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    486 views94 pages

    Honda CT70 Manual PDF

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    adeelyaseen1

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    © All Rights Reserved
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    FOREWORD This manual covers information on models ST 50, ST70, CT 70, CT 70 K1, CT 70K2, CT70K3, CT70H, and CT 70HKI. This manual should be kept in a place for easy reference with 50/65 Shop Manual (Code No. 620401). If properly used it will enable the service shops to provide reliable ser- vice to the owners. All information, illustrations and specifications contained in this publica. tion, are based on the latest product information available at the time of publication, Honda Motor Co., Ltd. reserves the right to make changes at any time without notice. Following are the initial serial numbers of each model at the time of change: ST50E (England type) ST 50— 111528~ ST70DI (General type) ST 70— 108801~ ST 70D General type) ST 70— 503971~ ST70E (England type) ST 70— 137314~ CT70H (U.S.A. type) CT 70H—100001~ CT 70HKI(U.S.A. type) CT 70HK1—2000001~ CT70 (U.S.A. type) CT70— 100001~ CT70K1 (U.S.A. type) CT 79-2000001~ CT70K2 (U.S.A. type) CT 70—2100001~ CT70K3 (U.S.A. type) CT 79—2300001~ HONDA MOTOR CO., LTD. Service Publications Office CONTENTS Reference Page —> ‘Shop Manual ‘Shop Manual 150/70, CT70H, HKI |” 50/65 C170, Ki, K2, K3/70H Specifications 1 Specifications Special Tools 10 Engine 3. 1 Engine Removal and Installation 2 3. 2 Lubrication System n 5. 3 Cylinder and Cylinder Head ne So Tos24 3. 4 Cam Chain Tensioner . 2 oa 4 3. 5 Piston and Piston Rings 2 19-23 3. 6 Clutch. 2 + 26-28 3.7 Crankshaft... 25 29~31 3, 8 Transmission 31~33 3. 9 Gear Shift Mechanism 3.10 Kick starter - 30 . 33534 3.11 Carburetor 3H . 35-45 3.12 Tightening Torque Limits 33 Frame 4. 1 Handlebar 34 a. Handlebar Construction .. 34 b. Disassembly 44 ©. Inspection’ 35 &. Reassembly 35 4. 2 Front Fork 35 a. Disassembly 35 Inspection 35 ©. Reassembly - 36 4. 3. Front Cushion 7 36 a. Front Cushion Construction 36 b. Disassembly 36 Inspection 38 a. Reassembly 38 4. 4 Rear Cushion 38 a Rear Cushion Construction nc. 38 b. Disassembly 39 Inspection 39 4. Reassembly 39 Date of lssue: February, 1982 HONDA MOTOR CO. LTD. ‘Shop Manual | Shop Manual 150/70, CT70, KI, K2,K3/70H | 50/60 4, 5 Front Wheel 39 a. Front Wheel Construction 40 Disassembly... ee 0) Inspection one 40 d._ Reassembly 41 4, 6 Rear Wheel . eo a2 a. Rear Wheel Construction... oo 'b, Disassembly a Inspection : . 6 4. Reassembly a 4. 7 Braking System core a, Disassembly essen 44 . Inspection creme . 45 c_Reassembly os. orem 4, & Reat Fork oe 45 a, Disassembly — 45 bi. Tnspection 5 c.Reassembly Seer 46 4. 9 Drive Chain - sn 46 4.10 Air Cleaner soon —— 46 5. Electrical System 1 A.C. Generator Inspection 2 Ignition coil 3 Condenser Inspection 4 Silicon Rectifier... 5 Battery 6 Switches 41 Wiring Diagram. snes $5 Index ess Ol Periodic Adjustment 83-99 een e Trouble Shooting 101~109 10. CT70 K4 ADDENDUM .. 11. CT70 K6 ‘77 ADDENDUM 12. C170 K7 ‘78 ADDENDUM. 13. CT70 Z'79 ADDENDUM 14. CT70 A ‘80 ADDENDUM 15, CT70B’81 ADDENDUM . 16, CTT0 € °82 ADDENDUM 2... aa AS 61 eid Date of Issue: February, 1982 © HONDA MOTOR CO,, LTD. 1. SPECIFICATIONS LL Specifications TENS SP 50 (Enaland OP) (Gana ype) CF 70 (USA. Tyne) _CTTON (USA. Type) DIMENSION “Gea gh Slee Gb) : Overall Width, ‘0mm G28) — a ‘Oval Helen ~«CMOmm GTB) = Wheel Base 1035mm G0.Tin) a = Ground Charice 168mm (Sin) Wana ‘arb Wace wig ahi) Gig WHAT) Se IT FRANE. 