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SHOP MANUAL
C70
-15,

' I. .. ' -- '1 '--::.'......: I';:".'-"555? ::- :: -FII35 5'53--'7'3§:'-E" . '

 h IIIFBRTMIT SAFETY IIEITIEE
Indicate: H‘ strung nrmibllfly nfsrwrr ,I:'.rI-unul mm arias ufflfie lfmnmm.-u amnnl ms» mr.
CRUTIDNI I-'m‘I1'-fin :1 pm:-fbi£fl,1' nf pmwrw-' |'n,r-ur_v ur cq-ulpmrn: -nlarrangir if immwrinn: are nu: fiaflowei
DEIIHECI dfltflpllnns d1‘ itifldird workshop pruuadmai, safer»; prindpiaa, and qnrvncn upgmium Ir‘ |1|ut|nclud||d_
It II |1'l'll§lfll'12I'l'l'I tn nu-tl that this lTE|‘lL|B.| cnnmlru. some warning: and flurinnq qggirrai nml amdfiu survive ninth-
-Udl W|"l|G|'l cuuld EBUII FEREONIL INJURY ISO flrultl bflfnnrlll (I |:;r|.|Id during 5 ulhiflq qr rgnpfgr 11 |_mgu!q_
F1845! I-1I'1d=B1'lT-Bfld ‘III! 17105! '-I‘mH1i-flgi Dquld mt cmrlr 51! oonnlivubl: my: in which ierlnce, wh-&Ih|:r nr_ not
Flm"""""!"'5=l‘1 1'-W Humtln Ififlhl bl ilflfll fll B7 ‘U1! pflflibli hue:-rmu-.1 :flfl|=q\llrIc=i cn‘ each mnoaiuablu way, nur
|:|:I-uld Honda unvasrlmta I|| uunh warn. Anyone udrlg 11-rwlm |iI"DCIl2|\|l'Ii_ or tools, whether or nut re-|:urnrnam:Iefl
by HONDA must aan'sFy h-l'I'1'1iE” Hlwnughfy lhnt l'lI|l|'lIf plfsunal safety nor ualflcla ufelv wlill be iauuardimd |.'|\,r
thfl I-H11-'|rl.‘|! methflfli ur Tu-tllli illiutad.

‘K’
In — —
 d__—-

H-.
cto A
u-—\.
.- 1

HUW 'l'[| USE THIS MMIULI.

Frallctw the Mairttertance Sflhcdulu fgggm
mtmdutiolis to ensure lltat the ye1|i|;||g i5 G EN E RA L IN F DHMATTDN
always in peak operating isnnditit-.-n. Perform-
ing the first ttt:|‘|~|11rJu||.tr.i maintenance |5 very.- LUBRJCATIDN

=A
impartarit. It cttrnpensatas for the initial wear
that {llIE.1JF5 rlur ing the |:|r-zal-t-in nerFr_'|d_
INS? ECTIDN AND ADJ USTMEN T
Sacti-ans 1 thrttugh 3 annl-,r to the 'l'l||'hQ-|fl
motorcycle, while sections '11 through 1? FUEL SYSTEM
1'“- dc-scribe parts of the muturcycle, grnunea
at:-tsnrriing tn In-r;atinn,
E HG I NE Fl EMDV-it LII |'tlS'|"A L LATIDN
Firirl the section ‘|'D|.l want an this page, then
turn ta tha tabla ui tnnt-ents |:|n page t Qt
that $s't:t|¢.1n.
CYLINDEH HEADNALVE
ad
d
Must serztinns start with an fl5st3mi:||y ur CVLIN DE HIPISTOH
E
system irlustrallari and specificatrnns, torque
values, ganaral instrui:tians_ tools and 'lri':iu|:iFa- ENGHE CLUTCH
shunting far the satttltm The subsequent
D6965 giirfl dilfililfld nrncettttres tor the section. GEARSHIFT LINKAGE
Ii
r"~- ll‘ yau d|:in’t i-tirtuw the sir:-urtpe of the trciub-|e_
se-e iatttinn 15, THDUE-LESH DUTING. TRANSMISSIDNIDRANKSHAFT

Hater to the adctandum at the hank af the CAM CHAIN TEHSIDNEH

shop manual 1'0!‘ infnrmatign un the IQ-B2
ETD.
F RDNT WHE E LISUSFENSID N _L D-J

F
ALL H-IFDHMATION, ILLUSTRATICINS. DI
HECTIDHS AND SPECIFICATIONS IM- Fl E A Fl WHE E LISUSPENS ION . -I‘ DJ
CLUDED II“-I THIS PUBLICATION AFIE
3"" BASED Di‘-.| THE LATEST Peuuuct rm
FORMATION r1VA|LA£LE AT THE TIME BATTEHYICHAHGING SYSTEM

HQ
UF APFHUVAL Ftjln PRINTING
HONDA Mt':|T|I:-H C-:1, Lrn. HE5E|=tyE5 IGNITION SYSTEM
/"~. THE HIGHT TD MAKE CHANGES AT ANT
CHASE
S
TIME WIIHDUT Nutice AND WITHDLIT
INCUHHING ANY DHLlt3ATtUN WH.=.T E LEG-TH TC STAR TE H
EVEH. HO PAHT OF TI-H5 PUBLICATION
i MAY HE HEPHDDUDED WITHOUT watt
. TE?-J PEHMFSSIDN. EWITCHES

F“

aae
THDUBLESHDDTIHG
HONDA MDTDH C-U., LTD. _
S-anriaa Publications Office wmms DMBHAM

IF-
'32 ETD ADD E HDU M

_,|-

Datfl ttf lssu-is: NOIL, 1951

‘El HDNDA HIDTDH ELL, LTD.
 I-Iona‘na.
ctn _h

_.~'--_
MIJIIEL IDENTIFICATION

I It ..._L'
I

.' ;.-f
.' i I.

