HONDA 9O MODEL C90 OWNER’S MANUAL © HONDA MOTOR CO.nu Thank you for purchasing the HONDA C90 motorcycle. The HONDA C90 motorcycle incorporates many new and special features and is produced employing the latest production techniques and test equipment. We at HONDA are confident that your new motorcycle will provide you with more than complete satisfaction. particular product which is supplied or offered for sale, The manufacturers reserve the right to vary their specification with or without notice | and at such times and in such manner as they think fit. Major as well as minor changes may be involved. Every effort, however, is made to ensure the accuracy of the particulars contained in this brochure. Consult the Dealer with whom your order is placed for details of the specifica- Hm PREFACE sn “These specification details do not apply to any mn This manual has been prepared as a guide to the proper operation and servicing of your new motorcycle: Read the manual thoroughly to better maintain the motorcycle in the best pos- sible condition for the utmost in riding pleasure. HONDA wishes you many safe happy miles of motorcycling. tion of any particular product. | This publication shall not constitute in any circumstances whatsoever an offer by the Com- | pany to any person. All sales are made by the Distributor or Dealer concerned subject to and with the benefit of the standard Conditions of Sale and Warranty given by the Distributor or Dealer, copies of which may be obtained from him on request.” 1umn CONTENTS wwii ene HoH SERIAL, NUMBER LOCATION, (5. cu. vc sas sta} oe ae so rea tee « 5 NOMENCLATURES. . . & OPERATING INSTRUCTIONS. . Main Switch Instrument and Indicator Lamps. Main Lighting Switch Headlight Beam Selector Switch and Horn Button Turn Signal Switch Handle Lock Helmet Holder. FUEL AND OIL. Fuel Valve... Fuel Tank . Engine Oil Recommendation Viscosity ..... PRE-RIDING INSPECTION... STARTING THE ENGINE Starting a Cold Engine. Starting in Extreme Cold Weather.Starting a Warm Engine : RUNNING PROCEDURE ..........- RIDING THE MOTORCYCLE Gear Changing . Deceleration and Braking: PARKING sis sges seg sett ons se Vantaa TOOL KIT MAINTENANCE SCHEDULE ..........+ MAINTENANCE OPERATIONS... Engine Oil Level...... Engine Oil Change... Greasing....... sae Spark Plug. Replacement and ‘Adjustment x 24 Contact Breaker Point Adjustment......... Hata: Ignition Timing. . Valve Tappet ‘Adjustment. Air Cleaner Servicing. Throttle Cable Inspection Throttle Cable Adjustment. . Carburetor Adjustment ........ Fuel Filter Maintenance ..Clutch Adjustment. Drive Chain Maintenance Front Brake Adjustment... Rear Brake Adjustment....... Front Suspension Inspection Battery Maintenance Headlight Beam Adjustment........+- Stoplight Switch Adjustment. . Headlight Bulb Replacement .. Tail/stoplight Bulb Replacement. SPECIFICATIONS ...........AMMAN Him SERLAL NUMBER LOCATION 3) The frame serial No. is stamped on the These numbers identify your~motorcycle center left side of the frame, directly above for purpose of registration and when order- the left crankcase, and the engine serial No. ing replacement parts from your dealer. is stamped on the lower left side of the crankcase, just above the foot bar @ Frame serial number “~ @ Engine serial numbermmo NOMENCLATURES «nun0nnun000n 8s ‘ava ® Speedometer @ Main lighting switch (U.K. type) ® Kick starter pedal © Front brake lever © Air cleaner Headlight beam selector © Throttle grip @ Rear brake pedal Horn button @ Turn signal switch @ Foot bar ® Gear change pedalaun MMMM OPERATING INSTRUCTIONS Main Switch The main switch is located on the tool box at the left side and is operated by the ignition key. The functions of the switch in respect to the key positions are described in the table. @ *OFF" p ® “ON" posit © Parking position Key Positions Functions Key Removal | Electrical circuit is open. Key can be OFF 7 Fi iP yo Engine will not start and lights will not operate. | removed ON Engine will start and lights can be operated Key'can not ke : The taillight circuit only is active, taillight can | Key can be Farias be turned on. removed.