Honda Common Service Manual
Contents
1. Date of Issue Sep 1988 HONDA MOTOR CO LTD V MATIC BELT DRIVE SYSTEM INSPECTION Clutch Ourar Measure the I 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 service limit is exceeded Refer to page 12 12 for clutch shoe reptacement Driven Pulley Spring Measure the treo length of the driven pulley spring and replace if tha service limit is exceeded Driven Pulley Cheek the following Both facas tor damage or excessive wear Guide pin groove for damage or deformation Replace damaged or warn parts as necessary Measure the O D of the driven face and the LD of the movable driven face Replace either part if the service limit is exceeded m a CLUTCH OUTER LINING CLUTCH SHOE FREE LENGTH DRIVEN PULLEY FACE GUIDE PIN MOVABLE FACE GROOVE Date of Issue Sep 1988 HONDA MOTOR CO LTD 12 11 V MATIC BELT DRIVE SYSTEM Driven Face Bearing Inspection Check the innar bearing oil seal lit installed for damage replace as necessary Check the needle bearing for damage or excessive play and replace as necessary Tum the inner race of the outer bearing with your finger Check that the bearing tums smoothly and quietly and that the bearing outer race fits securely Replace the bearing if necessary2. NOTE NEEDLE BEARING OUTER BALL BEARING Ser modus wae two bal icing Refer to page 12 13 for bearing replacement CLUTCH SHOE REPLACEMENT Remove the snap rings and washers than remove the clutch Shoes and shoe springs fram the drive plate NOTE Some models use one retainer plats instead oF tree nap tings Check the shoo springs for damage or loss of tension Check the damper rubbers for damage or deformation replace a necessary Apply a small amount of groase on the pivot pins Install new clutch shoes on the pivot pins and push them into place Use a small amount of grease on the pivot pin and keep grease off of the brake shoes Replace the brake shoes if thare is any grease on them CAUTION Grease or oll damages clutch shoes and can load too loss of engaging ability SHOE SPRING ORIVE PLATE DAMPER RUBBERS r DAMPER RUBBER CLUTCH SHOE J 12 12 Date of Issue Sep 1988 HONDA MOTOR CO LTD V MATIC BELT DRIVE SYSTEM SHOE SPRING 1 Use pliers to hook the springs to the shoes Instalt the snap rings and washers or retainer plate onto the pivot pins ORIVEN FACE BEARING REPLACEMENT Remove tha inner boating NOTE Af the driven face has an oil seal at inner bearing sid remove the oi saal first Ifa ball bearing is used on the inside remove the snap ring first then remove
3. Bent fork claw Damaged shift drum cam grooves Bent shift spindle Transmiesion jumps out of gaar Worn gear dogs or slots Bent fork shaft Broken shift drum stopper Worn or bent shift forks Broken shift linkage return spring Date of Issue Sap 1968 HONDA MOTOR CO LTD 13 1 a 14 CRANKCASE CRANKSHAFT SERVICE INFORMATION 14 1 CRANKSHAFT MAIN BEARING 14 3 TROUBLESHOOTING 14 1 CONNECTING ROD BEARINGS 14 8 SYSTEM DESCRIPTIONS 142 CONNECTING ROD 14 10 CRANKSHAFT INSPECTION 14 3 SERVICE INFORMATION Refer to the Model Specific manual for removalrinstallation of the crankshaft Mark and store tho bearing inserts to be sure of their correct locations for reassembly If the inserts are improperly installed they will block the oil holes causing insufficient lubrication and eventual engine seizure TROUBLESHOOTING 1g rod big end bearing ing rod Worn crankshaft main bearing Date of Issue Sep 1988 HONDA MOTOR CO LTD 14 1 CRANKCASE CRANKSHAFT SYSTEM DESCRIPTIONS The crankshett changes the reciprocating action of the piston and connecting rod into rotary motion so the energy can be tansmitted to the clutch and transmission Reciprocating movement Itis necessary that the reciprocating and rotating components aro properly balanced to produce a smooth running engine Rotary movement Stresses on the components increase proportional with an in i crease i