I J d |- "FE ,‘._ '-‘I*_.'-. - - - 3

'_ E
-1|

_i_ ,I *1
III

\ .

.r
we
.—"'

TI'IB Ifflme -}ari.;|I r|t|rrthur is slafltpéd IJI1 lII'|B I'I’DI'I'1'l'it I-III I-II-Ill The Vahictu Identification Humhlr it rm the '5-at-My C-err!" 1"».
I]ahI||cI the tide cover. qriurt LnheIon1h&Irarna's left tide.

“H

-1

The e-tqing strriii nurr|I|qr is :It1n1|'J|-ad 0:1 IIIE IDWBF IEI1 crank
\
The :,arb4_[et1;r:t-r i|,'Lur\tiIir:l|nn |1umI'JI!r ts stem-pad on 1ID|:| 0-‘
--"w

LBJB. the carburetor fume. .1-\

Date uf Issue: ‘May. I935

§_'-IHDNDA MD TOH CCI._. LTD.
 ~i%§¢§?"%%”“I . GENERAL INFIIRMATIIIN
. _-_

GENERAL SAFETY ‘I-1 CABLE 3: HARNESS EIULFTING 'I—B

SEFIVICE FIULES ‘I-1 MAINTENANCE SCHEDULE ‘I-B
In SPECIFICATIONS I-2 EMISSIDN CCINTFICIL SYSTEM 1-5
TDHDUE VALUES I-4
TCIDLS ‘I-5

.-'_. 1

GENERAL SAFETY
[M
-II Irhr rnginr mmrr be mania; to uin mm wt-mit, math- The -Ivmrm-_y eiercioiyrc contain: .:m.[|"'|.rtI'|':' m-int. -H'[rF£:.I‘
sure the ems Lt‘ itch‘-tleariiutigd, ,'IIIrti¢',|' rm-| my engine .IwIi1' ¢:I-'-H. 1-It-in me‘ starting. In me of ccnnttct, Hid:
in II‘ riruwt arm. Ht: en-Jamar ca-n.r-urn: nnismwm I-Imruu_|;Itt[t= wt'.*It mtrcr end -t-uI'I' III deem: If nlarrraijtrre
/"'\,| -nsrbnn monoxide gels. rel: In your tI_t't*.\i.

Eitercihre I: exrrertmhi flammable and is -t'.tt,tI.ItJ.ts'ntr TM bdrffly gcnieretes hydmgm gar which curt -In:
Hnrffr -rtrrmtirt rrlnditiunr. Lin not smoke air III‘-cw Aigailv rxpfosfm Du nor make nr n.II'u-w fluntirs or
flumexur sparks In your wrists; mes. .spn-rl.-: near Eh‘ Ira.I‘trr_t', eqxchlbi i||.=.tI¢|I|I|: margin; Er.

I-\-

SEIWIIIE IIIILES
a“"'*. I
I-Ii" liI'""'-1I"B HUNDA nr HDIIIDA-rec:tmn'ienr-Id! parts ind: Iuhsicents or The-Ir equivalents. Part: that don't meet Hence’:
design speuzlficati-ens may tilemege this nntnrsycle.
3- Use the special tcctls designed T1',I|"TI'|Ii pm-|;Iui:t_
3. Use only l"l"lETI'IlI Inn-ls when servicing !I'tI: n-nturcyi:,iu_ Metric Iitfl-I‘I:, hull, at-tit ntrnws are not Intucluingaable with Engllgh
IflEIEI'IErs, TI1: use cf inccrtect taut; e.I'trJ llittlnrrri may der-neqe the n-|amn,:yi;.Iq~_
4. Ins!-all new gaskets, D¢in|;|s, ccttm pins, I-ucit plates, etc. trmen renssinnialing.
_r"-. E. Wltttn tightening bu-Its at nu-It, begin with the Ierger-iiiamutn or inner he-It first, and Iighlnn ta the specified I;t,||-qua yilugg
itiaqc-nally III 2-3 I-ltrpr-. unless a IIIiI‘|II-£LtI:t ttqslflrlcc is specified-
5- CIB9" FWFH I" H0"-Tlflmmabifl Or high llttsh point scIu'e'nt upcn dis-lsscrnhly. Luhricete any siittlrg ;t.tr|';|m; hefcre reassembly
T. -"’i'Il=r rlisscntily, check :tI1 parts Inr prune! Initellettttn en|:I uni-itin-n,

Ff-e

IF-"

Date-at I=.a.ni.~: May, I961] 3 1 _ 1

EHDNDA MDTCIFI C-0.. LTI3.
 I-I£lE1¥lfiD.l\.|
G ENEFIA L IN FDHMATIDH .-="-"1

SFEIIIFIIIQTIIIIIS
ITEM

DIME N5-1DN5 Dvlrnll llnqth 1.305 rnrn 1T1.1 inl

Dvarull width BB5 mm 120.2 inl
Uvflnll heigh: Q95 mm 139.? lnl
Wheelbase 1.180 mm I-43.5 Inl
Sear helgl-11 FED mm 119.9 inl
Fn-utp-sq height 250 mm 110.2 inl
Minlmmn grnurfl dmruhm I-Ill mm I 5.1 lfll
Dry weight B15 kg I IE-4 lb-I "'5-
FRAME Tvul Backhu nu
Fmn: gugpenflun, [uni Lflldlrq-L inll 55 mm 12.2 In]
Flair iu.q:lminn,1.'ra1.Il| Swlnqirm B0 mm 12.4ln1
Fmn: llre 11:2, presmra 2.25-I I-HF!-'t an kq.*cn'|:125 pxil -*1
Hair tlr-I me, are-saura 2.50-1?-EH 2.5 km‘ cm’ 140 psil
Fm nl Intuit: Clhll upnmrmi llndlrg in:
HBIF brake Had up-armed Ina-dmg shoe
Furl rlpl cit-,r 11.0 lit H.125 U5 Bil. 0.58 Imp gnlil
Fuel tamrva l.fl|I0l1Z'|l 0.151 Ill 10,21 Ufigai, 0.'tB lrnp gall
B4.
Cairn’ will
Trail TD mm 12.H lnl