@ Speedometer dial © Odometer 8 Instrument and Indicator Lamps Speedometer is mounted on top of the steering handle. The speedometer unit includes an odometer, neutral indicator lamp, a meter lamp, and on the meter dial a gear speed range indicator is dis- played. @ Neutral indicating lamp @ Speed range indicator Main Lighting Switch (U.K. type) A three position main lighting switch is located on the handle just below the speedometer. The functions of each switch position are described in the table. Switch Positions I Functions OFF 4 PILOT LIGHT af MAIN LIGHT @ Main lighting switchHead Light Beam Selector Switch and Horn Button This switch is located on top of the left handle bar switch housing and can select the low beam (L) or high beam (H) of the head light when the head light is ON. The horn button is also located on the switch housing just below the beam selector switch. LOW BEAM cy HIGH BEAM @ Beam selector switch @ Horn button Turn Signal Switch The turn signal switch is located on the right handle bar switch housing. Switch- ing from the center OFF position to the “R” position will turn on the right winker lamps at the front and rear, and in “L” position, the left winker lamps at the front and rear will be on. © Turn signal switchHandle Lock A lock is provided on the steering handle to discourage anyone from riding the motorcycle when left unattended. Turn the handle all the way to the left, insert the key into the lock from the right side and turn clockwise. The handle will be locked in that position. @ Handle lock 10 Helmet Holder The helmet holder eliminates carrying your helmet when parking. The holder can be locked to prevent theft, 1. Hang your helmet on the holder pin and push the pin to lock, This action automatically locks the holder. 2. Unlock the holder with the switch key, main @ Holder pin @ Key‘annum Fuel Valve The three position fuel valve is mounted on the carburetor and is easily accessible through the opening on the right side of the front cover. “$”" position Fuel valve is shut when the valve handle is in the vertical position. When the motorcycle is not in use, set the valve to this position so that the fuel in the tank will not flow to the carburetor. me @® Fuel valve emt FUEL AND. ODL wnnnsnsusnounnn nnn uu “ON” position Set the fuel valve to this position before starting the engine so that the fuel is supplied to the carburetor “RES” position This is an auxiliary position and should only be used when the main fuel tank is empty and it becomes necessary to use the reserve supply of fuel in the tank. There is only 1.8pt. (1. Oliter) of fuel in the reserve supply, therefore, refuel as soon as possible when travelling on the reserve supply WFuel Tank A fuel tank with a total capacity of 1.2 Imp. gal. (5.5liter) is located under the seat. To refuel, raise the seat by first releasing the latch located under the front end of the seat, and twist the filler cap counterclockwise to remove. Quality gasoline of 85 octane or higher is recommended X @ Seat lateh 12 CAUTION: Gasoline is highly inflammable, therefore, always stop the engine and keep away open flame and sparks when refueling. Further, exercise care not to contaminate the fuel with dirt and water or mix oil with the gasoline. @ Filler capEngine Oil Recommendation Use only high detergent, premium quality motor oil certified to meet or exceed US automobile manufacturer's requirements for Service Classification SD (previously Service Classification MS). Motor oils intended for Service SD or MS will show this designation on the container. The regular use of special oil additives is unnecessary and will only increase operat- ing expenses. Engine oil should be changed at the inter- vals prescribed in the Maintenance Sche- dule on page 20. NOTE: Engine oil is a major factor affect- ing the performance and service life of the engine. Non-detergent and low quality oils are specifically not recommended. Viscosity Viscosity selection should be based on the average atmospheric temperature in your riding area. Change to the proper visco- sity oil whenever the average atmospheric temperature changes substantially. Recommended oil viscosity: General, all temperatures SAE 10W-30 Extreme, high temperatures SAE 20W-50 Alternates: Above 59°F SAE 30 or 30W 32° to 59°F SAE 20 or 20W Below 32°F SAE 10W 13ann Prior to starting your motorcycle, it is advised that you perform a general inspec- tion as a matter of habit to make sure that the motorcycle is in good, safe riding condition. This inspection will only require a few minutes and can save you much time and expense in the long run. Check the following items and if adjustment or servicing is necessary, refer to the appro- priate section in the manual. 