the vacuum remains steady but the fuel flow is not VACUUM GAUGE PUMP smooth it indicates a clogged filter or incorrectly installed diaphragm 3 If the fuel flows without the vacuum applied the diaphragm is incorrectly installed Refer to the Model Spacific manual for replacement procedure CARBURETOR DISASSEMBLY INSPECTION a Refer to tha Model Specific manual for carburetor removal and disassembly separation THROTTLE VALVE BYSTARTER VALVE INSPECTON RELIEF VALVE Move aach valve and be sure that it oparates smoothly STARTER VALVE THROTTLE VALVE PIVOT Check the throttle valve shaft for play Push the relief valve if it is installed on the throttle valve and he sure that it opens and closes smoothly THROTTLE VALVE INSPECTION CV type Rotate the throttle drum and be sure that it operates smoothly Check tha throttle valve shaft for play THROTTLE DRUM THROTTLE VALVE ee Date
14. While applying the vacuum to the AYCY hosa that goes to the vacuum tube fitting pump air through the air vent fitting Air should flow through the AVCY and out the hose that goas to the carburetor CAUTION a Damage to the air vent control valve may result from use af a high prassure air source Use a hand operated air i pump only Plug the hase that goes to the carburetor NOTE If the AVCY has two hose fittings that go to open air connect the blocked tube onto the other fitting to pre vent air leaks While applying vacuum to the AYCY hose that goes to the vacuum tube fitting apply ait pressure to the air vent fitting It should hold steady Replace the AVCY if pressure is not retained Remove the pumps install the AYY on its mount route and reconnect the hosas according ta the vacuum hose routing diagram label EMISSION CONTROL SYSTEMS _ TO VACUUM PORT AIR VENT PORT PRESSURE PUMP VACUUM PUMP PRESSURE _ PUMP Date of Issue Sep 1998 HONDA MOTOR CO LTD EMISSION CONTROL SYSTEMS SECONDARY AiR SUPPLY SYSTEM Start the engine and warm it up to operating temperature Stop the engine and remove the air cleaner element Check that the secondary air intake ports are clean and fraa of carbon deposits Check the raed valve in the secondary air passage if the ports are carbon fouled Disconnect the air cleaner to air injection cantrol valve hose from t
15. see the chart below For the first check DO NOT charga the battery i before tasting tast it in an as is condition i Capacity B 3 5 Ah 5 Ah CAUTION To avaid damaging the tester only test batteries with an amperage rating of less than 30 Ah Tester damage can result from overheating when The test button is pushed in for more than three seconds The tester is used withaut being allowad to cool for at least one minute when testing more than one battery Maora than ten consecutive tests are performed without allowing et least a 30 minute cool down period NOTE The result of a test on the meter scale is relative to the amp hour rating of the battery ANY BATTERY READING IN THE GREEN ZONE I OK Batteries should only be charged if they register in the YELLOW or RED zone EXAMPLE Gold Wing batteries YS0 N19L A 18 AMP HOUR using the 16 5 30 amp haur setting may read in the GREEN zona but close to tha YELLOW charge zone As fang as the meter reads in the GREEN zone the battery is OK Eee Se NO GOOD Replace soon j 9 5 Ah Ah 12N9 4B 1 YEB25L C 1 2 TB4L B YTAL 12 YB3L A YB4L B Ca YT4L 12B YBSIL B YB5L B YTSL 12 Y89 B CA i YB5L B Ca YTSL 12B YBSA A YTHS 12B Bottery Chack First chock YBIZAIL A B12A4 B YB9 B Ca YBV4L A1 YB14A A2 9 5 Ah 16 Ah 16 5 Ah 30 Ah YB16B A YB1Si
16. FUEL SYSTEM ACCELERATOR PUMP P ROJECTIQNS N AD Align the projections on tha diaphragm with the grooves in the NM iy float chamber install tha Spring on the diaphragm cover and install the cover on the float chamber being careful not to pinch the diaphragm Adjust the accelerator pump page 8 24 FLOAT JETS ASSEMBLY lnstall the needia jet needle jet holder main jet slow jet throt THROTTLE tla stop screw and pilot tor air screw on the carburetor body STOP SCREW ae CHAMBER Tighten the pilot tor air screw until it saats lightly then turn it M ea ae SiDE aut as much as the number recorded during removat amie ont NEEDLE JET HOLDER CAUTION Tightening the pilat tor air screw against Its seat re a RAIN GET ee PILOT SCREW SLOW JET Be sura to install the needle jet with the smaller hale toward the float chamber install the pilot ar air scraw and its O ring and washer in the order as shown in the drawing If the pilot tor air screw and carburetor body are replaced with the new ones adjustment is necessary Motorcycles with emission control systems Rafer to page 8 20 for the pilot lor air scraw installation U S A only install the float float vatve and float pin FLOAT VALVE FLOAT PIN Install the O ring on tha float chamber and tighten the float chamber with the screws NOTE if the float valve must be hung from the float arm lip n
17. LTD _ 11 CLUTCH SERVICE INFORMATION 11 1 CLUTCH INSPECTION 11 19 TROUBLESHOOTING 11 1 HYDRAULIC CLUTCH SYSTEM i SYSTEM DESCRIPTIONS 11 2 SERVICE 11 27 SERVICE INFORMATION Clutch maintenance can be done with the engine in the frame Refer to the Madel Specific manual for ramoval installation of the crankease cover and specifte clutch maintenance Engine oil viscosity and level have an effect on clutch disengagement When the clutch does not disengage or the vehicie creeps with clutch disengaged inspact the engine oil leval before Servicing the clutch system On wet centrifugal clutches the clutch will not engage properly if the engine oil contains additives such as molybdenum disutfied Oils with a molybdenum disulfiad additive tend to reduce Clutch friction TROUBLESHOOTING Clutch lever too high Damaged kinked or dirty clutch cable Damaged ctutch lifter mechanism Faulty clutch lifter plate bearing Sticking clutch slave cylinder piston Clogged hydraulic system Clutch will not disengage or motorcycle creeps with clutch disengaged Too much clutch lever free play Warped plate Loose clutch lock nut Ott levet tao high improper oil viscosity ar oil additive used Airc in hydraulic system Low fluid level Hydraulic system leaking or clogged Ciutch slips Clutch iifter sticking Worn clutch discs Weak clutch springs No clutch lever free play Hydrauli
18. Pivoting link front suspension cannects the axle to the fork by means of a pivoting link extending from tha ends of the axle to tha uppar front portion of the fork Between the pivot points on the fork and the axle are eyelets to which the spring damper units are attached The top of each shack absorbar is attached to the fork up naar tha lower steering head bearing This design is divided into two basic categories The trailing link design has the axle supported by links and shack absorbers that trail from the leading edge of the lower partion of the fork Leading link typa front suspension has the links pivoting toward the front and the shock absorbers mounted to the leading edge of the fork BOTTOM LINK TYPES TELESCOPIC TRAILING LINK LEADING LINK Axle is at the rear of the link Axle is on the front of the fink BASIC DAMPER OPERATION PISTON RING Friction Damper Operating Principles By far the simplest form of damper is the triction type Instead DAMPER ROD of using oil to dampen tha mavament of the spring and suspen sion the friction type uses anly the friction of a singla nonmetallic piston ring on the top of the damper rod prassing against the greased damper inner cylinder wall This dasign is used primarily on only the smallest and simplest of vehicles GREASE 1 g 2 Date of issue Sep 1985 gt HONDA MOTOR CO LTD c ie FRONT SUSPENSION Oil Damper Operating Principles Tha prima
19. Ps CLUTCH LIFTER REASSEMBLY LIFTER ARM Typa A and a part of type B Coat the lifter arm and dust seal with grease Install the lifter arm and raturn spring Drive in a new spring pin using a pin driver until the pin does not interfere with the lifter arm Reset the return Spring in the place Install the lifter rad into tha cutout in the lifter arm Install the crankcase cover see the Model Specific manual Type D Cuat the lifter arm with grease Replace the O ring with new one and install the return spring and lifter arm in the crankcase cover Install the stopper pin inte the Ain hole on the crankcase cover install the lifter plate and set plate then tightan the screw Install the lifter rod by aligning the bass of the lifter rod with the groove in the crankcase cover Install a new gasket and the clutch lifter cover Tighten the screws Install the crankcase cover see the Model Specific manual PLATE i Z PLATE 11 26 oe g HONDA MOTOR CO LTD F O S CLUTCH CLUTCH HYDRAULIC CLUTCH SYSTEM SERVICE RESERVOIR COVER FLUID REPLACEMENT Before ramoving the reservoir cover turn the handlebar yntil the raservair is level Place a rag over painted plastic or rubber parts whenaver the system is serviced Remove the reservoir cover diaphragm cover and diaphragm CAUTION Spillied fluid will damage painted plastic or rubber parts e_ oS a o
20. Refer to the Mode Specific manual for information of shim thickness INSTALLATION Refer to tha Model Specific manual for side gear case installation If the damper spring has been removed install it according to the following procedure Place the damper spring and damper cam over tha shaft Install the damper spring compressor and compress the spring then instal the snap ring securely SNAP RING DAMPER SPRING FINAL DRIVE FINAL DRIVE ASSEMBLY REMOVAL Drain the final gear oil and remove the rear whaet Remove the mounting nuts and remove the final drive assembly DRIVE SHAFT REMOVAL FINAL DRIVE ASSEMBLY With Damper Case Hold the drive shaft in a vise with soft jaws and separate the final gaar case from the drive shaft CAUTION Clamping the damper casa section of the final drive assembly in a visa can damage it DRIVE SHAFT Date of Issue Sep 988 D HONDA MOTOR CO LTD 1 5 5 FINAL DRIVE OUTPUT SHAFT Without Damper Case Separate tha driva shaft from the final gear case by gently turning the drive shaft and pulling Remove tha spring and oil seal DRIVE SHAFT DRIVE SHAFT DAMPER DISASSEMBLY Drain the oii from the damper casa Sat the drive shaft in the shock absorber compressor with the proper attachments DRIVE SHAFT sto ATTACHMENT Compress the damper spring and remove the stop ring STOP RING Remove the tool Remove the following SPRING spring seat dam
21. STARTER CLUTCH INSPECTION Refer to Modal Specific manual for starter clutch removal and installation Install the driven gear into tha housing With all parts assembled check the starter clutch Check that the gear or Sprocket turns smoothly in ane direction and locks up in the other direction Disassemble tha housing ROLLER CONTACT SPRING PLUNGER a Check the rollar contact surface of the gear or sprocket for damage Replace with a new one Check tha roller contact surface of tha housing for damage Replace with a new one Damage to roller Replace with a naw one Deformation or damage to the spring Replace with a n w one HOUSING ROLLER CONTACT SURFACE Date of Issue Sep 1988 24 8 HONDA MOTOR CO LTD For one way sprag clutch check each sprag clutch housing and all innar portion cantact surfaces Abnormal wear or damage ta spraq Replace with a new ong irregular movement of the sprag Replace with a new one Damage ta tha clutch housing or inner portion contact sur face Replace with a new one STARTER PINION INSPECTION Refer to the Model Specific manual for startar pinion removal and installation Wear or damage to the pinion reduction gears Replace with a new one Worn journals Replace with a new one Check if the pinion gaar moves smoothly along the axis Pinion gcar does nut move smoothly Replace with a new one Da
22. Sliding surfaca for scratches or wear Remove any smali surface scratches using 600 800 Sandpaper if there fs deep scratches replace the piston Piston ring grooves for excessive wear Replace the pistan as Necessary 4 stroke angines Cit Pass holes in the oif ring groove for clogs Clean the oil holas with compressed air 10 6 HONDA MOTOR CO LTD CYLINDER PISTON Measure and racord the piston O D 90 to the piston pin bore and at the point spacified in tha Mode S pectific manual naar the bottom of the piston skirt Replace the piston if the service limit is exceeded Calculate tha pistan to cylinder laarance see Page 10 5 SPECIFIED DISTANCE NOTE Always replace piston rings as a set Measure the piston pin bore ID in an X and Y axia Take the maximum reading to determine the D Replace the piston if the D is over the service limit Inspect the piston rings and replace them if they are worn NOTE a amme ee Reinstall the piston rings see page 10 8 inte the piston grooves Push in the ring until the outer surface af the piston ting is PISTON nearly flush with the piston and measure the clearanca Using a feeler gauge Replace the piston ring if the service limit is exceeded FEELER GAUGE Insert the pistan ring into the bottom of the cylinder squaraly using the piston as shown FEELER Measure the end gap using a feeler
23. With the Ignition switch off measure the leakage currant NOTE GROUND CABLE When measuring current using a testar sat it to a larga range and then bring it down the range to an appropriata level Current flow larger than the range selected may blow out the fuse in the tester While measuring current da nat turn the ignition an A sudden surge of current may blow out the fusa in the tostar If current laakaga exceeds the standard value a shorted circuit is likely to exist Locate the short by disconnecting connections ane by ane and measuring the current CHARGING VOLTAGE INSPECTION NOTE Be sure that the battery is fully charged before perform ing this test The amount of current flow may change abruptly if not sufficiently charged For MF battery use a battery whose voltage betwaen its terminals is greater than 13 0 Y For conventional battery usa battery whose specific gravity is greater than 1 27 20 C 68 Fh When the engine is started using the startar motor a large amount of currant may flow from the battery tem porarity Use the kick starter to start the engine for models equipped with both a starter motor and a kick starter Date of Issue Sep 1988 HONDA MOTOR CO LTD 22 1 9 BATTERIES CHARGING LIGHTING SYSTEM After warming up the engine replace the battery with a fully DIGITAL MULTITESTER charged battery 7 i AMME FER l
24. i ings with the narrow pitch end facing down Compress the valve springs with the valve Spring compressor and instali the valve catters CAUTION P Compressing the valve spring more than necessary when installing tha valve cottars may cause logs of valve spring tensian aay fpr rte NOTE To ease installation of the cottars grease them first ns SO u ama M Tap the valve stems gently with a soft hammer to firmly seat the cotters 9 1 4 Date of Issue Sep t988 HONDA MOTOR CO0 LTD Clean any gasket material from the cylinder mating surface Reface the mating surface using ait stone if necessary INITIAL CAMSHAFT LUBRICATION Apply molybdenum disulfide grease to the camshaft journal Surfaces in the cylinder head Fill the oil pockets in the head with the recommended oil i a are ees eee a ee a Date of Issue Sep t988 HONDA MOTOR CO LTO 9 1 5 ees 10 CYLINDER PISTON SERVICE INFORMATION 10 1 CYLINDER 10 5 TROUBLESHOOTING 10 1 PISTON PISTON RING 10 6 SYSTEM DESCRIPTION 10 2 CYLINDER INSTALLATION 10 10 SERVICE INFORMATION 8e careful not to damage the mating surfaces by using a scrawdriver when disassembling the cylinder Do not Strike the cylinder too hard during disassambly even with a rubber or plastic mallet ta Pravent the passibility of damage to the cylinder fins Take care not to damage the cylinder wall a
25. resistance will be smaller because the resistance of the headlight is connected in parallei For lighting systams whose headlight connector is con nected to arasistor when the headlight is turned OFF aither disconnect the handlebar switch connector or discannect tha lighting output line of the alternator Refer to diagram at right RESISTOR CHARGING LIGHTING COIL For lighting systems that have a headlight ON and OFF switch just turn off the headlight switch Refer to diagram at right HEADLIGHT SWITCH OFF Disconnect the auto bystarter connector if applicable See diagram at right CONNECTOR If there is an abnormality in the diagnosis above check the following Battery wire Broken wire harness irepair or replace Ground wire Broken wira harness repair ar raplacet Charging coil wire charging lighting cail wire Check the charging coil charging lighting coil of the alternator If the resistance value of the alternator is normal tia the resistance value measured by tha above method is different from the altarnator resistance check for a brakan or shorted wire harness between the r gulator rectifier and alternator or for poor connection at alternator connector BYSTAATER Date of Issue Sep 1986 22 22 HONDA MOTOR CO LTD ETN p UNIT INSPECTION Provided that all inspections on the wira harness side are nor mal and there are no loose connections
26. too far out laaving minimal thread engagement Whan there is morg than 8 mm of threads showing scraw in j the adjuster most but not all the way and make ad justments on the brake panel end of the cable Check for looseness of the following Brake lever and pedal fasteners and adjuster lock nuts Brake torque rod fasteners Brake rod cable imechanically aparated drum brake Brake arm mechanical linkage drum brake lt Caliper attachment bolt hydraulic disc brake Check that the cotter pins an the brake rod torque rod etc are securely in place Operate brakes independently while riding in order to deter mine the effectivaness of each brake j PEDAL HEIGHT ADJUSTER BOLT LOCK NUT BRAKE LIGHT SWITCHES Check the brake light switch aperation and adjustment hy ap plying the brakas Visually inspect far any damage and make sure the reflector plate is clean within the light Adjust the rear brake light switch 0 that the brake light comes on just prior to the brake actually being engaged If the light fails to carne on adjust the switch so that the light comes on at tha proper time NOTE The brake light switch on the front braka lever cannot be adjusted If the front brake light switch actuation and brake engagement are off either replace the switch unit or the malfunctioning parts of the system Make all raar brake light switch adjustments after the height adjustment and the brake peda
27. CDI UNIT es oe c BATTERY TRANSISTORIZED IGNITION SYSTEM PULSE GENERATOR The transistorized ignition system also utilizes tha battery but its ignition operation works differently Since the duration of time tha spark plug fires is longer than that of the CDI a larger ignition system is well surted for large displacement engines Operating Principles Tha battery feeds current ta the ignition primary coil via the ig nition switch and engine stop switch when the transistor in side the spark unit is turned ON This current is turned off when the transistor is OFF When the engine is turnad on the pulse signal from the pulsa generator is fed to the ignition timing control circuit The igni tion timing control circuit determines the ignition timing based on the pulse signal and sends current to the hase of transistor After current pulse flows through the primary coil tha tran sister ig turned OFF and current is cut off to the coil At that moment an induced voltage on the secondary coil ignitas the spark plugs TRIGGER es es IGNITION COIL SPARK PLUG a lt PULSE GENERATOR IGNITION ENGINE STOP SWITCH IGNITION f SWITCH HA IGN TION TIANG CONTRO CIRCUIT BATTERY SPARK F7 PLUG TRANSISTOR PRIMARY COIL CURRENT Data of Issue Sep 1988 HONDA MOTOR CO LTD IGNITION SYSTEMS As the engine speed increases the duration of cu
28. DRIVE CHAIN ADJUSTMENT Inspecting the drive chain while tha engine is running ven When there is too littla slack a change in the distance bet ween sprocket centers due ta suspsnsion movement results in excessive tension an tha chain In this condition the chain and transmission or crankcase may be damaged and the large amount of friction adversely effects the running performance of the vehicle Too excessive slack in the chain laads to large oscillations whan the vehicle is running In this condition the chain may come off the sprockets or damage parts it contacts With the vehicle in neutral support on the center or side stand Some models need to be checked with the raar wheel raised Refer to the Modal Specific service manual for detaits Check the slack in the chain at the mid paint between the two sprockats On models with a chain tensioner loosen the tensioner before checking Carry aut the following procedure for adjustment Loosen the rear axle nut unti the wheel can be maved Loosen the adjuster jock nut turn the adjuster nut or bolt and adjust the play On snail cam types rotate the adjuster plates A scale is included on the adjuster Be sure that the reading on the scale is the same far both sides CAUTION Ff the adjustment value is not the sama the wheel is out of alignment and can cause axcessive tire sprocket and chain wear As the rear Suspension moves through its
29. Do not store the tubeless tires or rims in thase areas Where the ozone is produced near motor battery charger Hot area ingar heater steam pipe etc Where oil or grease is stored In direct suntight Wet of humid araa Date of Sep 1988 1 6 1 0 HONDA MOTOR He LTO WHEE S TIRES TIRE REMOVAL Rafer to page 16 17 for ATV s whaei tire servicing Ramoye the wheel NOTE Single brake disc type To prevent damage to the disc place the wheet on the ievel surface with the disc facing up Doubles brake disc type Remove one disc first then place the wheel on tha level surface with the other disc en rr a a a S o e Remove the valve cap and bleed air by pressing tha valve core Remove the valve cora after bleeding air completely Remove the valve stem nut and push the valve stem lightly If a bead stopper is installed loosen the lock nut and push the bead stopper down BEAD STOPPER Collapse in the bead with a tire bead breaker lf no tire bead breaker is available step on the aide wall to col lapse tha bead NOTE Do not step on the rim Collapse the bead inte the rim canter and slide the tite out of position NOTE ja Tire can ha easily removed once the beads ars collapsad camplately _ _ _ u i RIMA CENTER Date of Sep 1988 HONDA MOTOR CO LTD 1 6 1 1 WHEELS TIRES Apply a mild deterge
30. FRONT WHEEL NUT BEVELED SIDE Date oF Issue Sep 1988 HONDA MOTOR CO LTD 16 17 WHEELS TIRES TIRE REMOVAL U S A ONLY NOTE This sarvice requires the Universat Bead Breaker GN AH 958 B611 available in U S A only Remove and install tires from the rim side opposite the valve stern Remove the core from the valve stem A tire bead tool is raquired for tire removal Use a Coats 220 Tire Changer or equivalent to remove the tire from the rim If a tire changer is not available rim protectors and tira irons may be usad PRESS BLOCK CAUTION BREAKER ARM ASSEMBLY ls Take care to avoid da maging the head seating area of the k rim Install the proper size blade for the rim you ara working an onto the breaker arm assembly CAUTION Use of an impraper size tira tool may result in damage to i the rim tire or tool Place the proper size adapter onto the thraaded shaft and then BREAKER ARM ASSEMBLY put the wheel over the threaded shaft and adapter Lube the bead area with water pressing down on the tire RM sidewall baad area In several placas to allow tha water to run into and ground the bead Also lube the area where the breaker arm will contact the sidewall of the tire Use only water as a lubricant when removing or mounting tires Soap or other tire lubricants may leave a slippery residue that can cause the tire to Shift on the rim A tire that shifts on the rim may lead
31. Faulty coolant temper green blue wire ature gauge THERMO SENSOR INSPECTION Drain the coolant see page 5 6 Disconnect the wire from the tharmo sensor Ramova the thermo sensor Suspend the thermo sensor ina pan af coolant 50 50 mixture over a burner and measure the resistance through the sensor as the coolant hests up Keep flammable materials away from the burner Wear Insulated gloves and eye protection be te er te ee pE wee NOTE Soak the thermo sensor In coolant up ta its threads with at least 40 mm 1 57 in from tha bottom of the pan to the bottom of tha sensor Kasp temperature constant for 3 minutes before testing A suddan change of tamparature wiil result in incorrect raadings Do not let the thermometer or thermo sensor i touch the pan Apply sealant to the threads on the thermo sensor prior to installation FUSE COOLANT IGNITION SWITCH oo TEMP GAUGE Gr Bu CONNECTOR a Sy THERMOMETER Date of Issua Sep 1988 HONDA MOTOR CO LTO FUEL GAUGE Fuel unit resistance changes in accordance with the float in the fuel unit maving up and Gown The fuel gauge needle is moved by the change of amperage that flows through tha fuel gauge Thera are two types of fuel gauges The Return typa where the needle returns to Empty when the ignition switch is turned OFF and Stop type where the naedle sta
32. HONDA MOTOR CO LTO 1 2 1 1 V MATIC BELT DRIVE SYSTEM Driven Face Bearing Inspection Check the inner bearing oil seal if installed for damage replace as necessary Check the needle bearing for damage or excessive play and replace as necessary Turn the inner race of the outer bearing with your finger Chack that the bearing turns smoothly and quiatly and that the bearing outer race fits securely Replace tha bearing if necessary NEEDLE BEARING OUTER BALL NOTE BEARING Some modais use two ball bearings Refer to page 12 13 for bearing replacemant CLUTCH SHOE REPLACEMENT SHOE SPRING pee A Remove the Shap tings and washers than remove the clutch shoes and shoa springs fram the drive plate NOTE ee Some models use one retainer plate instead of three Snap tings m _ a Check the shos springs for damage or loss of tension CLUTCH SHOE Check the damper tubbers for damage or deformation raplace aS necessary PIVOT PIN Apply a small amount of grease On the pivat pins Install new clutch shoes on the pivot pins and push them into place Use a small amount af grease On tha pivot pin and keap grease off of the brake shoas Replace the braka shoes if thare is any grease on them CAUTION y Grease or oil damages clutch shoes and can lead to a loss of engaging ability _ _ CU j CLUTCH SHOE D fl Sep
33. RTS as ALUMINUM BASE MATERIAL SILICON CARBIDE PARTICLE NICKEL Date of Issue Sep 1998 10 2 HONDA MOTOR CO LTD CYLINDER PISTON PISTON The piston moves at high speed in the cylinder and is exposed to the extrema temperatura of combustion Pistons are therefore made of a specially forged light alloy type aluminurn which is not only lightweight but also less Susceptibte to ther mal expansion The piston itself is a high temperature part being coaled only by tha release of heat ta the cylinder through the inhaled air fuel mixture and tha pistan ring The piston head is therefore fabricated ta have a somewhat smaller outer diameter then the skirt due to the high temperature xposura and large thermal axpansion With a 2 stroke engine the cylinder is distortad and the clearanca with the piston tends to partially decrease as there are two different parts with inequal thermal expansion in the cylinder a part cooled by the air fuel mixture around the piston such as the Scavanging port and a Part exposed to the extreme heat near the exhaust port To resolve this problem the piston head of the 2 stroke engine is aval and dasigned to have appropriate clearance during driving At the small and af the connecting rod of the 2 stroka engina neadie bearing is used For the 4 stroke engine however a plain bearing is used at this point The reciprocating motion af the piston is converted into a rota tional motion of the
34. TESTER ane F 1 S Connectad connection PUMP CANNEETOR CONNECTOR CONNECTOR EYELET TERMINAL P of pin COLOR Round type Flat type 0 IE CEM N ae Female side Mala side Femate sida Male side 1 o4tlite side side IGNITION SWITCH IGNITION SWITCH SWITCH SWITCH SWITCH l Circuit symbol Wiring symbol Two terminal Three terminal Combination type T type Hi i Soe a NO NC ote coos we RELAY NO type RELAY NC typel UGHT BULE RAGING nwo e oO amp DOUBLE FILAMENT THREE PHASE SINGLE PHASE PULSE GENERATOR IGNITION COIL IGNITION COIL ALTERNATOR ALTERNATOR Single type oua aye SPARK PLUG RESISTOR VARIABLE RESISTOR l aay i Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 1 1 3 ELECTRICAL FUNDAMENTALS BASIC ELECTRICAL DIAGNOSTIC METHODS VOLTAGE MEASUREMENT D Measuring voltage is a fundamental method of checking circuit components The measurement is conducted for the following reasons T gt To check if voltage exists A test light could be used 2 To measure the actual voltage value A voltmeter is used to detarmine if electrical componant is operating normally HOW TO MEASURE VOLTAGE USING CONNECTED IN PARALLEL CONNECTED IN SERIES t VOLTMETER iGOOD BAD NOTE Make sure tha ground surface is clean and free of paint VOLTMETER Use a holt attached directly to the frame Select a
35. The spring adjuster changes the coil spring length and the ini tial spring preload Thera are several types of Spring preiaad adjuster systems pre set type mechanical type and bath mechnical and hydraulic remote control types all of which ad just the spring scat position The Pre set catagory includes both the cam type preload ad juster and the near infinitely adjustable threaded double lock ing nut type Cam Type The cam type preload adjuster uses a collar with recessed Steps that fits around the damper body As each step is pasi tioned against a stop or pair of stops built in to the damper body the spring preload can be adjusted to ftom threa ta five fra set positions to bettar suit vehicle load requirements CAM TYPE ADJUSTER Date of Issue Sep 1988 HONDA MOTOR COQ LTD REAR SUSPENSION Threaded Type l THREAD TYPE ADJUSTER LOCK NUT Spring preload is set by moving an adjuster nut to eithar cam press or extend tha haight of the spring Once the desired preload is established a lock nut is tightened against the ad juster mut to prevent it from changing position amp munimum and ADJUSTER p msximum spring height ispring preload is recommended for NUT a SPRING LENGTH each model These dimansions must be complied with s Failure to comply with the minimum and maximum spring length specifications may rasult in the spring coil binding naar full SUSpansion Compression or the spring perch retainers com i
36. Throttle grip free play is correct if there is a prescribed amount af play on the outer circumferance of the throttle grip flange Throttle lever free play is correct if there is a Prescribed amount of play at tha tig of the throttle lever Minor free play adjustments Gan be made with the adjuster on the throttle grip side Loosen the lack nut and turn the adjustar to obtain the desired amount of free play Tighten the lock nut after the adjustment has been made FF the adjuster has a baot reposition it properly attat adjust ment is made Major adjustments are made on the carburetor end of the cable with one of the adjuster types shown here With a forced apening closing type throttle the adjustment af free play can be made by loosening the lock nut on the pull side of the cable and turning the adjuster Tighten the lock nut after the adjustment has bean made Date of Issue Sep 1988 HONDA MGTCA CO LTD THROTTLE LEVER TYPE an Bo si a ate AP AJ a 3A FREE PLAY ots Tea h z ny s TYPICAL LOCK NUT ADJUSTER MAINTENANCE lf the throttle cable has an adjuster anywhere within its length besidas the ends major adjustmant is made there f THROTTLE CABLE Adjust the frae play by loosening the lock aut and turning the adjuster CARBURETOR Tighten the lock nut after the adjustment has been made If the adjuster has a boot repasition it properly
37. When a small current flaws fom the base to the emit ter a large current flows from the collector to the amitter In this way the transistor resembles an amplitiey in that the amount of collector to emitter current is contralled by the base current Transistors also resemble switching devices The transistor is turned an allowing collector to emitter currant to flow when there is basa currant and turn off whan no base current exists Thermistor In ganeral the resistance value of most metals including cop per increases as the temperature rises In contrast tha resistance of a thermistor decrases as the temperature rises When heat is applied to a substance the activity of its molecules increases and prohibits the flow of trea electrons This increases tha resistance For the thermistor the number of frea alectrons increases as haat is applied In this case the activity of tha molecules no longer obstructs the flow of elactrans and the resistance decreases BASE CURRENT THERMISTOR SYMBOL RESISTANCE S a TEMPERATURE 21 12 Date of Issue Sep 198 HONDA MOTOR CO LTD j ELECTRICAL FUNDAMENTALS ELECTRICAL SYM BOLS Abbreviations used in switching devices are as folluws NO iNormally Openl Switch is open at rest The symbols below are the most common type of symbols NC Normally Clased Switch is ciosed at rest used in electrical circuits BATTERY CONNECTION MULTI
38. With the throttle valve closed and the vacuum in tha main bore increased vacuum in the air cut off valve also increases and moves the diaphragm to shut the air passaga With the vacuum in the main bore decreased the spring moves the diaphragm backward and opens the air passage REED VALVE INSPECTION Refer to the Model Specific manual for removal installation Check the read valve for fatigue or damaga and replace the reed valve assambly if necessary Check the reed valve seat for cracks damage and clearance from the raed and replace the reed valve assembly if necessary NOTE Be sure to replace the reed valve as an assembly Disassembling or bending the reed stopper will cause Throttle valve opens ACCELERATOR NOZZLE OUTLET CHECK VALVE INLET CHECK VALVE DIAPHRAGM Throttle valve closes VACUUM CHAMBER DIAPHRAGM AIR PASSAGE This moves to the left te shut up the air passage REED STOPPER Date of Issue Sep 1988 HONDA MOTOR CQ LTD FUEL SYSTEM FUEL LINE NOTE Rafer to section 2 for fuel filter inspection i 1 Check the fuel tank cap and or fuel tank breather tube for clogging ino breather tube on California on road models 2 Vigually inspect the fugl strainer for contamination Check the fuel flaw with the fuel strainer installed and with tha strainer removed Replace the fuel strainer if it is excessively contaminated or if the
39. Worn cam sprocket teeth Worn rocker arm andor shaft Kick starting difficult Incorrect decompressor adjustment Seized engine Date of Issue Sep 1988 9 1 HONDA MOTOR CO LTD a ma ab eee th CYLINDER HEAD SYSTEM DESCRIPTION CONSTRUCTIONS Tha cylinder head ancloses a combustion chamber A hemisphere shape is mast cammon providing minimum Possible Space for improved combustian efficiency Where four valves per cylinder ara us d in a 4 stroke engine the combustion chamber is shaped like 3 shed feof according to the valva arrangement Some models of both 2 and 4 stroke engines ara Provided with squish areas On the outer circumference of the combustion chamber This has the effect of impraving combustion fficiency at the final staga of the comprassion process by extra compression of the air fuel mixture in the squish areas between the piston and cylinder head and forcing it to the center of the combustion chamber There is also the added advantage of decreased Carbon adhesion The Construction of the cylinder head with 2 stroke engines is simpla 4 stroke engines however have a complicated cor figuration containing extra parts due to the necessity of valve actuating mechanisms and exhaust Ports Furthermore the in take axhaust part configuration of a 4 stroke engine has a direct relation to the engina performance There is therefore a tendency to adopt a layout allowing a very direct inlat for a smoother air fuel mix
40. a Inspect the spokes for loosenass by tapping them with a screwdriver oS If a spoke does not sound clearly or if it sounds different from hs SPOKE WRENCH the other spokes tighten it Tap on the spokes and be sure that the clear metallic sound of the same tone can be heard on all spokes Ee een Tha spoke nipples ara made of soft material Be sure to tighten the spakes with the proper size spoke wrench After tightening check the nim for runout Check the pressure of each tire with a pressure gauge Check tire pressures when the tires are cold to assure ac curate comparative measurements Checking tires after they are warm will give inaccurate readings Riding with incorrect tire pressure can affect and impair staering rasponse and may result in a sudden tire deflation CAUTION Operation without optimum tira pressure will causa uneven tire wear Tire pressure specifications differ with each model Refer to the Model Specific rmanuali for the correct pressures Bate of Issue Sep 1988 HONDA MOTOR C LTD 2 37 MAINTENANCE Check for cracks and damage to the tire tread and walls and replace the tire if nacessary Chack for nails pieces of metai and stones etc which may have become lodged within the tread ar embedded in tha tires Tread depth can ba observed directly or by use of the depth Gauge If the tread depth is below minimum tread depth tha tire s
41. been removed inspect the pistan seals for signs of leakage Disassembie the slave cylinder and replace the piston seal as required Place a clean pan under the slave cylinder to catch the draining fluid and squeeze the clutch lever slowly ta push out the piston Drain the clutch fluid Temporarily install the slave cylindar then disconnect the clutch huyse Remove tha spring from the piston Check the piston and cylinder far Scoring or seratchas Remove the oil seal and piston seal fram the piston and discard them The seals must be replaced with naw onas whenever they have been removed Assembly Assembie the slave cylinder in the reverse order of disassembly Apply a medium grade of hi temperature silicone grease or braka fluid to the new piston seal and oil seal PISTON SEAL SLAVE CYLINDER BODY OIL SEAL f i SPRING Carefully seat tha piston seal in the piston groove Install the oil seal Place the piston in the cylinder with the sea end facing out Install the spring in the cylinder with small end toward the pistan Date of Issue p 1988 HONDA MOTOR CO LTD 1 1 31 CLUTCH Make sure that the clutch lifter push rod is installed properly DOWEL PINS LIFFER PUSH ROD Pea a Install the dowel pins and a new gasket onto tha stave cylinder and install the cylinder by aligning the push rod with the aif seal hole Tighten the mounting bolts to the Specified tor
42. centrifugal force worn or damaged weight rallars Wilt in terfere with this force Check the rollers for wear or damage and replace as necessary Measure the O D of each roller reptace if the service lirnit is excaeded ee Date of Issue Sep 1988 HONDA MOTOR CO LTO 1 2 7 V MATIC BELT DRIVE SYSTEM Check the drive face shaft for wear or damage and replace as MOVABLE DRIVE FACE necessary Z r A Measure the O D of the drive face shaft Replace tha shaft if the service limit is exceeded DRIVE FACE SHAFT Measure tha ID of the drive face Replace it if the service limit is exceeded IF a dust seal is installed on the drive face check it far damage and replace as necessary ASSEMBLY INSTALLATION Pack the insida of the mavable drive face with the specified amount of grease then install the weight roflers SPECIFIED GREASE NOTE Use only tha specified greasa in the specified amount or the clutch operation will be affected Apply the greasa equally aver the inside of the pulley face SPECIFIED GREASE Lithium Basad Graase Mitsubishi HD 3 Nippon Sakiyu Lipanox Deluxe 3 Idemitsu Coronax 3 ROLLER Sta Luba MP 3141 Bal Ray Moly Luba 126 EP 0 Apply grease to a naw O ring and install it RAMP PLATE Install the ramp plate Install the face seai and tighten the bolts ta the specified tarqua NOTE Make sure that the O ring is correctly installad
43. gt E 19 mm A Z Special type type 5 1H 127mm S Wim cuppe B Ausistor spark plug j wick ft 16 mm 14 Hotaype E 19 mm Pareglany prujactad P inunuslas W 14mm 16 type shai the pluy gu X 12mm 20 Spacisl plug 1s 0 9 mm lt na u 10mm 22 l Aerator perrk plug i purnber is usted 24 Porcelain nar It uA ally In 27 Cold tywel qrujeuied ivpe dicatas thai ihe i Wih CU geeeee in yup it 0 7 cam the sde aliccirado 7 W Narrow center B octrals 1 3 Cale cypel K Sane slecwoda Number indicates the plug gap 3 0 9 mm omen Date of Issue Sep 1988 HONDA MOTOR CO LTD 23 9 IGNITION SYSTEMS SPARK TEST Remove spark plugs fram tha cylindar head and connect spark plugs to the plug caps Ground the spark plug to the cylinder haad and turn the igni tion ON Check if a good spark occurs while cranking the engine with the starter l a aa m me A high voltage spark will appear at the gap of the spark plug AWARNING Avoid touching the spark plug to pravant electric shock For multi cylinder engines remove spark plug from each cylinder For Some models with the CDI system there is a circuit within the CDI unit dasigned to turns off the spark at low cranking speeds ibslow 200 500 rpm In this case Jeava the spark plug in the cylinder head and try the spark test with known good spark plug Some CDI units are designed to turn off the spark when the
44. have identification marks near the end gap of the top and se cond rings Thase ring marks must face upwards on the piston PISTON PISTON RINGS NEEDLE BEARING 2 STROKE TOP RING SECOND RING PISTON RING GAP RING MARK when assembling Date of Issue Sep 1988 1 0 3 HONDA MOTOR CO LTD CYLINDER PISTON The oil ri g is needad to ramova oil fram the cylinder wali and return the residua from the hole of tha of ring groove If the oil ring fails oil flows into the combustion chamber and burns causing smokes The oif ring is either of a Split type arranged with two side rails and a slotted expander ar an integral type with a slotted square edge 2 STROKE As the 2 strake engine has a different lubrication system it is arranged with only the tap and second rings and without an oil ring As the 2 stroke engine has a cylinder wail with part a piston ring dowel is added to the ring groove of the piston to Prevent the rings from moving and hooking an adge in a por causing breakage The piston rings of the 2 stroke angine must therefore be assembied by aligning the and gaps to the dowels The design and shape of piston rings for 2 stroke enginas are different than that of 4 stroka engines A taper is provided over the entira cross section in 2 stroke ring design This is because with the 2 stoka engine burning engine ail carbon tends to adhera to the ring groove If not remedied the ring sticks to t
45. i tt fam O RING FACE SEAL Date of Issue Sep 1988 1 2 8 HONDA MOTOR CO LTD V MATIC BELT DRIVE SYSTEM DRIVE FACE SHAFT Coat the inside of the drive face shaft with 4 9 of grease Install the shaft with the splined hole facing out lt lt Do not get the grease on the pulley face Ramova any L misplaced grease with a degreasing agent ep ee aat Install the movable faca assembly on the crankshaft DRIVE FACE CRANKSHAFT DRIVE PULLEY FACE INSTALLATION SQUEEZE Squeeze the drive belt inte the pulley groove and puil the drive belt over the drive face shaft Install the drive pulley face washer and nut NOTE Ba sure both pulley faces are free of oil and grease eee ee O r Hald tha drive pulley face using the drive pulley holder and tighten the nut to tha specified torque DAIVE PULLEY HOLDER 07923 KM10000 50 DRIVE PULLEY HOLDER Date of Issua Sep 1988 HONDA MOTOR CO LTD 1 2 9 V MATIC BELT DRIVE SYSTEM NOTE Jf the pullay holder cannot be used remove the cooling ene g Sme UNIVERSAL HOLDER fan and hold the flywheel with the universal holder 5 Too UNIVERSAL HOLDER 07725 0030000 Install the left crankcase cover see Model Specific manual CLUTCH DRIVEN PULLEY DISASSEMBLY Remove the drive belt and clutch driven pulley see paga 12 5 Install a cluteh spring comprassor on the Pulley assamb
46. ing into the pilot screw CAUTION Use extrema cara when drilling into the pilot tor ain scraw to avoid damaging it Force a salf tapping 4 mm screw IHC 669399 P N 93903 3541 into the drilled plug and continue turning the screwdriver until the plug rotates with the screw Puli on the screw head with pliers to remove the Plug Use compressed air to clean the screw area and ramove metal shavings Turn the screw in and carefully count the number of turns until it saats lightly Make a note of this to use as a reference whan rainstalling the screw CAUTION i Tightening the pilot jor alr screw against its seat will damage the saat k Remove the screw and inspect it Replace it if it is worn or datnagad Date of Issue Sep 1988 HONDA MOTOR CO LTD FUEL SYSTEM PILOT OR AIR SCREW INSTALLATION Ze Em Install the screw and return it te its original position as noted Ki ste ts Nae during ramoval SS Perform the pilot screw or air screw adjustment if a naw screw is installed WASHER NOTE SPRING Jf you replace the pilot screw in one carburetor you must replace the pilot screws in tha other carburetors for pro per pilot scraw adjustment Bo not install a limiter cap or Plug over a pilot or air screw until the screw has been Properly adjusted LE ce Sy PILOT SCREW a a LIMITER CAP PILOT SCREW ADJUSTMENT IDLE DROP PROC
47. it may not necassarily hava any affect on its func tion In this case check all of the related components for trouble in other areas oars commen ou CDI UNIT PERFORMANCE TEST XCEPT U S A The CDI unit is checked by the Full transistar CDI tester Follow the tester manufacturer s instructions Refer to the Madel Specific manual for the type of inspection adaptor r quired CAUTION Improper connections could damage the CDI unit or testar For inspection adaptor refer to the Model Specific manual Switch Good condition Bad condition OFF i No spark P No spark EXT No spark ON1 Spark No spark ON2 Spark No spark IF there ace any Bad symptoms in the checks above replace the CDI unit IGNITION SYSTEMS E EXCITER COIL AC 100 Y rt r FULL TR CDI TESTER Not available in USA s toot INSPECTION ADAPTOR Date of Issue Sep 1988 HONDA MOTOR CO LTD 23 15 IGNITION SYSTEMS TRANSISTORIZED IGNITION SYSTEM CIRCUIT INSPECTION NOTE Foliow the steps in the troubleshooting flaw chart for servicing Refer ta the Model Specific manual for service data wir ing diagrams and wire colors SPARK UNIT CONNECTOR Disconnect the connactor from the spark unit and conduct these tests at tha connector Spark unit connector inspection itam Inspection item agnosis Power sourc
48. not in the opposite direction Raplace the one way clutch if the clutch center turns in both directions ONE WAY CLUTCH Primary Drive Gear Type DI Check the drive gear grooves for nicks or wear Caused by the clutch plates replace as necessary m aj Maasure the D of tha primary drive gear Replace if the l i service limit is exceeded PRIMARY DRIVE GEAR GROOVE Date of issua Sep 1988 1 1 1 8 HONDA MOTOR CO LTD Ease on oo ee a pass Ce CLUTCH Clutch Center Guide Coftar Type DI Measure the 1 0 andor O D of the clutch canter guide at the sliding surface Replace the guide if the service limit is exceeded Measure the 0 andar height of the collar replace if tha service limit is exceeded Crankshaft Type D Measure the O D of the crankshaft at the clutch center guide sliding surface replace if the service limit is exceeded CLUTCH REASSEMBLY Type A install the needle bearing or clutch outer guide onto the mainshaft Install the clutch outer onto the mainshaft NOTE If the pump drive sprocket is installad on the mainshaft align the holes ef the clutch outer with tha pins on the ail pump driva sprocket If the primary driva gear is tha anti backlash type install the clutch outer onto the mainshaft while moving the drive sub gear to align the two gear tasth using a i screwdriver Take cara not to damage the gear teeth Install the th
49. will damage the ammeter Date af Issue Sep 1988 21 18 HONDA MOTOR CO LTD EN FN 22 BATTERY CHARGING LIGHTING SYSTEM SERVICE INFORMATION 22 1 CHARGING SYSTEMDESCRIPTIONS 22 12 TROUBLESHOOTING 22 2 CHARGING SYSTEM INSPECTION 22 19 BATTERY DESCRIPTIONS 22 4 REGULATOR RECTIFIER INSPECTION 22 21 BATTERY REMOVAL INSTALLATION 22 8 HEADLIGHT VOLTAGE INSPECTION 22 23 BATTERY TESTING CHARGING 22 9 ALTERNATOR 22 26 gt SERVICE INFORMATION The battery gives off explosive gases keep sparks flames and cigarettes bway Provide adequate ventilation when charging or using the batteries in an enclosad spaca The battery contains sulfuric acid electrolyte Contact with skin or ayes may cause savera burns Wear protective clothing and a face shield If electrolyte gets on your skin flush with water If electrolyte gets In your eyes flush with water for at least 15 minutes and cail a physician immediately Elactrolyta is poisonous If swallowed drink large quantities of watar or milk and follow with milk of magnesia or vagetable oi and call a physician KEEP OUT OF REACH OF CHILDREN j Always turn off the ignition switch before disconnecting any alactrical component CAUTION Soma alectrical components may be damaged if terminals or cannactors are connected or disconnected while the Igni tion is ON and current is presant For extended storage remove the battery give it a full c
50. 1988 12 12 HONDA MOTOR GD LTD V MATIC BELT DRIVE SYSTEM Use pliers to hook the springs to the shoes SHGE SPRING Install the snap rings and washers or retainer plate onta the pivot pins DRIVEN FACE BEARING REPLACEMENT Ramove tha inner bearing OUTER BEARING NOTE df the driven faca has an oil seal at inner bearing side remove the gil saal first If a ball bearing is used on the inside remove tha snap ring first then remove the bearing a WINER BALL BEARING INNER NEEDLE BEARING Ramove the snap ring then drive out the puter baaring toward the inner bearing side Drive a new outer bearing into place with the sealed nd toward the outside Install the snap ring securely Apply the specified amount of specified grease as shawn SPECIFIED GAEASE Lithium Based Greasal Mitsubishi HD 3 Nippon Sekiyu Lipanox Deluxe 3 Idamitsu Coronax 3 Sta Lube MP 3141 Bel Ray Maly Lube 126 EP 0 SPECIFIED GREASE Date of Issue Sep 1988 HONDA MOTOR CO LTD V MATIC BELT DRIVE SYSTEM Install in a new inner bearing NOTE Install the bearing with the sealed side facing out Install the needie bearing using a hydraulic Press Install the ball bearing by driving it in or using a hydraulic press a etic eal gt lt L bres Install the Snap ring into the groove in the driven face Install a new oil asal with the lip toward the bearing if
51. 5 NORMAL If measurements differ ABRORMAL NO SPARK Same measure Poorly connected component connector ments Faulty or shorted ignition coil Broken wire harness between unit and componsnt Faulty related components No spark at all piugs Faulty Input system lt Transistorized ignition system gt If there is no spark at all plugs the problem could be at tha input of the ignition system pulse generator power supply circuit of the unit spark unit Laas Laka RE E i ETE Check for loose or pooriy connected spark unit connector ies r ABNORMAL Poorly connected connector NORMAL Check if battery voltage i measured between input line for the battery and ground wire of the spark unit with the ignition switch ON and the engine stop switch at AUN NO VOLTAGE Faulty ignition switch or engine stop switch Broken wire harness BATTERY bicelles MEASURED Measure pulse generator resistance at the con ABNORMAL o Check the pulse generator Isee page 23 16 nectar l i ae NORMAL ABNORMAL ce sae Faulty pulse Check the spark unit using FULL TAYCDIT a tester except USA Loose or poorly connected connactors Broken wire between pulse generator and unit ABNORMAL Faulty spark unit Data of Issua Sep 198E 23 2 HONDA MOTOR CA LTD m t IGNITION SYSTEMS No spark at elther ignition group lt Multi cylinder tansistorized ign
52. 60 Max load code Rim diameter t8 inch Radial indication mark Bate of Issue Sep 1988 HONDA MOTOR CO LTD WHEE1LS TIRES Tubeless tire x2 TUBELESS TIRE APPLICABLE MAAK Any attempt to mount passenger car tites on a motorcy cle tim may cause tha tire bead to separata from the im with enough explosive force to cause serlous injury or daath Tubeless tires have TUBELESS stamped an their side walls Tubeless tire rims have TUBELESS TIRE APPLICABLE Stamped on them Each rim valve has Snap in valve TR412 or FR413 on it The rim and tira mating areas and rim valves are different from tube types in construction SEN SART f TUBELESS TIRE Replace the tire if it is punctured or its side wail is damaged Use care to protect the sealing surfaces when handling and T storing tubeless tires and rims SNAP IN VALVE Identi fication i TUBELESS TIRE APPLICABLE TUBELESS TIRE not stamped APPLICABLE j stamped Rim valve hole 11 5 mm diamater Storage Store tubeless tires upright with a spacer or thick paper placed between the tire beads lf the baad to haad clearance is narrower than the rim width it is difficult to install the tire onto the rim Do nor stack or lean tires against gach other To stora the tire that is to be re used adjust the air pressura to 1 2 of the recommended pressure Be sure that the valve cap 3 is securely installed co a
53. Connect a multitester between the battery terminals T S DIGITAL MULTITESTER 07411 0020000 Pi FUSE TERMINALS Connect an ammeter between the terminals of the main fuse NOTE i BE MEQ If the probes ara connected in reverse order the r gistered current Flaw direction when charging and discharging the battery will ba reversed as well Refer to the Model Specific manual for proper connection of tha multitester Use an ohmmetar that registers both positiva and negative currant flow An ammetar which registers in only one direction will measure OA for discharging MAIN FUSE CONNECTOR RECONNECT FUSE TERMINALS SWITCH NOTE i Be careful not to shart any wires i Although the currant could be measured when the arm meter is connected between the battery positive ter f minal and the positive cable a sudden surge of current i to the starter motor could damage the ammeter Always use the kick Starter ta start the angine Always turn tha ignition off when conducting the test Disconnecting tha ammeter or wires when currant is flowing may damage the ammeter For models with no tachometer connect an engine tachometer Turn the headlight ON Hi beam and start the engine Gradually increase the engine speed and measure the charging voltage at the specified rpm NOTE If tha charging currant and voltage measurements ara normal when the battery is replaced with a
54. DE current is then supplied te components Operating on DC For example some models use DC for their headlights and others use AC For headlights aparating on AC the lights turn off when the current flow is zero and then go back on again as the polarity bacomes reversed This ON OFF cycle is repeated at a high fre quency number of cycles in one second and is not noticable Direct currant Direct Current is a current whose magnitude and direction re main constant Its form is shawn ijn the graph Direct current is abbreviated as OC Motorcycle batteries and household bat teries supply DC DC has the following characteristics as opposed ta AC DC can be stored in batteries and discharged whan needed AC cannot be stored OC is capable of a large current Flow Good for starter motors DC voltage cannot be stepped up or down AC can change its voltage by using a transformer ELECTRICAL FUNDAMENTALS ALTERNATING CURRENT t CYCLE DIRECT CURRENT CURRENT Date of Issue Sep 1986 HONDA MOTOR O LTD ELECTRICAL FUNDAMENTALS i a aaa VOLTAGE As illustrated in the figure to the right when two watar tanks A and B are connected water flaws from tank A to tank B This flow is the result of a pressure diffarance between the two tanks ots co tg PRESSURE GIFFERENCE HEIGHT DIFFERENCE This same concept applies to electricity The pressure differanca called the electrical po
55. Faulty headlight rasistor Open headlight circuit Faulty lighting switch connection Broken regulator rectifier ground wira or faulty connection On a Single phase half wave ractifier check the following areas Brokan regulatar ractifiar ground wire or faulty connaction Cn regulator rectifiers with a battery voltage feedback circuit check tha fallowing areas A check is unnecessary for a voltage feadback typs Check if battery voitage is measured at voltage feedback line black wiret If nat the problem may be a broken voltage feedback line Check the valtage feadback line for a loose connection at the ragulator rectifier connector On alternator with field coil chack the following areas Continuity batwaan fiaid coil wire and ground If thera ara no problams in tha above areas replace the raqulatar ractifiar with a naw one Date of Issue Sep 198 22 2 D HONDA MOTOR CO LTD BATTERIES CHARGING LIGHTING SYSTEM CHARGING SYSTEM Nema ebay cure wake Leak L connect Check the reguiaranracanar pave 22 71 INCORRECT CORRECT S harted RR wire CORRECT Faulty ignmon switch a a Faulty requlatoriree tifier OVERCHARGED Inspect the charging voltage ipage 22 191 NOT CHARGING SA and ground wire of regulator rectifier page 22 22 CORRECT Battery is failing ABNORMAL Open circuit in wita harness Poorly connected connector Check if battery voltaga i
56. HEX HEAD BOLT STRENGTH MARKINGS Strangth marks indicating material type are visible on the haad of some hex headed bolts Bolts are classified into stan dard bolts and high tension balts by material types During assembly take care not to install any high tansion bolts in the wrong place Note that while standard bolts are tightened to a Standard torque unless otherwise specified high tension bolts always hava their own specified torque values 6 mm SH boits without strength marks ismali headed flange bolts with a width across flats af B mm and a thread size of 6 mm are all considered standard bolts DA type ior dished headed bolts without strength markings flange bolts with hex heads and weight reduction hotes in them ate classified by outer flange diameters Be careful about the installation points and the torques of high tansion bolts having the same hexagan dimensions as standard bolts but having larger flanges Date of Issue Sep 1999 HONDA MOTOR CO LTD strength Width Thread cliameter _ He wanes pomon across flats x pitch sa 8 5x 60 8 B Bx 1 0 f 10 6 x 1 0 STRENGTH MARK Strength Class go 100 100 120 kgm ky im Standard Salts 50 70 kgirnm Tension 1 20 140 kgimm Class High tensian DISHED HEAD JEN 19 STANDARD HI TENSION BOLT BOLT 1 7 GENERAL INFORMATION WES balts are in the high tension category
57. Honda V matic belt automatic transmission The belt must be checkad periodically according to the maintenance schedule shown in the Modal Specific manual WY UH iy CB esni Chis Yi wy tii his tis i Yi Yi yf performance WEE A worn or damaged drive belt may cause a loss in scooter Remove the drive belt cover see the Model Specific manual and check the drive beit for waar cracks or peeting of the cogs or plias repiace with a new one If necessary Date of Issue Sep 1988 2 24 HONDA MOTOR CQ LTD MAINTENANCE BELT CASE AIR CLEANER On scooters with a cleaner element in tha air inlet to the drive belt case remove the element and clean AIR CLEANER Wash the element in water and dry it thoroughly before rainstalling FINAL DRIVE OIL LEVEL INSPECTION HO Check for leakage and proper oil level Remove tha inspaction level hole cap from the gear case and check that the oil level is up to the lower edge of the hole It the oil leval is low refill to the lower edge of the hole with tha recommended ail NOTE Oil level checks should be carried out on level ground with the vehicle on the center stand OIL CHANGE Refer to tha Modal Specific service manual for information on the oil changa interval Remova the lave hole cap from the final gear case Remove the oil drain bolt from the lower partion of the gear case slowly turn tha reas wheei and drain the oil When the oil is carm
58. MATIC BELT DRIVE SYSTEM SYSTEM DESCRIPTION OPERATION WEIGHT ROLLER GUIDE PIN DRIVEN FACE CLUTCH AND ROLLER SPRING OUTER RAMP PLATE DRIVE FACE MOVABLE DRIVE FACE DRIVE PULLEY DRIVEN PULLEY DRIVE PULLEY DRIVEN PULLEY When the engine is running at low speed the unit increasesor As the engine rpm increases or the load on the rear wheel muttiplies torque This delivers more torque than a higher decreases centrifugal force on the weight rollers throws engine speed at a greater drive ratio the rollers outward When the rollers are forced outward they push the movable face of the drive pulley closer to the REDUCTION LOW drive face The result is a reduced drive ratio between the driven and drive pulleys REDUCTION HIGH Date of Issue Sep 1988 1 2 2 HONDA MOTOR CO LTD V MATIC BELT DRIVE SYSTEM DRIVE PULLEY OPERATION gt WEIGHT ROLLER KIN RS gt RAMP PLATE DRIVE FACE MOVABLE DRIVE FACE The drive pulley consists of a fixed anda movable face The movable face is capable of sliding axially on the shaft of the fixed face The ramp plate which pushes the weight rollers against the drive face is attached to the shaft of the drive face with a nut AS SPEED INCREASES DRIVE BELT MOVABLE FACE a RAMP PLATE DRIVE FACE WEIGHT ROLLER As the engine rpm increases centrifugal force on the w eight rollers is increased This pushes the movable drive face toward th
59. MOTOR CO LTD Oa FUEL SYSTEM 9 Turn the No 1 carburetor pilot scraw counterclockwise to the final opening from the position obtained in step 6 FINAL OPENING Refer to the Modal Spacific manual 10 Adjust the idie speed with the throttle stop scraw 11 Parform steps 8 9 and 10 for all the carburetor pitot Screws 12 Install the naw limiter cap or plug onto the pilot screw head page 8 23 IOLE DROP PROCEDURE 4 stroke single carburetor emissions control applicable models NOTE j Tha pilot screw is factory pra set and no adjustment is nacessary unless the pilot screw is replaced Use a tachometer with graduations of 100 rpm or PILOT SCREW L smaller that will accurately indicate e 100 rpm changa 1 Turn pilot screw clockwise until it seats lightly than back it out te the specification given This is an initial setting prior to the final pilot scraw adjustment PE INITIAL OPENING Refer to the Model Specitic manual CAUTION Tightening the pilot screw against its seat will damage the saat 2 Warm up the engine to oper ating temperature Ten minutes of Stop and go driving is sufficient 3 Attach a tachometer according to its manufacturer s instructions 4 Adjust the idle speed with the throttle stop screw IDLE SPEED Refer to the Model Specifi manual 5 Turn the pilot screw in or aut slowly ta obtain the highest engine speed 6 Readjust the idl
60. Medal Specific manual far the service timit or refer to the wheel hub if the service limit is stamped on it NOTE If the brake drum is rusted clean with 120 emery paper Be sure to use the inside vernier calipers to measure the brake drum J D because tha drum have a waar ridge pan nanes ammet i Te Date of Issue Sep 1988 1 7 1 6 HONDA MOTOR CO LTD 1 BRAKES Brake Lining Thicknass BRAKE SHOE Measure the brake liring thickness at 3 points both ends and oy BRAKE LINING center Replace the brake shoes in patrs if the smallast measurement is less than tha service limit or if they are contaminated with greasa DISASSEMBLY SHOE SPRING NOTE Replace the brake shoes in pairs When the brake shoes are reused mark on the side of each brake shos before disassembly so that they can ba installad in their original positions U Spring Type Move the brake arm and expand the brake shoes Remove the shoe spring from the anchor pin with a screwdriver Remove the braka shoes Coil Spring Type Pull the brake shoes away from the anchors and remave the shoes Date of Issue Sep 1982 E HONDA MOTOR C LTD BRAKES Remave tha following from the brake panel brake arm wear indicator plate felt seal dust seal baka cam ASSEMBLY Apply a smalt amount of grease to the brake cam and anchor pin Install the brake cam in the brake panel Keep grease
61. SHIFT LIFTER Whan the shift pedal ia oparated the rotation of the gear shift spindle rotates the liftar carn through the clutch lever When the lifter cam is rotated the ball Posrtions of the ball re tainer and the lifter cam are dislocated causing the lifter cam to lift for the distanca shown in the figure a and the prassure plate is pressed When the pressure plata is pressed the ctutch outer cantracts the spring and the whole clutch outer ig pushed inwards At this tima even though tha clutch weight is closely joined to the disc and plata a gap will exist between the dise and plate from the mation of the clutch Outer and the clutch is then disangaged As the pada is released after completion of shifting gears the tifter cam returns to its original position When the clutch outer returns to its original position by the tension of the clutch spring the disc and the plata Closely join again and the clutch is then engaged DRIVE PLATE CLUTCH PLATE INCREASE CENTRIFUGAL FORCES PRESS FO LIFTER CAM BALL RETAINER O 11 8 Date of issue Sep 1988 HONDA MOTOR Q LTD TYPE B SEPARATED SHIFT CLUTCH combinad type described on Previous pagas Differing from the type has a mechanism whereby the clutch shoe attached to the crankshaft is expanded outwards by centrifugal farce nd tha Shoe is pressad against the inner Surface of the clutch drum allaw
62. SHOCK ABSORBER 19 7 TROUBLESHOOTING 19 1 SWINGARM 19 17 SYSTEM DESCRIPTIONS 19 2 PHO LINK SUSPENSION LINKAGE 19 11 SERVICE INFORMATION Usa only genuine Honda bolts and nuts on all suspension swingarm shack absorber and suspension linkaga mounting lacations TROUBLESHOOTING Soft Suspansion Weak spring s Qil leakaga fram damper unit ir or gas faakage Incorrect damper adjustment Hard Suspension Incorrectly mounted suspension components Incorrect damper adjustment Bent swingarm pivot Bent dampar rod Damaged swingarm pivot bearings Faulty suspension linkage Damaged linkage pivot bearings Date of Issue Sep 1988 1 9 1 HONDA MOTOR C LTD a REAR SUSPENSION SYSTEM DESCRIPTIONS Swingarm type rear suspension systems provide a camfor table ride whila offering goad traction and wheel cantrot capabilities Using the front swingarm pivot as the fulcrum and maunting the rear axle at the trailing end of the swingarm allows the wheel ta respond quickly to variations in the road or trail surfaca At present almost all motorcycles have adopted this basic configuration for rear suspension On some scooters the gn tira engine and drive unit pivots as the swingarm This basit swingarm type rear suspension design can be broken down inte a few categories depending on the number of dampers used and the design of the swingarm Conventional Dual Spring Damper Typa In the caventio
63. SYSTEM DESCRIPTIONS The U S Environmental Protection Agency and California Air Resources Board CARB require manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life whan operated and mainrained according to the instructions provided and that motorcycles built after January 1 1983 compiy with applicable noise emis sion standards for one year or 6 000 km 3 730 miles after the time of sale to the ultimate purchaser when operated anc maintained according to the instructions provided Compliance with the terms of the Distributor s Warrantias for Honda Motorcycla Emission Control Systems is necessary in order to keep the emissions systam warranty in effact SGURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons Control of hydrocarbons is very important because undar certain conditions they react to form phatochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Honda Mator Co Ltd utilized lean carburetor settings as welt as other systems to reduce carbon monoxide and hydrocarbons CRANKCASE EMISSION CONTROL SYSTEM The crankcase emission control system routes crankcase emissions through the air cleaner and into the combustion chamber Condansed crankcase vapors are accumulated in an air oil separator and drain tube which must be emptied periodically Refer to the Maintenance Schedule for ea
64. Sep 198B 14 10 HONDA MOTOR U LTD nie CRANKCASE CRANKSHAFT Install the bearing caps and connecting rods on the correct BEARING CAP crankpins ke D NOTE Install tha connecting rods and bearing inserts in their original positions Do not rotate the crankshaft and connecting rods during the plastigauge procedure afi C pare P Da y o Qil the threads of the connecting rod bolts and nuts so that the bolts will be tightened evenly Tighten the nuts to the specitiad torque After tightening check that the connecting rods move freely without binding i if GA et D me E j a ad s be Date of Issue Sep 1982 HONDA MOTOR CO LTD 14 11 15 FINAL DRIVE OUTPUT SHAFT ror SERVICE INFORMATION 15 1 OUTPUT SHAFT 15 2 TROUBLESHOOTING 15 1 FINAL DRIVE 15 5 SYSTEM DESCRIPTION 15 2 SERVICE INFORMATION Perform the gear contact pattern and backlash inspection and adjust the shim whenever you replace the bearings gears or gear case The extension iines from the gear engagement surfaces should intarsect at one point POINT OF INTERSECTION Check the ring gear to gaar case cover stopper pin clearance on the final gear case Adjust if it is out of specification Replace the final driva shaft side gear case output shaft and the ring and pinion gears of the final gaar case as a set Protect the gaar casa with a shop towel whi
65. a change in the mixing proportion during usage Therefore for best perfor L _ mance change the coolant ragularly See page 5 6 COOLING SYSTEM To pravant injury keep your hands and clothing away from the cooling fan it may start automatically without L waming Check the radiator air passages for clogging or damage straighten bent fins with a smail flat blade screwdriver and remove insects mud or other obstructions with compressed air or low water pressure Reptace the radiator if the air flow ts restricted over more than 1 3 of tha fin surface Remove the body panels and fual tank and check for any coolant leakage from watar pump water hoses and hosa joints Check for any deterioration or damage to the water hoses A rubber hose detariorates naturally over time dua to heat and wear If the hose deteriorates too much it will rupture due to the pressure in the cooling system Squeeza the hose and look far cracks 2 18 UPPER LINE LOWER LINE WATER HOSE Date of Issue Sep 1988 HONDA MOTOR CO LTD SECONDARY AIR SUPPLY SYSTEM Ra 2 a To prevent injury keep your hands and clothing away from the cooling fan It may start automatically without warning NOTE The secondary air supply system introduces filtered air into the exhaust gases in the exhaust port The segon dary air is drawn into the exhaust port whenever there is a negative pressure pulsa in the
66. adjuster s alignment matk is within the red zane of the chain wear indicator fabel replace the drive chain and both sprockets Only for vehicles with an indicatar label affixed NOTE P Always replace both sprockets when replacing the drive L chain for optimum waar characteristics After replacing and adjusting the drive chain attach a wear in dicator tabel so that the alignment mark is at the start of the green zone On modais without a drive chain wear indicators measure the langth betwean the chain s pins as shown in the figura and replace the chain if the prescribed limits ara exceeded Drive chain length 41 pins 40 links CHAIN SI STANDARD SERVICE LIMIT Z PITCH CODE fan in mm int mm fin 415 420 428 12 70 0 500 608 120 0 511 20 1 520 525 50 fisas za 635 24 0 638 125 14 839 19 05 0 7501 782 30 0 766130 2 CHAIN CLIP ROTATING DIRECTION Some endiess chains require ramoval of tha swingarm for drive chain replacement Others use a special tool ta remove and install the master link The outer plate of this type of master link is secured by expan ding the ends of the pins with the special tool Position the masterlink clip so that its apen end is opposite the normal rotation of the chain This prevents the clip being knocked off through contact with the chain guide or passing objects Check that the clip is fully seated CAUTION Improper p