E.NG1NE I Tvu-I
Cyllndar arrarngamant
Air cuulud 4-illflll
snqm, lnifiinad ao°1=mm unrtlcul -Fm
Ema mu mcflcu flflxHAmMLfi:LfiM|
Displacement 1'2 um‘ 14.-I uu nu
Curnpruslu n rs: in 8.13:1
Vim lrlln Chum driwqn overland mmmuh
Maximum hu-raapuvm 5.0 B!-|P."1',0£I3l rpm
Maximum mrqua 0.55 hq-rn."5_ECKI| rpm
Ull qDI¢it'||' DJ Iir 1fl.?4 U5 qr. 0.52 Imp qr} nflur dlmsllmbli
0.0 lit 10._B5 US q1,0.531m|:| qll lfilf drllr-Frg
LI.flJri-Cllidfi :1-rtnm Fund fl|'BI.11.I'E and wet-aumu
’_"+
Air filtration F-BIII1‘
Gqrllrlllr cnmpresflnn 12.5 : 0.5 l¢q.'cm= 11'.I'B 1? pair:
Intake vulva 0|:-um. u” arm:
Ginsu 20" man:
25. Ham: I
ll'||'TlI11||t
Exhaust value 0|:-an-5
|:|U'i-I-‘I 5" ATIJC
Valve clmranaa [Co1d1 IN: 0.05 mm 10.1I.~l2in|\
El." 0.05 mm |U.lIJi'ln1
Enqma weigh: 1B kg 130.? lb?
Id]-I spud 1,500 :1: 100 rpm
/_'-.

GA-FIBLFH ETIDH Garhmnur I'f|'JI Filtun vulva, 14 m1'n10.55 inJ vervrturi L-are
ldcrlllfilz-‘Hun numb-er 'Bflr PB32A
'-ET‘ PBIWC
Pllnt screw Initial fitting SH page 4-?
Flam hm-I H1? mm [0,-I12 In}
.»—=.._
- |

|'_I
. II

1-2 * Date M‘ Issue: May, 1_9BU'

Eli-IUNDA MCITDH C1'J., LTD.
 F"-"-.

I-‘In-_
v
“'“I=‘?'I3”“ _ _
E-EH ERAL INFD FIMATI DH

ITEM

DFINE ‘|"i'-‘IAIN 1 C1|.rt=h Wu muiti-ptata aummatic nuntrihqai

Tranuniannn 3-spud mnillnt mI!!l'I
Primary rei.‘i1:|I!tI0r| 4.053
Final raduutiun 1.521
“I Gear ratio I 3.???
Gagr ruin ll 1.1122
Gnr ratin-Iii 1 .190
Gmrshifi pattern Ln!-r fnul Upflffltflfl re-tun :-psram H-1-2-3

i ELECTRICAL ignitinn Fiywhaal rmqruam

Paint 98:3
lgnltian liming "F" rrnlrk
F1..liill21l.lIl'lOI
: Stating system
, G-anlratur
""1 Banary I31-Zlfll‘[\'
Splfh ping
0.3 - 0.4 n1n1i0.0I2-0.-iII1fiiniI
15* awn. Sum:
an‘ aruc at 3,1911 rum
Kick nlrtlr ariri mrtlr ninnr
Fiywha-alA.C,g:ar1a|r|tur E7 '|'iI.15_.iII0 mm
B1.I'~11AH-
icmmnal

i
For nu-Id .-Jlmmu Fur vuiendnrl high
bubw 5°C, 11°F STANDARD -spud D|JIl'l11Dl'l

Qaai ad F65 ' Ha .~a.1'-.=__

u2m=a can uzzrs cm-is umaa ' can
Iu2nFsa lcnsnsi liufizrsn [CHTPHSI |[UL1;4FSH i0RBH5i
_'.Li. .1 |.
"1 Ba-lrk mun ma 0-5 — 0.1’ mm 10.014 — 0.023 1|-1,1
Fuse aanatfltv IDA
T.
LIHTS Hndiiqht 1high.I'lnw hnml l5.|'1E‘|'iI
Tallfunplighl 5.3|"25W 3.-'.'i1'=|=
Turn Biflflli WW 21c:p aaa 010.113
Speadnmatlr 1.7171‘ IFFI SAE Nu, 51
Nu-uml India-|u:rr 1-'I"W 1w EAE Nu, 51
Tun _I1Il1I| indicator 11'W 1\=P SAE ND. 51
Hhh balm in|:Iic.at|:|r l.'i'W ‘IE9 $15. E No, 51

1'“--1

r""'~

F-‘ll

n“"‘\-.

E
Data of laturr M31, 1050
EIHDNDH MDTDH EU‘... LTD.
1-3
 Henna.
GEN E HAL INFO Fl Ml. ‘HUN
1:10 '~$§,»'
'"-1..
""1

T011002 '1'l|.|.|E§
ENGINE
1 tam - - Turquc
'0 .tv Thraaci
ma. [mm 1-
“Elm .
1 _
ft-1b <—~.
-1- 1
Cylinder 11.11.1111 l:rn'|:r I D 0— 1 2 .5
Camshaft spvru-1:1-let 0.5-0.9 -T
Clutch 1:11:11. nut 1 3.0--1.5 -33
Final driwr aurwkat 1.0-1.-I1 -11]
Flywheel‘ 1i 5.5-0.5 -4?
50211 ativlnugr -I -ru-1 :| .h @130’-13-U'|m 0.0-1.2 1-.-S- lg;-9
- .1
P“-"~.