1. Engine oil level—add engine oil if it is lower than the lower mark on dipstick (page 20) 2. Fuel level—make sure there is sufficient fuel for the trip (page 12) 4 wo Him PRE-RIDING INSPECTION: Front and rear brakes—adjust free play in the front brake lever and brake pedal if it is incorrect (page 36). Tyre air pressure—adjust the tyres to the following pressures. Front tyre: 26psi (1.8kg/cm?) Rear tyre: 28.5psi (2.0kg/cm2) . Drive chain—adjust chain tension if it is too loose (page 33) Throttle operation—adjust or correct if play or function is not proper (page 29). Tail/stoplight and headlight—adjust or correct if they do not operate properly (page 38). TTT STARTING THE ENGINE wnnnnvnmnvnnnnnin Starting a Cold Engine 4. Turn the fuel valve to the SON” posi- tion (page 11) 2. Insert the key into the main switch and turn to the “ON” position. At this 14 time, make sure that the gear change pedal is in the neutral position by ob- serving the green indicator lamp on the speedometer.3. Raise the choke lever to the full close position. 4. Twist the throttle grip inward slightly and operate the kick starter with the right foot, starting from the top of the stroke and following through to the bottom with a rapid and continuous kick. Do not allow the foot to come off the kickstart at the bottom of the stroke. Operate several times until engine starts. If the engine fails to start after several repeated attempts, turn off the main switch and lower the choke lever to the full open position, twist the throttle grip inward fully and crank the engine using the kick starter pedal. This is then followed by turning the main switch to the “ON” position and following the starting procedure out- lined in step 1 through 4, however, at this time the use of the choke is not necessary. 5. After the engine starts, operate at ap- proximately 1,500rpm_ until the engine properly responds to the throttle with the choke fully open Starting in Extreme Cold Weather Prime the engine before starting by crank- ing several times with the kick starter pedal. The main switch should be turned “OFF”, the choke fully closed and the throttle opened. Followed by the pro- cedure for starting a cold engine. Starting a Warm Engine When the engine is to be re-started while it is still warm, proceed as for cold engine starting, however, the use of the choke is not necessary. 15The engine of your C90 is designed with close tolerances and is semi run-in on the bench, therefore, requires no formal runn- ing period. It is recommended, however, that during the first few days of riding RIDING THE ‘nn ni Gear Changing 1. Start the engine and after it has been warmed up for a few minutes, the motorcycle is ready for riding. 2. With the throttle closed, depress the gear change pedal with the heel to shift into low. 3. Slowly open the throttle to start the motorcycle rolling smoothly, and when the speed has increased to 10-15mph, close the throttle and depress the gear change pedal with the toe to shift into 2nd gear. 4. Accelerate in 2nd gear not to exceed 30mph, and then shift into top gear by depressing the gear change pedal with the toe. snntit RUNNING-IN PROCEDURBunnnnnsnnnnnnnninnnannn the engine be operated at moderate speed and not overstressed. This simple consideration will extend the service life of the engine measurably MOTORCYCLE ininiiienmenanmnnnnn 5. When down-shifting in gear, first close the throttle, and then depress the gear change pedal with the heel. Down- shifting from 2nd to low gear requires two successive gear change pedal actions to shift through the neutral position.Deceleration and Braking Deceleration can be by either down-shift- ing in gear or use of brakes, depending upon the situation. A little practice is required to be proficient since coordina- tion of the gear change, throttle, and both front and rear brakes are necessary. 4. The smooth gradual application of both the front and rear brakes together with the required throttle coordination will, under most conditions, assure good control and stability during deceleration. As the motorcycle speed is reduced, it is common practice to shift the trans- mission progressively into the gear appropriate for the motorcycle. This assures maximum control through better braking effectiveness, and provides ac- celeration when necessary. 