- SHOP MANUAL $90 CLIOL C90 i CL90 CD90 CT90FOREWORD This stop monal is a reference end a ide book for the proper servicing of the Honda 90 series motoreyle, The Infomation contained horin i based on the 590 with equal opelicabilly to the CL.90, CLPOLL, tener POe> poers po e> CONTENTS, Inspection. . Serre Pocenenbhy <5 ssyreaeceevensary=tevacewssvsversvecrsventetcwieerie GEAR SHIFT MECHANISM. saeeiNl Constuction. 2 z CRANKSHAFT... Constuction. Dicassomoly Inspection ‘ Reassembly TRANSMISSION, Constwuction Disassembly... lespecticn. Recssembly CRANKCASE Construction... Deassombly Inspection. Recssonbly KICK STARTER AND GEAR INTELOCK MECHANISM, POSL-TORGUE MECHANISM (CT 90)... Constretion Discsserbiy « CARBURETOR . Construction . Function of Each Comechent Adjust sees Adjustment for High Speed. . Adjament for inermeciate Speed, Achusment for Slow Speed... e+e et ‘Acting the Fost Level. "4 STEERING HANDLE 78 ‘Conetnction ee 75 DlassenHY racine -veneeeger ree aren 76 78 179 Inspection Isteerng handle! Rooscombly. oas PRESEN PFoDNP Pe PKPUFNOPrF OQ DNP Pao POPP. ONO Fee TDN PPD CONTENTS STEERING STEM, ‘Construction . . Disassembly ..... Inspection Reassembly . FRONT FORK. ‘Construction . . Diuseribiyesncinnscheton ser te tee ase Inspection....... Reassembly....... FUEL TANK .. Construction Disassembly inepectlon Bocce 5 ananw Mn RRMA a Wha cosas Resse bl Gee Ie seo ndecnnecrinen FRAME BODY... ‘Construction Disassembly Inspection... .. Reassembly Construction... +++ Disassembly Inspection. Roassombly. : BRAKES SYSTEM enscn ergs Steen Jao acs tune eeatuanimemmeraty srs 94 Construction Disassombly MUFFLER, . Construction Disossembly inbpoctonivesterrivieder veweresner wees ROGESOMBIY, cece veces se nccenstetedeeewerenereneeeseeeeeernereeeene 7 AIR CLEANER, . « Construction Disossembly Inspection. Reassombly. REAR FORK AND CUSHION DAMPER, .0..scvsseessereveessstnussnieenes 100 Construction . . Disossombly ...+ 04+contents - 100 2. Reasenbly st etal 4.11 REAR FOR CUSHON DaMER, 101 AL COMIREHON..sseessesesenseeeretee Soe iw 8 Diosrertly aan . ote toa Ctpection, . coe 108 4.12. FRONT Wet 104 A. Comtrction ee Gerri stunt etaneyeenisn 10% 3 Diowently 105 Cregeen 106 De Romsomby. eee z 107 413 REAR WHE ccc cease Pee A Consttioa. eo esesseee S18. Be DOSER, ose ssecsersecsecesee cies 108 C_hepecton : i 0 D. Reowerbly. Pecsares caesetl 5. PERIODIC ADJUSTMENT... Eeaiheaerane 4 ns 5. 1. MAINTENANCE INSPECTION Sioa lis A. Engine Adistro ns. 3 Lubvicalng <2 © Dive Chain Acisnent os 1a3 2. Brcko Adistnent . = 124 Mer Coming . a . 128 Be Soke WOO. nck es nannssssn sone sever ere cl G. fetta Fepecton. ievectavawnu tier 126 H. Diva Orin Senco, ssesceeee 5? “7 1. Opercting nvwetion foe Svie Testor, Type ST AD4 . 128 J. Secuity spoction of Pas. cess esevveveess ets 5, 2 PROD INFECTION AND SERVICING . +135 1A. Coty Ipocton ia iss 2. Pores lpecion se eres ste ASE 65, TROUBLE SHOOTING 2138 6. 1 MAIN ENGINE TROUBLE. 2138 6 2 CARBURETOR TROLALE, ee ar) 3 ENGNE NOE. Mr 6. 4 STEERING SYSTEM. 142 4&5 QWUICH system. ey 6. 6 GEAR CHANGE SYSTEM... 143 6.7 SUSRINSION. ss sses 4 er1. FEATURES 1.1 ENGINE ‘The engines used on the HONDA 90 series ore besicaly identical with the mojor diferonce in that the 590, CL90, CL9OL ard CD90 ore equppod with a mans opercted clutch ord tho C90 ord CT90 faving on cutometic cluch A. Chein driven ov ‘The camthaft is driven by © constant tension chain, cisuing quiet operation ord precio valve timing. Further, it enables greater power output due to avalcbilty of higher opercting RPM. OHY and somi-spherical combustion chamber Tre overhsod woe design provides greater cir intake Volumetric efficiney. Tre temi-schercal contustion chonber assures 0 smooth fame propagotion which is further enhanced by tho incorporation of © special squish area. _ Dovble oil filter Tre oil system incorperctes 0 fine mesh screen fltar ord cerisfupal fiir 19 sypply the engine with a highly cleon il. This minimizes the wear fo the engine components, reducing maintenance ond ‘oxtoncing the life of the engine. D. Clutch Right ection ctch lever is employed on the $90, CL90, CL90L ard CD90, with curorctic clutch Fstolled on the €:90 ond C790. E. Transmission All speeds ore constant meshed to provide smacth geor chonges. The $90, CL90, CL90L end. C790 have four forward speeds whereas the C9D has three speeds. Further, tha CT'90 is equipped with @ positorque mechanism for selecting the low speed |, reduction range. fod camshaft 10 the cylinder ore a consequent Figher 1.2, FRAME AL Rigid lightweight frome Tre frame of the $90, CL90, CL90 and CD90 ore mode of pressed steel seet of monocoq.e design. Frane of the C90 end CT90 is @ combination of pressed steel sheet with a large dianeter see! pipe supporting the steering hea. Thase designs give rigid lightweight frame of high strength, B. Rear suspension Swing crm suspension is