7 - ‘Type ‘T-bone type = — — “Rupesion Fee fork = Se TSapemion Ring acm —- = Tie Sie 3010 GPR) = = Tee Se RCW PRY — —_ Wake Interna expanding shoe = —— = Fes Gap aswezusm Tire Prowre, ETM lo _ (is.2osh (is.6ps-ta.3 pa) Tie Peswe RCL kno 7 Gro TGuerane —_ Talim e TI) ENGINE re earn ana _ - one aa) See ee trom veal cecidiwe I = —— (85x63 Darian ~ re tevin —7 = Compression Ratio 8.8 — = CT TKI (USA, Type) CF TKS (USA. Ty) ‘3mm (89.615), = 660mm 06.010) = = 1,010mm G9.8in) 1,050 mm (1.3m) _ = somm (sim =r! Tag (161) : = Steel pressing a Telescope Fork - Te — ‘Swing arm 7 — = 4-00-10 @PR), Knobby tre - = _ = 4.000 @PR), Knobby tie — = Thermal expanding shoe = _ = Sti (5.28U. S. PL - : = 3.46 Imp pt) 1 2 kgjem* _ _ rps _ 1a kgiea* = -_ ops a or = =< 0,070m (2.7) 0.071 @.8i0) Air cooled, 4stroke 0.H.C _ : Single 80° inclined = _ from vertical oe ‘rx, fmm _ = (2.8531, 689) — 7 — ‘Thee (4 ein) TEMS ST 50 England 10) (Gene ype)_CE 70 (USA. Type) CF T0H (USA. Type) Carburetor KEIHIN, piston _ _ valve type Valve Train (Chain driven over a _ _ head camshaft (8 Capacity 0.8 A.7US. pt. oe 0.7 it @.74US. pt 1.4 mp.ne) 1,62 Imp. pt) Lubrication System _ = = Eagine Weight 18.5kg 40-816) 18ke 9.716) Goctudes oid) = = DRIVE TRAIN ‘Guch Wet, mali-pate, Wer, multpiate, automatic centri — - manual type fogal type ‘Transmission Constant mesh, : “peed speed = Primary Reduction 3.722 — 7 = (Gear Ratio f 3.364 = = 2692 Gear Ratio 11 Lm — — 14 (Gear Ratio IT 1.190 = = 1300 Gear Ratio IV 2.958 Final Reduction 27s 2.533 — = (Gear Shift Pattern [Left foot operated return system N23 Ni23 N1284 PERFORMANCE Max. Speed 7Okm/H Ski 7Skm/H 3,0 mie/#) 47.0 ie/#) a 7. omite/#) ‘Maximum Horsepower 45/5000 56/8000 5.0/8000 “4-0/8000, HPfepm Maximum Toraue 0. 87/8000 0-s11/7000 0. 50/8500 0. 50/4000 kem/rpm Climbing Ability Sin @ 0.276 — 0.309 = Tarniag Circle 3.2m (10.508) — = = Cre USAT AR OORT WSA. Type CF T0K3 (USA. Type) Valve pe — - _ ‘Chain driven over. a = i head camshaft othe _ a _ (0.7 US. qt 0.6 Impat) - Forced and wet = _ = sump | a ee 18,08 ib) — _ _ Wet, mulipate, ‘manual type 058 am a) 1.84 — _ = 1,200 - - = Fe 2.333 = Na = = _ 25 km/#4 (47, Omile/#) — - = +.5/8800 4-07/8000| _ mn 361/400 - _ 3. 64/3500 - i = — = 3.2m (10,50 Fe) — — — ee TNS SE naka WO ope CFM USA Tae) CTH USA. Tee) Tang Diaose Lew tan 65m G30 Tes tan Tm 03.008) Apuasimye Go, = assum ahammar me Hace - Ignition — _ aa i Aiemtor Poked Gamer [ aay Gocty YUASA BOS WAH “San Fog Cais UBS TS mG, CTS NOD x) ZFSOD) UAB FSD) ian ee “orurW lO easisw ernsw Tully Law -WSWiisW SSC TW Tarn ial = — i : Tur Signal Indiator = ee _ na USA Te Ca aa USA Te Cha WA Tas than Pm (5.000) at 33km/H (21.9 mile/H) ~ a Tibe mewe i i Kick starter oO — a "Flywheel A.C. generator — — YUASA Bo0-6 6V2AH —— 6VaAH C-7 HS (NGK), V-22 FS (ND) = _ any 6 VAIS WIS W — — ev WITW - a 6V-5.3.W/25W evaw 6 V-18W Front/Rear ov 10 Tool No (07984-0980000 o79s7-3290000 07942-1180100 o7942-3290100 .07908-0010000 .07933-0010000 (07923-0400000 Deserpton Valve Guide Reamed 5.48 mm dia ‘Valve Spring Compressor Vale Guide Dever Valve Guide Remover ‘Tappet Adjust Wrench Fiywheet puller Clutch Outer Holder ie we Commonly used with C30 1 Bet Xe | Tal No | _ po vos o7916-2830000 1mm Lock Not Wrench ° 7945. 580000 Bearing Driver Ath fee | oeee fou 19-00 | eae Cin Dianenbly Toot Comment wsed (2 o7902-0010001 Pin spanner 36mm sin co | a 7925010001 Fiywhel Holder 4 (07401-0010000 Fuel Level Gauge 3. ENGINE 3.1 Engine Removal and Installation Engine Removal 1. Drain the engine oil by removing the drain plug and fille cap. Drain the oil while the engine is warm t0 assure complete draining. (CT7, Ki, K2, K3/CT70 H, HKD) Ente rte Remove the engine protecter by removing the to fixing bolts. (ig. 1) 3. Remove the two 8 mm nuts as shown in Fig 2 and detach the muller by removing the two am 6 mm fixing nuts. 4, Remove the spark plug. 5. Disconnect the throttle wire from the car- Dburetor throttle valve (C70, K1, K2, K3/CI70 H, HKD) Remove the crankease protector from the feame the top by removing four bolts. (Fig. 3) Remove the chain ease caver by removing the three serews. 