2. For maximum deceleration and stop- ping, close the throttle, apply both the front and rear brakes simultaneously This manoeuver requires smooth coordi- nation of the control and to maintain skill it should be practiced frequently, Independent application of either front or rear brakes is possible, but if only ‘one brake is applied strongly enough to cause the wheel to lock, braking effectiveness is greatly reduced and it will be difficult to control the motor- cycle. Refrain from sudden braking or turning on wet roads. 7TiO PA RIKEN GaeeeneMnneemeMMnnMN When parking, turn the main switch to the “OFF” position, remove the key, and it is also recommended that the steering handle be locked and fuel valve turned off if the motorcycle is to be left unattended or parked for a long time. SAFETY HINT: The main switch should be turned to the “parking” position when stopping on the road at night to warn the traffic. IIAACOOOTOTOOOTOTOCOMOOOOMO TOOL KAT nnn ETOK Tool kit containing all the necessary tools to perform minor adjustments and part replacements are located in the plastic case mounted on the left side of the frame. Adjustments and repairs which cannot be performed by these tools should be referred to your Honda dealer : Bd ® Tool kitHiT! MAINTENANCE SCHEDULBm Periodic maintenance, in accordance with the schedule on the following page, is necessary to ensure continued trouble-free operation and peak condition. Your authorized Honda dealer is equipped nn to handle your service needs and should be consulted for specific recommendations applicable to your individual riding con- ditions 19Months or Miles, whichever occurs first == ira |, Thereafter 7 : First Second) Third |pe neat Every| Page Service Required yee EIT I oterence | Mile | 200 | 3,000 _6,000| 3,000 | 6,000 Km_|_300__5,000_10, 000] 5,000 |10, 000 Engine Oil—change O_|_Every 1,000 Miles (1,600km) | __22 xSpark Plug—clean and adjust or replace Eo. 1 6: [0 HRA xContact Breaker Points—check or service [oto [26 Tis Ignition Timing—check or adjust i oO oO ©. |r ze Valve Tappet Clearance—check or adjust oO 1 dg Oo 27 x Air Cleaner—servicing ° 28 Throttle Operation—check o;| 2 ~ Carburetor—check or adjust 3 30 xFuel Filter—servicing 3 St ~ Fuel Tank and Fuel Lines—check oO = Clutch—check or adjust ° Eat w brieate oF replace en nS ° 2 Front and Rear Brake—adjust ° 7 Front and Rear Brake Shoes—check or replace| ae Front and Rear Brake Links—check | ° (om ie) Wheel Rims and Spokes—check ololoto = 20Service Required Months or Miles, whichever oceurs first First Second sa], Thereatter Third |Repeat Every Page Reference “Tyres—check or replace Steering Head Bearings—check or adjust Steering Handle Lock—check for operation Main Stand Spring—check xBattery Electrolyte Level—check and replenish if necessary xLights, Horn and Speedometer—check for operation or adjust Items of asterisk are checked by user. 21THOM MATNTENANCE OPERATIONS muni Engine Oil Level Check engine oil level at the start of each day the motorcycle is to be operated. Unscrew the oil filler cap located on the right crankcase cover near the kick starter and measure the oil level with the cap dipstick. Oil level must be maintained between the upper and lower oil level marks on the dipstick. Checking must be done with the motor- cycle standing upright on level peace and the oil filler cap touching the fill but not screwed in. jer opening PER ot LeveL, ~Lower OW LEVEL @ Filler cap dipstick 22 Engine Oil Change Engine oil should be changed in accord- ance with the maintenance schedule on Page 20. Use only motor oil of the grade and viscosity recommended on page 13. When changing oil, drain the used oil from the crankcase while the engine is warm. This will ensure complete and rapid draining. 1. Remove the oil filler cap. 2. Place a drip pan under the engine to catch the oil, and then remove the drain plug with a 17mm wrench. @ Drain plug3. After the oil stops draining from the crankcase, operate the kick starter several times to drain any oil which may be left in the engine. 