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    Honda SA50 Service Manual, MOPED ELITE

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    Honda SA50 Service Manual, MOPED ELITE

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    386 views162 pages

    Honda SA50 Service Manual

    Uploaded by

    JIMJEO
    Honda SA50 Service Manual, MOPED ELITE

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
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    ” 88-01 9 SASO/SASOP ELITE 50 LY/SR/S HOW TO USE THIS MANUAL Follow the Maintenance Schedule recommen: dations to ensure that the vehicle is in peak operating condition. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 through 3 apply to the whole motor scooter, while sections 4 through 18 describe parts of the motor scooter, grouped according to location. Find the section you want on this page, then Tum to the table of contents on page 1 of that section Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subse- quent pages give detailed procedures. If you don’t know what the source of the trou- ble is, refer to section 19, Troubleshooting. fications included in the latest product Information availa time of approval for printing. Handa Motor Co. Led. reserves the right to make changes at any time without notice and without incurring any ab: ligation whatever, No part of this publication may be reproduced without written permis HONDA MOTOR CO., LTD. Service Publications Office CONTENTS | Genenat inronmarion | wwenicaon MAINTENANCE FUEL SYSTEM ENGINE REMOVALIINSTALLATION CYLINDER HEAD/CYLINDER/PISTON Ea m4 5 mG Hi EI a a w eee g |_ALTERNATOR ©" DRIVE AND DRIVEN PULLEYS; KICKSTARTER( | FINAL REDUCTION ED | CRANKCASE/CRANKSHAFT FRAME COVERS 11 3| STEERING/FRONT WHEEL/BRAKE/ << |_SUSPENSION ©) REAR WHEEL/BRAKE/SUSPENSION oA BATTERY/CHARGING SYSTEM [14 @__ IGNITION SYSTEM }15 eee E[ mecrne franren ~ i 5 i) LIGHTS/METERS/SWITCHES 117— | |_WIRING DIAGRAM | TRoustesHooTiNG INDEX. sas Eg Dato of issue: January, 1098 © HONDA NCTOR CO., LTD, 1, GENERAL INFORMATION GENERAL SAFETY WW ‘SERVICE RULES WW MODEL IDENTIFICATION 1:2 SPECIFICATIONS 13 TORQUE VALUES 15 TOOLS 16 CABLE & HARNESS ROUTING Ww NOISE EMISSION CONTROL SYSTEMS (U.S.A. only) wy GENERAL SAFETY IF the engine must be running t0 do some work, make sure the ‘area Is well-venullated. Never rum the engine in a closed area. The exhaust coniains poisonous carbon monoxide gas thot ean cause loss of conselousness and may lead to death. Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow open flames or sparksin your working area or where gasoline is stored. Inhaled aibesios fibers have been found to cause respirerory disease and cancer. Never use an air hose or dry brush 10 clean brake or cluteh assemblies, Use an OSHA-approved tacuum cleaner or altemater method approved by OSHA designed 10 minimize the hazard coused dy airborne asbestos fibers, SERVICE RULES The battery electrolyte contains sulfurie acid. Protect your ‘exes, shin and clothing. In case of contact, flush thoroughly with water and cail @ doctor if electrotvte gets in your eves. ‘The battery generates hydrogen gas which can be highly explo- sive. Do not smoke or allow flames or sparks near the battery, especially while charging it 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that do not meet HONDA’s design specifications may damage the scooter, 2. Use the special tools designed for this scoater. 3. Use only metric toals when servicing this scooter. Metric bolts, nuts, and screws are not interchangeable with English fas: te 5. When tightening bolts or in 2 oF 3 steps, unless @ partic F sequence is spocitied, 1s. The use of incorrect tools and fasteners may damage the scoater Inotall new gaskets, O-rings, cotter pins, lock plates, exc. when reassembling, its, begin with largar-diameter or inner bolts frst, and tighten to the specified torque diagonally 6. Clean parts in non-flammable or high flash point solvent upon disassembly. Lubricate any sliding surfaces before re: assembly 1. After reassembly, check all parts for proper installation and operation 8. Routo all electrical wires as shown on pi 1-7 theu. 1-11, Cable and Horness Routing, and eway from sharp edges anc ‘areas where they might be pinched between moving parts 4-1 GENERAL INFORMATION MODEL IDENTIFICATION "8 Shown: After ‘88 similar » i (1) FRAME SERIAL NUMBER] ‘Tho frame sorial number is stamped on the left side of the frame. The carburetor identification number is on the lett side of the carburetor body. (9) VEHICLE IOENTIFICATION NUMBER The vehicle identification number ig attached to the left side of the trame body 14) CARBURETOR IDENTIFICATION NUMBER i The engina serial number is stamped on the left side of the engine case. [ey COLOR CODE LABEL The color cove label is attached 10 the fuel tenk below the seat. When ordering a color coded parts, always specify designated color 1-2 GENERAL INFORMATION SPECIFICATIONS TEM SPECIFICATIONS DIMENSIONS | Overall length 7,650 mm (65.0 in| 1,655 mm (65.2 in] ‘Overall width {860 rom (266 in} Overall hexght 1,010 mm {38.8 in| Wheelbase 1,160 mm (45.7 in| 5 1,170 mm (46.1 in| Ground clearance 4100 rnrn (3.9 in) 105 mm (4.1 in) Dry weight 62.4 bg (138 ib) SABO; 650 ko (143 ib} SABOP:652 kg (144 Ibs) FRAME Type Under bone Front suspension, travel Trailing link. 73 mm (2.9 in) Trang link, 58 rm (2.3 in) Root suspension, travel Final deve unit/swingatm, 60 mm (2.4 in) Maximum weiant capacity 81 kg (200 Front te size, proesure 3,00--10—4PR, 125 kPa (1.26 ko/em?, 18 psi) 3.00—10 424, 125 kPa (1.25 kg/cm 18 ps) For tie seo, pressure 3.00—10-4PR, 226 kPa (2.26 kg/em®, 23 ps) 3.00—10 424, 225 kPa (2.26 ka/em*, 33 ps) From brake intemal expanding shoe Roar brake Jtarnal expanding shoe Fuel tank capacity | 4.6 liners (1.22 US gal, 1.01 Imp gal) | Caster angle a7 Tra 77 mm (3.0 in) 81 mmm (3.2 in) | 73 mm (2.9 in) ENGINE Tyee ‘Air cooled 2-siroke Cylinder arrangomont Bore and stroke Displacement Compression ratio Transmission oil capacity il tank capacity Lubrication system Port timing Intake open close Exhaust open bite Scavenge open Egnine dry ane ie sone ‘Carburetor type Mdentification number Air screw initial setting Fioat level ‘Single cylindar inclined 15° from vortical 41,0 x 37.4 mm (1.61 x 1.47 in) 39.0 < 41.4 mm (1.54 X 1.63 in) 49.4 om (3,01 cu in) 69:1 70:1 90 cc (3.0 US oz 2.5 Imp oz) 0.8 litor (0.85 US at, 0.70 Imp at) 0 automatically mixed with gasoline Read valve controlled Reed valve controlled 80° BEDC 79° BEDC 80° ABDC 79° ABDC 56° BBOC 56 ABDC 14.7 kg (32.4 1b) 16.8 ka [364 ib) 1,800 + 100 rpm Piston valve PASM SABO: PASBJ SABOP: PAK 1-3/8 turns out SA5O: 1-7/8 turns out SASOP. 