8, Remove the left side cover by removing the two screws, (Fig. 9, Disconnect the drive chain at the joint, (C770, Ki, K2, K3/CT70 H, HKD) Remove the crankease protector from the tngine at the bottom by removing the two bolts. (Fig. 5) Remove the step har by removing the two bolts. (Fig. 5) Hook the brake pedal spring to the top 10 simplify engine removal. (Fig. 6 Remove the twa 6 mm bolts and disconnect, the intake pine from the cylinder head intake flange The engine can then be separated from the frame, by drawing out the two 8 mm engine ‘mounting bolts. (Fig. 6) Engine Installation 1 Perform the engine installation in the reverse order of removal ‘The drive chain should bec onnected so that the closed end of the link clip faces the normat chain rotation, Fie. 5 14 3.2 Lubrication System (Oil Pump) Description The engine oil from by the tochoid pump is di- verted into two routes. (Fig. 8) Route one: itis sent through the right crankease—right crank- case cover-scentrifegal Iter—connecting rod large end rollers. Route two: Oil fs sent through the cylinder stud bolt--rocker ‘arm side cover—ccamshaft profiles and bearing-> valve mechanism. beige UWE ‘Centrifugal filter’ Fig. 8 Disassembly 1, Unserew the right crankcase cover mounting screws the cover. 2, Remove the elutch outer cover Unscrew the 14 mm clutch Tock nut and a- sher, Remove the clutch assembly. 4. Loosen the three 6 mm ofl pump mounting bolts and remove the oil pump assembly. 5, Loosen the three cross screws attaching the oil pump cover. The oll pump can then be disassembled (Fig. 9) Inspection 1. Tum the oil pump drive shaft by hand to ake sure it turas smoothly. 2. Measuring the clearance between the outer rotor and the pump body. Insert the thickness gauge between the outer rotor and the pump body (Fig. 10). sum (ioehy Sandard Valse | — Servibeabie Dimi 0,10~0.15 Replace i over (a, 008~0. 006) 0.20 (0.0078) 5, Measuring the end clearance of the rotor Place a straight edge across the pump housing and check the clearance of .he rotor with a tickness geuge (Fig. 12). sm Cinch) Tan Vale] Serre Cit n02~007 Replace if over (o-0608~0.0027 048 to.00st) Reassembly Perform the reassembly in the reverse order of sisassembly the following items (Fig. 12): Nate: 1. Clean Parts thoroughly before assembling. 2, After completing pump reassembly, check to make sore that the pump is operating smoothly by turning the shaft by hand before ‘mounting the pump in the crankcase 33 Cylinder and Cylinder Head Deseripiton ‘The cylinder head is aluminum alloy 10 improve the cooling effect. The ey provide good against wear high temperature and der ig cast iron to Disassembly 1. Drain the engine oil by removing the drain plug. 2. Unscrew the left crankcase cover mounting screws and remove the cover. 3. Loosen the 6 mm hex bolt from the left ¢y- Timder head side cover, and remove the side cover. Loosen the two cross screws and remove right eylinder head side cover. 4, Remove the flywheel with the flywheel puller. (ool No, 07933-0010000). Remove the stator assembly Fig. 13) Note 1. For convenient disassembly, set the piston atthe compression top dead center (Gee Reassembly on page 20) @ Ot pump body gasket @ Oil pump dowel pia {@ Oil pump body ) Gmm hex bofe Oi purep outer Foter @ Oil pumip inner rotor @ Oil pump drive shaft @ Oil pump cover gasket & Oi puny cover @ Smm spring washer | Simm cross serew a 6mm hex bolt 1 Cam chain guide sprocket spindle Fig. 12 16 “Sprocket ‘Setting: Bots Fig. 16 5. Loosen the three cam sprocket mounting bolts and remove the cam sprocket from the camshaft (Fig. 14). 