4. When the oil has been completely drained, reinstall the drain plug making sure that the packing used on this plug is in good condition. Fill the crankcase through the oil filler opening with approximately 1.6 Imp. pt. (0.9 liter) of oil. Make sure that the oil level is at the upper level mark. Add more oil if necessary NOTE: Change the oil at more frequent intervals than shown in the schedule the oil is excessively dirty from riding under unusually dusty condition, or very short journeys. Greasing Lubricating grease prevents wear to the metal friction surfaces and provides longer service life to the motorcycle. Greasing points are on the front suspension and hub. © Greasing pointsSpark Plug Replacement and Adjustment An NGK D-6HS spark plug is recommended for normal riding conditions. The spark plug can be removed for cleaning ‘or replacement by using the spark plug wrench provided in the tool kit. Inspect the firing tip and if the electrodes and insulator appear unusually fouled or burned. you should contact your Honda dealer for analysis of the problem. A fouled spark plug indicates excessively cold spark plug heat range selection, rich fuel mixture, or excessive oil consumption, ‘A spark plug with burned electrodes and a glazed or blistered insulator indicates excessively hot spark plug heat range selection, lean fuel mixture, or excessively advanced ignition timing. CAUTION: The use of spark plug of incor- rect size or heat range can cause serious engine damage. 24 Check spark plug gap by inserting a thick- ness gauge between the electrodes. Adjust the gap to 0.024-0.028in. (0.6-0.7 mm) by carefully bending the side electrode. Before installing the spark plug, clean any oil or dirt from the spark plug seat in the cylinder head. Install the spark plug by hand until finger tight. Then use the spark plug wrench to tighten the plug an additional 1/2~3/4 turn or until the sealing gasket is compressed. ~@ Spark plug gap @ Side electrodeContact Breaker Point Adjustment 4. Remove the point and generator covers. 2. Open the contact breaker points with your finger or small screwdriver blade and examine for pitting. If pitted or burned, the points should be replaced and the condenser checked. A gray discoloration is normal and can be removed with a point file. Filing should be done carefully and kept to a mini- mum. Clean the point contacts after filing with a clean piece of unwaxed paper such as a business card or chemi- cal point cleaner. 3. Rotate the generator rotor in the coun- terclockwise direction to find the point where the breaker point gap is at maximum and then check the opening using a thickness gauge. 4. The standard gap is 0.012-0.016 in. (0.3- 0.4 mm). 5. When adjustment is necessary, loosen the contact breaker plate locking screws and move the contact breaker plate to achieve correct gap. When properly gapped, retighten the locking screws CHU Fae Ra aC care @ Contact breaker plate locking screwsIgnition Timing Ignition timing must be checked after completing the contact breaker point ad- justment, as any change in breaker point gap will affect ignition timing. Rotate the generator rotor counterclock- wise until the “F” mark on the rotor aligns with the index mark on the crank- case cover. When the timing marks align, the contact breaker points should just begin to open. If ignition timing is found to be incorrect, loosen the two base plate locking screws and reposition the base plate to advance or retard ignition timing as necessary Rotate the base plate clockwise to advance ignition timing. Rotate the base plate counterclockwise to retard ignition timing. Tighten the base plate locking screws and recheck the contact breaker point gap (see page 25) to be certain the gap has not changed. Static timing is relatively accurate and will give satisfactory engine _ performance. Flowever, dynamic timing with the use of a stroboscopic timing light will assure more precise timing. Your dealer may be equip- ped with the stroboscopic timing light (idle speed is 1,200rpm) | @ Base plate locking screws @ Base plateValve Tappet Adjustment Excessive valve tappet clearance will cause tappet noise, and little or no clearance will cause valve damage and loss of power. Therefore, the valve tappet clearance should be maintained properly. The valve tappet clearance must be check- ed when the engine is cold. 1, Remove the generator cover and tappet adjusting hole