1-3/4 tuins out 122 mw (40 in} | GENERAL INFORMATION - Iker Z Specifications | ORIVE TRAIN | Cluten type Diy, automatic centrifugal clutch Primary reduction V-bott Gear ratio 2.45-0.85: 1 | . SASOP: 2.40-1.16: 1 Final reduction 88-'93 | 11.087:1 | S| toe ELECTRICAL, ignition system Condenser capacitive discherge ignition (CDI) Starting system Electric starter motor and kickstartar Alternator 12V 86W/5,000 rpm 12V 8BW/5,000 rpm | { 12V 100WW/S,000 1pm. | | Spark plug NGK [ DENSO 8893 | Standard BPRGHSA W20FPR-L | BPRAHSA | -WI4FPRL | Fer eatended: high-speed BPRAHSA W2arPR-t - riding | After ‘83 | Standard BRGHSA W20FR-L | For cold clmate BRAHSA Wi4FRL emer eh spon BRBHSA W2aFR-t "Spark plug gan : | 0.80.7 mm (0.024—0.028 in) | Ignition timing *F mark 17" BTDC at 1,800 + 100 rpm Battery capacity 12V 24H | Fuse capacity 108 UGHT | Headlight Low/High *a8—00 | 12V 25W/25W. Aiter‘00 | 12V 35W/35W | ‘ail/brake tight 12v ew/27W | Tur signal hight tv Wx 4 | ‘Speedometer light | 12v 1.7Wx2 | | High bear indicator 12V 1.7W Turn signal indicator 12v 3.4w 1-4 GENERAL INFORMATION TORQUE VALUES ENGINE a [aw | tedtnew | Toon wmiem Sn [Romane Cylinder head bolt 4 6 10 (1.0, 7.2) NOTE 1 | teat ' re segezn | ‘eet 99 1 10 40 (4.0, 29) After ‘93 Clutch outer nut 1 10 38 (3.8, 27) | ‘88 thu ‘93 1 0 1818635) | aer'93 inet i 8 3038.27) e093 1 28 ~ 55 (5.5, 40) ‘After 93 Movable dv aoe sel bok ; 2 #3 i645.9'9 seein ' 0 See 2h 36 mu 93 i % 018.0, 40) ci oe bot ‘ : tonsa) BE cecut i : Base ime Sarees \2 é 32132 29 inoue ; a tata io et a 3 : iottorai Eee naa i ' 0 ols0. 26) eterno iar wa $ : i ae ot cetces ancene Oo | 3 8 iolre: 73) FRAME iim aw Torque Nim zm a) | Remarks Geoieg on bok me : za 9108, 6.9 Stren ston nt ' 33 soar en en ' 0 ean ee ce | S108 3) a ' 3 ear Fen sieck sector sonar noun ott | 2 3 e739) Rastooecemece | 2 : aire) cnackiocceme | 2 8 Toon Brot am nt 3 3 07,95 eee wanmmieaan | 2 3 Ba8 nore 2 oie ‘ a folie ao Nota. '22 1 14 120(12,0, 87) —+—+ After ‘93 Rear brake arm bolt 1 5 5 (0.5, 3.6) NOTE 1 Rorretech cbeoerppermvount bot | | 5 so25 Ferrstwotsbanerowermount ton | $ ioe 18) ‘26 mu 93 ; : Pees aoe mumenwacnacwmmein. | | 8 iat) note? Auto fuel valve 1 16 23(2.3,17) if 10 60 (5.0, 36) Engine bracket bolt NOTE 1: Apply oil to the threads and seating (or flange) surface. NOTE 2: Apply locking agent to the threads. ‘Torque specifications listed above are for specific fasteners. Others should be tightened to the standard torque values below. STANDARD TORQUE VALUES Torque Values Torque Values | ion Nem (kg-m, feb) ai Nem (kgrm, ft-lb) ‘5 mm bolt and nut 5 (0.5.3.5) 5 mm screw 410.43) | mm bolt and nut 10(1.0, 7.2) 6 mm ecrow 9(0.9, 7) 6 mm bot with 8 mm head 9(0.9, 7) 8 mm bolt and nut 22(2.2, 16) 6 mim flange bolt and nut 12(1.2.9) 10 mm bolt and nut 35 (3.5, 25) 8 mm flange bot and nut 27 (2.7.20) 55 (5.5, 40) 10 mm fiange bolt and nut 40 (4.0, 29) 12mm bolt and nut GENERAL INFORMATION SPECIAL Description ‘Too! Number Alternate Too! Too! Number Vacuum pump A937X—041— Vacuum pump (U.S.A. ST-AH-260—MCT (USA only) 290% | only: Included in turbo Lock nut wench, 38mm | 07916—-KS40100 Clutch spring compressor | 07936—KM10000 Bearing drives 07945—GC80000 Bearing remover set, 1 mm 07936—KC10000 remover handle 07936—1660100 remover weight 077410010201 Bearing remover set, 12 mm 079361660001 remover handle 07936—1860100 “remover waight 077410010201 Assembly colar (07965—GM00100 Assembly shaft 07985—GM00300, * Assembly shaft 07965-1660200 Case puller 07935—GK80000 Case puller 07935-80000 Universal bearing puller 076310010000 Thvead protector 079311870000 Lock nut wrench 07916-1870000 Lock nut wrench 07916—-KM10000 Avachment, 28% 80mm | 07946—1870100 kit) 39 mm socket Clutch spring compressor Remover weight Remover weight Equivalent commercially available in USA. Equivalent commercially availabie in USA. (07960-KM1000A, 07936-3710200 07936—3710200 | Attachment, 32%35mm | 07746-0010100 Attachment, 37%40mm | 07746—-0010200 ‘ssAttachmont, 4247 mm | 07746-0010300 ‘sAttachmant, 52%55mm | 077460010400 Filot, 10mm 077460040100 Pilot, 12mm, 07746~-0040200 Fiolt, 18mm. 07746-0040300 Piclt, 17. mm, 077460040400 Piolt, 20 mm 07746-0040500 Bearing driver 077490010000 Bearing remover shaft 07746-0050100 Bearing remover head, 10mm 077460050200 Shoch absorber compressor | O7GME™-0010000 tock ut wrench, 30%32 mm | 07716--0020400 Extension bar 07716-0020800 Equivalent commercially available in U.S.A. Equivalent commercially avaiable in U.S.A Ball race romover | 07948~GA70000 Shock absorber compressor sttachment | 07967—Ga70101 ‘Spring attachment 07867—GM90100 Digital multimeter M9360-277— | Digital muitimeter KS—AHM-—32—-003 91774 COMMON = Description Too! Number ‘Aharnate Tool ‘Tool Number Ret Sec Float level gauge 07401-00100 | Universal holder 07725-00300 Fiywee! puller 07733~-0010000 | Flywheel puller 1079330230000 “After 93 only #488 thru. ‘93 only 1-6 GENERAL INFORMATION CABLE & HARNESS ROUTING [Note the following when routing cables and wire harnesses. © A loose wire hamess or cable can be a safety hazard. After clamping, check each wire to be sure it is secure. © Do not squeeze wires against a weld or end of @ clomp, ‘© Secure wires end wire harnesses to the feame with thei re spective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contect the wires or wire harnesses. '@ Route harnesses so they are not pulled tight or have exces: sive slack, ‘© Provect wives and harnesses with electricel tape or tubes if thay contact a sharp edge oF corner Clean che attaching surface thoroughly belore applying tape. © Do nat use wites or hamesses with broken insulation. Repair by wrapping them with protective tepe or replace them @ Route wite harnesses to avoid sharp edges and comers. ‘Also avoid the projected ends of