6 Unscrew the four cylinder head holddown nuts and 6 mm hex bolt and separate the ey linder head from the cylinder. 7. Loosen the cam chain guide roller pin and remove the cam chain guide roller from the cylinder (Fig. 15). 8. Unscrew the cylinder mounting bolt (1 each) and remove the cylinder. 9. Disassemble the valve rocker arm and the ceamshaft from the eylinder head. Use the 6 mm bolt for pulling the rocker arm pin out 10, Disassemble the valve with the valve remo- val tool (Tool No, 07957-3290000) (Fig. 16). Inspection TL. Inspecting the cylinder head machined gasket surface. Place a straight edge across the machined gasket surface and measure the clearance between the straighk edge and the machined surface with a thickness gauge. If the clear ance exceeds 0.05 mm (0.002 in), the eylinder hnead should be repaired or replaced (Fig. 17. 7 To perform the repair, place a shect of fine tzit emery paper on the at surface, and rework the eylinder head. The condition of the ma- chhined surface can be checked by using prussi- an blue or red lead (Fig. 18) 2 Hnspect the valve set STANDARD: 1.0-1.3 mm (0-04-0095 in) SERVICE LIMIT: 20 mm (0.08 in.) ov etue — If the seat is too wide, too narrow, or has low spots, the seat mnist be round, Ifthe salve seats most be ground, the use of @ poster grinder is recommended abe Sut Ouse Dimes xm (oh) ar 7679.5 ais a. ree ation ‘sete ve Sst sinder (Fol No. O71E2-03000, A st) to correct the vane at wth and _ Set rind he tment att (1) PINK (2) BLUE (3) WHITE 63.5" o | | _ 45 «ST50> | TR 713-020100 (3 nm) | IN! O71-G00200 23mm) | TN? O7E-2068300 2 EX: O77 00100 3mm) | EX: O7E-2090100 Qt mm) | EX: O7EDIN0100 mm) cern, st) corn, sr cern, $1 TN OT73-0250900 9m) | IN! GTE-0020500 9 mam) | IN: O7ED-ADD400 29 am Beene (6mm | Examen em | EX OT-ONOI Gsm Fig. 2041 Fig, 202 Fig, 203 18 If the valve seat has been repaired or the valve replaced, the valve must be lapped to the seat, To lap the valve, apply a small amount of lapping compound to the valve contact surface and rotate the valve back and forth ‘against the seat with a surction cup tool; lifting the valve off the valve seat occasionally. After valve lapping is completed, wash the lapping compound off thoroughly from both the valve seat and face, Check the valve seating with prussian blue or red lead to assure that a good seat has been obtained, ‘Note: 5. Apply a small amount of oll to the valve stem when inserting the valve into the guide, 2. After the valve has been assembled into the cylinder head, check the valve sealing by pouring a small quanty- ty of engine oll into the combustion chamber until the valve heads are covered and then apply compressed flr at 2 kgiem™ 28.4 psi) alternately into intake and exhaust ports and check for any bubbles around the valve seats. If there are no bubbles, the valves ure seating property. 3. Measuring valve stem and valve guide wear Place a dial gauge against the valve stem and move the valve sideways and fore and aft, The amount of wear in any direction will be Indicated on the gauge (Fig. 21), ‘mm (neh) 3 9.01~.03 5 place if over ake | Pa one- ob onizy | ods C6000) = 00S | Replace th ove? —|6.0012~0.002)_} 10 (0.004) 4. Measuring the valve dimension. The valve stom diameter is measured with a micrometer. i. 2. mm Gach) inake Replece funder : Sap 020 tame [piston [Be a Eetawst | (6.20700. 