caps. 2. Rotate the generator rotor counter- clockwise until the “T” mark on the rotor lines up with the index mark on the crankcase cover. In this position, the piston may either be on the compression or the exhaust stroke. The adjustment must be made when the piston is on top of the compression stroke, when both the inlet and exhaust valves are closed. This condition can be determined by shifting the tappets with fingers through the tappet adjusting holes. If the tappets are free, it is an indication that the valves are closed and that the piston is on the compression stroke. If the tappets are tight and the valves are open, rotate the rotor 360° and realign the “T” mark to the index mark. Check the clearance of both valves by inserting the 0.002in. (0.05 mm) thickness gauge between the ad- justing screw and the valve stem. @ °T" mark ® Index mark 27If it is necessary to make an adjust- ment, loosen the adjusting screw lock nut and turn the adjusting screw so that the valve clearance will offer a slight resistance when the thickness gauge is inserted. After completing the adjustment tighten the adjusting screw lock nut while holding the adjust- ing screw to prevent it from turning Finally, recheck the clearance to make sure that the adjustment has not been disturbed. @ Adjusting serew lock nut @ Adjusting serew © Thickness gauge 28 Air Cleaner Servicing When the air cleaner is clogged with dust engine performance is affected. Therefore it should be cleaned periodically. Remove the air cleaner cover nut and the cleaner element can be removed. First, tap the element to shake off the dust and then blow dry compressed air from the inner side of the air cleancr element to remove the remaining loose dust. If no com- pressed air is available, a stiff bristle brush will serve equally well ®D Air cleaner clementThrottle Cable Inspection Check for smooth rotation of the throttle grip from the full open to the full close position. Check both when at full left and full right steering positions, Inspect the condition of throttle cable from the throttle grip down to the carburetor. If the cable is kinked, chafed or improperly routed, it should be replaced and/or rerouted. Re- check cable for tension or stress at both full left and full right steering positions Throttle Cable Adjustment Standard throttle grip free play is approxi- mately 10-15° of the grip rotation. This free play can be attained by adjustment of the throttle cable adjuster. Turn the adjuster until the grip free play rotation becomes 10-15" @® Throttle cable adjuster 29Carburetor Adjustment The carburetor should be adjusted only after the engine has attained operating temperature. 1. Adjust the idle speed screw until the engine idles at approximately 1,200rpm Turn the idle speed screw clockwise to increase idle speed or counterclockwise to decrease idle speed. 2. Turn the air screw clockwise until you hear the engine miss or decrease in speed, then counterclockwise until the engine again misses or decreases in speed. Set the air screw exactly be- tween these two extreme positions. Turning the air screw clockwise creates a richer fuel mixture, while turning the air screw counterclockwise creates a leaner fuel mixture. Usually, the correct setting (between extremes of richness and leanness) will be found to be 7/8 to 136 turns open from a fully closed position 30 3. If idle speed changes after adjusting fuel mixture, readjust the idle speed screw. @ Idle speed serew @ Air serewFuel Filter Maintenance The fuel filter is incorporated within the carburetor unit and is accessible from the left side. Accumulation of dirt in the filter and water in the carburetor will cause the carburetor to malfunction therefore, the filter should be serviced periodically in accordance with the maintenance sche- dule. 1. Turn the fuel valve to the “S” position, 2. Unscrew the two filter cover screws wae and remove the fuel filter cover. Remove the O-ring seal and filter screen. Wash the filter screen in gasoline. Reinstall all the parts, making sure that the seal and screen are in good condition. Turn the fuel valve to the “ON” posi- tion and make sure there are no leaks at the cover © Fuel filter cover @ O-ring seal @ Filter sereen 31Clutch Adjustment The model C90 incorporates a centrifugally operated clutch which is synchronized to