provided with a two stogo cushion ll dampor to provide comfortable riding under various losding ond road conditions. C. Front suspension Telescoping type front cushions ore employed on the $90, CL90, CL9OL and CT 90 models from frame serial No. OOOUOIAL. Bottom lick tyres are sed on the C90, CD90 ond CT 90 models (from frome soriel No. 100001). D. Broke Trolling leading type ro fede brckes cre wed on both the front ord recr wheels, The right handle lever operates the front broke ond the sight foot pedal operotes the rear broke, The CT 90 is ‘equipped in oxkdtion with a left hond lever to operate the rear broke.2. SPECIFICATIONS AND PERFORMANCES 2.1 SPECRicATIONS = es] im | exso, eusoe | Miercbicoware | [naute Von 50 Dinetione ‘Overall length 1,890 mm 1,830 mm aan es an | Ove with 50 nn 1000 Ba ee Over ict 920 nn 1,050 rm Beet lige — 1195 ne 1,200 tipco'n Le iit d| ee nel ene in Weiot Wik npy asia 22019 5603 ka 23 - Betig cts fos Fone sein Max 139 60k (22,960 fr at 21.75 mile/h! (47.6 ft @ 31 mile/hl Foal consumption 75 mil ot AO kh 80 kn/l et 40 bh T176mileWV. S. gel. @ 24. BSmile/bl | (188 mile/US. go, @ 25 mi Climbing obiiny: 18° 20 | a -2.) SPECIFICATIONS a @ | Tr 90 00 | a ee (from F, No, 000001) | Honde 90 Hondo 99 Honda 90 | Honda 90 o sien ae ee eee em 072i 210% wore 736i 640 am 640 am 6500 680 nm (25.22 (522) (25.61) (26810 955 0m 995 0m 980 am 1,040 am (97.63 0 39.201 (38.61 a (41.010 1.1820m 1,190.8m 1,188 mn 1215 om (45:39 (46.89! (46.81 7310 130m 130/mm 137 mm 175 nm 6120) 6.12) (40ia (69 85.040 B1.si9 9ka @ (187.00 tot (179.30 les {200 te Mor. 475m ot 35th |Max 68m ot 354m | Max. 5.5m ot 30km/h | Mot, 5.5m ct 30 km/h (2a 4th @ 21.75 rien) | (22.69) (21.75 mle) | CBI (19 meh BH 8 ley BOkm/l at 35km/h BDkm/2 ot 30 ken/h TS kenfl ot 40 km/h 75kmjl ot 40km/h TBS. go (188 mie/US. 901 C74 mie/US. ok (76g. oa @2A7mioh | @ 16.64 milo) a) 25 milo/h) @ 25 mile/hl 1° High range 18° High ronge 18° | Low range 25° Low ronge 25° 1 i‘ 2. SPECICATION AND PEFORMANCES eee ] $90 L990, CLSOL Min, turing ox 1,950 mm 1,890 mm 76830 1) aan) Nowe and Model Hondo $908 Honda C1908 Type fool used Gorstine Same o& lot Type ergo | Ate cooled 4. stoke cyclo Sano ce loft No.of cylinder and onangoment, Srgle cylinder, ted forward 75° | Sane os loft Valve crrongement Overhead valve Samo of left Totel piston displacement | 69.8.0 89.60 (5.47 cain (5.47 eu. iv Boro Stoke 50% 45 om 5045.6 nm (137x177 0.97 x1.80'n) Conpresson iio 82 82 Comprescn presire 12kgjont 12kglent (170876 bjt 11702676 bist Max, output 8.0 PS/9500 rpm CL 90 + 8.0 PS/9500 rpm CLOOL: 4.9 PS/8000 rpm Max. torque 0.45 ig.0/8000 rom CLO + 0.85 keen/8000 rm (4.701. t/8000 rpm) (4.7. 1/8000 raed CL9OL: 1.97 ke-y/3500 rem (14.261. 1/3500 rpm ees) eee eee ST voor eal aE Marufocturer | Tokyo Roki ‘Same os left (tebe 8) rst (EUs x) Fee eee ie Pe ae eared ar eae beter | ames foot (BUS) | one (Bus 2crv OW i cee {from F. No. 000001) 1,630 mm 1,910 00 1900.00 1900 mm 64.22 in (75.2519 (74.86 in) 174,86 i) Honda CD 90 E Honda G90 Hondo CT 90E | Honda C908 Some ot lof Sono as left Same oe loft Some as left Soro of loft Some os left Same o& loft Some os left Some os loft Sane o3 loft Same ce loft Some as felt Somo os loft Some os left Some oft Sone ot left 89.6 cc | 7.6.00 89.6 co Same os left (547 ox i) (5.47 ev. id (5.7 oxi 50% 45.6 mem 50% 45.6 mm 50% 45,6 mm Same os lett (1.97 1.89 in) (0.87 1.80 in 0,971.80 in 82 82 a2 Some os left 12kalen® 12 ka) 12iglem® Some os left (170.676 ton (170.876 lof’ (1701876 tie 7.5 PS/9000 rem 7.5 ?5/9500 1pm 7.0 P5/8500 cpm Some os lot 0.72 4g-m/6000 rem | 0.67 kgen/4000 rer 0.6? ka-m/5000 rm | Some ot loft (S216. 1/6000 rpm | (4.848. 1/6000 rpal | (4.791. 1/6000 rpm 350 g/PS-h/7000 rem 505%280%345mm | 550% 280%945 mn (17.90 311.00 13.59 il) (91,7 3011.2%13.6 ed Sane os lel 2A lg (52.8 bs) 241g (52.8 ks) 25ko (55k Some os felt Some 3 left Same loft j Sone os let Same os felt Some os loft Some os lft Sane os left Piston valve type, 1 each | PY 1SHAL, 1 exch Peton vohe typo, 1 each | Same as left Kehin Sei Kein Sok Keltin Sot Some os left Soma at lo | some os tof Sane os left | Samo as fit | Some os tot Same os lof 150.5. pt) | N1SUS. A3TULS. pe 1,6U.S. oo 701 (38mm) | 85! (aot ee) [654 (aime) | 6° Siena) Presse type Presue type Frossre type Sone as left Trochcid type Trochoid type Trochsid pump Sane os left Some os loft Samo as left Some os loft Sane os left 1.9 U.S. pl 1.9 U.S. pl 1.90U. 8, Pr) 1.9 U.S. bt a9 (etme ee) | °%F (Nein pe) | 29% (rtm tu) [094 (etn i)2. SPECIFICATIONS AND PERORMANCES Medel Typ0 ion System leetion Method. Type Ipttion Coil Manufacturer Type Spark Plug Manufacturer Electrical System Battery No. and type Volt ond AH ‘Manufoctror ‘Type generator Monufactret Princry reduction method Reduction ratio ‘Clutch type ‘Type transmission Gear change method Gor ratio, lt gecr Gozr ratio, 2nd gecr Gorr