4. care not to damage the inside surface of tha new i bearing during Installation CRANKCASE CRANKSHAFT ATTACHMENT AND DRIVER ALIGN LINES MAIN BEARING P DRIVER AND MAIN ATTACHMENT BEARING lt gt CRANKCASE GROOVE Date of Issue Sep 1988 HONDA MOTOR CO LTD 14 7 CRANKCASE CRANKSHAFT CONNECTING ROD BEARINGS OIL CLEARANCE INSPECTION Check the bearing inserts for unusual wear or damage and replace as necessary Wipe oll oil from the bearing inserts and crankpins Put a piece of plastigauge on each crankpin NOTE Do not put the plastigauge over the oil hole in the cronkpin Install the bearing caps and rods on the correct crankp ns and tighten them enly NOTE cay Do not rotate the crankshaft during inspection J Remove the caps and measure the compressad plastigauga on each crankpin If the rod bearing clearance is beyond tolerance select raplacament bearings IWF DAMAGE PLASTIGAUGES 14 8 Date of Issue Sep 1988 HONDA MOTOR CO LTD CRANKCASE CRANKSHAFT 4 STROKE BIG END BEARING SELECTION Record the corresponding rod D code number 1 2 or 3 or measure the I D with tha bearing cap installed without bearing inserts Record the corresponding crankpin O D coda letter A Bor C or measure the crankpin O D Cro renc
5. the bearing Ramove the snap ring then drive out the outer bearing toward the inner bearing side Drive a new outer bearing into place with the seated end toward the outside Install the snap ring securely Apply the specitied amount of specified grease as shown SPECIFIED GREASE Lithium Based Greasel Mitsubishi HD 3 Nippon Sekiyu Lipanox Deluxe 3 Ideriitsu Coronex 3 Sta Lube MP 43141 Bel Ray Moly Lube 126 EP 0 CIR cup OUTER BEARING ie INNER BALL BEARING SNAP RING INNER NEEDLE BEARING d SS SNAP RING SPECIFIED OUTER GREASE BEARING SEALED END 12 13 V MATIC BELT DRIVE SYSTEM Install in a new inner bearing E SEALED SIDE NOTE 7 Install the bearing with the sealed side facing out Install the needie bearing using a hydraulic press install L_the bali bearing by driving it in or using a hydraulic press Install the snap ring into the groove in the driven face Install a new oil seal with the lip toward the bearing it required CLUTCH DRIVEN PULLEY ASSEMBLY 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 Lipanox Deluxe 3 Idernitsu Coronax 3 St Lube MP 3141 Bel Ray Moly Lube 126 EP 0 Install the movable face on the driven pull
6. 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 2 Avoid getting grease and oil on the V belt and pulley drive faces in order to prevent belt slippage dt Refer to the Model Specific manual for removallinstallaion 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 1 Engine stalls or vehicle creeps Broken clutch shoe spring Poor performance at high speed or lack of power Worn drive belt Weak driven face spring Worn weight roller Faulty driven pulley face V MATIC BELT DRIVE SYSTEM SYSTEM DESCRIPTION OPERATION BALL BEARING GUIDE PIN DRIVEN FACE CLuTCH AND ROLLER SPRING OUTER RAMP PLATE DRIVEN FACE DRIVE FACE MOVABLE DRIVE FACE DRIVE PULLEY DRIVEN PULLEY DRIVE PULLEY DRIVEN PULLEY When the engine is running at low speed the unit Increases or As the engine rpm increases or the load on the rear wheel multiplies torque This delivers more torque than a higher decreases cem ifugal 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 res