function automatically with the engine speed and during gear changes. Clutch should be adjusted under the following conditions: 4. Clutch slips during kick starting, pre- venting the engine to turn over. 2. Engine stalls or the motorcycle jolts when starting out or when changing gear. 3. Motorcycle does not accelerate in re- sponse to the throttle. Adjust the clutch by the following pro- cedure 1. With the engine shut off, loosen the clutch adjuster lock nut. 2. Turn the adjuster clockwise about one turn. 3. Turn the adjuster in the opposite direc- tion until it starts to become heavy 32 and from this point turn the adjuster clockwise again 1/8 to 1/4 turn and tighten the adjuster lock nut. @ Cluteh adjuster lock nut @ Clutch adjusterDrive Chain Maintenance Proper tensioning and lubrication will help extend the service life of the drive chain and ensure smooth power transmission to the rear wheel. Under normal usage, the drive chain should be lubricated and ten- sion checked according to the maintenance schedule. Under severe usage, or when the motorcycle is ridden in unusually dusty areas, more frequent maintenance is necessary. Tension Adiustment: 1, Place the motorcycle on its main stand to raise the rear wheel off the ground. Shift the gear change into neutral. 2. Remove the inspection cap in the drive chain case and move the chain up and down by hand and observe the amount of slack. Drive chain should be ad- justed to approximately 0.4-0.8 in, (10-20 mm) vertical movement at this point. Rotate the rear wheel and check drive chain tension throughout its length. Drive chain tension should remain constant as the wheel is rotated. If the chain is found to be slack in one segment of its length and taut in another, this indicates that some of the links are either worn, kinked or binding. Binding can frequently be eliminated by lubrication. Worn or damaged drive chain must be replaced. @ Inspection cap3. If the drive chain is found to require adjustment, the procedure is as follows: A. Loosen the rear axle nut and sleeve nut. B. Turn the adjusting nut on both the right and left chain adjusters to increase or decrease chain tension. Align the chain adjuster index marks to corresponding scale on both sides of the rear fork. N @ Rear axle mut @ Sleeve nut @ Chain adjuster index mark @ Corresponding seale © Adjusting nut 34 C. Tighten the sleeve nut, rear axle nut, and then tighten the adjusting nuts. D. Recheck drive chain tension. E. Rear brake pedal will be affected when the drive chain is adjusted Check rear brake pedal free play and adjust as necessary (page 36). Lubrication: Commercially prepared drive chain lubri- cants may be purchased at most motor- cycle shops and should be used in pre- ference to motor oil or other lubricants. Saturate each chain link joint so that the lubricant will penetrate the space between adjacent surfaces of link plates and rollers. Removal and Cleaning: When the drive chain becomes extremely dirty. it should be removed and cleaned prior to lubrication. 1 Z Remove the drive chain cover. Carefully remove the master link retain- ing clip with pliers. Do not bend or twist the clip. Remove the master link.v Remove the drive chain from the motorcycle. Clean the drive chain in solvent or gasoline and allow to dry. Inspect the drive chain for possible wear or dam- age. Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable. Inspect the sprocket teeth for possible wear or damage. Replace if necessary. Never use a new drive chain on badly worn sprockets or a badly worn drive chain on new sprockets. Both chain and sprockets must be in good condi- tion, or the new replacement chain or sprocket will wear rapidly. Lubricate the drive chain. Pass the chain over the sprockets and join the ends of the chain with the master link. For ease of assembly, hold the chain ends against adjacent rear sprocket teeth while inserting the master link. Install the master link retaining clip so that the closed end of the clip will 8. face the direction of forward wheel rotation. The master link is the most critical part affecting the security of the drive chain. Master links are reusable, if they remain in excellent condition, but it is recom- mended that a new master link be installed whenever the drive chain is reassembled. Adjust the drive chain to the proper