67. aligned with the hole in the switch 25 12 yt ue a ea Yi E SCREWS cut and discard Data of Issue Sep 1988 HONDA MOTOR CO LTD Py LIGHTS METERS SWITCHES Tighten the contact base with the threa screws Clamp the wires with a wire band and cut off the excess por tian of the band Check tha ignition switch When the contact base s secured with tabs Remove the ignition switch and band Insert the ignition switch key and turn it to the position b tween ON and OFF Push the contact base tabs in with a screwdriver so that they ara out of the slots in the ignition switch body and remove tha contact base Insert the contact hase on tha ignition switch body with its tabs aligned with the slots in the ignition switch body NOTE Ba sure that the ignition switch key is in the positian be tween ON and OFF before attempting to remove the con tact base Clamp tha wires with a wire band and cut off the excess por tion of the band Check the ignition switch D f Sep 1988 HONDA MOTOR CO LTD 2 5 a 1 3 LIGHTS METERS SWITCHES NEUTRAL SWITCH When the ignition switch is ON and the transmission is in neutral the neutral switch turns the indicator on Some models are equipped with a change switch and or over drive switch The change switch detects the gear position by the position of the shift drum and sends a signal to the gear position in dicato
68. allow those dimensions depth distance or pasitign to ba correctly duplicated upon reassembly Non reuseable parts are always replacad whenever something is disassembled These include the gaskets metal sealing washers O rings ail seals snap rings and cotter pins CAUTION Coolant or braka fluid will damage the appearance of painted parts In addition these fluids can damage tha structural integrity of plastic or rubber parts ee 1 3 GENERAL INFORMATION Ball bearings are removed using tools which apply force against ona or both linner and outer baaring races If the force is applied against only one race either inner or outer the bearing will be damaged during removal and must ba replaced If the force is applied against both races equally the bearing will not ba damaged during removal Both examples ruin the hearing Bali bearings are claaned in high flash point solvent then dried with compressed air Air dry the bearing while holding both races to prevent it from spinning If the bear ing is allowed to spin the high spaed generated by the air jet can overspeed the bearing and cause permanent damage Bai baarings are checked after cleaning by slowly rotating the inner race while holding the outer race sta tionary If any radial play or roughness is falt it must be replaced The bearing should have no axial play if it has noticeable axial play it must be replaced Ball bearing
69. and gear case in comparison to the chain drive Both types require no maintenance and Provide raliable strength and durability REAR CYLINDER CAMSHAFT DRIVE VELT REAR CYLINDER EXHAUST CAMSHAFT INTAKE CAMSHAFT FRONT CYLINDER INTAKE CAMSHAFT EUS Puget y a IDLER GEARS S FRONT CYLINDER EXHAUST CAMSHAFT CRANKSHAFT Date of Issue Sep 1988 D 9 3 HONDA MOTOR O LTD CAMSHAFT CYLINDER HEAD VALVE LIFTER MECHANISM ARRANGEMENT Tha currant camshaft arrangement in 4 stroke engines can be divided into Single Ovar Head Camshaft SOHC and Double Over Head Camshaft 0OHC configurations The SOHC follows the basic design of 4 stroke angings operating IN and EX valves through rocker arms with ona camshaft Compared ta the DOHC the SOHC type is less expansive to manufacture and is easier ta maintain due to the reduced number of parts However valve jump where the valve cannot accurataly follaw the cam when the angine rotates at high speed can occur Causing the valve to contact the piston and causing severa engine damage To decrease valve mass and reduce the possibility af engine damage during high engine speeds 4 stroke engines requiring high power generally use the DOHC design in which the valves are operated directly with two Separate camshafts for IN and EX valves The DOHC configuration can be of two designs a type pressing the valve bucket directly or a type lifting the valva through the use of a
70. arm Install the shoa spring on the brake shoes and secure it on the anchor pin SHOE SPRING install the brake panel on the wheel hub SPEEDOMETER DRIVE GEAR Instalt the wheel Front wheel Check the Model Specific manual for the poarper installation procedures Rear whecl Chack the Model Specific manual for tha proper installation procedures Date of Issue Sep 1998 HONDA MOTOR TO LTD ee ee Sy pe pee 18 FRONT SUSPENSION i SERVICE INFORMATION 18 1 i FORK 18 5 TROUBLESHOOTING 18 1 HANDLEBARIS 18 71 SYSTEM DESCRIPTIONS 18 2 STEERING STEM 18 15 SERVICE INFORMATION A WARNING os Riding an damaged rims or spokes impairs safe operation of the vehicie o When servicing the front wheel suppart the motorcycle secural Refer to the section 17 for brake system information TROUBLESHOOTING Hard steering Steering head bearing adjustment nut too tight Faulty steering head bearigs Damaged steering head bearings Insufficient tire pressure Faulty tira Steers to one side or dows not track straight Unev aly adjusted right and left shock absorbers Bent tork Bent front axte wheel installed incorrectly Faulty steering head bearings Bent frame Worn wheel bearing Worn swing arm pivot components Front wheel wobbling Bent rem Warn front wheel bearings Faulty tire Wheel turns hard Brake misadjusted Faulty wheel boaring Fault
71. at the regulator rec tifiar connectar inspect the regulator rectifier unit by measur ing the resistance between the tarminals Refer to Modet Specific manual for specific data a sal a c cml E Resistance value will not be accurate if the probas touch your fingars Use the following recommended multitester Using another manufacturer s equipment may nat allow you to obtain the specified values This is due to the i charscteristic of semiconductors which have different rasistance values depending on the applied voltage SPECIFIC MULTITESTER 07411 0020000 KOWA Digital type KS AHM 32 003 KOWA Digital type USA only 07308 0020001 SANWA Analaque type TH 5H KOWA Analogue type Select the following range SANWA Taster k KOWA Taster x 1002 1 Anold weak multitester battery could cause inaccurate raadings Check the battery if the multitester registers incorrectly When using the Kowa multitester ramamber that all readings should be multiplied by 100 Replace the regulator rectifier unit if the resistance value be tween tha tarminals is abnormal HEADLIGHT VOLTAGE INSPECTION Raguistor Rectifier With Built in AC Ragulatar For a reguiator rectifier with a built in AC regulator measura the headlight lighting voltage CAUTION i Failure to measure the headlight voltage may lead to alactrical damage of lighting components if the model is not equip
72. between the lifter an Push rads Te ee a Remove judder spring and spring seat if they are installed rf PLATES bie JUBDER SPRING AND SPARING SEAT If the lock nut is staked to the meinshaft unstake the lock nut CLUTCH OUTER and remove it Remove the lack Washer Remove tha clutch center and clutch outer LAND LOCK i WASHER a CLUTCH CENTER Type C Remove the sat ring litter plate lifter rod and bearing Slowly squeeze the clutch lever immediately aftar removing the clutch lifter plata then tie the lever to the handlebar CAUTION Ambiant air can contaminate and may damaga the clutch system oS 6 A ___ a CK WASHER toa LOCK NUT PER coe 5 Shift tha transmission inta top gear and apply the rear brake Remova the lock nut NOTE r ee ee If the engine is not in the frame shift the transmission in to top gear and hold the drive Sprocket using the univer _sat holder 07725 0030000 _ _ A Remove the lock washer clutch Spring set plata elutch spring and washers O ae CLUTCH SPRING AND WASHER Date af Sep 1988 1 1 1 2 HONDA MOTOR co LTD CLUTCH Remave the clutch pressure plate clutch plates and discs PRESSURE PLATE ee Remove clutch center B and tha one way clutch as an assembly z 5 1 ra as so Ne
73. braka disc Caliper not sliding properly Contaminated master cylinder Ciogged restricted brake hose joint Bent brake lever pedal Brakes drag Contaminated brake pad disc Misatigned wheel Worn brake padidise Warped deformed brake disc Caliper not sliding property MECHANICAL DRUM BRAKE Poor brake performance Brake lever hard or slow ta return Improperly adjusted brake Worn broken return spring Worn brake linings Improperly adjusted brake Worn brake drum Sticking braka drum due to contamination Worn braka cans Worn brake shoes at cam contact areas Improperly installed brake linings Brake cable sticking needs lubrication Brake cable stcking needs lubrication Worn brake cam Contaminated brake linings tmproperly installed brake linings Contaminated brake drum Worn brake shoes at cam contact areas Improper engagement between brake arm and cam Brake squeaks shaft serrations Warn brake linings Worn brake drum Contaminated brake linings Contaminated braka drum I ge ee Date of Issue Sep 1988 1 7 1 HONDA MOTOR CO LTD BRAKES BRAKE SYSTEM DESCRIPTIONS Braking systems on motorcycles like virtually all braking systems dissipate the vehicles kinetic energy by transforming it into heat energy known as friction heat Two basic types of braking systems are used on Honda motor cycles and scooters the drum type and the disc type Bath the drum and the d
74. compare the oo 222222222 an resistance value at lt 2 maasured on the previous page and i sree oT am i ifthe two values are not the same a broken black red wire or loose alternator connector is suspect If both resistance values are the sama but not in the correct range the exciter coil may be faulty 3 Shorted wire or wire harness To sae if the green or black red wire is shorted check the continuity betwaan different colored wiras If you have con tinuity between other wires replace the wire harness MEASURING CURRENT SERIES CONNECTION PARALLEL CONNECTION IGOOD WRONG Current is not normally checked during motorcycle service pro cedures Though it is used for testing components currant Measurements ara not used for chacking continuity within circuits How to measure current using ammeter Ammater is connected in saries in the circuit and measuras the currant flowing through it Place the in circle symbol red probe to the positive end of circuit and in circle symbol black probe to the negative end Make sura the current flow does not exceed the maximum range selected CAUTION Placing the ammetar in parallel like a voltmeter can damage the ammeter from a current overflow Connecting the ammeter batween the battery terminals will damage the ammeter Turning on the starter motor while tha ammeter is con nected betwaan tha battery terminal and battery cable
75. disc and tha caliper bracket on each sida after installation The clearance should be at least 0 7 mm 0 03 in lf the clearance is not 0 7 mm 0 03 in or more loosen the haldear nut or pinch bolt at the axle shaft side and adjust tha clearance Then tighten the holder nuts or pinch balt to the specified torque 0 7 mm 0 03 in 16 4 Data of Issue Sep 1988 HONDA MOTOR CO LTD i WHEELS TIRES REAR WHEEL Grease on the brake linings will raduce stopping power Keep gresse off the brake linings Wipe excess grease off the cam and anchor pin Inhaled asbastos fibers have bean found to cause respiratory disease and cancer Naver use an air hose or dry brush to j claan brake assembtias Use an OSHA approved vacuum cleanar or alternates method approved by OSHA designed to minimize the hazard caused by sirborne asbestas fibers Support the vahicla securely with the rear wheal off the ground Rernove the muffler and or other parts necessary to gain access to the wheel For drum brakes disconnect the brake rod or cable and brake torque tod from tha brake panel For hydraulic disc brakas it may be nacessary to remove the brake caliper Asfer ta tha Madel Specific manual Note the side collar position and diraction so thay can be installed properly After installing make sure that the rear wheal turns smoothly without excessiva free play CHAIN DRIVEN TYPE Removal Loosen the axle nut and drive cha
76. driver shaft with a wrench and tighten nut A to ATTACHMENT 6 55 mm remove the upper race Date of Issua Sap 1988 HONDA MOTOR CO LTD 1 8 1 7 FRONT SUSPENSION Bottom Race Removal Set remover B into the steering head place attachment B anto DRIVER remover B and secure it with nut B DRIVER SHAFT install attachment A onto the top of the steering head BEARING REMOVER Install the remover shaft through attachments and B and set B 55 mm the base with the big end toward the head pipe and screw in LOWER nut A DUTEA f RASE ASSEMBLY Asmove the bottom race in tha same manner as the top race DRIVER BASE ATTACHMENT 6 55 mm NUT A Top Race Installation DRI Install a new top race and attachment A onta the tap of the rein peers GROOVE A 47 mm staering head Install the driver shaft attachment and base with the small UPPER side of the base toward the steering head as shawn OUTER RACE Tighten nut A DRIVER Hold the driver shaft to prevent the new race from turning and install the top race by turning nut A gradually until tha groove af attachment A aligns with the top end of the head pipe Bottom Race Installation Install a new bottom raca and attachment B onto the driver shaft and install them into the stegring head Precinct Sat attachment A and base on the top of the steering head and A 47 ORNER T ASSEMBLY tighten nut A SHAFT f LOWER Hold the driver shaft securely and install the bottom ra
77. engine Refer to chapter 2 far servicing spark plugs TROUBLESHOOTING The diagnostic steps presented here are general methods af troublasheeting the CD and transistocized units The steps and methods used in diagnosing may differ dapending on aach model Refer to the Model Specific service manual for details concerning the ignition system No spark at spark plugs CDI unit Replace with known goad spark plugs conduct SPARK Speier caine z the spark plug test S i o eee ome E NO SPARK Check for poorly connected or loose spark plug wires If loasa screw spark plug cap securely in to the spark plug wire SPARK Luose wires NO SPARK Check for loose or poorly connected CDI unit SPARK Poorly connected CDI unit connector Correct it and conduct the spark plug tast again NO SPARK cont d Date of Issue Sep 1988 HONDA MOTOR CO LTD 23 1 IGNITION SYSTEMS cont d Disconnect CDI unit connector and check related circuit at the connectar A i NORMAL Check the CDI unit performance with FULL l Measure resistance of the secondary coil see TRICDI tester except USA page 23 13 D aS Se e 7 a NORMAL ABNORMAL ABNORMAL t ae ee Faulty CDI unit Check campanants individually os a Check ignition coil using FULL TR CDI tester except USA mF Compare results with the measured value above r Ael ieee eh
78. formance but at great increase in cost and complexity In this type pistons facing each other on opposite sides press the pads against the disc The amount of braking force available depends on tha magnituda of force pressing the pads against the discs the size of the contact area between the brake pads and discs the distance betweaan the center of the wheel and the canter of the brake pads and on the outsida diameter of the tira Rectangular brake pads were introduced to increase tha area of tha pad against tha disc But it was found that these pads do not press against the dise uniformly so the braking farce is not as effective as it could be Hence the dual piston caliper was introduced so that a jarge braking forca and uniform Pressure against tha brake pads is ensured Some dual piston calipars have different piston sizes to further balance the brak ing force across the pad the trailing piston being larger than the leading pistan As previously touched on increasing the area of contact bet ween tha brake pads and disc increases the braking force This increased contact means increased heat energy The increas ed haat energy requires greater capability for heat dissipation With the exception of in board disc brakas and the GL1500 front brakes all brake discs are axposed To protect tham from rust the discs ara made of stainless steel alloy Because tha material the discs can be made of is limited the discs can onty be
79. from play and tighten to tha specified torque using a flare nut wrench HYDRAULIC DISC BRAKES BRAKE FLUID REPLACEMENT Before removing the reservoir cover turn the handlebar until the reservoir is level Place a rag over painted plastic or rubber parts whenever the system is serviced CAUTION Spilling fluid on paintad plastic or rubber parts damages them Remove the master cylinder cover and diaphragm COVEA Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent COVER PLATE DIAPHRAGM A contaminated brake disc or pad reduces stopping ability Refill with the same type of fluid Mixing incompatible fluids will Impalr braking efficiency Foreign materials can clog the system causing a reduc tion or camptete loss of braking ability Date of Issue Sep 1988 1 7 8 HONDA MOTOR CG LTD BRAKES Connect a bleed hose to the bleed valve Loosen the caliper bleed valve and pump the brake lever or pedal Stop operating tha lever or pedal whan fluid stops flaow ing out of the bleed valve Close the blead valve and fill the master cylinder with the specified brake fluid Refer to the Model Specific manual CAUTION 4 Reusing drained fluids can impair braking efficiency Connect a commercially available Brake Bleeder to the bleed valve NOTE When using a brake bleeder follow the manufacturer s Operating instructions
80. gauge Replace the ring if the service limit is exceeded PISTON RING Date of Issue Sap 1988 HONDA MOTOR CO LTD 1 0 7 CYLINDER PISTON PISTON PIN INSPECTION Measure the piston pin O D at three points Replace the pistan pin if the service fimit is exceeded Calculate the piston pin to pin bore clearance by subtracting the piston pin O D from the Rin bore D SMALL END BEARING SURFACE INSPECTION 2 stroke Engines Install the needle bearing and piston pin in the connecting rod small end and check for excassive play if the piston pin 1 0 is aver the service limit the crankshaft must ba replaced Measure the 1 D of the connecting rod small end 4 strake Enginas Measure the D of the connecting rod small end Replace the connecting rod or crankshaft assembly if the ser vice limit is exceeded PISTON PISTON RING INSTALLATION 4 stroke Engines Clean the piston heads ring lands and skirts Carefully install the piston rings onto the Piston with the mark ings facing up J Top RNG NOTE F Ba careful not to damage the piston and rings during SIDE RAILS Ae Np assambiy Do not confuse the top and second rings The top ring is chrome coated and tha second ring is not caatad black After installing the rings they should rotate freely without sticking Space the ring end gaps 120 degrees apart j Space the sida rail gaps 40 mm 1 6 in or more apar
81. gear D replace if the service limit is exceeded Check the bushing far wear or damage Measura the bushing D and D replace if the sarvice limit is exceaded Calculate the gaar to bushing clearance replace the compo nent if the service limit is axceeded Maasure the O D of the countershaft or output drive shaft at the sliding area Replace the shaft if the service limit is exceeded Calculate the shaft to bushing clearance If the service limit is exceeded determine if a new bushing would bring the claarance within tolerance If o replace the bushing If the Clearance stilt exceeds tha service limit with new bushing replace the shaft Measure tha damper Spring free length Replace the spring if the free length exceeds the sarvice dimit BACKLASH INSPECTION Clamp the output gear case in a vise that has soft jaws or use a shop towel Sat a horizontal type diat indicator on the countershaft or out put drive shaft as shown Hold the driven gear with the shaft holder and cotate the countershaft or output drive shaft by hand until gear slack is taken up Turn tha countersheft or output drive shaft back and farth to read the backlash Remove tha dial Indicator Turn the countershaft or output driva shaft 120 and measure backlash Repeat this pracedure once more Compara the difference of the three measuraments Date of Issue Sep 1988 HONDA MOTOR C LTD FINAL DRIVE OUTPUT SHAFT lf
82. headlight Thus na resistor is required When the negative output of the charg ing coil reaches a certain voltage the AC regulator feeds cur rent to the gate of SCR2 and turns it ON The SCR2 is shorted and a negative current to the coil regulates its output voltage Since the negative output voltage of the charging coil is not used for charging the battery tha AC regulator has no affect on charging the battery However since when the negative Output of the coil is cut off the headlight voitaye is also cut off the AC regulator regulates the output voltage to the headlight Single Phase Full Wave Rectifiers This type is used on medium engine displacement models Compared to the half wave ractifier the full wave rectifier is more efficient in using tha alternator output for charging the battery In order to convert the AC output of the alternator to DC the diodes are arranged as in the right diagram inside the regulator rectifier When the alternator is positive the current flows through 01 battery D2 and when the alternator is negative the current flows through D3 battery D shown by the white arrow and black arrow respectively In this way the AC output of the alternator is converted to a DE waveform This circuit is called the full wave rectifier and is distinguished from the half wave rectifier Similar to the single phase half wave rectifier the full wave rectifier has a battery voltage feedback method
83. helaw ELECTROLYTE TEMPERATURE pAn Date of Issue Sep 1988 2 26 HONDA MOTOR CO LTB MAINTENANCE C NOTE If the difference in specific gravity between cells ex ceeds 0 01 ra charge the battery If the difference in specific gravity is excessive raplace the battery Thera is a change in specific gravity of approximately 0 007 per 10 C change in temperature Be sure to con sider this when taking measurements Reading of the hydrometer s fluid lavel should be taken in the horizontal position Refer to section 22 for details of battery testing and charging Condition of terminal connections Make sure that terminal connections are not loase If corrosion is evident remove the battery wash rust with warm watar and use a wire brush ta remove completely Reconnect the battery and lightly coat the terminals with grease WIRE BRUSH r p baras sn BRAKE FLUID Firmly apply the brake and check for fluid leakage from the brake system If there is any leakage of fluid fram any part of the system quickiy raplace the damaged parts Check for degradation and damage of the hoses pipes and joints Check fer looseness of joints and clamps Also make sure that hoses and pipes do not come into contact with mechanical parts when the fork is turned or due to vibration whan the vehicle is running Before removing the reservoir cover turn the handlebar until the resarvoir is
84. ic SHAFT i HANDLE i WEIGHT REMOVER SET _ _ 6000 26 Included w j 6200 10 320 07936 GE00200 07926 GE00100 rh 07741 0010201 079386 GE000QO 6300 35 Aa i r j 12 07936 1560110 079358 1680120 eluded with 07741 0010201 07936 166000 07936 KC 10000 included with 077410010201 079a8 KC10500 a 77 nee 6202 18 35 07 36 KC10200 o7936 KC 10100 yates 630 42 az IMo including ywaight 6003 35 5203 17 40 0928 3710300 cluded with 07936 3710100 j 07741 0010201 oo 6303 a7 remover 6004 42 i o T 6704 20 47 o79a8 3710600 Ncluded with 07936 3710100 07741 0010201 07928 3710001 6304 52 remover 6005 47 aA cad 7 a co ko 6205 25 52 07936 4250100 SERE WI 073936 3710100 07741 001020 6305 62 remover 6008 if 55 Included TR ere ae 6206 30 62 07936 Ssag0200 07936 3710100 07741 0010201 o7936 sag0101 l 6306 i 72 remover 6007 in 6207 25 07936 3710400 ntluded with 07936 3710100 07741 0010201 6307 remover 1 Date of Issue Sep 1988 1 E 6 HONDA MOTOR CQ LTD GENERAL INFORMATION Tool Compatibility Chart POTTING POINT OUTER RACE NKEA DACE i AKER INKER P anra ATTACH ATTACH AT ACHIVENT PLOT CHIw 2 saree ATT ORIVER WENT H MENT paid TIOL NAME
85. injury 19 10 SPRING COMPRESSOR ATTACHMENT SPRING C gt STOPPER RING LOCK NUT SHOCK ABSORBER COMPRESSOR LOWER JOINT Date of tssue Sep 1988 HONDA MOTOR CO LTD RN Refer to the Model Specific manual for each mode for swing REAR SUSPENSION SWINGARM arm ramoval disassembly reassembly and installation CHAIN SLIDER INSPECTION GREASE FITTING Remove the chain slider chair uide and brake torque rod if installed If the motorcycle is a shaft drive type remove the rubbar boot Check the removed parts for waar or damage and replace if necessary Check tha center collar distance collar if installed far wear scoring or scratches and replace if nacessary PRO LINK SUSPENSION LINKAGE SHOCK ARM LOWER MOUNTING BOLT NOTE Mark on the suspension linkage befora disassembly The cushion arm and connecting rad aften have specific in stallatian directions and they shauld be installed propar ly They may interfera with the frame and or change the vehicle height unless installad properly PINCH BOLT REMOVAL CUSHION ROD Remove the following Rear wheel MOUNTING BOLT Bolts from the frama side of the connecting rod Rear shock absorber lower mounting bolts Bolts from the swingarm side of the shock arm SHOCK ARM INSPECTION Check the shock arm and connecting rod tor deformation cracks or other damage and replace as necessary CUSHION AOD
86. level Placa a rag over painted plastic or rubber parts whenever the system is serviced CAUTION gt Brake fluid will damage painted plastic ar rubber parts Refill with the racammended fluid Mixing incompatible fluids can impair braking afficiency j Foreign materials can clog the system causing a reduc Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 27 MAINTENANCE a a ra a o 0y RESERVOIR COVER When the fluid level is low i e near the LOWER level inscribed on the reservoir remove the raservoir cover and diaphragm and rafill to the UPPER level Check the braka pads for wear when refilling with brake fluid A low fluid lavel may ba due to wear of the brake pads If the pads ara worn the caliper piston is pushed out and this ac Counts for a low reservoir lavet If the brake pads are not worn and the fluid level is law check far leakage Awanuns il A leak in the brake system can lead to seduced braking efficiency and possible loss of braking ability Tha racommanded braka fluid differs according to models Cartain madaig take DOT 4 and others take aither DOT 3 or DOT 4 Do not use DOT 3 standard brake fluid in a model dasignated for DOT 4 brake failure may result F y e NS BRAKE SHOE WEAR if the wear indicator arrow aligns with the A mark on the brake panel when the braka is applied ramove the wheal and brake panel and check f
87. lighting coil is not stable the charging of battery will be unstable To prevent this from happening when the headlight are off the output from the charging coil is connected to a resistor equivalent to the im pedanca of the headlights It is clear from above that if the lighting output lines are broken or shorted or if the switch has contact problams the charging system is adversely affected Date of Issue Sep 1988 HONDA MOTOR CO LTD BATTERIES CHARGING LIGHTING SYSTEM LIGHTING CHARGING COIL VOLTAGE CUT OFF ee REGULATOR jREecTiFier REGULATED VOLTAGE 22 15 BATTERIES CHARGING LIGHTING SYSTEM Battery This method is similar ro the method mentioned previously ax cept that the voltage regulation is done after the signal is con verted to DC at the input of tha battery Since this method regulates output voitage of alternator aftar it is rectified its charging is precisely controlled In orders to regulate the current going to the headlight thare is sometimes a resistor connected to the ground wire of the reguiator rectifier through a switch Since the charging coil powers the headlights as well the headlight flickers and dims when the output of tha charging coil is shorted to ground through the SCR This happens because when the ground wire of the regulatar rectifier is connected ta ground tha rasistance AB becomes less than AC thus less current ts diverted to tha headlight In order ta
88. los of consciousness and may lead to death CAUTION Run the engina at the lowest necessary rpm javel to avoid possible engine damage if oii flow ts restricted Stop the engine and again bleed air from the oil inlet line and oil pump if oil dogs not flaw out within one minute Then recheck oil flow Connect the oil outlet line to the intake pipe joint Date af Issue Sep 1988 4 1 1 HONDA MOTOR CO LTD Bs LUBRICATION OIL COOLER INSPECTION FIN Check the oil line connections for leaks Check the oii coalar for bent or collapsed fins Straightan the bant or collapsed fins with a suitable small biade type screw driver if necessary Chack the air passages for clagging or restriction Blow dirt out from betwaen core fins with compressed air or wash off dirt with water a le dE i 4 1 2 Dats of Issue Sep 1988 HONDA MOTOR CO LTD 9 COOLING SYSTEM SERVICE INFORMATION 5 1 SYSTEM TESTING 5 7 TROUBLESHOOTING 5 1 THERMOSTAT 5 8 SYSTEM DESCRIPTIONS 5 2 WATER PUMP 5 8 COOLANT SERVICE INFORMATION Sm i Wait until the ngina is coal bafore slowly ramoving the radiator cap Removing the cap while the angina is hot and the coolant is under prassura may cause seriaus scalding i Radiator coolant Is toxic Keep it sway from eyes mouth skin and clothes If any coolant gets in your ayas rings them with water and consult a dactor lmmediataly If any coolant is swal
89. made so thin in order to reduce unsprung weight before thermal distortion of the disc becamas a problem As the temperature of the brake dise rises the disc expands Because the dise is bolted to the wheel its expansion is limited and soma dagraa of distortion occurs The VTR250 with its in board front disc uses a plain cast iron disc since rust is not a problem The design of the GL1500 front brake with its covered discs and calipers transfers much of its heat to the cast hollow wheel Date of Issue Sep 1988 HONDA MOTOR CO LTD OPPOSITE PISTON CALIPER SINGLE PUSH CALIPER YOKE SLIDE PIN CALIPER PISTON PAD EFFECTIVE DISC DIAMETER BRAKE DISC DUAL PISTON CALIPER SINGLE PISTON CALIPER DUAL PISTON CALIPER 17 5 BRAKES To cope with tha axtrame heat typically generated in competi tion road racing floating type discs have been developed In this system a floating disc is installed by means of spring washers and rivats or clevis pins with an aluminum carrier be tween the disc and the wheel In this manner deviations in radial directions ar permitted distortion is prevented and weight is raduced in addition to the design basics already stated discs are com manly drilled or grooved to remove dust or dit from the disc surface tharaby preventing what are known as sympathatic vibrations Contrary to popular beliefs holes drilled in the disc da not significantly
90. motorcycle is secure before proceeding In case the motorcycle scooter or ATV is equipped with tubeless tires valves and wheel rims use only tires marked TUBELESS and tubeless valves on rima markad TUBELESS TIRE APPLICABLE Never mount tiras designed far use on automobiles Any attempt to mount passenger car tires on a motorcycle tim may causa the tire bead ta separate fram the Hm with enough expiosive force to cause serious injury or death TROUBLESHOOTING Hard steering From wheel wobbling Steering head bearing adjustment nut too tight Bent rim Faulty steering head bearings Worn front wheel bearings Damaged steering head baarings Faulty tire Insufficient tire pressure Faulty tire Steers to ane side or does not track straight Wheel turns hard Unevenly adjusted right and left shock absorbers Misadjusted brake Bent fork Faulty wheel bearing Bent front axte wheel installed incorrectly Faulty speedometer gear Faulty stearing head bearing Bant frame Worn wheel bearing Worn swing arm pivot These items are addressed in this section All other items are addressed in the Front or Rear Suspension or Brake Section hh ee Date of Issue Sep 1988 HONDA MOTOR CO LTO 1 6 1 WHEELS TIRES WHEEL REMOVAL INSTALLATION FRONT WHEEL Greasa on tha brake linings wili reduce stopping power Xeep grease off the brake linings Wipe excess gre
91. mounts Slip the mounts into position Tighten the upper and lower mounts to the specifiad torque On Pro Link ar Pro Arm systems refer to the Model Specific manual far shock absorber remoyal installation procedures DISASSEMBLY Certain types of dampar units are filled with high prassure nitrogen gas Do not disassemble gas damper units Ba sure to release tha gas from the damper unit before discarding it Te prevent loss of tansion do nat compress the spring more than necessary to remove it Remove the shock absorber Compress the spring and ramave the damper unit Shock Absorber Comprassor Use Install the shock absorber compressor on the rear shock absorber Certain types of shock absorber compressors require adapters when the attachment is instatted while others do not Refer to tha Model Specific manual for the typa af compressor Install tha shock absorber compressor holder securely onto the coil spring end that is near tha lock nut of stopper ring Turn the compressor handle and slowly compress tha spring Hydraulic Preas Usa stall the spring compressor attachment and compress the Spring with the hydraulic press Alway use a specified teol to compress the spring Refer to Model Specific manual Use of a hydraulic prass ta compress tha pring can jead ta the spring or shock absorber flying out of the press and causing a serious injury Certain types of shock absorbers are mounted with a st
92. moves smoothly without play or binding TOP CONE RACE OR INNER RACE FRONT SUSPENSION BOTTOM RACE io STEERING STEM oO 3 OOL STEERING STEM Is toot WRENCH Date of Issue Sep 1988 HONDA MOTOR C LTD FRONT SUSPENSION Reinstall tha top bridge and fork iegs temporarily Tighten the stem nut ta thea specified torque TOP BRIDGE F Retalner Type Ball Bearings ve Apply grease to both the top and bottam bearings ADJUSTMENT NUT Place the lower baaring onta the steering stem with tha re tainer facing downward Insert the steering stem into the steering head and install the upper bearing into the steering head race INNER RACE While holding the steering stem with one hand install the top 2 mor STEERING race and besring adjustment nut onto the stem STEM NUT La Tighten the hearing adjustment nut to 25 Nem 2 5 kg m 18B ft lb Move the steering stem right and left lock to lock several times to saat the bearings Make sure that tho steering stem movas smoothly without a play or binding than loasan the nut Retighten the adjuster nut te 25 N m 2 5 kg m t8 ft lb ADJUSTER NUT dm install a new lock washer by aligning the tabs with the grooves LOCK WASHER in the adjustment nut Screw tha lock nut all the way in with tha your fingers Hold the hearing adjustmant nut and further tighten the lock nut enough tu atign the grooves with the tabs of the lock washer Bend
93. new battery it is likely that the original battery s effactive life span has passed Date of Sep 1988 22 20 HONDA MOTOR CO LTD ra BATTERIES CHARGING LIGHTING SYSTEM ee For the following conditions the problem is most likely related to the charging system Follow the steps in the trouble shooting chart G Charging voltaga fails to increase beyond battery terminal yoltaga and charging current s in the discharging direction SA Both charging voltage and current greatly exceed the stan dard value For conditions other than the ones mentioned above the pro blem is most likely associated with an area other than the charging system conduct the following inspection and follow the traublashooting chart 7 Standard charging valtage current is reached whan the engine rpm exceeds the specified rpm xcessive electric load due to tha use of light bulbs beyond the specified rating Tha caplacement battery is old or underrated D Charging voltage normal but charging current abnormal The replacement battery is old or underrated The battery used was undercharged or overcharged Blown aut ammeter fuse Incorrect connection of ammeter 3 Charging current rormal but charging voltage abnormal Blown out valtmeter fuse Check for faulty fusa by O 2 adjustment REGULATOR RECTIFIER INSPECTION REGULATOR RECTIFIER Service accarding to the troubleshaoting chart Since the regulator rect
94. of the fork sliders loose but do not unscrew them oil will leak out To loosen the fork cap bolts Because the clamping action of the pinch balt s can distort the fork tubes slightly and prevent tha caps from loosening itis sometimes better to reposition the legs in the clamps so that the caps are 2 to 3 inches above the clamps as shown in the first illustration on this page prior te loosening them DISASSEMBLY Remove the following SOCKET BOLT FORK SLIDER Fork boot tif used on the particular modai c Fork cap balt isee note above pring saat Collar Fork Spring Drain the fork oil by pumping the fork up and down several times Hold the fork slider in a vise with soft jaws or a shop towel Remove the socket bolt with a hax wrench NOTE TN se a ee eae rh en EA na a ia DUST SEAL Temporarily instali the fark spring and fork cap bolt to sg loosen the socket bolt ee ite Remove dust seal washer and snap ring iE Te0L SNAP FING PLIERS 07914 3230001 SNAP RING Date of Issue Sep 1988 HONDA MOTOR CO LTD 1 8 5 FRONT SUSPENSION Pull the fork tube out from the fark slider NOTE If the type of fork being disassembled has guide bushing installed ramova tha fork tube as follows Pull the fark tube out until resistance from the slider bushing is felt Then move it in and out tapping the bushing lightly until the fork tube separates from the slidar The slider bushi
95. off any excess fuel to tha outside af the carburetor should the valve and seat became separated due to the intrusion of dirt ar othar foreign matter Starting system To improve starting when the engine is cold and the fuel is not sufficiently gaseous the carburetar is equipped with either a choke or bystarter to enrich the mixture lt Choke system gt A valve is fitted to the air cleaner side of tha carburetor Tha valve is shut down during starting to reduce the mass flaw af air and creste an increase in negative pressure in the main bore The resulting mixture is rich having amp proportionally low volume of air The choke valve is provided with a raliaf mechanism which gn Sures the optimum opening of the valve under conditions of negative pressure above a certain level thus preventing the supply of an over rich mixture to the engine Wes ee a el MAIN JET JET NEEDLE Clip position oo ETB JEF NEEDLE Straight section SLOW JET and AIR SCREW OT S Iauto Full 18 14 152 3 4 Full Closed Open Certain haight OVERFLOW TUBE FLOAT VALVE SPRING VALVE PIN AIR FLOW 8 4 Date of Issue Sep 1988 HONDA MOTOR CO LTD FUEL SYSTEM lt Bystarter system manual gt As the bystartar is opened the bystarter circuit connects with the main bore As a vacuum is created in the main bore on star ting air and fuel drawn from the bystarter air jet and bystarter fuel jet respe
96. on a surface plate using 2 feelar gauge replace if the sarvice limit is amp xceaded NOTE E Warped clutch plates prevent the clutch from disengag ing properly ne FEELER GAUGE Clutch Center Check the clutch center for nicks grooves or abnormal wear from the clutch plates raplace as necessary NOTE A damaged clutch center causes engine nol damaged clutch center causes enging noise k A aM mmm GROOVE CLUTCH CENTER Lifter Push Rod Types E and Cc Check the push tod for trueness or damage repiace if necessary lf there is a steel ball batween the lifter rod and push rod check the ball for waar or damage replace as necessary STEEL BALL Date of issue Sep 1988 1 1 1 6 HONDA MOTOR CO LTD CLUTCH duddar Spring Spring Seat JUDD Types A and B UDDER SPRING Check the judder spring and gpring saat for deformation war page or damage replace as necessary A damaged or warped spring s st will cause the judder spring to be pressed unevenly A damaged judder spring also Causes the waak contact bet ween the discs and plates or uneven diseplate contact SPRING SEAT Mainshaft Types 4 B and C Measure the mainshaft O D at the sliding surface if the clutch outer guide slidas on the mainshaft Replace the mainshaft if the service limit is exceeded MAINSHAFT Clutch Spring Tynes A B and D Measure the clutch spring free langth replace
97. outside Both sides sealed type bearing install the bearing with its stamped size mark toward the outside i 1 6 8 Gate of Issue Sep 1988 a HONDA MOTOR Q LTD WHEELS TIRES BASIC TIRE INFORMATION CAUTION Be careful not to damaga the rim area when using tire mounting tools lt TUBE TIRE gt This type uses an air filled tube within the tire s casing Therefora air in the tire leaks out instantly when a nail or other sharp objacte penetrates tha tire and tuba lt TUBELESS TIRE gt Tubeless tires have a rubber layer inner liner which pravents INNER LINEA air from filtering through glued to the inside This acts in place of a tube It also has a special bead area which together with the specialized rim makes a tuba unnecessary RIM LINE This inner liner is sufficient in thickness and doas not stretch like a tube Even when a nail penetrates the tira the hole does not get any bigger Instead it closes around the nail preven ting air from leaking out TUBELESS TIRE TIRE CODE fInch indication 4 00 H 18 4PR Speed limit code J 100 km h max N 140 kmi h max P 150 km h max Tread width 4 inch Ply No 4 pliy rating ISI 180 km h max H 210 kmh max 210 km h min Speed limit code Rim diameter 18 inch Metric indication Height Width Ratio 170 60 R 18 73H Tread width 170 mm I A limit code Height Tread Ratio
98. over Crankshaft does nat turn due to engine prablems Excessive reduction gear friction Faulty starter pinion engagement Date of issue Sep 1988 HONDA MOTOR CO LTO 24 1 ELECTRIC STARTER STARTER CLUTCH Starter motor wiil not turn Check for a blown out main of sub fuse before servicing For modals with a centrifugal clutch check that the brake light switch is correctly adjusted With the ignition switch ON and engine stop Connect the starter motor terminal to the switch at AUN check for a click sound CHGS battery positive terminal from starter relay switch Because a large amount of currant flaws da noone not use thin wires Starter motor turns Starter motar does not turn Loose or discon Faulty starter motor nected wire or NO CLICK cable Faulty starter relay switch For operation check see page 24 6 Disconnect starter relay switch connector mad check the relay coll ground wire no CONTINUITY Faulty neutral switch oe _ Appropriate model only Faulty clutch switch Manual clutch model anlyt Faulty starter switch Centrifugal clutch model only Loose of poor contact at connector pen circuit in wire harness CONTINUITY Connact the starter relay switch connector Measure the starter relay voltage at the starter NO VOLTAGE Faulty ignition switch relay switch connector Broken starter switch wire Manual clutc
99. piston or cylinder Stickad piston ring in the ring groove NOTE On ths 2 stroke engine inspect the follawing items when compression is low or uneven with signs of lean air fuel mixture Crankcase primary compression too low 2 stroka engines Damaged reed valve Damaged crankshaft saal Damaged crankcase or cylinder base gasket High cylinder compression Excessive carbon build up on pistan or combustion chamber Date of Issue Sep 1988 3 4 HONDA MOTOR COQ LTD ENGINE TESTING KK eeeeeSSeSSSSSeeNOSSsS COMPRESSION TESTING GENERAL A compression test is a quick and easy way to check the general candition of an engine This test should he performed priar to any tune up work especially if the machine did not come in undar its own bower If the engine has a burnt vatve for instance the customer should be notified that the tune up will haye no benefit without the other necessary engine wark A compres sion test should aiso be done if you feel that the motorcycle scooter or ATV facks power especialy during accaleration A compression tast can be inconclusive though if the engine is not campletely stock if the bettery is not in perfect condition in electric start models engine cranking speed may be low or if the test instructions are not fallowed completely In each yf these situations the compression registered will be iawer than the service limit in the Modal Specific service manual When you do g
100. question TROUBLESHOOTING Hard to shift Improper clutch operation Incorrect engine ail weight Incorrect clutch adjustment Bent shift forks Bant fork shaft Bent fork claw Damaged shift drum cam grooves Bent shift spindle Transmission jumps out of gaar Worn gear dogs or slots Bent fork shaft Broken shift drum stopper Worn or bent shift farks Broken shift linkage return spring Date of Issue Sap 1988 HONDA MOTOS CO LTD 1 3 1 14 CRANKCASE CRANKSHAFT SERVICE INFORMATION 14 1 CRANKSHAFT MAIN BEARING 14 3 TROUBLESHOOTING 14 1 CONNECTING ROD BEARINGS 14 8 SYSTEM DESCRIPTIONS 342 CONNECTING ROD 14 10 CRANKSHAFT INSPECTION 14 3 SERVICE INFORMATION Refer ta the Model Specific manual for removal installation of the crankshaft Mark and store the bearing inserts to be sure of their correct locations for raassernbly If the inserts are improperly installed they will black the oil hales causing insufficient lubrication and eventual engine saizure TROUBLESHOOTING Excessiva noise Warn connecting rod big end bearing Bent connecting rod Worn crankshaft main bearing ee eee Date of Issue Sep 1988 HONDA MOTOR C LTD 1 4 1 CRANKCASE CRANKSHAFT SYSTEM DESCRIPTIONS The crankshaft changes the reciprocating action of the piston and connecting red into rotary motion so the energy can he transmitted to the clutch and transmission It ig necessary that the
101. range that is one scale highar than the desired voltage LIGHT BULB value Apply the red probe to the positive end and the black proba ta the nagative end of circuit Fhe diagram on the right shows that tha voltmeter registers the voltage across the light bulb Voltmeters are always connected in parallal not in saries Example 1 First study the circuit diagram If ight bulbs B and do nat work and A is OK the malfunction is between the grounds at B and C and switth A If fight bulb 4 does not wark also the problem is between the grounds at A B and and the ignition switch m 1 With the ignition switch ON and both light bulbs B and C do not wark check voltage at gt 2 If na voltage is maasured at check voltage at 3 in case of fatse connection at connector A If voitage exists at i CONNECTOR A IGNITION SWITCH and not at 40 there is problem in the connection at connec BLACK acres tor A L ql 1 N bes Ra if voltage ragisters at bath 4 and switch A should be oF checked a SWITCH A LIGHT BULB 8 BULB C Date of Sap 1986 21 14 HONDA MOTOR CO LTD ELECTRICAL FUNDAMENTALS 3 1f voltage at T and 2 do not exist check voltage atid and Si in a similar manner Ifthereis no voltage at 3 and 4 check wiring between ig nition switch and battery Hf there is voltage at and 43 check for a broken wire or a short circuit in the wire harness Exchan
102. readjusted as follaws to improve driveability and decrease exhaust emission Warm up the Engine to operating temperature Ten minutes of Stop and go driving is sufficient Turn the pilot screw clockwise to the spacified opening tor turn the air scraw counterclockwise to tha specifiad opening Refer to the Madet Specific manyal for standard nd high altituda setting UPDATE LABEL NOTE amp This adjustment must be made at high altitude to ensura Proper high altitude operation On some models the Standard main jet must be replaced i with an optional smaller high altitude jet VEHICLE EMISSIDA CONTROL INFORMATION UPDATE HONDA MOTOR CL LTD THIS VEHICLE HAS BEEN ADJUSTED 10 Y IMPROVE EMISSION CONTROL PERFORMANCE WHEN GPERATED AT MIGH ALTITUDE ALTITUDE PERFORMANCE ADIUSTMENT INSTRUCTIONS ARE AVAILABLE AT YOUR AUTHORIZED HONDA DEALER Attach a Yehicle Emission Control Information Update Labal in the location spscifiad in the labei position illustration Refer to the Model Specific manual for the specified position NOTE f Do not attach the Jabel to any part that can ba eset removed from the vahicla x Operation at an altitude lower than G00 feet 1 500 m with the carburetors adjusted for high akitudas may Cause the engina to idle roughly and tha engine may stall s E n rs When the vehicle is to be operated continuously below 5 000 feet 1 506 m turn the pilot screw coun
103. rockar arn For the former a shim is provided in the bucket tor valve clearance adjustment The valve clearance is adjustad by replacing the shim The shim is usually provided betwaan the bucket and the cam lobe Soma typas have small shim inserted betwaen the under side of the bucket and the valve stem allowing iess valve ac tuating mechanism waight Some DOHC types are also equipped with rocker arms allowing easier adjustment of valve clearance The DOHC has a further advantage whan combined with the 4 valves per cylinder engine type A larger valve area can be pro vided in the 4 valve type in comparison to that of the 2 valye type anabling a greater intake volume of air fuel mixture and a smoother exhaust Valve weight is also less Consequently reducing the likelihood of valve jump associated with high angine speeds Furtharmore with a 4 valve type the spark plug can be placed at the center of the combustion chamber allawing an gasy flame propagation balance during combustion EXAMPLE OF SOHC 4 VALVE SYSTEM CAMSHAFT ROCKER ARM EXAMPLE OF DOHC WITH VALVE BUCKET TYPE CAMSHAFT SHIM BUCKET VALVE SPRING 9 Date of Issus Sep 1988 4 HONDA MOTOR CO LTD CYLINDER HEAD CAMSHAFT CAMSHAFT INSPECTION Inspect the cam lobes and raplace cams that are worn scored or scratched NOTE Inspect the rocker arm if the cam lobe is warn or damaged Inspect the journal surfaces Replace t
104. seconds after it reaches the end of its travel 3 Repsat tha above steps 1 and 2 until bubblas caase to ap pear in the fluid at tha and of the hose Tighten the bleed valve Be sure that the brake fluid is up to the upper level of the master cylinder and refill tf necessary Reinstall the master cylinder cover BRAKE PAD REPLACEMENT Removal There are two types of the brake pads Typa A pad pin is secured by the retainer plate Type B pad pin is secured by the pad pin plug Type A Loosen the pad pin retainer balt Type B Remove the pad pin plug and loosen the pad pin Rafar ta the Model Specific manual for the caliper re moyal instailatian NOTE aAa Remove the pads without removing tha bracket from the caliper If the pads cannot be removed remove the brackat Push the piston all the way in to allow the installation of new brake pads Type A Remove the pad pin retainer bolt and the pad pin retainer Before ramoving the pads mark them so you can reinstall them in their original pasitions if they are to be reused thereby assuring even disc pressure Always reinstall the brake pads in their original positions to prevent loss of braking afficiancy Type A Pull out the pad pins and ramove the pads Type B Loosen the pad pins and remove the pins and pads NOTE Pad pins can be easily ramovead by pressing the pads in the caliper Install the pad shim if there is ane in the ori
105. shock an compression As the fork nears fuli compression the tapered oil lock piace comes into play to hydraulically prevent the fork fram bottoming On the rebound stroke oi in Chamber A flaws through the orifice in the top of tha fork piston into Chamber C Here the resulting resistance servas as a damping farce and the tandan cy of the spring to rebound quickly is controled The rebound spring absorbs the shock of the fork legs extend ing outward Oil in Chamber C flaws through the orifice in the bottom of the fork piston inte Chamber B at this time 18 4 EXTENSION I Resistance resulting from the passage of oil through the arifice creates a damping torca an the rebound stroke FORK TUBE The wheel encounters FORK PISTON p PISTON RING es REBOUND SPRING FREE VALVE FREE VALVE REBOUND STOPPER COMPRESSION REBOUND STROKE Date of Issue Sep 198f HONDA MOTOR CO LTD RN FRONT SUSPENSION FORK TOP BRIDGE PINCH BOLT REMOVAL Remova the following Handlebar s Front wheal Front fender Front brake aliperis and bracketis Fork brace Loosen the fork pinch bolts LOWER BRIDGE Pull each fork leg out of the fork bridges by twisting while puit PINCH BOLTS ing them down Press the air valve core to release air pressura from the fork SPRING NOTE If the fork legs are to be disassembled Break the socket boits in the bottom
106. skin while disconnecting tha battery breather tubs i INSTALLATION Be sure to route the breather tube properly on conventional hatteries mm Take cara to prevent spilling slectrolyte from the braather tube bacause it can corrode components Taka cara with the breather tube Pay attantlon to the following points Connect the breather tubes securely Follow the caution tabe and route the tube accordingly Avoid banding or squeezing the breather tube Gheck that tha breather tube has not been bent or squeezed by the surrounding components Failure to replace a bent of squeezed breather tube may isad to a pressure buildup that can cause the battery to explode Place the battary into the frame Secure the battery with tha battery holder CAUTION Improper installation may cause vibrations which can damage the battery case To prevent shorting always connect the positive cable first After installing the battery coat the terminals with clean grease to prevent corrosion 22 g Date of Issue Sep 1988 HONDA MOTOR C0 LTD E7 BATTERIES CHARGING LIGHTING SYSTEM BATTERY TESTING CHARGING BEFORE USING THE TESTER Place the tester on a clean flat and leval surface Be sure the work area is well ventilated clear of flammable materiats and free from heat humidity water or dust Always take the battery to the work bench test area con tinually movi
107. spark plug and inspect or replace as described in the Model Specific manual maintanance schedule INSULATOR inspection Check the following and replace if necessary insulator for damaga electrodes for wear burning condition coloration dark to light brown shows good condition axcessive lightness shaws faulty ignition timing or lean mixture REUSING A SPARK PLUG Clean the spark plug electrodes with a wire brush or special plug cleaner SIDE ELECTRODE Check the gap between the center and side electrades with a wire type faslar gauge If the gap is not as specified bend the side electrode to adjust Replace the spark plug in the cylinder haad and hand tighten Torque to specificatian CAUTION Make sure thara is no dirt or debris on the seat of the spark plug hole before inserting the spark plug To prevent damage to the cylinder head hand tightan tha spark plug before using a wrench to tighten to the spacified torque REPLACING A SPARK PLUG In the casa of new spark plugs set the gap with a wite type feele gauge Install and hand tighten then tightan about 1 4 of a turn after the sealing washer contacts the seat of the plug hole Reused plugs should be tightaned to the specified torque Do not overtighten the spark plug CAUTION Overtightening the spark plug may damage the cylinder j haad Ba eure to use the proper spark plug torque 2 g Date af Issue Sep 1988
108. starting will be difficutt 8 1 0 Date of Issue Sep 1988 HONDA MOTOR CO LTD FUEL SYSTEM AUTO BYSTARTER REMOVAL Remove the bystarter cover Remove the screws and set plate Remove the auto bystarter from the carburator body AUTO BYSTARTER SET PLATE BYSTARTER VALVE Manual Loosen the starter valve nut and remave the valve spring and valve Check the valve face for Scores scratches or wear and replace if necessary Check the seat at tha tip of the valve for Stepped wear and replace if necessary If the valve seat is worn or damaged it will not closa the fuel line of the bystarter circuit resuiting in a constantly rich fuel mixture THROTTLE VALVE Piston valve type CAUTION gt Some carburetoricables have a one piece asera cable carburetay top assembly Do not try to remove the throttle cable from the carburetor top Remove the carburetor top and pull the threttla valve out of the carburetor While compressing the spring disconnect the throttle cable from the throttle valve NOTE if the throttle vaive is linked t the cable refer to the Model Specific manual for each model for removal disassembiy steps i es THROTTLE VALVE Date of Issue Sep 1988 HONDA MOTOR cO LTD 8 1 1 FUEL SYSTEM Remove the jat needle retainer and jet needa from the throttle valve Check the jet needle for stepped wear The fuel supply to the mai
109. the cytinder head mating surface Do not Scratch the surface Check the cylindar for warpage by placing a straight edge and a feeler gauge across the stad holes Replace the cylinder if the service limit is exceeded NOTE Any clearance hatween tha cylinder and haad due to damage or warpage will result in compression laaks and reduced performance CYLINDER HEAD SIDE t S WEAR INSPECTION Inspect the cylinder wall for scratches and wear NOTE Inspect the area near T D C Top bend Conai caer 7 area is especially subject to wear due to tha possibility of borderline lubrication from heat and top ring compression a aaa am m Measure and racord the cylinder ID at three levels in both an X and Y axis Take the maximum reading to determine the cylinder wear NOTE Two stroke engines avoid the intake end exhaust ports when measuring a r aaam _ _ _ _ Measure the piston Q D sae paga 10 7 Calculste the piston te cylinder Clearance Take the maximum reading to determine the clearance Calculate the cylinder for taper at threasa jevels in an X and Y axis Take the maximum reading to determine the tapar Calculate the cylinder for out of round at three levels in an X and Y axis Take the maximum reading to determine the put of round if any of the cylinder measurements exceed the service limits and oversized pistons arg available rebore to
110. the CDI unit or ignition coil using the CDI FULL TR testar If there is an anbnormal circuit in tha above inspection check all items first and then check each component individually PULSE GENERATOR INSPECTION Disconnect pulse generator wire from thea wire harness and measure resistence of coil betwaen the two wire terminals If the resistance valua is within the specified range the pulse generator is good If the resistance is far off the specified range replace the pulsa generator NOTE If the resistance valua is slightly off the standard vatue it may not nacessarily have any effect on its function In this case check all of the related componants for trouble in other areas PULSE GENERATOR For removal and replacamant of pulse generator rafer to the Model Specific manual Date af gt Sep 1986 23 14 HONDA MOTOR CO LTD a EXCITER COIL INSPECTION Disconnect the altarnator from the wire harness and measure the exciter coil resistance For engine ground type measure the resistance between the excitar coil output line and body ground For exciter coil with ground wire measura tha resistance be tween the exciter coil output ling and ground wire if the resistance value is within the specified range the excitar coil is good If the resistance value is far off the specified value replace the stator with a new one NOTE If the resistance value is only slightly off the standard value
111. the bottom 1 4 of the old seat for Using a 45 degtee cutter cut the seat to the proper width SEAT WIDTH Date of Issue Sep 1988 HONDA MOTOR Co LTD 9 1 3 CYLINDER HEAD After cutting the seat apply lapping compound ta the valve MOVE THE face and lap the vaive using light pressure VALVE UP AND DOWN WHILE CAUTION ROTATING Excessive lapping pressura may deform or damage the TEH VALVE unaven seat wear Lapping Compound can cause damage H it enters be tween the valve stem and guide seat Change the angla of lapping tooi fraquently to Prevent Aiter lapping wash any residual Compound off the cylinder ROTATE THE VALVE head and valve AND PRESS LIGHTLY NOTE Lapping has no effect on Ong term durability or performance lt only ensures that tha valve and valve seat will Pass a solvent test OUTER RETAINER STS a i i ee ee Recheck the saat contact after lapping CYLINDER HEAD ASSEMBLY Instali new stem seals SPRING SEAT NOTE Raplaca the stem seals with new ones whenever a stem seal is removed m Lubricate each valve stem with molybdenum disutfida grease and insert the valve into the valva guide CAUTION r Turning a valve too fast can damaga the stem seals So Install the spring seats valve Springs and retainers NOTE iw For valve spring with varying pitch install the valve spr
112. the difference in measurements axcaeds the limit it in dicates that the bearing is not installed squarely Inspect the bearings and reinstall if nacessary OUTPUT DRIVEN If backlash is excessive replace the cauntarshaft or output drive shaft adjustment shim with a thinner one lf the backlash is too small replace the countershaft or output drive shaft shim with a thicker one Geart tooth contact pattern chack Remove tha countarshaft or output drive shaft from the side gaar case Apply Prussian Blue to tha output drive gear teeth install the countershaft or output drive shaft and the shim Rotate the drive shaft several times in the normal direction of rotation Remove the shaft and check the gear tooth contact pattern NORMAL OUTPUT ORIVEN Y SHAFT AE Contact is normal if Prussian Blue is transfered to the approx imate center of each tooth and slightly to the side If the pattern is not correct remove the output driven shaft and replace the shaft adjustinent shim SHIMS DAIV SIDE CONTACT TOD HIGH Replace the shim with a thinner one if the contact pattern is too high DRIVE SIDE p a COUNTERSHAFT OR OUTPUT COUNTERSHAFT OR OUTPUT DRIVE SHAFT COAST SIDE COAST SIDE 15 4 Date of Issue Sep 1988 HONDA MOTOR CO LTD rms FINAL DRIVE OUTPUT SHAFT Replace the output shaft adjustment shim with a thicket one if CONTACT TOO LOW tha contact is too law
113. the lock is securely fastened Make sure that the harnasses are secured to the motorcycle properly GOOO CLICK O a fy E Befora connecting connectors check that the pins are Straight and that all the wire terminals ara intact and tight Milf a tarminal is Gorroded clean it thoroughly before cannacting NO GOOD x lt NO GOOD Date of Issue Sep 1988 2 1 2 HONDA MOTOR CO LFD ELECTRICAL FUNDAMENTALS E Check for torn protectiva cavers and oversized loose fit ting female terminals before installation GOOD NO GOOD E Replace damaged wires with naw ones 600D NO GOOD When installing a connector push it until it clicks inte place E Check that connector protectors cover the terminals completely E Connectors with protectors facing up must have a drain hole GD D DRAIN HOLE M Secure wires and wire harnesses to the frame with wire bands at the designated locations Install the bands a that only the insulated surfaces contact the wires or wire harnessas GOOD NO GOOD NO GOOD O X X ok e Do not squeezs a wire against a weld or the nd af its clamps Good NO Goon O x Ow Aa Check that harnesses cannot come in contact with hat parts after clamping NO GOOD E Protact wires and harnesses with at least two layars of electrical tape or with electrical harness tubes if thay con tact 6 sharp edge or corner D ate of Issue Se
114. the lock washer tabs up into the groove af the lock nut Bend the tab Date af Sep 1988 18 20 HONDA MOTOR CO LTD FRONT SUSPENSION Install the top bridge and temporarily install the fork legs Tighten the stem nut to the specified torqua Check the steering head bearing preload Ipage 18 22 Reinstall tha removed parts Tapered Reiler Bearing Typa Apply graase to the top and bottom bearings Install the bottom bearing anto the steering stem with the re tainer toward the bottom Insert the staering stem into the steering bead then install tha top bearing and dust seal if a seal is used on the particular modeli Install bearing adjustment nut while holding the steering stem Tighten tha adjustment nut to 11 N m 1 1 kg m 8 ft lb Move the steering stem right and left lock to lock several times to seat the bearings Make sure that the steering stern moves smoothly without play or binding Retighten the adjustmant nut to 14 Nem 1 t kg m amp ft lb TOP BRIDGE TOP BEARING STEERING STEM BEARING ADJUSTMENT NUT STEM NUT 5 Toa WRENCH w Date of Issue Sep 1988 HONDA MOTOR C LTD FRONT SUSPENSION Install the tap bridge and temporarily install the fark legs Tighten the steering stem nut to the specified torque Check the steering head bearing preload Reinstall the remaining ramoved parts T P BRIDGE e an STEERING HEAD BEARING PRELO
115. the piston merely flows to tha upper side of the piston At the same time some oil is also allowed to flow out of the bottom valva The quantity of oil that flows out of the cylinder bottom valve is equivalent to tha amount drawn into the top The combinad resistance to flaw through each of these valves is tha campression damping COMPRESSION STROKE OIL ORIFICE REBOUND STROKE COMPRESSION STROKE OUTER CYLINDER QIL SEAL LOCK GUIDE PISTON VALVE CYLINDER Resistance which results from the passage of ail through the orifice raduces the compression forca When the whaal encounters a projection Date of Issue Sep 1988 HONDA MOTOR CO LTD FRONT SUSPENSION The rebound stroke is illustrated in this drawing Qnce the whael has overcome the bump the spring forces the damper tod to force the piston back through tha damper Here ail fiows with little resistance into the cylinder but thare is con siderable resistance caused by damping valve in the piston Telescopic Fork The telescopic fark serves as a skeletal member of the vehicle framework a means for turning the vehicle and as the front suspension When the fork sfidars move telescopically on the compression stroke oil in Chamber B flaws through the orifice In the fark tube into Chamber C while tha oil in Chambar B pushes past the free valve and up into Chamber A The resistanca in this oil flow absorbs
116. to a sudden loss of air pressure while riding and an accident could occur White holding the breaker arm assembly at an approximate 45 position insert the blade of the breaker arm between the tire and rim Push the breaker arm inward and downward until it is in the horizontal position with its press block in contact with tha rim THREADED SHAFT SS a hy yp SSS yyy Date of Sep 1988 16 18 HONDA MOTOR CO LTD WHEELS TIRES With the breaker arm in the horizontal position place the braaker press head assembly over the breaker arm press block Make sura the press head bolt is backed out alf the way and then pasition the nylon buttons on the press head against the inside edge of the rim Insert the threaded shaft through the appropriate hole in tha breaker press head assembly and then tighten the lever nut un tit bath ends of the breaker press head assembly are in firm contact with the rim Tighten the press haad bolt until the refarence mark on tha press black is alignad with the tap edge of the prass head 1f the rest of the bead cannot be pushed down into the center of the rim by hand joosen the press head bolt and the lever nut Rotate the breaker arm assembly and breaker press head assembly 1 6 to 1 4 of the circumferance of the rim Tighten the lever nut and then tighten the press head bolt as dascribed Repeat this procedure as necessary until the remainder of the bead can be pushed down into the center of th
117. to synchronize the vacuum in gach carburetor s intake port whenever 2 or more carburetors are reassemblad Synchronize the carburators with the engine at normal opsrating temperature the transmission in neutral and li the motorcycle on its center stand Carburetor numbers match the cylinder number Remove the plugs from gach cylinder head port and install the vacuum gauge adapters lf tha motorcycle is equipped with the fue auto valve discon nect the vacuum tube from the intake manifold of the car buretor draw vacuum and pinch the tube with a clip as shown Connect the vacuum gauge Vacuum Gauge 07404 0030000 for both two and four carburetor engines 07404 0020000 for dual carburetor engines 1 Adjust the idle rpm ta the specified idle speed Rater to tha Model Specific manual for the specification 2 Turn the synchronization adjusting screw so that the dif ference between the vacuum in the base carburetor s in take port and the vacuum in the other carburetor s intake port is below the specification Alafer to the Modal Specific manual for base carburetor iacation of gach synchroniza tion adjusting scraw and difference in vacuum betwaen the carburetors 3 Be sura that the synchronization fs stable by snapping the throttle grip several times 4 Repeat steps 1 through 4 for each carburetor 5 Snap the throttle grip several times and recheck the idle Speed and differences in vacuum betwee
118. transmission is at neutcal or reverse position SPARK PLUG If the plug firas the spark plug is goog Nota that the plug is more difficult to fire in danse air than in normal atmospheric conditions Thus evan though spark occurs under normal atmaspheric conditions it may not occur in the compressed cylinder environment For this reason you should check that the secondary coil has sufficient voltaga by following the procedure that follows Attach a spark plug adaptor Ground the black wire to the engine and conduct the spark plug test Hf there is a spark across tha gap in the adaptor the ignition coil is good SPARK ADAPTOR 07GGK 0010100 Except USA If Spark occurs across the spark plug gap but no spark occurs with the adaptar on the secondary coil voltage is insufficient Date af Issue Sep 1988 23 1 0 HONDA MOTOR CO LTD rs me IGNITION SYSTEMS IGNITION TIMING Warm up tha engine Connect timing light to the spark plug wire For models with no tachometer connect an engine tachometer NOTE Read the instructions for timing light and angine tachometer before oparating Remove the timing hole cap from the engine Refer to the Modei Specific manual for position of cap Start the angine and check if the following results are obtained if the F mark on the rotor is aligned with the index mark on the case at the correct idling speed then the timing is corract incr
119. travel the distance between the driva and driven sprocket canters varies Therefore it is important to adjust the chain so that it has at jeast the minimum amount of acceptable slack when the Sprockets ar farthest apart or whan the center of the drive sprocket swingarm pivot bolt and the rear axle are in align ment Tha Modei Spscific manual provides a proper dimension for each model based on this minimum slack and maximum distance position but it is measured in a much more conve nient suspension position DEPENDING ON MODEL l LOCK NUT INDEX MARK ADJUSTER BOLT LOCK NUT ADJUSTER NUT LOCK NUT ADJUSTER re tres Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 21 MAINTENANCE After adjustment retighten the axla nut to the specified torque NOTE Pulling the lower chain row firmly up toward the swing arm when tightening the axla nut helps ensure that the adjusters on beth sides are seated against their stops and that the axle is in proper alignment Always check to be sure both sides are adjusted to the sama marks on the l adjustment scales Re check the chain play eS e Tightan the adjusters and lock nuts Adjust the rear brake pedal play This step can be omitted in the case of disc brakes Adjust the rear brake light switch actuation point fon cable Operatad rear drum brake models lf after adjustment the
120. vehicle after such device or element of design has been ramaved or rendered inapsrative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW 1 Removal of or puncturing the muffler bafflas header pipes ar any other component which conducts exhaust gases 2 Removal of or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving parts of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manufacturer yyy yyy 7 4 Date of tssue Sep 1988 HONDA MOTOR CO LTO SYSTEM INSPECTIONS EVAPORATIVE EMISSION CONTROL SYSTEM California model only Check the system hasas for deterioratian clogging damage and loose joints and connactions Replace any hose that shows signs of damage or deterioration Check the canister for cracks or damage PURGE CONTROL VALVE PCV NOTE o The purge control valve should be inspected if hot restart is difficult Disconnect the PCV hoses from their connections and remave the PCY from its mount Refer to the vacuum hase routing diagram label for hose connections Connect a vacuum pump to the hase that goes to the vacuum tuba Fitting Apply the specified vacuum to tha PCY TNL VACUUM PUMP ST AH 260 MC U S A only SPECIFIED VACUUM 250 mm 9 8 in Hg The specified vacuum should be maintained Replace the PCY if vacuum is not maintained Re