FRAME _
mm | GW Th-rear! Ternuw
di-a. (mini _' Irg-m H:-ll: “"71
' Steering rtam nut | 15.0 — 0.0 | 43-65
Har1-cilabaraa-rtinq nur. 2.0 - 3.0 H-22
Shearing in-ck 0-G -1.3 1- H
Fmnt axia nut 3.0 - 4.0 22-29
Englnu 11|n|j1|r bu!-1 2.5 — 3-5 18- 25
Hair axle nut 11.0 1* 5.0 25-BB
Firtai driven sproairut 2.0 - 2-5 1-1--15
Hear braita tr:-rqua link 1.0 — 2.0 T-14 "'3
Flea-I |hn|:i< abm-rber 2.0 — 2.0 -2?
F0121 nag 2.0 — 2.5 1‘ I

5-wingarm pivot lznh IIIii

_l. 3.0 - 4.0 -29
Frflnt mmlrmun nivnt hnit 1.0 — 2.0 -IE3}:-1.1
Frnflt 1u1nen1Furr stunner bull. 2.0 — 3-0 1»:-21
Fnunt 51191:-it absorber upper hair l1.'\‘l-1 .-Ih -r\.:h-1n.J-|~,}q-.| m mumu u m fi 2.5 — 3.5 1a-as
F mnt tu m aignai :!.a',r -III 0.35 - 0.5 2. 5-3.5
.. ...__..-n...-_-- __

TOITII-IE IP-H-‘|1‘i\=I1i1=rI= limd lbmw are fur the mun irmnnmnr tigfiilning 1:1-Dinti. If e tulnua auacificstiun -is nut mire-a, |'u1hw.r
the atlndlrda given beiurw-
"'1
STANDARD TUHDUE "u"ALUE$
.1-1"‘-\-_.
i Turqua Tnrqul I -.1
ltam - 1'
_ ’ kg-m 11-111 : mm kg-rm 11-111 .|
5 mm halt. rwt 11.115 - a.a -3.:-1 - 4.1 ' 5 mm -mw 0.35 -- 0.5 2.5 — 3.5
5 mm 11°11. "01 0.3 -1.2 0 -— 5 Gmm snraw 0.?-1.'l 5- H
5 T‘l'li‘l‘l 0011, I'll-I1 1.5 2.5 13 — 1B B mm flatge hn|t_ nut 1.0-1.4 7-10
15 mm 01111. T"-I1 3-0 — L0 2'2 — 20 B mm fianga belt, nut 14-10 12 -22
12-mm h-nlr. nu: i 5.11 - a.a as - as 10 mm fling: r~.-=11...-1.1 3.0-4.0 22-29

-' '1.

.-1-1.

1-4 1 0-ate of lssua; May. 1900

EHDND-A MDTGH C-0,, LTD.
 GEN EFlA\L IN FUHMET ION
1"“.
r"'-"K.
'fl0LS
5PECl.P.L
Tupi Name T-pol l"-in. 'l1"I'r' Flaf. DIIJIJ
-'-*-. 0?5B#-0550000 1 ea, a-9
Valve midi: rflfllnlflr
Flwmeel h-nlclai 02922 12111101] 1 1.1.1, we
1 Dpmmrrnlally‘ available hand flrflp
wrnacm may ha used.
Bali rat: rrrmuvar 11‘04fl1?0D1'Il0 1 12-13
_"'_‘\ M9310-2??-01??-4 1U.5~fl-. 0n1'r'1
Fin s-p-anrfltr. 30 mm 019131;!-uclruflflfl 1 12-12,12-10
Value guide driwr med?-1 1301110 1 0-9

COMMON
’? Tu-:11 1"-lo. Ref. page
Tupi l'1l-I111: T.m;|| N¢_ (Pry Alternate Tuul

F lpat lrnlil qluqll 07401-0110300 1 -1-5

"|.I'||1r\1 guide re-rrnwar 07211-2-0010100 1 \l'1!l1H'0-fl|J1l2lU I'IH'I;W!ll' 0T9-12-32510100 a-9
5.5 mm
Unlwrial huldnr 0l|"'|'2E1-00101111 1 Cl1.11l‘;1F l"lfl-lad-Ir [1-T023-01100000 a.:1, aa
Cmnnvarualhr IV ltll
11-1.. adjunlnq wnmrh, D??D’3~0UI|11'I1 l:11l B:-19mm eflla 1 E a-a
B_:rr__0 mm- hm:-a1r1d wrench
""1 "|"ra1HI lvI!l1Llfllfl-ll 'nwnch. B 02208-0030-1111
U.S.A. nniv, rifnr to
3-5
S,T,11l, No. -117
L,-1:1-pl: nut wrench, (‘Jam-1.111-ar1:irl B-3
07215-0020202 1
20 11 Ii mm Ii|1'Il10'l!lB
Erlrtrrniln 11 mr 0721541120500 1 5-3

Flptpr puller 02733-00210001 1 1111mmring bolt 013015-350-0'11 1-I1-i‘

0??-1-0-11110013 Driver 1111111111

rrra4a-a1 1 crane 12-9,13-'1
Bearing driur l'liT\l1llI, A n19-an-aanueuu 13-9
Bauring driver miter. Baring driver attach. 02945-313201 DD 12-9
1--1.. 32 1: 3-5 mm 07711-5-00101011
nremnaatnua.
Earning clrlvar u-utar, 1 Ba-lrinp clrlvrur -ltmch
31' mm 13-'4
07245-1111 0300 |JTii¢1-5-30011000.
3? 1: -'10 mm
-111 mm
1”‘-. Bearing driver pibt,
err-1a-up-1=u1m 1 12-9
10 mm
Baarinig tlrinmr pi1r.|t, urna-no-10200 1 13--1
12 mrn
B-"ring drlu-ar pilnt, 13-5
‘IT mm
071-111-011-11:1-inn 1
f'\ lieu [M21011 ablclrb-ar 13-10.13-11
an nrpraarur
111959-32900111 1

Hipplt manner 5. aTr1r1-002112110 1 3-15

-1-5 1 5.1 mm
Vnhfl mrlaa urea:-arraeaar 6-5. 6-11
.3"-"‘.'\ Valve spring cumptfltflt erramnruuea 1 1X1I'l'1|I'I'iW|'

Lm;R'nur wrench. 0711641020100 1 5-3, 3-1:1

20 11: 2-'1 mm 1| l .-
{"1
._ _

2
Data pf lsauer May. 1930
@l‘1¢1"~l1L'lA MCITUR CD., LTD.
1-15
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 HON"-B
_. C70 GENERAL INFORMATION

TH11:1J‘l"I'LE mats II'~--17 l ?w_H__ "T'-.