ratio, Sid gear Goxr ratio, 4th gear Sub troremision Secondary reduction method Reduetion rerio Steering System Steering fondle wining racius Steering honda width Coster Teal Tie, froot Tie, Broke System Type broke, front $90 Battery ignition R68 29700-101-0 ‘Kokusan Denki Nihon Dereo DeHW NGK Spek Plug Co. Lid MA36A oF 836-6, 1 each 66 Yuosa Denki 37000-026-0 EG-21 Nippon Denso | Koluson Derk Cox 372 Wet multisle disc type Constont meshed gears Left foot opercted return type 254 1.83 1.09 0.88 | Chin 321 se 620 me (24.426 In) 6s | 75mm 12.985 in) 250-18 (4 PR) 250-18 (4 PR Internal expanding shoe cL 90, CL9OL K 205, NGK Spork | Nippon Dewso Plug Co.,Ltd, | Some os left 66 Some ot left 37000-026-0 | EG-26 Nippon Denso Kokuson Danki Same os left 372 Some cs left Some cs left Some os left 254 1.61 19 0.96 Some a: left 321 ea 770 men (30.3 i) je 73 mm (2.87 in) 250-18 (4 P2) | 275-18 (4 FR) Sore as left2.1 SPEORCATONS QO aa 7 oe on cree (tom F: Nor 0200014) | | ‘Same os left Some. os left Some os left Some os left @ s178 s79 Eee a ef Kokuson Denki Kokusan Denki Some os left sus Noxzors| O-8HW oars eee NGK Spark Nippon | NOK Spa Fluo Co.-L. | GK Spark Hug Co., id. Sono as lft a Ys Cont "Bono B 108-6, leach B37-6A, Lech 837-6 A, | each Same as left 6-6 &6 6-55 ‘Seme os left Same os left ‘Some os loft ‘Some os left Same cs left | s7e00-088-0 aoe | es On inn | Sone okt soe os let sone ste ry 372 372 372 3.722 ‘Same os left ‘Automatic wet multiple | Some os left ‘Some os loft @ Sarma Seow Seno amt cores fone cs kit See ot ome dae Be 2308 2.598 7981 Sore vet 1.565 wt) 008" san ce ot 19 1.000 10 e202" Stn bk 096 aisee 1.769% | Sano ott 1000 267% | Sone os lat foe ene sam a heath Sivw-c ih 3.00 2.887 2.000 shaw ath @ | as as as Sore os 1oft 40mm 25226 | 630 am (2482210) 635° 6" 63. Same as left 75mm (2.985in) 75 mm (2.955in1 751m (2955) Visa i 260-17 (4 280-17 ltt) 250-17 275-17 478 280-17 220-17 PR 27617 276-17 48 eae Sot sew 3 eh Senn ot om° 2. SECITICATIONS AND PERFORMANCES Model Tye | 590 190, cL90L Type beck, r0or Ineo expandina shoes Some 5 ltt Motnod of apelcstion, front Right hand lover opaccted Samo os left Mattod of opslcatin, rear | Rglt foot pedal oporcted Samo os let Suspension System Suspension method, fren! | Telescope type “Telescorie type Sispersion wethod, rear | Swing cnn type Same as left Donpening system, fent | Hycroie Same os lft Danpening sytem, rear | Hyetoulie Same as lft rome Tyee Bectbone type Same os let Lighting System Beodigh type 46-0109 Monufoctuer Sterley Fcc, Kilo Sehsisho Stanley Flere Heodight cotiag 6V—25/25W 6V—25/25 W Teitohtrateg 6v—2w ov-sw Tollanp conbination with License fight Sane os left Sep bit rong év-8w ov-17W Tum sige type Magnetic. beating element Some os left Tum sign rating é6v-8w ev—1ew Instrument Hom type Fleere Fat type Some os lot Meruioctuer Mistba Deskt Speedometer Typo Wledereter Wlodoneter Merufochrer Nippon Sei Feflox ceector type £2 20 Walon 830 Whim Morufactier Sonley Flere Sane os let2.1 gromcanions . on cw ain uaa ‘Some os loft | somo os tft Soo os left Some left Same os lot Sone os let Some 0: lft Sone ot left Same os lot | Sore o2 let Baht Foo! peda end oft | Same os left | ted lover cpsrced | Botom link type Sane os let fottom rk typo | Telescopic Type Some ot lt | Same Sone 0 lt | Sane es lf | Sone os lot | Sore os lit Some os let | Some os let | some os ttt Sane os let Same as lot Sone os left | Some os lot Sane os let Some at lot Sone of lef | ASS-11 ASS Sane of left Stonley Hectic Some os lo Sane af lef 6v—25/25 6v—2525W 6v—25/25 W Some os let sv-3W ov-5w Sone os lef Sao 0s lot | Sa Same os lot Sane of left | 6v—10w |“ 6y—tow 6v—18w ey-11W Sawa he | Sen es tte 6v—10W 6v-8w 6N-18W option) Sore os lot | Some os lett Same os let Some os let Mitba Sei or Nippon | Sane os left Denso Mogeticaly diven | Sam os lft Sve os le | Niton Set or Nipon | Sane os ll 30 Wisillonp 8820 Witallone Some 03 lft Sane os lef10 2. SPECIFICATIONS AND PERFORMANCES 2.2. PERFORMANCES MODEL $90Shatt output Torque km) 5 2.2 FEREORMANGES 5.90 PERFORMANCE CURVES 0B AO 10 Driving speed ikm/¥r) $90 ENGINE PERFORMANCE ter 7 ae Engine speed R. P.M) Driving force (Ke)2.2 FERFORMANCES CL90 PERFORMANCE CURVES Engine speed RPM. 00 Diving speed (Kim /+4) C90 ENGINE PERFORMANCE CL9OL ENGINE PERFORMANCE rey r3) | i i E [ : : a Py fresh £ is | Ieee i is i ; — roe 8 3 re st (nA)pst Saft output | ae a 2.2 RGFORMANCES (CD 90 PERFORMANCE CURVES loxio? Engine speed RPM won ime ay ca Driving speed. (Km Hr) CD90 ENGINE PERFORMANCE a8 ios. es 8 8.8 Fuel consumption (57/PS-4:) 3644 3 tox10* Engine speed (P.P.M) is 100 viving force (Ke)2, SECIRCATIONS AND PeReORMANCES ‘MODEL C90 >‘att outout ms ps7. bo. 300 Ey 2.2 BRORMANCES (C90 PERFORMANCE CURVES 1oxt0* 100 so 2 2 Driving speed (Kin Hr) C90 ENGINE PERFORMANCE & consumption (G/PeHn)2. SECIFICATIONS AND FESFORMANES MODEL CT 90 