121. voltage Battery voltage Faulty fuel level sensor Poor connection of the connector 2 Chack for battery valtage between the battery side of the wire from the indicator light and ground No battery voltaga Battery voltage Faulty sub fuse Blown bulb Faulty ignition switch Broken wire between the Poor connection of tha warning light and sansar fuse holder connector Faulty ground FUEL PUMP DESCRIPTION Certain models ars squipped with a low pressure electro magnetic fuel pump to send the tuel to the carburetor When the angine is starred the switch is turned on by tha function of the fuel cut off ralay refer to the description of tual cut off relay which generates the electromagnetic force at the coil and moves the plunger and diaphragm up The valve A is then opened by the vacuum and the fuel flaws to the diaphragrn chamber The plunger pushes the switch up and turns it off As the electromagnatic force at the coil goes out this time the plunger and diaphragm are returned by the spring and the fual in the diaphragm chamber is sant te the carburator through the valve B Certain types of this fuel pump have tha fuel cut off relay built in LIGHTS METERS SWITCHES IGNITION MAIN FUSE SWITCH FUSE SPRING Date of Issue Sep 1988 HONDA MOTOR CO LTD 25 9 LIGHTS METERS SWITCHES with ignition switch ON FUEL CUT OFF RELAY With the ignition switch ON current flows to t
122. 7 Na spark at one plug Trouble in secondary coil side lt Multi cyjinder transistorized ignition system gt For models with independent coils for each cylinder the Problem is suspactad on the primary coil side Rafer to the above flow chart No spark at either ignition group For doubie ignition coil fone coil igniting two spark plugs faulty spark plug is most likely Replace suspected bad sperk plugs with known good spark plugs conduct spark plug SPARK Original spark plug no good test NO SPARK Put the spark plug cap on and measure rasistance of ignition secondary coil see page 23 12 7 i s NORMAL Conduct Spark test an good ignition cail l SPARK OUT OF STANDARD VALUE Remove the spark plug cap or spark plug wire OUT OF and measure the resistance af the ignition STANDARD Faulty ignition coit sacondary coil VALUE NORMAL Poor contact of spark plug wire Faulty spark plug wire or faulty spark plug cap Date of Issue Sep 1988 HONDA MOTOR CO LTD 23 3 IGNITION SYSTEMS SYSTEM DESCRIPTIONS Mast motorcycles use electrically controlled ignition systems Fhese ignition systems can be divided into two types depen ding on how they operate Namaly thare is the COI and the transistorized type Althaugh their function is the same the way they operate is differert In order to service these systems one neads ta undarstand their basic operation Since both contr
123. 8 TROUBLESHOOTING 24 1 STARTER CLUTCH INSPECTION 24 8 STARTER MOTOR 24 3 STARTER PINION INSPECTION 24 9 STARTER RELAY SWITCH 24 6 SERVICE INFORMATION Always turn tha Ignition switch OFF before servicing tha starter motor The motor could suddenly start causing serious injury a 5 ee ee S OO Refer to tha Modai Specific manual for ramoval and installation of the starter motor A weak battery may be unabla to turn the starter moter quickly anough or supply adequate ignition current if the currant is kept flowing through the starter motor to turn it while the engine will not be cranking the sterter mator may ba damaged For models with a centrifugal clutch incorrect adjustment of tha brake light switch could prevent the starter motor from operating TROUBLESHOOTING Starter motor turns slowly Low specific gravity in battery or Dead battery Poorly connected battery terminal cable Poorly connected starter mator cable Faulty starter motor Poorly connected battery ground cable Starter motor turns but engine doas not turn Starter motor is running backwards Brushes assamblad improperly Case assembled improperly Terminals connected improperly Faulty starter clutch Damaged or faulty starter pinion Damaged idler gear or reduction gear Broken starter motor drive chain Faulty starter clutch Starter motor relay clicks but engine does not turn E
124. 988 HONDA MOTOR CAO LTD r rem IGNITION SYSTEMS SECONDARY COIL WITHOUT PLUG CAPI Measure resistanca between the primary coil terminal and Spark plug wire Far double ignition coil measure the rasistance betwean the Spark plug wires If the resistance value is within the specified range the coil is good PERFORMANCE TEST EXCEPT U S A FULL TR CDI TESTER SPARK ADAPTOR Test the spark performance of the ignition coil using the Full O7GGK 0010100 transistor CDI tester Replace the coil if no spark occurs inside the spark adaptor Read the instructions for the tester carefully and conduct tha IGNITION tests correctly The type of inspaction adaptor used differs from model tu model Refer to the Model Specific manual for information on the type of adaptor requried CAUTION CDI UNIT Fran INSPECTION kon Aoh a sated ADAPTOR The CDI unit or tester could be damaged if they were connectad incorractly Refer to the Mogel Specific manual for the connections af in spection adaptor 07508 0010400 whose wires are con nected to the unit ona by one CDI SYSTEM CIRCUIT INSPECTION NOTE For diagnosing the ignition system follow the steps in the troubleshooting flow chart CDI UNIT Refer to the Mods Specific manual for service data wir CONNECTORS ing diagrams and wire colors WIRE HARKESS SIGE Discannact the connector fram the CDI unit and diagnose the ignition relate
125. AD MEASUREMENT Steering head bearings applicable to on road models over 125 cc that are too laose or too tight may cause handling problems After the steering stem and bearings have been raassembled make sure that the steering head bearings are installed correctly by measuring the preload An average measurement is given hare refer to tha Made Specific manual for the correct preload specification PRELOAD kg m in lb M t R d l e Sa S easurement a yi on Spring scale DISTANCE batween stem and fork tube centers icem in Examplo Distance 7 5 om 3 0 in Preload 15 kg cm 13 0 in b DISTANEE Measurement should ba 2 0 kg 4 3 Ib in the spring scale STEERING FRONT ies STEM FORK Date of Issue Sap 1988 1 8 22 HONDA MOTOR cQ LTD FRONT SUSPENSION MEASUREMENT Place a jack or stand under the engine and raise the front wheel off the ground Set the steering stem in the straight ahead position Hook the spring scale to the fork tube betwaan the top and bottom bridges Pull the spring scale keeping the scala at a right angle to the steering stern STEERING Read tha scale at the point where the steering Stem just starts STEM to move Compare this with the specification in the Model Specific manual Adjust as necessary FORK TUBE SS yy heyy Pate of Issue Sep 1989 HONDA MOTOR COQ LFD 1 8 2 3 cs tae ee a ee 19 REAR SUSPENSION SERVICE INFORMATION 19 1
126. AING SPRING l ye A i 1 Wy W FREE LENGTH oo DAMPER UNIT G BUMP AUBSER 19 8 Date of Issue Sep 1998 HONDA MOTOR CO LTD REAR SUSPENSION Compression Farca Gas Filled Damper Only 1 amp Examine the damper rod and replace the damper unit if it is bent of scored Mark the damper rad at the st spacified compressed stroke lie 10 mm O 4 in expose irom the damper body Place the dampe rod on a scale and measure the farce ra quired to compress the damper until the mark is flush with the damper body Refer to tha Model Specific manual for the compression force and the specified comprassed stroka If the force required is less then service limit gas is leaking Chack the upper joint and collar for waar or damage and replace if nacessary Check the rubber bushing for wear or damage and replace if necessary NOTE Apply specified grease to the sliding surfaces of tha col dar and bushing and reinstall them i If a needle roller and spherical bearing are installed in stead of the bushing and collar rafer to the Mode Specific manual for their replacement AA COLLAR SHOCK ABSORBER DISPOSAL PROCEDURE Center punch the damper case to mark the drilling point Refer ta the Model Specific manual for the precise drilling paint THE DRILLING POINT iNDICATED BELOW IS EXAMPLE ONLY REFER TO THE MODEL SPECIFIC MANUAL FOR PRECISE DRILLING POINT Wrap the damper un
127. AM LOBE FEELER arm and the cam in the case of valve lifters in direct push type enginas the clearances between the cam lobe and lifter or shim is measured with a feeler gauge ADJUSTING SHIM If adjustment is needad loosen the lock nut and the adjusting screw and insert tha proper dimension feeler gauge Proper in take and exhaust valve clearance dimensions are given in the Madel Specific manual Turn the adjusting scraw and adjust the clearance until the in ADJUSTING SCREW sartad feeler gauge can only be pulled out with a little LOCK NUTS difficulty T Leaving the feeler gauge inserted and being careful not to turn the adjusting screw tighten the lock nut ta the designated torque 5 fu CAUTION aerate te WRENCH An improperly tightened lack nut may loasen and cause engine damage Be sura to use any special tools specified for valve adjustment 2 1 0 Date of Issue Sep 1988 HONDA MOTOR CO LTD MAINTENANCE When the lock nut is tightened the clearanca may changa So lt DIRECT PUSH TY PE gt be sure to racheck the clearance after tightening the lacknut Adjustmant is properly carried out only when the feefar gauge can be pulled out with a littte difficulty lf tension aon feeler gauge is too great or too little readjust in the Case of vaive lifters in direct push type engines change the shim and adjust the valve clearance Refer to the Model Spacific manual for the Appropriate a
128. Be sure to install the dust cover aftar replacing the bulb A continuity tast can be made with the switches installad on the motorcyctis Check the battery condition before parforming any inspaction that requires proper battery voltage There are two types of lighting systems AC lighting that takes powar from the alternator coil and DC lighting that takes power from the battery On DC lighting systems the headlight comes an without starting the engine On AC lighting systems the headlight comes on when the engine is running Refer to section 21 Date of Issue Sep 1988 HONDA MOTOR CO LTD 25 1 LIGHTS METERS SWITCHES OIL PRESSURE WARNING LIGHT 4 stroke engine THEGRY IGNITION MAIN FUSE SWITCH FUSE TEP a o o q nT BI Br Whan the oil pressure is below the specifications the ail pressure switch senses it and the ail pressure warning light comes on It should be OFF while the engine is running INSPECTION WARNING ti LIGHT OIL PRESSURE SWITCH Qil pressure warning light does nat come on with the igni tion switch turned ON 1 Disconnect the oil pressure switch wira and turn the igni tion switch ON Check for battery voltage between tha wira and ground No voltaga Voltage Oil pressure switch fauity 2 Chack for the voltage between the black brawn terminal of the instruments and ground No voltage Voltage Ignition switch faulty Broken wire between tha
129. CARBON TYPE FLOATING PISTON amp a RESERVE TANK TYPE GAS CHAMBER RESERVE TANK 19 4 Date of Issua Sep 1988 HONDA MOTOR CO LTD REAR SUSPENSION Rear Damper Springs A variaty of spring designs are used on motorcycles and scooters Amang these types are straight wound progressive wound wide pitch and narrow pitch and even tapered spring wite types Each provides different comprassive force characteristics i STRAIGHT WOUND PROGRESSIVE WOUND NOTE Unsprung weight is reducad slightly when the widely pit chad or spaced spring coils are positioned toward the swingarm One maans of achieving a progressive overall Spring rate is to allaw the spring rates of two or three different springs to tossover or combine thait individual qualities by simply Stacking the springs atop one another This method is known s a combination type spring arrangement Anather variation towards achieving a progressive Spring ac tian is to add an air assist bladder to the Spring damper unit On these types air pressure is added up to a specified amount to compensate for increased load requirements rather than ad justing the pretoad on the spring The right shock on GL1500s is actually only an air spring It has no dampening properties aside fram a very slight seal friction and is filled with only a vary small amount of oil to lubricate its shaft and oil seal Spring Praload Adjuster Designs
130. CH Chack the cammutator far Damage or abnormal waar Replace with a new one Giscoloratian of the commutator bar Replace with a new ane Metallic debris between commutator bars Clean it off Check for continuity between pairs of commutator bars Make a continuity check between individua commutator bars and the armature shaft There should be no continuity Check the bearings For applicable models only Do not rotata smoathly Replace with a new ane Loose bearing Replace with a new ane ASSEMBLY Align tha case notch with the brush holder pin and install the case Place the O ring seal ring on the case For applicabla models only COMMUTATOR BEARING 24 4 ati CAUTION Overtightening tha cable terminal nuts may cause the Carefully insert the brushes inta the brush haldar CAUTION The sliding surfaces of the brushas can ba damaged if they are not instailad properly Apply grease to both ends of the armature shaft Push and hold the brush inside the brush halder and insert the armature through the brush holder When inserting the armature into the case hold the armature tightly to keep tha magnet from pulling the armature gainst the case CAUTION The coil may be damaged if the magnat pulls the ar matura aguinst tha casa Insert the shims in tha correct ordar to the armature shaft For applicable modals only Insert the O ring Fo
131. CH Judder Spring Purpose When the clutch lever is released to 6ngags the clutch tha clutch discs and platas sometimes engage intermittently caus ing judder or vibration to some degree To lessen this symptom some models ara equipped with a jud der spring The clutch discs and plates ars pressed by the judder spring tension and each disc and plate engages smoothly A judder spring is not installad on motorcycles on which the judder is not bothersome SPRING SEAT JUDDER SPRING Damper Spring Purpose When the engine is running the combustion pressura that the DAMPER SPRING piston receives is applied to the crankshaft intermittently and the ciutch outer primary driven gesr receives the striking force from every gistan stroke Due to the puising nature of the power input a damper spring is installed between the clutch outer and primary driven gaar closa ta the crankshaft The damper springs absorb the impact of the power pulses o they ara not transmitted through the rast of the drive Jina The drive train is thus protected from unnecessary damages and overall vibration is reduced TYPE B INNER PUSH TYPE The clutch lifter machanism of this type is aquipped on tha opposite side of tha clutch and is diffarent from the type A The push rad is installed through the mainshaft and presses the clutch pressure plate located outside af tha clutch outward ta disengage the clutch All but the above characteristic are the sa
132. CLEANER REED VALVE Date of Issue Sep 1988 7 3 HONDA MOTOR CO LTD EMISSION CONTROL SYSTEMS EVAPORATIVE EMISSION CONTROL SYSTEM California model only All Honda motorcycles and scooters sold in California for street use comply with the California Air Resources Board re quirements for evaporative emission regulations Fuel vapor from the fuel tank and carburetors is routed into the charcoal Canister where it is abso bed and stored while the engine is stopped When the engine is running and the purge control diaphragm valve is open fuel vapor in the charcoal canister is drawn into the engine through the carburetor At the same time tha air vent control valva is open and air is drawn into the carburetor through the valve CARBURETORS PURGE CONTROL JE t DAAIN CHARCOAL F CANISTER AIR VENT L _ CONTROL VALVE AIR VENT CONTROL i y i VALVE IAT ENGINE STOP TO OPEN gt AIR lt FRESH AIR FUEL VAPOR NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED Federal law prohibits the follawing acts or the causing thereof 1 Tha ramoval or rendering inoperative by any person other than for purposes of maintenanca repai or raplace ment of any devica or element of design incorporated into any new vehicle for the purpose of naise control prior to its sale or delivery to the ultimate purchaser or while it is in use ar 2 the use of the
133. CO LTD Install the clutch damper springs Install the collar and clutch center guide anto the crankshaft Install the primary driven g ar onta the mainshaft and secura it with a snap ring Install the clutch assembly onto the crankshaft Install a naw lock washer B Itonguad washer onto the mainshaft NOTE a Replace lock washer B with new one whenaver it is removed Install lock washer A with tha OUTSIDE mark facing out side If there is no mark instali the lock washer with the con vex side toward the outside Install tha lack nut with the chamfered edge toward the inside Hold the clutch outer using a Special holder tool and tighten the lock nut to the specified torque Band the tab of lack washer 8 up into the lock nut groove NOTE oo maaaaaaaaaaaammm a If the tab and groove aren t aligned turn the lock nut in the tightening direction ta align do not loosen the nut te set the locking tab Date af Issue Sap 19288 HONDA MOTOR CO LTD CLUTCH SNAP RING CENTER GUIDE l OUT SIDE MARK LOCK WASHER B E oo CLUTCH OUTER HOLDER BEND TAB LOCK NUT 11 25 CLUTCH Install a new gasket ante the clutch outer install the clutch outer cover and tighten the mounting screws Install the lifter spring and oil through guide onto tha clutch assembly SPRING OIL THROUGH GUIDE
134. COMPRESSOR i DRIVE SHAFT INSTALLATION With Damper Case Fill the damper case with the recommended type and amount af gear oil 1 5 8 Date of Issue Sep 1988 HONDA MOTOR CO LTO FINAL DRIVE OUTPUT SHAFT Hold tha drive shaft upright to avoid spilling the damper casa ail Carefully position the gear case on the shaft CAUTION Avoid damaging the dampar case oil seal during assambly Without Damper Case SPRING Install a new oil seal stop ring and the spring Then install the shaft on the final drive assembly STOP RING UNIVERSAL JOINT INSPECTION Remove the spring arm see the Model Specific manuall Remove the universal joint from the output shaft Check that tha universal joint moves smoothly without binding BEARINGS or noise Check the splines for wear or damage and replace if necessary Instali the universal joint on the output shaft than install the swing arin SPLINES Date of Issue Sep 1988 HONDA MOTOR CO LTD 16 WHEELS TIRES SERVICE INFORMATION 16 1 TIRE REMOVAL 16 11 TROUBLESHOOTING 16 1 TIRE INSTALLATION 16 14 WHEEL REMOVAL INSTALLATION 16 2 WHEEL BALANCING 16 17 WHEEL BEARING REPLACEMENT 16 8 ATV WHEEL TIRE 16 17 BASIC TIRE INFORMATION 16 9 SERVICE INFORMATION Support the motorcycle on its center stand and ar with a jack or other suitable support under tha engine or frama when ser vicing the front wheel Be certain that the
135. CRANKSHAFT OIL FILTER Ai NOTE Some systems include a relief valve that i opens to maintain the ail flaw whan the filter is excessively restricted due ta contaminants or whan tha oit temperatura _ is so low that it will not OIL STRAINER SCREEN fiow through the filter ROCKER ARM CONNECTING ROD SMALL CAMSHAFT s mmm BE ROCKER ARM SHAFT END PISTON CYLIND R m Forced VALVE pressure path VALVE SPRING ORIFICE gt Sway path OIL FILTER OIL RELIEF PUMP VALVE OIL STRAINER SCREEN OlL SUMP Date of Issue Sep 1988 HONDA MOTOR CO LTD 4 3 OIL PUMP ONNECTING ROD AIN BEARING TRANSMISSION LUBRICATION FOUR STROKE ENGINES Wet Sump Type Wat sump engines contain their total oil volume within thair crankcases In these systems oil is pumped from the sump in the crankcase through a strainer screen and or oil fittar and then is pressure fed to various engine components Oil return ing from these now lubricated areas flows back into the sump by gravity Some wet sump angines use only a strainer screen to filter the ait Others usa a combination of a strainer screen and a centrifugal type filter or a more conventional pleated paper type filter Dry Sump Type Dry Sump systems use an axternal oil tank and dual functian oil pumps In this System tha pump draws in oil for delivery to the various components and pumps oil out of the sump and back to the ail tank
136. DA MOTOR CO LTD BRAKES a a e e Bleed the hydraulic system if it has been disassembled or if the braka feels spongy If brake pads or shoes have baan overheated iglazed they must be replaced Overheating changes the compasition of the friction material and merely wire brushing or sanding the friction surface cannot change this fact Always replace hydraulic hne hose seating washers with naw ones when reassembling These sealing washers are made of aluminum alloy for effective sealing and are distorted once they are used Use caution when handling and installing brake lines and hoses When installing front brake lines be sure that there is no possibility of damage or stress to the lines ar hases whan the fork pivots fully in either direction or whan the suspension compresses or extends In the rear allow pro per clearance so that the lines or hoses do not rub against the tire frame or swingarm and so they are not caught he tween the coils of the spring whan the suspension HOSE GUIDE compressas K z BRAKE HOSE All brake lines or hoses should be installed using the clamps HOSE CLAMP provided Each clamp should be positioned around the rubber hose ds to pravent any damage to the li n ose guar p Y ge t the lines and hoses HOSE GUARD Eyelet type line and hosa joints STOPPER Use new sealing washers whenever syelet type joints are gt e reinstalled Ba sure the hose bolt fluid passaga is free from clogging p
137. DA MOTOR CO LTD CONTENTS c GENERAL INFORMATION _ Ki man MAINTENANCE ENGINE TESTING LUBRICATION _coouna svsr SYSTEM i o EXHAUST SYSTEM ig emission N CONTROL SYSTEMS f gt FUEL SYSTEM S i Cc oo _ a Or a a CYLINDER HEAD VALVES 9 2 acs y _CYLINDER PISTON o dol E CLUTCH _ E E L J V MATIC BELT DRIVE SYSTEM 5 ii L TRANSMISSION GEARSHIFT LINKAGE f a I5 FINAL D DRIVE OUTPUT S T SHAFT a oe ST BRAKES _ FI i FRONT SUSPENSION STEERING CHASSIS rs FRAME BODY PANELS pi ELECTRICAL FUNDAMENTALS 3E BATTERIES CHARGING LIGHTING SYSTEM F IGNITION SYSTEMS 23E ELECTRIC STARTER STARTER our CHAE LIGHTS N TS METERS SWITCHES ES sE ELECTRICAL F Symboi Marks Thas symbols used throughout this manual show specific service procadures if supplemantary information is required per taining to these symbols it would be explained specifically in the text without the use of the symbols Use recommended engine oil unless otherwise specified i I y G Use moiyhdenum solytion mixture af the engine oil and molybdenum grease with the ratio 1 1 ae ma ia a eo pe H Usg multi purpose grease Lithium based multi purpose g
138. DIAPHRAGM Remove the screws and diaphragm cover Remove the spring and diaphragm Check the rod for bends or damage Check the diaphragm for damage or pin holes Damage to tha rod and or diaphragm reduces the fficiency of the pump leading to hunting during acceleration a at E GM DIAPHRA Blow open the fuel Passages in the diaphragm cover with low Pr ssure air AIR CUT OFF VAVLE Remove the Screws air cut off valye Cover spring diaphragm and O ring Check the diaphragm foe damage or pin holes Check the O ring far damage or fatigue A worn O ring and or damagad diaphragm causes air to leak from the air cut off valve vacuum chamber Blow open air passages in the cover with Compressed air CARBURETOR CLEANING After removing all Parts blow open air and fuel Passages n tha Carburetor bady with compressed air CAUTION Cleaning the air and fuel passages with a pieca of wire will damaga the carburetor body or fue pump Ramove the diaphragms to Prevent damage to tham 2 before using air to blow open the passagas CARBURETOR ASSEMBLY AIR CUT OFF VALVE Install the diaphragm on the carburetor body Install the O ring with its flat side pointed downward install the Spring on the cover and install the cover an the car buretar bady Be sure that the diaphragm and O ring do not in terfere with the cover Date of Issue Sep 1988 8 1 4 HONDA MOTOR CO LTO
139. DISC ROTOR CAUTION Spilled brake fluid will damaga painted plastic or rubber L og es Remove the brake caliper assembly and the pads from the CALIPER caliper Disassembly Remava the folowing Caliper bracket pad spring pivot collar boot Remove the piston If necessary apply compressed air to the caliper fluid inlet to get tha piston out Place a shop rag under the caliper to cushion the piston when it is expelled Use low pressure air in short spurts convents sos Be careful not to damage tha caliper cyhnder bore when removing the sepis Push the pistan seal and dust seal in and remove them Clean the caliper especially the brake piston seal grooves with fresh brake fluid CALIPER LOWER CALIPER PIN BOLT PAD SPRING CALIPER 17 12 Date of Issue Sep 1988 HONDA MOTOR CO LTO k aS BRAKES Caliper cylinder Inspection Check the caliper cylinder bare for scoring scratches or other damage Measure the caliper cylinder D in X and Y axis at several points Raplace the caliper cylinder if the largest measurement is bayond the specified service limit Refer to the Model Specific manual for the servica limit Celiper Piston Inspection Measure the caliper piston O D in X and Y axis at several points Replace the caliper piston if the smalast measurement is tess than the spacified service limit Refer to the Mode Specific manual for the
140. Date of Issue Sep 1988 HONDA MOTOR CO LTD ee a ee 3 ENGINE TESTING SERVICE INFORMATION 3 1 COMPRESSION TESTING TROUBLESHOOTING 3 1 LEAK DOWN TESTING SERVICE INFORMATION Compression and leak down tests affer important knowladge of tha mechanical condition of the angine in question Both tests must ba done to accurately evaluate engine condition A comprassion test can quickly show if ail contributing factors allow engins operation within basic service limits ar if either the piston rings cylinder s or the valves valve saats in the Case of 4 strokes are suspact In order for a compression test to be accurate the instructions must be followed closely tha engine must contain anly standard components and the battery on electric start modais must ba in perfect condition A leak down test can effectively pin point whethar the piston rings cylinder s vaives valve seats haad gasket or crankcase saals and gaskets in the case of 2 strokes individually or all together are in need of service TROUBLESHOOTING Cylinder compession is low or uneven Faulty valve mechanism Incorrect valve clearance Bent burned or sticking valves Worn or damaged valve seat Incorrect valve timing Broken valve spring lt Faulty hydraulic valve adjuster Faulty cylinder head Leaking or damaged head gasket Warped or cracked cylinder head surface Faulty cylinder or piston Worn or damaged piston ringis Worn
141. E LEVER 16 14 Date of issue Sep 1988 HONDA MOTOR CO LTD WHEELS TIRES Tuba type only Inflate tha tube with a small amount of air Push the tube into the tire Insert the valve through the valve hole and oasely install the nut Install the tube so that it is aligned with the concave partion of the rim center Ba sure that the tube is not twistad and the valve stem is Straight Install the other side of the bead while halding the assembled portion of the bead with your knee to prevent it from coming off NOTE posite side is postioned in the center of the rim Install the bead a little at a time using care not to damaga tha tube r wheel with the tire levers After 1 2 of the bead has been installed insert the two tire lavers at a distance of 30 40 mm 1 to 2 in ta install it Repeat this pro edura until 3 4 of the bead has been installed ee ee MA ee o a a Hold one tire lever upright to remove the other lever After 3 4 of the bead has been installed check the bead on the opposite side Be sure it is still in the center of the rim NOTE The last portion of the bead is more difficult to install The rim and bead may be damaged if the bead on the op posite side of the point where you are working is nat in the rim center inne oO oga ee When the remaining baad is anly 50 80 mm 2 to 2 5 in pull the two levers up and over RIM PROTEC TGR TIRE LE
142. E PRIMARY DRIVEN GEAR CLUTCH OUTER PRIMARY DRIVE GEAR CLUTCH PLATE CLUTCH DISC Clutch springs are compressad clutch is disengaged Clutch springs are released Clutch is engaged CLUTCH LEVER OPERATION Clutch levar is Lifter rod liftar Clutch outer is Clutch springs Clearances ap Ciutch pulled __ piate are depressed arp compressed t paar betwean disengaged dapressad plate and disc Clutch jevar is Lifter rod is Cluteh springs Clutch outer is Disc is con Clutch released releasad are released pushed out tacted to plata engagad 11 6 Date of Issue Sep 1988 HONDA MOTOR CO LTD CLUTCH WET MULTIPLATE CENTRIFUGAL CLUTCH The centrifugal clutch achieves a connection disconnectian of the clutch by tha centrifugal forca applied on the clutch rotated by the crankshaft With this Mechanism the vehicle will net start when idling because the centrifugal force is less and the clutch is disengaged However as the rotation of the engine increases the clutch wil be sngaged and the vehicle tan be moved without manual Operation of the clutch When the centrifugal clutch is cambined with tha transmission it wilt be Provided with an independent machanism to disengage the clutch by the motion of tha pedal when Operating the gear shift This ig to disengage the clutch temporarily when changing gears and to aliminate the pressure applied on the toothed Surface af tha gear transmission to ena
143. EDURE 4 stroka multi carburetor emi slons contrai applicable models NOTE teeta Make sure tha carburetor synchronization is within specification before pilot screw adjustment The pilot screws sre factory pre set andno adjustment is Necessary untess the pilot scraws ara replaced Use a tachometer with Graduations of 50 rpm or Smaller that will accurately indicata a SO FAM Change ee ee O 1 Turn each pilat screw clockwise until it seats lightly then back it out to the Specification given This is an initial set ting prior to the tinal pilot screw adjustment INITIAL OPENING Refar to the Model Specific manual CAUTION l Tightening tha pilot scrow against its seat wil damage the saat vy 2 Warm up the engine to Operating temperature Tan minutes of Stop and go driving is sufficiant 3 Attach a tachometer according to its manufscturer s instructions 4 Adjust the idle speed to the specified rpm with the throttta Stop screw IDLE SPEED Refer to the Modei Specific manual Turn all pilot screws 1 2 turn out from the initial setting If the engine spaed increases by 0 rpm or mare turn all pilot screws out by successive 1 2 turn increments until engine speed does not increase 7 Adjust the idle spesad with the throttle Stop screw 8 Turn the No 1 carburetor pilot scraw in until the engine Speed drops 50 rpm Date of Issue Sep 198g 8 20 HONDA
144. ES OIL P ley mn F ion f eb on K oa a SYA CAMSHAFT E AO l Ry P OIL FILTER eo i QIL PUMP MAIN GALLERY Date of Issue Sep 1988 4 7 HONDA MOTOR CO LTD LUBRICATION PLUNGER TYPE Virtually all non premix lubricated 2 stroke engines are equip ped with a plunger type oil pump ie f ON SPRING Soma plunger pumps are driven by crankshaft via the oil pump y y ONTROL gaat shaft and others are directly drivan by crankshaft PUMP GEAR n ey LARM The oil pump cam is depressed under a spring Turning the cam PLUNGER causes the plunger to reciprocate so that tha pumping move CAM ment is repeated The amount of lubricant is controlled propor PIN tionally with the cam rotation Be The pump is designed to control the amount of lubricant discharged per crankshaft rotation by varying the plunger Stroke through the operation of the cam interlocked with the carburetor throttle CAM DRIVE _ GEAR The combinad function of these two mechanisms allows the proper flaw of lubricant depending on load conditions and engine rpm ve d DRIVE SHAFT Wes Oil Pump Oparating Principle SUCTION VALVE PLUNGER PORT PUMP 1 2 3 id m j5 CHAMBER Suction process Discharge process j i VALVE DISCHARGE CAM PORT 11 As the valve dascends it blocks the outlet passage while gradually opening the inlet passage 21 Hara at the bottom dead cen
145. ETOR As the piston begins its descent at the start of the induction phase the period when the air fuel mixture ig drawn inj pressure in the cylinder drops Causing air to flow from the air claanar through the carburetor and into the cylinder The function of the carburetor is to atamize the fuel and create an air fuel mixtura As in the figures on the right air drawn into the carburetor passes through constriction A where it gains speed Tha con striction is known as the venturi section of the carburetor This increase in flow speed is accompanied by amp fall in pressure in the venturi which is used to draw off fuel from the outlet Tha fuel is atomized as it is drawn into the venturi undar the in fluance of atmospheric pressure and is mixed with the incom ing air Carburetors ara also equippad with mechanisms for regulation of the air and mixture volumas A throttle valve is used to ragulate the flaw of air fuel mixture and a choke is included for adjusting the air flow under starting conditions Types of carburetors Carburetors which alter the diameter of the vanturi by throttle valve movement ara known as variable venturi types Honda uses this kind of carbur tor on its motorcycles and scootars Carburetors in which the venturi diameter is not altered are called fixed venturi type carburetors The variable venturi con tinuousty changes in diameter from tow to high speed in pro portion to the intake air volume to give smo
146. For models not aquipped with tachamater connect engine tachometer Remove the headlight as shown Start the engine and switch the headlight on Hi beam With the hesdlight wires connected measure the headlight lighting voltage between the blue and grean wire tarminals Increase the engine speed gradually and read tha voltage at the specified engine rpm Refer to the Model Specific manuat for service data Select the AC range on your multitester AC currant flows to the headlight Use the Specifiad multitestear Tha measured headlight regulated voltage may vary depending on the multitester usad because of the characteristics of the output waveform SPECIFIC MULTITESTER 07411 0020000 KOWA Digital type KS AHM 32 003 KOWA Digital type USA anly 07308 0020001 SANWA Analague type TH 5H KOWA Analogue type 22 24 Date of Issue Sep 198 HONDA MOTOR O LTD If the headlight lighting voltaga is abnormally high check the alternator cannectar and the alternator unit If there is no headlight lighting voltage check the follawing areas Loose of poor contact at a connection in the lighting circuit Continuity test for dimmer switch AC regulator Lighting coil in tha alternator AC REGULATOR INSPECTION After checking that tha connectors have no loose or poor or nections inspect the alternator unit by measuring the resistance between the terminals Reter
147. HICKNESS SHOWN Example Crankpin code amp Connecting rod code 1 Bearing code Pink Tha pink code bearing should be selected CONNECTING Jil ROD I D CODE 3 CRANKPIN I D CODE Date of Issue Sep 1988 1 4 9 HONDA MOTOR CO LTD CRANKCASE CRANKSHAFT BEARING REPLACEMENT BEARING INSERTS Remove the bearing inserts fram the connecting rad and cap OIL HOLE Wipe all oil from the connecting rod and the new bearing inserts Install the bearing inserts by aligning the tabs with the grooves in the connecting red and cap NOTE The ail hale in the connecting rod should be aligned with the bearing insert oil hole Appty molybdenum disulfide solution to the inside bear ing surface for initial lubrication a pee ee a CONNECTING ROD SELECTION If a connecting rod requires replacement you should select a rod with tha same weight code A B or C as the original NOTE mal engine vibration if a rod with tha same weight coda is unavailable use a replacement within one code letter of the original WEIGHT CODE INSTALLATION Coat the inside bearing surfaces with molybdenum disulfide solution far initial lubrication and reinstall them into the original positions and directions If the connecting rod has an oii hole install the rod sa that the holes is behind the crankshaft rotating diraction as shown ROTATING DIRECTION Date of
148. HONDA MOTOR CO LTD MAINTENANCE Te a ye penne yee ye VALVE CLEARANCE Adjustmant ig unnecessary on motorcycles equipped with hydraulic lash adjusters hydraulic tappeti However ap propriate clearance is needed between both the intake and ex haust valves and the valve opening clasing mechanisms in all other 4 cycle engines This clearances allows a change in tha siza of the valve by thermal expansion as the heat of the com bustion chamber is transmitted to the valve If there is too much clearance it may result in engine noise tappet noise If there is too little clearance the valve is push ed during the heated period causing a drop in compression resulting in bad idling and sventually burnad valves NOTE Inspect and adjust the valve clearance when the engine 1 is cool under 38 C S35 F A Inspection and adjustment of valva clearence should be per formed with the piston at top dead center of the comprassion Stroke This position can be obtained by confirming that there is slack in the rocker arm when the stampad T mark on the flywheel rotor and the indax mark on the crankcase cover are aligned If there is no slack in the rockar arm evan when tha T mark and index mark are aligned it ig because the Piston is moving through the exhaust stroke to tap dead center Turn the crankshaft one full rotation and match up the T mark again The piston will then be at the top of the compression stroke top dead centert
149. HOOTING CARBURETOR DISASSEMBLY SYSTEM DESCRIPTION INSPECTION ACCELERATOR PUMP CARBURETOR ASSEMBLY AIR CUT OFF VALVE PILOT OR AIR SCREW ADJUSTMENT REED VALVE ACCELERATOR PUMP ADJUSTMENT FUEL LINE HIGH ALTITUDE ADJUSTMENT SERVICE INFORMATION Gasolina is axtramely flammable and is explosive under certain conditions A Work in a well ventilated area Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fira or explosion CAUTION Bending twisting the contro cables will impair smooth operation and could cause the cables to stick or bind rasulting in logs of vahicle control Be sure to remove the diaphragms before cleaning air and fual passages with compressed Bir Tha diaphragms might be damaged aa An a ee rs a aaia a ods Refer to Model Specific manual for carburetor and reed vatve remoyal installation When disassembling fuel system parts note the locations of the O rings Replace them with new anes on reassembly Before disassembling the carburetor place a suitable container under the carburetor drain bolt loosen the balt and drain the carburetor After removing the carburetor wrap the intake port of the engine with a shop towel or cover it with piece of rape to pre vent any foreign material from dropping inta the angine NOTE If vahicla is to be stored far more than ane month drain the float bowls Fuel left in the float bowls may cause clogge
150. IN JET Date of Issue Sep 1988 8 6 HONDA MOTOR CO LTO FUEL SYSTEM ACCELERATOR PUMP When the throttle valve is opanead suddenly air fuel mixture drawn into the cylinder momentarily becomes lean Because the vacuum at the venturi drops air flow at the venturi slows dawn and the drawn up fuel becomes toa little comparad with the air To avoid thinning of the mixtura under thase condi tions an accelerator pump is used for temporary enrichment The principle of operation of the pump is as follows As tha throttle valve is opened the pump s diaphragm ls depressed by the pump rod At this time the inlet check valve is shut so the pump chamber undergoes a risa in pressure The autiet check valve is then opened and fual is supplied to the main bore via the pump hole As the throttle valve is shut down the accalerator Ppump s diaphragm is returned by spring action At this time the inlet check valve is apanad and fuel from the float chamber enters the pump chamber The outlet check valve is closed at this point to prevent air being drawn in through tha pump hole AIR CUT OFF VALVE When the throttle lever is turned in the clase direction and engine braking ts apphed the fuel mixture becomes lgan An ignited air fuel mixture is discharged into the exhaust pipe resulting the afterburn To prevent this afterburn the air cut off valve shuts the air passage to the slow jet to temporarily make the fuel mixture rich
151. ISASSEMBLY NOTE ee Keep track of the disassembled Parts gears bushings SNAP RINGS washers and snap rings by Stacking them on a toot or slipping them onto a Piece of wire Do not expand the Snap ring more than necessary for removal To remove a snap ring expand the snap ring and puil it aff using the gear behind it L LAE TRANSMISSION INSPECTION Check the following Gears Teeth for damage or excessive wear Dogs and dog holes for damaga or excessive waar Measure the gear lD except splined holes and holes with neadle baaringst Bushings For wear af damaga Measure the i D and O D Calculate the gear to bushing and bushing to shaft clearances Mainshaft Countershaft Spline groove and sliding surface for abnormal wear or darnage Measure O D at the gear sliding areas Calculate tho gear to shaft and shaft to bushing clear ances Date of Issue Sep 1988 1 3 6 HONDA MOTOR CQ LTD TRANSMISSION Shift Drum The guide groove for abnormali wear or damage The bearing for axcessive play or damage if required GUIDE GROOVES Shift Fork For deformation or abnormal wear Measure the fork claw thickness Measure the I D of the shift fark NOTE Some fark claws are measured at A and C iclaw en Othars are measured at B ithe center Shift Fork Shaft Far damaga and straightness j Measure the O D at
152. ITCHES 2 30 ENGINE OIL 2 11 HEADLIGHT AIM 2 31 ENGINE OIL FILTER ZN piieeverea ae ENGINE OIL FILTER SCREEN BAAS ieee ie DECARBONIZING 2 stroke engine 2 15 SUSPENSION 2 34 CARBURETOR SYNCHRONIZATION 2 16 SPARK ARRESTER USA ii oe CARBURETOR IDLE SPEED 2 17 NUTS BOLTS FASTENERS 2 36 RADIATOR COOLANT 290 OS pe COOLING SYSTEM 2 18 STEERING HEAD BEARINGS 2 38 SECONDARY AIR SUPPLY SYSTEM 2 19 EVAPORATIVE EMISSION CONTROL SYSTEM 2 19 TRANSMISSION OIL 2 stroke engine 2 20 WHEEL ALIGNMENT FOUR TRAX 2 39 NOTE This section covers the normal inspections and adjustments that are necessary to maintain the vehicte in good condi tion Perform this maintenance at each scheduled maintenance period Refer to the Model Spacific manual for the pro per maintenance schedule and applicable itams Date of Issue Sep 1988 2 1 HONDA MOTOR CO LTD MAINTENANCE FUEL LINE Check tha fuel line for Gasoline leakaga Loose or improperly positionad line clip Deteriorated or damaged jing Replace any defective parts FUEL STRAINER SCREEN Turn the fuel valve to OFF position ot O RING SCREEN STRAINER CUP _ we Remove the strainer cap below the fuel valve and drain the gasoline into a suitable container l wu Gasolina is extremely flammable and ls explosive under certain conditions FUEL VALVE Work in a wail ventilated area
153. Keep cigarettes flames or sparks away from the work area or any area where Gasolina i stored Remove the O ring and strainer screen Clean the cup and strainer screen with non fiammable or high flash paint solvent Raplace the O ring with a new one Reinstall the strainer screen O ring and cup than tighten the Cup to tha specified tarque CAUTION j gt Overtightening the cup may braak or deform the O ring causing a fuel leak a _ Turn the fuel valva to ON and check that there are no leaks 2 2 Date of Issue Sep 1988 z HONDA MOTOR CO LYD MAINTENANCE STA THROTTLE OPERATION Check for any deterioration or damage to the throttle cable Check that the throttle autamatically closes completely in ail steering positions IF the throttle grip does not return property lubricate the throt tle cable and avarhauil and tubricate the throttle grip housing lf the throttle grip still does not return properly the cable may need raplacament With the engine idling turn the handlebar atl the way to the right and left to ensure that the idle speed does not change If idle speed increases check the throttle grip free play and the throttle cable connection 7 Reusing a damaged or abnormally hent or kinked throttia cable can prevent proper throttle slide operation and may lead to a loss of throttle control whila riding OF 0 Throttle free play should ba checked and adjusted as follows
154. L A HYB16A A Y50 N18L A T12 12 TH12 128 YTH14 128 YELLOW i 1 GREEN i 4 2 31 te YELLOW ma gono 22 10 Date of tssue Sep 198b HONDA MOTOR O LTD BATTERIES CHARGING LIGHTING SYSTEM eee ys BATTERY CHARGING Bafora Operating The Charger Be sure the area around the charger is well ventilated clear af flarmmable materials and free from heat humidity water and dust Clean tha battery terminals and position the battery as far away from the charger as the leads will permit Do not placa batteries below the charger gases fram the battery may corrode and damage the charger Do not place batteries on top of the charger Be sure tha air vents are not blockad EXAMPLE 1a 2A sa Sa Amp Hour Rating we fe ah ait il slit rity Always clear the work area of flammable materials such as gasoline braka fluid electrolyte or cloth towels when operating the tester or the heat generated by the taster may cause a fire BATTERY AMP HR 1 Turn the Power Switch to the OFF position SELECTOR SWITCH Stn92 dom tsaw 2 Set the Battery Amp Hr Selector Switch for the size of the battery baing charged ania wines 3 Set the Timer to the position indicated by tha Honda Battery Tester RED 3 RED 2 ar YELLOW 1 If you are charging a Set the appropriate amp hour cating new batt
155. MOTORCYCLE MOTOR SCOOTERS amp ATV s HONDA COMMON SERVICE MANUAL This manual is provided at no charge and may be distributed freely Pages were scanned from photocopies as Honda no longer print originals The alphabeticised index is not available COMMON SERV MANUAL OWNERS MANUAL PART NO 61CM000C Ci HONDA MOTOR CO LTD 1988 PRINTED IN JAPAN 61CM000 QY R 1508811 IMPORTANT SAFETY NOTICE eI Indicatas a strong possibility of severe personal injury or death if instructions ara not followed CAUTION Indicates a possibility of aquipment damaga if Instructions are not foillawed NOTE Givas helpful information Detailed descriptions of standard workshop procedures safety principles and service operations are not included It is important to nota that this manual contains some warnings and cautions against some specific servica methods which could causa PERSONAL INJURY to service personnel or could damage a vehicie or render it unsafe Please understand that thase warnings couid not cover all conceivable ways in which service whether or not recommended by Honda might be done or of the possibly hazardous consequences of each conceivable way nor could Honda investigate all such ways Anyone using service procedures or toals whether or not recommended by Handa muse satisfy himself thoroughly that neither personal safety nor vehicle safety will ba jeopardized by the service methods or tools sele
156. NERATOR Refar to the Model Specific manual for removal and replace ment of pulse generator Date of Issua Sep 1988 23 16 HONDA MOTOR CO LTD r SPARK UNIT PERFORMANCE TEST EXCEPT U S A Use the Full TRYCDI tester to test spark unit performance Follow tha tester manufacturer s instruction Refer to the Mode Specific manual for tha type af inspection adaptor required CAUTION Improper connections could damage the CDI unit or tester Switch Good condition Bad condition OFF No spark P No spark EXT No spark ON Spark Spark Spark No spark No spark For digital contralied spark unit use spark adaptor 07508 0013600 Select the proper position far the selector switch befora testing Selector IG Coil Selector P Selector A Number of ignition coil Pulse signai No Refer to Model Specific manual far switch position P Selector B Firing interval No of cylinder t 2 4 cylinders 2 3 amp cylindars IGNITION SYSTEMS FULL TR CDI TESTER Nel available in USAI SPARK UNIT INSPECFION ADAPTOR IGNITION COIL PULSE SELECTOR SELECTOR A PULSE SELECTOR B 1 3 4 1 2 4 oe Se G G 2 INSPECTION ADAPTOR SWITCHES a a a O O e 23 17 ate of Issue Sap 1988 HONDA MOTOR CO LTD y 24 ELECTRIC STARTER STARTER CLUTCH SERVICE INFORMATION 24 1 CLUTCH SWITCH DIODE INSPECTION 24
157. OUTPUT DRIVE GEAR CAM OUTPUT GEAR Power from the engine is transmitted ta the rear wheel as follows Countarshaft for output drive shaft output driven shaft drive shaft pinion gear ring gear rear wheel OUTPUT DRIVEN GEAR To prevant harsh or jerky acceleration or deceleration a damper Spring is placed in the drive line The spring absarbes sudden applications of torque and provides smooth starts and stops UNIVERSAL JOINT The damper mechanism is attached to sither the output gear case or drive shaft Unlike the drive chain the system requires only periodic final gear off change for maintenance DAMPER MECHANISM PINION SHAFT OUTPUT SHAFT OUTPUT GEAR REMOVAL NOTE When a damper spring is installed to the output gear remove the sida gear case only after the damper Spring has been ramoved Follow the staps below j Refer to the Model Specific manual for output shaft removal i ts Remove the output gear Using the damper spring compressor comprass the damper Spring and remava tha snap cing Remova the damper spring compressor and then take out the dampet cam end damper spring SNAP RING DAMPER SPRING 1 5 2 Date of Issue Sep 1986 z HONDA MOTOR CO LTD r FINAL ORIVE OUTPUT SHAFT INSPECTION DOG HOLES Check the gear for damage or axcessive waar and the gear dog holes for damage raplace as necessary Measure the
158. On in line 4 cylinder angines with the firing order 1 2 4 3 the inspection of valve clearance can ba conducted by rotating the crankshaft twice Aftar the above procedure has been properly carried out the inspection and adjustment of all cylinders is complete In tine 4 cylinder engines are numbered 1 2 3 4 starting from the laft cylinder Cylinder at top of compression stroka Cylinder number On Y twin and V 4 engines inspection and adjustment are performed by placing aach cylinder in the compression top dead center position ADJUSTING LOCK NUT VALVE 7t CLEARANCE i 1 _ T MARK a ee Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 9 MAINTENANCE The valve clearance adjustment is correct when tha specified ADJUSTING SCREW tealer gauge fits snugly but the next size larger feeler gauge en anor i will not fit in NOTE On motorcycles that have a decompression mechanism which lifts the valve when starting the engine the ad i justment for decompression must bs carried aut first in i Order to provida an accurate valve clearanca inspection Valve clearance inspection on engines with common scraw type adjusters is measured by inserting a feeler gauge directly between the end of valve stem and the adjusting screw In the case of one sided ball jaint type engines the clearance is measured by inserting the feeler gaugs between the rocker C
159. Prevent contaminants or any foreign material from entering the system whan filling the reservoir A WARNING B Contaminants in tha system may cause a reduction ar pus ot rete SOM E M a UPPER HOLDER HANDLEBAR Avdaid spilling the fluid on painted plastic or rubber parts Place a rag over thase parts whenever the system is Serviced CAUTION Spilled brake fluid will damage painted piastic ar rubber parts Holder bolts Handlebar upper holders Handlebar Installation Place the handiebar onto tha tower holders aligning the punch mark on the handlebar with the upper surface of the lawar holders Install the upper holders with the punch marks facing forward Tighten the front bolts first then the rear to the specified torques Refer ta the Model Specific manual for the proper torque valye LOWER HOLDER Connect the choke cable to the choke lever Install tha left handiebar switch aligning the pin with the hele in the handiebar Tighten the forward screw first then the rear screw Date of Issue Sep 1988 HONDA MOTOR CO LTD 1 8 1 1 FRONT SUSPENSION Apply a light coating of grease to the throttle cable ends and THROTTLE GRIP throttle grip sliding surface Connect the throttle cable to the throttle grip and install the grip ta the handlebar Install the right handlabar switch aligning the pin with the hole in the handlebar Tightan the farward screw first then the rear
160. R 07733 0020001 To remove the rotor screw in the attachment hold it securely with a wrench and then screw in the puller shaft CAUTION Strong hammering on tha puiler shaft may damage the rotor Always use a holder and a puller ta remove the rator Do not try to ramove the rotor by hammering directly on it The crankshaft or componants could be damaged i ae Remove the woadruff key with care not to lose it STATOR REMOVAL Discunnect the alternator connector Remove tha bolt or screw on the alternator cover or engine Ramova the stator Stator bolts are often securad with locking agents For this reason use an impact driver BATTERIES CHARGING LIGHTING SYSTEM ATTACHMENT WOODRUFF KEY I CRANKSHAFT STATOR BOLTS STATOR Date of Issue Sep 1988 HONDA MOTOR CO LID BATTERIES CHAAGING LIGHTING SYSTEM STATOR INSTALLATION Note the direction af stator and install the stator on the crankcase Apply a locking agent ta the bolt ar screw threads and tighten it to the specified tarque CAUTION 1f the stator bolt bacomes loose it may come into con tact with the rotor and cause damage sists os o ee es S Route the stator wire correctly on the crankcase cover NOTE Route tha stator wire so that it does nat came into con tact with the rotor f there is a wire clamp or clip secure the wira with it Apply sealant to the gromme
161. R CLEANER CASE DRAIN TUBE off road motorcycles and ATVs Loosen the drain tube clip and remove the drain tube to empty any accumutation of fluids or dirt fram the air claaner case into a proper container Check the drain tube for damaga and replace if necessary Reinstall the drain tube and set the clip in place CRANKCASE BREATHER Same motorcycle engines are equipped with a closed La crankcase system to prevent discharging crankcase emissions 7 ay into the atmosphere Blaw by gas is returned to the combus tion chamber thraugh the air cleaner and carburetor A breather separator is necessary within the system ta prevent 7 moisture from contaminating the engine Vapor is allowed ta SEPARATOR pass through the air claaner and into the engine to be burned off Moisture is collected in a sealed drain tube Pariodic DRAIN TUBE maintenance is to remove the drain plug and drain deposits in DRAIN PLUG to a suitable container then reinstall the drain plug A portion of the drain tube is transparent so it is easy to con firm the amount of accumulation yy fy Date of Issue Sep 1988 2 7 HONDA MOTOR CO LTD ms MAINTENANCE eee SPARK PLUG _ NOTE CENTER Oo ena eal At ae aT ES eens et Ra CT Clean around the spark plug seat with compressed air ELECTRODE before removing and ba Sure that no dabris is allowed to enter the cambustion chamber om ELECTRODE Remova the spark plug cap and then ramave the
162. RESTER USA only Wait until the pipe has cooled befora ramoving at install ing the muffler lid Touching the hot exhaust may result MUFFLER LID in savera burns Parform this operation in a well ventilated araa frag from i combustible materials Carbon particles may blow out of the clean out hole when performing this service Waar safety glassas ta pravent possible eye injuries j Remove the muffler tid Black the and of the muffler with shop towel Start engine and rev it up to blow accumulated carbon deposits out of the muffler Date of Issue Sap 1988 HONDA MOTOR CG LTD 2 35 MAINTENANCE Le Be sure that the muffler id bolts and gasket are in good condi tion Replace the bolts and gaskat if necessary Install tha muffler lid and gasket and tighten the bolts securely NOTE j Do not remove the two scraws that hold the exhaust baffle in tha and of the spark arrester muffler The two mounting screws must be installed in the spark arraster body at all times for the spark arrester to be effective GASKET SPARK e MUFFLER LID ARRESTER BOLTS NUTS BOLTS FASTENERS Check that all chassis nuts bolts and screws ara tightened to their correct torqua values at the intervals shown in the Maintenance Schedule Check all cotter pins slip pins hose clamps and cabie stays WHEELS TIRES Making sure the fork is not allowed to move raisa the front wheel and check for play Turn t
163. S TIRES n aa AXLE INSPECTION en aaaaaaaaaaaaamamaaaaamamamamamaeaiuu u LL DIAL INDICATOR Set the axla in V blocks rotate the axle and measure the runout using a dial indicator The actual runout is 1 2 of the total indicator reading replace if the service limit is exceeded Check the Model Specific manual for the actual service limit WHEEL BEARING REPLACEMENT NOTE n A n Disc brake typs Be sure to remove the brake discs before removing the wheel bearings j Refer to page 1 16 for the table of bearing remover driver size REMOVAL Removes the wheel Remove the dust seal side collar and braka drum and remove the speedometer gearbox retainer Rear wheel Chain drive type Remove the driven sprocket Shaft driva typa Remove the drivan flange Remove the right and left wheet bearings with the bearing remover shaft and remover head INSTALLATION NOTE Right and left bearings hava a spacific installation order Refer to the Model Specific manual for which bearing to Install first mr fh AA ra f v7 NARE Too a C cem 105 m mamape oa Seneca Drive in a naw bearing Check the distance collar far its proper installation direction and install DISTANCE COLLAR Install the other bearing NOTE Raplace right and left hearings in pairs Do not r use old bearings One side sealed type bearing Install the bearing wrth its sealing face toward the
164. Since this design eliminates the need for space to contain the oil within the lower portion of the crankcases the engine can be positioned lower than would otherwise be Possible This design often incorporates routing and oil storage configura tions that aid in lowering oil temperature General A spray tyne system is often utitized in either design illustrated here as well as in some two strokes engine designs Hare oil is litaraily sprayed through oil jets diractly into intarnal com ponents such as the connecting rod to help ensure lubrication and coaling of the rods and pistons Same systems includa oil pressure contralling reliaf valves to help ensure lubrication even if the filter is cloggad or the oil temperature is 0 low that it will not flow through the filter Oil filters and or strainer screens are postioned within the lubrication sytem to trap contaminants before the ail ig routed back into the lubricant pathways OIL STRAINER SCREEN OIL FANK Olu STRAINER OK STRAINER SCREEN AND OR FILTER OIL PUMP 4 4 Date of issue Sep 1988 HONDA MOTOR O LTD LUBRICATION TWO STROKE LUBLICATION SYSTEMS SCAVENGING SCAVENGING PORT Unlike four stroke engines twa strake engines use the internal crankcase area as a suction chamber and therefore cannot CRANKSHAFT use a Sump type oiling system Consequently the following CRANKSHAFT _ i at SEAL two systems hava been adopted in order to provide l
165. Sub fuse blown warning light and oii pressure switch Bulb blown Oil pressure warning light stays an while the engine is running 1 Check the engine oil level Specified oil level Law oil level Qil insufficient 2 Disconnect the oil pressure switch wire and turn the igni tian switch ON Indicatar fights Indicator does not light Shorted blue red wire be Faulty oil pressure twaen the warning light switch end pressure switch Low ail pressure see section 3 OIL LEVEL INDICATOR 2 stroke engine THEORY The ail level switch float in the oil tank moves up and down in accordance with the volume of oit in the tank When the oil na level is law the float also goes down and the reed switch ail ier a A level switch is clased by the magnetic force of the float REED SWITCH When the ignition switch is turned ON currant flows through the reed switch and the oi ievel indicator comes on IGNITION SWITCH Bate of Issue Sep 1988 25 2 HONDA MOTOR CO LTD LIGHTS METERS SWITCHES INSPECTION IGNITION SWITCH FUSE Oillevel indicator comes on whan tha oil in the tank reaches OO pe a specified level 1 Disconnect the wires from the ail leval switch and turn the ignition switch ON Indicator lights Indicator does not light l Shorted wire b twaan Faulty oil level switch tha indicator and oil level switch i INDICATOR OIL LEVEL 7 SWITCH Qil l
166. TEM DESCRIPTIGNS 2 Stroke Engine OIL PUMP DESCRIPTIONS ON COOLER INSPECTION OIL PRESSURE CHECK SERVICE INFORMATION 4 Stroka Engines Refer to the Model Specific manual for Oil pump removail installation Oil strainer screen cleaning Qil filter replacement Oil level inspection ail change The service procadures in this section can bs performed with the engine oil drained When ramaving and installing the oil pump use care not to allow dust or dirt to enter the engine If any portion of the oil pump is worn beyond the specified service limits replace the oil pump as an assembly After the oil pump has been installed check that there are no oil Jaaks and that oil pressure is corract 2 Streke Engines When removing and installing the oil pump clean the engine around the pump and ail pump itself Do not atternpt to disassemble the oil pump Bleed air from the oil pump if there is air in the oil inlet ling and each time tha oit line is disconnected Fill the oi outlet line with oil whenever the oil outlet ling is disconnected Refer to sectian 2 for oil strainer screen cleaning and oil pump control cable adjustment SERVICE DATA Use only recommended oil far your vehicle Viscosity requirements Vary according to the air temperature range encountered during operation Refer to tha Modet Specific manual for specific ail recommendations for the modal You are servicing GENERAL Oil recommendations 4 Stroke e
167. TION SYSTEMS Principle of Ignition Timing Advance Another function of the electrically contrallad ignition system is that the ignition timing advance tor retard is controlled elac trically This systam requires no mechanical advance and has no mechanical wear The overall design eliminates periodic ad justments and maintenance This sectian explains the operating principles of the ignition timing advanve The ignition timing retard system operates under the same principles The trigger circuit consists of a wave A and wave B generating circuit which converts the output from the pulse generator to wave forms A and B and an ignition timing selactor circuit CDI UNIT DIODE CAPACITOR EXCITER COIL IGNITION COIL ir GENERATING WAVE B GENERATING CIRCUIT eee PULSE IGNITION TIMING GENERATOR i DETERMINATION p GATE CIRCUIT CIRCUIT The pulse generator produces positive and negative voltage pulsas when the rotor reluctor crosses the generator PULSE GENERATOR OUTPUT PULSE OF PULSE GENERATOR Date of Issue Sep 1988 HONDA MOTOR CQ LTD 23 5 IGNITION SYSTEMS The output From the pulse generator is converted inta basic PULSE GENERATOR OUTPUT waves A and B Basic wave A is unaffected by engine speed and remains i constant Basic wave B changes its gradient as the engme spaad in creases as shown in the right graph Tha ignition timing determination circuit sen
168. They can ba recognized by undercuts under their bolt necks UBS bolts ara marked either with or withaut strength marks Furtharmora these bolts are so structurad so they will not easily loosen oy the provision of a slight slope af 5 to 80 on the bottam of the fiange UBS BOLT UNDERCUT TORQUE VALUES Tightening Force When two or more parts are connected by a fastener their er F TIGHTENING FORCE connection should not be affectad by external forces i e there Be f BOLT AXIAL FORCE should ba no gap between the parts which are fastenad together The first priority of threaded fastener connectad Aarts is the state of being tightened with a sufficient force When any tightening farce is sufficient for the intended func tion it is called proper tightening force The tightening forca of one bolt is equal to bolt axial tensile Strength Bolt tightening force is therefore often called bolt axial force A decrease in tightening force initial tightening force due to the passage of time extarnal forcas or vibration applied during use is called fastener lapsening Even when the initial tightening force was correct loosening may cause it ta decrease in later use finally damaging some parts As a countermeasure against fastener loosening retightening is carried out after a certain period of time Periodically tighten ing wheel spokes is an example of this operation Proper tightening forces are specified a
169. URRENT FLOWS gt NO CURRENT FLOWS The thyristor s turned on when a certain amount of voltage is applied to the gate This input to the gate is called gate voltage or trigger voltage On a the thyristor is turned on there is no need to continuous K ly apply voltage to the gate and its characteristic becomes identical to a regular diode eee VOLTAGE CURRENT FLOWS WHEN SCR IS ON NO CURRENT FLOWS SEMICONDUCTOR TRANSISTOR SYMBOLS The eglactrical conductivity of semiconductors lies between that of conductors and insulators Before understanding how thay work in circuits you need to have a basic knowlege of its characteristics PNP TYPE NPN TYPE Transistor A transistor has three terminals emitter E collector C and base BI There ara two types of transistors PNP and NPN type E EMITTER C COLLECTOR B BASE In PNP type transistars when a positive voltage is applied to tha emitter and negative voltage to the collector almost no current flows from the collectar to the emitter If tha amittar voltage is raised slightly higher than the base voltage and a small amount of current flows from tha emitter to the basa a large amount of current flows from the emitter to the collector Date of Issue Sep 1988 HONDA MOTOR CO LTD ELECTRICAL FUNDAMENTALS In the NPN type almost no current flows when a positive voltage is applied to the collector and a negative voltage to the emitter
170. VERS Data of Issue Sep 1988 HONDA MOTOR CO LTD WHEELS TIRES Apply a mild detergent solution to the baad again awannins M Use only water as a lubricant when removing ar mount ing tires i j Soap or othar tire lubricants may faave a slippery residua l which can cause the tire to shift on the rim RUBBER HAMMER Tap on the tire tread surface with a rubber hammer so that the tira and tim fit evenly around the circumtarance Be sure that the tire centar and rim center are aligned Inflate the tira to 1 5 times the standard recommended pressure to seat the bead on the rim Awanuns M i Use the tira pressures specified in the Modei Specific manual or on the tire labet Overinflation may cause e tira to burst with sufficient force to rasult in serious injury or death NOTE RIM LINE For tubaless tires you may hear a loud sound as the baad seats onto the rim This is narma For tubeless tires if air leaks out from between the rim and bead jet the wheel stand with the valve at the bot tom and put air in while pushing down on the tire Check that the tira heed seats on the tire rim sacurely and the rim fing of the tire is concentric with the rim Adjust the tira pressure to the specified pressure Check the wheel balanca Tightan the rim lock nut to specified torque if available On the tube type tira tighten the valve stam nut Install the
171. aast 6 sacends if the system will not hold the specified pressure chack the following and correct as necessary All hose and pipe connections Water pump installation Water pump seal for lsakage COOLING SYSTEM TESTER COMMERCIALLY AVAILABLE THERMOSTAT Remave the thermostat refer to the Modet Specific manual THERMOSTAT Inspect the thermostat visually for damage Suspend the thermostat in heated water to check its Operation NOTE Do not let the thermostat or thermometer touch the pan or you will get false readings Replace the thermostat if valve Stays open at room temperature or if it responds at temperatures other than those specified Chack for the correct valve litt temperatura with the water heated to oparating temperature for 5 minutes Refer ta the Model Specific manual for the specific temperature THERMOMETER a Reinstall the thermostat WATER PUMP MECHANICAL SEAL INSPECTION inspact the telltale hola for signs of caolant laakage If there is leakage the mechanical seal is defective and must be replaced See the Model Spacific manual for mechanical saal replace Ment procedures If tha mechanical seal is the built in typa the water pump must TELLTALE HOLE be replaced as an assembly Date of Issue Sep 1988 5 8 HONDA MOTOR CA LTD COOLING SYSTEM ss REPLACEMENT BY PASS TUBE Drain the engine ail and coolant Remove the water pump m
172. aftar adjust ment is made ADJUSTER LOCK NUT OIL PUMP AND OIL LINE 2 stroke separate oil supply motorcycles The oil supply on some 2 strokes is controlled by a throttle cable that is coupled with an oil pump Qil flow is regulated in a direct relation to throttle movement and position by a combined oi control throttle cable that CF simultaneously moves tha throttle slide in the carburetor and a BR LEN control arm on the oit pump ogee When the innar cable of the oi control cable stratches tha CONTROL ARM amount of the gil flow changes and is not suitable for the size of throttle opening Therefore it is necessary to inspect and readjust it periodically There is matching mark on the oil pump that must be aligned with the matching mark on tha control arm pump body etc Refer to the Model Specific manual before making any adjustments Oil lina Check the oil fina for leaks detarioration or damage Replace parts if necessary Oil strainer Leosen the tube clip located on the bottom of the oil tank Drain oii into a suitable container Remove the nil strainer joint fram the bottom of the tank OIL STRAINER i E OIL TUBE TUB CLIP SA l OW straner JOINT Remove the strainer screen 2 4 Date of Issue Sep 1988 T HONDA MOTOR CO LTD MAINTENANCE Clean strainer screen by blowing it out with compressed air To replace screen reverse the ramovat procedure Afte
173. aid cooling These holes are perpendicular to the flow of air so little additional cooling occurs Among tha many combinations of materials used to make brake pads are wear resistant resin metallic mixtures and sintered metal These materials are combined in brake pad manufacturing according to the design raquirements of the particular application Asbastos was dropped from use in pad manufacturing by Handa beginning around 1985 86 Just as disc brakes are used where greater than typical drum brake stopping force is required dual disc brakes a disc on both sides of a singla wheel ara usad where an even greater braking capability ar a smailer diameter front wheel is required GENERAL INFORMATION FOR SERVICE Do not allow dust dirt water ar any foreign material ta enter the system when refilling oc replacing the brake fluid a To maintain proper sealing and initial fit replace the parts specified for raplacement at the time of service Replace the required parts as a set when specified for the sare reason Clean the sliding surfaces of the brake pads and disc with brake cleaner Replace the pads if thay are contaminated with oil or grease as this significantly reduces braking force The brake calipers can ba ramoved from the motorcycle and the pads can be replaced without disconnecting the hydraulic systam FLOATING TYPE 5 BRAKE DISC DOUBLE DISC TYPE ii 17 6 Date of Issue Sep 1988 HON