7. Check the drive belt for cracks pry separation and wear replace as necessary Measure the width of the drive belt 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 groase on tha drive belt or pulley faces Clean off any grease or oil before reinstalling INSTALLATION Temporarily install the driven pulleyiclutch assembly on the drive shaft Turn the pulley clockwise and spread the faces apart while in Stalling the drive belt G UNIVERSAL HOLDER CLUTCH DRIVEN PULLEY DRIVE BELT coc MOVABLE DRIVEN PULLEY FACE Date of Issue Sep 1988 HONDA MOTOR CO LTD 12 5 V MATIC BELT DRIVE SYSTEM Remove the pulley assembly once with the drive belt installed NOTE Put the drive belt over the drive pulley Reinstall the driven pulley on the drive shaft with the drive belt attached Install the clutch outer and the universal holder Tighten the Nut to the specified torque UNIVERSAL HOLDER 07725 0030000 Reinstall the latt crankcase cover see Modol Specitic manual DRIVE PULLEY REMOVAL Remova the laft 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 DAIVE PULLEY HOLDER 07923 KM10000 If the drive pultey holder cannot
8. bo used remove the cooling fan at the right side of the crankshaft and hold the flywheel with tha univarsal holder UNIVERSAL HOLDER 07725 0030000 DRIVE PULLEY RVE BELT Sin UNIVERSAL HOLDER FLYWHEEL Date of Issue Sep 1988 HONDA MOTOR CO LTD ATIC BELT DRIVE SYSTEM DISASSEMBLY Remove the movabie drive face and drive face shaft from the crankshatt Remove the three bolts attaching the movable driva face seal and remove tha seal Remove the ramp plate Remove the weight rollers and the O ring from the movable drive face Discard the O ring INSPECTION The weight rollers push on the movable drive pulley face by centrifugal force worn or damaged weight rollers wi terfere with this force Check the rollers for wear or damage and replace as necassary Measure the 0 0 of each roller replace if the service limit is exceeded CRANKSHAFT MOVABLE DRIVE FACE DRIVE FACE SHAFT MOVABLE DRIVE FACE SEAL PLATE WEIGHT ROLLER MOVABLE DRIVE FACE O RING WEIGHT ROLLER x lt Date of Issue Sep 1988 HONDA MOTOR CO LTD 12 7 V MATIC BELT DRIVE SYSTEM Check the drive face shaft for wear or damage and replace as necessary Measure the O D of the drive face shaft Replace tha shaft if the service limit is exceeded Measure tha I D of the drive face Repla
9. ce it if the service limit is exceeded t a dust seal is installed on the drive face check it for damage and replace as necessary ASSEMBLY INSTALLATION Pack the inside of the movable drive face with the specified then install the weight rollers only the specified groase in th the clutch operation will be affected Apply the grease equally aver the inside of the pulley ecified amount a SPECIFIED GREASE Lithium Basad Gra Mitsubishi HD 3 Nippon Sakiyu Lipanox Deluxe 3 Idemitsu Coronex 3 StrLube MP 3141 Bal Ray Moly Lube 126 EP 0 Apply greasa to a new O ring and install it Install the ramp plate Install the face seal and tighten the bolts ta the specified torqua NOTE Meke sure that the O ring is correctly installed 4 12 8 DRIVE FACE SHAFT SO DUST SEAL L FACE SEAL Date of Issue Sep 1988 HONDA MOTOR CO LTD v IATIC BELT DRIVE SYSTEM Coat the inside of the drive face shaft with 4 5 o of grease Install the shaft with the splined hole facing out NOTE F Do not get the grease on the pulley face Remove any Install the movable face assembly an the crankshaft DRIVE PULLEY FACE INSTALLATION Squeaze the drive belt into the pulley groove and pull the drive belt over the drive face shaft Install the drive pulley face washer and nut NOTE aire oth ploy fac