bolts and screws, © Keep wire harnesses away from the exhaust pipes and other hot parts © Be sure orammets are seated in their grooves properly © Aftor clamping. check each hamess to be certain that itis riot interfering with any moving or sliding parts. © Wise harnesses routed slong the hendlebars should not be pulled taut, have excessive slack. be pinched, or intertere with adjacent ar surrounding parts in all steering positions. ‘© Afier routing, check that the wire harnesses are not twisted or kinked 8.0 not bend or twist control cables. Damaged control cables wil not operate smoothly and may stick or bind, ©: ConnecT x: INCORRECT GENERAL INFORMATION FRONT BRAKE CABLE ” (2) SPEEDOMETER CABLE ——_—*[3) REAR BRAKE CABLE |a) INSTRUMENT WIRE (8) THROTTLE CaBLé (7) IGNITION SWITCH WIRE (5) RESISTOR (6) REGULATORIRECTIFIER (14) R. HANDLEBAR SWITCH WIRE (9) L. HANDLEBAR SWITCH WIRE (12) R. TURN SIGNAL WIRE (VL, TURN SIGNAL WIRE 1-8 Gn GENERAL INFORMATION (9) OW INLET TUBE (8) OW OUTLET TUBE (1) THROTTLE CABLE (2) CRANKCASE BREATHER TUBE (4) REAR BRAKE CABLE (5) ALTERNATOR WIRE, 1-9 GENERAL INFORMATION (7) FUEL SENSOR WIRE (1) AUTO FUEL VALVE VACUUM TUBE (5) FUEL TUBE NO \ |4) SPARK PLUG WIRE 7 2, GENERAL INFORMATION G (1) REAR BRAKE CABLE (5) FRONT BRAKE CABLE 1-11 LUBRICATION 2. LUBRICATION ‘SERVICE INFORMATION 2-1 OILSTRAINER 24 ‘TROUBLESHOOTING 21 OILTANK 25 oll PUMP 2-2 LUBRICATION POINTS: 26 OIL LINES/PUMP BLEEDING 23 OIL PUMP CONTROL CABLE ADJUSTMENT (SA50) 24 SERVICE INFORMATION GENERAL ‘© When removing and installing the oil pump, use care not to allow dust oF dirt to enter the engine and ol '# Do not attempt to disassemble the oil pump. {© ized air from the oll purnp if there Is air in the oil inlet line (trom the oil tank to the oil pump) oF whenever the oil fine hes, been disconnected. ‘© leed arr from the oll outlet tine (from the ail purnp to the carburetor) whenever the line has besn disconnected (page 2-3) © Use HONDA 2-etroke injector oil or equiv TROUBLESHOOTING Excessive smoke and/or carbon on spark plug + Faulty oll pump + Low quality engine oil + SA5O; OM! pump not properly adjusted (excessive oil) Overheating + Faulty oil pump + Low quality ol! + SA50: Oil pump not properly adjusted (insufficient oil Seized piston + No oi! in tank or clogged cil line + Air in oll ines + Faulty oil pump + Clogged oi! strainer + SA5O: Oil pump net properly adjusted (insufticiont oil), 0 not flowing out of tank + Clogged oil tank cap breather hole + Clogged oll strainer LUBRICATION OIL PUMP REMOVAL Remove the center trunk (page 11-5) NOTE + Before removing the all pump, clean the oll pump and erank. Except SABOP: Remove the oil control cable trom the cable stay and oil pump control lever Clamp the oil knoe s0 oil does not flow out; then disconnect the oil lines trom the oll pump. Disconnect the alternator wite from she clamp, Remove the oll pump contiol cable stay attaching bolts. Remove the oil pump. INSPECTION CAUTION + Da not disassemble the oil pump, Inspect for the folowing: ~ Damaged or weak O-ring — Damage to crankcase mating surface Damage to pump body Except SABOP : Control lever operation — Worn oF damaged pump gear — Oil leake INSTALLATION Lubricate the O-ring with grease or ol Apply molybdenum disutide grease ‘0 the oll pump gear anc in stall the oil pump, Make sure that the oil pump ie properly inzerted into the crank case (1) BOLTS: 1) O-RING = \ (2) MATING SURFACE (3) PUMP Lever (4) PUMP GEAR 2-2 Instal the oll pump control cable stay and attachina bolts and tighten the attaching bolts securely. Connect the oi inlet and ourtet tines Connoct the oil cantrol eable to the conteol lever Clamp the alternator wire ‘Attar installation, bleed the oll pump and tines and check for leaks. —Excopt SASOP: Adjust the oll control cable (page 2-4) OIL LINES/PUMP BLEEDING caurion + Ait in the oil system will block or resirict oll flow and may ‘result in severe engine damage. * Bleed air from the oil lines whenever the oil tines or pump have been removed or thore is air in the oi lines * Bleed air from the oil inlet line fist, then bleed ait from ihe oil cuter line, OIL INLET LINE/OIL PUMP 7 (4) CONTROL CABLE Fill the oil tank with the recommended oil (page 2-1), J3) CABLE STAY_| lace a shop towel around the oil pump and disconnect the oil Inlet line frarn the oil pump. Fil the oil pump with the cecommended oil atthe cil pump inlat joint Let al dria from the inlet line to bleed air in the line. Connect tbe oil inlet fine to the oil pump, OUTLET LINE 1. Remove the outtet line from the intake pipe and ail pump. Fil the cuter line with the tecommended oil as shown. Install the outlet line to the oil pump. 2. Start the engine and allow it ta idle and make sure that oil is forced out from the intake pige end of the oli outit tine. fl is not forced out within cna minute, stop the engine ‘and repeat steps 1 and 2 Connect the oil outlet line ta the intake pipe ie ‘CAUTION + Perform this operation in well-ventilated area. Do not ee the ensine up. /—|1) OL OUTLET Je LUBRICATION OIL PUMP CONTROL CABLE [TT AUGNgS WaRK NOE HARK ADJUSTMENT (SA50) [ ~ ( NOTE +The oll pump control cable should be adjusted after the throttle grip free play adjustment. Remove the center trunk (page 11-5). : ff FUEL SYSTEM. 4-0 4. FUEL SYSTEM ‘SERVICE INFORMATION 44 THROTTLE VALVE ‘TROUBLESHOOTING gz, MNBTALLATION ae THROTTLE VALVE DISASSEMBLY a3; BEDNALVE #8 CARBURETOR REMOVAL 4.4 AIRSCREW ADJUSTMENT an HIGH ALTITUDE ADJUSTMENT AUTO BYSTARTER 4 TUR om) an FLOAT/FLOAT VALVE/JETS ‘AUTO FUEL VALVE INSPECTION’ fsdinnamnpenid 4-8 MAINTENANCE 42 Ses ST VALVERLOAT 47 FUELSTRAINER CLEANING 413 FLOAT LEVEL INSPECTION qe FURLTANE +3 CARBURETOR INSTALLATION cg: “AIRCLEANER GABE bas SERVICE INFORMATION GENERAL ‘Gasoline is extremely flammable and is explosive under certain conditions. Work in a welbventilted area withthe engine stopped. Do not smoke orailow open flames or sparks in the work area or where gasoline is stored. (CAUTION ‘Do not bend or twist control cables. Damaged control cables will no ope fe smoothly and may stick 0° bind. © The fuel tank ie equipped with an auto fuel vaive that is turned OFF automatically when the engine is stopped © Use caution when working with