174. ailure Install the washer and snap ring making sure the snap ring is seated firmly in the groove SNAP RING PLIERS 07914 3230601 or equivalent tool m commercially available F i Etoo SNAP RING PLIERS Install the boot and Push rad BOOT Set the push rod end piece into the clutch faver hole Than in a 1 stall the lever with the and piece aver the push rod P m L PUSH ROD Screw in the pivot bolt making sure that the laver moves smoathly then tighten tha pivot nut securely Place the master cylinder on the handlebar and install the UP MARK PUNCH MARK holder with the UP mark facing up HOSE BOLT Align the end of the holder with the handlebar punch mark Tighten the upper halder Mounting bolt first then tighten the tower balt Install the clutch hose with the bolt and two new sealing washers Cannect the clutch switch wires to the switch terminals Fill the reservoir and bleed tha clutch system page 11 28 D f Sep 1968 11 30 HONDA MOTOR CO CT CLUTCH CLUTCH SLAVE CYLINDER SLAVE CYLINDER Place a rag over painted plastic or rubber Parts whenever the system is serviced CAUTION Spilled fluid will damags painted plastic or rubbar parts Remove the slave cylinder Mounting bolts and then ramove the slave cylinder from the crankcase NOTE Do not disconnect the ciutch hose until the piston has HOSE BOLT
175. al oil leaks Incorrect oil baing used Low ail lavel No oil presure Gil level too low Qil pump drive chain or drive sprocket broken Oil pump damaged pump shaft Internal oil leaks 2 Stroke Engines With Separate Oiling System Excessive smoke and or carbon on spark plug Faulty of pump toe much oil flow Low quality engine oil Cvarheating or seized piston No olf in tank at clogged oil line Air in ait lines Faulty oil pump toa little oil flow Clogged oil strainer Qil not flowing out of tank Clogged oil tank cap breather hale Clagged oil strainer 2 Stroke Engines Using Pramixed Fuel Gil Excessiva smoka and or carbon on spark plug Improper jetting for altitude air tamperature and track conditions improperty mixed fuel oil too much ail in fuel Fuel oil mixture too old gasolina has evaporated qane bad Overheating or saizad piston Improper jatting for altitude air temperature and track conditions Fualfoil mixture too old oxidized oil degraded lubrication Premix Gil too old oxidized degradad lubrication Poor quality premix gil improperly mixed fuel oil too little oil in fugl Using fuel oil premix ratio other than 20 1 ee ay yy ayy SS A 2 Date of Issue Sep 1988 HONDA MOTOR CO LTD LUBRICATION SYSTEM DESCRIPTIONS 4 STROKE SYSTEMS TYPICAL OIL FLOW PATTERN On T SHIFT FoRK CONTROL SHAFT ORIFICE z ie
176. al sur rounds the engine This frame is mainly applied to off road vehicles light waight and middle size on road sport type vahictas due to light weight greater strength and ease of serviceability DOUBLE CRADLE FRAME The double cradle dasign is similar to the above mentioned single cradle frame but has two down tubes and main tubes resulting in increased rigidity A part of the down tube can be removed to facilitate engine removal on some models This frame is mainly used on darga displacement on road motorcycles DOWN TUBES Date of Issue Sep 1988 HONDA MOTOR CO LTO 20 3 FRAME BODY PANELS ALUMINUM FRAME The aluminum frama has a lighter weight than the steel frame The use of rectangular and square cross sectian tubing as a structural material provides a greater strength in the direction of stress Tha sub frame can be removed to improve the sar vice aceass on some models This frame is mainly used on Sport type on road motorcycles SUB FRAME INSPECTION Visually check thea frame for damage or bent tubes and components Straighten the handiebar and check the alignment between the front wheel and rear wheel If the rear wheel doas not align with the front check that the drive chain adjusters are adjusted correctly If the above rear wheel leans to either side whan viswed from above check whether the right or left arm is twistad or bent from the horizontal viewpoint of the arm section of th
177. all claarance specifications PLUNGER TYPE NOTE Bo not disassemble and try to repair a two stroke oil pump it will not operete properly once reassembled Replace the pump if it is worn or damaged Remove the oil pump and inspect for the follawing Warn or damaged pump gear Qil leaks from seals Binding pump shaft Connect the oil tube from the oil tank to tha suction side then turn the shaft Check that oil flows out of the outlet PRESSURE RELIEF VALVE Remove tha snap ring washer Spring and valve fram the valve body Check the valve and body for waar scratches or damage Check the snap ring groove for damage If the snap ring groove is damaged the oil supply will be reduced and the engine may 6lze WASHER NOTE install the valve with the open side facing toward the jis 2 Spring E a o In Set Type Oil pump Remove the cutter pin seat spring and valve Check the valve for wear or damage NOTE Install the valve with the closed side facing the spring i Sego A Date of Issue Sep 1998 4 10 HONDA MOTOR CO LTD LUBRICATION OIL PUMP OIL LINE BLEEDING OIL OUTLET LINE aia 2 STROKE ENGINES CAUTION n i ooooooie Be sure to blead ali alt from tha oil system Air in the ail system wili block or restrict oil flow and can cause A a ee 6arious angine damage gt SA x fe NOTE
178. all the camshaft holders and tighten the mounting balts to the specified torque Refer to the Model Specific manual for the correct torque specification NOTE a Do not rotate the camshaft during inspection Remove the camshaft holders and measure the width of each Plastigauge The widest thickness detarmines the oil clearance When the servica limits are exceeded replace the Camshaft and recheck the oil clearance Replace the cylinder head and camshaft holders if the clearance still exceeds service limits Reptace tha rocker arm andor shaft if the Measurements ex SLIDING SURFACES esas ROCKER ARM SHAFTS ceed the service limits a SS A M Date of tssue Sep 1988 9 6 HONDA MOTOR Co LTD ROCKER ARM ROCKER ARM SHAFT Inspect the Sliding surface of the rocker arms for wear or damage where they contact the camshaft or for cloggad ail holas Measure the D of each rocker arm Measure each rocker arm and shaft Q D inspect the shaft for wear or damage and calcutate the shaft to rocker arm clearance CYLINDER HEAD CYLINDER HEAD INSPECTION SOLVENT TEST Remove the cylinder heag 8e sure that the valve is installed on the cylinder head and place the cylinder head with the intake port toward up WN Pour the kerasine from the intaka port inta the cylinder head Ww Wait for a taw minutes then check the combustion chamber side valve area for kerosine leakage COMBOSTON With the exhaust port
179. ance batwaen the connector terminals with the float in up and down positions lf the resistance is normal chack the Fuel gauge lf the resistance is not normal replace the fuel unit LOW FUEL INDICATOR A thermistor is built inta the fuel level sensor in the fuel tank and the fuel warning fight turns on dus to the thermistor s self radiation of haat When the thermistor is in tha gasolins radiation of heat in creases and the self heating action is reduced As the resistance increases and the current dogs not flow at this time the fuel warning light doss not turn an When the thermistor is out of gasoline i e fuel laval is low radiation of heat decreases and the self heating increases As the resistance is low at this time currant flows and the low fuel indicator turns on INSPECTION H the low fuel indicator dogs not go off check as noted below Check for battery voltage between the fue level sansar con nector terminals Battery voltage No battery voltage Faulty fuel level sensor Poor connection of the connector Shorted wire between tha indicator light and sensor Faulty ground 25 8 IGNITION SWITCH MAIN FUSE FUSE THERMISTOR INDICATOR LIGHT Date of Issue Sep 1988 HONDA MOTOR CO LTD Ff the fuel warning light dues mot turn an check as noted below 1 Check for battery voltage between the fuel level sensor connector terminals t No battery
180. and internal voltage feedback method The circuit at right uses tha battery voltage feedback method Date of issue Sep t988 HONDA MOTOR CO LTO AC REGULATOR RECTIFIER m ee ee ee ee es ee ee ee e m REGULATOR KD BATTERY BATTERIES CHARGING LIGHTING SYSTEM AC Regulator Most medium angine displacement motorcycles have indepen dent lighting and charging coils For these models the lighting coil has its own indepandant AC regulator The regulator detects the AC voltage of the lighting coil inside the regulator rectifiar and shorts out all excessiva output There are regulators which regulate both positiva and negative outputs and anas which regulata negative output only Since thesa regulators have lighting and charging coils that operata independently avan if ane of the coils does nat work the other is not affected Triple Phasa Fuli Wave Ractifier This type is mainly usad in madium and large engine displaca ment models The rectifier is connected directly to the three phase alternator This circuit has no lighting coil but instead the battery feeds DC current to the lighting system The rectifiad wavaform of tha triple phase AC output is more stable than the single phase AC type Triple Phase Full VWYave Rectifiers With Fleld Coils This type regulates the alternator output by the current flow ing through the fiald coil The regulator rectifier has a voltage regulator fo
181. and push the rear wheal onto the final drive gear Install the side collar NOTE Note the proper direction of the wheel side collar Set the rear wheel in place and install the axle Far mechanical drum brakes connect the brake rod ar cable to the brake arm and install the adjusting nut loosely Connect the torque rod to the brake panel and tighten tha tor que rod nut to the specified torque Tighten the axle nut first then tighten the axla pinch balt to the specified torque For mechanical drum brakes adjust the rear brake pedali free play UNIT SWING TYPE Removal Remove the frame covers and exhaust muffler if necessary Apply rear brake and loosen the axle put NOTE If the raar axle spins with the axle nut apply torque to tha wrench allowing the scooter to tilt raarward and the rear wheel to contact tha ground Remove the axle nut and rear wheel Installation install the rear wheel by aligning the splines of tha wheel hub with the final drive shaft splinas Apply the rear brake and tighten the rear axle nut to the specified torque NOTE If the rear axle spins with the axle nut apply tarqua to the wrench allowing the acooter to tilt rearward and the rear wheel to contact the ground Install the removed parts AXLE NUT A ONAN SPLINES OA i Eg pee e N eoan Date af Issue Sep 1988 HONDA MOTOR CO LTO WHEEL
182. aquire the higher boiling point characteristic of DOT 4 Avoid mixing different brands of brake fluid Improper mixing such as this may lead to chemical decomposition and cantaminatian It is also important to use only frash brake fluid from a sealed container Once a new container of brake fluid is openad be sure to resaat it tightly and ptan on discarding the fluid after six months This is because brake fluid teft in tha container tends to absorb moisture from the air it is hydroscapic Moisture can form even within a sealed brake system because of this par ticular property Moisture in the brake fluid contaminates the brake systam and lowers the boiling point of the fluid It alsa corrodes the brake cylinders and pistons which eventually causes seal damage and leakage For this reason you should note tha date on the container that it was first opaned for later raference BRUM BRAKE Data of Issue Sep 1988 HONDA MOTOR CO LTD 17 3 BRAKES ee LTE Never reuse brake fluid due ta the possibility of contamination from dust or moisture absorption lf the brake fluid in a system shows any visual signs of con tamination it should be replaced even if the recommended replacement interval has not passed You must be careful when handling brake fluid because it can quickly damage many painted or plastic surfaces on contact In certain plastics structural damage can occur if brake fluid penetrates the matarial
183. arved exclusively for sport type on road motorcycles usually of middle to large angine displacement Virtually all other frames are made of steal Aluminum alloys are lighter than steel of tha sama strength but are bulkier and more expensive to produce A wide variety of tubing and pressed steel shapes as well as castings and forgings are combined to form tha optimal framework for a particular model Many of the earliest Honda models used primarily a round steel tube frame Later models up to 305 cc used a frama made mostly or antirely of pressed steel plate Same of today s frarnas ara made almost entirety af round steel tubing of various sizes and thicknesses Others ara made up mainly of square steel tubing Most aluminum frame members ara some form of rectangular tubing though a few pieces are square The highest stressed rectangular aluminum members are often relatively complex extrusions designed to fulfill a specific set af requirements Most aluminum and steel frames include some castings ar prassed steel sections in order to farm strong and compact tube joints and for pivot or major attachment points Round tubing has the same strength in alt directions Square and rectangular tubing as weli as other variants have different strength characteristics in different diractions When the maximum strength is required in a vertical diraction and the strength in amp horizontal direction is not as important rectangular tubing with greater stre
184. arward screw install the brake Havar and clutch lever brackets or both master MASTER CYLINDER cylinders by aligning the punch mark on the handlebar with the On cable type Slit of the lever brackat On hydraulic type Master cylinder and set the master cylinder holder with the UP mark facing up ar punch mark facing forward or up Tighten the upper or forward balt first then tighten the lower or rearward bolt to same torque HOLDER Apply grease to the cable ends and throttle grip sliding surface THROTTLE CABLE Connect the throttle cable to the grip and install the thractle grip Set tha right handlabar switch by aligning the pin with the hole of the handlebar Tighten the forward screw first then the rearward screw Check that the throttle grip moves smanthly Route the wires praparly and secure them with wire bands Adjust the threttle grip free play Date of Issue Sep 1988 HONDA MOTOR CO LTD FRONT SUSPENSION HANDLE GRIP INSTALLATION IF choke lever is attached to handlebar it must be installed onto the handlebar before you install the grip Apply Honda Bond A or Honda Hand Grip Cement U S A on ly to the inside surfaces of tha grips and to the clean surface of the left handlebar and throttle Wait 3 6 minutes and in stali the grips Rotata the grips for even application of the adhasive Apply sufficient but not sxcessive adhesive to the throttle Ex cassive a
185. ase off the cam and anchor pin Inhaled asbastos fibers have heen found to cause respiratory disaasa and cancer Never uga an air hose or dry brush clean braka assemblies Use an CSHA approved vacuum cleaner or alternate mathod approved by OSHA designed to minimize the hazard caused by airborna asbestos fibars Support the vehicle securely under tha angine to raise the front wheel The speedometer cable and front brake cable must be disconnected On vehicles with hydraulic disc brakes if the wheal cannot be removed with brake caliper s installed on the front fork s remove the wheal after the brake caliper has baen removed with the caliper bracket attached After installing check that the wheel turns smoothly and without play a sh AXLE NUT TYPE BRAKE CABLE Co a T ieee acl Removal Remove the axle nut Full the axle shaft from the fork legs while holding the wheel then remove the wheel f Poon f Installation Drum brake Align the speedometer gearbox retainer tabs with the cutouts and install the brake drum on the wheel hub Install the side callar Coat tha axia shaft with a small amount of grease Place the wheel between the fork legs while aligning the boss of the fork leg with the groove of the brake panel Insert the xle through the fork legs Turn the front wheel so that the speedometer gear retainer will a T angage properly with the wheel hub Hydraulic disc brake Align the stop of tha spaado
186. at a valid compression test there is something else to consider What if tha compression is below the service limit or if the compression is relatively even hatween each cylinder and the engins is not smoking There may be no reason for an expasive rebuild on a good running gngine If an tha other hand the compression on any one cylinder in a twin or multi cylinder engine is significantly lower the engine must be rebuilt TESTING NOTE ing system as first introduced on the XR6OOAR and NX650 tha decompressors must be deactivated Orier to checking Warm up the engine to normal Operating temperature Ten minutes of stop and go riding is sufficient Install the compression gauge attachment to the cylinder to ba tested Connect the compression gauge if the motarcycle has a decompressor be sure it ig ad justed properly before checking compression Qn motar cycles equipped with an automatic decompression start C COMPRESSION GAUGE Stop the engine and remove a spark piug fram each cylinder NOTE Make sure that there are no leaks around the attach a et A s TOOL COMPRESSION GAUGE 07305 0010000 Kick start models Fully open the throttle and choke valves strongly kick the Starter pedal through several times and check the s rce compression ATTACHMENT Elactric start models Turn the engine stop switch OFF OUT Fully open the throttle and chaka valves crank the engine with the s
187. ate a isack of lubrication Try to push the swingarm from side to side to check for worn damaged or loose suspension pivot componsnts If any play is detected check for looseness of the swingarm pivot bait Check also for wear or damage to the pivot bearings for bushings If looseness is detected in the up down motion at the end af the arm on Pro link suspensions check far wear or damages to tha shock absorber mount pivat point Check for leakage from the oil saals on the fork scratch marks on the working surface of the fork tubes and wear and peeling of the chrome plating On models equipped with rubber boots on the fork legs turn back the boots to allow mspaction If the fork is in poor condition disassemble and replace parts a necessary NOTE Replace any fork tube that is heavily scored Date of Issue Sep 1988 2 34 HONDA MOTOR CO LTD MAINTENANCE On models with bottom link typa front suspension check for lt s FORK ROCKER AAM cracks and damage to the fork racker arms bottom links S aes Check for play in the fork rocker arm bearing section and in NPT spect all fasteners for looseness Check for ail leakage around the shock absorber pistan rad Inspect the rod fer scoring wear and peeling of the chrame plating on the working surface Check for looseness cracks and damage to the attachment points nf tha shock absorber assembly Ra tighten nuts bolts if necessary SPARK AR
188. ation qualities Vegetable type premix oils separate from gasoline more easily than mineral oils especially in cold weather It is advisable to use mingral oil when ambient temperaturas below 0 C 32 F are expected CAUTION Mixing vegetable and mineral based damage O O OO oils will cause premature engine wear ar Date of Issue Sep 1988 4 6 HONDA MOTOR CO LTD LUBRICATION OIL PUMP DESCRIPTIONS TROCHOID TYPE GASKET Tha trochoid type oil pump is the mast common ail pump design used in 4 stroke engines It is designed to turn two rotors within a casing with an inner rotor fixed on the pump shaft drive shaft and an outer rotor on its circumfarance When tha inner rotor is turned by means of the ail pump shaft the outer rotor also turns with the clearanca betwesn the two rotors varying Lubricant is drawn through by suction when the claaranca is anlarged Oil is delivered ta the opposite side through this clearance and is then routed into the discharge passage when the clearanca lassens The more teath the inner and outer rotors have the less the amount of pulsation The oil flow volume increases in direct proportion with the increase in thickness of the rotor dimension PUMP BODY PUMP SHAFT INNER ROTOR Some models hava a double rotor trochoid type ail pump which collects oil directly from both the oil cooler and the OUTER ROTOR DISCHARGE sump IP
189. attery voltage may recover after battery charging but under heavy load battery voltage wih drop quickly and eventually die out For this reason the charging systam is often suspected to be the problem Battery overcharge often rasults from problams in the battery itself which may appear to be an ovarcharge symptom ff one of the battery cells is shorted and battery voltage does not increase the raguiatar supplies axcess voltage to the battery Under these conditions tha eleg trolyte level goes down quickly Before troubleshooting the charging system check for proper use and maintenance of the battery Check if the battery is frequently under heavy load such as having the headlight and taillight ON for lang periods of time Tha battery will self discharge if allowed to stand idle for a long time For this reason charge the battery every two weeks to prevent sulfation from forming whan the vehicle is not in use Filling a naw battery with electrolyte will produce sama voltage but in order to achieve its maximum performance always charge the battery Also the battery life is lengthened when it is charged When checking the charging system always follow the steps in the troubleshooting flow chart TROUBLESHOOTING BATTERY OVERCHARGING On combined lighting charging coil systems check the following areas A check is unnecassary for an independent lighting and charging system Headlight bulb rating Wattage tao low Broken output wire
190. atural rebounding action of the springs Many of the simplest and mast lightweight motorcycles and scooters are equipped with single damping or single eftect type dampers This design provides damping force only an the rebound stroke and relies on the compression rasistance of the spring alone to absorb riding surface irregularities Tha most effectiva damper dasign is the double damping or double effect type In these damping force is provided for both compression and rebound strakas Soma damper designs includa nitrogen gas within their bodies or within a reservoir to prevent the oil from foaming in emulsion type dampers tha nitrogen is fillad in tha damper body Same of this typa has a saparatar in the gas chamber by which gas ig hard to he mixed with tha ail Decarbon design dampers keep the nitragan gas separated from tha oil by maans of a frea floating piston which acts as a diaphragm This way the oil can pass through the damping orifices without interference from the gas bubbias Reservoir equipped dampers are a variation of the simplest Decarbon design A more consistant oil temperature and therefore more consistent damping is provided due to an in creased oii Gapacity the shock body can be entirely filled with oil since the gas chamber is elsewhere A rubber bladder is us ed within the reservoir to saparate the nitrogen gas from the damper oil DOUBLE DAMPING iDOUSLE EFFECT TYPE we EMULSION TYPE _ SEPARATOR DE
191. aws of the Suter circumference of the clutch disc are engaged with the grooves of the clutch outer The mainshaft of the transmission and tha clutch centar are however fixed with a lock nut Furthermore the clutch center and the clutch plate are engaged with the spline Thus the Clutch plates rotate with the rear wheel through the transmission gt CLUTCH CLUTCH OUTER PLATE ears bi PLATE PRESSURE gt CLUTCH a PLATE CK NUT ens sy end eat d CLUTCH M LIFTER THRUST CENTER nen WASHER CLUTCH CLUTCH SPRING DISC When the ctutch lever is pulled in the clutch lifter mechanism presses the pressure plata through the litter plate resulting in a gap between the disc and tha plate Ths power of the crankshaft is now not transferred to the rear wheel When operating the transmission gears and gradually relaasing the clutch lever the Pressure plate bagins to press the disc and plate by the tension of the spring and the dises and the plates begin to transmit power by sliding contact At this time the vehicle will start to mave When the clutch lever is compietaly relaasad the dises and Pilates are camplately caught between the pressure piate and CLEARANCE APPEARS the clutch centar and no longer mutually slip The power of PRESSURE the crankshaft is thus completely transmitted to tha rear CLUTCH DISENGAGED CLUTCH ENGAGED wheel Date of issue Sop 1988 1 1 2 HONDA MOTOR CO LTB CLUT
192. ble the clutch PRIMARY SET AING DRIVE GEAR CLUTCH INSPECTION LIFTER PLATE Lifter Plata Bearing Type A B C and D The liftar plate bearing inner raca is loaded by the lifter rod whan the clutch is disengaged Inner bearing raca damage ef fects the clutch operatian Turn the bearing inner race with your finger and check that the bearing turns smoothly and quietly without play Also check that the outer cace fits tightly in the lifter plate Clutch Outer Types A B and D Check the primary driven gear teeth for wear or damage replace as necessary Check the slots of tha clutch outer for nicks damage or waar from the clutch discs replace as necessary DRIVEN GEAR Ciutch Outer Guide Needle Bearing Types A B and C CLUTCH Measure the LD and or O D of the elutch outer guide CUTER Replaca if the service limits are excasded Check the naedle bearing for damage or exessive wear replace if necessary NEEDLE BEARING Date of Issue Sep 1988 HONDA MOTOR C LTB CLUTCH Clutch Disc Types A B C and w Check the clutch dises for scoring ar discoloration replace as nacessary Measure the disc thickness and replace the discs if the ser vice limit is exceeded NOTE Replace tha clutch discs and Plates as a sat aaa Clutch piate Typas A B and D Chack the clutch Plates for warpage or discoloration replace if necessary Check for pfate warpage
193. ble the gear ta slide smoothly resulting in an easier shift TYPE A SHIFT CLUTCH COMBINED The centrifugal and shift clutches are combined to be mounted to the crankshaft CLUTCH i CLUTCH DRIVE f WEIGHT PLATE 7 PLATE CLUTCH CLUTCH gt CLUTCH CENTER DISCS SPRING DRIVE pe e _ i PRIMARY OUTER F GEAR Sal LPS Te D DAMPER 5 SEs eee SET RING a ye i PRIMARY pn DRIVE GEAR J CLUTCH LEVER 43 CLUTCH LOCK NUT SHIFT LIFTER 8 BALL ely MECHANISM PETMINERT ini ea LIFTER PLATE CAM i BEARING At low engine speeds the centrifugal forca applied on the When tha engine speed is increased the centrifugal force clutch weight is less The weight does not work anda gap applied ta tha clutch weight increasas The weight moves exists batween the clutch pilates and dises The Clutch is outwards and presses the clutch plate The plates and the disengaged dises therefore losely join and the power of the crankshaft will ba transmitted to the primary drive gear CLUTCH PLATE ChuTCH disc CLUTCH OUTER CRANKSHAFT CLUTCH WEIGHT PRIMARY DRIVE GEAR Date of Issue Sep 1988 1 HONDA MOTOR CO LTD 1 7 CLUTCH In some cases a roller is usad instead of a clutch weight be tween the drive plate and the clutch plate In this type cen trifugal force shifts the rollar to tha outside of the drive plata Causing the pressure on the clutch plate to engage the clutch GEAR
194. c manual Remove the screws and lifter cover Remove tha following LIFTER ROD LIFTER Stopper pin and lifter arm ARM STOPPER Screw and set plata PI Lifter plate and lifter rod SET PLATE Date of Sep 1988 1 1 ne 1 0 S HONDA MOTOR CO LTD CLUTCH Check the following Lifter arm for straightness Return spring for weakness O ring for damaga Sliding surface of the lifter arm for a6normal wear or damage RETURN SPRING CLUTCH REMOVAL DISASSEMBLY CLUTCH SPRING Type Aj Loosen the clutch Spring bolts in a crisscross pattern in 2 or 3 staps Remove the clutch spring bolts lifter plate and clutch springs If the clutch is secured with staked lock nut unstake the nut Remove the lock nut and iock washer using a special toal lf a Snap ring is used Remove the snap ring and clutch assembiy CLUTCH CENTER HOLDER Type B CLUTCH SPRING Logsen the clutch Spring bolts in a crisscross pattern in 2 ar 3 OLT steps Remave the clutch spring bolts pressure plate and clutch springs NOTE Hydraulic Clutches To Protect the clutch system from air contamination slowly squeeze tha clutch lever im mediately after removing the pressure plata then tie the i lever ta the handlebar grip an Date af Issue Sap 1988 HONDA MOTOR CO LTD 1 1 1 71 CLUTCH Remove the lifter rod push rod discs and clutch platas NOTE Some models have a steel hall
195. c acid felectrolyta Con tact with skin or ayas may cause severe burns Weer protective clathing and a face shield If electrolyte gets on your skin flush with water If electrolyte gets in your ayes flush with water for at least 15 minutes and call a physician Electrolyte is poisonous If swallowed drink larga quantities of watar or milk and follow with milk of magnasia or vegetable oil and call a physician KEEP OUT OF REACH GF CHILDREN er 1 GENERAL INFORMATION FASTENERS BALL BEARING REPLACEMENT Coclant Under some conditions the athylene glycol in engine coolant is combustible and its Flama is not visible f tha ethylene glycol does ignita you will not Sae any flame but you Can be burned A WARNING Avoid spilling engine coolant on the exhaust system or engine parts They may be hat enough to causa the coolant to ignite and bum without a visibia flame Coolant ethylene glycol can causa some skin irrita tion and is poisonous if swallowed KEEP OUT OF REACH OF CHILDREN Do not remove the radiator cap when the angine is hot The coolant is under Prassure and could scald j yau Keep hands and clothing away from the cooling fan ie as it starts automatically If it contacts your skin wash the affected areas im mediately with soap and water If it contacts your eyes flush tham thoroughly with fresh water and get immediate m dical attention If it is swallo
196. c system claggac Date of Issue Sep 1988 HONDA MOTOR COQ LTD 1 1 1 CLUTCH SYSTEM DESCRIPTIONS The clutch system is to disconnecticonnect the power of the crankshsft Most Clutches are placed between the primary reduction and transmission With some models however thay are attached directly to tha crankshaft The actuation of the clutch can be roughly divided inte two types the manuali clutch controlled by tha rider and tha centrifugal clutch Perfarming connection disconnaction of the power according to engine rotation The clutch contrals the transmission of power by frictional force When the clutch is completely disengaged power cannot be transmitted to the rear wheel When the vehicle is started the clutch gradualty increases its frictional torce and smoothly transmits power ta tha rear wheel When the clutch is completely engaged the power of the Crankshaft will ba directly transmitted to the rear whagl If the clutch is Partially raleased with the enginea at high ram the raduction in friction farce Caused by heat or waar in the clutch causes the clutch to slip evan when completely engaged As a result power transmission is lost WET MULTIPLATE MANUAL CLUTCH TYPE A OUTER PUSH TYPE This is the most conventional clutch type used on Motorcycles The primary drive gear of the crankshaft drivas the primary driven gear Integrated in tha clutch outer The clutch dise and the clutch outer rotate with the crankshaft as the cl
197. capt able wear resistance on tha inner surface of the brake drum the drum itself is made of cast iron The remainder of the drum hub is made of aluminum alloy with cooling fins cast into the auter circumference again for heat conductivity and dispersion but also for reduced unsprung weight To spaad conductivity the cast iron drum is captured within the aluminum hub and cannot ba removed The drum thickness is ralatively thin which further aids heat conductivity and must not be machined in a brake lathe If tha drum surface is severely damaged tha hub must be replaced HYDRAULIC BRAKES Brake Fluid Tha designations DOT 3 and DOT 4 specify the brake fluid s ability ta withstand heat without boiling Tha greater the number the higher the boiling point It is necessary for the brake fluid to have a high bailing point so that the fluid doas not boil within the brake ling due to the high temperature af the brake discs and components Boiling brake fluid leads to a drastic toss of braking force due to the air bubbles that form within the brake lines Never mix DOT 3 and DOT 4 brake fluid within a system It is important to add only the sarie DOT number and even the same brand of braka fluid when adding fluid If you are unsure of the type within the system drain the system and refill it with DOT 4 systems designed for DOT 3 can use DOT 4 But DOT 4 systems must never be filled with DOT 3 DOT 4 systams generate greater heat and thereby r
198. ccording to fastener Strength strength of fastened parts and intensity of external forces Tightening must be carried out in strict accordance with this specification especially at important points Tighten ing a connecting rod bearing cap with a stronger force than is proper for example will deform the tightened part ibearing cap slightly and cause the oil clearance for the bearing ta become smaller than specified which may lead to the bearing seizing An insufficient tightening force on the other hand may allow the nuts or bearing caps to loosen and fall off during engine operation leading to serious engine trouble iae CS 1 8 HONDA MOTOR CO LTD METAL BEARING A REDUCED OIL CLEARANCE As mentioned garlier the most important point in fastaner tightening is the tightening force The problem is that this tightening Force axial tension is difficult ta measure Using a predetermined tightening torque is therefora the most cammon method of controlling fastener tension t must be nated that in this control method using torque values the axial tension is proportional to the torque under certain conditions Under other conditions this important axial tension varies even when the fastener is tightensd to the same torque The table on the tight gives some oxatnples of friction co efficient whan oil has adhered to the threaded portion Under the same conditions from the viewpaint of the tightening t
199. ce into OUTER RACE the steering head by turning nut A gradually until the groove of x DRIVER the attachment aligns with the bottom of tha staaring head Steering Stem Battom Race Replacement Temporarily install the steering stem nut anto the steering stem to prevant damage to the threads Remove the bottam race and dust seal using a drift and discard them DUST SEAL AND BOTTOM RACE Date of Issue Sep 1988 1 3 1 8 HONDA MOTOR CO LTD rN radon Install a new dust seal and bottom race onto the staering stem Press in the bottom race using the steering stem drivar and a hydraulic press STEERING STEM INSTALLATION Loose Ball Type Apply greasa ta the top and bottom cone races Install the Steel balls anto the top and battom races making sure you have tha correct amount insert the steering stam taking care nat to dislodga the steel balls fram the grease Hold the steering stem in the place and install the top race and bearing adjustment nut Tighten the bearing adjustmsnt nut to the proper torque Refer to the Model Specific manual for this specification Move the steering stem right and left lock ta lock several times to seat the bearings Make sure that the steering stem moves smoothly without play or binding then loosen the bearing adjuster nut Retighten the bearing adjustment nut to 15 N m 41 5 kg m 10 ft lb then loosen the adjustment nut 1 8 turn Racheck that the steering stem
200. ch model The drain tube needs to be checkad for oil accumulation more frequantiy if tha machine has been consistantly ridden at high speeds or in rain W AIR OIL SEPARATOR CS D TRANSPARENT SECTION DRAIN TUBE i DRAIN PLUG lt E FRESH AIR BLOW BY GAS 2 Date of Issue Sap 1988 7 HONDA MOTOR CO LTO EMISSION CONTROL SYSTEMS EXHAUST EMISSION CONTROL SYSTEM SECONDARY AIR SUPPLY SYSTEM Ths exhaust amission cantrol system is composed of lean carburetor settings and no adjustment shouid ba made except idie speed adjustment with the throttle stop screw The exhaust emission contral system consists of a sacandary air supply systam which introduces filtered air into the exhaust gases in the exhaust port Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system This charge of fresh air pramates burning of the unburned exhaust gases and changes a considerabla amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water A reed valve prevents raversa air flaw through the system The air injection control valve reacts to high intake manifold vacuum and will cut off the supply of fresh air during engine deceleration thereby preventing afterburn in the exhaust system No adjustments ta the secondary air supply system should be made although periodic inspection ot the components is recommended AIR INJECTION VACUUM TUBE CONTROL VALVE AIR
201. ched to the top fork bridge Retar to the Model Specific Manuat for specific procedures FUSE HOLDER Remove tha following Stem nut and washer STEERING STEM NUT Front wheel and fork Fork top bridge Horn and or brake hose joint if either ara attached The lack washer tab must be bent down in order to remove the lack nut LOCK NUT Remove the lock nut and lock washer LOCK WASHER D fl Sep 1988 HONDA MOTOR cO LTD 1 8 1 5 FRONT SUSPENSION Remove the bearing adjustment nut lf the bearings are the loose balt type place a shop towal under the staasiny stem to catch the steel balls Remove the dust seal and top cone race or inner race while hoiding the steering stem with your other hand Thon remove tha stearing stem from the frame NOTE Where loose balls are used be sure you have the correct number of balls to ensure none have begn lost Tapered roller beatings or ratained ball type bearings shovid be removed from the steering stem after tha stem has been removed from the trama Inspection Check all of the races and balls for damage or abnormal wear and replace as necessary LOOSE BALL TYPE STEERING STEM SOCKET a TOP CONE RACE iOR INNER RACE BALL RACE TOP CONE RACE BOTTOM CONE OR INNER RACE RACE OR INNER RACE p OUTER RACE RETAINER TYPE STEEL BALL TAPERED ROLLER BEARINGS 18 16 Date of Issue Sep 1988 HONDA MOTOR CO LTB
202. cid alkaline SQUEEZE 80 90 for four strokes Honda 2 stroke oil for two strokes or organic volatile type oil may cause improper ignition Gaterloration of the element or a loosening of the ale ment adhesive Be sure to allow the elemant to dry thoroughty before applying ail Otherwise the oil wilt be diluted by the salvent and tha filtering ability of the filter wil be much less affective Spread clean 80 90 gear gif 4 strokes Honda 2 stroke oil for 2 strokes on the element rubbing in thoroughly over the surface with both hands and then Squ 62e out any excess ail CAUTION Using air filter ail whan ridieg in axtremely dusty condl j tions prevente premature engine wear due to dust dirt drawn into the engine Apply air filtar oll to tha entira ur face of the element and rub it with both hands to saturate the element with oil Squeeze out excess oil Date of Issue Sep 1988 2 6 HONDA MOTOR CO LTD MAINTENANCE Paper Elament ELEMENT If the surface of the element is dirty remove the dust first by tapping the element gently Then blow away any remaining Gust on the surface of the filter with compressed air from the inside jor carburetor sida toward the outside Viscous Paper Element This particular type of paper element cannot be cleaned as the element contains a dust adhesive These must be changed periodically AIR CLEANER AI
203. crankshaft through the connecting rod To smooth the motion conversion the pin hole of the piston is slightly offset against the canter shaft of the crankshaft if the piston is assambled in an incorrect direction the piston Strikes the cylinder wall due to reversed offset causing rapid wear or seizure To assemble the offset correctly the assambly must be done by following the marks indicating tha piston head assembly direction PISTON RING 4 STHOKE The piston rings are inserted within the grooves in the piston Rings are made of a mmatarial with considerabla wear resistance as the piston rings mave at high speed with the pistan while baing pressed against the cylinder wall by their own tension The ring arrangement for the 4 stroke engine is with twa com Pression rings sealing the combustian gas and a pair of ail rings temoving the oil from the cylinder wall Atthough the twa compression rings are similar in appearance they are different in detail Therefore when removed their in Stallatian position must be noted and marked before staring to Prevent incorrect reassembly If identification is difficult tha difference in shapes should be remembered the top ring is usually plain and the second ring has a bevelad edge Most of the top rings ara chroma plated on their sliding surfaca in order to increase wear resistance A few Second rings are howaver also plated Piston rings for 4 stroke engines and also far 2 stroke engines
204. cted HOW TO USE THIS MANUAL This manual explains the theory of operation of the various systems common to HONDA motorcycles and motor scooters and ATVs It also provides basic information on troubleshooting inspection and repair of components and systems found on these machines Refer to the Model Specific Service Manual for the model you are servicing for ad justments maintenance and repair informa tion for components on that model Section 1 provides general information on the whole motorcycle as well as Warnings and Cautions to remember when performing maintenance and repairs Sections 2 through 15 cover all aspects of the engine and drive train Sections 16 through 20 include all of the component groups that make up the chassis Section 21 through 25 apply to the various electrical components and systems found on Honda motorcycies An extensive alphabetized Index provides rapid access to information on specific com ponents or systems an information illustrations directions and specifications included in this publication are bas ad an the latest praduct information available at the time of appraval for printing Honda Motor Co LTD reserves the right ta make changes at any tima without notice and without incurring any obligation whatever Ne part of this publication L may be taproduced without written permission HONDA MOTOR CO LTD Service Publications Office Date of Issue Sep 1988 HON
205. ctively are injected into the main bore to supply a rich mixture lt Auto bystarter system gt The auta bystarter PTC is a device for incraasing the volume of fuet itis comprised of components such as a heating element thermo wax liquid medium piston and the bystarter valve The principle of operation is as follows When the engine ts stopped and there is no production of cur rent from the alternator the starter valve is maintained in the raised position by a spring in this position the fual increase cir cult is fully open ready for supply at any time When the engina starts fuel is supplied through the fue in crease circuit At the same time the alternator sends current to tha PTC for heating The increase in heat is sensed by the thermowax which begins to expand The movement is transmitted through the liquid medium to the piston set callar and set spr ing and the startar valve is depressad As the valve is lowered the jet needle starts to shut off the fuet increase circuit which after a faw minutes closes fully ending fuel compensation Siow system low degres of opening As the throttle valve is anly slightly open at iow angine speeds tdegree of opening fully clased 1 4 pressure an the intake side is low which allows same residual gas from combustion being sucked back into the intake manifold where it is mixad with fresh charge from the carburetor The resulting mixture is lean Low engine speed is lin
206. ctrolyte gots in your eyes flush with water for at laast 15 minutes ang cail a physician immediately Electrolyte is poisonous If swallowed drink large quan titias of water or milk and follow with milk of magnesia or vegetabla oil and call a physician KEEP OUT OF REACH OF CHILDREN PLATF Se es Sa LEAD i LEAD PEROXIDE ELECTROLYTE Usa only distilled water in the battery CAUTION Tap water will shorten the service lifa of the battery CAUTION Avoid filling tha battery above the UPPER LEVEL lina to pravent an alactralyte Gvercflow which could corroda the j engine or nearby parts Date of Issue Sep 1982 22 4 HONDA MOTOR Q LTD When yau charge the leadacid battery electrolysis breaks the water down irto tts components hydrogen and oxygen Because of the generation of thase gases you must remova the filler plugs while charging the battery The battery ig equipped with a vent Usually routed overboard into tube to rid it of the gases produced during normal use The battery is said to be overcharged when an excess current is Supplied to the battery When the battery is overcharged volatile gas is emitted from the plates and electrolyte temperature rises This temperature rise causes more rapid loss of water from the battery electrolyte This watar loss and tamperature rise will shorten the battery life If left unchecked water loss and high temperature wil damage th
207. d jets rasulting in hard starting or poor driveability FUEL FRESHNESS AND TROUBLESHOOTING Engine performance is directly related to the quality and freshnass of the gasolina consumed Therefore it is important to ba sure the fuel within the motorcycle scooter of ATV you ara servicing is usable for your testing procedures You may sava valuable troubleshooting time by replacing fuel if its quality or age is in doubt Detonation or pinging on acceleration is an indication that the fuel is either not of good quality or is too jaw in octane rating for your application Fuel should be no more than six to eight weeks old in the case of a minor performance problem and no more than three months old in the case of more serious performance problems Date of issue Sep 1988 8g 1 ONDA MOTOR CQ LTD FUEL SYSTEM TROUBLESHOOTING Engine won t start No fuel to carburetor Fuel strainer clogged Fuel tube ciagged Float vaive stuck Float level misadjusted Fuel tank breather tube for hole clogged Fuel pump malfunetion Fuel auto valve malfunction Too much fuel getting to the engine Air cleaner clogged Flooded carburetor Intake air leak Fuel contaminated deteriorated Slow circuit or bystarter circuit clagged Lean mixture Fuel jats clogged Float valve fauity Float leve too low Fuel line restricted Carburetor aw vent hole or tube clagged fntake air leak Fuel
208. d components by testing the connectors on the wire harness side Data of Sep 1988 HONDA MOTOR co LTD 23 1 3 IGNITION SYSTEMS Checking items at tha CDI unit connector ev Checking item Diagnosis CE E AS a a a A o a spasi Ignition switch Engine stop switch When the ignition switch is ON and engine stop switch at AUN chack for con wire excluding DC CO tinuity between body graund and ignition switch wirc Exciter coil wire excluding DC CDI Chack if the specified resistance value is obtained between body ground and exciter coil wire Check if the specified resistance value is abtained between body ground and pulse ganerator wire Pulse generatar wire Ignition primary coil wire Check if the specified resistance Value is obtained between body ground and primary col wire Chack far continuity between ground and the w wire corresponding to the transmission gear position Neutral raverse change switch for certain models only When tha ignition is ON and enging stop switch at RUN check if battery voltage appear between battery input line and ground wire Battery input line onty far DC CDI Ground wire Wire harness Check for continuity between ground wire and body ground wira Ifthe above inspections are normal but the spark plug still does not fire the problem could be related to the CDI unit or igni tion coil Check
209. d removing i Measure and record each valve guide I D using a ball gauge or inside micrometer STEM TO GUIDE CLEARANCE Whan using a dial indicator Measure the guide to stem claarance with a dial indicator while rocking tha stem in the direction of normal thrust wob bla method REPLACEMENT Refinish the valve seats whenever the valve guides are replaced to prevent uneven seating Flanged Guides Chill the valve guides in the freezar section of a refrigerator for about an haur Heat the cylinder head to 130 C 140 C 275 F 296 F Do not heat tha cylinder head beyond 150 C 300 F Use temperature indicator sticks available from welding supply stares to be sure the cylinder head is heated to the proper temperature VALVE GUIDE REMOVER or DRIVER CAUTION Using a torch to heat the cylinder head may cause warping Wear insulated glaves to avoid burns when handling the heated cylinder head LC Support the cylinder head and drive the ald guides out of the combustion chambar side of the cylinder head Date of Issue Sep 1988 HONDA MOTOR C LTD 9 9 CYLINDER HEAD CAUTION Co Avoid damaging the haad when driving tha valve guida Tan tL a ee se VALVE GUIDE REMOVER or DRIVER Apply oil to a naw O ring and install it onto a new valve guide Drive the naw guide in from the camshaft side of the cylinder head while the cylinder haad is still heated
210. d to loosening or shearing of the fastener Therefore it is important to identify both these specially designed bolts and the positions where these are required Always clean fastenars thoroughly if there is any dirt present anywhere on the fastener installing fasteners with dirt or other foreign matter on their threads or on the bolt or nut bearing surfaces will result in im proper axial tension despite the use of the proper torque specificatian As the dirt or foreign matter breaks down due to vibration and the attached parts working against each other the fastener will soon werk its way loose There are Several methods of preventing the various types of fasteners from loosening Some rapresentative example are Ar sented on the next page together the necessary instruc tions for proper use im 100 cm te SPECIAL BOLTS i 1 kg m 110 kg cm 1 kg m 100 kg crn 1 10 Date of Issue Sep 1988 HONDA MOTOR CO LTD GENERAL INFORMATION Locking TYPES OF FASTENERS APPLICATIONS CAUTION 1 Lock washer Conventional split Various points on frame Do not use lock washers which have Inst ring type Bolts incorporating washers their efasticity ar are deformed nr eccentric j are also available Excessive tarque will open or deform the washer and render it useless Usa an appropriate size tor thread dia or hex point When using with a plain washer always put t
211. d valve if the seat rubber is cracked os damag EEG ad or if there is clearanca between the reed and seat CAUTION Disassembling or bending the reed stoppar ar raad valve will damage it Replace the reed valva as a unit If the stopper reed or seat is faulty EMISSION CONTROL INFORMATION EXAMPLE LABELS Labels for the emission control system consist of three kinds of information labels as described balaw 1 Emissian control information label Gives basic tune up specifications SENEE TWISUON CONTROL BEGARATION UPDATE POND MOOK CO ITA wo N ADMSTED 10 2 Emission control information update labe Se KAI pE D A H AL After making a high altitude carburetor adjustment at ALE PLAFRAARCE ADISSTHENT INcTROCTIONS tach this label at the specified location ARE AVARLURE KT TOUR AUTMORZED HINDA DEALER Instructions for obtaining the update lebel are given in Service Letter Na 132 3 Vacuum hose routing diagram labe California model only Route the vacuum hasas as shown on this label On efter 85 models all hoses used in the secondary air supply and evaporative emission Systems are numbered for identification so Compara the hose number with this label whan connecting one of these hoses NOTE Refer to the Model Specific manual for the location of F each labal i Date of Issue Sep 1988 HONDA MOTOR CO LTD 7 9 8 FUEL SYSTEM SERVICE INFORMATION FUEL AUTO VALVE TROUBLES
212. de inward Turn tha snap ring to ba sure that it js seated in the groove D f Issue Sap 1988 11 20 HONDA MOTOR CO LTD ee 2S RG NUT SS CHAMFERED CLUTCH LOCK NUT WRENCH Tightan the lock nut to specified tarques using a special tool Where a staked lock nut is usad Stake the nut ta the mainshaft NOTE Replace staked type lock nut if the old staked area of the nut aligns with the graove of the shaft after tighten ing the nut to specified torque Ba careful not to damage the shaft whan Staking the lock nut Make sure that the peen paint covers at least 2 3 of the width of the mainshaft groove Set tha bearing in the lifter plate than install the clutch springs and the lifter plate Install the clutch spring baits and tighten them in a crisscross pattern in 2 or 3 steps LIFTER PLATE iType B Install the clutch outer guida needle bearing and clutch outer see page 11 19 Install the clutch center Install the lock washer and lock nut sea page 11 20 Tighten the lock nut using the special tool to hald the lutch center Stake the lock nut if necessary Date of Issue Sep 1998 HONDA MOTOR CO LTD CLUTCH A iag Coat the clutch plates and discs with clean engine ail CLUTCH 2 j Install the judder spring sgat ang spring discs and clutch pilates NOTE ij The ludder spring and spring seat should ba installed ag shown The disc
213. dels power electrical component with the electricity generatad by the alternator which is regulated by an AC regulator For Gamponents using transistors which re quire DC current a smal rectifier ICD power unit is used ta rectify alternator signals to DC and feed DC current to these componants Voltage reguletor To provide 3 stable current without using a battery a high power output alternator that feeds sufficient current at low engine rpm is utilized If the altarnator continues supplying cur rent as the engine rpm incraases the axcessive current mey burn out light bulbs To pravent this the AC regulator maintains the output voltage of the alternator in the spacified ranga Some AC regulators have a protection circuit built into the alternator regulator circuit to prevent abrupt voltage increases on cald angine starts The currant ganarated fram the alternator flaws directly ta the loads at voltage levals lower than the regulated voltaga valua As the engine rpm increases the regulator detects the risa and directs current ta thyristor shorting the alternator output to ground When the alternator voltage goes over the spacified voltage the regulator cuts off the excess valtage maintaining a constant voltage output BC voltage unit Although most electrical companants racaive AC currant there ara systams such as the engine oil warning system which require DC current to operate their transistors and LEDs Therefore a compac
214. dhasive forced into the interior bare of tha drum will H restrict free drum movement on the handlabar HANDLE GRIP HANDLE GRIP Allow the adhasive to dry for at least an hour before using Sos P INNER WEIGHT Any restriction of the throttle can cause a loss of throtta END WEIGHT control HANDLEBAR WEIGHT REPLACEMENT PIN DRIVER End Typa Waights Remove the mounting scraw and weight Inner Type Waights Remove tha handiabar grip Spring pin type Drive out the spring pin using a pin driver Retainer ring type Straighten the locking tab To remove pull the weight whila twisting it NOTE The inner weight is centered within the bar RUBBER SS RETAINER CUSHION T Ag RING INNER Y WEIGHT Install a new retainer ring to the inner weight and install the RETAINER LOCKING nd weight aligning the cutout HOLE LOCKING TAB Insert the weight into the handlebar and turn it to engure that the lacking tab aligns with the hole Date of Sep 1988 1 8 1 4 D HONDA MOTOR co LTD f FRONT SUSPENSION Insert the weight into the handlebar and align the spring pin SPRING PIN INNER WEIGHT holas by turning it Secure the weight with the spring pin using pin driver STEERING STEM 7a earn ey lf the vehicle has be n involved in a collision the steering stem may be damaged REMOVAL Telescopic Types Remove the handlebar Remove the ignition switch and or fuse holder if either are at ta
215. djustment method ENGINE OIL NOTE Do not screw in the ail cap level gauge when aaa ail level The oil level cannot be correctly measured if the motor cycle is not Supported perfectly upright on a level surface As the ail is gradually consumed it is necessary to periodically check the oil level and replanish tha oil j valume to its proper leval If tha oilievel is too high overall angine performance and the actuation of the clutch may be effected Tao fittie ail _ may cause engine overheating as well as premature wear ta various parts Wfadifferani brand or grade of oil or low quality oi is mix ed when adding ail the lubricating function deteriorates Check the oil level only after Starting the engine and allowing the ail to circulate through the angine throughly It is especially important to run the engins hefore checking the oil level on a dry surnp angine due j to the comparatively large volume of oil OIL LEVEL CHECK DIL CAP LEVEL GAUGE UPPER LINE LOWER LINE 4 stroke Wet Sump Engines Start the engine and let it idle for a few Minutes Stop the engine remove the oil level gauge and wipe the pif from the gauge with a clean cloth Two of three minutas after stopping the angine with the motorcycle in an upright position insert the level gauge into the angine without screwing it in The engine contains a sufficient amount of oil i
216. ds currant to the gate of SCR when a nagative voltage pulse trom the pulse generator is input to the determination circuit or when the wave A becomes greater than wave B The current to the gate of SCR turns on tha SCA and ignites the spark IGNITION TIMING DETERMINATION Since wave A remains constant and wave B changes its CIRCUIT DUTPUT waveform as the engine rotation increases wave B becomes smaller than wave A As the engine speed increases the tim ing at which wave A becomes greater than wave B advances When the engine speed increases above N4 ignition timing no longer advances because basic wave A is not inclined SCR GATE INPUT IGNITION TIMING At NI wave Bis larger than wave A and thus ignition timing is determined by tha negativa voltage pulse from the pulse generator Ti Tz Ts Ts peeked ANGLE 35 10 BTDC BTDC Date of Issue Sap 1988 23 6 HONDA MOTOR CO LTD IGNITION SYSTEMS a oy DC CD The DC CDI ignition system is basically a CDI system except that the battery is used far the source The DC CDI convol unit includes a DC DC canvarter which amplifies the battery voltage to about 220 V which is then stored in the capacitor Except for the DC DC convener the DC CDI control unit is identical to the CDI unit Compared to canventional exciter coil powered COI the DC CDI provides greater spark anergy at iow rpm since the power source is stable battery energy
217. dual adhesive remaining on the Bearing retainer bolts threads and dry them completely Shift drum stoppar plate Application of an excessive amount af boit adhesive may during loosening damage the Frama thread aor cause the bolt to be broken Apply Fork socket bolts ing a small amount of adhesive ta the and of Brake disc bolts the bolt threads distributes the adhesive throughout when the bolt is threaded in APPLY LOCKING AGENT Apply a thread locking agent to the D thread to prevent loosening 10 UBS bolt Used on the critical areas of The tightening surface where the bolt flange the engine frame where nut seats should be devel and smooth 1 cannot be used to tighten Engine cylinder cylinder head Frame foot peg bracket WS WY Wf The threads are pressed by the reaction on the inclined bolt flanga D ate of Issue Sep 1988 1 1 3 HONDA MOTGR CO LTD 7 GENERAL INFORMATION BALL BEARING REPLACEMENT Ramaving Ball Bearings Balt bearings are removed using tools which apply force against one of both dinner and outer races If the force is ap plied against only one race either inner our autat the bearing will be damaged during removal and must be replaced If the force is applied against both races aqually the bearing can be reused If the bearing is in a blind hole in the crankcase and cannot be removed by hammering
218. e swingarm In the same way check the alignment of the rear shock absorber mounts on dual shock models Apply penetrant to inspect the cracks NOTE Refer to the penetrant manufacturer s instruction manual far proper use and inspection procedure If cracks appear in the paint on the frame inspect the araa s more Closely to find out if the frame material itself is cracked 3 k BENDING CRACKS CRACKS 20 4 Date of Issue Sep 1988 z HONDA MOTOR CO LTD rN ae am 21 ELECTRICAL FUNDAMENTALS SERVICE INFORMATION 21 1 BASIC ELECTRICAL DIAGNOSTIC BASIC ELECTRONIC KNOWLEDGE 271 6 METHODS 21 74 ELECTRICAL SYMBOLS 21 13 This chapter illustrates the safety precautions and the basic knowledge required for servicing electrical systams Other chapters related to electrical systems do not contain the basic information prasented in this chapter Read this chapter thoroughly in order to understand the basic safety procedures and diagnostic methods before starting any sarvicing SERVICE INFORMATION Connect wires only with wires of the Same colar When measuring voltage and resistance of wire ter However in the faw instances when wires with dif minals using tasters insert the probes from behind the ferent colors are connected there is always a colored connector For water proof connectors insert the band near the connector probas from the front t avoid opening the wire E Connect connectors wit
219. e and recannact the hosas according to the vacuum hese routing diagram label AIR VENT CONTROL VALVE AVCYV NOTE The air vent control valve should be inspected if angine restart ts difficult Disconnect the AVCV hoses from their connections and remove the AYCY from its mount Refer to tha vacuum hose routing diagram label for hose connections ae Connect 6 vacuum pump to tha hase that goes ta the vacuum tuhe fitting VACUUM PUMP ST AH 260 MC7 Apply the specified vacuum te the AVCY SPEGIFIED VACUUM 250 mm 9 8 in Hg The specified vacuum should be maintained Replace the AVCY if vacuum is nat maintained a e e e i 7 6 Date of Issue Sep 1988 g HONDA MOTOR CQ LTD Connect the vacuum pump to the air vant fitting on the AYCV that goes to open gir NOTE If the AVCY has two hose fittings that go to open air cannect the blocked tube onto the other fitting to pre vent air leaks Apply vacuum to tha AYCY The vacuum should hold steady Replace the AYCV if vacuum leaks Connect the vacuum pump to the hose that goes to the vacuum tube fitting 5 TOOL VACUUM PUMP ST AH 260 MC U S A only Connect the pressure pump ta the air vent fitting an tha AVCY that goss to open air TOOL PRESSURE PUMP ST AH 255 MC7 U 8 A4 only NOTE ee If the AYCV has two hose fittings that go ta apen air connect the blocked tube onto the other fitting to pre vent air leaks i
220. e battary beyond repair Bacause the motorcycle battery is constantly subjacted to charging and discharging cycies tha water in the electrolyte is boiled off When the water is boiled off to the paint where tha plates become exposed a white crystalline daposit forms This pro cess is called sulfation lead sulfate The white crystalline lead sulfate unlike the lead sulfate pro duced by discharging ts difficult ta revert to lead peroxide and lead This causes damage to the battary and shortens the battery life This Gan occur not only when the electrolyte level is low but also when the battery is discharged for long periods Remember that the alactrolyte level goes down when the water in the battary evaporates Always add distilled water not alactralyte BATTERIES CHARGING LIGHTING SYSTEM BATTERY CHARGER OXYGEN GAS NAKED PLATES Fr F M Sy y Date of Issue Sep 1988 HONDA MOTOR CO LTD 22 5 BATTERIES CHARGING LIGHTING SYSTEM MAINTENANCE FREE BATTERY Tha Maintenance Free battery is a sealed hattery that requires no electrolyte level inspection or periodic refilling SAFETY VENT FILTER FILLER CAP PLATE SEPARATOR amp PLATE Similar in design to the conventional battery the MF battery praduces hydrogen and oxygen gas However tha plates are designed not to convert to lead completely This state of lead is callad sponge lead When the battery is overcharged and t
221. e bulb cool down before raplacement If you touch the bulb with your bare hands lean it with a cloth moistened with denatured alcohol to prevent early bulb failure CAUTION Avoid touching Halogen headlight bulbs Finger prints can Create hot spots that causa a bulb to break Be sure to install the dust caver after raptacing the bulb Date of Issue Sep 1988 HONDA MOTOR CG LTD JUMPER WIRE FUEL LINE FUEL PUMP fir BEAKER 25 11 LIGHTS METERS SWITCHES SWITCHES INSPECTION Disconnect the connector that is nearest ta the switch that you are to inspact and check for continuity between the switch side terminals of tha connector There should bea continuity between the positions on the continuity chart Refer to tha Modet Specific manual for the continuity chart Example Turn signal switch Wire color Orange Gray Blue Switch position With the turn signal switch in N neutral thare should ba no continuity batwaan the wires With the switch in L left there should be continuity between the orange and gray wires and with the switch in R right there should be continuity between the blue and gray wires CONTACT BASE REPLACEMENT When the contact bese is mounted with screws Ramave the ignition switch Remove the band and threa scraws than remove the switch fram the switch cylinder Reassemble the switch and cylinder with the cylinder shaft
222. e fixed face This reduces the drive ratio by a lowing the drive belt to run on a pulley of greater diameter Date of Issue Sep 1988 HONDA MOTOR CO LTD l 1 2 3 V MATIC BELT DRIVE SYSTEM DRIVEN PULLEY CENTRIFUGAL DRY CLUTCH BALL BEARING BALL BEARING CLUTCH WEIGHT DRIVE SHAFT CLUTCH MOVABLE OUTER DRIVEN FACE GUIDE PIN AND ROLLER DRIVEN FACE SPRING The centrifugal clutch is disengaged when the engine speed is low When engine speed increases the rotating clutch shoes of the ciutch weight will expand as the centrifuga force increases tn this way the clutch is automatically engaged The drive belt is pushed out towards the drive face circumference of the drive Pulley as the engine Speed increases As the belt remains constant in length the belt in turn is pulled in toward the center of the driven face pushing out the movable driven face and compressing the driven face spring By this mechanism the diameter of the belt on the driven Pulley decreases at high engine speed When the engine speed decreases the belt is pulled back towards the center of the drive pulley releasing the tension on the belt This allows the driven face spring to move the movabie driven face toward the origina position Pushing the beit back toward the cir cumference of the driven pulley In the manner described above the reduction ratio varies with engine Speed automatically without the need to manually shift between gear ratios
223. e fork wheal or even the axle TROUBLESHOOTING Failure of the front suspension steering or rear suspension may damage the frame enough to require replacement Refer to the section 18 for front suspension and steering inspections Refer to the saction 19 for rear suspension inspection Abnormal engins vibration Cracked or damaged engine mounts Cracked damaged or bent walded portions Bent or damaged frame Engine problems Abnormal noisa when riding banging or cracking Damaged or bent engine mounts Damaged welded points Damaged or bent frame Steers to one sida when under acceleration cr deceleration Bent frame Bant fork Bent swingarm Sn Date of Issue Sep 1988 HONDA MOTOR CO LTD 20 1 FRAME BODY PANEL i a DESCRIPTION Motorcycle scooter and ATV frames serve as a skeleton to which all other components are attached Various farms and in tensities of vibration and stress act against the frame from bath the engine and suspension when the vehicle is in usa These forces ara a majar tactor in determining the final design of each frame The various frame designs can be classified into ons of a few general catagories Certain types are chosen For particular models according ta their engine displacement the use the vehicle is designed for serviceability economic reasons and even visual appeal The material used for a frame is chosen by similar means Generally aluminum frames are res
224. e inlet tract with the assistance of th tion to the crankshaft and both connecting rod bearings as well as the piston rin ture is drawn into the crankcase by the suction of the piston movement FUEL OIL MIXTURE PREMIXED FUEL OIL MIXTURE It is important to USE ONLY A 20 1 FUEL OIL RATIO All Honda angines are designed to operate most efficiently and with greatest durability using a 20 1 premix ratio All standard carburetor jatting is based on this ratio Standard jetting is based on 20 1 at sea level and 20 C 68 F CAUTION E Use of a fual oit pramix ratio other than 20 1 may affect overall jetting engine performance and may lead ta prematuro engine wear or damuaga Freshness of the fueloil mixture is very important to both the overall performance of the machine as well as the lubricating ef ficiency of the oil Only use gasoline that has been pumped from a high volume station within the previous two weeks if optimal competition Performance is raquired Even general use applications call for gasoline that is no more than sight weeks old For optimal lubrication efficiency in this system use the premixed fuel ail within 24 haurs after itis mixed Two strake pramix oil that is not stored in rasealable containers should be discarded in a proper mannar if it is not used completely within one month after opening Oi stored in non sealed cantainer is subject to oxidation that degrades the oil s lubric
225. e input line Check if thera is battery voltage between the power Source input fine and the ground line when the ignition switch is ON and engine stop switch is at RUN Pulse generator conl Check if the resistance value between the wiras is in the specified ranga Ignition primary coil Check if the resistance value between the coil wire and body ground or ground wire is in the specified range Ground wire Check for continuity between tha ground wire and body qround If tha above diagnosis reveals no abnormality but the spark plug still will not fire the ignition coil or spark unit could be faulty Check tha spark unit or ignition coil using a CDI Full transistor testar If the above diagnosis indicates a faulty circuit check all circuits then check each of the components individually PULSE GENERATOR INSPECTION Disconnect the pulse generator from the wire harness and SOMERTON measure the resistance batween the wira terminals Tha pulse generator is good if the resistance value is within the specified range Replace the pulse generator if the value is far off the specified range TESTER NOTE 7 a ithe inca value is only slic If the resistance valua is only slightly off the standard value it may not necessarily have any effect on its func tian In this case check all related components for trou ble In other areas i en Ss e a PULSE GE
226. e jugglad to achieve best braking force and Pushing force lt Energy generated feal The leverage ratio offered by the design of the lever or pedal acting upon the master piston also helps to increase in farce to be transmitted to the caliper pistons compared to the force initially applied Return of piston due to the resiliance of the seal ft Bt A PISTON SEAL The caliper pistans are in direct contact with the back side of the brake pads Anti squeal shims are normally used betwaen the piston and pad As these pads press against opposite sides of the disc the rotation of the wheel is slowed When the brake lever is released hydraulic pressure decreases and the pads cease to prass against the disc Unlike drum brake systems where a spring retracts the shoes from the drum surface on disc brake systems tha resilience of the calipar piston seats retracts the pads from the disc and automatically self adjust for wear CALIPER 7 Date of issue Sep 1988 1 4 HONDA MOTOR CO LTD My BRAKES In single push type calipers both pads press against the brake disc through a reaction of the sliding caliper yoke Calipers of this type with single piston are mora common on earlier Hon das Mare current models use a single push type but with dual pistons both an tha same side Opposite piston calipers are most often used for road racing motorcycles today They do offer some improvement in per