2105) | 5.38 (0.2048) Fig. 22 5. Replacing the valve guide If the valve guide is worn excessively and requires replacement, follow the procedure below: a, Remove the valve guide from the eylinder head with the valve guide remover (Toot No. 07942-3290100) (Fig. 23). Install the new valve guide with the vavle ‘guide driver (Tool No. 07942-1180100), fand carefully drive the guide into the head, The replacement vavie guide should be oversized. & After the new vavle guide has been in- stalled, it must be reamed to the proper finish size with a guide reamer (Too! No, (07984-0980000), Excercise care when using the reamer and occasionally apply 4 small amoun of oil to the reamer when it becomes difficult to use, Pull the roamer out and remove the metal chip before continuing to ream. ‘The standard vavle guide inside diamerer is $4788.485 mm (0.2186-0.2159 in.). (Fig. 29, 6. Inspecting the vavie spring Measure the vavle spring fice length with a vernier caliper. (Fig. 25) 19 Vel Gude Reamer: ‘07984-0880000 mm (inch) Item Standard Vale Servicsble Limit Inner valve spring fee length to [Revs Ger 25.9 ‘Outer valve spring free length | Repaid 28.9 Inner valve spring compression | Rene eee ene [2.7 ‘Outer valve spring compression 7. Inspecting the,camshaft Measure the cam lift with a miecometer ( 26) mm (inch) 71,0 | Replace if under oe 20:8.0.819), 26.076, Replace if under {i'o%66) | 2s" G.012) Valve Timing take opens s° BDC Intake closes 20° ATDC Exhaust opens 2s" BBDC Exhaust closes st BTDC —Reples Wander 6 e7a.9 ba 0. 1416/0. Si Micrometer Fe. 26 8. Measuring the inside diameter of the cylinder Use a cytinder gauge and measure the inside diameter of the cylinder atthe top, center and bottom in both X and Y axes. Ifthe cylinder is excessively worn, it should be either rebored or replaced with a new cylinder depending upon the extent of weae (Fig. 27). sun (inch) Seabe Uni 39) _Santae-vate_ eE 4$7.10,854) ; Note: When cob bored to oversize wnits of 0.05mun (0.010 in) ing the cinder, it must be re {oa maximum of 1.0mm (0,040 in). The piston and piston ring sets are those oversizes onl Reassembly Perform the reassembly in the reverse order of disassembly described in page 13 section 5.3, Follow the procedure below for timing the valves. Position the key of the let crankshaft so that it is pointing toward the cylinder head, and position the cam so that the “O” marking on the cam sp- oeket is at the top (Fig28) Note: 1, When installing the cylinder head, the ea sprocket must be contained within the ey rider head (Fig. 29. Do not forget to install the respective gaskets, dowel pins and rings 3. The position of the cylinder head n ®, @ and @) for the blind nut, and @ for the plain nut, Do not omit the sealing washer ‘on the @ position (Fig. 30 4, When torguing down the eslinder head, tighten the nuts uniformly in a diagonal sequence as shown in Fig. 30 and torque t0 the foal specified torque value of (90-120 egeem (68.9 feb), 2. 34 Cam Chain Tensioner A constant force is applied 10 the cam chain ‘automatically by the hydraulic and spring- ‘operated cam chain tensioner. (Fig. 30). Check valve inspection Push the pushrod and check to see if oil is leaking from the check valve It the oil is leaking, it is probably due to dirt in the valve. Clean the valve by blowing out with compressed air. If the oil is diety, it should be changed. (Check the guide rollers for wea, The manual cam chain tensioner is equipped ‘on the CT70-70H KI, K2 and K3 models. (Cam Chala Adjustment 1. To adjust, loosen the lock aut and back off the tensioner adjusting bolt approximately 1/2 tun, 2. It the chain is still noixy after adjusting, Joosen the 14 mm seating bolt located at the ~~ left lower side of the crankcase and tighten the tensioner bolt gradually until the chain becomes quiet. Upon completing the adjus tment, tighten the tensioner adjustment, tgh- ten the tensioner adjusting bolt, Tock nut y and 14mm sealing bolt securely Tern Bt 35 Piston and