Prier to CT90 F, No, 122550 Posi-torgue (F. No. 122551 and subsequent)Posi-torque (F No. CT 90 ENGINE PERFORMANCE —Sx10* Ergne speed (RAM) 22 PERFORMANCES, 00001 ond subsequent) ‘CT 90 PERFORMANCE CURVES Dvir speed Indicate when3. ENGINE Tools Necessary for Disassembly and Reassemély - : | oC fw \--— @ cliche 3 o ® © 0 @ & « B oO ow oe @ ne Hh : we a“TOOLS NECESSARY FOR DISASSEMBLY AND REASSEMBLY. a 2 @ a TOOL No. DESCRIPTIONS @ 07022-20001 Drie sprocket holder @ 07024-01101 Chueh cuter roller ® 07086-03001 horde box wrench, 16 mm @ 07046-21601 Valve guide ceiver ® 07047-04001 Valve quide ronover ® 07046-02801 Valve guide cevor ® 07008-90101 Valvo guido roarncr ® 07031-20001 Valve lift @ 07081-00101 Topper axpsting wranch ® 07087-00101 Tappat lock mit cocker wrench @ 07024-03401 Church cuter holder ® 07007-02801 Valve seat culter holder ®B 07003-02801 Inlet valve fot sufoce seat cuter | 07004-07801 Exhaust valve fat surface seat cutter B 07001-02801 Valve seat cutter, 90 degree ® 07005-02801 Inet valve interior seat cxtter 07006-02801 Exhaust valve interior seat cur ® 07032-03301 Piston ring comprossor ® 07057-03301 il seal guide @ 07038-03301 Civich disassombling & assomling too! @ 07011-20001 Dyramo rotor puller @ 07033-03301 Piston boro @ 07061-0280) Timing inspection cover3. ENGINE a Gp 5 Cyl © Paton on con fee de © Com coin tensioner @ Drive sprocker @3.1 ENGINE DESCRIPTION All ofthe models incorporate the ©. H.C. design ven from the loft sido of tho engine by a ligit- ‘weight endless chain, This provides the engine with high speed ond high power output due to the elimination cf the recierceating movements ard mechanical losses, ond reduction in weight. Further the chain is clways melrtained in a conetant torsion by the cil pressure and soring operated cutomatic tensioner to esse quiet cperction ond procice valve timing at all speeds ‘Tre luericotion system ulllzes @ trockold type oll Pump driven through the cam chain guide sprocket 10 provide lubricction under pressure to oll of the primary moving parts of the engine and in corr tion, @ sereen and a centrifuga iter ore iocexpovated tho system to assure that only highly purified cil fs cleuated within tho engine to minimize the ps ‘weer end attoting to the extended engine Wie, Fig. 3.1) 3.2 POWER TRANSMISSION SYSTEM The evergy prosuced by the combustion of the fuel nixtire in the cylinder 1s applied to the top of the Piston, this 1s transmitted to conecting rod —> hich drive ploto — clich outer —> friction disc > chich center —> primary drive goor —> primary driven geor—> ronsmision main. shalt 3.1. ENGINE ofscuPTON a > main shaft gear—> counter sheft geor counter shalt —> drive sprocket —> drive. chain — diiven sprocket —> to the rear wheel, pro qrosively in succession, (Fig. 3.2) 3.9. ENGINE REMOVAL $90, CL90, CL90L, CD90 1. Ronove the step bor 2. Ronove to muff. 3. Fomovo the loft ereckease reor ver en un took the drive chan fom tho sprocket (Fig. 3.3) NOTE Tie c ples of ww fo both ends of the chain 10 provert the enis fem being drawn nto the chain ca:o. This will feclitate the work ding ergine instalation, ($ 90, CD 90) Fig. 3.3. Fewoving te dive an © ce taa 2. ENGINE 4. Discomect the clutch cable ©) from the clutch lever @. (Fig, 3.4) 5. Discomrect the air inlet pipe at the cylinder head end olso remave the high tension cord Feom the spark lg 6. Remove the battsry cover ond di bottery lead from the battery. romnect he Fig. 3.4 Dissomecteg © Gives cote 7 Unhook the brake podal spring. Fomove the nuts mounting tho ongina (3 for $90, CL.90, CL9OL, 2 for CD 90) ond the roar encine unser bolt. Pull cut the two 10mm hex bolt, and the engine can be separated from the frome, (Fig. 3.5) € 90, cr 90 Remo front cover (C90), remove milord (C190). Remove the min pipe cover (CT 90 rode from trrme No. 000001) 2 Remove the stop bar. 3. Remeve the leit crankcase rear cover and 1° nove the chain ont clip to dscereact the civo NOTE: Tia @ piece of wie to both ends of tho chain 10 proven the ends ‘tom being cravn ino the Fie 3:6. money et pea chon coe, This wil focitote the vesk rg © Inlet pipe @ Flonge mouning bat ‘engine instcllation (C90). > 4. Renove the mf: 5. Disconnect the or inlet pipe ot the oyinor head. (Fig. 3.6) -* 6, Disconnect the electiical leods at the con rector a 7. Fonove tho high tension cord fom the spot pg 8. Uno the broke pedal eping. 