227. e limit is stamped on it Check the brake diac fot warpage Inspect the wheal bearings for excessive play If the warpage exceads the specificatian Replace the brake disc if the wheel bearings are normal MASTER CYLINDER Disassembly CAUTION r ae MASTER CYLINDER gt Do not allow foreign materials to enter the master j cylinder NOTE Replace the master piston spring Cups and snap ring as a set whenever they ara disassembled j Disconnect the wire from the brake tight switch Drain the brake fluid page 17 3 Ramove the brake lever from the master cylinder Disconnect the brake hose Remova the master cylinder halder and the master cylinder Remove the rubber boot SNAP RING PLIERS Remove tha snap ring Toa SNAP RING PLIERS 07914 3230001 Remove the piston and spring SPRING RUBBER 80OT Clean the master cylinder with tha recommended brake fluid p PISTON SNAP RING Date of Issue Sep 1988 1 7 1 4 HONDA MOTOR co LFD t e aa BRAKES Master Cylindar Inspection MASTER CYLINDER Check the master cylinder for scores scratches or nicks and replace if necessary Measure the master cylinder 1 D in X and Y axis at several points Replace the master cylinder if the largast measurement is over the specified service limit Refer to the Model Specific manual for the service limit CYLINDER GAUGE Master Piston Inspection Measure the piston O D at t
228. e limiter cap should be placed against its stop as shown preventing further adjust ment that would enrich tha fuel mixture Pilot screw the limiter cap position permits clockwise rotation and prevants counterclockwise rotation Air screw tha limiter cap position permits counterclockwise rotation and prevents clockwise rotation NOTE Do not turn the pilot screw or air screw when installing tha limiter cap a auaaaaaaaaasaasaaaa i LIMITER PLUG Drive new pilot screw tor air screw plug into the pilot screw or alr screw bore with a 7 mm valve guide driver P N 07942 8230000 When fully seated the plug surface will be recessed 1 mm LIMITER PLUG Date of Issue Sep 1988 HONDA MOTOR cD LTO 8 23 FUEL SYSTEM ACCELERATOR PUMP ADJUSTMENT PUMP ARM NOTE ee 7 s an E Accelerator Pump adjustment is not nacessary unless the adjusting screw is replaced _ is Adjust the idle speed CLEARANCE Adjust the thrattle arip free play Measure the clearance between the accelerator pump rod and Pump arm CLEARANCE Refer to the Modei Specific manual if the clearance is not within specification adjust the clearance by carefulfy bending the Pump arm or by turning the adjusting scraw Refer to the Model Specific manual HIGH ALTITUDE ADJUSTMENT U S A only Whan the vehicle is to be operated continuously above 6 500 feat 2 000 m the carburetor must be
229. e rim Assembla the Universal Bead Breakar on the other side of the wheel and break tha baad following the sama procedures Remove the tire fram the rim using a tire changer machine or tira irons and rim protectors Remove tire from rim that has the smallest shaulder area to simplify removal REMOVAL EXCEPT U S A NOTE Applying water soapy water oil or other lubricants to the tire rim or tire tool whan ramoving the tire may cause the tire breaker arm to slip off the tire so that the bead cannot be broken a CAUTION Excessive lapping pressure may deform or damage tha Seat Do not damage the bead seating area of the rim So a o 9 install the tira breaker attachment on the rim with the wheel nuts and tighten the nuts securaly insert the narrow end A sida of the breaker arm between the tire and tha rim Date of Issue Sep 1988 HONDA MOTOR CO LTD f PRESS H AD PRESS HEAD BOLT ASSEMBLY LEVER NUT 8 RIM 9 RIM 7 RIM TOP EDGE OF PRESS HEAD REFERENCE MARK BREAKER ARM NARROW END A SIDE 16 19 WHEELS TIRES Position the breaker arm compressor on the tire breaker at tachment as shown i BREAKER ARM Kaep the breaker arm horizontal and align the end of the com COMPRESSOR pressor bolt with the breaker arm hole POTD PS a Ul y Scraw in tha breaker arm compressor bolt while pushing the breaker arm on the tire with your foot
230. e speed with the throttle Stop screw 7 Turn the pilot screw in gradually until the engine Speed drops 100 rpm 50 rpm on some models 8 Turn the pilat screw counterclockwise ta the final Opening from the position obtained in step 7 FINAL OPENING Refer to the Madel Specific manual 9 Readjust the idle speed with the throttle stop screw 10 install the new limiter cap tor plug onte the pilot screw head ipage 8 23 Date of Issue Sep 1988 8 21 HONDA MOTOR CO LTD FUEL SYSTEM AIR SCREW OR PILOT ADJUSTMENT R BEST IDLE PRO EDURE 4 stroka all modais NOTE 1 The air or pilot scraw is factory pre sat Adjustment is Not necessary unless the Carburetor is overhauled or a new air or pilot screw igs installed CAUTION f Tightening the air or pilot scraw against its seat wilt ie damage tha seat ss t Turn the air or pilot screw clockwise until it seats lightty then back it out to the Specification given This is an inttial Setting prior to the final ait or pilot Scraw adjustment AIR OR PILOT SCREW OPENING Refer to the Modal Specific manual 2 Warm up the angine to operating temperature Ten minutes of stop and go driving is sufficient 3 Stop tha engine and connect a tachometer 4 Start the engine and adjust tha idla speed with the throttle Stop screw IDLE SPEED Refer to the Model Specific manuai 5 Turn the ait or pilot screw in or out Slowly to obtain the highest eng
231. e the part is installed onty the motorcycle l Date of Issue Sep 1988 HONDA MOTOR CO LTD GENERAL t NFORMATION Bolt or screw langths can vary fot an assembly caver or case These different lengths must be installed into the correct locations If you became confused place the bolts into thair holes and compare the exposed lengths each should ba exposed by the same amount Torquing multiple sized fasteners should be done as fallaws tighten alt to hand tight then torqua big fastenars before littla fasteners Torque pattern shouid be crisscross from inner to outer To minimize distortion critical fasteners should be tarqued in two or three increments Uniess specified otherwise bolts and fasteners are install ed clean and dry do not use oil on the threads Dil seals are always installed with grease packed into the seal cavity and the manufacturer s name facing the aut side dry side When installing seals always check that the shaft over which the seal fits is smooth and free of burrs which could damage the seal TEH MANUFACTURER S NAME Old gasket matarial or sealant must be removed before reassembly If tha gasket surface is damaged slightly it may be possible ta smooth that area with an ail stona Date af tssue Sep 1988 HONDA MOTOR CO LTD Rubber hoses fuel vacuum ur coolant should be install ed so the end ts bottomed onto its fitting This allows arte quate area for the h
232. ease engine speed by rotating the stop screw on the carburaters Check if the F mark begins to move when the engina speed reaches the advance for retard start tpm However this check cannot be done on models with a targe ignition timing variation At full advance retard rpm the ignition timing is correct if the index mark is between the two advance ratard marks However because models with large ignition timing varia tion cannot be checked this way thara are no ad vance retard marks on the rotor for these models NOTE For models with no advanca ior retard mark check only tha F mark position ee qee am ES eee eo neemen TIMING LIGHT INDEX MARK F MARK F MARK IDLE SPEED ADVANCE RETARO ADVANCE MARKS FULL ADVANCE FULL RETARD Date of Issue Sep 1988 HONDA MOTOR CO LTD 23 11 IGNITION SYSTEMS Depending on the kind of timing light used when checking the ignition timing an abnormal advance timing could be observed This is because the spark plug wire being measured is not recaiving a negative pulse Mast timing lights are designed ta receive negative pulses If the spark piug wire being measured is receiving positive pulses the input of the timing light will be receiving the akter nated portion of the waveform Thus the timing light flickers Since the polarity of the waveform has no effect on tha spark plug connect the ignition primary coil wires to the opposite t
233. ed for use on automobiles on an original rim Data of Issue Sep 198 1 6 22 HONDA MOTOR ca LTD Y 17 __ BRAKES TROUBLESHOOTING 17 1 HYDRAULIC DISC BRAKES 17 8 BRAKE SYSTEM DESCRIPTIONS 17 2 MECHANICAL DRUM BRAKES 17 16 TROUBLESHOOTING Inhaled asbestos fibers have been found to cause respiratory disease and cancer Never use an air hosa or dry brush to clean brake assemblies In the United States use an OSHA approved vacuum cleaner or altarnate method approved by OSHA designed ta minimize the hazard caused by airborne ashestos fibers HYDRAULIC DISC BRAKE Brake lever pedal soft or spongy Brake lever pedal hard Air bubbles in the hydrautic system Clogged rastricted brake system Leaking hydraulic system Sticking worn caliper pistan Contaminated brake pad dise Caliper not sliding properly Worn caliper piston seal Clogged restricted fluid passage Worn master cylinder piston seal Worn caliper piston seal Worn brake pad Stcking worn master cylinder piston Contaminated caliper Bent brake lever pedal Caliper not sliding properly Worn brake pad disce tow fluid level Brakes grab or pull to ona side Clogged fluid passage Contaminated brake pad disc Warped deformed brake disc Misalignad wheel Sticking worn caliper piston Clogged restricted brake hose Sticking worn master cylinder piston Woarped deformaed brake disc Worn
234. ed with cooling fins and liquid cooled ngines are provided with a water jacket necessary to cool the engine With a 4 stroke engine the cylinder wall has a cylindrical shape With the 2 stroka enging however tha exhaust or scavenging ports are open and the characteristics of the engina depend on the shape location and size of the parts These ports are the key parts of a 2 stroke engine Because the piston rings and piston skirts move against the cylinder walls a Material with high wear resistance is requirad For the alurninum Cast cylinder a steel cylinder slaave is pressed into the part that directly contacts tha piston and rings In some 2 stroke engines the cylinder walls are plated with special hard metal tnickel silicon Carbide coating having considerabie Cooling ability seizure and wear resistance which is much lighter than the sleeva type With the slaeve type the cylinder wall is honed for a finish Fine grooves ara made in the surface to collect and spread the oil on the cylinder wall to lubricata the piston With the plated type neither modification of the cylinder walt nor rebaring is possi bla If the cylinder wall is flawed the cylinder must be replaced EXAMPLE OF 2 STROKE WITH SLEEVE TYPE SCAVENGING PORT CYLINDER SLEEVE COOLING FINS SCAVENGING PORT be i EXHAUST PORT EXAMPLE OF 2 STORKE ENGINE PROCESSED WITH NICKEL SILICON CARBIDE Nikasil SPECIAL COATING LAYER 4 ka setae gt F SENS i
235. eedle and needle jet see Carburetor Theory The fuel is atomized by air which has entered the air bleed hoie of the naedie jet holder from the main air jet JET HOLDER With a dagree of opening 1 4 3 4 the fuel drawn from the SMALL tapered section of the jet needle is ragulatad The gteater the CLEARANCE valve opening the further the tapared jet needle rises increas Fuel passage ing the cross sectional area for fuel passage and thus the js narrow volume of fuel supplied In piston type throttle valves the jet neadla contains clip grooves in fiva Stages Staga 1 2 3 etc counted from the tap The clip position staga number in creases with an increase in the degres of throttle Opening raising the cross sectional area af fuel Passage and hence the volurne af fuel Size of the main jet does not affect the air fuel mixture ratio at this stage as the fuel flaw at main jet is greater than at the needle jet Main system fully opan With a degrea of thrattle opening of 1 2 fully open the ven turi bore diameter and mass flaw of air became maximum At this time the valume of fual drawn from tha gap between the needle jet and jat needle becomes too great and exceeds tha s shai flow volume of the main jet _ Fuel is regulated Y atthis point When the clearance between tha needle jet and jet needle is too great the fuel flow is requiatad by the main jet to prevent an overly rich fuel air mixtura MA
236. eee bee ad eee TE ee Bleed air fram the oil suction lina and oil pump whenever the oil lines and pump have besn removed there ts na oil OIL Wer TUBE CLEAN in the tank or there is air in the oil hnes LINE CLAMP Bleed air from the oil suction line and pump first then j bieed the oil outlet fine Fill the oil tank with the recommended oil Place a shop towel around the oil pump Disconnect the ail lines from the ail pump and fill the pump with oil through the pump outlet Let oit drip from the inlet line to expel any air that may be in the line and then reconnect the suction lina ta the pump inlet If there is a bleed bolt loosen it until there are no air bubbles in the oil coming out of the bolt hole then retightan the bleed bolt a OIL INLET LING E Next blead air from the oil outlet line EED 7 OUTLET LINE BL ING RECOMENDED Remove tha oil outlet line and clase the intake pipe joint far Bend the oil outlet fine into a U form with both the ends fo r parallel and fill the oil utar line with clean ail A ra Connect the oil outlet line to tha oil pump joint g ia Start the engine and allow it to idla with the ail control lever in the fully open position making sure that gil is flowing out of the oil outlet line Check that there is no air in the gil line a a ooN y Parform this operation in a well ventilated erea Exhaust i contains poisonous carbon monoxide ges that cen cause
237. eir components Resistance is measured for the following raasons Q To check if components are warking properly The resistance value of a coil leg ignition coil indicates if it is normal or malfunctioning 2 To check for a broken wire A continuity check indicates if a wire is intact ar broken How to measure resistance using an chmmater NOTE Proper zeroing of the ohmmeter is necassary to obtain correct measurements Touch the two probes and adjust the ohmmeter so that it registers O ohms symbol Since the polarity of terminats is not important either probe may be applied to the terminal However since diades allow current to flaw in one direction only the polarity is important Unlike when measuring valtage it is necessary to disconnect the component from the circuit f resistance is measured with the entire circuit connectad the ohmmeter wili read a smaller value than the correct value Similarly if a citcuit has branches the connector laading to the specific branch needs to be disconnected in order to read correctly CHECKING COIL CHECK FOR BROKEN ZERO OHM ADJUSTER WITH CONNECTOR CONNECTED p _ Rix A2 WITH CONNECTOR R R1 R1 R2 DISCONNECTED CONNECTOR RI 21 16 Date of Issue Sap 1988 HONDA MOTOR CO LTD r ELECTRICAL FUNDAMENTALS When the ohmmeter is connected in series resistance Values ara large In the diagram measure resistance R1 by mov
238. embly Lubricate gears with clean recammended angine oil while turning the shaft ie ee HONDA MOTOR CO LTD
239. emperature and ream the new valve guida VALVE GUIDE REAMING When reaming new valve guides insart the vaive guide reamer from the combustion chamber side NOTE Take care not to tih or taan tha reamar in tha quide while reaming Otherwise the valve is installed slanted that causes oil leaks from the stem seal and improper valve seat contact and results in the valve seat refacing not able to be performed Use cutting ail on the reamer during this operation Rotate the reamer clockwise never counterclockwise whan inserting and removing Reface the valve seats and clean the cylinder head thoroughly to remove any metal particles VALVE SEATS INSPECTION Clean all intake and exhaust valves thoroughly ta remove car bon deposits Apply a light coating of Prussian Blue ta each valve face NOTE r Tap the valve against the valve seat Several times with your finger without rotating the valve to check for pro per valve seat contact __ _ Remove the valve and inspect the valve seat faces The valve seat contact should be within the specified width and evenly ali around the circumference if the valve seat width is not within specification reface the valve seat page 9 12 NOTE Most valve faces and stem tips ara coated with a thin layer of stallite so they cannot ba ground If 5 valve face of Stem tip is r
240. emperature as well as to retain pressure in the cooling systam Coolant bailing point Coolant of 50 50 mixture At atmospheric pressure approximate T00 C 212 F Under 12 8 psi 0 9 kg cm preasura approximate 125 C 257 F Wait until the engine is coc before slowly removing tha i radiator cap Removing the cap whila the engine is hot and tha coolant is under pressure may cause serious f scalding As the coolant temperature increases tha difference in temperature between the coolant and atmosphere becomes greater Due to the pressurized system coolant vapor loss is preventad while the cooling effect is enhanced TO i gt RESERVE ES The radiator cap is provided with a pressure vaive and vant TANK PRESSURE valve which maintain the pressure in the cooling system at a constant level PRESSURE If the pressure in the cooling system is increased due to the in crease in coolant temperature tha Pressure is kept constant by means of a pressura valve If the pressure exceads the prescribed limit the pressure valve is opened so that the pressure in the cooling system is regulated by releasing the coolant whose volume has xpand ed due to the increase in temperature The Pressure at which the pressure valve begins to open is called the radiator valve opening pressure When the coolant temperature is decreased after shutdown of the engine and the cooling system pressure is reduced with the coolant
241. engine oil into tha engine through the OIL LEVEL oil level gauga fillat hole The oil filler hole and cap are GAUGE separated from the oil level gauge on same engines a Pour in the oil periodically checking with the leval gauge until the upper line on the gauge is reached Install and tighten the lavel gauge and or filer cap after replenishing DRAIN BOLT ENGINE OIL FILTER Small dust particles and metal dust which do not filter through the net type oil strainer screen are trapped by the papar oil filter When the filtar is clogged the oil flow is reduced and contaminants may reach various parts of engine by way of the relief passage Causing premature wear and possible damage Date of Issue Sep 1988 HONDA MOTOR CQ LTD MAINTENANCE Cartridge Type Paper Filter Cartridge type oil filters are removed using a filter wrench Engine and exhaust systam parts become very hot and remain hot for same tima after tha engine is run Wear iti sulatad gloves or wait until the engine and exhaust systam have cooled before handling these parts a inina ie Se ae Ciean the filter araa of the engins with a clean cloth Spread engine oil thinly over the Q ring of the new filter and at tach filter to the engine Tighten the ail filter with the proper filter wranch Too Oil Filtar Wranch For small type cartridge O7HAA PJ70100 For large typa cartridgs 07912 6110001 Torque Smail type ca
242. ent solution to a replacement rim valve and insert it from inside of the rim NOTE Be sure to use tha recommendad rim valve Do not damage the valve hole Replace the rim valve whenaver installing a tubeless tire WHEEL CENTER ADJUSTMENT SPOKE WHEEL ONLY The wheel center adjustment is necassary when the spoke ee ee wheel has been rebuilt The distance indicated is 2s follows A Between the rim side and standard surface B Rim width measurement C Between the rim center and standard surface NOTE Refer to the Model Specific manual for standard surface and specific values of C on aach model Measure the distance B rim width and make tha following calculations A C Bi2 Example B 76 2 mm C 56 5 mm A 56 5 76 2 2 18 4 Adjust the rim position and distance A by tightening the spokes to specified torque in 2 or 3 pragressive steps Inspact and adjust the wheel rim runout WHEELS TIRES TIRE LEVER Date of Issue Sep 1988 HONDA MOTOR CO LTD 16 13 WHEELS TIRES TIRE INSTALLATION Refer to page 16 17 for ATV s wheel tire servicing For a tube tyne tire check the rim band and rim lock tA be sure they are installed properly Any attempt to mount passenger car tires On a motor i cycle rim may cause the tire bead to separate from the tim with enough explosiva farce to cause serious injury or death CAUTION j Always change rims which ha
243. er At the and of the exhaust stroke the gas flow slows down but dus to the inertia of liquid mass pressure in the cylinder goes down below the atmospheric pressure in other wards negative pressure is appiled to the cylinder for a short time As the Intake valve or scavenge part opens the air fuel mixture quickly drawn into the cylinder NEGATIUE PRESSURE AT END OF EXHAUST STROKE The discharged gas flaws through the muffler forming a high speed pressure wave Due to the inertia of liquid mass negative pressure is applied to the exhaust port where the pressure wave had passed When the axhaust valve or port opens on the next exhaust stroke the exhaust gas is drawn out by the negative prassure and the exhaust efficiency is improved EXHAUST VALVE OPENS NEGATIVE PRESSURE AT EXHAUST PORT 6 2 Date of Issue Sep 198 Z HONDA MOTOR CO LTD EXHAUST SYSTEM On 2 stroke engines thera is the possibility that the air fuel AIRIFUEL MIXTURE mixture that was scavenged just before the and of the exhaust stroke may leak out to some degree and ba discharged into the exhaust port The gas is discharged into the muffler forming a high pressure wave This pressure wave impacts against the taper at the and of the muffler rebounds and applies a positive pressure ta the exhaust port The air fuel mixture that was about to be discharged before the exhaust port clases is thus forced back inta the cylinder and the
244. er Clutch auter plate disc Sprag clutch mainshaft CLUTCH OUTER CLUTCH HUB OUTER ing splines CLUTCH RUE INNER fsplined l SPRAG CLUTCH r SPRAG CLUTCH MAINSHAFT INNER RACE splined _ POWER FLGW DIAGRAM CLUTCH OUTER me ee dd CLUTCH PLATE CLUTCH PLATE C Cwtch OSC SELTEN DEE z CLUTCH DISC CLUTCH HUB OUTER I m l _SPRAG CLUTCH D CLUTCH HUB INNER AY ee ed SPRAG CLUTCH INNER RACE _MAINSHAFT ORDINARY POWER FLOW BACK LOAD When thare is a backloading on the clutch caused by the rear wheal nearing lock up the sprag clutch will Slip just enough to prevent the wheel from locking without losing the benefit of maximum engine compression braking MAINSHAFT pure ree 7 n 4 agi A SPRAG TE I Wo CLUTCH LIC INNER Lao RACE Isplineril q r ia she These plateas discs will slip during backlaading Date of Issue Sep 1988 HONDA MOTOR CO LTD 11 5 CLUTCH a a a a YPE D CRANKSHAFT MOUNTED Clutch outar is on the crankshait T CLUTCH DRIVE PLATE PLATE 4 PRIMARY SET RING CLUTCH DRIVE GEAR SPRING E LIFTER ROD PRIMARY ee Om ORIVEN GEAR BEARING CLUTCH CLUTCH 4 LIFTER 2 a i OUTER LOCK NUT PLATE Power Flow Diagram CLUTCH DISENGAGED CLUTCH ENGAGED _ __ CRANKSHAFT LMAINSHAFT DRIVE PLAT
245. er access for damper adjustments and the simple design lends itself to easa of maintenance and cleaning Damper Design and Oparation Riding comfort and proper rear wheel traction are provided by a combination spring damper unit and to same degree by maintaining proper tire pressure The damper absorbs some Suspension compression force and controls the unwanted re bounding effects of the spring Typically comparatively little damping resistance is offered an the compression stroke as most af this shock is handled by the spring Oil dampars units are either the upside dawn type or the right side up type Running the damper body upside down with the shaft below and the body above raduces unsprung weight Date of Issue Sep 1988 HONDA MOTOR CO LTD REAR SUSPENSION r REBOUND DAMPER OIL DAMPER Vibration ispring only Upside down Aight side up type type COMPRESSED Vibration spring and damper Y 1 J 19 3 REAR SUSPENSION In addition to the inverted and conventional damper body types there are two basic damper designs each named for the method used to create the damping action tha friction type and the oil darnper tyne The friction type damper is comparatively simple in design and is used on only thea mast lightweight and acanomical models This dasign uses only the friction of a nonmetallic piston against the greased inside wall of the damper cylinder to counteract the n
246. erminals For double ignition coil types ia single coil firing two spark plugs connect the timing light to the opposite wire of the same coil The correct timing should then be observed IGNITION COIL NOTE Since the resistance value of the primary coil is inherent ly very small it is difficult to distinguish it from a shorted wire Measure the coif resistance as a guideline for checking the cail Check the performanca of the coil with the FULL TRICDI tester jexcept U S A PRIMARY COIL INSPECTION Measure the resistance between tha two terminals of the igni tion primary coil if the resistance value is within the specified range the coil is good If resistance ig infinite replace the coil with a naw one SECONDARY COIL INSPECTION With the spark plug cap on measure tha resistance between the primary coil terminal and the spark plug cap For double ignition coil measure the resistance between the spark plug caps If the resistance value is within the specified ranga then the coil is gaod If the resistance is open wire disconnect the spark plug cap and measure the secandary coil resistance POSITIVE WAVE FORM Connect the primary coil wires to the opposite terminals PRIMARY COIL SECONDARY COIL WITH PLUG CAP A TIMING LIGHT FLASH POINT NEGATIVE WAVE FORM DOUBLE IGNITION COIL Raconnect the timing light 23 12 Date of Issue Sep 1
247. erosene Oiled in a dry state applicd iu 0 09 0 14 i7 0 35 0 54 ip 0 22 0 34 AXIAL TENSION vm TIGHTENING FORQUE ee Date of Issue Sep 1988 HONDA MOTOR CO LTD 1 9 GENERAL INFORMATION Torque values are determined according to fastener size and strength and the strangth of the parts that ara fastensd together in many of our previous service manuais torque values are specified within a certain range Due to slight varia tion in torque wrench pracisian and fastaner friction co efficiant the target torque value should be the middle of tha range of the torqua value specified The Model Specific manuals pravida only the simplified middle range torque values Kg m is used as a tightening torque unit Example A torque of 1 kg m refars to the moment of force ob tained when a l meter lang wrench is Joadad with 1 kilogram At the sarme moment a heavier load is needed as the effectiva wrench length ts shorter 1 kg m 16 Nem 1 kg m 7 ft lb FASTENER LOOSENING In most of the cases fastenar loosening is due to axternal forces repeatedly applied to or working against the fastener such as vibration thus reducing screw axial tension Certain argas of the motorcycle or scooter are subject to repeated and severe extarnal forces Special bolts with a high percentage of elastic defarmation capability are used in these areas Installing common bolts in thase areas with special re quirements may lea
248. ert the AC output voltage to DC voltage far Rawering various components and charging the battery C Type of Regulator Rectifiers Regulator ractifiars ara categorized as one of several types based on its method of regulation and rectification The chart below shows the different types of ragulator rectifiers Input AC wave form Single phase Triple phase Since tha input wave form is the same as the output wave form of the alternator refer to the alternator section for the typas of input wave form Date of Sep 1982 22 1 4 HONDA MOTOR e LTD Rectification mathod Voltage feedback method Regulation method Half wave rectification Internal voltage feedback Full wave rectification Battery voitaga faedhack Singla Phase Half Wave Rectiflers Diode rectification method This mathod uses only a diode to convert alternating current to direct current The diode allows current to flow in one direc tion only Thus when a single phase AC waveform flows through the diode the negative voltage of the waveform is cut off and the positive voltage drops slightly As a result the out put consist of the positive half cycles of the input waveform Thus the signat is said to have been ractified because only half cyclas are Utilized this ts callad half wave rectification Single phase half wave rectification is used in models with smel electrical loads The single phase half wave ractifier u
249. ery set the switch to the NEW BATT position 4 Attach the clamps to the battery terminals RED to Positive BLACK to Negative Cannact the battery cables only when the Power Switch is OFF NEW TIMER BATT Inok Connacting the cables with tha Power Switch ON can produce a spark which could Ignite or axplode the battery 5 Tutn the Power Switch ta tha ON position 6 When the timer reaches the Trickle position the charg ing cycle is complete Turn the Power Switch OFF and disconnect the clamps NOTE The charger will automatically switch to the Trickle mode after the sat charging time has elapsed 7 Retest the battery using the Honda Battery Tester and recharge if necessary using the above steps NOTE for accurate test results lat the battery cool for at teast i ten minutes of until gassing subsides after charging RS SR AR a L la L Di f Is Sep t848 HONDA MOTOR CO LTD 22 1 1 BATTERIES CHARGING LIGHTING SYSTEM CHARGING SYSTEM DESCRIPTION The charging system basically consists of tha follawing components ALTERNATOR 1 l l o e o oe ed REGULATOR RECTIFIER BATTERY F Component name unction i Regulatar rectifier Regulates voltage so that it stays within the specified range a KO _ Converts alternating current 1AC to direct current DC Alternator l A generator producing current AC and which is p
250. et leak inte the adjacent cam chain or gear well and a leak past the piston rings Be sure to follow the leak down test tool manufacturer s instructions precisely when making this inspection 2 STROKE PRESSURE VACUUM LEAK DOWN TEST INFORMATION Regular crankcase leak down tasting is much more important te the lifespan of a 2 stroke engine than a 4 stroke Because the engine relies on a very pracise air fuel mixture to ensure proper engine lubrication the slightest air leak can dead to an ngine seizure Consider these ragularly scheduled tests as cheap insurance Pressure vacuum tests on 2 stroke engines should always include both a pressure and a vacuum tests both or which are per farmed with essantially the same equipment Pressure vacuum leak down test equipmant Specifically designed for 2 stroke angines is cammercially availabla through various motorcycle and general tool sources A pressure vacuum leak down test tool consists of hand pressure vacuum pump and various adaptors to saal your angine The test provides a clear indication of whare a leak or leaks exist Possible areas for leaks include anywhere upstraam of the carburetor until tha mixture is ignited and forced out the axhaust Leaks can occur between the mating surfaces of the crankcases if the gasket fails If this gasket fails batween the crankcase and the transmission the mixture will bacame much richer as transmission oil is slowly drawn into the engine Similarly a leak
251. evel indicator doss not come on with no or low oii ievel in the tank 1 Disconnect the wires from the ail lavel switch and con nect a jumper wire between the wira terminals Turn the ignition switch ON and check the indicator ki 5 Indicator does not came Indicator comes on JUMPER on a Faulty oil level switch Poor wire connection 2 Disconnact the wires from the oil lavel switch and check for voltage between the wire and ground No voitage Voltage Broken wire between the Faulty ail level switch oil level indicator and Poor oil level switch wire IGNITION lavel switch conneciten SWITCH QNI Blown bulb 3 COIL CONDENSER ees INDICATOR TIMER TYPE THEORY a 7 JiComes on tor a few sacand A timar type indicator has a bulb check function so as to check the oil tevei indicator for propar operation When the ignition switch is turned ON current flows through the exciter coil ta the condenser generates the elec tromagnetic farce at the exciter coil and closes the reed switch Current flows from the reed switch through the resister Rz to the oil level indicator and turns it on When the condenser is fully charged current flows through the exciter coil to the condenser decreases and consequently alec tromagnetic force at the coil decreases tha reed switch opens 4l and the oil level indicator turns off BOS f IGNITION SWITCH OFF 2 D Ri Te 3 L j T i aan ae 8 W
252. exhaust system This charged secondary air promotes burning af the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively i harmless carbon dioxide and water Check the air supply tubas between the valve and axhaust parts for deterioration damage or loose connections Make Sure the tubes are not kinked pinched or cracked NOTE ar a eee i Ses eae Eee 71 If the tubas show any signs of haat damage inspect the read valye in the system for damage i Check the vacuum hose between the intake pipe and valve for deterioration damage or a loose connection Make sure tha hose is not kinked pinched or cracked Refer to the vacuum hose routing diagram label for hose connections EVAPORATIVE EMISSION CONTROL SYSTEM Tao prevent injury kaop your hands and clothing away from the cooling fan It may start automatically without m a a ea canister while tha engine is stopped When tha engine is running the purge control valve opens and fuel vapor in the charcoal canister is drawn into the engine through the Carburetor The tubes deteriorate naturally due to wear and time Chack the condition of these tubes at the intervals specified in the Modei Spacific manual Check the hoses between the fual tank canister purge control valve PCY air vent control valve and carburetors for deterioration damaga or loose connections Check the charcoal canister for c
253. f fers minimal friction and waar Still periodic inspection for Wear of damage and replacamant is necessary as these parts ROLLER deteriorate Aie a GUIDE SLIDER The chain siider attached to the front of the swingarm near its Pivot point must be replaced when the depth of its waar grooves reaches a dapth specified for gach particular model Failure to replace a worn slider wilt rasutt in chain damages to tha swingarm and damage to the chain Off read and dual purpose motorcycles are fitted with a chain guide that ansures that the chain is guided directly to raar sprocket The guide itself should ba checked for proper align ment as it can be bent through contact with Passing objects rocks or crash damage Straighten or replace as necessary A plastic guide slider centers the guide on the sprocket with minimal friction and pravents the chain from wearing the guide A wear window is often provided to aid in determining a replacement time A lawer chain roller or a pair of upper and lower ralfars are us ed to take up excess slack in the drive chain as the tear suspension Comprasses and extends to its furthest points These rollers also help prevent the chain from cutting into other components on the motorcycle dike the airbox ar ex haust on some motorcycles when the Suspension is near or iuily compressed These must aiso be Periodically inspected for wear damage and security of mounting DRIVE BELT A drive belt is used on the
254. f nacassary Start the engine and check the oil prassure If it is normal replace the oil pressure Switch Stop tha angine Apply 3 BOND sealant or equivalant to the pressure switch threads and install Ovartightening the ewitch can causa crankcase damage Connect the ail pressure switch wire and start the engins Check that the oil pressure warning indicator goss aut in one or two seconds If the oil pressure warning indicator stays on stop the angine immediately and determina the cause OIL PUMP INSPECTION TROCHOID TYPE NOTE Where there are two pair of inner and outer rotors check each side of the pump as described below y Measure at several places and usa tha largest reading ta compare the service limit Disassembla the oil pump and clean the parts with clean oil Set the inner and outer rotors into the pump body properly Measure body clearance pump body to outar rotor and tip clearance tinmer rotor to oulter rotor using a feeler gauge ATTACHMENT NOTE Apply sealant only to the area shown APPLY SEALANT BODY CLEARANCE TIP CLEARANCE Date of Issue Sep 1988 HONDA MOTOR CO LTD LUBRICATION Measure the side clearance trotor side to body with a straight SIDE 7 edge and fteeler gauge CLEARANCE NOTE lf there is a cover gasket measure the clearance with the J STRAIGHT EDGE Refer to the Model Specific manua for
255. f the level is balween the upper and lower lings on tha gauge If the oil level is near or below the lower lina add the recam mendad engine ail up to the upper line Refer to the Model Specific manuali for the recommended oil Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 1 1 MAINTENANCE __ eee ees 4 stroke Dry Sump Enginas Start the engine and allow the engine oil to warm up thoroughly NOTE p Do not snap tha throttle or the oil levet reading will be inaccurate mm Ese Allow the enging to idte for about 3 minutes and stop the engine Remove the oil level gauge immediately and wipa it claan With the motorcycle in an upright position on level sur face check the ail level by inserting the gauge into the oil tank without screwing it in The engine contains a sufficient amount of oil if the oil teval is between the upper and lower lines on the gauge lf the ail level is near or below the lower lina add the tecom mended engina oil up to the upper tine See the Model Spacific manual for the recommended oil Leak Inspaction Inspect to see that there is no oii leaking from any part of the engine oi pipas oil hoses etc lf any oil ieaks are detected perform tha Proper maintenance to correct the problem Oil Change In 4 stroke enginas sludge can build up due in part to the gas which blows past the piston rings and the gasoline compasi tion contaminates the oil causing a weakening
256. for use in aluminum engines ethylana glycol base solution Mix only distilled low mineral water with the antifreeze Mix the distilled water and ethylene glycol base solution with about 5 C 41 F of tolerance in respect to tha minimum temperature RECOMMENDED MIXTURE 50 50 Distilled water and coolant REPLACEMENT RADIATOR CAUTION Wait untll the angine is cool befora servicing the cooling system Removing the radiator cap while the engine is hot and tha coolant is under prassure may cause serious scalding Refill the reserve tank with new coolant Ramave the coolant reserve tank Empty the coolant and rinse the inside of the reserve tank Remove the radiator cap and drain bolt s and drain the coolant Rainstall the drain beltis Refer to the Modal Specific manual for drain holt locations Psr the recommended coolant through the radiator filler opening up to the filler neck Reinstall the reserve tank and fill it to the upper level line with fresh coolant Bleed air from the system DRAIN BOLT 5 6 Data of Issue Sep 1988 x E HONDA MOTOR CO LTD COOLING SYSTEM AIR BLEEDING Shift the transmission into neutral Start the engine and run it at idie for two to three minutes EEE GEG thee Snap the throttle 3 4 times to bleed air from the system Stop the engine and add coolant up to filler neck Check the coolant level of the reserve tank and fill to t
257. fuel flaw is not smooth NOTE Note the Installation direction of the fuel strainer Be sure to install it as shown in the drawing i e with the cup facing down Fuel flaws sven though the strainer is in stalled upside down but it contaminates the inner wall of the strainer and prevents visual inspection of the Strainer i 3 Remove the fuel valve jock nut and check the fuel strainer screen for contamination Tighten the lock nut to the specified torque FUEL AUTO VALVE The fuel auto valve has two diaphragms which are intercon nacted with an aluminum link When the engine is started vacuum force is applied to the smaller diaphragm through the larger diaphragm and link tha fuel line opens and the fuel starts ta flow Whan the engine is stopped the diaphragms are returned to their original positions by the spring and the fuel line is blocked by the small diaphragm INSPECTION Gasolins is oxtramaly flammable and is axplosive under certain conditions om Keep flames and sparks away from gasoline and wipa up spill ed gasoline at once CAUTION Ba sura to remove the diaphragms from the fual auto valve before using comprassed alr to blow out the gir passages Compresssd ai will damages the diaphragms or may forca tham off the aluminurn link Inner watts get contaminated making visual inspection difficult SMALLER DIAPHRAGM VACUUM LINE AIR VENT m e yy 8 8
258. ge the wira harness with a new one it necessary f there is voltage at 3 and not at then check for loose connector B Example 2 Sometimes it is easiar to diagnose a component by measuring from its input terminais directly Here the probe goss to the positiva input terminal and probe goes to the ground wire of the camponent If no voltage is measured there are two possible causes T No voltage at the positive input terminal 23 A loose ground wire For i check for voltage between the input termina leading to the battery and ground Far 2 check for continuity between the green wire terminal ta ground Example 3 Voltage maasuremant is frequently used ta check if a system is working Correctly For instance if a light bulb blows out frequently it needs ta be checked with an AC voltmeter to see if an excessive voltaga is apparent In this case measure the AC voltage of the light bulb tarminals to see if it is within the specified voltage range ante m t CONNECTOR B x ge Oe WIRE HARNESS a K4 IGNITION hl ie lard A pan SWITCH l l l J BLACK a A ff i GREEN VOLTMETER l LIGHT SWITCH ree ah WEHITEFYELLOW I T DIMMER SWITCH GREEN LIGHTING COIL ee i Date of Issue Sep 1988 HONDA MOTOR CO LTD 21 15 ELECTRICAL FUNDAMENTALS MEASURING RESISTANCE Along with voltage resistance is another basic parameter for diagnosing circuits and th
259. ginal position PAD PIN Date of Issue Sep 1988 1 7 1 0 E HONDA MOTOR co LTD hi Installation PAD SPRING Press in the piston st to install tha new pads lf the caliper and bracket are separate apply silicone grease to tha Caliper pivot bolt baot pin bolt collar bore and insert the caliper into the bracket Sat the boot lip in the pin bolt groove securaly Install the new pad align the holes in the pad and retainer and install the pad pin Note the instalation direction of the pad Type A Install the retainer by aligning its hole with the pad pin groove and loosely tighten the bolt Install the caliper Refer to the Modet Specific manual Type A Tighten the pad pin retainer bolt to the specified PAD PIN PLUG torque Typa B Tighten the pad pin to the specified torque arid install the pad pin plug Apply the brake tever to force the caliper piston out of the Caliper Rotate the wheel by hand and check for the brake operation BRAKE LEVER D f Issue Sep 1988 HONDA MOTOR CO LTD 17 11 BRAKES BRAKE CALIPER Removal Refer to tha Madal Specific manual for the brake caliper ramoval installation Purp the hrake lever to farce the caliper piston out of the caliper Flaca a clean container under the caliper and disconnect the brake hose from the caliper Claan the removed parts with fresh brake fiuid Avoid spilling brake fluid on painted surfaces
260. h lever squeezed and not be operated with the iever released If the systam is normal check the following Disconnect the wira from the clutch switch and check for con tinuity betwaan the clutch switch terminals while operating the clutch lever When the clutch lever is pulled in There should be continuity between the inals n termin CLUTCH When the clutch lever is relaased SWITCH There should ba no continuity betwaen the terminals f If the clutch switch is normal check the Following IGNITION MAIN SWITCH FUSE Check for shorted wira betwean the starter relay switch and the clutch switch Check the neutral switch BRAKE LIGHT SWITCH FRONT BRAKE LIGHT The brake light comes on when the brake iever or pedal is SWITCH applied 0 REAR BRAKE LIGHT SWITCH Starter motor equipped scootats To pravent the accidental start up of the scooter currant does not flow to the starter motor unless the brake lever or pedal is applied INSPECTION Brake ight does not come on 1 Check for tha following Burned bulb Poor connection of the brake light switch connectar BRAKE LIGHT SWITCH i Date of Sep 1988 HONDA MOTOR CO LTD 25 15 LIGHTS METERS SWITCHES 2 If normal disconnect the brake fight switch connector and check far continuity between the terminals while operating the brake lever or padal When the brake fever or pedal is depressed There
261. h modet only Faulty brake light switch VOLTAGE APPEARED Centrifugal clutch madal only Loose or poor contact at connector Open circuit in wire harness Check the starter relay operation H NORMAL Loose of poor contact at starter relay switch connectar ABNORMAL lt Faulty starter relay switch rs 24 2 Date of Issue Sep 1988 HONDA MOTOR CO LTD a For models with shims between the armature and cover ELECTRIC STARTER STARTER CLUTCH MOTOR COVER STARTER MOTOR DISASSEMBLY INDEX MARKS Before disassembling the starter motor mark the position of the case and cover so the starter can be assembled correctly later Remove the starter motor case screws and remove the cover NOTE record the jocation and number of shims i Record the order so the parts can be instalted correctly later SCREWS INSPECTION CABLE TERMINAL Check for continuity of the starter motor case Between cabla terminal and case normal if no continuity Between cable terminal and brush black wirel normal if there is continuity lf abnormal replace with 3 new one Maasure the brush length Replace tha brush if it is worn beyond the service limit Check for continuity between and terminals of the brush TERMINAL TERMINAL Lelde l TE f ies Oe gp 3 ak TERMINAL TERMINAL ad f i 24 3 ELECTRIC STARTER STARTER CLUT
262. h the same colored connectors terminal Cn wires with stripes the stripe color is indicated aftar the color of wire ES WATER PROOF CONNECTOR BLACK TEST PROB WHITE GREEN TUBE WHITE RED STRIPE GREEN u E Connect the positive terminal first when connecting tha WHITE RED WIRE battery BLUE E Coat terminals with clean grease aftar connaction Make sura the protective cover is secured on the terminal M Disconnect the negative cable of ths battery before working on any efactrical component M Do not let the tool contact the frame when disconnect ing the cable After completing the job check that all tarminal pro tecters are placed correctly Date of Issue Sep 1988 HONDA MOTOR CO LTD 21 1 ELECTRICAL FUNDAMENTALS E if a fuse blows out diagnose the cause and repai it When separating connectors pull only on the connector Replace the fuse with one of the correct rating housing Do not pull on the wiras CORRECT INCORRECT e ee oe x B Always separate the connectors with the ignition switch in ace the OFF position E Before separating the connector check whether the con E Maka sure protectors completely cover the cunne ctors neactar is of the push in type or pull up typa For cannectors with lacks push the connector in lightly then unlock the lock befara disconnecting Good NO GOOD CED Ey E Insert connectors alt the way in E For connectors with locks check that
263. ha groove causing to lose tension and resulting in dacreasad compression The ring and tha ring groove therefore have a tapered form ta remove the carbon in the ring groove when the ring is compressed during engine movement The rings of this type are called keystona rings Some 2 stroke piston rings are provided with an expansion ring inserted between the inside of the second ring and the Piston The tension of the expansion ring absorbs the impact generated when the piston contacts the cylinder wail with a resuitant decrease tn engine noise OIL RING Steel Rail with Slotted Expander Slottad Expander Bes I o OMh LRIROAITLELOLT RSACLEARAAS RAPE NEZ EARR ERAO p EIE AANO EE At tags COMPRESSION RING GROOVES 2 4 pad amp a im a w T m a G a Venere a E ETTA OIL RING __ ip PISTON PIN HOLE SNAP RING GROOVE PISTON PIN BOSS PISTON RING DOWELS A piston ring dowal is Press fittad to each ring groove to prevent the ting from rotating in the groove After fitting the ring in tha ting groove check that the dowel engages the ring end gap properly TOP AING PISTON 2nd RING RING EXPANDER 10 4 Date of Issue Sep 1998 HONDA MOTOR Co LTB CYLINDER PISTON CYLINDER PISTON CYLINDER STRAIGHT EDGE WARPAGE INSPECTION Remove the cylinder ses Modal Specific manual Carefully remove any adhering gasket material from
264. harge and store it in a cool dry place For a battery remaining in a stored motorcycle disconnect the nagativa battary cable from the battery terminal Conventional Battery Usa only distilled water in the battery CAUTION Tap water wilt shortan the servica life af the battery j Immediately wash off any spilled electrolyte CAUTION Avoid filling the b filing the battery above the UPPER LEVEL Tine to prevent Bn electrolyte overflow which could corrade tha engine or nearby F parts Maintenance Free Battary NOTE The maintenance maintenance free battery must ba replaced when it it reaches tha end of it its service life i CAUTION wef E lt The battery battary caps should not bs ramoved Attempting to ramove the sealing caps fram the cells may damaga tha battery TE Refer to saction 21 for basic electrical service and safety steps Refer to section 2 for battery fluid and specific gravity This section explains the basic steps for diagnosis and service Refer to the Model Specific manual for the location of specific camponents Date of Issue Sep 1988 HONDA MOTOR CO LTD 22 1 BATTERIES CHARGING LIGHTING SYSTEM Batteries can be damaged if overcharged or undercharged or if left to discharge far long periods These same conditions contribute to shortening the life span of the battery Even under normal use tha performanca of batteries deteriorates aftar 2 3 years B
265. he air cleaner case Ramove the vacuum tube fram the carburetor intaka pipe in stall a plug to keep air fram entaring Connect a vacuum pump to the vacuum hose VACUUM PUMP ST AH 260 MC7 U S A only Start the engine and open the throttle slightly to be certain that air is sucked in through the air cleaner tu AlCV hase If air is not drawn in check the air cleaner to AICV hose and vacuum hase far clogging With the engine running gradually apply vacuum to the vacuum hose Check that the sir intake port staps drawing air and that the vacuum does not bleed SPECIFIED VACUUM Refer to the Mode Specific manual If air is Still drawn in or if the specifiad vacuum is not maintain d install a new AICV If aftarburn occurs on deceleration even when the secondary air Supply system is normal check the slaw air cutoff valve for correct vacuum operation AIR CLEANER CASE SECONDARY AIR INTAKE PORT VALVE VACUUM PUMP REED VALVE HOSE AIR CLEANER TO AICY ST a ary hy 7 8 Date of Issus Sep 1988 HONDA MOTOA CO LTD EMISSION CONTROL SYSTEMS REED VALVE REED VALVE REED STOPPER Certain typas of sacandary air supply systems have the reed valve built in the AiCV Refer to the Model Specific manual for reed valve location Remove the reed valve covers and read valves Check the reeds for damage or fatigue and raplace if necessary Install a new ree
266. he camshaft if any of the working surfaces are warn scared or scratched CAM LOBES NOTE Inspect the oil passages and camshaft holders for wear or damage if the journal surface is worn or damaged Measure the journal O D and cam height Replaca any carn shaft if its measurements are beyond the service limits Check camshaft runout with a dial indicator Support both ends of the camshaft with bloeks CAMSHAFT BEARING INSPECTION Check that the bearing inner race fits the camshaft tightly without play Turn the outer race and check that tha bearing turns smoothly and quietly BEARINGS CAMSHAFT OIL CLEARANCE INSPECTION The oil clearance is the difference between the camshaft bolder I D and the journal Q D Measure tha camshaft holder journal I D with a dia indicator Subtract the camshaft journal O D fram the camshaft holder journal 1 0 te obtain the oil clearance When the service limits are exceaded replace the camshaft and recheck the ail clearance Replace the cylinder head and camshaft holders if the clearance still exceeds sarvice limits Date of Issue Sep 1988 HONDA MOTOR CO LTD 9 5 CYLINDER HEAD If a dial indicator cannot he used measure the oil clearances CAMSHAFT PLASTIGAUGE using plastigauge Clean aff any aif From the camshaft journais Put the camshaft in the cylinder head and place 4 Strip of Plastigauge on top of each camshaft journal Inst
267. he carburator body Install the spring Install the vacuum chamber cover with its cutout aligned with the hale in the tab of diaphragm NOTE jo Be careful nat to pinch the diaphragm and te keep the Spring straight gt _ FUEL SYSTEM FLOAT LEVEL INSPECTION i FLOAT LEVEL GAUGE VACUUM PISTON JET NEEDLE HOLDER SPRING 9 i aH Ep so traat Fa WASHER SPRING HOLDER JET NEEDLE Date of issue Sep 1988 8 16 HONDA MOTOR c LTO FUEL SYSTEM THROTTLE VALVE Piston valve type RETAINER The lower the clip is set in NOTE the grooves tha richer the F 4 mixture becomes Cabie operated throttle vaiva type carburetor throttle valve is connected to the cabie via tha link Refer to the Medel Specific manual for throttle valve removal disassembly Install the clip on the jet needle Refer to tha Madel Specific manual for tha standard clip position Install the jat needle into the throttle valve and secura with the retainer Route the throttie cable through the spring and compress the Spring fully Attach the threttla cable end ta the bottom of the throttle valva and thread the throttle cable through the slot in the valve Align the cutout in the throttle valve with the throttle stop screw on tha carburetor body and install the valve on the carburetor Be sure that tha throttle valve cutaway
268. he digital signal it processes signals containing information on the crankshaft angie and angine speed The microcomputer then reads the information on ignitian timing which is based on the engine speed from its maemary and determines the ignition timing Then tha microcomputer sends currant to tha base As the current from the microcomputer flows to the base of transistor the transistor is turned ON and ignites the spark plug identical to the transistorizad ignition system ENGINE PULSE GENERATOR STOP SWITCH IGNITION SWITCH ROTOR To MICRO COMPUTER ae BATTERY ABITHOMET C teat IGNITION MEMORY solk PULSE SPAR GENERATOR ER i SPARK UNIT THYRISTOR Date af Issue Sep 198b 23 8 HONDA MOTOR CO LTD r IGNITION SYSTEMS SPARK PLUG Due to the high voltage generated at the ignition cail sparks jump across the center elactrade and side electrode of the spark plug and ignite the fuel mixtura in tha combustion chamber Use spark plugs of the proper size and heat range appropriate for the engine or the enging will not perform to its full potan tial and damage to the engine may occur Heat dissipation Spark plug heat range lt Spark plugs of each heating value or heat range As the spark plug is constantly exposed to the engine combus based on heat dissipation gt tion gas if is necessary to dissipate heat in order to keep the spark plug at a certain temperature
269. he lock washer between the nut and plajn washer NUT LOCK WASHER PLAIN WASHER When the washer is compressed under the bearing surface pressura the alasticity of the spring and the edges of the ring ands prevent lansening 2 Self locking nut Impartant points on the frame Avoid using spring plate nuts with defarmed PRO Link pivot point nuts or damaged spring plates SPRING PLATE Axie nuts The bolt head must be held during nut in Stailation and removal due to the resistance of tha nut spring plate against the bolt If the bolt length is too short the spring plate portion of the lock nut will not engage with tha thread fully This is a nut with a Spring plate on tap This spring plate presses against the thread making it dif ficult for the nut to loosan Aftar removal this type of nut can be used again 3 Double nut Chain adjusters Lee Lock nuT Cable adjusters the lock nut sl Also used for removing or jn Any attempt to loosen both nuts adjusting stalling the stud boits and lack nutst simultaneously will damage tha bolt threads Hold the adjusting nut securely and tighten The lack mut applied to the ad justing nut from outside presses against the latter thus preventing lagsening ADJUSTING NUT
270. he positive plates produca oxygen gas the negativa platas are not completely con verted to laad There is no hydorogen gas is produced The axygen produced from the positive plate reacts with tha active material lead on the negativa plate and produces water Therefore the water does not need to be addad to MF batteries The MF batteries have safety valvas dasigned to open up when excessive gas is produced The safety valves close and seal the battery again when the internal pressure returns to normal A ceramic filter is placed over the safety valves to prevant any internal ignition of the gases produced oo TTS abe o 8 oe cmemamn wane cance o as Electrolyte Is poisonous Explosive gas can vent out from a battery when it is overcharged For this reason keep an open flame or lit cigaratta away fram a battery Use the electrolyte container designated for the specific battery CAUTION The MF battary life depends largely on the proper amount of alactrolyte being added at the start of service fe es SS Ss E 0O NOTE a Avoid interchanging conventional and MF batteries They have different charging components CAUTION Removing the sealing caps from the calls may damage the battery Date of issue Sep 198 22 6 HONDA MOTOR CO LTD rmx BATTERIES CHARGING LIGHTING SYSTEM MOTORCYCLES WITHOUT BATTERIES Some motorcycles do not have batteries in their electrical sysrams These mo
271. he saveral points on the secon dary Cup side and replace it if the smallest measurement is less than the specified service limit PISTON Refer to the Model Specific manual far the service limit NOTE hd Replace the master cylinder if it leaks with a new piston MICROMETER MASTER CYLINDER PRIMARY CUP SECONDARY CUF Assembly NOTE Replace the piston spring cups and snap ring as a set _ Be sure that each part is free fram dust or dirt before I i reassembly aa SNAP RING Coat the piston cup with the fresh brake fluid and install it on the piston Install the spring with its larger diameter and toward the master cylinder wi Se SPRING Install the primary cup with its concaved sida toward the inner side of the master cylinder Install the snap sing SPRING PISTON ASSEMBLY SNAP RING PLIERS 07914 3230001 CAUTION When installing the cups do not allow the lips to turn in side out Rafer to the drawing Note the Installation diraction of the snap ring j Ba certain that the enap ring is seated firmly in tha groove al PRIMARY CUP install the rubber boot in the groove properly Date of Issue Sep 1988 OHONGA MOTOR O LTD 1 7 1 5 BRAKES Place the master cylinder on the handlebar and install the MASTER CYLINDER holder and halder balts with the holer s UP mark facing up Align the spiit between the holde
272. he transistor and thyrister but it does not flow to the fuel pump Te fill the carburetor float chamber with fuel when the ignition switch is turned ON certain types of the fuel cut off relay have a timer function that sends current to the fuel pump for a few seconds To BATTERY To SPARK UNIT While the engine is running pulses are transmitted from the spark unit to the ignition primary circuit and when it is transmitted to the transistor current flows from the transistor to the thyrister to turn it ON The battery current fiows to tha fuel pump this way To BATTERY To SPARK UNIT As the fuel cut off relay is controlled by the ignition primary circuit the relay does not operate unless tha ignition primary circuit operates properly INSPECTION Turn the ignition switch ON and perform the following inspections 1 Check for battery valtage between the black wire of the fuel cut off ralay connector pump connector if the relay is built in the purnp and ground IGNITION FUSE SWITCEHI FUEL CUT OFF RELAY i MAIN Battery voltage No battery voltage Broken black wire Faulty sub fuse Faulty ignition switch Poor connection of the fuse holder connectar 2 Check fer continuity batwean the black blue wire of the relay connector and ground or black yellow wire and graen wire of the pump connector if the relay is built into tha pump TO IGNITION CIRCUIT No c
273. he upper level if the level is fow SYSTEM TESTING HYDROMETER TEST Check the coolant gravity using a hydrometer Look far contamination and raplace the coolant if necassary Coolant gravity chart COGLANT TEMPERATURE aC F 10 15 25 30 35 t77 486 fe 1 008 1 007 1 006 1 005 1 1 016 008 1 007 1 005 1 018 4 016 1 014 1 012 1 033 27 1 025 1 023 1 021 1 019 1 042 1 040 1 038 1 036 1 034 1 031 1 028 1 026 1 049 1 047 1 045 1 043 1 l 1 035 1 058 1 056 1 054 1 052 1 1 046 1 066 1 053 1 072 1 070 1 064 1 062 1 059 1 056 1 050 1 047 1 080 1 078 1 076 1 063 1 060 1 057 1 054 1 062 1 059 1 096 1 093 1 091 f l 1 070 1 067 1 100 1 098 1 095 1 092 1 089 Date of Issue Sep 1988 HONDA MOTOR CO LTD 5 7 COOLING SYSTEM RADIATOR CAP TEST RADIATOR CAP COOLING SYSTEM TESTER COMMERCIALLY AVAILABLE Test the radiator cap using the cooling system taster Replace the cap if the ralief pressure is tao high or too low or if the cap does not hold the specified Pressure for at least 6 seconds NOTE _ AS EAN Before installing the cap on tha tester wet the sealing surfaces with clean water SYSTEM PRESSURE TEST CAUTION r Exsading the radiator cap relief prasstire can damage caciing system componants Check that the system holds the specified pressure for at l
274. he wheel and check that it rotates smoothly with no unusual noises If faults are found inspect the wheel bearings Raise the rear wheel and check for play in either the wheel or the swingarm pivot Turn the wheel and check that it rotates smoothly with no unusual noisas If abnormal conditions are suspected check tha rear wheel bearings NOTE As the swingarm pivot is included in this chack be sure to confirm the location of the play i e fram the wheel bearings or the swingarm pivot 2 36 Date of Issue Sap 1988 HONDA MOTOR CO LTD MAINTENANCE AXLE HOLDER NUT Chack for looseness of bolts nuts in connection with the Following Axles Axle nuts Rim hud bolts RIM BOLT On modals that have cotter pins check that the pins are at tached correctly Check for cracks deformation damage and corrosion atc of the following parts Rim Wheel Spokes COTTER PIN AXLE NUF Raise the wheel turn slowly and check far lateral and vertical oscillation Ss Chack oscillation by changas in the Usable limit front and raar whaals Lateral diraction Up to 2 0 mm 0 08 in Vartical diraction Up to 2 0 mm 0 08 in Qscillation of Comstar or cast wheels cannot be corrected Therefore chack for bearing play or a bent axle shaft If nacessary replace the wheel assembly Hf there is deformation of the rim on spoked wheels replaca the rim
275. hen the ignition switch is tured OFF current stored in the p INDICATOR condenser flaws through the exciter coil and through resisters ea go off Ri and R to tha oil lavel indicator The oil level indicator doas not come on this time re Date of Issue Sep 1988 HONDA MOTOR CO LTD 25 3 LIGHTS METERS SWITCHES TIMER TYPE INDICATOR INSPECTION Qitlevel indicator cames on when the oil in the tank reaches a specified lavel Faulty oil level switch Shorted wire harness Oil level indicator does not came on with no oil or low oil level in the tank 1 Disconnect the oil tevel switch connector and connect a jumper wire to the power supply wire black or black brown terminal and the indicator wire green red terminal to shart Turn the ignition switch ON and check the oil level indicator Indicator does indicatar comes on not come on Fautty off level switch Poor connection of the connector 2 Disconnect the ail level switch connector and check for voltage between the power supply wire black or black brown and ground Voltage No valtage Broken power supply wire Faulty sub fuse Fauity ignition switch Poor connection of the Sub fuse connector 3 Connect the jumper wire to tha power supply wire and oil levet indicator wire to short and check for voltage ba tween the indicator wire and ground Voltage No voltage Blown bulb Broken indicator wire Fault
276. hift arrn to rotate the shift drum When the shift drum rotates the shift forks move sideways dus to the cam action of the groove cut in the shift drum body LEFT GEARSHIFT FORK CENTER GEARSHIFT FORK RIGHT GEAR SHIFT FORK RIGHT GEARSHIFT FORK TRANSMISSION MAINSHAFT TRANSMISSION COUNTERSHAFT GEARSHIFT PEDAL GEARSHIFT SPINOLE Date of Issue Sep 1988 13 2 HONDA MOTOR D LTD TRANSMISSION PLANETARY GEAR TYPE OPERATION This system is comprised of a shift spindla assembly guide plates drum shifter and twa Stopper assemblies The shift spindle assembly is comprised of tha shift spindla and the three planetary gears The shift spindle assembly plus the guide plates transmit the gaar shifter movament to the sun gear on the drum shitter As the drum shifter turns ona of its pawls will engage a detent in the shift drum turning the drum Turning the drum causes the shift forks to move by the same cam action as with the conventional type shift mechanism The two stopper assamblies locate tha shift drum at the proper gaar and neutral Positions DRUM SHIFTER RATCHET PAWL GEARSHIFT DRUM RATCHET GUIDE PLATE SHIFT SPINDLE PLANETARY GEAR _ PLANETARY GEARS SHIFT DRUM STOPPER PLATE Date of Issue Sep 1988 HONDA MOTOR CO LTO 1 3 3 Shift Scart Pushing down on the shift pedal turns the spindle counterclockwise Because the g r plate is fixed the planetary gears turn cl
277. hould be replaced WEAR LIMIT Replace the tire if the wear limit indicator can be observed creado INDICATOR Check also for uneven wear of the tiras Tp ead 2 NOTE Wear indicators A ara distributed at several locations around the tire s side wall for easa of inspection J STEERING HEAD BEARINGS Sacurely support tha vehicle from beneath the frame with the front wheel off the ground Turn the handlebar from left to right and check that the movement is smooth if the operation is not smooth or the handlebar Snags or has a heavy feel in cer tain lacatians check that thera is no interference from cables or wire harnesses f these are not tha cause check for wear or damage to the steering head bearings Check for misalignment of the front wheel with respact to the handlebar tf tha wheel is out of alignment loosen the wheel and fork assembly balts nuts align and re tighten If the wheel cannot be aligned check for bent SUSPENSION Components or a bent frame If the handlebar shows unusual shako during normal tunning Conditions check the handlebar mounting fasteners and whee etc Turn the handlebar fully feom left to right and vice versa to check that there is no difference betwean the two directions of mavement Check aiso that there is no interference between the handlebar and frame Also inspect for snagging of wires and harnessas on the fork Stops on the lower fork bridge If the handiebar move
278. ifier ts an electrical component using semiconductor davices the component itself is not servicad Instead the connector on the reguilator rectifier ts checked Inspect the regulator rectifiar at the terminals of each connector 4 REGULATOR RECTIFIER CONNECTOR WIRE HARNESS SIDE REGULATOR RECTIFIER CONNECTOR WIRE HARNESS SIDE Date of Issue Sap 1988 HONDA MOTOR CO LTD BATTERIES CHARGING LIGRTING SYSTEM Items wire colors Inspection ee Battery wireired white or red Ground wire green Check continuity between ground and frama Check that there is battery voltage between voltage detection line and ground wire when the ignition is ON Voltage datectian lina black iexternal voltage detection type Charging coil wire Check that the resistance of the coil is within the specified range Check that the resistance of the coil is within the specified range Bacausa the lighting system effects the rasistance value follow the steps below Charging lighting coil wira refer to Model Spacific manual For the charging lighting coil charging and lighting shared by CONNECTOR a singla coil disconnect the output connector when measur Disconnected ing rasistance The headlight resistance will be includad in the ohmmeter measurement it the connector is not disconnected REGULATOR RECTIFIER f the headlight connector is connected the measured CONNECTOR
279. in adjusters Move tha rear wheel forward snd disengage the drive chain from the driven sprocket For mechanical drum brakes remove the rear brake adjusting nut and depress the pedal to disconnact the brake rod lor cable from tha brake arm lf the brake panel is mounted with the brake torque rod discannect the torque rod from the brake panel by ramaving the tarque rod mounting nut CHAIN ADJUSTER pean AXLE Remove the axle nut and rear axle For hydraulic disc brakes move the caliper assembly away from the disc to avoid interferance Remove the rear wheel Installation For drum brakes instali the brake panel and side collar on the wheel hub NGTE Note the proper direction of the axle side collar Place the rear wheel into the swingarm while Jaying the drive chain between the sprocket and wheel hub In case that the swingarm on the brake panel is not mauntad with the brake torque rod insert the stoppar on the swingarm into the groove of the brake panel when installing tha wheel in to the swingarm Data of Issue Sep 1988 HONDA MOTOR C LTD 1 6 5 WHEELS TIRES For hydraulic disc brakas install the rear wheel by working the braka disc between the hraka pads Be careful not to damage the pads Set tha rear wheel in the place Install the rear axle with chain adjuster NOTE Note the proper direction of the chain adjuster e Instali tha chain adjuster and axla nut to the
280. in jet systams etc Thea fuel supply system varies with the degree of throttle open ing and regulates fue according to a slow systern at law throt tle openings throttle opening fully clased to 1 4 openl At medium throttle openings fopening 1 8 3 4 the main system s jet needle is used to regulate the fuel The straight section of the jet needla regulates at 1 8 1 2 and the jet nge die clip position or jet needle tapered section diamster regulates at 1 4 3 4 When the throttle is fully open factually arange of 1 2 futly open the fuel is regulated by the main jet of the main system Float system The float chamber holds a constant levei of fuel in order that the engine may be provided with a stable supply of the re quired air fuel mixture As fuel is consumed and the level in the chamber falls the flaat and float valve are lowerad and the chamber is irn mediately refilled to a specified level A rise in fuel level causes the float and its valve to rise the valve contacts the valve seat and the fuel supply is cut off This operation is repeated con tinually as the engine is run The float valve contains a spring which lightly depresses the valve so that it does not become dislodged from the seat by vibration when the vehicte is running To keep the inside af the float chamber at atmospharic pressure thera is a connection to the outside of the carburetor known as the air vant passage An oveciow tube is provided to vent