10. e Refer to the Model Spacific manual for measuring and i supporting paints 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 CRANKCASE CRANKSHAFT FEELER GAUGE MEASURING POINTS DIAL INDICATOR PEELING DAMAGE Date of Issus Sep 1988 HONDA MOTOR CO LTD 14 3 CRANKCASE CRANKSHAFT Two Piece Type Wipe at oil from the bearing inserts and journals Reinstall the upper crankcase s main bearing inserts then Carefully lower the crankshaft in place Put a piece of plastiguage on each journal NOTE Do not put the plastigauge over the oil holes 1 Do not rotate the crankshaft during the inspection J Install the main bearing inserts on the correct journals in the lower crankease then assemble and tighten the bolts eventy in 2 or 3 steps to the specified torque Remove the lower crankcase and measure tha compressed plastigauge on each journal If the ci replacemi Ince is beyond the service limit select the correct it bearings One piece Type Wipe alt oil from the bearing and the crankshaft journals Measuro and record the crankshaft main journal O D MICROMETER 14 4 Date of I
11. e rod so that the holes is behind the crankshaft rotating diraction as shown BEARING INSERTS d OIL HOLE WEIGHT CODE ts oit HOLE C DIRECTION 14 10 Date of Issue Sep 1988 HONDA MOTOR CD LTD E Install the bearing caps and connecting rods on the correct crankpins NOTE Install tha connecting rods and bearing inserts in their original positions Do not rotate the crankshaft and connecting rods during the plastigeuge procedure Oil the threads of the connecting rod bolts and nuts so that the bolts will be tightened evenly Tighten the nuts to the specified torque After tightening check that the connecting rads move freely without binding CRANK CASE CRANKSHAFT BEARING CAP Date of Issue Sep 1988 HONDA MOTOR CO LTD 14 11
12. e the crankpin and rod codes to determi replacement bearing color the Example Crankpin code A Connecting rod code 1 Bearing code Pink Tha pink codo bearing should be selected 7 CRANKPIN I D CODE aE CONNECTING Yellow ROD CODE 2 Yellow Green 0 0 CODE LETTER COLOR CODE THICKNESS SHOWN HONDA MOTOR CO LTD 14 9 CRANKCASE CRANKSHAFT BEARING REPLACEMENT Remove the bearing inserts from the connecting rod and cap 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 rod and cap NOTE The oil hale in the connecting rod should be aligned with the bearing insert oil hole Apply molybdenum disulfide solution to the inside bear ing surface for iritial lubrication CONNECTING ROD SELECTION If a connacting rod requires replacement you should select a rod with tha came weight code A B or C as the original NOTE An unbalanced connecting rod weight may cause abnor vibration If a rod with the same weight coda is unavailable use a replacement within one code letter INSTALLATION Coat the inside bearing surfaces with molybdenum disulfide solution for initial lubrication and reinstall them into the original positions and directions If the connecting rod has an oil hole install th
13. elt remains constant in length the belt in turn s pulled in toward the center af tha 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 rassas the belt is pulled back towards the center of the drive pulley releasing the semuis on the bett This allows the drove face spring to mave the movable driven face toward the original position Pushing the belt back toward the cir Curnference of the driven pulley nthe manner described above the reduction ratio varios with engine speed automatically without the nead to manually shift between gear ratios 12 4 Date of Issue Sep 1988 HONDA MOTOR CO LTD v MATIC BELT DRIVE SYSTEM DRIVE BELT REMOVAL Remove the left crankcase cover sse Model Specific manuatl Hold the clutch outer using the universat holder and remove the nut and clutch outer UNIVERSAL HOLDER 07725 0030000 CAUTION Use the special tool when loosening the lock nui Holding the rear whee or raar brake will damage tho final __ reduction system Squeeze the drive belt into the pulley groove as shown so that it slackens enough to remove the driven pulley from the drive shat Remove the driven pullay olutch with the drive belt in place Remove the drive bait from the driven pulley groove and drive pulley groove INSPECTION