9. Ronove the 2 engine mounting nts and thon pal ou! the rr engine order bolt ond ear engine hanger boi Fig, 8.7 ge cay (0) 10, The engine con be removed. (Pig. 3.7)3.4 ENGINE INSTAILATION a oe 3.4 ENGINE INSTALLATION Genaraly, the engine Installenion is performed in the reverse order of removal 1. Set the engine on @ black and sido funder the frome. ooocuones Tove the orhe wire kanes 1p ino to SSSEOCTSSS battery box where the engine ard frame, ond @-@ tenporarly inset a sciendiver o a 103 of == Lo, -eprceisto diameter to spond the engine 2. inert th encne mounting bolts rom the left Fi 3.8. Seting deston of chan cip Sid, lo roploce the serwsriver ond stall oc roe es ee ® Drive chain torque the nuts. Hock the broke arm retun @ Cohn jon spring on the lower mounting bolt. ees ere pe 3. Comect all electrical laods 40 the wire harness, © Chain ji to 4. Comect the batieyy leads 10 the battery fesmirals, push the wire bundle op into the top of the bottery box where it will not interfere With battery installation. install battery ond hack to make swe that the wires ore nat being eS ~ pinched. ‘mm / 5, Route tho battery vont tube though the floor a of the bottory comporinont ond moto swe that the tue Is not pinchod or kinked, preventing proper venting 4. Recomect the clutch oable to the dutch lover 7. Install the inet pipe on the corburstor and bolt 40 the cylinder tec. Install the high tension Coble hold down clip under the ight inlet pipe mounting bolt. Mae sire that the O ring is Frstolled betwoan the cylinder heed on ink! Pipe. 8. Intoll the mufer. 9. Loop the drive chain over the drive sprocket ‘ond comect the chain. Tho open end of the chain jolet clip myst be Ietollad focing In the ‘opposite direction of the chain movement, (Fig. 3.8) 10. Ista the choin cose, the rear crarkeare cover ond the footest bar. 11, Adjust the chain with the chain axiuster ruts fon both sides of the rear wheel so that there sa slock of 1~Zem (0.4~0.8 in) when chockod with finger on the bottom loop ct mide point between the sprockets. (Fig. 3.9) 3.9 Adilbe the chin2. Viren Fig. 3.10 Cylinder heod Figs 8.11 Sauk oa Fig. 212 Revove the ster esenbly @ Siler cxsently Fig, 9.13. Renovng the ror © toer @ fete euler ENGINE 3.5. CYLINDER HEAD AL Construction, ‘The cylinder heal is mode of lightweight cost alurinm clloy for good haat cisipotion ond in- corporates the camshaft, con sprocket, valves, valve rocker arms, spark advancer ond breaker assomly ‘Tho ovethoad conshalt ie diiven by the cam chain through tho cam sprocket, Combustion chamber is of som spherical dosign for better cocling ond Increased combustion offcioncy. (Fig. 3.10) (Squish Ares) This is on ares provided between the piston ond cylinder head to futher comeress pert of the fuel ce mixture ot the end of tho compression ecko to create o turbulence of the rein fuel mixture, The switing fuel misture is directed toword tho spark play whore it Js ignited, The fame propaga: tion 18 cealercted, allowing the leanee than nome fuel aie ratio or the slower buming fuel minke to bum smoothly, futher, decrecsing the tendency for rocking. (Fig. 3.11) 8. Disossembly (Cylinder Head Block) Remove the point cover ord then the left cronkeseo cover. CAUTION: Oil may flow our when removing the left crankcase cover. 2. Remove the stator cssenbly ©, (Fige 3.12) 3. Remove the rotor @ using a dynamo rotor pallor @) {Tool No. 07011-20001), (Fig. 3. 13) CAUTION: When removing the rotor. caution not fo apply excossive force so a3 to bend the cronksha8.5 CYUNDER HEAD 4, Remove tho rocker arm side cover. 5. Remove the contact brecker osvenbly D ond disconnect the lead wie @. (Fig. 3.14) move the spark advarcer by removieg the hex bolt and renove the 3%5.2 dowel pi 7. Remove the point base D by king off the three menting screws. (Fig. 3.15) 8. Rotote the cranksratt so that wooduff toy © ib aligned with the 325.2 dowel pla hole in the camshalt and then tomove tho camshaft by inscewieg the 10 tals. (Fig. 3.16) ‘caUTION Pecform the with the cylinder stud bolt ny salt dic ly cred ese Yighiened 9. Remove the cylinder head cover red the cylinder head. IF the head is light, top around the patting sxface of the cylinder head lightly with o soft tose hares 0. Discssonble the valves csing o vaive lifter Teo! Ne. 07031-20011. (Fig. 3.17) Fla. 2.15 Reng te pot bore @ Feit boxe ‘Wostndl ley Dowel vin tte Fig. 3.17 Dsmonbing th voles © Valve Whee 22» 3.18. Chestng evinder bead worrrae © cyindae tant 2.9 mann epee ore @ Sons pope Fig. 9.20 Cheeling te valve guide censor © Oyindie gaze ENGINE C. Inspection ond Repoir The cylinder head () is exposed to. the high Pressure ond temperature resulting from the combus- tion of the fusl mixture: futher, when the eyliner hood is unevenly torqued, it may develop cracks oF warpage and will be the case of defective sacting botwoon the food ond the cylinder ord realt in 965 eck, oir sucking, with consequent crop in com pression, The worpoge of tho cylinder hood does not develop suddenly ond it may be overlooked, there fore, coution should bo exercised during reatsonbly sipce the uneven torquing of the cylinder hood is 0 very common fault To inspect for woxpage of the cylinder head copply a thin cont of bling or red lead @ on o surface plate ond work the moting surface of the clinder head on the suface plate: the warpoge can bo determined by the transfer of the thing on 10 the cylinder hood. (Fig. 3.18) To comuct tie warpoga, lop the eylinder head fon the sufoce plore with a £200 sancpaper, finally finih by wsing @ £400 sondpacer ond than inspect ‘ogsin with the bing. (Fig. 3, 19) Te Inspect the combustion chorber, extoust pots for crocks 2. Cylinder head combustion chamber, jet ond | Sndad vole Velie ctrrenca| Sie vlve = 001~0030e | o08m jo00o%~c.00r2 4 | 120028) 0030.05 | Olam ooorz~o.002beu | .008zh) ‘Chock the valve guide dianster ot the top, ‘center ond bottom in both tho X ord Y axes, ling © precision cylinder gauge D. Check the volvo stom with @ micrometer. (Fig. 3. 