Piston Rings Description The piston is made of special SAE 332 alminum alloy to minimize material deformation caused by high temperature and also because of its good ‘wear resistant qualities. The piston rings specially should be highly resistant and therefore, they are hard chrome plated or wet honed to give it the desired characteristics, 22 Disassembly 1. ‘The piston is disassembled from the connecr- ing rod by first removing the piston pin clip ‘and then the piston pin (Fig. 32) Note: ‘When removing the piston pin clip, place 1 rag under the piston so that the clip will, not fall into the crankease if it should acc dentally be dropped. 2, To remove the piston rings from the piston, itis recommended that the piston sing remover be used, however, if itis not available, they can be removed by hand, but care should be exercised so that they are not broken. Tnspeetion 1. Measuring the piston Measure the piston diameter at the piston skirt at right angle t the piston pin axis using 1 micrometer (Fig. 3) sm (inch) Standard Value | Serioeable Limit Sr a0 | 38,9=39,00 Replace if und 2 cusiveci. sss |S 11,33) STOR) 46.98~47,00 | Replace if under KRG) aisib2~1. 8500) | 46.9°C. 847), 2, Measuring the piston ring end gap Insert the piston ring into the cylinder bottom tend and measure the ring end gap witha thick: ness gauge nm finch) Tent Sa Vale | Servis Li Top and 0.15~0. scond Fng | (0,0659~0.0138) | 0.8 (0.0187) eae 0,150.40 | Replace & | co.o6s9~o.0187s) | 03.0197) ‘Measuring the piston ring side clearance Measure the clearance between the piston ting and piston land with a thickness gauge (Fig. 34). rma (inch) Tem _]_Sanars Vale | Seiceable Limit ‘Top and | ~0.015~0,045 | Replace if over second ines, 0.120.004, Oi rine | Gon=OOS, | Renee Raver Ot rng | co.c0ot~o.0010 | 0.12 (0.0047) 23 4. Piston and piston rings are available in four Standard oversizes of 0.2mm (0.01 ia) t0 |.Omm (0.04 in), Reassembly Perform the reassembly in the reverse order of disassembly as deseribed on page 24 Note: 1. When assembling the piston to the connecting rod, make sure that the arrow mark on the piston head is pointing down ¢Fig. 35) - Apply oll when mounting the piston rings and piston pin Make sure that the rings move smoothly in the ring groove, and that the ring end gaps ‘do not form a straight line. 3. Check the top surface of the ring. The rings should be mounted so that the R (or T) mark faces the top. 4. Use a new piston pin clip when fixing the piston pin (0 the piston. 3.6 Cluteh Description ‘The clutch is the coaveational wet two-dise clutch which is automatically operated according to the centrifu al force generated by the engine rotation, The CT 70H, HKI incorporates the manual type clutch. inn omit | Pinay Die Gar mm / vv Gear utr Lock Wester ball ei J ouenee / [od a eb (ich Out! Cor Fig. 361 ST50-70-CT70 CF70, Ki, K2, K3 Clutch Fig. 362 CT'70H, HKI Clutch assembly ‘sembly 24 Remove the clutch outer cover. 3. Straighten the tab on the lock washer, and using the clutch outer holder (Toot No. 07923- {040000) and lock nut wrench (Tool No. 07916- 230000), loosen the lock mut and remove the clutch assembly (Fig. 37). The clutch is then disassembled, Disassembly coun ouge Moy 1, Loosen the right crankease cover retaining o7516-2830000 screws and remove the cover, 2 Inspection And Adjustment 1. Clutch adjustment. The clutch must be adjusted with the engine off, Loosen the adjuster lock nut, b. Turn the adjuster clockwise about one tum, Do not tuen excessively Slowly tum the adjuster countercolckwise and stop when the adjuster to turn heavy. 