gasoline, Always work in a well-ventilated area and away from sparks or flames. © When dizaszembiing fuel system parts, note the locations of the O-rings. Replace them with new ones curing assombly © Blood air trom the oil outlet line whenever itis disconnected, SPECIFICATIONS eM SSSSSdYSS ICAI — Wenifeaton number —~—=S~*~S | AT : | ‘tr "93 | SABO: PASE - SABOP: PABK [Type | Pieton vate Yertun diameter [4mm 088 in) Fiat vel [12.2 mm (048 i) A crew opening [863 | 1-9/8 wi ‘twer'93 | SABO: 1-7/8 wns out SASOP: 1-9/4 wins out ii speed 1,800 = 100 pm [ Main jet "88—'93 | #88 ‘ator'98 | SABO! #78 sA80P: #68 [Slow jet 5 Tote gip feo play ——SSSSS~«*d em VAT TI er nesdle - _ 2nd groou 41 FUEL SYSTEM TOOLS Special Vacuum pump Common Float level gouge TROUBLESHOOTING Engine cranks but won't start + No fue! in tank. + No fue! to carburetor + Too much fuel getting into cylinder + No spark st piug lignition maifunction) + Air cleane: clogged + Faulty auto bysterter + Clogged fuel line + Clogged fuel strainer + Stuck {uel valve disphragm Engine idles roughly, stalls, or runs poorly + Idle speed incorrect + Ignition malfunction + Low compression + Rich mixture + Lean mixture + Air cleaner clogged + Air leaking into inlet pine + Fuel contaminated 07401—0010000 A937X—041—XXXXX oF ST-AH~260-MC7 (U.S.A. only, included in Lean mixture Carburetor fvel jets clogged Fuel cap vent clogged oF blocked Fuel strainer clogged Ful line kinked of restricted Float valve faulty Float level 100 low i vent tube clogged Rich mixture + Disconnected auto bystarter wires Faulty float vaive Float level too high Cerburetor air jets Clogged Air cleaner dirty FUEL SYSTEM THROTTLE VALVE DISASSEMBLY Loosen the sir cleaner connseting tube band Remove the two air cleaner case mounting bolts Remove the heat insulator from the air cleaner case, then remove the air cleaner case. Remove tho carburetor cap and pull out the throttle valve. 1) CARBURETOR CAP Disconnect the throttle cable fram the thrattle valve. Remove the throttle velve spring ‘caurION + The corbureror cap &s an intesral part of the throtile cable as sembly. The cap cannot be separated from the assembly with: out causing damage 10 the cable FUEL SYSTEM Pry out the retoiner and remove the jst noodle Check the jet needle and throttle valve for wear or damage and (1) RETAINER replace tham if necessary. “iar ets GLie (3) SET NEEDLE @ THROTTLE VALVE CARBURETOR REMOVAL Remove the following: ‘center cover (page 11-2), left side cover (page 11-2) — lett frame rear cover (page 11-3). air elooner case (page 4-13) Disconnect the euto bystarter wire connoctor. Remove the carburetor cap and pull out the throttle valve, Disconnect the fuel line from the carburetor body, Remove the carburetor mounting bolts and remove tho carbur- rotor AUTO BYSTARTER INSPECTION I the engine has been running, let it cool for 10 minutes oF Measure the resistance between the auto bystartar wires. Re: place the auto bystarter with a new one if resistance is out of specification or if there is no continuity. RESISTANCE: 10 11 max. 4-4 FUEL SYSTEM Let the carburetor ait for 30 minutes, Connect 2 pressure tester to the envichening circuit end apply pressure 10 the circuit If the passage is blocked, replace the atsto bystarter with 3 Connect # 12 V battery between the auto bystarter wires and wait five minutes. Connect » pressure taster to the fuel enrichening circuit and apply prossure to it Replace the outo bystorter with @ new one if there ia na restric tion to the pressure applied, REMOVAL/INSTALLATION (1) screws Remove the two screws, set plate and auto bystarter from the carburetor body (2) set PLATE Inspect the auto bystarter valve for wear or damage, and the (1) VALVE Ging for deterioration (2) O-RING 4-5 FUEL SYSTEM PUBL SYSTEM (2 scREWS (9) SET PLATE FLOAT/FLOAT VALVE/JETS DISASSEMBLY 1) orain screw Place a drain pan under the carburetor and loosen the carbura- {oF drain screw to allow fuel 10 drain into the drain pan. Remove the (leat chambe rom the carburetor body, Remove the carburetor float and float valve by removing the (1) FLOAT (2) SCREW ‘attaching sore, Remove the O-ring from the carburetor body. FLOAT/FLOAT VALVE INSPECTION Check the valve and seat for wane or damage. Replace the valve and seat as a set if either part is worn ot damaged, 4-6 FUEL SYSTEM ‘Turn in the throttle stop screw and record the number of turns intakes bofore it soats lightly. Fepeat this procedure with the air screw. CAUTION + Do not force the screws against their sears to prevent damaging them. Remove the throttle stop screw and air scrow. Remove the auto-bystarter set plate and the bysterter by re- moving the two scrows. ‘Check all parts for weer or damage. Blow open all jets and body openings with compressed ai. JETS/FLOAT VALVE/FLOAT ASSEMBLY Install the main et. Insta the air and throttle stop screws to their original posi- tone recorded during disassembly. ‘instal the float vaive, float and float pin Tighten the float screw securely, Instal the O-ring onto the carburetor body oroove.. ‘Instal the auto bystarter with the set plate and two screws. (1) THROTTLE STOP SCREW sf (2) AIR SCREW (2) THROTTLE STOP SCREW (1) FLOAT, (2) FLOAT PIN FUEL SYSTEM FLOAT LEVEL INSPECTION Remove the O-ring fram the carburetor body. Measure the float level with the lat lip just contacting the float valve FLOAT LEVEL: 12.2 mm (0.48 in} TOOL: Float level gouge 074010010000 Replace the float ifthe level ia incorrect Reinstall the O-ring onto the carburetor body groove. Check the operation of the flost and install the float chamber. CARBURETOR INSTALLATION ‘CAUTION + Do not allow Joreian particles to enter the carburetor. ‘Be sure the O-ting is in place on the carburetor. Install the heat Insulator and carburetor mounting bolts. Install the carburetor cap (poge 4-8) Connect the Tue! line and auto bystarter wires, THROTTLE VALVE INSTALLATION =| AL Install the needie clip on the jot needte, (1) RETAINER STANDARD SETTING: 2nd groove : (2) NEEOLE CLP instal the ot needle into the throttla valve and secure with the JET NEEDLE a THROTTLE VALVE 4-8 FUEL SYSTEM Jnstal the spring on the throttle cable assembly, IN) THROTTLE VALVE SPRING. Connect the thrattle valve to the cable. (2) THROTTLE