281. ine speed 6 Readjust the idle Speed to the specified value with the throt tle stop screw 7 Make sure that the engina does not miss or run erratically Repeat steps 5 and 6 until engine speed increases smoothly 8 Readjust the idle Speed with the throttle Stop Screw 9 Install tha limiter cap for plug on to the air or pilot screw head if applicable paye 8 23 AIR SCREW ADJUSTMENT 2 stroke engine oniy Warm the engine up to operating temperature Turn the air scraw clockwise until it seats lightly then back it Out to tha specification given AIA SCREW OPENING Refer to the Modei Specific menual CAUTION Tightening the air screw against its seat will damage the seat a AIR SCREW Date of Issue Sep 1988 8 22 HONDA MOTOR CO LTD FUEL SYSTEM Adjust the idie speed with the throttle stop screw IDLE SPEED Refer ta the Model Specific manual Rev the engine up slightly from the idle speed and make sure that engine speed rises and returns smoathly Adjust by turning the air screw in or out within a 1 4 turn if necessary If the engine cannat be adjusted by turning the air screw within a 1 4 turn check For athar engine problems LIMITER CAP OR PLUG INSTALLATION LIMITER CAP If the pilot screw for air screw is removed a new limiter cap must be installed after the screw is adjusted After adjustment cament the limiter caps over the screws us ing LOCTITE 601 or equivalent Th
282. information v Press the old bearing out of the crankcase paga 11 7 Record the D code letter A B or C or measure the crankcase 1 D after the bearing has been removed I D CODE Record the main journal O D code number 1 2 or 31 0 0 CODE Cross reference the case and journal codes to determing the COLOR CODE replacement bearing color code Example I D code on the crankeasa A O D code an the crankshaft 1 Bearing coda Brown CRANKCASE B CODE MAIN a JOURNAL i eit REMOVAL BEARING INSERT Two piece Type Carefully remove the bearing inserts from the crankcase Wipe all oil from the insert seating areas rere e ee Date of Issue Sep 198B 1 4 6 HONDA MOTOR CO LTD CRANKCASE CRANKSHAFT One piece Type Press out the main hearing using the special tool and hydraulic press CAUTION When removing bearings always use a hydraulic press and bearing removal tool to prevent crankcase damaga MAIN BEARING INSTALLATION Two piece Type Install the main bearings inta the crankcase Tha bearing tabs should be aligned with the grooves in the case and caps Apply molybdenum disulfide solution to the upper and lower main bearings Mark a line perpendicular to the baaring surface from each edge of the notch as shown Apply molybdenum disulfide grease to the outer face of tha bearing Place the bearing in the crankcase by aligning the two lines
283. ing that electrical current flows fram the positive to tha negative side whila elactrans ilow from the negative to the positive side It is canvaniant to think of the flow of electrical current as the flow of water The number of electrons passing any given point in a circuit in one second determinas the current flowing through the circuit The amount of current flow is measured in Amperes A FREE ELECTRON NUCLEUS a SILK CLOTH FLOW OF CURRENT _ FLOW OF ELECTRON oo h 21 6 Date of Issue Oct 1998 HONDA MOTOR CO LTD ALTERNATING CURRENT AND DIRECT CURRENT All electrical components are supplied with either alternating currant or direct current abbreviated as AC or DC raspectively The fundamantal characteristic of the two currents differ com pletaly and for the purpose of servicing you need to have a good understanding of these differences Alternating current Alternating current AC changes in voltage value and polarity with time AC current flows in one direction until peak voltage is reached and then drops to zero volts AC current then changes direction or polarity untit peak voltage is achiaved and again drops to zero and again changes polarity From paak positive voltage to peak negative voltage and back again to peak positive voltage is known as a cycla In motorcycles all electricity generatad is AC However AC can be canvarted to direct currant DC by ractificatian The
284. ing crankshaft seal on tha transmission primary gear side will aiso consume transmission ail Other air leaks include the cylinder base gasket the magneto side crankshaft seal leaks between the read valve assembly and its gaskets end leaks in the carburetor mounting boot batween the carb and the raed valve The first step in the tasting procedura is to remove the exhaust and to affectively seal the exhaust port This is done witha plate fastened to bolt over the exhaust port backed by a rubber sheet or with some form of expandable rubber plug Next the Carburetor is removed and a plug is clamped snugly in place where the carburetor was This leaves only tha seals and gaskets to show any defects they may have Then an attachment is insertad into the spark plug hole and pressure applied with a hand pump Often a brake bleeder pressure vacuum toot is used for this purpose Spraying soapy water around the inlat tract reed valve and crankcase mating areas will produce bubbles where there are laaks The vacuum partion of the test ensuras that the negative seating characteristics of the crankshaft seals are adequate Be sure to follow the leak down test tool manufacturer s instructions precisely whan making this inspection a_i yy yen 3 4 Date of Issue Sep 1988 z HONDA MOTOR CO LTD wee ee ye yy 4 LUBRICATION SERVICE INFORMATION OIL PUMP INSPECTION SERVICE DATA PRESSURE RELIEF VALVE TROUBLESHOOTING OIL PUMP OIL LINE BLEEDING SYS
285. ing power transmission This is a simitar mechanism ty a drum brake The shift Clutch is attached to the mainshaft as with a manual clutch The work of eogaging disengaging is afsa the same as with the manual clutch The gear shift lifter mechanism is the same a that of the Combined type described in the Previous section E CLUTCH i PRESSURE 8 CLUTCH PLATE PLATE CLUTCH L a LIFTER isc BEARING SHIFT CLUTCH Oho CENTRIFUGAL CLUTCH PLATE T WASHER E FRICTION SPRING Wy sat H DRUM OPERATION PRINCIPALS Centrifugal Operation refer to belt automatic transmission Lifter mechanism of change System refer to wet Muttiptate centrifugal clutch Type AJ Clutch mechenism of changa system r fer to wet multiplate centrifugal clutch Type Aj Date of Issue Sep 1988 1 1 9 HONDA MOTOR CO LTO CLUTCH CLUTCH INSPECTION LIFTER ARM CLUTCH LIFTER DISASSEMBLY INSPECTION PIN DRIVER Fype A and a part of Type B Remove the crankcase cover Refer to Model Specific manual Remove the lifter rod and return Spring lf a spring pin is used drive out the pin using a pin driver Remove the lifter shaft from the crankcase cover RETURN SPRING Chack folowing lifter rad for bending needle bearing for play or damage dust seal for damage return spring for damage or weakness DUST SEAL Type D Remova the right crankcase cover see the Model Specifi
286. ing temperature while preventing overheating and over cogling The coolant is pumped through tha system by means of a water pump Combustion heat is absorbad by the coolant in the Course af its passage through the water hoses water jacket around the cylinder and through the cylinder head The coolant then passes into the radiator through the thermostat and upper radiator hose The hot coolant is covled by air in the course of its passage through the radiator and is then retuened into the water pump through the lower radiator hose SYSTEM FLOW PATTERNS TYPICAL 4 STROKE ENGINE RADIATOR ae UPPER CA Se P ALD Ps HOSE COOLING FAN THERMOSTAT RADIATOR TYPICAL 2 STROKE ENGINE THERMOSTAT CYLINDER RESERVOIR TANK 5 2 Date of Issue Sep 1988 z HONDA MOTOR COQ LTD COOLING SYSTEM RADIATOR Caolant temperature is decreased by dissipating haat inte the air by means of the radiator fins as the coolant passes through j the sadiator tube The larger the fin s surface area thea more the radiator exerts its cooling capacity It is important that air is permitted to pass through the radiator fins so that the heat is dissipated from the coolant to the fins and into the atmospheres Crushed or twisted fins wil not per mut heat to be dissipated because of inability of the air ta pass through tham resulting in lowered cooling capacity If 1 3 or more of the fins are crushed or twisted the fins sho
287. ing tha oil seal during the oil seat installation Apply fork oil to the ail seal lip inspect the oil seal with tha marked side facing up Placa the fork slidar in a vise with soft jaws or a shop towel by the brake bracket or calipar bracket as shown Be careful not to distart the slider by clamping it in a vise incorrectly Apply a locking agent to the socket holt and thread it into the piston Tighten the balt with a 6 mm hex wrench NOTE Temporarily install the fark spring and fork cap bolt sa that the piston is held in place when the sockst bolt is tightened 18 8 FORK TUBE FORK PISTON REBOUND SPRING FORK PISTON STOP AING OIL LOCK PIEC OIL SEAL MARKED SIDE FACING UP GUIDE BUSHING FORK TUBE TOP END BACK UP RING BRACKET FORK PISTON Date of Issue Sep 1988 HONDA MOTOR CO LTD Jaf FRONT SUSPENSION Place the slider bushing aver the fork tube and rest it on the slidar Put the back up ring and an ald bushing or equivalent toal on top Drive the bushing into place with the seat driver and remove the old bushing or equivalent taal Coat 3 new ail seal with ATF and install it with the seat mark ings facing up Drive the saal in with the seal driver install the snap ring with its radiused edge facing down Saat the snap ring firmly in the groove Failure to firmly seat the snap ring may cause tha fork assambly to come apart unexpectedly and lead
288. ing the proba shown at gt ta a ground Example To check the CD exciter coil rasistance can be measured at BLACK MED 1 and 2 Measuring resistance at 4 automatically checks for a broken wira iblack red and for a bad connection at the alternator connector If the resistance is normal at 4D need WIRE HARNESS not ba chacked it was checked first and correct resistance was measured CDi EXCITER COIL CDI UNIT there is still possibility of a broken wire and loose connec tion That would raquire more investigation ta locate the fault ee ee we If whila measuring resistance at 1 the negative probe is plac ad on the ground wire green then the connection ta ground is checked as well To check the operation of an exciter coil place the probes as shown in the diagram If the resistance is normal then the ax citer coil the Wire connectad to the coil iblack red and the ground wire gr en are all normal BLACK RED GROUND WIRE If the resistance is far off the standard value check the following 1 Broken ground wire grean Place a probe at 3 and measure resistance If Of is measured then the green wire is properly grounded If infinity is measured then a broken wira green or loose Connection at the ground terminal is suspect Date of Issue Sep 1988 HONDA MOTOR CG LTD ELECTRICAL FUNDAMENTALS 2 Faulty exciter coil Disconnect the alternator connector
289. is toward the air cleaner case side as it determines tha volume of air for fuel mixture ee BYSTARTER VALVE MANUAL Install the starter valve spring and nut VALVE SPRING LSTARTER VALVE Date of Issue Sep 1988 HONDA MOTOR CO LTD 8 1 7 FUEL SYSTEM AUTO BYSTARTER Apply a small amount of grease to the O ring and install the auto hystarter inta the carburetor hody Refer to the Model Specific manual for the auto bystarter installation angle Secure the auto bystarter with the set plate and screws Install the auto bystarter cover AUTO BYSTARTER SET PLATE CARBURETOR SEPA RATION ASSEMBLY INSTALLATION Refer to the Mode Specific manual for carburetor sapara tion assembiy Check and adjust the carburetors as described balow after the assembly MAES SYNCHRONIZATION ADJUSTING SCREWS Move the choke arm by hand and be sure that the starter valve operates smuothly Ae Ratate the throttle drum and be Sure that alf the throttle valves Open and close smaothly Turn the throttle stan screw to align the throttle valve with the edge of the by pass hole in the base carburetor Base car buretor is the one n which the throttle stop screw is installed Refer to the Mada Specific manual Align each throttle valve with the by pass hale edge by turning the synchronization adjusting screws Refer ta the Model Specific manual for the location of aach synchro
290. isc rotate together with tha wheel Each is slowed by the friction af either shoas or pads that press against thern MECHANICAL DRUM BRAKE Singla Leading Shoe Type Or Leading Trailing Shoe Type Force applied against the braka lewar or pedal activates a cable or rod attached to the brake mechanism A threaded adjuster on the end of the brake actuating cable or rod offars ona of two adjustmants to control the precisa brake actuation point The adjuster acts against a pivot on the end of the brake arm which is clamped onto and turns a brake activating cam As shown in the illustration to the right this cam transfers a rotating force from the outside of the drum through the pro tective brake panel to the inside of the drum Here the cam spreads one end of two crescant shaped shoes The other end of the shoes pivot against a common pin Set into the brake panel Both shoes press against the inside surface of the drum creating friction and slowing the rotation of the whael The first shoe to act Upon the drum beyond the cam in relation ta the rotating direction of the drum is called the leading shoe The second shoe arcing cut against the drum from the com mon pivat pin is called the trading shoe Dua te its position within the system the leading shoe creates mors for a against the drum than that which is applied to it This increased force capability is called a self anargizing af feet In contrast the trailing shoe again becau
291. it inside a plastic bag DRILLING POINT Support the damper unit upright in a vise DRILL BIT Through tha open end of tha bag insert a drili motor with a sharp 2 3 mm 5 64 1 B in drill bit PLASTIC BAG Use a sharp drill bit to minimize heat buildup Using a dull drill bit allows a build up of excessive heat and prassure insida the dampar which may cause an explosion The shock absorber contains nitrogen gas and ol under high prassure Drilling farther into the damper case than specified can puncture the cil chamber Oll escaping under high prassure may cause serious injury Always waar eye protection to avoid getting metai shav ings in your eyes whan gas pressure is released NOTE a The plasti bag is only intended to shield you from the escaping gas Hald the bag around the drill motor and briefly run the drill motor inside tha bag this will inflate the bag with air from the motor and help keep the bag from getting caught in tha bit when you start DAMPER UNIT Date of Issue Sep 1988 HONDA MOTOR CO LTD 19 9 REAR SUSPENSION On dampers with nitrogen gas filler valves depress the valve cor to release the nitrogen and then remove the valva fram the shack absorber Paint the valve away from you Always wear eye protection to avoid getting dabris in your eyes put ASSEMBLY Assemble the shock absorber in the r verse ordea
292. ith distilled water DISTILLED WATER Check the battary capacity with a battery tester paga 22 9 If the battery tester is not available check the gravity of the battery fluid sea below CAUTION Always refill battaries with distilled water Tap water contains minerals that will shorten the lifa of tha hattery Filling the battery above the UPPER lesve mark may causa spillage while riding and subsequent corrosion of vehicle parts After refilling replace gach of the filler caps firmly and re install the battery Follow the instructions on the battary s CAUTION label Make sure that the breather tube la correctly positioned and not kinked trapped or bant in such a way as to obstruct the passage of air CAUTION H the tuba is blocked the battary s internal prescure will not be ralleved the breather may come off or the bat tery could crack as a result et 13s ug BATTERY TEMPERATURE VS SPECIFIC GRAVITY Specific gravity of thuid 1 30 Checks are unnecessary in tha case of MF Maintenance Free batteries The specific gravity of the battery fluid should be checked on IW UENZ 1275 SPECIFIC GRAVITY open type batteries elt os oe t 236 Measure the specific gravity of aach cell with a hydrometer i 12a Specific gravity of fluid at 20 C 68 F Rt a E Fuily charged condition 1 27 1 29 oF ww we dY ay a tow charge condition 1 23 and
293. ith the recam mended ail NOTE Qil level chacks should be carried out on level ground with the vehicle on the center stand or while in an upright position D Transmission oil change Two stroke engine transmission lubrication is achieved by the Spray of transmission oil within the sealed crankcase Com pared to 4 stroke engines there is dittle oil degradation and the period for change is longer Consult the Model Specific manual for the proper oil changa interval Used engine oil may cause skin cancar if repeatedly left in contact with the skin for protonged periods Although thls is unlikely unless you handle used oil on a daily basis it is still advisable to wash your hands with soap as soon as possible after handling used oll NOTE Oil is more easily drained when the engine is warm Remove the oif filler cap Remove the drain bolt located at the bottom of the crankcase and drain the oil When ali the oil is drained clean the drain bolt with its sealing washer and tighten to the designated tarqus NOTE Ba sura to replace the sealing washer if it is damaged Remave the oil check bait and rafill to the prescribed levet with the recommanded oil Replace the check bolt or cap LEVEL CHECK BOLT SEALING WASHER CORRECT OIL LEVEL SEALING WASHERS rr r r pe 2 20 Date of Issue Sep 1998 HONDA MOTOR CO LTO MAINTENANCE
294. ition system gt If there is no spark at eithar group the problem is suspected in the primary coil side of the ignition system i e ignition toil unit and ignition coil cireuit However for models with several spark units where each fires its own group faulty input components are suspected Check input components described on the previous page Ignition group is determined by the type of engine Refer to Model Specific manual for details PE ET Pre ae OE a NP Disconnect ignition coil and check the coil see Conduct spark test on the good ignition coil _ SPARK pige 23 124 NO CHANGE NORMAL ABNORMAL No spark at either group Poorly contact of Faulty ignition coil primary coil wire Corea eT eae QUT OF Measure resistance of the ignitian primary coil at STANDARD Poor contact of primary cail wire Lthe spark unit connector VALUE Broken wire bet ignition coil and unit oo To ween ignition coil an ee EE TaD SOATEST CR ee EEE Cee OUT OF j Measure the resistance of the pulaa generator i tth AE s pulse generator at the STANDARD individually see page 23 16 a n a aoa VALUE Compare with previous results shat dani NORMAL ABNGRMAL Loose or poorly con Faulty pulsa NORMAL nected connectors generator Broken wire e tween pulse generator and unit t Check parfarmance of spark unit with FULL TRICDI tester except U S A isee i Faulty spark unit 23 1
295. its recess Caution should be taken regarding the direction in which tha bearing is installed Ball bearings are always installed with the manufacturer s name and size code facing out This is true for opsn single sealed and double sealed bearings Apply the proper grease ta the baaring before reassambly The outer race should ba installed with a driver attachment and pilot The bearing must be installed in a paralla manner CAUTION Dust in the bearing racees or failure to instal tha bearing parallal to the case may result in hearing ailura If a new bearing fails to fit tightly in the bearing recass replace the case CAUTION NO Te The pilot must not be used if thara is an oil guide plate that the pilot contacts whan driving the hearing in Before removing the bearing make sura whether or nota pilot can be used When the bearing is installad anto a shaft the innar race shouid ba set by using an inner driver hands and inner driver Clean the bearing recesses thoroughly before installing the naw bearing The bearing must he installed in a parallel manner CAUTION Dust in the bearing recess or Improper fit may result in bearing failura S 5 Sa a Sg t If a naw bearing fails to fit tightly onto the shaft replace the shaft CAUTION An improper fit between the bearing and shaft may _ eause baaring damage when in usa For adaptability between drivers attachments and pilots ref
296. ked with lower comprassian in the cylinder resulting in a richer mixture and it is necessary to raise the combustion velocity For this purpose the engine includes a slow fuel supply system which is separate from the main system BYSTARTER BYSTARTER FUEL JET From PTC HEATER ALTERNATOR Cegine staris Current generated a alrarnniae PTG hale Thennowax expards IPIC Cesnpersiure Getectad SET COLLAR Set sping Byate lar valen upursles Fuel cur ntt ny nadia pn NEEDLE JET If uel enricnerung c icuit ehur off by byslurier vavel re THROTTLE VALVE SLOW AIR SLOW JET Date of Issue Sep 1988 D HONDA MOTOR CO LTD 8 5 FUEL SYSTEM Piston valve type throttle valves have a cut out on the intake THROTTLE VALVE PISTON VALVE TYPE sidg The larger the cut out the greater the volume of air entering and the leaner the mixtura STAMP indicates cut out The larger the number is the leaner the mixture becomes Main system medium throttle Opening When the throttle valve is opened to raise tha engina Speed greater volume of air fuel mixture is required than for idling The carburetor is aquipped with the main system for this pur poss The degree of opaning of the throttle valve is divided into two stages With a degree of opening 1 8 1 2 the air flow in the main bore facilitates a drawing up of the fuel from the gap between the jet n
297. keep current flowing to the headlight staadily aresistor whose value is greater than resistance bet wean AC is placed betwaan AD SCR switching regulatian AC regulator built in type This type is used for models with small displacement engines Unlike the type above the SCR is used far switching and the ZD zener diode is used for voltage regulation The output of the alternator goes to the gate of SCR1 via the OC voltage regulator When the voltage at the cathode of the SCR1 is less than the voltage at the gata it is turned ON and thus SCR1 conducts current to the battery When AC output of the alternator changes from the positiva ta negative tha gate voltage of SCA1 becomes zero hence turning OFF the CA1 and cutting off the negative signal to the battery The output voltage is regulated by the ZD1 and the ZD2 which turns ON and shorts ta ground when the output voltage of the charging coil increases beyand a specitied value The regulator may overcharge the battery if the ground wire is broken or if there are poor connections at the terminals AEGULATOR RECTIFIER ___ i VOLTAGE DETECTING REGULATOR RECTIFIER ALTERNATOR ALTERNATOR HEAOLIGHT SWITCH c DC VOLTAGE REGULATOR CATHODE SCR1 y A BATTERY GATE Th 22 16 Date of Issue Sep 1986 HONDA MOTOR CO LTD Fs ATTERIES CHARGING LIGHTING SYSTEM AC ragulator function The AC regulator ragulates the voltage ta the
298. l clutch Loosen the lock nut tighten the adjuster bolt by abaut 7 turn then screw jt back in until pressure is felt on the boit From this position loosen the bolt 1 8 to 1 4 of a turn and tighten the lock nut NOTE it When tightening the lock nut be sure that the adjuster l bolt doas not turn with it Chack the oparation of tha clutch after adjustment a i ummm Clutch fluid level Adjustment for play cannot be made on hydraulic clutches Howaver a check should be made of the fluid level If the level is naar the LOWER limit inscribed on the reservoir remove the reservoir cover and diaphragm and refill ta the UP PER lavel with tha proper type of fluid Before ramoving the reservoir cover turn the handlebar until the reservoir is level Place a rag over painted plastic or rubber parts whenever the 4 se y system is servicad LEVEL LINE CAUTION Splhing fluid on painted plastic or rubber Parts wilt damage them Refill with the recommended of fluid CAUTION Mixing incompatible fluids cen impair clutch operating Sfficlency H j Foreign materials can clog the system causing a reduc tion or complete ioss of clutch ability Date of Issue Sep 1988 2 32 HONDA MOTOR CO LTD MAINTENANCE SIDE STAND SIDE STAND RUBBER Conventional Type Check the wear of the side stand rubber Replace it if it has become worn Support the motorcycle in an upright and level position using a sup
299. l free play adjust mant have been made REFLECTOR PLATE Date of Issue Sep 1986 2 3 HONDA MOTOR CO LTD MAINTENANCE Turn the adjusting nut an the brake light switch and not the switch body and wires to make switch actuation adjustments Be Sure to hoid the switch body firmly while turning the ag justing nut CAUTION Allowing the switch body to turn during adjustment can braak tha wires in the switch a After adjustment recheck to he sure tha brake ight comes on at the proper time HEADLIGHT AIM To make a vertical adjustment loasen the headlight mounting bolts matching the punch mark on the case and the bracket by moving the headlight up or dawn Some motorcycles have an adjusting screw on the bottom of tha headlight In this case turn the screw to make the vertical adjustment For those having an adjusting screw on the side of headlight rim turn this screw to make the horizontal adjustment On some models the headlight is camplately encased The ad justment can be made either with the light beam adjustment knob on the back of the light case or with a remote type cable and knob Refer to the Model Specific manual for the proper adjustment method CLUTCH SYSTEM Check the play at the end of the lever on cable operated clutches A Jot of play results in clutch drag and stiffness in operation of the shift pedal Too little play however rasults in clutch slippage When the c
300. l relay l d EE RE connectar with a jumper wire Turn the ignition switch FUSE Be NALE E ON and check the turn signal light by turning the switch Ley OW 2 RELAY fei Toa Light cames on Light does not coma on t_ Broken wire harness 2 Check for continuity between the green terminal of the relay connector and ground Continuity Na A nuity t Faulty turn signal relay Broken ground wire Poor connection of the connector HORN IGNITION FUSE SWITCH Hom doen not sound 5 1 Check the ignition switch and horn switch If normal check the following HORN SWITCH 2 Disconnect the wire from the horn Turn the ignition switch ON press the horn switch tor start the engine and press the horn switch if your motorcycle is battary iess type and check for voltage between the light graen wire and ground Voltage No voltage Broken light green wire Faulty sub fuse 3 Check for continuity between the green wire and ground Continuity No continuity Faulty horn Broken green wire Faulty ground a f mer i A TURN SIGNALS a a a a Date of Issue Sep 1988 HONDA MOTOR CO LTD 25 17 TRANSMISSION GEARSHIFT MECHANISM CONVENTIONAL TYPE The gearshift mechanism consists of three gearshift forks a gearshift drum a gearshift arm a shift drum stopper and a gear shift positive stopper Whan tha gearshift pedal is depressed tha gearshitt spindle rotates Causing the gears
301. l the piston and insert the piston pin EDLE NOTE NE hes BEARING should he l Tha mark that is stamped on the piston head b facing tha correct direction IN MARK TO INTAKE SIDE VEX ar A MARK TO EXHAUST SIDE install naw piston pin clips f g CAUTION a N PISTON ker us new piston pin clips Reinstalling used piston j PIN CLIP pin clips may lead to serious engine damage NOTE Fake care not to drop tha piston pin clip inte the crankcase Set the piston pin chp in the groove Proparly Do not align the clip s end gap with the piston cutout Date of issue Sep 1988 HONDA MOTOR CO LTD CYLINDER PISTON CYLINDER INSTALLATION Make sure that the pistan ring end gap fs correct install a new cylinder gasket and dowal pins Coat the cylinder wall with clean engine oil and install the cylinder Route the cam chain through the cylinder Be careful not ta damage the piston rings ee a ie _ Single cylinder Install the cylinder over the pistar while compressing the piston rings by hand Multi cylinder Position the piston at T D C and install two Pistan bases to hold the 2 3 pistons Compress the rings with the piston ring compressor and install tha cylinder Paralla four cylinders First install 2 3 then 1 4 SINGLE CYLINDER 1 0 1 0 Date of Issue Sep 1988 HONDA MOTOR CO
302. le holding it in vise Do not clamp it toa tight as it could damage the gear case When tightening the lock nut with a lock nut wrench actual torque on the lock nut is greater than tha reading by the length of the lock nut wrench Refer to the Medel Specific manual for specified torque Do not overtighten the lock nut Description of the toath TOE inside of gear COAST SIDE contacts when engine brake is applied x icontacts when engine HEEL 7 a power is applied outside of gear Te TROUBLESHOOTING Excessive noise in final drive Excessive rear wheel backlash Worn or damagad ring gear and driven flange Worn drive shaft splines Damaged driven flange or wheel hub Excessiva backlash between ring gear and pinion gear Worn or damaged pinion gear and or pinion joint splines Worn driven flange and ring gear splines Excessive backlash between pinion and ring gears Excessive play in final drive case bearings Low oil level Worn driva shaft universal joint and ar pinion joint splines Excessive noise in side gear Excessive play or worn universal joint bearing Worn or damaged output shaft and final drive shaft gears Oil leak at final gear casa Wore or damaged side gear case bearing Clogged breather hole Incorrect adjustment shim Too much oil Faulty oil sealls Data of Issue Sep 1988 1 5 1 HONDA MOTOR CO LTD FINAL DRIVE OUTPUT SHAFT SYSTEM DESCRIPTION DAMPER gt
303. leaning agent or use gasoline to clean the chain Clean dirt off the chain with suitable detergent dry completaly and thoroughiy and apply 80 90 gear oil Wipe off excass oii to prevent it from flinging off whan in operation Chains without O rings Remove dirt fram the chain with cleaning ail or paraffin dry completely and thoroughly and apply 80 90 gear oil or a Suitable spray on chain tubricant Wipe off the excess oil to prevent it fram flinging off when in operation Check for wear and damage to the drive and driven sprockets CAUTION Be sure to replaca the chain and sprockets as a set The combination of an elongated chaln and new sprocketts or the combination cf a worn sprockatis and a naw chain will result in rapid wear of the new componentis Check for looseness of the attachment bolts or nuts on the driva and driven sprockets and if loose re tighten Cate af Issue Sep 1988 HONDA MOTOR CO LTD CHAIN CLIP KINKING or BINDING GEAR OIL SAE 80 OR 90 rae ee GEAR OIL SAE 80 OR 90 2 23 MAINTENANCE DRIVE CHAIN SLIDER CHAIN GUIDE Ps ee a GUIDE SLIDER AND ROLLERS SLIDER GUIDE Tagether the drive chain slider chain guide guide slider and rollers alt da their part to keep the chain unning in its proper path while prevanting it frorn Cutting into the swingarm frame or other components Each of these components is made of a type of plastic that o
304. lightly different frame designs may have significantly different vibration absorbing or generating characteristics which makes one design correct and the other unsuitable even with the same engine installed Therefore the particular frame structure a machine ends up with is chosen according to the engine type and by the specific use the machine is intendad Far in order to prevent unpleasent vibration to the rider and premature fatigue to structural members Frames are classified as follows according to differences in basic structure Date of Issue Sep 1988 20 2 HONDA MOTOR CO LTO FRAME BODY PANEL BACK BONE TYPE This type of frame is made up of a combination of pressed steel plata and steel tubing This basic frame design is used mainly on scooters and some of Honda s early motorcycle designs This type of construction allows added freedom in the overall design of the vehicle and ralatively economical production DIAMOND FRAME The lower section of the down tubs is not connected with other frame tubes The engine farms the final partion of the frame structure Mounting the engine generates the frame strength The diamond frame is used mainly on small and middfe size vehicles due to simplicity of the structure light weight and ex cellent serviceability SINGLE CRADLE FRAME MAIN PIPE The singie cradle frame has one down tube and one main pipe at the front af the engine The frame structual materi
305. liian Exhaust side Exterior side STD ee Standard OP iciatis na Optional OS eee Oversized LOQOL Number of links 100 links C2 viene sseseereeee Countersheft 2nd gear Number indicates the stage of gear M5 ae Mainshaft 5th gear Number indicates the stage of gaar TRIM sirians Rotating speed per minute BIDC Bafare Top Dead Centar AT diiiiisnocssis After Top Dead Center BADC Before Bottom Dead Center ABDC After Bottom Dead Center A ersin Alternating current DC saaran Ditegt current CDI 2 Capacitive discharge ignition ig AP asa Number of coupler pins Following letters or marks stamped on the Parts indicate the installation direction IN vereeetsceeeeeeeveees Jostal with IN toward insidefaxhaust side TOP oo esses INStall with TOP toward up Do not install with the letter upside dawn UP ooo ere Install with the UP toward up Do not install with the fetter upside down UPA Vee Install with the triangular mark toward up Some paris might be stamped with an arrow Fe asse Instal with the arrow toward front Soma parts might be stamped with a triangular mark RRHb lastall an the right side viewed fram rear side If an arrow or triangular mark is Stamped install with the mark toward right L LHI aiian Install on the left side viewed fram rear side If an arrow or triangular mark is stamped install with
306. low fark oil to leak past the seals aaiae amaaaaaaaaaamamamm Io Do not reuse tha fork tube if it cannot be perfectly straightened with minimal effort FORK TUBE Visually inspect the slider and fork tube bushings Replace the bushings if there is excessive scoring or scratching or if the GUIDE BUSHING teflon is worn 50 that the copper surface appears on more than 3 4 of the entire surface Check the back up ring replace it if there is any distortion at the points shown BACK UP RING Check the fork sliders for internal scratches dents that ara visible from both the inside and outside or abnormal wear Replace if necessary Date of Issue Sep 1988 HONDA MOTOR CO LTO 1 8 7 FRONT SUSPENSION Check the fork piston and other components for damage cracks straightness or abnormal wear Replace if necessary ASSEMBLY Insert the fork piston into the fark tube Install the following stop ring ante the fork piston rebound spring onto the fark piston if the rebound spring has been removed ail lock piece Replace the dust seal with a new one whenever it is removad insert the fork tube into the fark slider Install the back up ring and 4 new oil saal Install the guide bushing if it has been removed NOTE Inspect the fork tube sliding surfaces for damaga whenever the oii sgal is replaced due to oil laaks Wrap vinyl tape around the fork tube top end to avoid i damag
307. lowed induca vomiting gargle and consul a physician immediately If any coolant gets on your skin or clothas rinse thoroughly with planty of watar KEEP QUT OF AEACH OF CHILDREN am Add coalant at the reserve tank Do not remove the radiator cap except to refill or drain the systam Ait cooling system service can be mads with the engine in the frame Avoid spilling coolant on painted surfaces After servicing the system check for leaks with a codling systern tester Refer to section 25 for fan motor thermostatic switch and temperatura sansor inspections TROUBLESHOOTING Engine temperature too high Faulty temperature gauge or gauge sensor see section 25 Thermostat stuck closed Faulty radiator cap Insufficiant coolant Passages blocked in radiator hoses or water jacket Air in system Faulty cooling fan motor Faulty fan motor switch ises section 25 Faulty water pump b Engias temperatura too iow Faulty tampe rature gauge or gauge sensor Thermostat stuck apen Faulty cooling fan motor switch isee section 25 Coolant leaks Faulty pump mechanical seal Deteriorated O rings Faulty radiator cap Damagad or deteriorated gaskets Loase hose connection or clamp Damaged or deteriorated hoses Date of Issue Sep 1988 H 1 HONDA MOTOR CO LTD COOLING SYSTEM Ne yee SYSTEM DESCRIPTIONS A liquid cooling system allows optimal engine Aperat
308. lutch play is not adjusted within the prescribed amount correct this using the adjuster lacatad at the end of the cable Major adjustment is carried out at the clutch arm Loosen the lock nut and turn the adjuster nut to adjust play NOTE Before adjusting cable play at the clutch arm screw the adjuster at the lever end of the cable in most but not all the way This makes subsequent adjustment at the lever end easier After adjustment is completa hold tha adjuster nut securely while tightening lock nut BRAKE PEDAL D c oO ADJUSTING MOUNTING BOLT 2 UNCH MARKS CLUTCH LEVER ADJUSTER 21 ADJUSTER Date of Issue Sep 1988 HONDA MOTOR CQ LTD MAINTENANCE Minor adjustments are mada at the levar On models equipped with a dust cover turn back the cover to allow adjustment Loosen the tock nut and turn the adjuster to correct the play ADJUSTER l LOCK NUT ADJUSTER LOCK NUT CAUTION The adjuster may be damaged if it is positioned too far out jaaving minimal thread angagement When mare than 8 mm of thread is showing screw the ad juster in most but not ali the way and make adjustments on the clutch arm end of tha cabie On models with the adjuster located within the langth of the cable i e not at the end loosen the tock nut and turn the ad juster ta alter the play in the same manner s deseribad above On centrifuga
309. ly and tighten the tool to gain access to the nut NOTE Do not overtighten the compressar Oe Hald the clutch spring camprassor in a vise as shown and ramova the lock nut using the lock nut wrench Loosen the clutch spring comprassor and disassemble the clutch and spring fram tha drivan pulley Remove the seal collar from the driven pullay Remove the guide pins and guide pin rollers and the movable MOVABLE DRIVEN driven pulley face L FA Remove the O ring and oil seats from the movable face PULLEY PACE GUIDE PIN GUIDE PIN ROLLER HONDA MOTOR c0 LTD V MATIC BELT DRIVE SYSTEM INSPECTION a Clutch Outar Measure the 1 D at shoe contact surface of the clutch outer Replace the outer if the service limit is exceeded Clutch Shoe Measure the thickness of each shoe replace if the sarvice lirnit is exceeded Refer to page 12 12 for chitch shoe replacement CLUTCH SHOE Driven Pulley Spring Measure the free length of the driven pulley spring and replace if tha Service limit is axceedad FREE LENGTH Driven Pulley DRIVEN PULLEY FACE Check the following Both facas for damage or axcessive wear Guide pin groove for damage or deformation Replace damaged or warn Parts as necessary Measure the Q D of the driven face and the I D of the mavable driven face Replace either part if the sarvice limit is exceeded GUIDE PIN MOVABLE FACE GROOVE Date of Issue Sep 1988
310. mali hole and lever resistance is felt Than bleed the system l Date of issue Sep 1988 HONDA MOTOR CO LTD 1 1 27 CLUTCH A IR BLEEDING UPPER LEVEL DIAPHRAGM 1 Squeeze the clutch lever open the bleed valve 1 2 turn then clase the valve NOTE Do not release the clutch levar until the bleed valve has j been closed Check the fluid level often while bleeding the system to prevent air from being pumped inte the system 2 Release the clutch lever slowly and wait several seconds after it is fully falaased before repeating the procedure Repeat the above procedures until air bubbles no longer appear at the and of the hase BLEED VALVE Tighten the biasd valva te the specified torque Fill the clutch fluid raservoir to the upper level Install the diaphragm diaphragm cover and reservoir cover CLUTCH MASTER CYLINDER Remaval Disassembly Piace a rag over painted plastic or rubber parts whenever the system is Serviced CAUTION at Spilled fluid will damage painted plastic or rubber parts Disconnect the clutch switch wites and remova the clutch hose bolt and two Sealing washers Caver the end of the hose with a clean rag to prevent con tamination of the system Then Secure the hose to the handlebar Remove the holder bolts and holder then remove the master cylinder from the handlebar Remove tha clutch lever Pivot bolt nut and clutch lever Rem
311. me as type A 2 gt CLUTCH 2 CLUTCH CENTER DISC z T 5 1 CLUTCH OUTER CLUTCH 2 CLUTCH ih ram E PUSH ROD A m 7 a g i r es E i ni 2 LIFTER aN BOB 33 CLUTCH 8 BEARING SPRING CLUTCH PRESSURE PLATE Power transmission and operating principle are the same as typa A see page 11 2 Bate of Issue Sep 1988 HONDA MOTOR O LTD 1 1 3 CLUTCH ONE WAY CLUTCH SYSTEM TYPE C INNER PUSH TYPE WITH BACK TORQUE LIMITER MECHANISM On rapid downshifting fram high RPM the compression braking forces treated by the engine can exceed the rear wheel s traction the engine becomes a rear wheal brake This can Cause Momentary jockup of the rear wheel until the compression braking force drops below tha leval necessary to make the rear tire break traction If multiple downshifts are made the result traction CLUTCH HUB INNER l thas splines ra ONE WAY SPRAG CLUTCH splinad to mainshaftt CLUTCH HUB OUTER ino spiinas but receives power via the one way sprag clutch INNER PORTION Always locked during deceleration OUTER PORTION Can slip during deceleration The major difference between this system and a convantional clutch is a two piece clutch hub inner and auter in addition SPRAG CLUTCH CLUTCH HUB the outer partion of the cluteh hub that which controls the Majority of the clutch plates and dises is drivan by special one
312. meter gear box with the boss of the fark leg Set the wheel su that the brake disc is positioned between tha brake pads Use care not to damage the brake pads Install the axle shaft Tighten tha axle nut to tha specified torque Refer to the Model Specific manual Connect the cables Date of issue Sep 1988 1 6 2 HONDA MOTOR CO LTD SINGLE HOLDER TYPE FRONT WHEEL f l i T Removai Loosen the axle shaft holder nuts Loosan the axle shaft while holding the wheel Remove the ax la shaft Remove the wheel tnstallation Hydraulic brake Place the Front wheel betwean the fark legs while Slipping the disc between the pads Take care not to damage the pads Set the wheel into the place and insert the axla shaft through the wheel Loosely instali the axle holder with its UP mark toward up and tighten the axle shaft ta tha specified torque With the front hrake applied pump the front suspension up and down several times then tightan the halder nuts to specified torqua NOTE Holder nut should be tightened On vertically split type upper first then lower nut On horizontally split typa frant first then rear nut Reconnect the cables DOUBLE HOLDER TYPE Removal Remove both side holders and then ramowe the front wheal Disassembly Remove the axle nut from the axle then remove the axle shaft collar and speedometer gear Assembly Install the side coliar and speedometer gear b
313. move the vacuum pump and cannact it to the hase fitting PCY output port that goas to tha carburetaris NOTE lf the PY has two hose fittings that go to the car buretorish connect the blacked tube onto the other fit ting to prevent air leaks Apply the specifiad vacuum to the PCV SPECIFIED VACUUM 250 mm 9 8 in Hg The specifiad vacuum should be maintained Replace the PCV if vacuum is not maintained EMISSION CONTROL SYSTEMS TO CARBURETOR PC OUTPUT PORT j VACUUM PUMP re ae e m a ee ee ere Date of Issue Sep 1988 HONDA MOTOR CO LTO 7 5 EMISSION CONTROL SYSTEMS TO CARBURETOR TO CANISTER PCV OUTPUT PORT PCV INPUT PORT PRESSURE Connect a pressure pump to the hose fitting that goes to the charcoal canister NOTE If the PCV has two hose fittings that go ta tha charcoal canister connect the blocked tube onto the ather fitting to prevent air leaks While applying the spacifisd vacuum to the PCY hase that goss to the vacuum port pump air through the canister hose Air should flaw through the PCV and out the hose that goes ta the carburetor Replace the PCY if air does not flow out Gian PRESSURE PUMP ST AH 255 MC7 U S 4 only VACUUM PUMP CAUTION i Damage to ths purge contral valve may rasult from use of a high pressure air source Use a hand operated pir l pump only Remove tha pump instal the PCY on its mount rout
314. n circuit cannot be adjusted if the jet needle is worn VACUUM PISTON CV type Remove the screws vacuum chamber cover spring and vacuum piston assembly from the carburetor Check the piston for smooth Operation in the carburetor body Turn the jet needle holder counterclockwise while prassing it in and remove it Remove the spring spring holder jat needle needle holder ang washer from the vacuum piston NOTE Certain models are not PQUipped with 4 spring holder PNG der Check the jat needle for stepped wear and replace if necessary Check the vacuum piston for damage and replace if Necessary Check the diaphragm for damage pin holes wrinkles and bends and replace if necassary Air leaks out of the vacuum chamber if the diaphragm is damaged in any Way ven 2 pin hale THROTTLE VALVE f JET NEEDLE i NEEDLE VACUUM CHAMBER COVER VACUUM PISTON SPRING NEEDLE CLIP RETAINER a JET NEEDLE HOLDER SPRING HOLDER JET NEEDLE pe HOLDER DIAPHRAGM JET NEEDLE SPRING 8 12 Date of Issue Sep 1988 HONDA MOTOR CO LTD Remove tha float chamber Remove the float pin float and float Valve Check tha float for damage If it is a hollow float type also check it for deformation and fuel in the float FLOAT PIN Check the float valve and valve seat for scores scratches clogging and damage Replace it necessary Check the ti
315. n each carburetor VACUUM GAUGE tom SYNCHRONIZATION ADJUSTING SCREWS 2 16 Date of issua Sep 1988 HONDA MOTOR CO LTD MAINTENANCE CARBURETOR IDLE SPEED dl Chack for any unusual noise while the angine is idling If noisa THROTTLE STOP SCREW is detected investigate with a stethoscope to locata the source Carry out the appropriate maintenance inspection depending on results of noise investigation Check to see that the engine speed increases smoothly fram idle Check the idle speed and adjust if necessary by turning tha throttle stop screw NOTE Check and adjust after first warming up the engine There are differences in idle speed batween hot and cold angines Place tha vehicte on the centar stand or support upright on level ground when checking and adjusting the idle speed If the vehicle is tilted there will be fluctuations in fuel flow from the carburetor which pravents an ac Curate datarmination of the idie speed RADIATOR COOLANT THERMOSTA Wait until the engine i cool before removing the radiator cap Removing the cap while the engina 6 hot and the coolant is under pressure may cause serious scalding Radiator coolant is poisonous Take care to avoid getting coolant in your eyes on your skin or an your clothes H coolant gets in your ayes flush rapaatediy with water and contact a doctor immediataly If coolant i
316. n output line and ground If the measurad value is not correct check the cantinuity be twean stator ground wire and ground and between ground wire of alternator cover and ground 8 For coils with two output lines measure resistance be twaan tha two lines Check that there is no continuity bet wean engine ground and the output lines C For singla phase combined charging tighting coils measure the resistance at the charging output ling and at lighting output line Di For three phasa coils measure resistance betwesn each output line and check that there is no cantinuity between gach output line and ground If tha resistance values are much larger than the specified value replace the stator if measuraments are only slightly off the specified value the stator may not need to be raplacad Check other areas and decide if replacement is required STATOR REMOVAL Remove alternator cover Watch for ail spilling aut Hold the flywhes rotor with a holder and remove rotor bolt UNIVEHSAL HOLDER 07725 0030000 or ROTOR BOLDER 07725 0040000 CAUTION Choose tha corract holder Using the wrong tool may damage components Aefer to the Model Spacific manual for the correct holder 25 ROTOR HOLDER i 22 26 Date af Issue Sep 1986 HONDA MOTOR CO LTD rs Insert flywheel puller into the totor and remove the rotor 5 COL FLYWHEEL PULLER 07733 0016000 or ROTOR PULLE
317. nal typa system two spring damper units sup part the reat of the frame from the rear section of the swingarm as illustrated here Today this type of suspension is found primarily on small displacement motorcyclas because of the simplicity of installa tion the small number af components necessary and due to the systems basic economy Up until around 1981 this dual spring damper design was also used on most larger displace ment motorcycles as well A rising rate type rear suspensian is also possible on dual shack types if the shock angles are correctly positioned Pro Link Prograssive Link Type Honda s Pro Link suspension system is designed to provide both comfort and contral without compromise Its progressive action rising rate delivers an ideaal proportion af springing and damping over 4 wide range of riding conditions Initial rates are soft for supple response ta small bumps and ripples Should the riding surface become rougher increasingly stiffer ratas provide tha control necessary to pravent bottoming and keap the rear wheel in contact with the surface The swingarm and damper unit of the Pro Link type rear suspension ara connected to the swingarm by a link Tha damper unit travel in relation to the rear wheel movament can be changed relatively freely during the design stage in accor dance with the combination of the cushion arm and cushion connecting red that is selectad As the axle stroka distance increases the piston s
318. nd piston With multi cylinder engines store the pistons pistan rings and piston pins in the same ordar they were installed so thay can be reinstalled in the Original positions TROUBLESHOOTING Four stroke angines If performance is poor at low speads check for white smoke in the crankcase breather tuba If the tuba is stnokay check for a seized piston ring NOTE a R ton far ayindar conan co tas Tte ian e a efer ta section 3 for cylinder compression and leak down test procedures l uu Compression tao low hard starting or poor performance at low speed Leaking cylinder head gasket Loose spark plug Worn stuck or broken piston sings Worn or damaged cylinder and piston Compression too high overheating or knocking Excessive carbon build up in cylinder head or an top of piston Excessive smoke Worn cylinder piston or piston rings Improper installation of piston rings Scored or scratched piston or cylinder wail Abnormal noise piston Worn cylinder and pistan Warn piston pin or pistan pin hole Worn connecting red small end bearing Date of Issue Sep 1988 HONDA MOTOR CO LTO 1 0 1 Pek eae a an a ih CYLINDER PISTON SYSTEM DESCRIPTION CYLINDER As the cylinders are affected by cambustion heat and Pressura they are made of a ong pi ce aluminum or steel Casting with considerable strength and cooling abilities Air cooled ngines are provid
319. next smallest siza possible and install the Proper pistons Otherwise raplace the cylinder Date of Issue Sep 1988 HONDA MOTOR CO LTD CYLINDER PISTON PISTON PISTON RING REMOVAL NOTE Se et a a a a Pace a clean shop towei over the crankcase to prevent the possibility af tha clip falling into tha crankcase Remova the piston pin clip using pair of pliers Prass the piston pin out of the piston 2 stroke anginas Remove the needle bearing from the small end of the connect ing rod NOTE ee Do not damage or scratch the piston Do not apply side force to the connecting rad s Do not tet the clip fall inte the crankcase j Mark and store tha pistons and piston pins so that thay can be rainstalied in their original positions INSPECTION Clean carbon daposits from the Piston NOTE _ Clean carbon deposits from the piston ring grooves with aring that will be discarded Never use the wire brush it will scratch the groove Inspect the piston rings for mavement by Pressing the rings The rings should be able to move in its groove without catching Spread each piston rning and remove it by lifting it up at a point Just opposite tha gap CAUTION Do net damage the piston ring by Spreading the ends too far Some 2 stroke engines Remove the expander from the se cond ting groove Inspect the piston
320. ng loose near full suspension extension Remote Contral Type The remote type of spring preload adjuster uses hydraulic pressure to reposition the spring seat An adjuster knob on a conveniently located control mechanism presses against a F diaphragm which in turn forces hydraulic fluid through a line gol E ADJUSTER to tha damper unit This hydraulic systam camplately ores KNOB separate from the damping system incraasas or dacreases the height of the spring to achieve the desired preload Rar Renan SPRING ADJUSTER SPRING ADJUSTER Damping adjuster In oil damper units a damping adjuster sarves to control the oil flow by regulating the orifice diameter On certain types other than those shown in the drawings the damping force is controlled by adjusting the pre set load on the valve Decreasing the orifice diameter increases resistance and REBOUND tampar hardnass SIDE Increasing the orifice diameter decreases resistance and damper hardness ORIFICE DIAMETER PISTON SPEED DAMPING FORCE kg 1 9 6 Date of Issue Sep 1988 7 HONDA MOTOR CO LTD REAR SUSPENSION SHOCK ABSORBER REMOVAL Support the vehicla securely and raise the rear wheel off the ground Remove the mounting baltis or nutls than remove the shock absorber INSTALLATION Install the shock absorber on the upper mount noting the pro per installation direction Raise tha rear wheel enough to allow installation of the lower
321. ng of the tester or operation on an uneven Sur face may shorten its service life and raduce sensitivity over a pariod of time NOTE Always claar the work area of flammable materials such as gasoline brake fluid electrolyte or cloth towels when operating tha tester tha heat generated by the tester May cause a fire BATTERY TESTING Use the following staps to remove the battery fram the motorcycle 1 Disconnect the negative terminal lead 2 Remava the battery holder 3 Ramave the battery cover when applicable 4 Disconnect the positive terminal lead 5 Remove the battery breather tube when applicable 6 Pull out the battery 7 If necessary clean the battery terminals Securely connect the tester s positive cable first then connect the negativa cable NOTE For accurate teast results be sure tha taster s cables and clamps are in good working condition and that a secure connection can be made at the battery Set the temperature switch to HIGH or LOW depending an tha ambient temperature Date of Issue Sep 1988 HONDA MOTOR CO LTD HIGH BOF 15 C or higher LOW Escoo0 o F 15 C or lower BATTERIES CHARGING LIGHTING SYSTEM Push in the appropriate test button for threas sacands and read tha condition of the battary on tha mater NOTE Be sure you ve selected the correct test button that cor i responds to the battery baing tested
322. ng will be forced out by the fork tuba bushing FORK TUBE Remova the foltowing Qil seal Back up ring Fork tuba bushing Guide bushing if installed Rabound spring if possible BACK UP RING NOTE Oo not remove the fork tuba bushings untess it is necessary to replace them with new ones OIL SEAL FORK TUBE GUIDE BUSHING BUSHING NOTE On tha fork type that has no guide bushing the fark tube might come out of the fork stider and the oil seal may re main in the slider Remove the oil seat with care not to damage the sliding surface of the slider FORK SLIDER rN Remove tha fallawing Oil lock piece from the fork slider OIL LOCK PIECE Stop ring from the fork piston i Clean all disassambled parts STOP RING 1 8 6 Date of Issue Sep 1988 HONDA MOTOR CO LTD _ res FRONT SUSPENSION SS Sy a es INSPECTION g Measure the fork spring free length by placing the spring on a flat surface Replace the spring if it is shorter than the service limit at FREE LENGTH W ENS i Ry ula i at wel i ie ii i la fiy EE Wi qi Nyt Ni i A i fit i FORK SPRING Set the fark tube in V blocks and measure the fork tube runout DIAL INDICATOR by rotating it with a dial indicator mounted against it The actuat runout is 1 2 of the total indicator reading repiace if the service limit is axceeded or there ara scratches or nicks that will al
323. ngine API Service Classification SE or SF transmission and Viscosity SAE 10W 40 2 Stroke transmission oil Other viscosities shown in the chart may be used OIL VISCOSITIES when tha average temperature in your riding area is within the indicated range a 20 46 60 80 100 F 20 10 0 i0 20 30 40 C 2 Stroke engine oil t Separate lubrication Pro Honda Two Stroke oil or equivalent Mechanical lubrication systems Premix Type systems Pro Handa Two Stroke oil or aquivalent no concentrates 20 1 is the only recommended fueloj ratio Dats of Issue Sep 1988 4 1 HONDA MOTOR CO LTD LUBRICATION EE a yy wre TROUBLESHOOTING 4 Stroke Engines Oil level low Oil consumption External ail leaks Worn piston ring or incorrect piston ring installation Warn valve guide or seal Qili pump warn or damaged Dry sump engine Oil contamination White appearance From coolant mixing with oil liquid cooled engine Faulty water pump mechanical seal Faulty haad gasket Water leak in crankcase Low ar no oil pressure Clogged ail orifice and or orifices incorrect oil being used Only On Models Eguippad With Oil Pressure Switch High oil prassure Pressure religi valve stuck closed Plugged oil filter gatlery or metering orifice Incorrect ail being used Low gil pressure Pressure relief valve stuck open Clogged oil filter screen Oil pump worn or damaged Intern
324. ngth in the areas needed is chosen At times a frame is lightened by changing the combination of the types of tubing Thinwall ractangutar aluminum tubing is given a greater strength by adding an internal stiffening ribs and producing it in the form of an extrusion Some models use a special modified pentagonal or hexagonal extruded aluminum tubing with internat strengthening ribs in order to improve the frame member s strength to weight ratio its rigidity in one or mora specific direc tions and in some cases to allow a more compact and unobstructed riding position The various material types farms and dimensions used in frama design are linked directly to the experience gained from Honda s ongoing racing programs around the globe As naw knowledge is gained through competition itis combined with in put from non competition testing and utilized in the canstruction of each new generation of praduction machine ae are e zi RECTANGULAR MODIFIED HEXAGONAL EE aaien EXTRUDED ALUMINUM EXTRUDED ALUMINUM TUBING RECTANGULAR TUBING ROUND TUBING TUBING T n Lj TRENGTH EQUAL STRENGTH DIFFERENT rd port pelea a DEPENDING ON DIRECTION MODIFIED PENFAGONAL OF FORCE APPLIED EXTRUDED ALUMINUM TUBING The frame also serves to absorb vibration from the angina and to some degree from the road surface The difference in basic frame structure is determined according to the engine type and the type of use the machine is designed for Twa only s
325. nization screw Install the carburetor and adjust the synchronization PILOT OR AIR SCREW ADJUSTMENT PILOT OR AIR SCREW REMOVAL NOTE Adjust the pilot tor air scraw atter all other engine ad justments are within specifications i The pilot screw or air Screw is factory pre set and should nat be removed unless the carburetor is over hauled j The screw limiter cap tor plug is factory installed to pre vent misadjustment Do not remove the limiter cap tor plug Untess the sctew is being removed PLUG TYPE ONLY Cover ail openings with tape to keep metal particles out when the Plug is drilled 818 HONDA MOTOR CO LTD FUEL SYSTEM Limiter cap type CARBURETOR Using a pair of pliars break off the pilot screw or air screw limiter cap and discard it Turn the pilot screw tor air screw in and carefully count the number of turns hefora it seats lightly Make a note of this to use as a referenca when reinstalling the pilot screw CAUTION Tightening the pilot or air screw against its seat wil LIMITER cap PILOT SCREW damage tha seat _ EE Remove the pilot or air screw and inspect it Replace it if it is worn r damaged Plug type Center punch the pilot screw lor air scraw plug ta center the drill point Drill through the plug with a 4 mm 5 32 in drill bit Attach a drill stop to the bit 3 mm 1 8 in from the and to prevent drill
326. nt solution to the rim and tire mating TIRE LEVER surtaces Be sure that the bead is completely collapsed in case of the tube type tire insert the tire lever from the p posite side of the valve and raise the bead over tha rim On tubeless tires insert the tire lever from the valve side and raisa the baad ovar the rim Always use a rim protector whan using tire levers CAUTION To avoid damaging the rim when using tha tira tavar RIM PROTECTOR always use rim protectors TIRE LEVER Be sure to use motorcycle tire levers Do not apply the mild detergent solution ta the rim and tira mating surfaces of low pressure tira Apply water s only Insert another tire lever at 30 50 mm 1 to 2 in from the first tire lever and remove tha tire from the rim Irttle by little NOTE Bo not try ta remove the bead too much at ona time fo Do nat pry against or scratch tha bead stopper arga with tha tira lever RIM PROTECTOR Renest the abova procedures until half of bead is ramoved Then remove the remaining bead by hand TIRE LEVER Tube type tire only Press the valve into the tira completely and remove the tube from the tire Date of Sep 1988 16 12 HONDA MOTOR CO LTD Bi gt N Remove one side of bead using same procadures as the tubeless tira Remove the tire from the rim RIM VALVE REPLACEMENT TUBELESS TIRE ONLY Cut off the rim valve at its base Apply mid deterg
327. nt the possibility of an explosion relsase the nitrogen by pressing the valva core Then remove the valve stam from the shock absorber reservoir Dispase of the oil in a manner acceptable to the Environemant Protection Agancy EPA Before disposal of the shock absorber release tha nitrogen by pressing the valve core Than remove the valve stem from the shock absorber Hat Components Engine and exhaust system parts become very hor and ramain hat for some time after the angina is run Wear insulated gloves or wait until the engine end exhaust system have cooled before handling these parts Used EngIne Transmission Qil Usad angine oll or transmission oil in ee may causa skin cancer if repeatedly left in contact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a dally basis it is still advisabla te thoroughly wash your hands with i soap and water as soon as passible after handling used ail KEEP OUT OF REACH OF CHILDREN oS n Iua auaa muma ouse 1 2 Date af Issue Sap 1988 HONDA MOTOR CO LTD GENERAL INFORMATION n SERVICE RULES Use only metric tools when sarvicing this motorcycle or scooter Metric bolts nuts and screws are not inter changeable with English fasteners The use of incorrect tools and fasteners may damage the motorcycle or scooter Special taals are designed to remave ar raplace a specifie part or assemblies withou
328. ockwise turning tha drum shitter counterclockwise As th drum shifter turns counterclockwise the right pawl engages the detent in tha shift drum while the left pawl is pushed out of the way into the shifter by the guide plate With the pawl engaged the drum shifter turna the shift drum mov ing tha shift forks into place Shift Finish To prevent the drum from ratating too far a shift drum stopper plata is usad Tha shitt drum stopper plate rotates on an eccen tric pivat maved by the spindle assembly As the spindla reachas the end of its travel one leg of the stap per plate is moved up to contact a Positive Stop on the shift drum At the same tima the Spindle assembly is Prevented from moving too far by the shift arm stapper pin Shift Return When the shift pedal is released the shift return spring brings tha spindle assembly back ta the centered position At this time the drurn shifter ratates and the ratchet feature allows the right paw to disengage from the shift drum As the drum shifter rotates the drum Stopper arm prevents the shift drum from moving TRANSMISSION RATCHET GUIDE PLATE SPINDLE COMP PROJECTION SHIFT ARM STOPPER PI SHIFT DRUM RATCHET GUIDE PLATE 13 4 Date of Issue Sep 1988 HONDA MOTOR C LTD TRANSMISSION _ CONSTANT MESH TRANSMISSION ___ __ _____ The constant mesh transmission consists of the following com
329. of Issue Sep 1988 8 9 HONDA MOTOR C LTD a FUEL SYSTEM AUTO BYSTARTER VALVE AUTO BYSTARTEA Connect an chmmetaer to the auto bystarter wire connector terminals and measure the resistance if the resistance is greatly out of specification it indicates a faulty PTC in the auto bystarter Replace the auto bystarter NOTE The auto bystarter might be normal if the resistance is i only slightly out of specification However be sure to check all related parts for trouble Refer to the Modet Specific manual for specified resistance Remove tha carburetor and let it caol dawn for 30 minutas Insert 2 vinyl tube into the fuel enrichening circuit and blow in ta the tube Air should flaw into the circuit If air does not flow into the circuit replace the auto bystarter Connect the battery to the auto bystarter terminals and wait for 5 minutes Insert a vinyl tube into the fual anrichening circuit and blow in to the tube Air should nat flow into the circuit If air flows into the circuit replace the auto bystarter Check the resister if the auto bystarter is normal but angine is still hard to start ALTERNATOR lf there is a braken wire in the resister current will not flow to the PTC and the auto bystarter will not operate if there is a shorted wire in tha resister current of a higher voltage than spacified will raach the PTC This will cause the fuei enrich ning circuit to close toa saan and
330. of oll s parfor mance To allaviate this contamination Problem change the oil periodically Because many newly machined surfaces are moving against one another for the first time in new motorcycle engines a noticeable amount of powdered metal circulates with the oil during this early stage of use Therefore it is extremaly important to change the engine ai and to replace the oil filter or clean the oil strainer screen at the first maintenanca interval aftar 1 000 km 600 miles in arder to prolong engine tife See the Model Specific manual for oli change intervals NOTE Draining the engine oil while it is still warm is the most rapid and efficient method LEVEL GAUGE IL TANK 2 12 Data of Issue Sap 1988 HONDA MOTOR CO LTD MAINTENANCE Remove either the oil level gauge or filler cap to allow rapid draining Remove the oil drain boit at the bottom of the crankcase and drain the oil A WARMING Used engine oil may cause skin cancer if rapeatedly left in contact with tha skin for prolonged periads Although this is unlikaly unless you handle used oil on a daily basis ft is stl advisabie to thoraughly wash your hands with soap as soon as possible after handing used oil After the oil is completely drained clean and instal the drain belt and sealing washar and tighten to the designated torque NOTE HRaplacea the sealing washer if it is damaged Pour the recommended
331. off the brake linings Wipe excess grease off the cam and anchor pin Grease on the braka linings will raduce stopping abllity and may cause brake failura i Felt seal Apply a small amount of engine ait to tha felt and in stall the felt seal on the brake panel Dust seal Apply 4 small amount of grease to the dust seal lip and install Install the wear indicator plate by aligning its large serration with the large serration of the brake cam Install the brake arm on the brake cam while aligning the punch marks Tighten the arm boit and nut to the specified torque WEAR INDICATOR PLATE aD n LARGE N Buann me Nis ode BHAKE ARM WEAR INDICATOR PLATE 17 18 Date of Issue Sep 1988 HONDA MOTOR CO LTD BRAKES Me ae Se BRAKE SHOES instali the brake shoes according to the mark on the side of each brake shoe Kaep grease off the brake linings lf the brake drum and linings are contaminated with grease clean the braka drem with brake cleaner and replace both brake shoes Grease on the brake linings will reduce stopping ability Col spring typa n Install the shoe springs on tha brake shoas SHOE SPRING Install a brake shoe on the brake panel then install the othar BRAKE ARM shoe with care that the shoa springs are in position BRAKE SHOES U spring type Instali the brake shoes on the brake panel and expand tha brake shoes by moving the brake
332. ol their ignition systern tum ponents a lectrically there is no mechanical wear and periodic maintanance and adjustment is unnecessary CDI The term CDI is on abbreviation for Capacitive Discharge Ignition The CDI produces quick and stable secondary voltaga and is resistant to spark plug fouling It is alsa designeg to increase its secondary voltage as rpm incraases The CDI is used mainly on small engine displacement modeis je L Oparatiny Principles 4 IGNITION ENGINE STOP SWITCH As the alternator rotor turns current is induced in the alter DIODE CAPACITOR natar exciter coi This current ACH is fed to the CDI unit with a voltage of 100 400 volts This AC current is half wave rec IGNITION COIL tifiad hy a dioda and is storad in tha capacitor inside the CDI unit When the engine is turned off the currant induced by the ex citer coil is shorted to ground thus cutting off current to the capacitor and turning off the spark CDI UNIT The capacitor cannot discharge until the SCR is turned ON The SCR is turned ON as the pulse generator sends pulses to the triggar circuit which in turn faads current t the gate of SCR PRIMARY IGNITION COIL f When the SCR is turnad ON tha capacitor discharges current SPARK PLUG WIRE to the ignition primary coil A high voltage surge included in the secondary coil jumps the spark plug gap SPARK PLUG i Date of Issue Sep 1986 23 4 HONGA MOTOR CO LTD IGNI
333. on depends on the cylinder arrangement or the required engine characteristics For exampte an inline four cylinder engine can be connected with 4 into 1 systam oar 4 2 2 system etc 4 into 1 EXHAUST Date of Issue Sep 1988 6 3 HONDA MOTOR CO LTD 7 EMISSION CONTROL SYSTEMS SERVICE INFORMATION 7 1 SYSTEM INSPECTIONS 7 5 TROUBLESHOOTING 7 1 EMISSION CONTROL INFORMATION SYSTEM DESCRIPTIONS 7 2 LABELS 7 9 SERVICE INFORMATION CAUTION a To prevent damage be sure to remove the diaphragms dafora cleaning air and fual passages with compressed air All hoses used in the secondary air supply and evaporative emission control systems are numbered for identification When connecting one of these hoses compare the hose number with the Vacuum Hose Routing Diagram Label Refer to tha Modal Specific manual Refer to the Model Specific manual for emission cantrol system application TROUBLESHOOTING Engine stalie hard to start rough idling Purge control valve faulty Air vant control valve faulty Hoses in the emission control system faulty Afterburn when engina braking is used Secondary air supply system faulty Hoses in emission control system faulty Poor performanca driveability and poor fue acanomy Faulty air vent control valve Damaged misconnected emission control system hoses Date of issue Sep 1988 HONDA MOTOR CO LTD 7 1 EMISSION CONTROL SYSTEMS