14. es oe foe ofa an sae Hold tha drive pullay face using the drive pulley holder and tighten the nut to tha specified torque DRIVE PULLEY HOLDER 07923 KM10000 Date of Issuo Sep 1988 HONDA MOTOR O LTD DRIVE FACE SHAFT PULLEY FACE ORIVE FACE CRANKSHAFT SHAFT SQUEEZE GE DRIVE PULLEY HoLOER 12 9 V MATIC BELT DRIVE SYSTEM NOTE E UNIVERSAL HOLDER 07725 0030000 1f the pullay holder cannot be used remove the cooling fen and hold the flywheel with the universal holder Install the teft crankcase cover see Model Specific manual CLUTCH DRIVEN PULLEY DISASSEMBLY Remove the drive belt and clutch drivan pulley see page 12 5 Install clutch spring comprassor on the pulley assambly and tighten the tool to gain access to the nut NOTE Do net overtighten the compressor ji Hold tho clutch spring compressor in a vise as shown and remove the lock nut using the lock nut wrench Loosen the clutch spring compressor and disassemble the clutch and spring from the driven pulley Remove the collar from the driven pullay Remove the guide pins and guide pin rollers and the movable driven pulley face Remove the O ring and oil seats from the movable face TE UNIVERSAL HOLDER Gait y CLUTCH SPRING COMPRESSOR al MOVABLE DRIVEN On SEAL GUIDE PULLEY FACE
15. ey face Instali the guide pins or guide pins and guide pin rotters Install the seal collar INNER BEARING OIL SEALS SPECIFIED GREASE WOVABLE DRIVEN PULLEY FACE GUIDE PIN GUIDE PIN ROLLER DRIVEN PULLEY Face GUIDE PIN SEAL COLLAR Date of Issue Sep 1988 HONDA MOTOR CO LTD V MATIC BELT DRIVE SYSTEM Assembla the driven pulley spring and clutch in the clutch Spring compressar Compress the assembly by turning the tool handle until tho lock nut can be installed Clamp the clutch spring comprassor in a vise and tighten the lock nut to the specified torque using the lock nut wrench Remave the spring compressor Install the clutchidriven pulley and drive belt onto the drive shaft see page 12 51 Sea LOCK CLUTCH SPF NUT WRENCH RING COMPRESSOR Date of Issue Sep 1988 HONDA MOTOR CO LTD 12 15 M M Ss es a es 3 13 TRANSMISSION SERVICE INFORMATION 13 1 TRANSMISSION DISASSEMBLY 13 6 TROUBLESHOOTING 13 1 TRANSMISSION INSPECTION 13 6 SYSTEM DESCRIPTION 13 2 TRANSMISSION ASSEMBLY 13 7 SERVICE INFORMATION Retar to the Model Specific manual for proper servicing information on the particular model in question TROUBLESHOOTING Hard to shift Improper clutch operation Incorrect engine oil weight Incorrect clutch adjustment Bent shift forks Bent fork shaft
16. n rpm s Because of this increased strass it is critical that the balance is maintained whan components are replaced There sre two types of crankshafts the assembly type in Assembiy type crankshaft Grut ia wrgioset me cta a termes conem 0 should be exercised when handling it because If it is dropped Needle bearing Crankshatt The unit type employs plain type main bearings While the crankshaft is designed to rest directly on the metal bearing material strictly speaking tha crankshaft and metals are lubricated on their surfaces by an oil tilm Q quently scratchas burrs or dust on the bearing surface the oll film leading to bearing seizure Ball bearing Crankshaft sss Osta of Issue Sep 1988 14 2 HONDA MOTOR 6 LTD CRANKSHAFT INSPECTION SIDE CLEARANCE Measure the side clearance by inserting the feolor gauge botwaen the crankshaft and connecting 10d big end as shown RADIAL CLEARANCE ASSEMBLY TYPE CRANKSHAFT ONLY Measure tha side clearance at the connecting rod big end with a fealor gauge Replace the cranke af if the service limit is exceeded Measure the connecting rod radial clearance in both X and Y directions Replace the crankshatt if the service limit is exceeded Measure tha crankshaft runout using dial indicatora NOTE The single unit cranksholt uses the plain bearings at the maia journal Excessive runout can cause engine seizur