20)3.5 CYUNDER HEAD 4, Inspect valve guide Valve ide, lot Senseo serdard vie | See Ta0ss—in.066 Cunide Din | iiseuawo.3se6in) leefernce FH | pgcharco.anz6ia | — felace Ini 2 owen 8525 a2isy—0.r6l mn | om 5825 IF the valve guide inside diameter is. beyond servicenble linits. may be repaired by using a reaner @) (Tool No, 07008-00101) and replacing the valve with ono of on oversize, (Fig. 3.21) 5. When replacement of the valve guide becomes necessary, remove and replace with on oversize uide, use the valve guide remover (Tool Ne. (07047-04001) nd the valve guide diver (Too! No, 07046-21601) for replacement eporaticn. ‘After instaling the valve guide, uso rearrer to ‘obtain the proper valve clearance, (Fig. 3. 22) 6. Volve Seat “The condition of the valve sect plays ‘prominent roll in determining the performance of the engine, further, it serves as @ means for ssipating the hea! from the valves ‘A valve seat in good condition should have «2 full sxface contact with the valve face. Standard volvo D—0.7~1.2 rem (0.028~0,048 in Sorvicocbo lint —in excess of 2 mn 10.08 I) “The volvo soot contact con bo checked. by ‘eppiying «thin coating ‘bing or ted Toor evenly on the entie surface of the valve foco cd roteo the wave while Fotdng It fly agaist the valve seo! A goed valve seating crdiin will show © uniform end centinoss width of ‘Buing on the valve sect Rawotting of the valve, seas performed by The 90” culer is ted for fing te valve contest crea, end the locaton ond width of the soot conrct aren is ‘ecconplithed with the 60° and the 30” cutters Final. the valve opping operation i parfermed by lapping the gud vaN face 10 the volvo feet ising © literal avout of loppng corpowrd atthe volve face end work the valve back ard ‘oh ising @ seton cup lapping tec. Wash off tho compeund coreletly before making the test oF before csserbly. (Fig. 3.24) 2 sel of irae cutters O. 1-21) Valve guide veorme —@) yedor two rea Yee ate ae 8 Gitte! a, Figs 29 valve wot ovis area 1D Yolve so conch wid Fig. 2.24 Renoling te yoNe sat Vave aot eer2» 3. ENGINE Fig. 3.25 eka aod i © tera @ Siem sonster © Hone cine ig 3.27 Mecsrieg velve @ Dis gane @V beet 7. Inspection of valve sealing Assemble the valve into tho cylinder heod os shown in Fig. 3.25 20 that the valves are well seated ord fil he cylinder bead conustion cham- berwith ol, ject blast of oir 2ko/em? (28.4 psi in from the ilot ord orhast ports and if ony bubbles should appear, itis an indication that the valve seats cre rot completely cooled. (Fig, 3. 25) (el_Exoust valve (Fig. 3.26, 27) 060 ® love if under lerath @ | ipS9a~26nn in esa astm p |, sasesans | tela alee Sone gzistwaztes | Sue 73009 | eed elocn if uncer Micnaet @ O30 Geconicty 002TH | Bepice if toon | as woo (bl Inlet volve (Fig. 9.26, 27) Wen | Sandard woke | Servceale th won |g Z2eirs | Rosaceae asiomassein | “tos tassdin Stem da ®| qaitpoihssin | $198 aa hd veo 0508 | Replace if ver cls @| lWaze~oos2w | C3 wor Cencenery| 00218 | Rapice 4 over atvelvetaca| —@a0r2iy | Ou3 W.0012') Valve Mechanism oth the inlet and exhaust valves ore incorporoted in tho coméustion chamker. The inlet valve is de- signed larger than the exzoustvalvo 10 afford groater volumetric effeioncy. The exh! vive i constantly exposed to extremely high temperature; teeters, It Is made oF special high heat resisting matoral to Withstand the high tengerorue at wall atthe weer, The com chain revolves ot @ very high speed within the cam chain chanber which Is located on the left side of the cylinder. making i necessary Yo uso a hoot resstent as well os a wear resistant ruber on the com chain giiso sprocket and com Chain tensioner roller to proven! chan noise, Further, in contrast 10 tho conventional push rod type of mechanism, this system has loss recierocateg mov. Ing pars to coxse hing noses, mekina the operationsuch sebolter ord cunt I Is very atl for igh spane to erble the increase In power ou. (Fs 3.28) 1. Valve Spring Dual valve springs ee uted for oe ‘ard 10 prover? valve oct speed, They cre onorges siege wl rege omed or bave (al Oster vole spina (Fig, 8.29) 3.5 Cuno HAD S Ow oreFla, 3.30 conten @ 721.982 @973in) Tg 3 con Gorn tae cree 2 Comat ln a four woke ele eng, she eonctott mates ere evel for avery