tension, following the instructions on page 33~34. Install the drive chain covers. @ Retaining clip 35Front Brake Adjustment Free play measured at the tip of the front brake lever should be maintained at 0.8- 1,2in. (20-30 mm). Adjustment is made using the front brake adjuster located on the brake arm at the front wheel hub. Turn the front brake adjuster clockwise to decrease free play or counterclockwise to increase free play. 0.8~1.2in. Free play “@ Front brake lever ® Front brake adjuster 36 Rear Brake Adjustment Free play measured at the tip of the rear brake pedal should be maintained at 0.8-1.2in. (20-30 mm). The rear brake adjuster is located on the brake arm at the rear wheel hub. Turn the rear brake adjuster clockwise to de- crease free play or counterclockwise to increase free play @ Rear brake pedal Rear brake adjusterFront Suspension Inspection Check the action of the front fork suspen- sion by applying weight on the steering handle with the front brake locked. Sus- pension should function smoothly without binding. If action is irregular, check for broken spring or loose cushion spring mounting points. Battery Maintenance The battery is mounted in the center of the frame and is accessible by removing the battery cover on the right side. Check the battery electrolyte every month to make sure that it is being maintained at a level between the upper and lower level markings. If the electrolyte level is low and requires filling, the battery must first be removed to get access to the filler cap. Use a small syringe or a plastic funnel and fill the low cell with distilled water. When reinstalling the battery, wash the battery if electrolyte has been spilled to prevent corrosion to the frame, and then route the vent tube down under the battery bracket and make sure that vent tube and electrical cords are not pinched. If the motorcycle is to be stored for a long period, it is recommended that the battery be removed and stored. 37Headlight Beam Adjustment Always maintain the headlight in proper adjustment for safe night riding. Vertical adjustment is made by the adjusting screw located at the bottom of the rim. Turning the adjusting screw clockwise will raise the headlight beam to focus at a farther distance. Stoplight Switch Adjustment The stoplight switch must be adjusted so that the stoplight will come on when the rear brake is applied. Rear brake free play (page 36) should first be adjusted before performing the stoplight switch adjust- ment. The procedure for adjusting the stoplight switch is as follows: 1. Turn the main switch to the “ON” position. 2. Turn the stoplight switch adjusting nut to position where the stoplight will come on just before the brake pedal 38 is depressed to the limit of its free play. Turn the adjusting nut indirec- tion A to advance switch timing or in the opposite direction to retard the switch. Stop switch Adjusting nutHeadlight Bulb Replacement Tail/Stoplight Bulb Replacement . Remove the two headlight assembly 1. Remove the two lens retaining screws. mounting screws located at the neck 2. Press the bulb in and twist to the left of the headlight case. and remove. 2. Lift the bulb unit by the insulator and 3. When installing the lens, do not over- unhook the tab on the bulb flange. tighten the retaining screws, as it may 3. Press the bulb in and twist to the left damage the lens. and remove. D Tail/stoplight bulb @ Bulb unit 2) Headlight bulb 39amc 40 mmo PECIFIC A TION Summum ITEM | DIMENSIONS Overall length 72.1in. (1,830 mm) Overall width 25.2in. ( 640mm) Overall height 39.1 in. ( 995 mm) Wheel base 46.9 in. (1,190 mm) ‘WEIGHT Curb weight 187 Ibs. (85 kg) CAPACITIES Engine oil 1.6 Imp. pt. (0.9 liter) Fuel tank 1.2 Imp. gal. (5.5 liter) ENGINE Bore and stroke 1.97 * 1.795 in. (50 45.6 mm) Compression ratio 82:1 Displacement 5.45 cu-in. (89 cc) Horse power 7.5 BHP/9,500 rpm Contact breaker point gap 0.012~0.016 in. (0.3~0.4 mm) Spark plug gap 0.024~0.028 in. (0.6~0.8 mm) Valve tappet clearance (cold) | _0.002 in. (0.05 mm)ITEMS CHASSIS AND SUSPENSION Caster Trail Tyre size, front Tyre size, rear | POWER TRANSMISSION Primary reduction Final reduction Gear ratio, ‘st. 2nd. ELECTRICAL Battery Fuse LIGHTS Headlight Tail/Stoplight | Turn signal light Pilot light 63° 2.95 in. 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