SFEED1JlrlE'l'EF1 maua .- ‘-5- _

rnnm SHAKE mam _ _ I .I I

,'-I -H. I I I-_ "' H _ —-_,_

BAHO 1'.’ .4 - _
.‘ _ . ,_5'.':‘ J2. '._ '-F

F3 REAR I-l.i.|1NE§ l
"1 __ if l

F“T_11" '1
'7.‘-= 111- l 1| 2 ’“.\
1" -,
lfi , 1"-'&' I | I

J _ H __ ._\
___ '
1. _ .- -=1
.
;’- Ill - l
:3 ll-;\-'
\_.— _
'5=:-If-".F'
'--. .-r_-- .' I 1 F ¢
1'1.‘
c H‘.
1

'
' '

I
{f_.-'é;’_.
||l
"'_' ll“-12¢
r__,- .
"1;
. 1.;-" l -=1?‘
.1 -. \-._____:|._...-:_.:_ .

l ||||" Ii
— j US, ;'=r- "" " . ' -.

.»’_
.-f"~, \' ~.I 11* '
‘I -

F1 IGNITION 0011.

Pi .1‘ i-HI ‘ll ‘ll

nIrII=l1.|-r — I -- 1|‘
nEc111=1E1=| -,_ -"""""“ l '
- ._, 1*

F21 -*".|-
__—'

—r.r/L!
all
~-..2
l.
-'_F"'-If "I
_»=-_'f5I)/
- -- .5.-1'-l
B-l.TI'ER‘|' _ __‘-._\"
_-_-, __,___ .1‘--5*’-'~=i_-'_ ——
-'1-W,-r’-”
P. _—i H.‘ "1':-_.|,-:2

."-1' PM
1-""1
9 —

Datadf Issue: Mn, 1900

an-ruuna MDTDFI up-., 1.11:. 1-7
 HONDA .-’
GENERAL INFORMATION [:10 .-\\.,_

IMINTEIIMIBE SGHEIIIILE
P-mnrm 1h: PFIE-F1 llI|l'; INS-F'E1T.'1'l0i"-l in 111: 111.1111:-'5 I1.'h11Ll1:Fal éuch scheduled 11m.111'ar1:an1:e p-arind.
INSPECT AND CLEAN, ADJUST, LUBFIICATE, DR REPLACE IF NECESSARY.
. C CLEAN
REPLACE
ADJUST
I-123 LLIBFHCATE
i_ .._, _ . ____

FREDUENCV‘ WHICH EVER CDDMEFER READING INCITE 3,1

(111111 ES I
__ 1= mar ’Fim‘1:r
E100 m1 2,5-I'll] rr1'- 5_,l'.l[llIJ 111l 2,500 11'|l ta page
T‘ I-
11,000 llml H.000 l1I.fl1I 13,000‘ l¢I'I1l |12,DUO I";I'I1l
ITEM EVERY
I
FUEL LINES 1 I 1 3'-3
I-
THHDTTLEDPERAHDN 1 I 1 S3
.—1.
i 1
CAHBUFIEFDFI IJHDKE l I I 3-1
AIR CLEANER NOTE 1 C = C I-I 3-11-
TEM5 CRANNCASE EIREATHEH NOTE 2
CLEAN E'u"EFl'1" 35
1,2511 rni 12.:1n1£11<m,1
ED
sa.-111: 1=1.uc __ __ R Fl Fl 3E
VA L-"1' E C I. EAR A NCE I I I 3-0
0U
-CONTACT BREAKER PDINTS I R I 3- F
_ _ ' lGNl_1'l0N_TlIr'llNG I I I 3-B -*-.
REPLACE E‘-'ER‘1"'
ENGINE OIL YEAH R
EMSSCINRELAT 1,250 mi 12,1100 11.111 2'2
I-
ENGINE DIL FILTER SCREEN . _I
I-
CAM CHAIN TENSION A A 1- _.-1“ :1-a
-I
CARBLIRFTDR lI'-‘Ii E SPEED I I I 3-10
DRIVE CHAIN 1=. 1. 15111.1.-21111 :g§u_m1'1§11a 1-1-11 -1-1 1
em-ranrr _11-_11;;i111f1=.1-1 1 I 313
1-1-‘1.
EMS BRAKE SHOE '|'I.'EAFl I 1 113 _

il
B RAKE E-"r‘..'?1 EM W-_
BRANE LIGHT SWITCH n_ Z1-15
I
HEADLIGHT AIM 1,_ _. ,._ 1 :1-15
1:1.u"rr.1-1 __ _ .,_ 1 |_ i a1e
REanwLATEDT 51.1] E ST AND :-1-115 I
1-
-Ira
'lsu 51-151-151:1:-1 _1, 1. 1, 1. 1,1. :1-11
NUTS, EDI T5. FASTENERS I 1 1 1_ _ 3.111 .1‘-‘"1-.