VALVE 1) THROTTLE CABLE Slide the throttle valve into the carburetor body, (1) GROOVE (OTe + Align the groove in the valve with the throtile stop screw on the carburetor body. Tighten the carburetor cap, Perform the following adjustments and operations: = throttle cable free play adjustmont (page 3-3) = ol pump and line bieeaing (page 2-3), ~ idle speod adjustment (page 2-5) not REED VALVE REMOVAL. the loft side cover (page 11-2) Remove the following parts = carburetor (pege 4-4) cylinder head shroud (page 6:2) = vacuury tube. Remove the four inlet pipe mounting bolts, the inlet pipe and Geshe, FUEL SYSTEM Remeve the reed valve and gasket. INSPECTION Check the reed velve for damaged or weak reeds, Check the valve seat for eracks, damage or clearance between the seat and reed. Replace the valve if necessary. CAUTION + Do rot disassemble or bend the reed stopper. To do so con ‘cause loss of power and engine damage. Ifthe Stopper, reed or salve seat is foulty, replace them a& a unit (1) VALVE SéAT (2) REED INSTALLATION The installation sequence is essentially the reverse order of re: NOTE ‘+ Align the tabs on the gasket ond roed valve and install tho seed valve. After instalation, check for secondary leaks. (_) REED VALVE| 4-10 FUEL SYSTEM AIR SCREW ADJUSTMENT (1) AIR SCREW NOTE The engine must be warm for accurate sir serew edjust mont When the engine misses or runs erratically, proceed as fot lowe Turn ia the aie screw in until it lighuy seats, then turn it ‘ut as spect. CAUTION © Darmage to the air screw seat will oceur if the air screw iaihtened against the seat. AIR SCREW INITIAL OPENING: ‘88—'93: 1-3/8 turns out ‘After ‘93: SA5O: 1-7/8 tuns out SASOP: 1-3/4 turns out Feset the idle speed with the throttle stop screw. IDLE SPEED: 1,800 + 100 rpm ily by Make sure that the engine does not miss or run erratic lightly snapping the theottle arp. necessary, turn the air screw 1/4 turn (maximum) in either direction to find the best performance. ithe engine cannot be djusted within 1/4 turn, refer to Troubleshooting. POOR PERFORMANCE AT LOW AND IDLE SPEEDS (page 19-2) HIGH ALTITUDE ADJUSTMENT (U.S.A. Only) When the vehicle is to be aperated continuously above 2,000 m {6,500 fectl, the carburetor main jet must be replace with 3 high altitude type main jet to improve driveability ond ‘deerense exhoust emissions. [Disin the fuel from the float chamber into an approved ‘line container. + Gasoline is extremely flammable and is explosive ander certain conditions. Work in a well ventilated area, Do ot smoke or allow flames or sparks in the work arca or tere gasoline is stored. Romove the carburstor (page 4-4), Femove the float chamber, Repleca tho standard main jot with 2 high altitude main jat High ottiude main jot:'88—'93: 285 Alter ‘93: SASO: #75 SASOP: #65 Berea te Hoot chamber and ita the carburetor (eae . eee 4-11 FUEL SYSTEM ‘eso: Turn the air screw out 1/2 tun, Agjust the idle speed with the throttle stop screwy. IDLE SPEED: 1,800 + 100 rpm After ‘93: Turn the theottle step screw in 1/2 turn for SABO and 3/8 tutn for SABOP. Attach @ Vehicle Emission Control Information Update LLeble onto the as shown, Refer to Service Bulletin No, SL 132 for information on obtaining the label, {that can be easily removed from the vehicle. + Operation at an altitude lower than 1,500 m (3,000 fee) ‘with the carburetor adjusted for high altinude may cause fhe engine toile roughly and all. When the scooter is to be operated continuously below 1.500 1m (5,000 feet), remove the carburetor, replace the main jet with the standard main jet and adjust the idle speed. main jet: '88—'93: #88. After ‘93; SASO: 278 SASOP: 368 Remove the Vehicle Emission Control Update Lable that is attached (0 the rear fender (as shown above) after adjusting {or low altitude operation. AUTO FUEL VALVE INSPECTION/MAINTENANCE 1, Disconnect the {ual line from the carburetor and chack if fuel s flowing out of the fuel line. am + Gasoline is extremely flammable and is explosive under certsin conditions, Perform this operation in a well-ventilated area and do not smoke or allow sparks én th “The fuel valve is normal if fuel ceases to flow out of the line after the fuel valve and fuel line have been drained. Should {uel continue to flow cut of the fuel line, partorm the follow: ‘ng operation’ + Clear the vacuum tube of any obstruction, + Diract a jot of comprossed air through the fuel valve from the top. 2. Disconnect the vacuum tube from the intake pipe and apply vacuum to the vacuum tube. The {uel valve ie normal if {uel flows out of the fuel line when vacuum is eppled. If fact does not flow out of the fuel line when nogative pres sure is applied: do the folowing: + Clean the vacuum tubs with compressed air. + Clean the fue! strainer with compressed ait Loceen a stuck diaphragm by directing a jet of com [Bressed air to the fuel valve trom the bottom. Hold the air rnozele about 3 inches from the inlot Stan ——— 4-12 FUEL SYSTEM ASSEMBLY (2) FUEL LEVEL SENSOR (1) FUEL TANK . Ascombly ig tho reverse order of disossembly, 16) SEAT L af (5) FUEL TUBE INSTALLATION Installation is essentially the revaree of removal. Note + Align the arrow on the fuel unit retainer with the errow on the fuel tank. AIR CLEANER CASE (2) AIR CLEANER CASE Remove the lott side cover page 11-21 Loosen the ar cleaner connecting tube band, fRerove the two air cleaner case mounting bolts. Remove the host insulator from the air cleaner ease, then remove the air cleaner case. FUEL SYSTEM INSTALLATION Installation is the reverse of removel, lig? (a) CONNECTING TUBE BAND (3) AIR CLEANER CASE (2) AIR CLEANER CASE COVER ENGINE REMOVAL/INSTALLATION 12 Nem (1.2 kgiam, 9 fetb) 25 Nem (2.5 komm, 18 fb) 95 Nery (9.5 kgm, 26 ftb) 5-0 5. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION 5-1 ENGINEINSTALLATION 53 ENGINE REMOVAL 82 SERVICE INFORMATION GENERAL © The engine must be removed to service the crankshaft. SPECIFICATION Engine dry weight "B8—'93: 14.7 kg (32.4 Ib} After ‘93: 16.5 kg (38.4 Ib) TORQUE VALUES Engine mount bolt 50 Nem (5.0 ka-m, 36 ft-ib) Engine bracket bolt 50 Nem (5.0 kg-m, 36 ft-lb} Fear shock absorber upper mount bolt ‘BB~'93: 25 Nem (2.5 kgm, 18 ft-lb) After ‘93: 27 Nem (2.7 kg-m, 20 ft-lb) ‘Exhaust pipe joint nut 12 Nem (1.2 kg-m, 9 ft-lb) ‘Muffler mount bott 32 Nem (3.2 kg-m, 23 ft-lb) 5-1 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Remove the following: both frame rear covers (page 11-3). = center trunk (page 11-5). air leaner case (page 4:13) Disconnect the alternator, starter motor and auto bystarter wire connectors, (yconnecrons i) nove the exhaust muffler (page 13-2), Remove the spark plug cap. ~ - re Except SASOP: Remove the oll control cable from the cable (2) Olt TUBE EG) UPPER MOUNT BOLT stay and oil control levar Ls VACUUM TUBE Remove the carburetor cap from the carburetor Disconnect the oil, uel, and vacuum tubes from the carburetor and intake pipe, Disconnect the rear shock absorber upper mount bolt. Remove the reer broke adjusting nut, then remove the rear ‘brake cable fram the clamp on the left crankcase cover hh 1 hones 5-2 ENGINE REMOVAL/INSTALLATION Place a workstand under the engine to support it Remove the engine mounting bolt and nut and separate the fangine from the frame, / ¥ / (1) ENGINE MOUNT BOLT Femove the following parts when the crankease rated. ~ Carburetor (poge 4-4) ~ imake pipe and reed valve (page 4-9). 8 pump (page 2-2. = Rear wheel (page 13:2, = Akernator (page 7-2) = Starter motor (page 18-2) ~ Diive/driven pullays (page 8.5, 8) ~ Cylinder head/cvlinder (page 6-2, 4) to be sepa: ENGINE MOUNTING BRACKET REMOVAL. Remove the engine mounting bracket bolt and remove the tracker ENGINE INSTALLATION The installation sequence is essentially the reverse order at 10 moval Tighten the following bolt to the specified torque, ToRQUE Engine bracket bolt 50 Nem (5.0 kg-m, 36 ft.tb) Engine mount bolt: 80 N.m (5.0 kg-m, 36 ft-lb) Rear shock absorber lower mount bolt: "BR—'93: 26 Nem (2.5 kg-m. 18 ft-lb) After '93: 27 Nem (2.7 kg-m, 20 ft-Ib) Exhaust pipe joint nut: 12 Nem (1.2 kg-m, 9 ft-lb) ‘Muffler mount bolt: 32 Nem (3.2 kg-m, 23 ft-lb) ENGINE REMOVAL/INSTALLATION Inepect and/or adjust the following — Wire and cable routing (page 1-7) wear brake lever free play (nage 3-5) = Oll pump bleeding/priming (page 2-3) — Except SABOP: Oil contro! cable (page 2-4) 5-4 6. CYLINDER HEAD/CYLINDER/PISTON ‘SERVICE INFORMATION 6-1 CYLINDER HEAD 63 TROUBLESHOOTING 6-2 CYLINDER/PISTON 65 SERVICE INFORMATION GENERAL © All cylinder head, cylinder and piston service can be done with th ingine installed in the frame. © Belore disassembly, clean the engine to prevent dirt and dust trom entering the cylinder ang crankcase. Remove all gasket mat Use caun assembly SPECIFICATIONS ire from the mating surfaces of the cylinder and erankcace, when disessembiing and assembling the cylinder Ne © Clean all dieaszembled parts thoroughly before inspection. Coat all siding surfaces with cl cylinder and piston 10 avoid damaging ther. 1 2-str0ke injactot oil bafore E Unit: mom fn) [ STANDARD SERVICE LIMIT Cynder head warpage = 010 (0.004) Cyinder—|1D. AlMark A) | "BB thru.'93 | 47.000—41.006 (1.6142-16144) | 41.05 (1.616) After’93 | 39.000-39005 (16354-15356) | 3905 (1.537) BINo mark) ‘88 thru."93 o5—: 146) | 41.05 (1.616) Aer ‘93 5368) | 3905 (1.897) — (0:10 (0.004) 0.10 (0.004) warpage 0.10 (0.004) “Paton, [Piston 0.0, | 88 thru "93 piston ring, 40985-40966 (1.6124-1.6128) 40900 (1.610) piten pn Aer [Amark 38065-38060 TESTER) | 3800 8ST B mark 36,965-98970 (1.6341-1.5342) | 3890 (1.631) | L | |_Nomerk | 98960-98985 (1.6939-1.5341) | 98.90 (1.531) Fiston pin hole LO. ‘88 thru.'@3 | 10,.002~10008 (0:3938-0:3940) | 1003 (0.985) Atter'93 | 12.002~12008 (04725-04728) 1203 (0.474) Piston pin 0. 88 thru.93 | 9994-10000 (03935-03937) | 988 (0.393) After ‘93, 11.884—12.000 (04722-04724) | 1198 (04717) Picton-to-piston pin clearance 0002-0014 _(0.0001-0.0006) | 003 (0.001) Piston ring end gap [[88th'93 | 010-028 (0.0040-00100) | 050 10.020) | _ Cpacenel Aiter'93__| 0100.26 — (0.004-0010) | 040 (0.016) Connecting rod small end LO “88 thru.99 | 14005-14015 (0.5514-0.551) | 14.03 (0.552) ‘After'93_ | 17.005~17.017 (0,6685-0.6700) | 17.03 (0.6705) TORQUE VALUE Cylinder head bolt Exhaust pipe joint nut 10 Nm (1.0 kam, 7.2 feb) Apply oil to the threads and flange surface, 12 Nem (1.2 kgm, 9 Ftd) 6-1 CYLINDER HEAD/CYLINDER/PISTON TROUBLESHOOTING Compression too low. hard starting or poor performance at Abnormal noise- piston tow speed + Worn eylinder and + Leaking cylinder head gasket + Worn piston pin o piston pin hole + Loose spark plug + Worn connecting rod amall end bearing + Worn, stuck or broken piston rings + Worn or damaged cylinder and piston Abnormal noise + Faulty reed valve + Worn, stuck or broken piston rings + Worn or demaged cylinder Compression too high, overheating or knocking + Excessive carbon build-up in cylinder head or on top of piston CYLINDER HEAD/CYLINDER/PISTON CYLINDER HEAD TT FAA COVER, REMOVAL Remove the following = both side cover (page 11:2). rear cover (page 11-3). Remove the fan covar by remaving the twe mounting bolts. i Remove the air cleaner case (page 4-14) q Disconnect the spark plug cap. ) Remove the cylinder head styoud by removing the two mount ing bots, { Remove the exhaust muffler (page 13-2) Remove the spark plug. the cylinder dor aad, 1d bolts and the cylin- (2) BOLTS Pemove the cylinder head gasket (1) GASKET CYLINDER HEAD/CYLINDER/PISTON INSPECTION Remove the carbon deposits from the combustion chamber, and the piston head. Clean the head gasket surface. ‘CAUTION + Do nor damage the combustion chamber wall and gasket sur Soces. Remove the carbon deposits from the head pipe of the exhaust mule NOTE = Ifthe engine stil has poor performanee after decarbonizing, replace the muffler assembly, ‘Check the cylinder head for warpage with a stiaight edge and ‘a fosler gauge in each of tha directions shown, ‘SERVICE LIMIT: 0.10 mm (0.004 in) INSTALLATION it) gasker Install 3 new cylinder head gasket 6-4 CYLINDER HEAD/CYLINDER/PISTON Install she cylinder head on the cylinder. (2) BOLTS TTT SPARK PLUG Apply oil to the cylinder haad bolt threads and flange sur face. Install and tighten the four cylinder head bolts in a crisscross pattern, 2 oF 3 steps. TORQUE: 10 Nem (1.0 kgm, 7.2 ftab) Insta the spark plug instal the cylinder head shroue and tighten the mounting (ny SHROUD, bots. ee Inetall the spark plug