to vvcltors Cf the canal. The power to civ‘ cam Shalt ic touch the cam chan ckven by. tho sere! Te Libiatng oi prose fd no the gh Side cf tha conanf} ac ford cut of the totes tho com to Meat the com aefacs, the rocter arms ord tha sinpos. The cans | made of speci cost sel wilh the com and hs bang crea bal precionly ground oft oor teatrert. fis peated ot both es by Ire bearhgs in tho cinder bao. com pelt ‘5 Intoed on tho lft ond of the conchae wih ‘1m bas nd Ib ehiven ot cre tll cab speed by 1 “iehg splociat prse‘ted 10 the crorlsoft ond, though the ht welnhe endless lar. Fie. 3.30, 31] ‘he saad lope cleaancss reared cold cre .05%rm (0.00210) fer both tho inet ond exh The it the clemence momued when the rocker ‘1m is apc the he! of the com aba order to ahioin ths concn, the crank! mist bo refed so thatthe "7" fei mak cx tba drs rofer is aligned wit th Hn mak onthe str eruite, 79 oct 2m ray on th iting spe of tho can, Te oning ord cloing oF the vive te deter rived by tho sistem cioko ard is tm tothe coorkseft retain, Dang the inet cyte, the rlot valve ie opened ond closed. Dug the evant ‘ce, fhe sore opens end closing sence tales ce with the exaust valve Tho oper ange Letween th opening ances isthe same: os the pis tovel, However, shoo it Ie he same orth crtishatt rotation, js epee in toms of angio: roves ‘When point" nth Fig. 3. $2 pases bovord the rocker crm, tbo vetical nevernen of te vale eteoes. ort 0 erin pln where th com lobe ne: 10 © pool, tha mavenen! ofthe valve sows oun and. cones to a ballot point "b'* on the tapoel clarence i ested when the rector fon is ofthe expesed sition of the het oF the ‘con between ports "e" end "al a25 cn HAD 2 1. Vole tink Fig. 9.93) orm | tet wd | gs 8.64. ecg sarls it foo eaten Goto becom baer Mosinaien | predict eh diameter rd wlio —> 83.495~59. 285 (2103~ 21089 Savicebla fait —> Repos if ander 5300 207 ge 3.35 Honey cnet od dena @ Consett @ Mena4 Rocke con (Fig. 3.34) 26 Sek om Sipper fe 5. Recker com soft (Pi. 9.37) | 7 ie DL Re iy 1. Apply ergre silo te solve stews before ‘uorely ito to ender hows 2. Asontle reler am a vecler orm shll fo the cylnde hood ord Isto racer crm ee caver. 3, laste tho cylinder bead. (Fi. 3,38) NOTE: Beech coe 10 mate au thet the cher fea gusle', liter sh poste! a com choin guile: © retles pomely 12 prover ol leas * tyinen hes ean maser @ Cometan 4 Ina the eye hod cover on ghen tho ‘ats agora end wiley Ye 1S0~200kg-em (45~18.1bo+f). rere trqieg wal cose ol leak. (Fig. 2.39) 3.99 Toxin mame of ine4 cvinves s mo 5. Position tre craishott 0 thet the woodutt ey © te en tho cylinder artrino ond inthe ivi of the cylnlr tea Align he °O* ink © on me can sproctst to the redox mak cn the cyinde: hood he serclet rowntrg tol Foe wl ow 9h he er cota @ cand then eornoct the cam chain GD), (Fig. 3. 40) & Sco te cama @ 1 tn end bed though the speockr Iho toad cove ‘uth he pi Pole taverd The valve ord the psn are nthe top canter postin of he composi stoke, (Fg, Fig 2.40. Carr he om lon a a Bviane ey BD" nok) Can nde 7 Asoka te post bore @ on the camshaft ‘tenon ting on al seo) do too (loo) Na 530)). (Fa. 3.42) Donage 19 tha ol ol roy ea IF tool rot eed, eatirg oll bok, 8 otal the 3% 5.2 guide pln ond ane he 0. Aanble th A.C. geerator on heist 1. Pein texpet coerce cxhwtmnt ond nk CG tan thnk. Flas 841 eg ie a Geanemtt” GC sxecter 2 ala te pein covey and the elt cashes 3.6 CruNDER A. Consetion The eyihdor is mate el spacial cs ton. The insie ever wal ¢ expoens To heh tanperate ad prose ‘ogether th the woaing eatin of No rei acating piston operating ct High speedo - o Frosice a grt waning fect. Added to this a 8.42 eho teenie tok be fhe att it cod the Foreign object cre the netale dist ctenitng te ofl wil Ronen he 0 of wor Heroes, edomte ctomien should 2 given 10 te Gearing of tho of Tier aul the omer. (Fg. 2.42) @ The poten receives the combution cneay ond lonsils th High wecprocaing mation ar enk ‘fal where Wi coneited to the rotabona tion ae fo the Hoh spd lion between the ston (22 oyfedet, the nicton of the moti ond tho telaance of the movies arts kst be ein with @ ‘gest coe, Fi 2.43 oye3 ENGINE ia, 846 Peo Bote ‘THe pion a clorinm easing med. fem ‘lect rarer. (Fig. 3.44) This mac ght avd stale fr Hoh speed In ossiien to tavng good hoot oxductng propery to disipate the heat roxy, Furheor, the cor lfcion of boo caponion is ene, ts mining ‘na warpage a elovated larperoheo ond porting sal psn to cyledar cearoncs design The fxpe of the piton ison eligteal tcper. The heed Gf the pit, corpored fo te ait. omposed to Higher terparohra od sia tha expan i grea, Ih tpered emaler foward the top, The taper ing of th piston aso tds to lesen te pte Slop whe the stoma eighty marped witha the orgie boing loaied. The piston enploys 0 thee slop ‘ope The ion ph Eos ee wee clr, Hea, rel ing in gostor expaon of Hoh lerporonee. For ‘hs reasor the cloner