4. From this point, back off the adjuster in the clockwise direction 1/8 to 1/4 turn, tnd tighten the lock nut (Fig. 38-1). Fig. 381, (6150-70, C10, KI, K2, 3) Adjusting screw °@ Lock nut 1, Clutch adjustment (CT70H, HKD 8, The clutch adjustment should be made with the engine shut off b, Remove the clutch cover and loosen the fock mut. Turn the adjusting serew cloc wise until a sight resistance is felt, then back off 1/4 tuen (Fig. 38-2). Adjust the clutch exble so that the free play of 10-20 mm (0.4—0.8 in.) is avails- ble at the end of the clutch lever. (Check to make sure that the alutch operates properly after adjustment, = The engine should start easily with the kek starter without the clutch slipping «When changing gear, the clutch slipping should be smooth and light, especially ‘when shifting down in gear to the neuteal position. 2, Measuring the friction disc Measure the thickness of the friction dise with a vernier caliper Fig. 39)- Fig, 382 (CT70H, CT @) Adjusting screw" Lock mut mm (Inch) Tish Standard Value Services Git Thickness [2.50 cose) | Regie Hance | Replace if over — | 0515%0.006) Fetes | = Fig. 39 [3 Inspecting the clutch spring Measure the spring free length with a vernier caliper (Fig. 40). mm inch) kengih | Bis 0.931) ST 70| Free 214 | Replace if under Cr 70\ feng | (0°84) | 20.4 0.803), ont) Fee 20 ‘Replace if under C170 feng | 787) | 19 (0.748). — we 40 Reassembly Perform the reassembly in the reverse order of issembly described on. page 23 Not Tend the lock tab positively in the clutch Tock nut sot 37 Crankshaft Description The connecting rod is assembled on the crank pin, The bearing at the large end is lubricated by the pressurized oil which flows through the crankshaft (Fig. 40. Fig. 41 Oil flow Disassembly TL Remove the eylinder head and eylinder according to the procedure an page 15. 2. Remove the clutch assembly according to the procedure on page 23 3. Remove the primary driven gear and kick starter spring. 4. Remove the oil pump. 5. Remove the gear shift stopper and plate '. Loosen the left crankcase cover screws and remove the cov 7. Pull the rubber plug off and remove the gear shift drum stopper bol. 8. Remove the final drive sprocket 9. Remove the right crankcase, 10. Lift the crankshaft assembly out from the case Aywhea, stator and eam chain, Iyspection 1, Measuring the erankshaft balance Support the crankshaft on V-blocks at the bearings. Rotate the crankshaft and measure | Crankshaft the amount of runout at both ends of the crankshaft with a dial gauge (Fig. 42). sam (inch) Tee Sandee Vale [Senieable Lin Tait end, at 30 (1.3) rom the o os, | SE Sa Right end, at 25, ||{{0-0006) 0.05 (0.002) —s 0) he Fig. 2 wee 26 omega | A ickress Gee 2. Measuring the connecting rod side play. ‘Measure the amount of connecting 10d side play using a thickness gauge (Fig. 43). mm (neh) Sama Vale Sere Tit 0.10.35 Replace if over {6.000~0.014) 0.80 (0.0315) radial clearance of the connect- ing rod large end besring. Measure the amount of clearance at the connecting rod large end with dial gauge ig. 49. mm (inch) SESE Gat Replace if over 002) Reassembly Perform the reassembly in the reverse order of disassembly, 27 3.8 Transmission Description ‘The transmission incorporates the constant-mesh Jspeed gears. ‘The CT 70H incorporates the constant-mesh 4-speed transmission, The power train of the transmission is shown below. (SP 50-70, CF 70) Feo: a ig. 48 Neutral position Fig. 45 Low gear position ig. 47 Second gear position Fig. 4 Third gear position 28 (CT 70M. HEI, CTT0+ K1- KK; Fig, 48:1 Neutral position D Mainshaft @ Countershat Fig. 48-4 Third gear position Disassembly Perform the disassembly according to section Crankshaft Disassembly, Remove the right crank= case and separate the mainshaft assembly, coun: terchaft assembly and the gar shift fork assembly Fig. 62.8 ‘Top pea postion Inspection sam (nc Tren Sandor Value Senioeble Limit Gear backlash. 