334. on the apposita side remove it with a bearing remover For recommandad bearing removers refer to tha Tool Compatibility Charts an page 1 15 HANDLE SHAFT Operate tha bearing remover with the shaft threads pro perly engaged A poor fit may laad ta damege to tha thraads Replace the remover if it ls wom or damagad Do not reusa baarings that have been ramoved If the use of a bearing remover is not possible remove the bearing by thermally axpanding the case slowly and uniformly heating the case with a heat gun industriai dryer HEAT GUN To avoid burns wear insuiatad gloves when handing the heated case CAUTION Using a torch to heat the case may causa warping Remove tha bearing from the shaft using a bearing puller Graa Avoid using a bearing that has been removed by pulling on tha BEARING PULLER outer race with a bearing puller rary Universa Bearing Puflar 07631 0010000 or its equivalent should bs used 1 1 4 Date of Issue Sap 1988 HONDA MOTOR CO LTD GENERAL INFORMATION Remove the wheal baaring using a bearing remover shaft and remover head Do not reuse the removed bearing For recommended bearing remover shafts and remover heads refer to the Toot Campatibility Charts an the following pages installing Ball Bearings Clean the bearing recess hafore the bearing is installed to en sure that it is fras from dust or debris and that tha bearing seats fully in
335. onnector and ground No battery voltage Battery voitage Broken wire harness Faulty fan motor Blown sub fuse Faulty ignition switch Poor connection of the connector betwean the ignition switch and fuse box COOLANT TEMPERATURE GAUGE The thermo sensor changes the amperage of the current that flaws to the coolant temperature gauge in accordance with the change in coolant temperature and moves the temperature gauge needie LIGHTS METERS SWITCHES FAN MOTOR SWITCH bee g TN CONNECTOR IGNITION FUSE SWITCH FAN THERMO SWITCH IGNITION SWITCH COOLANT TEMP GAUGE THERMO SENSOR Date af Issue Sep 1988 HONDA MOTOR CO LTD 25 5 LiGHTS METERS SWITCHES INSPECTION 1 Disconnect the wire from the thermo sensor Ground the thermo sensor wire with a jumper wire Turn tha ignition switch ON and check the coolant gauge Disconnect the thermo sansor wire from the ground im mediately if the gauge needle moves fully to H CAUTION Immediately disconnect the wire from the ground when the naadla moves to H hat to pravant damage to the gauge iain tee 0 mte o Needle does not move Needle moves Faulty thermo sensor 2 Check for voltage betwaen the tharmo sensor wire and ground p No voltage Voitaga Faulty coolant gauge 3 Check for voltage hatween the black brown and grean blue wires of the gauge No voltage Voltage Broken black brown or
336. ontinuity Continuity IGNITION MAIM Fautty fuel cut off relay SWITCH FUSE ones FUEL CUT OFF _ FUEL PUMP 3 Short the black and black blue wires ot tha relay connector i with a jumper wire and check for battery voltage between the biack biue wire and green wire of the pump connector No battery voltage Battery voltaga Broken grean or black Faulty fuel pump IGNITION blue wire CIRCUIT Faulty ground Data of Issua Sep 1988 25 1 0 HONDA MOTOR a LTD rN L IGHTS METERS SWITCHES DISCHARGE VOLUME INSPECTION Turn the ignition switch GFF Disconnect the fuel pump to carburetor tube fram the car burator and place the tube end in a beaker If it is hard to reconnect the tube to the carburetor disconnect it from the fuel pump and connect the ather tube to the pump gasoline discharge port Refer ta step J of INSPECTION and shart the relay connectors If the relay is built into the pump shart the biack and black yellow wires Turn the ignition switch ON for 5 seconds and drain the pump Muttiply the drained tual by 12 It should be as spacified in tha Model Specific manual HEADLIGHT BULB Before replacing the bulb be sure to chack the switches for loose connection of the connectors AWARNING Halogen headlight bulbs become very hot while the headlight is ON and remain hot for a while after they ere turnad OFF Be sure to turn the ignition switch OFF and let th
337. opper ring while other types are mounted with a lock nut Refer to tha Model Specific manual Date of Issue Sap 1988 HONDA MOTOR CO LTD SHOCK ABSORBER i 7 iE ef tone oo Meee z REAR SHOCK ABSORBER COMPRESSOR COMPRESSOR SPRING COMPRESSOR ATTACHMEN eee HYDRAULIC PRESS al REAR SUSPENSION Lock Nut Removal Compress the spring and loosen the lock nut then remove the upper or lower joint and the spring Stop Ring Ramoval Compress the spring and remove the stopper ring Remove the spring INSPECTION Spring Piace the spring on a level surface and measure the free length Replace the spring if it is deformad cracked or its frea length is shorter than the servica imit Damper Unit Keep a gas filled shock absorber away from fire or heat Haating a gas filled damper can lead to an explosive release of pressure which can causa a serious injury Do not try to disassemble the damper unit if the i disassambly procedura ig not described in the Model Specific Manual Disassembly can lead to a ralease of ae under high pressure which can cause an Injury Check the damper unit for deformation or oil leakage and replace if necessary Check the damper rad for straightness or stepped waar and replace if necessary Check the damper bump rubber for fatiqua or damage and replace if necassary s SHOCK ABSORBER COMPRESSOR w ES SHOCK ABSORBER STOPPER
338. opposite side of the wheal Fit tha driva chain over the driven sprocket For mechanical drum brakes connect the brake rod or cable to the brake arm and install tha adjusting nut loosely In case ADJUSTER that the brake panel is mounted with brake torque rod con nact the torque rod to the brake panel and tighten the tarque rod nut to the specified torque REAR AXLE Adjust the drive chain slack Tighten the rear axie nut to the spacified torque Secure tha axle nut and torque rod nut with a new cotter pin if required For mechanical drum brakas adjust the rear brake pedal free play BRAKE ROD TORQUE ROD SHAFT DRIVEN TYPE AXLE NUT Removal For drum brakes disconnect the brake rod or cable and tar que rad from the brake panel Remove the axle nut and loosen the axle pinch bolt Remove the rear axle For hydraulic disc brakes move the caliper assembly away from the disc to avoid intarfarence Remove the side collar and pull the rear wheel fram the final drive gear Ramove the rear wheei Installation Caat the driven flange with molybdenum disulfide grease Install the brake drum onto the wheal hub Place tha rear whael into tha swing arm Cate of Issue Sep 1988 1 6 6 HONDA MOTOR CO LTD WHEELS TIRES For the hydraulic disc brakes work the brake disc between the brake pads Be careful not to damage the pads Atign tha splines of the finai driven flanga with the splines of ring gear
339. or que and the material of the parts that are fastened together lt p gt varies largely Out of tha tightening torque applied on an unlubricated fastener 8B to 92 percent is consumed by the friction of flanges and thread surfaces and only 8 to 12 per cent is effactively transformed into axial tension This percen tage of tansformation into an axial tension inctaases as the above mentioned friction decreases i e as the value lt p gt decreases the axial tension increases Axial tension varias when the same tightening torgue value is obtained Further more in a dry Junlubricated state the value lt p gt varies in a wider range and has a tendency to increase as the tighten ingfoosening procedure is repeated It is important to ail the threads of specific fasteners whan in structed to do sq in the Model Spacifi manual Oiling the threads of these fasteners ensures stable fastening tension in critical areas No other bolts besidas those specifically pointed out in the Model Specific service manual text raquire oil on their threads Lubrication of tha threaded portion of of the bottom af the flange reduces friction and the anti loosening effect However this iubsication also increases fastener axial tension and results in a sufficient lightening strength so that the fastener is less tikely to loosen GENERAL INFORMATION TO EE EE A ye yc Es AXIAL TENSION TIGHTENING TORQUE Thraaded portion K
340. or shoe wear NOTE if no adjustment ramains before the wear indicator limit is reached this indicates excessive wear and the brake shoes need to be replaced Specific brake shee checks are listed in the Brakes sectian of the manual Inspect the brake dtum for wear or damage any time you remove the wheel and brake panel lf the brake drum shows any signs of cracking or excessive corrosion thet cannot be removed with emery cloth be sure ta replace it BRAKE PAD WEAR Replace pads as a sat if worn to the brake pad wear limit line far wear limit gravel A quick visual inspaction can be made at the teading edga of the pads where the disc entars the calipar However if this proves difficult a check can ba made at the indicator an the caliper marked by the arrow a INDICATOR BRAKE PANEL WEAR LIMIT DISC LINE DIRECTION LEADING SIDE 2 28 Date of issue Sep 1988 HONDA MOTOR CO LTC MAINTENANCE BRAKE SYSTEM INSPECTION FOR AIR IN SYSTEM BRAKE LEVER On hydraulic brakes firmly apply the brake lever or pedal and check that no air has entered the system If tha lever or pedal feels soft or spongy when operated bleed the air from the system FREE PLAY ADJUSTMENT On mechanical brakes measure the frea play at the tip of the brake lever or pedal as indicated here and below Brake pedals on scooters should he measured for freg play as indicatad hara Make adjustment
341. ositioning af the masterlink may cause the drive chain to come apart and possibly damage the i __Clankcase rear wheal or exhaust 2 22 Date of Issue Sep 1988 F HONDA MOTOR CO LTD MAINTENANCE Check that each chain link pivots freely on the pins Where binding is light apply a little cleaning oil or paraffina making sure that it penetrates When the stiffness has been removed lubricate the chain On chains with O ring quickly wipe off the cleaning fluid ar paraffin oil and thoroughly dry the chain Replace tha chain if stiffness of the chain cannot be alleviated the movement of the links is not smoath or thera is damage to the link plates or rollers Master links with O rings have 4 O rings fitted betwean roters and master link plates Install tha O rings as shown in the iilustration to the right and fit the chain clip to the pins Be sure there is no gap between the master link plate and the clip Cleaning and Lubrication Adherence of mud and dirt and lack of lubrication severely shortens the life of the chain Cleaning and tubrication should therefore be carried out periodically Chains with Q rings CAUTION Chains with O rings should not ba treated to the follow Ing claaning and oiling procedure This treatment will j cause degradation of the O rings and loss of grease thus shortening chain lifa i a Da not use steam ar a high pressura water washing Use j a chain spray containing a c
342. ote the installation direction of tha float valve Date of Issue Sep 1988 HONDA MOTOR CO LTD NOTE f Check the float leval after checking the float valve and float page 8 13 Set the float level gauge so that it is perpendicular to the float chamber face and in line with the main jet EC malin jat L Set the carburetor so that the tip of the float valve just con tacts the float arm lip Be sure that the float vaive is securely in contact with the valve seat Measure the float level with the float level gauge toL FLOAT LEVEL GAUGE 07401 0010000 If the level is out of specification and the float arm lip can be bent adjust the float leval by banding the lip Non adjustable floats must be replaced Ba sure to keep the float leval at the specified height If the float level is low high fuel mixture becomes L_ fean rich oe VACUUM PISTON CV type install the washer an the jet needle and install the jet needle jn tha vacuum piston fasta the spring holder with its Pawts aligned with the grooves in the piston if installed Install the spring Turn the jet needle holder clockwise while pressing it into the vacuum piston until it locks Projections on the vacuum piston and jet needle holder should be aligned after turning Install the vacuum piston on the carburator body Lift the bottom of the piston with your finger to set the diaphragm rib in the groove in t
343. oth aspiration at low speeds and improved power output in the high speed range Honda matarcycles scooters and ATVs use one of twa variable venturi dasigns 1 The constant venturi type CV tha venturi diameter is altered automatically by vacuum piston that rises and falls to alter the diameter Tha throttle valve is installed as a Separate mechanism 2 Tha piston valve ar fiat slide type a throttle controlled piston is used to alter the venturi diameter Principle of the vacuum piston operated CV type As the engine is started and the throttle valve opens the air fiow in tha main bore exerts a strong negative pressure on the lower section of the vacuum piston see Carburatar thearyt At this point air is drawn out of the carburetor s vacuum chamber and pressura in the chamber drops The diaphragm is titted due to atmospheric pressure and the vacuum piston is raised When the throttle valve is closed air flow in tha main hore is obstructed Pressure returns to that of the atmosphere and the vacuum piston is lowerad by spring force Large drop in pressure Small drop in pressure AIR FLOW ATMOSPHERIC PRESSURE CV TYPE VACUUM PISTON THROTTLE VACUUM CHAMBER Date of Issue Sep 1988 HONDA MOTOR CO LTD FUEL SYSTEM Ny ee Operation of systems The carburetor is comprised of a starting system which uses either a choke valve or byStarter valve a float system for fuel supply and slow and ma
344. ough worn unevenly or contacts tha seat improperly the valve must ba replaced J le z m o a oe O Sy i VALVE SEAT Date of Issue Sep 1988 HONDA MOTOR Q LTD 9 1 1 CYLINDER HEAD Inspact the valve seat face for Uneven seat width l Bant or collapsed valve stem Replace the valve and reface the valve saat Demaged fece Replace the valve and reface the valve seat DAMAGED FACE UNEVEN f SEAT WIDTH Contact area too high or too low area Retace the valve seat TGO Low TOO HIGH VALVE SEAT REFACING NOTE P Fottow tha refacer ma nuiactvar s Operating instructions Reface the valve seat whenever the valye guide has been replaced Be careful not to grind the seat more than nacessary If the contact area is top high an the valve the Seat must be lowered using a 32 degree flat cutter CONTACT TOG HIGH OLD SEAT If the contact area is too tow on the valve the seat must be raised using a 60 degree inner cutter Refinish the seat to Specifications using a 45 degree finish cutter CONTACT TOO Low OLD SEAT Quorn Date of Issue Sep 1988 9 12 HONDA MOTOR C LTD _ CYLINDER HEAD Using a 45 degrea cutter ramove any roughness or ir regularities fram the seat ROUGHNESS 32 Using a 32 degree cutter remova 1 4 of the axisting valve seat matarial Using a BO degree cutter remove
345. ounting bolts Disconnect the water hoses and by pass tubs than remove the watar pump Remove the bolts and separate tha pump cover from the body O RING WATER PUMP Replace Replace the water pump with new one OQ O RING Raglace install a new O ring into the groove in the pump cover then in stall the cover on the pump Install a new O ring onto tha water pump WATER HOSES Align the water pump shaft groove with the water pump drive shaft and install the water pump Tighten the pump mounting bolts Connect the water hoses and secure the bands and clamp Fill tha cooling system and add the recommendad ngine ail WATER HOSE Date of Issue Sep 1988 HONDA MOTOR CO LTD ee a a 6 EXHAUST SYSTEM SERVICE INFORMATION 6 1 SYSTEM DESCRIPTION 6 2 TROUBLESHOOTING 6 1 SERVICE INFORMATION g n es Serious burns may rasult If the exhaust system is not allowed to cool bafare components are remove d or serviced Always replace the exhaust pipe gasket whan removing the exhaust pipe from the engine Nota the positions of the clamps installed between the exhaust pipe and muffter the tab on the clamp should align with the groove on tha muffler When instalting the exhaust system install all the fastners loosely Always tighten the exhaust clamp nut first then tighten tha mounting fastners If you tighten the mounting fasteners first the exha
346. ove the push rod and boot PIVOT mer rusHRon HONDA MOTOR O LTD CLUTCH Remove the snap ring from the master cylindar SNAP RING SNAP RING PRIERS 07914 3230001 or equivalent tool commercially available SNAP AING Remove the washer piston secondary cup primary cup and spring from the master cylinder bady Replace the master piston components as a set ai PRIMARY CAUTION k Replacing individual master piston components can a cause clutch systam failure FOG Pe WASHER q __ BOOT PISTON SECONDARY CUP SNAP RING Inspection Check the primary cup and secondary cup for wear damage or deterioration and replace as necessary Measure the master piston O D raplace if the service limit is exceeded Check the master cylinder for scoras or nicks and replace as necessary Measure the master cylinder J D in X and Y directions replace if the service limit is exceeded NOTE Date of Issue Sep 1988 HONDA MOTOR C LTD CLUTCH Assembly Installatian Clean all parts thoroughly SPRING SNAP RING PISTON Coat the primary and secondary cups with clean brake tluig before assembly Install the spring in the mastar cylinder with the small end out Install the primary cup and Piston secondary Cup CYLINDER SURFACE PRIMARY CUP C CAUTION Allowing the lips to turn inside our when installing the cups will rasult In brake system f
347. owered by engine revolution Battery Stores regulated DC current 7 i ALTERNATOR TYPES STATOR The ahernator consists of a rotor and a stator The rotor consists of a flywheel made up of a series of magnets and is usually driven by the crankshaft The stator consists of a series of soft iron polas arround which are wound coils of wire When the engine starts tha rotor rotates with the crankshaft Whan the auter for inner core of the coil passes through the magnetic field currant is generated This is called elec tromagnetic induction and other systems such as the ignition and AC lighting systems generates power under the same principie In addition the rotor acts a safely wheel on the crankshaft smoothing out engine pulsations at low engine rpm Permanent Magnet Type This is the most common type of alternator with the stator piaced inside tha rotar The permanent magnet is assembled on the inner walls of tha rotor In ganeral the statar consists of several coils producing power for the charging ignition and lighting systems Current for charging the battery is generated by the charging coil Date of Issue Sep 1988 22 1 2 HONDA MOTOR CO LTD BATTERIES CHARGING LIGHTING SYSTEM Brushless Excited Field Coil Type The alternators previously mentioned are located within the engine The alternator is exposed outside the engine because it is air cooled In general the rotor spear ig multiplied by gears o
348. ox onto the wheel hub Coat the axle shaft with small amount of grease and install the axie shaft Tighten the axle nut to the specified torque WHEELS TIRES AXLE NUT Data of Issue Sep 1988 HONDA MOTOR CO LTD 16 3 WHEELS TIRES Instailation Place the front whee between the fork legs Sat the brake disc between the brake pads carefully Do not Gamage the pads Slowly lower the front of the vehicle until the fork lags are aligned with the axla Install the axle holders with the allow pointing forward and align the speedometer gear box boss with the fork leg stop Tighten the upper nuts or forward nuts first then the lawer ar rear nuts Reconnect the cables PINCH BOLT TYPE Removal Loosen the axle pinch bolts on the axle bolt side and remove the axle balt Loosen the axle pinch bolts on the opposita side and remove the axle shaft while holding the whesl Ramove the front wheel Installation Place the front wheel between the fork legs and work the brake disc between the pads Be careful not to damages the pads Install tha axle Tighten the axle bolt to the specified torque Align the spesdomater gear box stop with the fork leg stop NOTE Make sure that the index line on the axle aligns with the fork leg surface Tighten all tha pinch bolts ta the specified tarque Refer to the Model Specific manual for the proper torque values Check the clearance between the brake
349. p 1986 HONDA MOTOR CO LTD 21 3 ELECTRICAL FUNDAMENTALS E Route wire harnesses to avaid shatp edges corners or the S Check that the wire Karness is securely clamped at all projected ends of bolts and screws locations Goon NO GOOD NO GOOD a E T unlock wire harnass or hase from a clip use a scrawdriver ta open up the tab When locking the clip press MB Seat grommets in their holes properly firmly until it clicks If the clip was removed from the frama replace n with new one GooD NO GGOD DRIVER Do not bend or twist wire harnesses Check that the wire harness does not interfere with any moving or sliding parts after clamping 6006 NO GOOD NO GOOD F ai E Before using testers read the instructions CAUTION Bo net drop parts containing semiconductors Semican ductore ara fragile and sensitiva to shack Dropping a semiconductor could damage or destroy it a a i a esl Date of Issue Sep 198E HONDA MOTOR CQ LTC 21 4 ELECTRICAL FUNDAMENTALS E Be careful not ta pinch or trap wires or harnesses under items during installation a E Route wires and wire harness so that they ara not too tight say or loose whan the handlebar is turned all the way to the right or laft E Avoid routing wires and harnesses through sharp bends and arround tight corners E Route harnesses 0 they ara neither pulled taut nor have ex cassive slack NO GOOD Date of Iss
350. p of the float valve where it contacts the valva Seat for steppad wear or contamination Replace the float vaive ff its tip ia worn or contaminated A worn or con taminated valve does nat seat properly and wilt eventually flood the carburetor TIP OF THE FLOAT VALVE FLOAT VALVE Remove the valve seat if it can be removed Refer to the Model Specific manual f Replace the sealing washer VALVE SEAT Check the filter for demage or clogging Blow the filter with low pressure air and clean it Remove the main jet needle jet holder needle jet and slow jet NOTE maaan THROTTLE Not afl carburetors have a removable needle jet and slow STOP SCREW z He NEEDLE JET jet Refer to tha Model Specific manual _ c c MAIN Turn in the pilot for air screw and record the number of turns it JET takas before it seats lightiy NOTE Do not force the screw egainst its saat the saat will be Km SLOW JET damaged PILOT SCREW E Motorcycles with emission control system Rafer to page 8 18 for pilot ar air screw ramaval f Clean the jats with cleaning salyent and if necessary biaw opan with compressed air If the motorcycle is equipped with an accelerator pump blow open the fuel passages in the float chamber with fow pressure air Date of Issue Sep 1988 HONDA MOTOR CO LTD 8 1 3 FUEL SYSTEM ACCELERATOR PUMP
351. p prompts the natural circulation of the coolant in the cooling system which is carried out by convection It also feads the coolant uniformly ta the cylinder and cylinder head water jacket so that effective cooling is maintained even if the radiator capacity is reduced When the impeller turns cantrifugal force draws the coolant through the water pump inlet and discharges it into the engine s water jacket RESERVE TANK COLD ENGINE FROM CYLINDER HEAD HOT ENGINE FROM CYLINDER HEAD TO ENGINE CYLINDER WATER PUMP IMPELLER Data of Issue Sep 1988 HONDA MOTOR CO LTD COOLING SYSTEM COOLANT ANTIFREEZE PREPARATION SOLUTIA S gt Radiator coolant is toxic Keep it away from eves PETRY LENE mouth skin and clothes GLYCOL BASE LOW MINERAL SOLUTION any coolant gets in your eyes rinse them with OA water and consult a doctor Immediately DISTILLED WATER ff any coolant is swallowed induce vomiting gargle j and consult a physician immediataly If any coolant gets on your kin or clothes rinse COOLANT thoroughly with planty of water q KEEP OUT OF REACH OF CHILDREN NOTE The affactiveness of coolant decreases with tha ac cumulation of rust or if there is a change in the mixing proportion during usage Therefore for best perfor mance change the coolant regularly as specified in the maintenance schedule Use coolant designed
352. par cam DAMPER damper lifter p damper case O ring snap ring spring 8s 8 DAMPER CASE SNAP RING SPRING SEAT 1 5 6 Date of Issue Sep 1988 a D HONDA MOTOR CO LTD Y rm FINAL DRIVE OUTPUT SHAFT Remove the oil seal oil seal guide and damper spring fram the DAMPER CASE damper case GIL SEAL GUIDE DRIVE SHAFT INSPECTION Measure the damper spring free length replace the spring it the free length axceeds the service limit Check the splines of the drive shaft for damage or wear DAMPER LIFTER replace as necessary i DAMPER if the splines are damaged check the universal joint splines CAM also Chack the damper cam and lifter for damage replace as nacessary SPLINE DAMPER CASE ASSEMBLY OIL SEAL Install the spring in the damper case Install the oi seal guide and a new oil seal using the special tool DAMPER SPRING Date of issue Sep 1988 HONDA MOTOR CO LTD FINAL DRIVE OUTPUT SHAFT Instal a new O ring onto the drive shaft DAMPER CASE l install the spring and secure the snap ring Insert the drive shaft into the damper case DRIVE SHAFT SNAP RING Install the dampar lifter damper cam and spring seat DAMPER LIFTER SN fr SPRING SEAT Set the drive shaft in the shock absorber comprassor and com press the spring Set the stop ring secureiy into the groove an the drive shaft STOP RING Remove the tools SHOCK ABSORBER
353. ped with a tachometer connect an engine tachometar Remove tha headlight and start the engine Turn the headlight on Hi beam With the headlight wires still connected measure the headlight lighting voltage between the terminals connected ta blue i and green wires Gradually increase the engine spaed and read the voltage at the specified ram Refar to Model Specific manual for servica data BATTERIES CHARGING LIGHTING SYSTEM na ne REGULATOR RECTIFIER HEADLIGHT Date of Issue Sep 1998 HONDA MOTOR CO LTD BATTERIES CHARGING LIGHTING SYSTEM Select the AC range on your multitester AC current flows ta the headltightt Use the specified multitester The measured headlight reguisted voltage may vary depending on the multtester used because of the characteristics of the output waveform SPECIFIC MULTITESTER 07411 0020000 KOWA Digital type KS AHM 32 003 KOWA Digital typa USA only 07308 0020001 SANWA Analogue type TH 5H KOWA Analogue type Resistor Inspection For models with headlight resistor or an auto bystarter measure the resistance of the resistor AC Regulator Type NOTE js This saction saxplains tha inspection procedures for models which hava an independent lighting coil powar ing the headlight system For models with combined lighting and charging coil refer to the regulator rectifier inspection section HEADLIGHT WIRES
354. peed of the damper and shock absorbing force increase progressively Therefore this type of suspension is characteristically suft on initial aval so it absorbs small riding surface inconsistencies well and provides progressively firmer resistance to prevent bottoming at full compression when a large bump is hit i Full camprassion Though tha amount of stroke A is the same the amaunt of stroke B a becomes greater 19 2 Bate of Issue Sep 1988 HONDA MOTOR Q LTD This rangement offars a greater amount of suspension Stroke compared ta tha amount the damper unit cCOMmpresses and therefore g aater control for improved suspension perfor mance It also enables the weight of the spring damper unit to be centralized more compactly nearer the center of the frame The Delta type Pro Link is a further refinement which lowers the motorcycles CG by a significant amount and reduces the weight of the cushion arm Pro Arm Type Honda s unique cantileyer typa Pro Arm is a stylish departura trom the conventional forkad type swingarms High rigidity and durability are achieved through the use of a Massive bex section design and large diameter axle The center pin mounting allows easy wheel ramoval instaliation and the design of the eccentric bearing carrier makes chain adjusting easy Other bensfits inciude minimal unsprung weight added room far compact exhaust routing slimmer overall machine shape easi
355. pletely drained clean the drain bolt replace the sealing washer and tightan to the specified torque NOTE DRAIN BOLT S SEALING Replace the sealing washer if it is damaged WASHER Refill to tha prescribed level with tha racommended oil Coat the level hale cap O ring with oil and replace the cap Tighten the cap to the specifiad torque A ye yr pyres Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 25 MAINTENANCE BATTERY Fluid ievel Battery fluid Jevel checks ara unnecessary on MF Maintenance Free batteries Open type batterias should ba checkad for fluid level UPPER Eye UPPER LEVEL LINE LOWER LEVEL LINE D a I Do nat allow battary fluid sulphuric acid ta come into m mDNER contact with the skin eyes or clothes as it will cause burning If acid is spilled on you be sure to wash otf Quickly with farge amounts of water If battary fluid enters the eyes wash with water and consult a physician Check for cracks in the battery casa If the battery s electrodes show accumulation of a white substance sulphation or heavy daposits are observed at the base of the hattery the battery should be replaced Check the level of each cell by the UPPER and LOWER level lings inscribed on the side of tha hattery If levels are approaching the LOWER level line remove the bat tery take off the filler caps and refill to the UPPER level w
356. ponents The mainshaft with its fixed and sliding gears The countershaft with its fixed and sliding gears The shift forks The shift drum COUNTERSHAFT C1 C4 C3 ch C2 Power is transmitted through the clutch to the mainshaft From the mainshaft power may be transmitted through several gear sets to the cauntarshaft M1 through M5 are the gears on the mainshaft and C1 through C5 are the countershaft gears The gear sets are comprised of opposing gears one gear on each shaft The illustration on the right shows the gear sets pairing the mainshaft number with tha countershaft number M1 C1 CLUTCH 4 M2 C2 ete Selection of tha proper gear set is done by maving a sliding gear into contact with the gear set desired daly 1 i dogs and dog holes on the sides of the gears CRANKSHAFT In the iliustration gears M3 C4 and S are the sliding gears B Connection of the sliding gear and the gear set is done using The sliding gears are moved by shift forks which ride on the shift drum Cam grooves cut in the shift drum move the shift farks as the drum rotates Rotation of the shift drum is done by working the gearshift pedal The relative pasitions of the transmission at the respactive changing position are shown balow rd gear C4 gear pee aid 4th gear M3 gear shifted J Sth gear M3 gear shifted Date af Issue Sep 1988 HONDA MOTOR CO LTD 1 3 5 TRANSMISSION TRANSMISSION D
357. port luse the center stand if available Hook a spring scala to the end of the side stand rubber and check the load before the stand starts moving GOOD wear LINE WORN Acceptable load measurements for side stands 2 3 kg 4 4 6 6 lbs Road type 3 5 kg 6 6 11 0 Ibs On Off Road type If the stand moves too easily tighten the pivot bolt and recheck If it still does not have the required tension measure ment replace the raturn spring See if the side stand movas smoothly and retracts fully If not grease the pivot Check the side play on the side stand If it is too great tighten the pivot bolt Recheck and if it is still too great replace the parts as necessary Dual Motion Typa The side stand should lower easily to its first stop then lock after moving farther forward to support the motorcycle as the rubber touches the ground When the motorcycle is lifted upright the stand should automatically move to the first position and retract whan kick d up Hf the side stand does not move freely disassemble it Remove the return spring at the retracted position Remove the pivot bolt and remove the side stand assembly from the frame Check the following parts far wear or damaga inside of the pivot and pivot collar pivot dust saats Lubricate the pivot area with clean grease and reassemble the side stand CAUTION Install the dust seal with its mark side facing in Make sura that the d
358. pump malfunction Fuel auto valve malfunctron Vacuum piston faulty CV type only Throttle valve fauity Rich mixture Choke valve or bystarter valve in ON position Float valve faulty lt Float level tao high Air jets clogged Air cleaner element contaminated Flaoded carburetor Hasitation during accelaration Accelerator pump malfunction Engine stalls hard to start raugh idling Fuel line restricted Ignition malfunction Fuel mixture too lean rich Fuel contaminatad detariorated Intake air feak idle speed misadjusted Fuel pump malfunction Fuel auto valve malfunction Air screw or pilot screw misadjusted Slow circuit or bystarter circuit clogged Float ievel misadjusted Fuel tank breather tube ar hole cloggad Air vent control valve faulty Hoses of the emission control system faulty Purge control valve faulty Afterburn when engine braking is used A cut off valve malfunction Lean mixtura in slow circuit Secondary air supply systam fauity Hose of emission contro system faulty Backfiring or misfiring during accelaration ignition system faulty Fuel mixture tao jean Poor performance idriveability and poor fua economy Fuel system cloggad Ignition malfunctian Faulty air vent control valve Damaged misconnectad emission cantrol system hoses Date of Issue Sep 1989 HONDA MOTOR CO LTD FUEL SYSTEM SYSTEM DESCRIPTION CARBUR
359. que NOTE Some modela have dowe bolts instaad of dowel pins to secura the slave cylinder positions Note the location of the dowel bolts or dowel pins for positioning the slave cylinder j Tighten the bolts in 2 or 3 Steps in a crisscross pattern j _ starting from the dowel bolt or the dowel pin boit Connect the clutch hose with the hase balt and two new saal ing washers then tighten the hosa bolt to the specified torque ay wW SEALING WASHERS Fill the clutch fluid reservoir and bleed the ciutch system page 14 28 11 32 1 HONDA MOTOR CO LTD 12 V MATIC BELT DRIVE SYSTEM SERVICE INFORMATION 12 1 DRIVE BELT 12 5 TROUBLESHOOTING 12 1 DRIVE PULLEY 12 6 SYSTEM DESCRIPTION 12 2 CLUTCH DRIVEN PULLEY 12 10 SERVICE INFORMATION Avoid getting grease and oi on the V belt and pulley drive faces in order to prevent belt slippage Refer to the Model Specific manual for removal installation of the left crankcase cover and specific clutch maintenance TROUBLESHOOTING Engine starts but vehicle won t move Worn drive belt Damaged ramp plate Worn or damaged clutch lining Engine stalls or vehicle creeps Broken clutch shoe spring Poor performance at high speed or tack of power Worn drive belt Weak driven face spring Worn weight roller Faulty driven pulley face Date of Issue Sep 1988 HONDA MOTOR CO LTD 1 2 1 V
360. r CBI unit The overdrive switch turns the overdrive indicator on when the transmission is in OD overdrive position INSPECTION Nautral Indicator does nat go off Disconnect the light green red wire from tha nautral switch and turn the ignition Switch ON Indicator does nat light Indicator lights Faulty neutral switch Broken light green red wire Neutral indicator does not coma on Disconnect the light green red wie from the neutral switch and turn the ignition switch ON Check for battery voltage between the light graan red wire and ground Battery voltage No battery voltage Faulty neutral switch Broken light green red wire between tha in dicator and neutral switch Blown bulb Blown sub fuse Poat cunnection of the fuse connector 25 14 HGNITION MAIN FUSE SWITCH FUSE INDICATOR J 4 l ka NEUTRAL SWITCH PON SHIFT DRUM Date of Issue Sep 1988 HONDA MOTOR CO LTD x LIGHTS METERS SWITCHES _ ee Eo ye ye CLUTCH SWITCH IGNITION MAIN SWITCH FUSE The clutch switch prevents the starter motor from ratating while the engine is running and the transmissian is in positions other than neutral STARTER SWITCH STARTER MOTOR CLUTCH SWITCH INSPECTION Check the starter system if the starter motor rotates with the transmission in positions other than neutral The starter motot should be Operated with the clutc
361. r and master cylinder with the punch mark on tha handlebar Tighten the upper holder bolt to the specified torque first than tighten the lower bolt to the same torque Install the brake lavar and connect the wire to the brake light switch Connect the brake hose with two new sealing w shers Be careful not to twist the brake hose PUNCH MARK HOLDER UP MARK Tighten the brake hose bolt to the specified torque ae Make sure that the brake hose is routed properly Route all cables hoses and lines carefully ta avoid kinking or pinching CAUTION Improper routing may damage cables hoses and lines Kinked or pinched brake cables hoses or lines may cause A lass of braking abillty d adamo Fill the system with specified grada of fluid and bleed the air from the system Rafer to page 17 10 MECHANICAL DRUM BRAKES Use an OSHA approved vacuum cleaner or alternate mathod approvad by OSHA designed to minimize the hazard causad by airborne asbestos fibers Inhaled asbestos flhars hava been found to cause raspiratory disease and cancer Never use an air hose or dry brush to clean brake assemblies erm Remove the whee Remove the brake panel fram the wheel bub D INSPECTION Brake Drum I D Check the brake drum for waar or damaga Replace the wheel hub if necessary Measure the brake drum I D at the lining surface in a savera points and taka the largest measurement Refer to the
362. r applicable models only Ajiign tha mark that you made earlier and install the cover CAUTION When installing tha cover taka care to prevent damag ing the ait saal lip with the shaft Tighten tha caver screws For starter motors that are mounted within a motor mount hole check for a damaged O ring In order ta prevent damage grease the O ring Refer ta the Model Specific manual for installation terminals to turn Ingle the startar motor resulting in serious damage to the inner connectors j Data of Issue Sep 1998 HONDA MOTOR CO LTD ELECTRIC STARTER STARTER CLUTCH B O RING ELECTRIC STARTER STARTER CLUTCH Te Clreult B gt Measure the voltage batwaan the green yellow wire and ground at tha starter relay switch connector If battery voltage is measured when the front or rear brake are CONNECTOR applied it is normal NOTE If the brake light adjustment is incorrect no voltage will appear when the brake is ON STARTER RELAY SWITCH Starter ralay switch ground line Clreuvit A gt Disconnect the connector from tha starter relay switch and check for continuity between the ground wire green red and ground If thera is continuity when the transmission is in neutral or when the clutch is disengaged thea ground circuit is normal In neutral there is a slight resistance dus to the diode Circuit Be Disconnect the connector from the starter relay and check for con
363. r chains connected to the crankshaft This type is the mast powerful among tha triple phase alternators and is primarily used for power on large displacement motorcycles Its structure differs fundamentally from the previous alternator in that it does not utilize a permanent magnet Instead the field coil magneuzges the ratar and generates power as the rotor passes the coil STATOR Excited Field Coll Type With Brushes This type has a field coil placed inside the rotor Current flows through the brushes to the field coil and elec tromagnetically induces the rotor This gangrator has a strong magnatic for a large output and is small and light weight STATOR ALTERNATOR FUNCTION ONE ROTATION OF ROTOR pariar Single Phasa Output Typa Since this type uses only ona charging coil the output voltage OUTPUT is single phase AC wave The output frequency varies dapanding an the number of magnets on the rotor ONE CYCLE The generator in the diagram on the right has two pairs af magnats and its output has two cycles for every rotation of the rotor The singla phase output type has a low output and its small size is best suited far engines of small displacement and a small electrical load ALTERNATOR SYMBOL Data of Issue Sep 1998 HONDA MOTOR cO LTB 22 1 3 BATTERIES CHARGING LIGHTING SYSTEM Friple Phase Output Typa This type cansists of three cails connected to each other pro d
364. r of disassembly If the shock absorber dues not have the regular pitch spring the spring should be installed in tha correct posi 1 tian Rafer to the Model Spacific manual for spring in tallation direction O Hydraulic Prass Use Compress the spring until the stopper ring can be installad us ing a hydraulic press Refer to the Model Specific manual Install the stopper ring in the groove in the damper Be certain that the stopper ring is seated firmly in the groove is Failure to firmly seat the snap ring may causa tha shock assembly ta come apart unexpectedly and lead to a i serious injury Comprassing the spring more than necessary may cause j a foss of spring tansion Always use a Shock Absorber Spring Compressor to compress the spring on dampers with a rod screwed into tha upper or lower joint tse ofa hydraulic press to campress the spring can lead i to tha spring or shock absorber flying aut of the prase A and causing a serious Injury Joint Installation Clean the lock nut threads before installing the lower joint Install tha lock nut on the damper red and tighten it by hand as full as it goes Apply a focking agent to tha threads Install the lower joint on the damper unit Hold the lower joint and tighten the fock nut to the specified torque CAUTION Loosening or ramaving a staked iock nut may cause the shock assembly ta come apart unexpectedly and lead to a serious
365. r pouring 2 strake engine oil back into the tank be sure to ramove the air in both oil tube and oil pump See paga 4 11 OIL STRAINER NOTE Check each part for oil laakage after completing the oil Strainer cleaning and oil tube and Pump air bleed procedures CARBURETOR CHOKE MANUAL CHOKE Qn tha manual choke system check to see if the choke lever CHOKE LEVER tor knob can be opened and closed completely Pd inspect the choke cable to see if it is bent crimped or damaged in any way Aausging a damagad or abnormally bent or kinked throttla i cable can prevant proper throttle slide operation and may lead ta a loss of throttla control while riding Check to be sure that cable movement is corract on machines with manually operatad chokes Check by pushing with your fingar ta see if there is a maximum of 1 2 mm of free play in the innar choke cable when the choke lever fs in its completely off position if the amount of free play is not sufficiant loosen the cable clamp screw and adjust the play of the inner cable by moving the position of the outer cable Tighten the cable clamp securely when the adjustment is complete BYSTARTER CHOKE The choke action on motorcycles equipped with auto by Starter type choka system can be checked by the way engine starts and runs NOTE Difficulty in starting before ft is warmed up igasy once it is warmed up starter valve is not completely opened off
366. r the field coil The voltage regulator detects the voltage at the battery and feeds current to the base of tran sistor turning it ON When the transistor is ON the battery feeds currant through ignition switch gt field cot transistor ground The fiaid coil magnatizes the rotor and the alter nator generates power When tha alternator reaches a certain voltaga the voltage regulator turns off the transistor and cuts off currant to the fieid coil hance the alternator stops generating power LIGHT SWITCH REGULATOR m E LIGHTING COIL L ae ee ee IGNITION SWITCH ALTERNATOR l l l Lig ee REGULATOR RECTIFIER __ REGULATOR REC TIFI FIELD COIL 22 18 Date of Issua Sep 1985 HONDA MOTOR C LTD rS BATTERIES CHARGING LIGHTING SYSTEM The voltage ragulatian is performed by a high frecuency ON OFF cycle of the alternator When the OC voltage of the output waveform ts measured by a voltmeter a value smaller than the peak voltage is measured A broken wire in the field coil in this type of system will resutt in insufficient charging of alternator if tha ground wire af the field coil wire is shorted to ground transistor shortedi the bat tery will be avercharged CHARGING SYSTEM INSPECTION LEAK TEST Turn off the ignition switch and disconnect the ground cable from the battery Connact an ammeter between negative terminal and ground cable
367. racks or other damage Refer to the vacuum touting diagram dabei for hose connections 2 19 Date of Issue Sep 1988 HONDA MOTOR CO LTD MAINTENANCE a a eT ANAPON Tian tabis r acl l EmMa vjana a VAUN POSE KOUTING DIAGRAM oe h 1 phamaj ve YENICLE EMISSION CONTROL INFORMATION UPOATE HONDA MOTOR CO LTO THIS VEHICLE WAS BEEN AQWSTED TO 5 IMPROVE EMISSHIN CONTROL PERFORMANCE RY WHEN OPERATED AT HIGH ALTITUDE ALTITUDE PERFORMANCE ADIUSTMENT INSTRUCTIONS ARE AVAILABLE AT YOUR AUTHORIZED HOMDA DEALER NOTE Fuel vapor from the fuel tank ts directed into tha charcoal eee O O MAINTENANCE TRANSMISSION OIL 2 stroke engine Check for gil leakage over all sections of tha transmission Check the oil level Excessive oil leakaga necessitates disassembly With the engina stopped remova the oi check bolt and make sure that the oil level is up to the lower edge of the bolt hole Refill to the iawer edge of the oil level check boit hola with tha recommended oil if the level is tow NOTE Oil level checks should be carriad out on level ground with the vehicte on the canter stand or while in an in scooters check for leakage and oil leval of the final reduc tion gear case in the same way as for the engina Remove the level hole cap fram the gear case and chack whether the oii level comes up to jawer edge of the hole If tha level is low refill to the lower adge of the hole w
368. rance is beyond the service limit select the correct replacemant bearings One piece Type Wipe all oil from the bearing and the crankshaft journals Measure and record the crankshaft main journal O D MICROMETER Date of Issue Sep 1988 1 4 HONDA MOTOR C LTD CRANKCASE CRANKSHAFT Measure and record tha main bearing I D CYLINDER GAUGE a Calculate the oil clearance by subtracting the journal O D frorn bearing I D Reptace the bearing if the service limit is exceeded tee MAIN BEARING SELECTION Two piece Typs Record the crankcase D code lettars NOTE m he Letters A B or C on the upper crankcase are the codes for the main journal 0 6 from left t right CRANKCASE I D CODE LETTERS Record the corresponding main journal O D code numbers or measure the main journal O D NOTE Numbers 1 2 r3 on each crank weight are the codes for the main journal O D s fram left to right MAIN JOURNAL 0 0 CODE Cross reference the case and journal codas to determine the replacement bearing color code Example COLOR CODE LD code on the crankcase A 0 B codes on the crankshaft 1 Baaring color code Pink CRANKCASE I D CODE MAIN JOURNAL Date of Issua Sap 1988 HONDA MOTOR CO0 LTD 1 4 5 CRANKCASE CRANKSHAFT One piece Type CYLINDER GAUGE NOTE Some bearings cannot be replaced Refer to the Model S pacitic manual for complete
369. rankshaft if the service limit is exceeded Measure the connecting rod radial clearance in both X and Y directions Replace the crankshaft if the service limit is exceeded Measure tha crankshaft runout using dial indicators DIAL INDICATOR NOTE MEASURING POINTS The single unit crankshaft uses the plain bearings at the main journal Excessive runout can cause engine seizure Refer to the Model Specific manual for measuring and i Supparting paints u CRANKSHAFT MAIN BEARING OIL CLEARANCE INSPECTION NOTE Main bearings may be either two piece or one piece bushing types Check the bearing inserts for unusual wear damage or peeling and replace as necessary PEELING DAMAGE Date of Issue Sep 1988 HONDA MOTOR CO LTD CRANKCASE CRANKSHAFT Two Piece Type Wipe all ail from the bearing inserts and journals PLASTIGAUGES Reinstall the upper crankcase s main bearing inserts then carefully tower the crankshaft in place Put a piece of plastiguaga on each journal NOTE Do not put the plastigauge over the oil holas l Do not rotate the crankshaft during the inspection L L L r a ne ins Install the main bearing insarts on the correct journals in the lower crankcase then assemble and tighten the bolts evenly in 2 or 3 staps to the specified torque Remove the lower crankcase and measure tha compressed plastigauge on each journal If the clea
370. rate Of currant flow Amperes increases or decreases electrical power output Watts The relationship is defined as W EJ Power Voltage x Currant ELECTRICAL CIRCUIT 4s shown in the right diagram when a light bulb is connected to a battery the current flows in the diractian of the arrow and the light bulb turns on The path in which an electric currant flow is cailed a circuit On Honda motorcycles scooters and ATVs the ground wire of an electrical ciscuit is connected to the angine or frame Grounding the negative terminal is called a negative terminal ground type All Honda motorcycles scooters and ATV share tha negative ground circuit shown in the right diagram Date of Issue Sep 1988 HONDA MOTOR C LTD lt OHM S LAW gt VOLTAGE tE CURRENT fi _ __ __ RESISTANCE RI VGLTAGE CURRENT x RESISTANCE gt CURRENT VOLTAGE AFSISTANCE RESISTANCE VOLTAGE CURRENT ELECTRICAL FUNDAMENTALS Series circuit A series circuit is an electric circuit in which the current flows through one device into another and then to ground There is only ane current path and the voltage is distributed by the loads The total resistance if can ba found by simply adding all the resistances ag R R1 R2 Parallel ciecuit A parallel circuit is an electric circuit which has two current paths one for the positive and one for negative The devices are connec
371. rease NLGI 2 or equivalent Use molybdenum disulfide graase containing more than 3 molybdenum disulfida NLG 2 or eguivalant Example Molykote BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mistubishi Oil Japan m Use molybdenum disuifide pasta containing mora than 40 meolybdanum disulfide NLGI 2 or equivalent Example Moiykota G n Paste manufactured by Dow Corning U S A Honda Moly 45 U S A only Reco ASP manufacturad by Rocot Limited U K Rocol Paste manufactured by Sumica Lubricant Japan na Use silicone grease a a me a asiLUAL Apply lacking agant Use the agent of the middle strength unless otharwise specified AS a a e a SEAL Apply sealant g Replace the partis with new oneis before assembly a Use brake fluid DOT 3 or DOT 4 Usa the recommended brake fluid unless otherwise specified So c aaa aaa aaaea SL Do Use Avtomatic Transmission Fluid ATF ea a A a MIle Use special tool Use optional tool These tools are obtained as you order parts Date af Issue Sep 1988 HONDA MOTOR CO LTD a Abbreviations Following abbreviations may be used in this manual They stand for ASSY si Assembly R n Right Right side viewed from rear side Litt Left Left side viewed from rear side IN isara Mtaka sigdeilnsideg EX
372. reciprocating and ratating components are properly balanced to produce a smooth running engine Stresses on tha components increasa proportional with an in crease in rpm s Because of this increased strass it is critical that the bafance is maintained whan componants are replaced There are two types of crankshafts the assembly type in Assembly type crankshaft which the right and left crankshafts are assembied with the aid iR of a crank pin and the single unit type in which a unibody Crankshaft crankshaft is amployed In the case of the former caution ta tL should be exercised when handling t because if it is dropped Crankshatt the Crank pin will be knocked out of alignment The unit type amploys plain type main bearings While the crankshaft is designed to rest directly on the metal bearing materiai strictly speaking the crankshaft and metals are lubricated on their surfaces by an oil film Cansequently scratchas burrs or dust on the bearing surface spoils the oii film laading to bearing seizure a aa e aaae Date of Issue Sep 1988 1 4 2 HONDA MOTOR CO LTD CRANKCASE CRANKSHAFT CRANKSHAFT INSPECTION SIDE CLEARANCE Om FEELER GAUGE Measure the side clearance by inserting the feeler gauge between the crankshaft and connecting red big end as shown RADIAL CLEARANCE ASSEMBLY TYPE CRANKSHAFT ONLY Measure the side clearance at the connecting rod big end with a fealer gauge Aepiace the c
373. required INNER BEARING CLUTCH DRIVEN PULLEY ASSEMBLY OIL SEALS Install new oil seals and O rings on the movable driven pulley face Lubricate the inside of the movable face with the specified amount of grease SPECIFIED GREASE Lithium Based Grease Mitsubishi HD 3 Nippon Seklyu dipanex Deluxe 3 tdemitsu Caronax 3 Sta Lube MP 3141 Sel Ray Moly Luba 126 EP 0 Install the movable face on the driven pulley face MOVABLE DRIVEN PULLEY FACE Install the guide pins ar guide pins and guide pin rollers OR GUIDE PIN ROLLER Install the seal callar 1 Pn 1 4 Date of Issue Sap 1988 HONDA MOTOR O LTD V MATIC BELT DRIVE SYSTEM Assembla the driven pulley spring and clutch in the clutch LoL LOCK NUT WRENCH Spring Corripressor Compress the assambly by turning the tool handle until the lock nut can be installed Clatnp the cluteh spring Comprassor in a vise and tighten tha lack nut ta the spacified torque using the lock nut wrench Remove the spring compressor Install the clutch driven pulley and drive belt onto the drive shaft See page 42 51 d Date of Issue Sep 1888 HONDA MOTOR CQ LTD 1 2 1 5 13 TRANSMISSION SERVICE INFORMATION 13 1 TRANSMISSION DISASSEMBLY TROUBLESHOOTING 13 1 TRANSMISSION INSPECTION SYSTEM DESCRIPTION 13 2 TRANSMISSION ASSEMBLY SERVICE INFORMATION Rafar to the Model Specific manual for proper servicing information on the particular model in
374. rior to installation Nate the position of the stopper that aids in positioning tha eyelet at the proper angle whan installing the hose onto tha master cylinder If only one stopper is provided press the hosa end against the stopper while tightening the bolt If two stop pers are provided install the hose between the stoppers so that the hose will not mave whan the bolt is tightened if the sealing washer includes a stopper with collapsible claws be sure ta note the direction these claws face so the new SEALING WASHERS washer can be installed in the same position cei JOINT NUT HOSE NUT Remove the hase by iaassning the joint nut while holding the hose nut stationary This method pravents the hose from being twisted or kinked BRAKE HOSE Date of Issue Sep 19B8 HONDA MOTOR CO LTD 1 7 7 BRAKES Installatian MASTER CYLINGER HOSE NUT i First install the hose joint onta the master cylinder with a new sealing washer and tighten it to the specified tarque if it was ramavet Then while holding the hose nut tighten the joint nut to the specifiad torque JOINT NUT Metal Braka Lines Removai If the metal braka lina is equipped with nuts as illustrated always loosen the flara nuts first using a flare nut wrench so that the hose may be easily maneuvered Remove the metal line using Care not to bent it Instatlation Always tighten brake line nuts first by hand Then confirm that tha connections ara frae
375. rrent flow i through the primary coil becomes shorter and thus the second eae Lee l ary coil voltage does not go high enough For this reason the BiacriGne ignition timing control circuit controls the duration of current flow through the ignition primary coil IGNITION PRIMARY COIL VOLTAGE oa OEE eee IGNITION SECONDARY AA COIL VOLTAGE DIGITALLY CONTROLLED TRANSISTORIZED IGNITION SYSTEM This system digitally controls the ignition timing by a microcomputer inside the spark unit and calculates the ideal ignitian tim ing at all engine speeds It also has a fail safa machanism which cuts off power to tha ignition coil in case the ignition timing becomes abnormal The control unit consists of a distributor a signal receiver which processes the pulse signals from the pulse generator and a microcomputer which has a memory and an arithmetic unit The pulse generator rotor has reluctors which are irregularily spaced When these raluctars move past tha generator pulses ara fed to the spark unit The number of reluctors and tha angle between sach reluctor diffar depending on the number of cylinders and their arrangament The circuit below is the ignition system of a 90 V type 2 cylinder engine D As the engine starts a pulsa signal from the pulse generator is sent to the spark unit The signal receiver converts the pulse signal to a digital signal and it is fed to the microcomputer As the microcomputer receives t
376. rtridge 10 N m 1 0 kg m 7 ft ib Larga type cartridgal 18 N m 1 8 kg m 13 ft lb Confirm that there is no ail teakage by starting the engine after the engine ail has bean set at its proper level Run the engine for about a minute then stop it and inspect carefully for leaks Elament Type Paper Filter Remova the oil filter covar and replace the filter glement Reinstall the caver with a new O ring OIL FILTER COVER RUBBER SPRING SEAL NOTE m Install the element with the rubber seal sida facing A making sure thet tha spring is installed between the ela ment and crankcase Replace the O ring on the filter cover with a new ane FILTER ELEMENT Replenish the engine oil with the proper type and viscosity and to the proper ievel Always run the angine and check far ail leaks after an oil or oil and filter change ENGINE OIL FILTER SCREEN Check to see if there is any dirt or debris on the oil filter screen which might hinder tha flow of oil Remove and clean the screen in solvent if any deposits are found an the screen Refer to the Model Specific manual for gil fitter screen removal cleaning and installation procedures for specific modals 2 1 Date of tssue Sep 1988 14 HONDA MOTOR CO LTD MAINTENANCE i DECARBONIZING 2 stroke engine Carbon accumulation occurs more rapidly in 2 stroke enginas than 4 stroke engines because 2 stroka engines burn engine oil If the build
377. rust washer if used Date of Issue Sep 1988 HONDA MOTOR CO LTD CLUTCH Coat the clutch discs and plates with clean oil PRESSURE PLATE CLUTCH CENTER Install the pressure plate discs plates and clutch center ante the mainshaft in the order shawn If a judder spring is used in Stall the judder spring and spring seat as shown below DISCS AND PLATES NOTE DISC The disc that is installed against the judder spring has a larger 1 0 than the other discs If the splinas of the clutch center cannot ba aligned with the mainshaft splines while installing change tha i transmission into any gear position and turn the rear wheel to ease instalation a y o SPRING SEAT JUDDER SPRING Make sure that the clutch canter is installed completely the CLUTCH CENTER PRESSURE PLATE grooves of the clutch center must align with the tabs of the pressure plates F the clutch is secured with a lock nut install the lock washer onto the mainshaft with the OUTSIDE mark facing outside if there is no mark install the lock washer with the convex sida facing aut Instat the lack nut and tighten it to the specified torque NOTE Use a new lock nut if the lock nut was staked al Face the chamfered side of the lock nut inward If the j lock nut is chamfarad lt dfa snap ring is used Set the snap ring into the groove in the mainshaft with the chamfered si
378. ry function of suspension dampers is to control the natural rebound anargy of the suspension springs so that trac tion and ride comfort is maintained An oil damper controls the spring action by forcing oil to flow through a specific set of holes in tha damper piston as the combined spring darnper compresses or extends The rasistance of the movement of the damper piston created by the oil within the damper controls the force of tha spring By varying the path the oil is forced to take on tha compression and rebound strokes the desired damping rates can be achieved On the comprassion stroke ail is forced through several large capacity damping orificas so thet the wheel can respond quickly ta terrain changes Since tha wheel is free ta move quickly the avarage ride haight of the machine is not disturbed On the rebound stroke the force of the compressed Springs is slowed by forcing the damper oil through fewer and or smaller damping holes The proper damping characteristics allow the suspension to extend quickly enough to meet the next bump but not s quickly that the motorcycle bounces fram one bump to the next In the iNustratian to the right the compression stroke within a double wall damper is dascribed As the damper bady is forced Up against the spring and damper piston oil is forced through the piston valve with little resistance The primary resistance to this Compression is the damper spring Tha oil that passes through
379. s Do not let tha cement dry insart and center a tubber plug through the eye of the inserting needle Apply cament to the rubber plug Push the inserting negdle with plug into the hole until the plug is slightly above the tire Twist the naedle and remove it from the tire the plug will stay in the tire NOTE F Ba careful not ta push the plug ail the way into the tire Trim the plug 6 mm 1 4 in above tha tire surface Repeat the sbove procedure if the puncture is larga Do not usa more than two plugs per hole Allow the repair to dry Drying time will vary with air temperature Refer to the tire repair kit manufacturer s recommendations Inflate the tire and test the saal by dabbing a smail amount af cement around the plug Escaping air will cause a bubble in the cemant f there is leakage remove the tire page 16 17 ond apply 4 cold patch to the inside of the tira as described If a plug has been inserted trim it evan with the innar tire surface Temporarily place a rubber patch that is st least twica the size of the puncture over the injury Make a mark around the patch slightly largar than the patch itsaif Remove tha patch Roughen the area marked inside tha tire with a tira buffer or a wire brush Ctean the rubber dust from the buffed ares Apply cemant over the area marked and allow it to dry Remove the lining from the patch and canter it aver the injury Press the patch against the injury using a
380. s accidentally swallowed induce vomitting and contact a doctor immediately KEEP OUT OF REACH OF CHILDAEN Fa RESERVE RADIATOR Coolant evaporates naturally so check it regularly Coolant is both an antifraeze and an anti rust agent CAUTION K Be sure to use the propar mixture of antifreeze and distill ed water to protact tha engine Use distillad water Tap water may cause the engine to rust or corrode oa an a a Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 17 MAINTENANCE LEVEL CHECK Always check tha coolant ieva with the motorcycle in a var tical position on a flat leval surface Always check the coolant level at the reserve tank not the radiator after tha angine has beer warmad up Check to saa if the coolant level in the reserve tank is somewhere between the upper and lower lings If the level is somewhere batween the upper and lower lines or below the lower line add a 50 50 mixture of antifreeze and distilled water to the upper line See Caotant Mixture Prepara tian page 5 6 Check to sea if there are any coolant leaks when the liquid level decreases very rapidly If the reserve tank becomes completely empty there is a possibility of the air getting into the cooling system So ba sure to remove all air from tha cooling system as described on page 5 7 NOTE gt The effectiveness of coolant decreases with the ac cumulation of rust or if there is
381. s are always installed with the manufacturar s name and size code facing out Facing out meaning th name and sizing cade should be visibile from the side the bearing is installed from This is true far open singla sealed and dovble sealad bearings Apply the proper grease to open and single sealed bearings before reassembly SINGLE SEALED TYPE DOUBLE SEALED MANUFACTURER S NAME BEARING No Snap rings are always installed with the chamfared rolledt edge facing away from the thrust of the Mating part This way prassure against the snap ring presses against the areas in the snap ring groave with the most parallel con tact area against one another Installed incorrectly Pressure against tha rolled or chamfered edge cavid com press the snap ring with the possibility of dislodging it Never reuse snap rings since they are often used to control end play and become worn with normal use Wear is especially critical on snap rings which retain spinning parts such as gaars After installing a snap ring always rotate it in its groove to be Sure it is fully seated CHAMFERED EDGE Grease or oil sliding or turning parts With the recommend ed lubricant before reassembly Replacement parts and fluids must be ganuine Honda or recommended by Honda The use of non Honda parts and non recommended fluids can have an adverse affect on performance and durability Reassembly operation should be tested whenever possi ble befgr
382. s for free play on cable apsrated brakes at the end of the cable BRAKE PEDAL Major adjustments ara mada n the brake panal end of the cabla Loasen the lock nut and turn the adjuster nut to correct play at the levar ABJUSTER NOTE If tha uppar adjuster an the lever is screwed in most but not all the way before adjustment is carried out subsequent adjustment by use of the upper adjuster can be conducted more easily When the brake cable is fastened to the fork by a clamp loosen the clamp baforea making brake adjustments al Secure the adjuster nut and tighten the lock nut on completion of adjustment Be certain to tighten the fork cable clamp as well BRAKE PANEL In cases where there is only an adjuster nut ag on many rear brakes turn the nut to adjust the brake pedal free play seat against one another as shawn here in the upper right portion of the illustration to tha right If they do net saat there may be a change in brake play whan the ad juster finally seats in its proper position SEATED Chack far play after adjustment UNSEATED ADJUSTER NUT I Date of Issue Sap 1988 HONDA MOTOR CO LTD 2 29 MAINTENANCE Minor adjustment is made at the lever end of the cable It is necessary t turn back the lever dust boot to gain access to the adjuster LOCK NUT Ooze ADJSUTER NOTE There may be damage to the adjuster if it is positioned
383. s measured at the voltage feedback line of regulator rectifiar con nectar page 22 221 For voltage feedback type only INCORRECT Broken wire harness a Bad connector Ee Faulty ignition switch a Check the resistance of the charging cail at the charging coil line of requiator ractifier con i INCGRRECT nector page 22 22 x Check the charging coil of the alternator page 22 26 lt mo PS ae ae ABNORMAL NORMAL t CORRECT Poorly connected alter nator connactor r FERITA Faulty charging cail Check the resistance of the lighting coil at the lighting coil line of ragulator rectifier Check the charging lighting coil af the alter page 22 22 t INCORRECT f gt For regulator rectifier with AC regulator built nator tpg 2220 int ABNORMAL NORMAL Poon ul ted alt INCORRECT oorly connected alter i nator connector l See t Faulty charging Measure the headlight voltage page 22 23 lighting coil For raguiatorirectifier with AC regulator built CORRECT Faulty battery inl nee INCORRECT a Check the resistance of the headlight resistor INCORRECT Faulty headlight resistor page 22 24 For appropriate models only SSS ibd CORRECT Disconnect reqgulator rectifier from connector Test it according to tha specification in the ABNORMAL Faulty regulator rectifiar Model Specific manual A jah icone
384. s surface Fhe only general exception is the components of the brake system that are designed to be resistant to the affects of brake fluid Brake fluid that is spitted on a motorcycle should be washed away with water immediately Before removing the reservair cover turn the handlebar until the reservoir is level Place a rag over painted plastic or rubber parts whanaver the systam is serviced CAUTION Spilled fluid will damaga painted plastic or rubber parts Refill with the same type of fluid from an unapanad container Do not allow foreign material to enter the system when refill ing the reservoir AWARNING Using the wrong fluid can cause loss of braking efficiency Contaminated fluid can clag tha system causing a loss of braking ability Lever stroke gt Caliper piston stroke LEVER Pressure applied against the brake lever or pedal moves the piston within the master cylinder unit Hydraulic fluid pressure is then transmitted through the brake iine to the caliper where it presses against one or mara caliper pistons Because hydraulic fluid cannot compress the caliper pistonish move at the same instant as does the master piston in the master cylinder The ris in hydraulic pressure that takes place between the master cylinder and the caliper because of the diffarences in the diameter of these parts is mast significant During devetop Master pistan diameter lt Caliper piston diametar ment these sizes ar
385. s unevanly binds or has vertical move Mant adjust the steering head bearings by turning the Stearing bearing adjustment nut Refor to the Model Specific manual for Proper procedure Date of Issue Sep 1988 2 38 HONDA MOTOR CO LTD MAINTENANCE WHEEL ALIGNMENT FOUR TRAX On FOUR TRAX models inspect and adjust the front wheel alignment toe in camber and caster as necessary TOE IN Place the vehici on level ground with the front wheels facing straight ahead Mark the centers of the tires with chalk to indicate the axle center height TOE IN GAUGE Align the toe in gauge with the marks on the tires as shown Check the readings on the gauges scales Slowly move the vehicla back until tha wheels have turned 180 so the marks on the tiras are aligned with the gauga height on the rear side Measure the toe in on the rear part of the tires at tha same points When the toe in is out of specification adjust it hy changing the langth of the tie rods equally while measuring the toe in CAMBER CASTER Remova the wheel cap cotter pin and front axla nut Install an attachment onto the frant axle Put the camber nd caster gauge onto the attachment Measura the camber Set the turn gauge under the front wheels Measure the caster Camber and caster are not adjustable If thoy ara out af Specification check the suspansign and frama for damage and replace any parts necessary then recheck alignment
386. screw Check that the throttle grip mavas smoothly and adjust the throttle grip free play GREASE LIGHTLY Install the brake lever and ciutch lever brackets aligning the punch marks with cable type slit in tha bracket hydraulic type master cylinder and set the holder with the holder punch mark facing up Tighten the upper bolt first then the lower bolts Route switch wires properly and secure tham with bands TWO PIECE CLAMP ON TYPE Removal Remove the following Both handlebar switches Throttle grip Master cylinder s or laver bracket s Remove the stop ring Remove the pinch bolt and handlebar STOP RING PINCH BOLT 18 12 Date of Issue Sep 1982 HONDA MOTOR CQ LTD FRONT SUSPENSION Installation FORK TUBE Install the handlebar by aligning the boss with the top bridge slot Install the stop ring into the groove af the fork tube Tighten the pinch bolts to the specified torque While turning the handlebar through its full range check for smooth handlebar movement Also chack that there is no in terfarence with cables or harnesses especially throttle and brake cables hoses and lings PINCH BOLTS safa vehicle operation Handlebar interference can have an adverse effect ak Connect the choke cable ta the chake laver Install the left handlebar switch aligning the pin with the hole in the handlebar Tighten tha forward s erew first then the re
387. se of its pasi tian within the system based on the rotating direction of the drum is pushed back by the rotating drum and creates less for a than that which is applied to it Dual Leading Shoe Type Dual laading shoe brakes differ from single leading shoe types in that they usa twa shoe activating cams each at opposite ends of the brake panel to simultaneously press the shoes against the drum isee illustration at the right Bacause bath shoas are leading in relation to the rotating direction of the drum and therefore operate against the drum in same way the effective braking farce is noticably greater than a similarly siz ed single leading shos unit with an identical amount of ac tuating force applied ta the brake lever or pedal DRUM BRAKE DISC BRAKE BRAKE CAM LEADING SHOE TRAILING SHOE BRAKE CAM LEADING SHOE LEADING SHOE BRAKE CAM 17 2 Date of Issua Sep 1988 HONDA MOTOR CO LTD BRAKES It is vital far brake systems to quickly dissipate the heat that is generated by the friction of tha braking action so their stop ping force remains consistent Since drum brakes contain almost all of tha brake components within the wheel hub it is important that thase brake companants be made of matarials that conduct heat rapidly It is just as important that the brake is of the proper size for the anticipated requirements of the vehicle In order to enhance heat conductivity white providing ac