cap. Install tho air eleanor ease (page 4-14) {instal the fan cover and tighten the mounting botts. TITAN COVER (2) BOLTS Install tho following parts: = center trunk (page 11-5). — both frame rear cover (page 11.3) — both sice covers (page 11-2) carrier (page 11-6) CYLINDER/ PISTON 11 CYLINDER. CYLINDER REMOVAL flemove the cylinder head (page 6-3) Remove the cylinder using care not 10 damage the piston, CAUTION © Do not pry between the evlinder and crankease or sirie the Sis. Pace a shop towel into the crankcase around the piston. CYLINDER HEAD/CYLINDERIPISTON | PISTON REMOVAL =, Remove the piston pin clip using a pair of needle nose pliers. Press the piston pin out of the piston. Do not damage or scratch the piston Do not apply eide force to the connecting rod, Do not let the cip fal into the crankcase. (1) PISTON PIN CLIP PISTON RING/EXPANDER REMOVAL Remove the piston rings. loan carbon deposits ‘rom the piston head and piston ring grooves, Note + Spread each piston ring and remove it by lifting it up at a point just opposite the gap. + Do not damage the piston rings by spreading the ends too for ot to scratch the + Use car CYLINDER/PISTON INSPECTION Check the cylinder end piston fer wear or demage Clean carbon deposits from the exhaust port area, CAUTION + Do not scratch or score the cylinder wall Inspect the cylinder walls for scratches and wear. Messure and record the cylinder I.0. ot theae lavels in both an X and Y axis. Use the maximum reading to determine the amount of cylinder waar Wty EXHAUST PORT (1) MARK SERVICE LIMIT: 41.050 mm (1.616 in} Aftor ‘93: 39.05 mm (1.537 in} CAUTION + Some exlinders are marked with the leter "A" in the location ‘shown, and some cylinders are rot marked. Uf the cylinder i replaced. be sure (0 use the matching re: placement parts. Calculate the piston-to-cylindar clearance. SERVICE LIMIT: 0.10 mm (0.004 in} CYLINDER HEAD/CYLINDER/PISTON ‘Check the cyinder tor warpage with straight edge and 3 feeler gouge in each of the ditections shown, SERVICE LIMIT: 0.10 mm (0.004 in) Measure and racord the piston 0.0. at a point 4.0 mm (0.16 in)/Mtor ‘93: 6.5 mm |0.26 in) from the bottom, and 90° to the piston in hole. SERVICE LIMIT: 40.900 mm (1.610 in) al After ‘93: 38.90 mm (1.531 in) ‘ Compare thie measurement againet the service limit and cals é late piston-to-eylinder clearance. Neasure the piston pin hole |.D. SERVICE LIMIT: 10,03 ren (0.395 in) After ‘83: 12.03 mm (0.474 in) Measure the piston pin 0.D. = SERVICE LIMIT: 9.98 mm (0.293 in) p ‘Afior '93: 11,98 mm (0.4717 in} Calculate the piston-to-piston pin clearance. SERVICE LIMIT: 0.03 mm (0.007 in) 7a PISTON RING INSPECTION Set each piston ring squarely into the cylinder 30 mm (1-1/4 ‘i) rom the bottom using the piston and measure the end gap “wih 2 teeter gauge. SERVICE LIMIT: 0.50 mm (0.0197 in) After ‘93: 0.40 mm (0.016 in) CYLINDER HEAD/CYLINDER/PISTON CONNECTING ROD INSPECTION Install the beating end piston pin in the connecting tod small end and check for excessive play Moasure the connecting ted emall end 1.0. ‘SERVICE LIMIT: 14.03 mm (0.552 in) After ‘93: 17,03 mm (0,6708 in} PISTON/CYLINDER INSTALLATION yy MARK Clean the piston ring grooves Lubricate the piston rings and piston ring grooves with clean y 2atroke oil Inetall the piston rings on the piston with the marks facing up. Nore > Locate the piston ring end gap on the pin in the ring aroove. - Coat the needle beating end piston pin with 2-stroke ol =~ Tex MARK Install the node bearing in the connecting rod, and install the piston with the "EX" mark facing the exhaust side. Install new piston pin clips (2) PISTON PIN CLIP we Remove all gosket material from the cylinder and crankcase mating surfaces (1) MATING sugFaces CYLINDER HEAD/CYLINDER/PISTON Remove the shop towel from the crankease. Be sure the ring end gaps are aligned with the piston ring pine in the ting grooves. CAUTION + Be sure the rings do not rotate in their grooves over the locating ins to prevert ring breakage and piston and exlinder damage. Instal'a new cylinder gasket onto the cylinder. Lubricate the piston and oylinder with 2-stroke oll and install the cylinder over the piston while compressing the piston tings caurion + Avoid damaging the siding surface of the piston. Insta the cylinder head (page 6-4) Ate assembly is complete, perform 3 compression test (Sec: tion 3) Check for any abnormal engine noise or air leakage past the orlinder ALTERNATOR 38 Nem (3.8 ka-m, 27 ft-tb) @ After '93; 40 Nem (4.0 kg-m, 29 ft-lb) 7. ALTERNATOR SERVICE INFORMATION 7-1 ALTERNATOR 72 SERVICE INFORMATION GENERAL This section covere alternator removel only. ‘© See Sections 14 and 15 for alternator inspection, TORQUE VALUE Fiywhee! nut 38 Nem (3.8 kg-m, 27 ft-lb) ‘After '93: 40 Nem (4.0 kg-m, 29 fib) Too.s Common Ayheo! puller 077330010000 or 079330230000 Universal holder 07725-0030000 7-1 ALTERNATOR ALTERNATOR REMOVAL Remove the both side covers (poye 11-2). Remove the fan cover by removing the two mounting bolts Remove the two bolts attaching the cooling fan and remove the coating fan. Hold the flywheo! with the universal hel ‘iheel flange nut. and remove the fly TooL: Universal holder 077260030000 Remove the flywheel with the flywheo! puller. Too. Flywheel pullor 07733—0010000 Remove and retain the woodrutt key. 7-2 ALTERNATOR Disconnect the alternator wire connectors. Disconnect the starter and ground wires from the starter Remove the pulae generator mounting bolts, Femove the stator maunting bolts, then remove and the stator with the pulse generator INSTALLATION Install the alternator wire grommet in the case groove: AS p | aA ks (2) PULSE GENERATOR: 7-3 ALTERNATOR Connect the akernator wire connectors, and the starter and ‘ground wires NOTE + Clean the taper hole in the flywheot + Make sure that th no foreign particle inside the fly wheel. Install the woodruff key onto the crankshaft. Install the flywheel onto the crankshaft Hold the flywheel with the universal holdar and tighten the fly- wheel flange nut TORQUE: 38 Nem (3.8 ko-m, 27 ft-b) ‘After ‘93: 40 Nem (4.0 kg-m, 29 fb) TooL: Universal holder 077280030000 7-4 DRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH "88 tnru. ‘93 8. DRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH After ‘93 55 Nem (5.5 kg-m. 40 ft-b) 40 Nem (4.0 kg-m, 29 ft-lb) 4.5 Nem (0.45 kg-m, 3.3 ft-lb) oO. 10 Nem (1.0 kg-m, 7.2 ftlb) 10 Nem (1.0 kg-m, 7.2 ft-lb) 8-1 DRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH SERVICE INFORMATION 8-2 DRIVEPULLEY ae ‘TROUBLESHOOTING 8-3 CLUTCH/DRIVEN PULLEY Bt KICKSTARTER 8-4 STARTER PINION 8.17 SERVICE INFORMATION ‘SPECIFICATIONS Unit: mm Gin) Tem ‘STANDARD SERVICE LIMIT Drive belt wath 15.60.61) 75.0 (0.58) Movable dive face | Bushing 1.0. 