oF tho pin sit fri sale inthe decion of he plzen piso hao the ich operating temperate, the pln wil end Ivo a tne chcor ope, Tha skit is corey povided wih Noity Ye cee tha no cferetion il real even fron exerded conus aig. “Tha pion pi & Ofset Irn (O4ie) from the Piston cererte nthe dtecton ofthe Inet side £9 that when the cion approaches the top-dosd- tier of the compression stk, he sido loa fron the cyt woves fom the vg seo tha lei Wik'2"O" feet, tho pont will mave to ain ‘sith tonchat-cnder of the conprasion stots (Pg. 3.45) ‘As shown in Foe 9.45, the poitt of wxainen contusion poise ocr aller the tocoad eer, ‘terfere, the pupore of te of! = to nove ho pont oward tho pot of weaker presse wich is fore top-eadcener, 8 by 10 dog, etapa: tte powerul presure rovenent ord mcks i) posible 4p eimino tha pster sp. ‘The pistn seg pina itl inetion of ass ‘rg pcper contusion ord tronaiton of fhe 10 allan fre, “he lop ord sicond reg sve oto zal forthe ‘onustion chorter, the ol cone! tng Leaps the ‘rene oll from the eyindor wel to carkol te feyinder wal WsictinFatter, thoy tro tho high fercorehio of the sition 19 the eyledor wall where it Is aspated cut trough the cylinder cooing fi.For this recto, 0 spec ally of cost en ie iad to provide crongth, voor restaree, ate Slee, and gore! heat conditng pcpntinn cr unter Ite ger paltieng yaatnen or ‘cx ein, Tha top tha expsctlly te pred om the over sufoco with hard chime ard fished by wet To peeve’ hier, te shkrae of the enge 6 rrada roower ar iter. neta is ads exer to facieoie te prose aga the c/keer wot Further a top and second ergt or ade at o Sait tar where It contacts the eyinde- wll 0 "har the tina tegdred for wearin ie laters (Fig. 3.46, 3.47), A. Disetrombly 2. Remove te rection 3-8-8 2. Renae tie can choir @ fom the inky sproctet ond raneve the cylinder D tageter withthe chon, (Fig. 3.48) as cyuNoER had seg oto Patt 8 Gr ses tw it 2 cm aona. 3.47 Seep te pt 2 Sra pa ee ro Grae ng Paice Pon tng waving So 0 Fig 182 eonrrg pt in ones Oras D Marae 3. The cam chan aide rolor ean be removed from the cyl by rewovaa to cam chan ito rater ph 4, emexe tho piston pin elp ond sh os the psn pi to clesonbie he isto fm te comsctrg tod. (Fig. 3.49) CAUTION: ‘When reraing te piston in cp. core sou be erercisd e tha th lp 6005 net 5. omove she pon vhge dD) feo He by wits a ring removing tool pci! toc. if no tool Is ove, the eg ay ob ber. roves by tend, by sposding the tng ot te opening wih both Fand,thy rno shad rat be ‘ws. (Fig. 3.50) Inspection 1, hace the cyte bore, top, ele! with © preebion eyindor gouge (D. Tako ta reoararent a ti top, nia od bottom both the X ond Y cams, (Fig. 251) Sprit asta | RES Tin Bas Sane | ME meee = 2, The cecscce balwsen he pstan cd ender ull greatly ake: he ergs pclrmonce Bos caus ofthe giston bias clipe, the-cecronca Is conrad vary closely, The closurees rot the save, towmor, ety cao i groter then O.lnm 0.0049, the eller shad be reecred ard fied th an eves pst voce pitare a9 alate i 0.25, 0.89, 0.75 ond 1.00 rm (0.01, 0.02. 0.03 rd 0.08 3 Wan removing caon devo from ite pston op ard ing coves, coe shoot be exersed seh tg coe a1) erate cx carogse 0 ro the skit fhe piton perpendiator oe paton pe tow. (Fig 432),5. Monaro tho piston tng do cence wih 2 res game. (Fig, 252) = [ten | Serine vote | Seeman tm Ma) as te pe ie done one Sree ae ater 4. Pon tng ove. (Pg. 2.54) Tas it a Boia Sachem oJ T 2. on ong Meesne the sig ent cap by iaitng the piston sing @ loo the eyBide a0 the the rg 2 @ gt onde to te cylinder onc. (Fg 3.55) ea ern Notes 1, Omelze pst irgs a ovatitle a far sizes; 0.28, 089, 0.75 ond 1.007 1001, 0.02, 003° ond 0.04 in).© 8. ENGINE 2. When king pian ing end gop esse rent, ner the ing coe ito te ender to rover scoihes geusee 16 th eye Di Reastorly 1. etl the pls sirgs en the pido in the {ere rereor ei woe removes. Tha berom ol papepeniars Shuts: 149.56 ce met ‘en non stn a Ela «check om sea be ne ce fl feay slr or ‘in the groove, This can be cone by rolling the: fe ice fre! coca. nl pin goo dM 20) The ig tn So aed eo down the wil cnse ot papa. Te opt of he D (rr |S etched at tho ord with the bitist oF the rede’ ne. Ra 3.57) ie othe cn thy oo wi ite inition oper psy in eae. 2. Anes pe to ant ad he cies tr 24/ caKYe pecrs be rensied $9 Iter the nitan pa. Alnave as 267 Pang Inuell new piston pin cs D Now CAUTION: Tha. clon st be sont 30 tht the "nN stomped on the pasion head ie toword tho top tho fe engi isin ho rome. tt (Fig, 3.58) 3. Rsanbie tho con eho oud cam oi guide ral to the syle A ntl thee ‘CAUTION, Te tng gop of the trae piston rings shel fe stogotes 120° opor se of the piston ring conpresor fool (Tool Ns. O7032~03901) for Fataing the cyl Fig, 248 Avenblag te pan wil prevrt danas to the een ing of BUN" mat Tr ll pty he wok Check to mote sw thet te ear cronser 5. Inetal the syindor head br cccondoce with pergh 3:50,