NIDN-I:'1|1S " ' '1"1'H EE LS,-'SP\D1(ES I _ 1 I 1

_i_,_ a-1a
STE EFI_I NG H EAD BEA RINGS
L. 1 , :1-1a
I
SHIDULD BE SERUICED BY AN AUTHORIZED l'iUNIJA DEALER. UNLESS THE CIWNER HAS PFICIFEFI
T1-DDI.5 AND -SERVICE DATA AND IS l".'1ECHA.1‘-lICALL'I1" CIUALIFIED.
-I-I
IN THE INTEREST DF SAFETY, '1.11'E HECID-I".-1I|IEND THESE ITEMS BE SERVICED DNL‘-r‘ BY AN AUTl-IFlU-
111251: 1-11:111n'r1 DEALEFI.
NCITE: I. SERVICE MCIHE FREQUENTLY WHEN RIDING IN DUST‘? AREAS.
2'. SER‘v.I'ICE MCIFIE FREQUENTLY Wl'lEN FHDING IN RAIN DH AT FULL TH RDTTLE. [I.l.S.A. Di‘-.lL"1"l
3. FDR HIGHER DDDMEIER READINGS, REPEAT AT THE FREQUENCY INTERVAL ESTABLISHED I-IE-FIE
10
1-B Date pf Issue: May, 105-III
'51-IIDNIIJA MDTCIH 1I‘.'tI1._ LID.
 Q FRHONDA
r"- CTU GENERAL INFORMATION
-'--
EI|Il5SIl]|'I GIIINTRIIL S'|'STEl|I
The BTU is un I_|i|'}nI!|:1 with |L‘lI'l- r:a|'l:|i.ireti:w settings and uthar :ws1.I:rris ti: rlduu uarhun monoxide and h\IC|Il'}lZ‘itrh!_‘.Ifl umiigig |15_

E I H RUST S“r'STE M
Thu lmhilm I?=lT'|i-i5iCl|'I contra! wmarn ll |:i:|mp-used of lean UHLILIIEIIJI se1t|r|g:_ ufld nu ni-|.'||u:.:me|1n shuuld be made ermepl lull:
F“- spend anljustmiam wllh l|lE |.|l?'lI|‘|!|E ump si:--aw
THE =1-thahsli rmi-ssiun izuntrul svstem is wparata from this urarlkizasa emission acntrul system.
CFIANKCAEE SYSTEM
Tlw Erlgirr-I: il nu I-Iirlrrrl with -: cininrl 1:r=m-kcaan wmm in pruwrrt diicha-rqinq crankcase rmissinns lntrl Th: Itmusuhnru.
.—.\_ Blow--by qas is raiurmad to the cumbuntinn 'E|1Ef‘l‘l|JE'f !hruuq|| the air cleaner and the caaburutor.

-351' Aiu Cleaner

:7?
.-n
*1"-' “ -=:::: Fr!-sh Air
-Ii Bligiw-b'yGa.1
|- I
F

__ Transparent
" Tultlfl

f-3 ‘El DrilIIPh.q 1

INFDHMATIDN LABEL
.-"-‘\ The Emiigig-n Cuntrul I-|1f|;||'|'|'|utiun Lghil in lnultlhll cl-n IHE :'\\'ll‘|QAl1‘lt iifl !|GB.

,r"“‘\

.-"""~

I |_ 1 "II. W11‘.
H ,. ‘.._‘

.-1% .’ K "
J‘
i‘

‘J'-1

"-"el1||::e|I E|T‘||3ElCII‘| Cuntrui lnfurmataun

Duh: :11 lame: Mu1|i'_ 1951] 11 1 -9
TJHDI‘-IDA MDTIJH CD, LTD
 H
:fi__
_l__ Enis‘
\HA
R_fi Kg J}
L U BR M_H U DN _\_
H
_“fix
H_H____
E N G W E LU B H m AT m N S STE M
_Y

3
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II ________
____
AF
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_{___
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_ __
_ _ ___
~__‘__:_ fl____
________

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fikx
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_________
______
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_

§£mnq
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%
u_kMyIJ_
1__i

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_'_h_____Il___
{Rx
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__ _

fi;EJ.
I fimiw
_ P __

F511

7;
mw _-
WK“
TGAVL D
‘Hm JN
HNE E
CH_CABnflmwflmWET
Hi mfl M
HM _ m mm
M ?UEL_MRW M_H|
CD“EGl_ CFT HH CHHEA ND H
G DH WW _H M M ___*| CCH AAN GMME
R H A FT KK E
&
q
w_
_

RC THH _E
GA S IL

20 12 ME HM
_mN wm mm“Bmm
 HONDA
I‘-‘I.
Qiéfij/' C70 2. LUBRIBATIUN
SERVICE INFDHMATIDN 2-‘I ENGINE OIL FILTER SCREEN
CLEANING 2-2
THUUEILESHDDTING Z-1
CENTHIFUGFIL GIL FILTEFI
-iENGlNE'.?- CLEANING 2-3
ENGINE UIL LEVEL 2--2 OIL PUMP 2-4
ENGINE OIL CHANGE 2-2 ~=-'.'CHA5SlSfI=-
LUBFIIIIATIDN POINTS 2-?

$EIIYIIIE IIIFUIIIIIITIIIII
GENERAL INSTRUCTIONS
Dll firter screen and pil pump inspection and maintflnnrloe HM L1! mid! W|‘ll1EH-I1 FBMUVIHG II"? WEI"!-

SPECI FIEATIDNS
STANDARD I SERVICE LIMIT
|

. Appmrilmntelv 0.6 lllur IELEE U5 ¢i1l II -Ml I-'l‘|lfll';|E'

final” [III wpluw U T Titer [l}.?:I LIE II|[I at Enpin-E assembly
lh

Hewrnmandscl oll HONDA 11-ETFICIKE CHL 5-AE TUW-db pr mulvnlant

Ml senrlce cflaniilmtlon: SE
Dtblr vim;-:;i1iz: mm; L1: wad when the average temperature In upur riI.1|rI;|
arfle is wllhin the indicated range.
Hepnmmwndud nil '|'l'5l=UI-|‘IIHl-

T T T' "' " |

|'—\ I

If--. i _ :
.;|;| 1| l|| Ii‘ I l.1I F

.| _ I #-Ill
|_ . _-|. Ill | ll ll _q_|

Tlp n-ieernnpe 0.15 mm |[|=.lJl3Bi1-il D.2{l n1m [H.008 Fnl

Dil pump Bodv DI'BBl'Il'lDlI I111‘) - 11.15 mm [C|.ClEl~'1 — D.DClB -nil D.2lI| mm lD.DDB Inl
r""‘~. End nlaarenpe I102 — [LI]? mm IIILDDI EI.DCl3- inl IJ-I? mm IU-UB5 IFIJ

TIIIIIIBLESHDIITIHB
.""-8- ' Dll level mp low Dil -annmmlnntlun
T. E1-lturn-nluil hanks I. Oil not phinppd pftlrn fln:Jll'EI‘l
2. Worn value pu lde pr seal 1? Heed gnl-iet1'uul't'|i
3, Wprrl B-|:£D|'| rlrgs 3. Worn piston ring:
.*I.