388. service limit Assembly NOTE Make sure that each part is frae from dust or dirt befare reassembly Replace tha dust seals and piston seals as a set whenaver they are removed Coat the new dust seals and piston seals with the racommend ed brake fluld and instali tham in the caliper cylinder grooves properly Coat the caliper piston with frash brake fluid and install it in the caliper There are two types of caliper pistons resin pistons mounted on light weight motorcycles and metal pistons on heavy waight motorcycles Note the installation direction as it is dif ferent according to the types of the piston Resin piston Install with the concaved side away from the pad Metal piston Install with the opening toward the pad Install the pad spring in the caliper Rafer to tha Model specific manual for the installation direction of the Spring Install the pad ipage 17 10 Instali the caliper Refer ta the Model Specific manual CALIPER CALIPER PISTON MICROMETER PAD SPRING PISTON SEAL DUST SEAL aba PISTON Date of Issue Sep 1988 HONDA MOTOR CO LTD 17 13 BRAKES BRAKE DISC INSPECTION Visually inspect the discs for damage or cracks Measure the brake disc thickness at the several paints and replace if the smallest measurament is lass than the specified service limit Refer to the Model Specific manual for the service limit Check the disc to see if the servic
389. should be continuity between the terminals Whan the brake lever or pedal is released There should be no continuity between the terminals 3 if the brake light switch is narmal check for the following Burned sub fuse Ignition switch Poor connection of the fuse connector Brokan wire betwaen tha sub fuse and brake light switch Broken wire between the brake light switch and brake light TURN SIGNAL LIGHTS If the turn signal tight does not blink check the following 1s the battery normal Is the bulb burned out is the bulb of the specified wattage Is the fuse burned out Are the ignition switch and turn signal switch normal is the connector proparly connectad if normal check as noted below When the turn signal relay has 2 terminals Disconnect tha connector from the relay and shart tha connec tor with a jumper wire Turn the ignition switch ON and check the turn signal light by turning the switch ON Light does not coma on Light comes on Broken wire harness Faulty turn signal relay Poor connection of the connector REAR BRAKE LIGHT SWITCH 2 TERMINAL RELAY IGNITION re SWITCH TURN SIGNAL RELAY MAIN FUSE LEFT TURN SIGNALS Date of Issua Sep 1988 25 1 6 HONDA MOTOR CO LTD LIGHTS METERS SWITCHES When the turn signal relay has 3 tarminats J TERMINAL AELAY IGNITION MAIR 1 Short the black and gray terminals of the turn signa
390. slip pin or cotter pin or from thrown stones on off road bikes Ha through a boit prevents the nut sure to bend cotter pins properly as shown from loosening below FORWARD Mma a RIGHT WRONG i Set the pin head in any position within the i range A shawn above Date of Issue Sep 1988 1 S 1 2 HONDA MOTOR CO LTD GENERAL INFORMATION TYPES OF FASTENERS APPLICATIONS i CAUTION Important paints inside the During disassembly eliminate the staking engina pornt ta loosen the nut Clutch center lock nut Replace the nut if the old staked area of the Wheal bearing retainer Nut aligns with the groove of tha shaft after Shitt drum stopper plate tightening the nut to specified torque i After tightening the nut to the specified tor que stake the nut collar by striking it with a drift punch m such a way that the staking point matches tha shaft groove Ensure that the staking point has entered into the groove at least 2 3 of the groove dapth Stake or indent the collar of the Hut to make it match the groove in the shaft 3 Thread lacking agent Rotating points inside the Application of a locking agent increases engine points which if loosening torque Take care not to damage Joasened may contact the balt during removal ratating parts Before applying a locking agent clean off all Stator coil bolt ail and or resi
391. special roller NOTE Allow cement to dry until tacky before applying patch 1 Do not touch the cement with dirty or greasy hands Date of Issue Sep 1986 HONDA MOTOR CO LTD WHEELS TIRES ASSEMBLY Clean the rim bead seat and flanges Appiy clean water to the rim flanges bead seat and base Install the tire on the rim where th rim shoulder width is tha narrowast to simplify installation Use oniy water as a lubricant when mounting tiras Soap ar other tire lubricants may leave a slippery residue that can cause the tire ta shift on the im resulting in a sudden lose of alr pressure while riding Install tha valve cora in the valva stem Install the tire and inflate it to seat the tire bead Tha maximum pressure for seating the tire bead is in dicated on the side wall Do not inflate the tira beyond this pressure The tire could burst with sufficiant torce ta cause severa injury NOTE mrem a Wf the tire has arrow mark install the tire with the mark pointing in the direction of rotation Do not interchange the right and left tiras Deflata the tira Wait 1 hour and inflate the tira to the specified pressura Check for air leaks and install the valve cap The ATVs are aquipped with tubeless tires valves and wheel rims Use only tires marked TUBELESS and tubeless valves on rims marked TUBELESS TIRE APPLICABLE Never mount tires design
392. ss of vaiva spring tension Remove the valve spring compressor then remove the re tainers valve springs and valves RETAINER OUTER SPRING NOTE i i a M Mark the valves sa they can be rapiaced in their Original positions for installation later Lra y Sn Remove and discord the stem seal if necessary NOTE Do not reuse the removed stem seal Oe VALVE SPRINGS Measure the free length of the inner and outer valve springs VALVES inspect each valve for bending burning scratches or abnor mal waar Insert the valves in their original positiens in the cylinder head Check that each valva Moves up and down smoothly without binding 9 8 Date of Issue Sap 1988 HONDA MOTOR CO LTD CYLINDER HEAD m Measure and record the valve stem O D in three places along tha valve guida sliding area Aeplace the valve with a new one if the service limit is exceeded VALVE GUIDES INSPECTION Insert the valve guide reamer from tha combustion chamber side and ream the guide to remova any carbon build up before measuring the guide NOTE Take care not to tilt or lean the reamer in the guide while reaming Otherwisa the valve ts installed slanted that causes oil leaks from the stem seal and improper valve seat contact and results in the valve seat refacing not able to be performed Rotate the reamer clockwise never counterclockwise when inserting an
393. st which carbon daposits are burned off The capacity of dissipating the heat is called heating value or the heat range It is important to install the spark plug of the proper heating Valua bacausa the combustion gas temperature varies accord ing ta the engine typa and driving conditions Hot type Heat is dissipated slowly Colg type Heat is dissipated quickly Heating valus ig indicated by a number Smaller number Hotter type Larger number Colder type If an improper cold type spark plug is installed the sparks do not jump across the electrodes as easily or it may contaminate the plug with oil gasoline lf an improper hot typa is installed it causes overheating or preignition and may result in malted elactrodas and or a hole in the piston Optional spark plugs are often listed for the Honda motorcycles Replace the plug with the optional ona whenever the heating value of the original plug does not comply with the driving conditions d ICeantarmn k Hot type heat range ination Smoldering Cold typa heat range Driving speed kmh 7 Q Z ao be 2 hud pad Q a a _ o a a ot pg oc a 19 There are several types of spark plugs grouped according to the heating value thread diameter and construction as shown belaw NGK plug ND plug D Coy E E E Thread du Thresd de Heanng salua Tread langth 0 7 P Paralun projected 4 1Hottyps
394. sxhaust pulsa scavenge effect is improwad E E TAPER OF THE WATEA EXPANSION Since the pressure wava cycle changes in accordance with the CHAMBER change in engine speed the exhaust pulse scavenge effect is not always as effective as it could be at all engine speeds The exhaust pulse scavange effect is regulated to a cartain range of engine speed Therefore the exhaust system is dasignad ta be most effective and most suitable for each model depanding on its intended use Note that if the exhaust system is deformed due to denting or exhaust 945 leakage it can effect the exhaust pulse and result in a drap in engine horsepower COMMON EXHAUST PIPE The muffler of the conventional 4 stroke muhicylindar engine uses an independent pipe for each cylinder but most recent modets adopt a common exhaust pipe for all cylinders The new system features a system in which the exhaust pipes join in tha exhaust chamber and another in which the exhaust pipes are diractly joined In both systams gas pressures ex hausted from individual cylinders intermingle The pulse wave in the muffler generated by the staggered combustion in ad joining cylinders promotes the pulsa scavenge effect which increases exhaust energy absorption and reduces ax haust noise affactivaly Tha resulting smaller muffler has a decreased capacity and increased silencing capability due to the reduced weight and decreased voluma The method of axhaust pips connacti
395. t and light weight DC voltage unit regulates the AC current to these systems There are systems and components used specifically tor AC alternating flash turn signals whose front and rear signals flash altarnately and AC horn which use electrical circuits and components dasigned for models without batteries AC REGULATOR THYRISTOR TO LOAD i E E REGULATOR ALTERNATOR WITH PROTECTION CIRCUIT 7 UNREGULATED VOLTAGE Fa f ir REGULATED YOLTAGC VOLTAGE V1 ENGINE RPM o AC REGULATOR DC VOLTAGE UNIT i LED LIGHTING CIRCUIT INDICATOR i OIL WARNIN LIGHT LED ae SPEED SENSOR OIL LEVEL SWITCH ALTERNATOR Date of Issue Sep 1988 HONDA MOTOR LTD BATTERIES CHARGING LIGHTING SYSTEM BATTERY REMOVAL INSTALLATION REMOVAL TERMINAL 4 POSITIVE NEGATIVE TERMINAL aa lit TERMINAL Wa Turn off the ignition switch Remove the terminal cover and disconnect the negative battery cable first and then disconnect the positive cabla ec Disconnecting the positive cable first could cause an accidental direct short betwsen tha two terminals when the tonl disconnecting the tarminal contacts the frame Tha spark could ignite ar damage the battary For conventional batterias always disconnect the braather tube before remaving battery NOTE Some electrolyte may remain in the breathar tubs i Keep slectrolyte away fram your eyes or
396. t as shown 20 mm id Date of Issue Sep 1988 10 8 HONDA MOTOR CO LTB CYLINDEA PISTON 2 stroka Engines 2 STAOKE ENGINE Clean the piston ring grooves TOP RING oo SECOND Baa RING Lubricate the piston rings and ting grooves with clean 2 stroke oil Install the piston rings on the Piston with the marks facing up NOTE EXPANDER i Do nat confuse the top and second rings Be sure to in stall them in the proper grooves Some 2 stroke engines use an axpander ring behind the second ring C a In 2 stroke angines the piston has locating pins that hold the 2 STROKE ENGINE LOCATING PINS piston rings away from the intake and exhaust parts _______ Align the piston ring end gaps with the locating pins Check the fit of each ring in its groove by pressing tha Ting into the groove Maka sure that it is flush with the piston at several points around the ring if the ring rides on the locating pin it is damaged during assembly PISTON INSTALLATION Coat the needle bearing 2 stroke engine only and piston pin 4 STROKE ENGINE with the recammendad oil Lubricate the piston pin 4 STROKE ENGINE Molybdanum solution 2 STROKE ENGINE Recommended engine oil NOTE j Place a clean shop towel over tha crankcase to prevent the clip from falling into the crankcese Install the needte bearing into the connecting rod Instal
397. t damage The use of ather pro cadures without using the specified speciai toals may damage the parts Clean the outside of a part or assembly before ramoving it from the motorcycle or opening its cover for service Dirt which has accumulated on the autside cauld fall into the angine chassis or brake system and cause damage later Clean the parts after disassembly but before measuring them for waar Parts should be washed in high ftash point solvent and dried with compressed air Beware of parts containing O rings or oil seals since these are adversely af foctad by most cleaning solvents Control cables must not be bent ar distorted This will lead to stiff operation and premature cable failura WRONG WRONG Rubber parts can deteriorate with age and are highly susceptible to damage from solvents and oils Check thesa parts before reassembiy and replace as necessary Date of Issue Sep 1988 HONDA MOTOR CO LTD Loasening a part with muitiple fastenars sizes should be done from tha dutside to inside in a crisscross pattern loosening tha small fasteners first Loosening the big fasteners first will place an excessive force on the smaller fasteners Complex assemblies such as transmission parts should be stored in the praper assembly order and held securely with wire This will simplify reassembly at a later date Reassambly position of critical parts should be noted before the parts are disassembled This will
398. t groove to prevant ail or water leakage ROTOR INSTALLATION Clean the taperad portion of the crankshaft lf the rotor is installed with dust or dirt on the taper the taper will not maka secure contact with the rotor and there will be axcessive force on the woodruff key Insert the woodruff key into the key groove in the crankshaft Set tha rotor groove to the woodruff key and install the rotor on the crankshaft Tighten the retor bolt ar nut with your fingers CAUTION Before installing the rotor check that no nuts or bolts are magnatically attached to the rotor Installing the rotor with anything attached ta it could damage the stator gail Hold the flywheal rotor with a hofder and tighten the bolt nut to the specified torque STATOR STATGR e WOODRUFF KEY CRANKSHAFT HOLDER Use the same holder used to remove rotor bolt 22 28 Date of Issue Sep 1988 HONDA MOTOR CO LTD it ry Pa fos PV BATTERIES CHARGING LIGHTING SYSTEM Before bolting on the crankcase cover check that the wires ar not pinched Install tha crankcase cover onta the engine CAUTION Use tha crankcase white metallic ground bolt to ensure continulty between the engine and crankcase cover All othar crankcase bolts are black The whita bolt must be grounded propery to allow the elactrical system ta operate normally NOTE WHITE METALLIC BOLT Forreassembly ins
399. tall the white metallic bott in the case bole with the unpaintad seating surfaca Date of Sep 1988 HONDA MOTOR CO LTD 22 29 ey es 23 IGNITION SYSTEMS SERVICE INFORMATION 23 1 IGNITION TIMING 23 11 TROUBLESHOOTING 23 1 IGNITION COIL 23 12 SYSTEM DESCRIPTIONS 23 4 CDE SYSTEM 23 13 SPARK PLUG 23 9 TRANSISTORIZED IGNITION SYSTEM 23 16 SPARK TEST SERVICE INFORMATION GENERAL Folow the steps described in the traubleshoating flow chart when servicing the ignition system Tha CDI unit and transistorized ignition system use an alectricaily controlled ignition timing system No adjustments can be made ta the ignition timing For multi cylinder engines a rough diagnosis can be made by idantifying the cylinder whose spark timing is incorrect The CDI unit and the transistorized unit may be damaged if dropped Also if the connector is disconnected when current is flowing the excessive valtage may damage the unit Always turn off the ignition switch before servicing A faulty ignition system is often related to Poorly connected connectors Check thasa connections before proceeding For models with an electric starter make sure the battery is adequately charged Using the starter motor with a weak bat tery results in a slower engine cranking speed as well as a weak Spark at the spark plugs Use spark plugs of the correct haat range Using spark plugs with an incorrect heat range can damage the
400. tar to the Tool Compatibility Charts on the following pages MANUFACTURER S NAME BEARING No APPLY GREASE BEFORE ASSEMBLY OH GUIDE PLATE ATTACHMENT INNER RACE Date of Issue Sep 1988 HONDA MOTOR CO LTD 1 15 GENERAL INFORMATION TYPE TOOL COMPATIBILITY CHART FOR STAN DARD BEARINGS SINGLE SEALED wee ee NN E r Bearing Size Select the bearing tool according to the size stamped on the bearing race ATU of ZY indicates a bearing with a metal shield or rubber saal respectivaly These letters have no connection with bear ing size and can be ignored U Single sealad type Z Singla sealed type UU Double metal sealed type MANUFACTURER S ZZ Double rubber sealed type NAME BEARING No Bearing Remover Compatibility for Wheel Bearing Lise the ramover heads listed below in combination with shaft BEARING NUMBER 07 746 0050100 ea e 10 BEARING REMOVER HEAD _TOOL NUMBER Thera is a kit comprising of 10 20 mm ramover heads and 6200 shafts 6300 Ese eo Wheal Bearing Hemover Kit 07746 0050001 6201 i 12 07746 0050200 6301 6002 6202 15 07746 0050400 6003 6203 1 0 746 0050500 6203 6004 6204 6304 07746 0050200 07746 0050600 Bearing Remover Compatibility Table BEARING ID TOOL NUMBER 7 60 lt __ ____ T NUMBER BEARING REMOV ARING REMOVER
401. tarter motor and check the compression NOTE To avoid discharging the battary do not operate the electric starter far more than seven seconds 3 2 Date of Issue Sep 1988 7 HONDA MOTOR CO LTO ENGINE TESTING ye gee eres lf compression is low drop smail amount of claan engine oil in to the cylinder than rachack the compression If compression increases to more than the previous reading Inspect the cylinder and piston rings If Compression remains low check the valvas valve seats and cylinder head If compression is high check for the accumulation af var bon dapasits in the combustion chamber and ar the piston head LEAK DOWN TESTING 4 STROKE LEAK DOWN TEST INFORMATION lt lt a ATTACHMENT PRESSURE SIDE A teak down test is an mora comprehensive engine diagnostic test than a comprassion test The eak down tester cansists of a calibrated pressure gauge connected to a pressure regulator and a flaw restrictor The taster allows you to measure the rate at which air leaks past a ylinder s rings and valves There are several tools specifically designed for leak down testing 4 strake angines that are commercially available from several general tool sources i Sette BRAKE BLEEDER VACUUM amp PAESSURE PUMP A leak down test provides a clear indication of whether ar not COMMERICIALLY AVAILABLE the combustion chamber is sealing properly The test involves press
402. te of issue Sep 1988 HONDA MOTOR CO LTD ELECTRIC STAATER STARTER CLUTCH CLUTCH HOUSING ONE WAY CLUTCH REDUCTION GEAR 24 9 25 LIGHTS METERS SWITCHES SERVICE INFORMATION 25 1 LOW FUEL INDICATOR 25 8 OIL PRESSURE WARNING LIGHT FUEL PUMP 25 9 4 STROKE ENGINE i ae ee ee 2 STROKEENGINE E ii aata ADTI STA 25 4 TURN SIGNAL LIGHTS 25 16 COOLANT TEMPERATURE GAUGE 25 5 HORN aii FUEL GAUGE 25 7 SERVICE INFORMATION Halogen headlight bulbs become very hot while the headlight is ON and remain hat for a while after they are tumed f OFF Ba sure to lat them cool down before servicing Use a flame and heated watar coalant mixture for the therma sansor inspection Keep all flammable materials away fram tha flame Wear protective clothing gloves and eye protection ee Refer to the section 21 for the general service rules This section covers the general inspection service procedures of the lights meters and switches Refer to the Maudel Specific manual for the location and arrangement of components on the model being serviced Nate the followings when replacing the halogan headlight bulb Wear clean gloves while replacing the bulb Da not put finger prints on the headlight bulb as they may craate hat spots an the bulb and cause it to break If you touch the bulb with your bare hands clean it with a cloth moistened with alcohol to prevent its early failure
403. ted across the two paths The voltage on each load is the same but the current branches out ta each load the cut rent flaw to each load can ba calculated as il 1r1 i12 Fra The total current l is the sum of all current fiowing to each load DIODE The diode allows current to ffow in only one direction Whan current is flowing thare is a slight voltage drap across the diode ZENER DIODE Tha zener diode allows current to flow in one direction similar to the diode above When a certain reverse voltage is applied current abruptly flaws in the reversa direction When the voltage is reduced below the ravarse voltage current flow in the reverse direction stops SERIES CIRCUIT CURRENT FLOWS NORMAL DIRECTION CURRENT DOES NOT FLOW REVERSE DIRECTION ZENER DIODE X CURRENT REVERSE VOLTAGE CURRENT FLOWS NO CURRENT FLOWS BELOW REVERSE VOLTAGE CURRENT FLOWS ABOVE REVERSE VOLTAGE 21 10 Date of Issue Sep 198 HONDA MOTOR CO LTD ELECTRICAL FUNDAMENTALS THYRISTOR SCR THYRISTGR Thyristors have three terminals anade cathode and gate Tha currant flowing from the anode to cathode is said to be in B 2 the positive direction Like diodes thyristors do not flow current in the negative ANODE A K CATHODE diraction Thyristars allow current to flow from anode to cathode only when the thyristor is turned an G GATE lt NO C
404. tential dif ference causes current to Flaw through a circuit The pressure of the current is measured as voltage V POTENTIAL DIFFERENCE VOLTAGE RESISTANCE As everyone knows water flows through a larger pipe easier than a smaller pipe This ts because tha smaller pipe provides greater resistanca Similarly electrical current flows through a thicker wire conductor more easily than a thinner wire The resistance limiting the flow of efectricity through a wire is measured in Ohms 2 ry Resistance increases as the size of wire become smaller and BATTERY longer This resistance value can be measured with an ohmmeter _ THIN WIRE THICK WIRE LARGE RESISTANCE SMALL RESISTANCE 74 g Date of Issue Sep 1998 HONDA MOTOR O LTD ELECTRICAL FUNDAMENTALS r cc OHM S LAW The amount of current flowing through a conductor in a closed circuit is propartional to tha voltage applied to the conductor The relationship betwean yoltage and current flow and resistance is known as Ohm s law For exempla if a 6 Q resistor is connected to the and ter minals of a 12 V battery the current flowing through the resistor can be calculated by Ohm s law Currant Voltage Resistance 12 6 2A POWER We use electricity to operate headlights ar starter motors ar we convert it to haat The amount of wark required ta do these things is measurad in Watts Changing voltage Volts or the
405. ter position the outlet Passage is completely closed while the inlet passage is completely opened allowing free flow of oil into the pump chamber 3 With the oil chamber filled the valve ascends closing the inlet passage i4 The valve ascends further allowing free flow of oil through the outlet passage 5 The plunger also ascends compressing tha oil insida the pump chamber and pumping oil aut through the outlet passage towards the intake pipe via the outlet ling ne yer yy Date of Issue Sep 19B6 4 8 HGNDA MOTOR CO LTD LUBRICATION OIL PRESSURE CHECK NOTE This procedure is for vehicles equipped with an oil pressura switch Ifthe engine is cold the pressure reading will be abnar mally high Warm up the engine to normal operating temperatura bafore starting this test Refer to the Model Specific manual for spacifications Stop the engine and pull off the switch cover Disconnect the switch wire by removing the screw Turn the ignition switch ON and check that the oil warning light does not come an lf the warning light comes on there is a shorted circuit in the switch wire Repair or replace as necessary Remove tha oil pressure switch isee the Model Spacific manual Install the attachment as necassary and connect the oh pressure gauge G Toar OIL PRESSURE GAUGE 07506 3000060 ATTACHMENT Refer to Modet Specitic manual Check the oil level and add the recommended oil i
406. ter to large diameter When tightening cylinder head bolts hand tighten the bolts and nuts then torque large bolts and nuts before small ones in a crisscross pattern from inn r to outer in two or three gradual steps If itis no longer clear which bolt belongs in which should be axposad the same amount TROUBLESHOOTING Engine top end problems usually affect engine performance by tracing noises to the top end with a sounding rad or stet Low compression Valves Incorrect valve adjustment sae section 2 Burned or bent valves incorrect valve timing Broken valve spring Uneven valve seating Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Cylinder piston see section 10 Leaking crankcase Primary Compression 2 stroke engine Blown crankcase gasket Damaged crankshaft oi seal Excessive white smoke 4 stroke engine Worn valve stem ar valva guide Damaged stem saal hole insert all bolts in the holes and check tha exposed lengths each These can he diagnosed hy a compression ar leak down test or hoscope Rough idte Low cylinder compression Incorrect decomprassion adjustment Comprassion tao high Excessive carbon buitd up on piston or combustion chamber Excessive noise Incorrect valve adjustment Sticking valva or broken valve spring Damaged or worn camshaft Loose or worn cam chain Worn or damaged catn chain lensioner
407. terclockwise the air screw clockwise to Its origina position and reinstall the stan dard main jet as necessary and adjust the idle Speed to the Specified rpm Ha sure to make these adjustments at low altitude 8 24 Date of Issue Sep 1988 HONDA MOTOR CO LTD es SERVICE INFORMATION TROUBLESHOOTING SYSTEM DESCRIPTION CAMSHAFT ROCKER ARM ROCKER ARM SHAFT CYLINDER HEAD INSPECTION CYLINDER HEAD DISASSEMBLY SERVICE INFORMATION 9 1 VALVE SPRINGS VALVES 9 8 VALVE GUIDES 9 9 VALVE SEATS 9 11 CYLINDER HEAD ASSEMBLY 9 74 INITIAL CAMSHAFT LUBRICATION 9 15 Refer ta Engine Testing section 3 for cylinder Compression and leak down testing Remove accumulated carbon from the cylindet head of two Camshaft lubricating oil is fed through oil Passages in the cylinder head Stroke anginas as described in the Mode Spacific manual ylinder head Clean the oil Passages before assembling the Clean all disassembled Parts with cleaning solvent and dry them by blowing them off wrth compressed air before inspection Before reassembly lubricate the siding surfaces of the Parts see each Madel Specific manual far lubrication When disassembling mark and store the disassembled Parts to ensure that they are reinstalled in their proper locations Loosen the cylinder haad boits in a crisscross pattern in two or three steps from outside to canter and fram small diame
408. that is installed against tha judder spring has a larger I D than the other discs r CO aua auaa aaaaaaaaa JUDDER SPRING SPRING Coat the push rod with grease and install it into the mainshaft Install the lifter rod and steel ball if removed Install the bearing in the lifter plate then install the clutch springs pressure plate washers and clutch spring bolts SPRING WASHER AND BOLT Tighten the clutch spring bolts Type Install the clutch outer guide naedle bearing and clutch outer See page 11 19 Install clutch center A and the washer WASHER HONDA MOTOR CO LTD CLUTCH Install the clutch center B the one way clutch and one way clutch inner as an assembly onto the clutch outer NOTE See page 11 18 for one way clutch assembly Make sure that the One way clutch is installed correctly by turning clutch center B Tha clutch canter should turn in the specified direction freely and should not turn in the opposite direction CLUTCH CENTER B ONE WAY CLUTCH AND ONE WAY CLUTCH INNER Coat the clutch plates and dises with clean engine oil and in Stall ther in the clutch outer and on the clutch center NOTE Two discs have different groove pattarns than the other discs Install thase two in tha SECOND and THIRD disc positions from the mainshaft De not move clutch center B after installing the discs and
409. the mark toward left F FRP Indicates the front side of the vehicle RRR e00 Indicates the rear side of the vehicle QUT OUTSIDE Instat with the letter toward out LOWER Indicates lower level UPPER FULL Indicates upper level 4e wore ss Indicates the rotating direction if stamped on the rotating part If a punch mark 4 is stampad on a part it indicates the installation direction or alignment point Pay attention to the mark when assembling Date of Issue Sep 1988 HONDA MOTOR CO LTD eeeeeeFsSsesesese GENERAL SAFETY SERVICE RULES GENERAL SAFETY Carbon Monoxide If the engine must be running to do some work make sure the area is well ventilated Never run the angine in an enciosed area Ac oo o o o i The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may j tead to death a Run the engina in an open araa or with an exhaust svacua tion systam in an enclosed area Gasoline Work in a wall ventilated areg Keep cigarettes flames ar Sparks away from the work area or whera gasoline is stored WARNING undar certain conditions KEEP OUT OF REACH OF GHILDREN Battary Hydrogen Gas amp Electrolyte The battery gives off axplosive gases keep sparka flames and cigarettes away Provide adequate ven i tilation when charging The battery contains sulfuri
410. the shift fork areas TRANSMISSION ASSEMBLY Claan all parts in solvent Apply molybdenum disulfide grease to all sliding surfacas of the mainshaft countershaft and bushings to ensure initial lubrication GEAR THRUST LOAD Reassemble all parts into their original positions NOTE E Always install the thrust washers with the chamfered i rolled edge facing away from the thrust load After installing a snap ring slightly open the ring and rotate it in its groove ta be sura it is fully seated Do not use worn snap rings which could easily spin in the groove It would be too loose to Properly seat in the groove Align the gap in the snap ting with the groove of the spline Date of Issue Sap 1988 HONDA MOTOR CO LTO 1 3 7 TRANSMISSION NOTE SPLINE WASHER Install the fock washar by aligning its tabs with tha grooves of the spline washer Do not forget to install the thrust washer at the end of the mainshaft and countershaft NOTE Align ail hole in the bushing or gear with shaft ait hole Instali the shift forks in the corract positions according to the location mark on each tork L mark Left side of the crankcase C mark Center of the crankcase VR mark Right side of the crankcase Turn the mainshaft or countershaft to ensure that the gears turn strioothly after reass
411. the springs if tha measurement is not within the sarvice limit NOTE x the vehicle has baan used for a long time the etutch spring free langth will ba shorten because the clutch Springs are compressed while the clutch is disengaged Replace the clutch Springs as a Set so that tha discs con tact evenly with the clutch plates Oo TF Cluteh Spring Type C Measure the free height of the clutch spring replace the spring if the measurement is lower than service limit ses fl Date of Issue Sep 1988 HONDA MOTOR CO LTO 1 1 a 1 7 One Way Clutch Typa Ci Check the inside surface of clutch center B for abnormal wear of damage replace as necessary Maasure the D of clutch canter B Replace if the service limit is exceeded CLUTCH Check the outside surface of the one way clutch inner for abnormal wear replace if necessary Measure the O D of the one way clutch inner Replace if the service limit is exceeded Chack the sprag for damage or excessive wear replace if ONE WAY CLUTCH INNER CLUTCH CENTER B Necessary Reassarnble the one way clutch as follows Install the sprag into the clutch center B with the flanged side facing up Install tha clutch inner into the spray by turning it in the specified direction with the gtoove facing up Hald the clutch inner and turn clutch center B as shown and check that the clutch center turns in the Specified direction but
412. ther way is acceptable oer However a spring with the coils on both ends tapered and the coils are closer together at one and progressive wound spring the widely spaced coils should be at the bottom FORK CAP Reassamble the removed parts spring colar etc Install a new O ring into the fork cap groava Scraw the fork cap into the fork tuba NOTE i ing into tha fork bridges and tightening the stem side pinch bolts INSTALLATION BOTTOM BRIDGE PINCH BOLTS Install the fork boot if the particular model uses ana Install the fork legs through the fork bridges by twisting while pushing them upward Position the lags in the clamps as specified in the Model Specific manual NOTE Sos a ed Fe Make sure that the cables and wire harnesses ara routed STEERING BOTTOM eo a correctly BRIDGE Tighten the fork bridge pinch bolts to the specified torque Tighten the fork caps ta the specified torque Install the ramoved parts in the reverse order of removal Reter to the Model Specific manualt With the front brake applid campress the fark up and down several times to check for proper fork operation FORK CAP BOLTS Date of Sep 1988 18 10 HONDA MOTOR CO LTD FRONT SUSPENSION a ra aa N HANDLEBAR S BRAKE LIGHT SWITCH 7 ONE PIECE TUBULAR TYPE Removal Remove the following Rear viaw mirraoris Handlebar switches Throttle cable Brake and clutch levar brackets
413. tilizes two voltage faed back mathads Internal voltaga regulation method The right circuit is the most basic regulator citcuit Tha signal from the charging coil is half wave rectified through diode D1 which is inside the regulator rectifier circuit and is then fed to the battery Voltage is reguiated by the voitage regulation circuit and the SCR thyristor As the engine rpm rotation per minute increases the output of the alternator increases and that output is rectified by diode D This singnal then goes to the zener diode ZD Current flows in the normal diraction of the zener diode but does not flow in the reverse direction until a certain amount of voltage is applied in the reverse direction Then this voltage is raached the zener diode abruptly conducts currant in the raverse direc tion In this way if the engine rpm increases and a certain voltage level is appliad to the ZO current is fed to the gate of SCA which then turns ON When the SCR turns ON the output from the alternator is shorted to ground through SCR For this reason if the ground wires of the regulatar ractifier are broken or poorly connected the battery becomes overcharged For alternators with the charging lighting coil combined icharging and lighting systems poward by the same coil the headlight lighting system affects the performance of battery charging Since the input of the lighting systam is taken from the charging coil if the load of the
414. tinuity between the ground wita yellow rad and ground CONNECTOR if there is continuity only when the starter switch is pressed the ground circuit is narmal OPERATION CHECK Apply battery voltage batween the two relay coil terminals Check for continuity between B ibattery and M rotor tarminals 4Clrevit Ae Apply battery voltage between yellow red and green rad terminals lf there is cantinuity between B and M terminals it is normal Date of Issue Sep 1988 HONDA MOTOR CO LTD 24 7 ELECTRIC STARTER STARTER CLUTCH lt Circuit B gt Whan battery voltaga is applied between the starter relay a Ayi greenyellow wire and yellow red terminals there should ba k SWITCH continuity between the red and rad white terminals The rer minals are distinguished by the corresponding wire color of the wire harness connector CLUTCH SWITCH DIODE INSPECTION The purpose of the clutch switch diode is to prevent ravarse current flow from the neutral indicator ta the clutch switch Fauity diode Neutral indicator turns ON when clutch is disangagad Loose connections at dioda terminal Starter motor do s not turn when transmis sion is in neutral Check for continuity between diode terminais When there is continuity a small resistance valua is measured CLUTCH SWITCH DIODE If thera is continuity in one direction the clutch switch diode is goad Turns in one direction only DRIVEN GEAR
415. to a serous injury i Troc SNAP RING PLIERS 07914 3230001 NOTE In case of stopper ring using a small scrawdriver install the stopper ring inta the groove taking care nat to damage the fork tube Install the dust seal using the fork seal driver Pour the specified amount of ATF into the fork tube Pump tha fork tube several times to remove trapped air from the lower portion of the tube Compress the fork leg fully and measure the oil lavel from the top of the tube Wipe the oil off of the spring thoroughly using a clean lint free shop towel FORK SEAL DRIVER ss ATTACHMENT DUST SEAL SNAP RING PLIERS DUST SEALD STOPPER RING OIL SEAL BACK UP RING GUIDE BUSHING STOPPER RING Date of Issue Sap 1988 HONDA MOTOR CO LTD 18 9 FRONT SUSPENSION Pull the fork tube up and insert the spring FORK SPRING NOTE BOTH ENDS TAPERED SHOWN Mast fork springs are designad to be installed with a ee re WN specific and toward the top and bottom One end tapered install the spring with the tapered end toward down Both sides tapered spring may be install WIDELY FORK SPRING ed with either end down SPACED ONE END mag If the coils on only one end ara taperad this and should COILS TAPER SHOWN be at the bottom If the coils at both ands are taperad j and the distanca between each of the coils is the same BOTTOM 4mm a straight wound spring ei
416. to break the bead from the rim NOTE Do not break the bead all at once Remove and reposition the compressor and arm 1 8 of tha circumfarenca of the rim Tighten tha comprassor bolt Break the bead by repeating this procedure 3 4 timas OE OE pu oY wam If the bead braaking is difficult with the narrow end A side of the breaker arm use the wide end B side of the arm and repeat the procedure in the previous step After removing the tire from the rim cut tha valva off at tha bottom being careful not ta damage tha rim NOTE Be sure to replace the valve with a new one whanaver the tire is ramoved from the rim TIRE REPAIR re Use the manufacturer s instructions for the tire repair kit you are using Mf your kit does not have Instructions use the procedures provided here Check tha tire for the puncturing objects Chalk mark the punc tured area and ramove the object Inspect and measure the injury Tira repairs for injurias larger than 15 mm 5 8 in shayld ba a section repair Section rapairs should he done by a professionali tire repair shop If the injury is smaller than 15 mm 5 8 in proceed with the repair as described here Date of Issue Sep 1988 1 6 20 HONDA MOTOR CO LTD w WHEELS TIRES 0 Scene ee Install a rubber plug into the hole as follows Apply cement to a plug inserting needle and work the needle into the hole ta clean and lubricate it Do this three time
417. to the Model Specific manual for service data NOTE Resistance value will not be accurate if the probes te probes touc your fingers Use tha following recammended multitester Using another manufacturer s equipment may not ailaw you to abtain the specified values This is due to the characteristic of semiconductors which have different resistance values depending on the applied voltage SPECIFIC MULTITESTER 07411 0020000 KOWA Digital type KS AHM 32 063 KOWA Digital tyne USA ony 07308 0020067 SANWA Analogue type TH 5H K WA Analogue type Select the following range SANWA Taster k2 KOWA Tester x 100 Anold weak multitester battery could cause inaccurate readings Check the battery if tha multitester ragisters incorrectly When using the Kowa multitester remember that alt readings should be multiplied by 100 Hi If the rasistanca batween the terminals is out of standard value replace the regulator with a new ane Date of Issue Sep 1988 HONDA MOTOR CO LTD BATTERIES CHARGING LIGHTING SYSTEM AC REGULATOR 22 25 BATTERIES CHARGING LIGHTING SYSTEM ALTERNATOR CHARGING CHARGING LIGHTING COIL INSPECTION baal It is not necessary to remove the alternator from the engine Disconnect the aiternatar connector and check continuity be tween the wires A For single phase coils whose end is grounded measure the resistance betwee
418. toward up pour the kerosing from the CHAMBER exhaust port inte the cylinder head wait for a few minutes and check for kerosine leakage If kerosina leaks from around the valve it indicates faulty seal ing of tha valve seat Remove the valve from tha cylindar head and check e following Valve seat for damage page g tt Valve seat contact face page 9 11 Valve stem far band or damage page 9 8 m WARPAGE INSPECTION a l STRAIGHT EDGE Remove carbon deposits from the combustion chamber and clean off the head gasket surfacas aa NOTE Gaskets will come off easier if soaked in high flash paint cleaning solvent 2 j CAUTION e Avald damaging the gaskat and valve seat surfaces T ee FEELER GAUGE Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a Straight edge and fealer gauge Repair or replace the cylinder head if Warpage axceeds the ser vice limit Refer to the Model Specific manual Date of Issue Sep 1988 HONDA MOTOR CU LTD 9 7 CYLINDER HEAD CYLINDER HEAD DISASSEMBLY E VAVE SPANG COMPRESSOR Remova the cylinder head according to the Modal Specific n manual l ATTACHMENT Remove tha valve cottars with the valve spring compressor TOOL VALVE SPRING COMPRESSOR 07757 o0010000 and ATTACHMENT as necessary CAUTION Compressing the valve springs more than necessary will cause lo
419. ture by aligning the intake port from the car buretor to the combustion chamber 2 STROKE ENGINES COOLING FIN CYLINDER HEAD t PISTON 4 STROKE ENGINES SQUISH AREAS CARBURETOR INTAKE PORT Date of issue Sep 1988 9 2 HONDA MOTOR O LTD CYLINDER HEAD VALVE TRAIN The current valve train designs used on 4 stroke engines is divided into 3 types a conventional chain drive a balt drive with considerabie noise reduction and a geat drive used in high performance engines A chain drive is the most commonly used mechanism for current valve train design Its simpla construction allows for lower cost of manufacture Some maintenance ig raquired however because eventually chain elongation increases chain noise Chain maintenance js not required with types using an automatic cam chain tensioner Tha automatic cam chain tensioner Provides spring support by pressing the chain in the direction of tension and locking against any Countat pressure This pro vides the automatic alimination of chain slack TENSIONER WEDGE hat used on Honda automobiles This type is usad on engines requiring by gear This type has minimal friction loss from valve driva and rnain tains accurate valye timing even at high engine speads Accardingly this type is adopted for spart Machines The camshaft driva gear machanism between tha crankshaft and the camshaft is of a cassette type allowing sasisr mount ing removal of the camshaft
420. ubrication fl to the cylinder piston rings connecting rod and crankshaft rel He a CRANKSHAFT bearings Each system type religs an oil ingested together with Eta the gasoline tn Separate Oi systems engine lubrication oil is CRANKCASES introduced downstream of the carburetor Oil is cambined with tha gasoline before it reaches the carburetor in Premixed systems CRANK WEIGHT CONNECTING ROD SEPARATE OIL SYSTEMS Virtually all street motorcycle and scooter two stroke enginas use a pump operated system to lubricate engine components Oil inthis typa of system is drawn from 4 separate oil tank by an oil pump that introduces the oil directly into the air fusl inlet tract heyond the carburetor Periodic lavel checks and refilling of the oil tank is required since the oil in the tank is continually drawn upon when the engine is running FUEL TANK CARBURETOR OH TANK on FILTER CHECK VALVE The amount of lubricant delivered to the engine is dependant on both engine rpm and throttle position Same of these systems include provisions for circulating the transmission ail within the gearbox portion of the crankcases with the same oil pump CONTROL ARM Data of Issue Sep 1988 HONDA MOTOR CO LTD LUBRICATION PREMIXED OIL IN FUEL SYSTEMS Premixing angine oil with gasoline is the most widely used system on competition models The combined air fuel oil mixture is introduced directly through th
421. ucing single phase alternating currents independently The output of the alternatar is thraa single phase AC wave forms where each is 120 out af phase with each other i TRIPLE PHASE AC WAVE A9 o TRIPLE PHASE ALTERNATORA The symbol for this alternator has only three coils as in the diagram The actual stator coil consists of several coils con nected in series The triple phase output type is used in angines of medium to i rge displacement with large etectrical loads Depending on haw the coils are connected there are two symbols tor this type Servicing is the same for both typas Most triple phase output types are used in electromagnetically induced type alternator which has a permanent magnet an the CHARGING COIL rotor The excited field coil type alternator feeds currant to the field coil to magnetize the rotor which then acts like a perma FIELD COIL nent magnet The symbol for this type has a field coil alang with the charging coil SYMBOL REGULATOR RECTIFIER The regulator rectifier uses semiconductors such as thyristors which radiate heat in operation Thus these companents use printed circuit boards which are resinad onto an aluminum case The aluminum case has many fins for better heat dissipation As tha anging revolutions increase the output valtage of the alternator aiso increases The function of the requlator rec tifier is to keep this AC output voitags within a cartain range and to conv
422. ue Sep 1986 HONDA MOTOR CO LTD 2 1 5 ELECTRICAL FUNDAMENTALS BASIC ELECTRONIC KNOWLEDGE All matter whether solid fiquid of gas ara a collection of molecules and each molecule is made up of ators Each atom consists of a nucleus which is made up of protons and neutrons and electrons which circle around the nucieus Electricity flows when these electrons freely move outward from their orbits Some materials become conductors when there are a lot of trea electrons and soma become insulators when there are no free electrons It is a well known fact that when a piece of glass is rubbed with silk cloth it generates Static Electricity attracting a piece of paper towards it This happens because the free electrans in glass move into the silk dua to tha heat ganatated by rubbing As a result the glass takes on a positive charge and the silk cloth takas an a negative charge CURRENT FLOW When a positive charged material and a negative charged matarial are connected with a conductor free electrons flow from negative charged tu positive charged material This flow of electrons is called electricity For a iong time it was thought that electrical current flowed fram the positive side of the sourca to the negativa side When il was discovered that electrons actually flow the other way it was tao late to change existing publications on alectricity As a result just for convenienca tachnical publications Gampromise by say
423. uld be repaired using a small flat blade scrawdriver COOLING FAN Heat is dissipated into the atmosphere because of the dit ference in tamperature between the air and the coolant which has absorbed the heat If however the engine is not in operation iait around the AIR ABSORBED radiator is stagnant or when the atmospheric temperature is COOLANT HEAT high since tha tamperature diffarence between the atomasphere and the coolant becomes smaller heat dissipa tion is decreased adversely affecting engine capacity A cooling fan maintains the cooling performance under savere conditions It forces air ta flow through the radiator and around COOLED COOLANT the engine to dissipate heat whether the machine is moving or not COOLING FAN SWITCH ae a ee COOLING FAN ray E COOLING FAN SWITCH The fan switch automatically starts or shuts down the cooling fan depending an the temperature of the coolant Vvhile the fan motor switch resistance is normally tao high to conduct a cur rent when the coolant temperature is low when the coolant temperature rises tha switch resistance is reduced enaugh ta conduct current and causes the cooling fan to turn Data of issue Sep 1988 HONDA MOTOR CO LTD COOLING SYSTEM RADIATOR CAP Tha boiling point of the coolant may be increased by providing a pr ssure type cap heraafter radiatar cap on the coolant in let The radiator cap serves to increase the coolant t
424. units Thread type used on bicycles BC 3 2 Spokes and nipples j Spark plug threads M 12S j Spark plugs f Automobile tire A Valva stem TVB Tira valve stam The figures given abova represent screw sizes An example is given for sach type of screw or thread type THREAD SIZES WIDTH ACROSS FLATS TOGL SIZE MALE THREAD GIAMETER THREAD SIZE Thread sizes are rapresented by mala thread diameters Wid ths across flats represent applicable tool sizes Note that these widths are not related to thread sizes On Honda motorcycles scooters and ATVs the size of tha bolt nut or screw is considered to be the thread diameter 1 6 Date of Issua Sep 1988 HONDA MOTOR CO LTD GENERAL INFORMATION WIDTH ACROSS FLATS The width acrass flats is the portion where tools such as 3 wrench or a socket are applied Applicable tool sizes are represanted by these widths The denamination of a 10 mm wrench for example represents a wrench to be used on hex heads with widths across flats of 10 mm On the right is a table to show representative widths across flats and thread sizes oftan used for Honda motorcycles Nat all widths across the flats are shown Soma other common widths across the flats are 22 24 27 30 32 mm ete Spark plugs have particular width across flats they should ba ramoved with spacial spark plug wren ches 116 18 and 20 6 mm
425. up of carbon is not removed periodically tha carbon accumulation increases to an excessive amount caus ing hot spots on tha cylinder head and pistan crown This may cause knocking due to praignition and may cause poor angine performance Accumulated carbon in tha exhaust part hinders the flaw of tha exhaust causing a drop in power output Therefore removal of accumulated carbon should be perform ad according to the maintanance schedute in the Model Specific manual PISTON HEAD CAUTION When removing carbon be caraful not to damage the combustion chamber piston and cylinder f COMBUSTION Take off the cylinder haad and remove the carbon From the piston crown whan the piston is in the top dead center position Remove carbon from the combustion chamber area of the cylinder head Take off tha cylinder and remove accumulated carbon fram the walls of the exhaust port EXHAUST PORT Remove any remaining carbon within the cylinder In liquid coaled engines be sure to remove carbon particles that may have fallar into the coolant jackets around the cylinder by blowing tham out with compressed air Refer to tha Madel Specific manual for the proper procedures for cylinder and cylinder head removal and installation a Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 1 5 MAINTENANCE CARBURETOR SYNCHRONIZATION NOTE A Carburetor synchronization adjustment is required to ad just the throttle valve opening and
426. urizing the combustion chamber and measuring the rate at which the air is lost past the rings and valves or head gasket A range of the allowable percentaga of feak down past the rings and valves is suggested by each tester manufac turer But perhaps more important than a determination of whather the engine needs repair is to find out more precisely where the problem fies The first step in the test is ta install the hose from the tool into the spark plug hole as you would in a compression tast Next position the crankshaft with the piston at top dead center Be sure to remove the wrench from the crankshaft after postion ing in case the air pressure against the piston puts the cranksahft in mation Then pressurize the combustion chamber with a steady regulated pressure again as instructed by the tastar manufac turer Now you simply listan to the airbox exhaust and crankcase filler cap to datarmine whether the intake valve s exhaust valve s or rings respectively are fsaking a a Date of Issue Sap 1986 3 2 HONDA MOTOR CO LTD ENGINE TESTING TUe Squirting a little soapy water around the cylinder and head mating area will teil you if tha head gasket is leaking to the autside atmosphere Checking for bubbles in the cooling system af a liquid cooled machine will tell you whethar or not the head gesket is laaking into the cooling passages The only thing this test wan t teil you is the differance between a head gask
427. use clip to grip the hose beneath the flared end of the fitting CAVITY eg ee Rubber or Plastic Dust Dirt Boots should be replaced securely in tha exact positions they were designed for q BOOTS 1 5 GENERAL INFORMATION OE ee FASTENERS A motorcycle is composed of a number of connected parts A variety of fasteners are used to connect these Parts Unlike permanant connection methods like welding riveting and glueing threaded fasteners are essential as a means of non permanent connection which can ba disconnected whenever necessary Roughty setimated the thread diameter is the O D of the male thread or the i D across the full width of the valleys of the female thread The pitch is the thread to thraad distance that a male female bolt moves in a turn TYPES OF THREADS Metric threads as specified by the International Standards Organization ISOQ are usad on HONDA motorcycles The typical ISO threads found an Honda products sre the following threads and pitchas Pitch imm Diameter imm Pitch mm Diameter mm 3 0 5 The few parts which do not have conventional ISO metric threads are listed below The threads are NOT INTERCHANGEABLE with conventional ISO matric threads Description Symbols typical axamples Parallel threads for tubes PF 1 8 7 Tapered threads for tubes PT 1 8 DIAMETER Example of application Oil pressure switch Thermostatic
428. ust be tightened further to align the tongue j Do not align the nut in a position where the locking tongue aligns but the nut torque is less than specified Bend the tongue ciaw to the flat face of nut or into the groove of 7 tha nut to lack the nut or bolt haad fom o gt O 3 yy RZ RIGHT WRONG Castie headed nut Important safety points on the Since repeated bending straightening frame damages cotter pins always use new cottar Axle nut j pins during assembly Brake torque rod Tighten the nut to the specified torque Then align the next possible pin hole while tighten ing the nut just beyond the specified torque Do not align the holes in a pasition where the nut torque is less than the specified torque inserting a cottar pin through a nut fbr p and bolt prevants loosening tL ath O gt RIGHT WRONG 7 Slip pin cetter pin Frame important safety paints j Since repeated bending straightening Brake rod damages cotter pins always use new cotter pins during assembly Although slip pins can be used again replace slip pins with new aneas if they are deformed or fatigued When using a cotter pin or slip pin on suspension and wheel components install the pin with the head facing forward Ii in Stalled in the opposite diraction thase pins may be bent and eventually brokan and knocked out due to hitting stationary objects Inserting a
429. ust pipe may nat saat properly Always inspect the exhaust system for leaks after installation TROUBLESHOOTING Excessive exhaust noise Broken exhaust system Exhaust gas leaks Poor performance Deformed exhaust system Exhaust gas leaks Clogged muffler Date of Issue Sep 1988 6 1 HONDA MOTOR CO LTD EXHAUST SYSTEM SYSTEM DESCRIPTIONS The exhaust systam servas other function in addition 10 discharging the exhaust gas Since the exhaust gas discharged from the exhaust part is pressurized and very hot it swalls suddenly and produces a lourd noise if it is discharged from the exhaust port directiy into the atmosphere It also lowers the exhaust efficiency as the gas is diffused from the exhaust port To prevent the above problems the axhaust gas is drawn from the exhaust port into the muf fler to be swallad and is discharged into the atmosphere after its temperature and pressure are lowered By varying the sizes and diameters of sactions of the exhaust system the air fual mixture can be drawn inte the cylinder more effectively This is called the EXHAUST PULSE SCAVENGE EFFECT Utilizing this effect in axhaust system design results in significant im provements in engine performance especially on 2 stroke engines EXHAUST PULSE SCAVENGE EFFECT INTAKE VALVE OPENS When the exhaust valve or part opans with the engine on the exhaust stroke the exhaust gas flows rapidly from the ex haust pert into the muffl
430. ust saal spring is seated on the out side of the saal lips after installing the pivot collar Recheck the side stand movement WASHER DUST SEALS _ PIVOT COLLAR Date of Issue Sep 1988 HONDA MOTOR CO LTD 2 33 MAINTENANCE Inspection For Side Stand With Ignition Cut off Switch Check the spring for damage or logs of tension t Check the sida stand assembly for freedom of movement Lubricate the pivot bolt and tha side stand pivot area if necessary Tighten the pivot bolt and nut Refer to the Madel Specific manual for spacified torque SIDE STAND Check the side stand ignition cut off switch Sit astride the motorcycle and raise the side stand Start the engina with the transmission in neutral then shift tha transmission into gear with the clutch laver squeezed Move the side stand full down The engine should stop as the side stand is lowered If there is a probtem with the systam check the side stand switch SUSPENSION Compress the front and rear suspension a few timas On models with exposed suspension springs check for cracks and damage Loose worm or damaged suspension parts Impair vehi ele stability and control Repair or replace any damaged components bafore riding Riding a vehicka with fauity suspension increases your risk of an accidant and possi ble injury m auM Chack for squeaks in the suspension movement that could ir dic
431. ve been bent or have cracks as they may cause air leakaga Always change tha r m if there are any flaws over 0 5 mm in depth and 1 0 mm in width on the surface touching the bead Check the tire for overall condition and use a mild detergant solution on the bead Use only water as a lubricant whan removing or mounting tres Soap or other tire lubricants may leave a slippery residue that can cause the tite to shift on the rim Atira that shifts on the rim may lead to a sudden loss of alt pressura while riding and an accident could occur NOTE Bo sura to use motorcycle tire levers i Oo not use the detergent solution on low pressure tires Use water only If tha tire has an light mark yellow paint mark install tha tire with this mark aligned with the valve lf the tire has an arrow mark install the tire with the mark pointing in the direction of rotatian Stand the tire upright hold it with one hand and starting from the opposite side to the valve install one side of the tire on the rim as much as you can by hand Be sure to assembla in the sequence shawn Place the wheel on the level surface and install the remaining portion af the tire using two tire levars NOTE For easy assembly apply a mild dstergant solution to the j tire and rim mating surfaces Do not use the detergent solution an the tire and rim mating surfaces of the low pressure tiras Use water only rN TIR
432. voluma contracted the vent valve is Opened by atmospheric pressure and coolant from the reserve tank flows back into the cooling systam 5 4 Date of Issue Sep 1988 HONDA MOTOR C LTE COOLING SYSTEM RESERVE TANK As explained in thea preceding paragraph Radiator Cap tha reserve tank serves to temporarily store the reserve volume of the coolant This aids to control the coolant level in the cooling system The reserve tank is connected to the radiator by means of a siphon tube THERMOSTAT The thermostat is installed between the water jacket of the cylinder head and the radiator Tho thermostat helps warm wp ths engine by preventing coolant circulation when the temperature of the engine coolant is low by closing a valve lt is an automatic valve designed so that when the engine temperature increases thermostat wax expands to apen the valve allowing tha coolant to circulate through the radiator Even if atmospheric temperature varies the thermostat con trols the engine temperature at a constant level Leaving the thermostat open altows the coolant to circulate aven at low temperatures This prevents aptinum engina operating temperature and leads ta overcoaling Leaving the tharmastat closed contributes to overheating since it prevents coolant circulation and prevents the radiator from dissipating the heat if the engina temperature exceads the critical limit WATER PUMP The water pum
433. way Sprag clutch The inner portion of the clutch hub is splined to the transmis sion s mainshaft as is normal But it only controls about two fifths of the clutch plates and discs This Portion of the clutch transmits power and deceleration forces in the usual manner The outer portion of the clutch hub is not splined to the transmissions mainshaft It contrals about three fifths of the clutch plates and discs This Portion transmits power when the Sprag clutch is locked up such as during normal acceleration cruising end deceleration But it wit slip during high RPM deceleration OPERATION When the transmission ig dawnshifted from high RPM it Causes a backloading at the clutch because of the forces generated by the engine s compression braking effact If these forces approach that which wil cause the rear wheal to lock up the one way clutch will disengage the outer portion and allow the inner portion to slip It will do this to a degree that allows the rear wheel to maintain traction while maintaining the highest effact of engine braking So rather than being a harsh ON or OFF mechanism the one way clutch determines the correct amount of slip for aach situation all the white maintaining maximum possible engine braking effect 1 1 4 Date of Issusa Sep 1988 HONDA MOTOR CO LTD CLUTCH OPERATION During acceleration cruising and normal decaleration power is transmitted through the clutch in the normal man n
434. wed the victim must be forced to vomit then rinse mouth and throat with fresh water before obtaining medical attention Because al thase dangers always store coolant in a safe place away from the reach of children Brake Fluid CAUTION Spilling fluid an painted plastic or rubber parts will damage them Place a clean shop towel over these parts whenever the system is servicad KEEP OUT o REACH OF CHILDREN Brake Dust Never use an air hose or dry brush to clean brake assemblies Use an OSHA appraved vacuum cleaner or alternate method appraved by OSHA designed to minimize the hazard caused by aitborne asbestos fibers AWARNING Inhaled asbestos fibers hava been found to cause respiratory disease and cancer a e L Date of Issue Sep 1988 HONDA MOTOR CO LTD 1 1 GENERAL INFORMATION Nitrogen Pressure For shack absorbers with a gas fillad reservoir Usa oniy nitrogen to pressuriza the shack absorber The use af an unstable gas can causa a fire or axpio i sion r aulting in sarious injury The shock absorber contains nitragen under high Pressure Allowing fire or heat naar the shock ab sorber could laad to an explosion that could result in serious injury Failure to releasa the pressure from a shock absorber befora disposing of it may lead to a possible expla sion and sarlous injury If it is heated or pierced p _ To preve
435. wheal D f issue Sep 1988 16 16 HONDA MOTOR CO LTD WHEELS TIRES WHEEL BALANCING Refer ta the Modet Specific manual to verify whether or r the model being serviced requiras wheel balancing Tha manual wili specify the type of weights required if necessary Wheel balance directly affects the stability handling and overall safety of the motorcycle Carefully check balance bafore rainstalling the wheel Mount the wheel tire and brake disc assembly in an inspection stand Spin the wheel allow it to stop and mark the lowest heaviest part of the wheel with chalk Do this two or three times to verify the heaviest area If the whael is balanced it will not stop consistently in the same position To balance the wheel install wheal weights on the lightest side of the rim the side opposite the chalk marks Add just enough weight so the wheal will no lunger stop in tha same position when ir is spun ATV WHEEL TIRE REMOVAL INSTALLATION Lousen the wheel nuts Raise the rear wheels off the ground with a jack or block under the engine Remove the wheel nuts and wheel Install the wheel tn its original positian NOTE Do not interchange the right and left tires If the tire has i arrow mark install tha wheel with the arrow mark point ing in the direction of rotation Install the whee nuts with the beveled sides facing inward and tightan to the specified torque INSPECTION STAND
436. with the crankcass groove Prass it into place using a hydraulic MAIN BEARING press DRIVER AND ATTACHMENT CAUTION i Take care not to damage the inside surface of tha new i hearing during Installation T s MAIN BEARING Dale of Issue Sep 1988 HONDA MOTOR CO LTD CRANKCASE CRANKSHAFT CONNECTING ROD BEARINGS OIL CLEARANCE INSPECTION Check the bearing inserts for unusual wear or damage and replace as necessary Wipe all oil from the bearing inserts and crankpins Put a piece of plastigauge on each crankpin NOTE Do not put the plastigauge over the oil hola in the crankpin ey Install the hearing caps and rods on tha correct crankpins and tightan them evenly NOTE Do not rotate the crankshaft during inspection Remove the caps and measure the compressad plastigauga on each crankpin IF the rod bearing clearance is beyond tolerance select raplacament bearings 14 8 SK WWE i DAMAGE PLASTIGAUGES Date of Issue Sep 1988 HONDA MOTOR CO LTD CRANKCASE CRANKSHAFT 4 STROKE BIG END BEARING SELECTION Record the corresponding rod 0 code number 41 2 or 3 of measure the 0 with the bearing cap installed without bearing inserts Record the corresponding crankpin O D coda letter A B or C or measure the crankpin O D 9 B CODE LETTER Cross raference the crankpin and rod codes to determina the COLOR CODE replacement bearing color T
437. y assembly once with the drive belt installed DRIVE PULLEY NOTE lasing ___ closing Hold the pulley faces apart Preventing tham from Put the drive bheit over the drive pulley Reinstall the driven pulley on the drive shaft with the drive belt attached Install the clutch outer and tha universal holder Tighten the nut to the specified torque UNIVERSAL HOLDER 97725 0030090 Reinstall the laft crankcase cover see Modal Specific manual DRIVE PULLEY REMOVAL Remove the left crankcase cover see Model Specific manual Hold the drive pulley face using the drive pulley holder and remove the nut and washer Remove tha drive pulley face 4 TOOL DAIVE PULLEY HOLDER 07923 KM10000 If the drive pulfey holder cannot be used remove the cooling ca fan at the right side of the crankshaft and hold the flywheel with tha univarsal hoider UNIVERSAL TOOL J UNIVERSAL HOLDER 07725 0030000 Date of Issue Sep 1988 1 2 6 HONDA MOTOR CoO LTD V MATIC BELT DRIVE SYSTEM DISASSEMBLY MOVABLE DRIVE FACE Ramove the movabie drive face and drive faca shaft from the crankshaft Remove tha three bolts attaching the mavabla driva face seai and remove the seal Aemeve the ramp plate Remove the weight rollers and the O ring from the movable drive face Discard the O ting WEIGHT ROLLER INSPECTION WEIGHT ROLLER The weight rollers push on the movable drive pullay face by
438. y ground FAN MOTOR SWITCH NOTE The fan motor may continue to run even when the igni tian switch is turned OFF However this does nat necessarily indicate trouble specification the fan motor switch turns on to operate tha fan mator When the coolant temperatura is below the specifica tion it turns off to stop tha fan motor NOTE go coame en eI Scr a Cheek the caalant level and bleed air from the cooling system if the coolant is apt to overheat see page 5 6 for coolant replacement and air bleeding NITION FUSE SWITCH T E OIL LEVEL SwitcH INDICATOR Le N am ye ray z e Fa IGNIFION SWITC MAJIN FUSE a et E Fap FAN MOTOR RADIATOR 25 4 Data of Issue Sep 1988 HONDA MOTOR CO LTD a INSPECTION Fan motor does not stop 1 Turn the ignition switch OFT disconnect the connector from the fan motor switch and turn the ignition switch ON again t Motor doas nat stop Motor stops Shorted wira between Faulty fan motor switch the tan motor and switch Fan motor dogs not start 1 Disconnect the connector from the fan motor switch and ground the cannectar to the body with a jumper wire r Turn the ignition switch ON and check the fan motor Motor does not start Motar starts Faulty fan motor switch Poor cannectiun of the fan motor switch con nector 2 Check for the battery voltage betwaen the fan mator switch c
439. y speedometer gear Soft suspansicn Waak fark springs Telescapic type Insufficient fluid in fork Low fluid level in fark Faulty anti dive system Hard suspension Bent fork components Bent damper rod bottom link type Telescopic type Incorrect fluid weight Bent fork tubes Clogged fluid passage Front suspension noisy Worn slider or guide bushings bottom fink typet Insufficient fluid in fork Lapse fork fasteners Lack of grease in speedometer gearbox Y with a jack or other support under the angine E S 18 1 Date of Issue Sep 1988 HONDA MOTOR O LTD FRONT SUSPENSION SYSTEM DESCRIPTIONS Telescopic and pivoting link type front suspension systems are by far the mast widely used types on motorcycles and scooters Telescopic front suspension systems are made up of a pair of upper fork tubes and lower fork sliders that telescope into one another Within tha sat of tubes an either side is a spring and an oil damping system Some systems utilize a cartridge damper within the fork sliders Basically tha oil controls the natural tandancy of the spring ta continus to rebound in ever decreasing amounts in both direc tions ance acted upon by outside forces Forcing the oil in each fork leg through a series of small holas in effect separates the rider bike combination from both the unwanted characteristics of the spring and fram height variations in the riding Surface
440. ys in posi tion whan tha ignition switch is turned OFF Chack the fuel gauge if its needle dees not move INSPECTION 1 If the fuel unit connector has 2 tarminals shart the gauge tarminals with a jumper wire if the unit connector has 3 terminals short the gauga side yellowfwhite tarminal and green terminal with a jumper wire Turn the ignition switch ON and check tha gauge needle Needle does not mova Needle moves Chack the fuel unit Check for continuity between tha unit and fual gauge Continuity No continuity Broken wire between the unit and gauge Check for voltage at the black or black brown positive power tine and ground wires of the fuel gauge No voltage Voltage Broken positive power line Faulty fuel gauga FUEL UNIT INSPECTION Refer to the Model Specific manual for the fuel unit removal installation 1 Connect the fuel unit connector Turn the ignition switch ON Move the float up and down to be sure that the fuel gauge needle moves to F and RES If the needle does nat move go to the step 2 Date of Issue Sep 1998 HONDA MOTOR CO LTD LIGHTS METERS SWITCHES a i 2 TERMINAL UNIT MAIN FUSE FUSE IGNITION SWITCH J FUEL GAUGE FUEL GAUGE SENDING UNII 3 TERMINAL UNIT FUSE IGNITION SWITCH BI co FUEL FUEL GAUGE SENDING UNIT FUEL GAUGE LIGHTS METERS SWITCHES 2 Measure the resist

Honda Common Service Manual MOTORCYCLES

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