20.035~ 20.085 (0.7888 0.7307) | 20.60(0.811) | Boss 0.0. "20.010-20.028 (0.7878-0.7884) | 19.98 (0.787), - Weight roller 0.0. 18.92— 16.08 (0.627—0.633) 15.40 (0.608) Clutch "1D. 107.0 107.2 14.21~4.22) 107.5 14.231 3 thickness | 3.0 0.118) 2.0 0.08) Driven pulley | Driven face spring free lenath 98.1 (3.86) 92.8 (3.651 Driven face 0.0. 33,965 —33,98511.9372—1.3380) | 33.96 (1.330) Movable driven face LD. [34,000~34.025 (1.3386—1.3396)_| 34.06 (1.941) TORQUE VALUES Drive puliey tock nut Cluteh outer nut Clutch tock nut Movable drive face seal bolt After ‘93 only Left crankoase rear cover special bolt Lat crankease front cover bolt TOOLS Special Lock nut wrench, 39 mm Clutch spring comaressor Beating driver Common Universal holder Bearing driver 38 Nem [3.8 kg-m, 27 ft-lb) ‘After '93: 80 Nem (6.0 kg-m. 43 ft-lb) 38 Nem (3.8 kg-m, 27 fib) After ‘93: Nem (4.0 ka-m, 29 ft-lb) 38 Nem (3.8 kg-m, 27 fib} After ‘93: 55 Nem (8.5 kg-m, 40 fib} 4.5 Nem (0.45 kg-m, 3.3 ft-tb) Apply oil to the threads and ‘seating surface. 10 Nem (1.0 kg-m, 7.2 fr) 10 Nem (1.0 kgem, 7.2 ft-lb) (07916 1870002 or Commercially available 39 mm socket (07980—KM 10000 or 07960—KM1000A (U.S.A. only) 07945 680000 07725—0030000 07749-0010000 8-2 DRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH TROUBLESHOOTING Engine starts, but motor scooter won't move + Worn drive belt + Broken ramp plate + Worn or damaged clutch lining + Broken driven face spring + Damoged driven pulley shaft splines Engine stalls or motor scooter moves suddenly + Broken clutch weight spring + Damaged clutch lining Poor performance at high speed or lack of power Worn drive bo Weak driven face spring Worn weight rollor Faulty driven face Worn or seized driven pulley bearing, Clutch noite or smell + Oi or grease on drive belt or pulley + Worn drive belt + Weak driven face spring + Worn oF seized driven pulley bearing DRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH KICKSTARTER LEFT CRANKCASE COVER REMOVAL ‘88 thru, “93: Remove the following: Left side cover (page 11-2), Kickstarter pedal Remove the left crankcase mounting belts and the cover Remove the gasket and dowel pins. NOTE + Never operate the starter motor with the left crankcase cover removed. After ‘93: Remove the loft side cover (page 11-2) Romove the five 6 mm special bolts and the Iaft erankeace tear cover Remove the rubber gasket from the cover Remove the kickstarter padal wa (2) 6 mm SPECIAL BOLT Remove the five 6 mm bolts and the left crankcase front Romove the gasket and dowel pins. — > oes HORN ‘The horn is goed if it sounds when 12 V is applied across the Replace if nacessary, » OIL LEVEL SENSOR Remove the fuel tank (page 4-12) Disconnect the wires and remove the sensor. (Check the continuity between the terminals with the float in \} the upper and lower positions: ‘Thare should continuity with the float in the lower position and ho continuity with the float raised, Operate the tum signals to sae that the battory citeuit is nor rml, then perform the faiowing in Raise and lower the float to make sure that the oil evel indica tor blinks on and oft NOTE + Should the indicator fal to go on and off ae the float ic moved up and cawn, check for @ loose conection and 17-3 LIGHT/METER/SWITCHES FUEL LEVEL SENSOR FUEL LEVEL SENSOR REMOVAL/INSTALLATION Disconnect the connectors aad remove the unit from the fuel tank CAUTION + Do not bend the float arm. UNIT INSPECTION Move the float with yout hand and measure the resistances be tween the terminals with the float at the UPPER (FULL) and LOWER (EMPTY! positions FULL EMPTY Greon and Velow/White 30-452 | 600—a50 2 Green ard Blue/White 400-700 2 | 190-200 2 YollowiWhita and Blue § eee 450-750 2 | 450-750 £2 FUEL GAUGE Connect the wire connectors and turn the ignition switeh ON, Before performing the following test, operate the turn signals to determine that the battery circuit is normal, If the signals tlash normally, the battery circuit Is normal Check that the gauge needle correctly indicates FULL and EMPTY by moving the float up and down, (1) FUEL LEVEL SENSOR UNIT 17-4 LIGHT/METER/SWITCHES HEADLIGHT REPLACEMENT Romove the handlabar rear cover (page 11-6) Disconnect the headlight coupler. Remove the headlight by removing the four mounting screws. Installation is the reverse of removal, BULB REPLACEMENT TAIL/BRAKE LIGHT Remove the two scrows and the taillight lens. Replace the tai/brake light bulb with a new one, Be) TAIL/BRAKE LIGHT UL. TURN SIGNAL LIGHT (1) TURN SIGNAL BULE Romove the screw and the lens Roplece the turn signal light bulb with a new one. LIGHT/METER/SWITCHES INSTRUMENT BULB (1) nSPROMEN ae NOTE + If the instrument bulbs burn out frequently, check the charging system resistor (page 14-4). A faulty or poorly ‘grounded resistor can be a cause of frequent instrument lamp faitture, Romove the handlebar rear cover (page 11-6) Pull out the bulb sockst and replace the bulb with a new ene. INSTRUMENTS REMOVAL Remove the handlebar rear cover Ipage 11-5) Disconnect the instrument connectors. Remove the thrae screws to separate the Instrument case from the ‘ear cover (1) INSTRUMENT CASE Push each of the switch tabs and remove the switch, (1) ENGINE STOP. [ | SWITCH DISASSEMBLY Remove the three screws and the lens fram the case, Disassemble the instruments by removing the screws and bulb sockets, ‘Assemble the inetruments end the ease in the reverse order of removal (1) DIMMER SWITCH 12) TURN SIGNAL| TC Install the rear handlebar cover. 13) HORN SWITCH: 17-6 o08v— 00S6 — 0049—283—Z0800 18-1 GENERAL INFORMATION 19, TROUBLESHOOTING ENGINE DOES NOT START ORIS CLUTCH AND DRIVE/DRIVEN PULLEYS 19.3 | HARD TO START 18 poonnaNsaNa’

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