7 | 0.0=0. 1s ‘Replace if over beck _|_e.bsee0m | "as io'oin heres bean par anda %07=0.06 Replace Wer ‘naan and pea) (obo 088) 0,009) ‘Clearance bareoeh pear and tO | Rite teaver Gunes gad ais.) of 008) 29 Reassembly Perform the reassembly in the reverse order of disassembly. Note: 1, Note the right postion of each component refering to Fig. 47~50. 2. Replace all crclips with new ones. 3. After combining the right crankcase withthe let crankcase, check the transmission if it engages smoothly in gears 3.9 Gear Shift Mechanism Description ‘The gear spindle arm which is connected t0 the gear shift spindle rotates the gear shift drum and this causes the gearshift fork to move left and right in the drum groove. The geer shift fork is controled by the groove in the drum and thie in turn causes the gears to slide and change gears Disassembly 1. Refer to the section on crankshaft disassembly ‘on page 24. By removing the right erankease, the gear shift drum and the fork assembly ccan be removed with the transmission gear 25 a complete unit Inspection Mion. 1. Measuring gear shift fork end thickness. ‘The shift fork end thickness is measured with 1 micrometer Fig. 9). mm (inch) Ties Sara Vat senate Limi Sa-63, | Reece fer Left sie | 9. t57m0. 205) | “4 '3'00.168), 2, Measuring the inside diameter of the gear shift fork “The inside diameter of the gear shift fork is ‘measured with a cylinder gauge or an inside micrometer (Fig. 50). finch (on) EE M.0~34.03 Replace if over (35051 3399) 34.2 (1.38) Gear Shift Drum 3. Messuring the outside diameter of the gear sift drums “The diameter is measured with a micrometer Miguel Fig. $1. sm (neh) Teale Senet Ti aags~3.98 | Replace if under We ss6~i3377) 5.9(1.389) 4, Check the fork end for bending. 30 Reassembly Guide Pin Clip Perform reassembly in the reverse order of dis- assembly. Note the following items: 1, Make sure that the guide pin and guide pin clip are properly installed on the gear shift drum for both the right and left shift forks (Fig. 52). Apply. screw locking agent to the stopper Plate fixing serew (Fig. §3) 3. Check that the transmission gears engage smoothly. 3.10 Kick Starter Stepping on the kick starter will move the pinion, Which is locked by the acme threads, to the teft ‘and meshed with the countershaft low gear and ttansmits the force to the crankshaft to start the the engine.(Fig. 54). Instruction for assembly 1) After completing the assembly, do not forget to install the ciclip. Replace with a new part. 2) Assemble the parts in the position shown in the figure below. Tre Screw Should te Fasten Tiehty Mick Slater Spring J Bam itp / \ Himm Thrust Washer \ 20 mm Set Ring 20 mm Washer ick Stare Spindle ck Starter Ratchet Spring Fig. 54 3.11 Carburetor Fg. $8 Carburetor Tt vale Fer cap_ Top ap 31 ‘The carburetor mixes the fuel and air taken into the engine in a correct proportion to produce ‘4 mixture and which is further atomized so that it is easily combustible. The carburetor con- struction is quite the same as that of 50/65 except ‘except that if has @ horizontal drought direction venturi unlike $0/65 series. For move information fn this carburetor, the 50/65 shop manual should be referred to, T Cable adjuster _— Ca sping Bar lp set ved Fat chamber body Vale sat ain jet 32 Theol stop i sen sping - i seen Thre sop sexta Bria rn Fi. 56 “The carburetor speification is summarized a8 below, Te [+ # st70 oH Maia det + 465 ft it Fis a | asdaxe o.6diaxa AB, a.sdiaxe Air led 48, Ni AB. aaseiaxa ag, ausuiax2 ay 2 5358 Guten | 300 25859 Gates) | 90 2.56 Gates), hie Sew Sot tet Air Sere wet det Guay 72.5 (widh

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