Di|IIElIIIIIi$1.-IFI M-=31. I950 ‘I3

f.'IHD.ND.Pi MDTUH Ell, LTD.
 HONDA /.a;t.t@\
Luen ICATIDN CH] _.__
I _

.‘—\-.
(lEI'I[IIlIE>
EIIGIIIE IJII. IIIIEL
Euhlloitt the mptdrwple un_ri!:ht pn Ielrel ground,
Chunk the oil lees-I with the llller D!p.I'(.Iip$l‘I|;I|t, Du
not screw in the pep Wh|.'n melting miq |;hl5¢|-t, If the
IBWI it bél-tnv Ihu lmutr lrnntl on the dipstick, Iilltp
Ulit! up-per lwel merit with tl1e fE11'l'L'rrII-'|'|1t'-trl|;|l7d~|{r|"|g|l'|B
oi .

EIIEIIIE l]IL IIIIMIGE

MUTE
I When elmnglng the oil, drelri the peed all hmii ‘BIL FILLEH CA-P.-‘DIPSTICK Lowsn _____
Thfl Crflrlltlilhu while the engine ls warm Thu I.EvEI. LEV EL '
L ensures ed-mplete end rapid urelnlng.

Flurnoue the pil fillet l1B|Ilu'IIII[HIlCI€. __,

Pltloe en oil drain pen ullder the Eng-.|-ii,-, I|'Il:I- reman-

the drain plug. When the all ha been oompletely
tlflllhod. he sure that the drain plug sealing 1,-,-eel-lgr is
In good up-ndition entl Irutell the drain plug.
TORQUE: 2.! — 1.5 ltg-m i'l-Ii - I8 H-lbl
Pour the rt-wnmnnrled I-'lII [page 2-1| slowlv lhrouqh
the ell tllser hpte.

CAPACITY: 0,6 llter {'lZl.BE- U3 qt] e'l all dung

_|.
Install the nil filler trap.-‘clip-stielt. Start the engine
and let it idle 2-3 minutet. Step the engine we
tI'lE¢l= 1l'\Bt the oil level is ut the upper level rnerlt on
thlt d=pstl|::lt with the m-ptprcyele upright, Cheek
that trt-are ere l"H.‘l ell leaks PLUG
'-"|_l

EIIIEIIIE llll. FILTER SGIIEEII F HUN T C‘-C|"-" E H

LOWER FIIGHT
BILIIIIIIB G HAN IICCASE COVE R BOLT _

"CIT? _.
Fiflflrm this rnnintennnoe with the engine EIIIU
driinud.

Remove the front covet lower risht mounting bolt,

Remove the ltielt starter pedel end murllur. 5|-l!:Ip-urt . ’_""~
the motmoytle 'Hili1 is mltohle stand end remove the
Ibfliptpsfside stand assembly.
Flimfll-‘E The tight I-;l‘ill‘lI¢lI-il5Ii' coves,

__\_

H-Hl'I_EFI PEDAL stamp _

2-2 Ditto of lsstlo: 5-‘lay, IHHEI

EIHDNDA MCITCIIH C11. LTD.
 LU BHICATIDN

Flerflovo untl cleen sh-e pil filler sflreen.

lnstell the Di‘: film,-r screen, right orenltcase pa-sltel
tlnrl cover. ltlelt starter pedal. mufflet and loutptgti
side stend assemble‘-
Fill the craltltcese with the recommended I=ngInl! tl-II.
Start 1315 mgirie and let it idln for I-3 minutes.
Etnp :!~|e enqina and t:I1El2-‘It II16 CIII III'tIl=I l-I-liI.II T.I1B
motcm:-,rr:iu u|1r'ighL
Melts sure that there rm: nu oil ieelts

FILTEFI SCREEN

IIEIITIIIFIIEIII. Illl. FILTER BLEIIIIIIIG

Drain the cnglnn t-HI l,l=|-lg! 3-3]-

FIllI'l1l‘JI'|'E the right crunlti:-else crslrer (page 2-El.

Flsr-noun the fllulflh I6'lI\'il|', tam and GLIDE! go-var.

CLUTCH LEVEFI

C111-en lhr: trlutch outer cover -entl II1ii-rk! pl the clutch

outer usinp a I:|-trim IInl'.-IIEE cloth.

NOTE
I‘ Du not allow uusr eno dirt to enter the
|:|'||r:rI€:hlII1 oll pessegn.
I; '1.'.'=i~1=s=*zr_'r_r'_r~"*":===' “ti _l
Install the lzlutoh oultr -trrvel. tram end Ieutlr.
Install th-n r-gm csenltoase oouor. Itioit starter pe-drr-1,
I-nulfler and font pr:gsl'sld: stand esel:-In IJI I-.
Fill the trrnrikcese with the retornmensled engine oll
inane 1?-21.