17. ng has been removed Record the main journal O D code number 1 2 or 3 Cross reference the case and journal codes to determine the replacement bearing color code Example I D code on the crankcs O D coda on the crankshaft 1 Benring code Brown CRANKCASE J D CODE J z A B MAIN 1 Brown Black JOURNAL i erum OD CODE Black Blue REMOVAL Two piece Typa Carafully remove the bearing insarts from the crankcase Wipe all ail from the insert seating areas 14 6 0 0 CODE coon cove BEARING INSERT Date of Issue Sep 1988 HONDA MOTOR CO LTD z5 Press out the main bearing using the special tool and hydraulic press CAUTION When removing bearings always use a hydraulic press and bearing removal tool to prevent crankcase damage MAIN BEARING INSTALLATION Two piece Typi Install the main bearings into the crankcese Tha bearing tabs should be aligned with the grooves in tho case and caps Apply molybdenum disulfide solution to the upper and lowar main bearings Mark a line perpendicular to the bearing surface from edge of the notch as shown ch jse to the outer face of the Apply molybdenum disulfide gr bearing Place the bearing in the crankcase by aligning the two lines with the crankcase groove Prass it into place using a hydraulic press CAUTION Take
18. ssue Sep 1988 HONDA MOTOR CO LTD CRANKCASE CRANKSHAFT Measure and racord the main bearing LD Calculate the oil clearance by subtracting the journal O D trom bearing LD Replace the bearing if the service limit is exceeded MAIN BEARING SELECTION Two piece Type Record the crankcase D code letters NOTE F Letters A B or C on the upper crankcase are the codes tho main journal 1 0 8 from lef to right Rocord the corresponding main journal 0 0 code numbers or measure the main journal 0 0 1 NOTE Numbers 1 2 or 3 on each crank weight are the codes for the main journal 0 0 8 from left to right Cross reference the case and journal codas to determine the replacement bearing color code Example LD code on the crankcase A O D eode on the crankshaft 1 Bearing color code Pink CRANKCASE LD CODE A 8 c MAIN 1 Pink Yellow Green JOURNAL ollow reen wn PI 2 yew E Bro CODE 3 Green Brown Black CYLINDER GAUGE MAIN JOURNAL 0 0 CODE COLOR CODE ESSERE a NN Date of Issue Sap 1988 HONDA MOTOR CO LTD 14 5 CRANKCASE CRANKSHAFT NOTE Some bearings cannot be replaced Refer to the Model Specitic manual for complete information Press the old bearing out of the crankcase page 11 7 Record the LD cade letter A B or C or measure the crankcase I D after the beari
19. ult is a reduced drive ratio between the driven and drive pulleys REDUCTION HIGH Date of Issue Sep 1988 12 2 HONDA MOTOR CO LTO V MATIC BELT DRIVE SYSTEM DRIVE PULLEY OPERATION WEIGHT ROLLER RAMP PLATE DRIVE FACE MOVABLE DRIVE FACE qq drive pulley consists of a fixed and a 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 tha shaft of the drive face with a nut AS SPEED INCREASES ved MOVABLE FACE RAMP PLATE t DRIVE FACE WEIGHT ROLLER g As the engine rpm increases centrifugal force on the weight rollers is increased This pushes the movable the fixed face This reduces the drive ratio by allowing the drive belt to run on a pulley of greater ciomet Date of Issue Sep 1988 HONDA MOTOR CO LTD V MATIC BELT DRIVE SYSTEM DRIVEN PULLEY CENTRIFUGAL DRY CLUTCH BALL BEARING CLUTCH WEIGHT DRIVE SHAFT CLUTCH OUTER GUIDE PIN AND ROLLER DRIVEN FACE SPRING que centitugoi clutch is disengaged when tho engine speed is low When engine speed increases the rotating clutch shoes of Tra auch weight will expand as the centrifugal force increases In this way the chatek ie automatically engaged rhe drive belt is pushed out towards the drive face circumference of the drive pulley as the engine speed increases As the b
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