C LUTl"H DIJTF H

Date uf Issue: May, F950

'EI'H-DNDF-. MlIIl'l'ClFl t'.;E|., LTD
 HONDA ("L3-E%\
LUBHICATI on Qjfl I ___
- _--.
[Ill PUMP CLEAHFF CDVFR__\__H_H-H-L ‘Q,FFlU'|'\|T CUVEH _ I

REMOVAL . I I I. ‘:5 I ' 1;‘

50115 Q! -fill
?|-II i'|.| ,_1 Ill .11.-'_ ___ hr .

Th! Bil |'IIll'|IJ- Eflrl be runwvud with ma angina J

|_ rl'1fl-ul11|:-e!| In 'll'|n frirnfl. 1“ !.:;'
"I 1
Ra muwna the ml Ur-aln plug and drain the nil fmwn thu
urlginn lnign 2-2]. Flumuw 1.“'hq I-#11 crankrme
cover-Image I-1').
Flcmuw thu clutch us-ambly [nag H-21,
" 0“--I?" J r ‘I, " i
.i'll'4‘1,|I _

‘Q: . .-_

MUFFLER KICK STII-HTEH FDCITPEGSISIDE RIGHT CFlANl€- ..-..

PEDAL 5-mrm ass"? BABE EEWEFI "
Fl!=rrm'u thu thrau |:||| pump am-.-.-5 an-d nu pur|-'|p_

-5-

SCH E'||"|I".5 ..-...

lN5PEl1TlDl'\l

Flflmuuu the |:||| pump h:l|;|'y' |:|;|wr_

."-1

PUMP BUD-"|" GGVEH _

4

2-4 "'- Dutw nl lss|.||:: ‘M-23'. IEHU

DHUNDA MUTDFI C'El._. LTD.
 ;, I-IIJHFIJIL
-1-I-._
BTU LUBFHCATIDN
__|I"""\

Measure use r'n1n| t||3 claaran:-2.

SEHWGE LIMIT: 0.20 mm lD.EHIlB ml
_

F“
---R I
//‘I fir-' D. ‘ _~,_';_ll

F“ ' ""

-»._
.<.;.:'”‘*»»»..$./" . . -.-~ J
Q“-___-__
1. -_
-..__--___
'
1
_
'\-ll:l"'.

- .- _.-"_
___-“___-' __,.-'
--__ Z __-- _.-'
“T-_ _
.-I-'l

___."

"'_"-..__h__ i _____.- -___.

.___ _ _ _ ___
.-'-
lkleasuru the |:||.|rr'.l:| i:||:|d\,' clearance
SERVICE LIMIT: I120 n1l'|'| lfl.0DB lnl

I l D anhhii

|f""~.

_-_‘___Fl_;,.~.1
.I|r

73-__'__- .-

\~'
@;
f‘
_ - l-'— - - -I ‘-.

|:- -:. _-d

_

.__.
.. E

. \I

F"
Measure the !'lJ‘ll'Jl and r.".l»::nn1nr.u
SERVICE LlMlT: 0.12 r'|1m'lD.DD5inl
-"""'*.

,.v""“a

.-'-'~-

.1‘

Date c|l' l-.-sue: May, IQHJJ

'1‘ HUI‘-JD.-5. MDTGFI CD., LTD
2-5
 HONDA. I’
LUBRICATIDN cm -I-1

DIEFKSSEMB L"r' ll‘-lh|E-Fl _HDTDFI EJLITEH FIDTDR

F'lerr1|:|'..'e the drive shaft.

Hcmrtvn thr: inn-er anti uutnr rcture

DRIVE SHAFT

ASS E MB LY

tr-tteil the nuter and inner rnto-re. Align

Invert the drive shaft and align the ftet din the shett
vnth the liat In the inner rctnr. l'he ftete -ahculd
face each ctr‘-et.

Ir-eteil the pump la-crltl liilJ\i':!r qeeitet end cheer -t

HIJTE __
Meite sure that the |'Jurrl|:t- reutee freely
l wt-tjhtjul handing. _ l

INNER RCITOFI OUTER HUTDH lJF'll‘u'E SHAFT

ll‘-JISTALLATICIN
ln!-t.|_|ll lhn ull pump with the! gtqliznl t:n|;le|| 1! altgrtlng
DRIVE SHAFT
the pump drive shah: with the aim in the cam chain
guide aplntlln,
lnetatl the clutch asea-mltlv lnege El-Bi.
In:-tell the riiht cranliww twcr. kir;k_ meter thcrlnl.
muffler and fact negefslde etand eeeemb-iv.
.15-Izlluat the -dluiith [page 3- ‘IE1.
Fill the camkceee with the secemrnenchtl engine nil
(meg 2-1|.

GAS!‘-'.ET OIL PUMP

2-6 ‘B Dertrt nl lame. May, IQEU

DHDHDH MDTDR C-CI., LTD.
 Hanna.
—- ETD LLIBHICATICIN

" <GilliSSlS>
LilBRii3iiTll]ii PIIIIIITS
Use general purpese giease w h i:n nnf specified hare

-""H“ Jinnl-,-' i:|il er grease ti:i the DlIl'lEl"Hlli'.l'l|1Q suttecite rint

ehciwn here.

CONTROL CAB LE LUBHICATIDN

PEr'lif:ilifli:II','_ rIIiii:i::inri<ii;r the thr|;|11_l'g_ from brake
3'-rli:l C l'i-eke cables at their ' upper erictt. Tltu-ruugiiyI
I,-""“ I|.|IJ|'i|2eitE Tlte cables and i.hi:lir |;||vi;i-t paint‘: with i
' Qornifliertlelltr eivaiiehle 1:-al:ila lubricant

ADVANCEFI
OIL FELT CAM THHDTTLE GFIIP
»""“~

.@ -E
I
/ ~&
StI'i'ii'~iGAFlM I EQQELQUMETER
Pivot BUSHIHES . .-
1
t.ue i=<'ic.t. tit I , I| {'4'
If "'

E Delve CHAIN , i I _,f ’ ' %

l .
.-"

r-;||=t,eii:E (_;_.¢i._1,|1 II i
I
_ '
Z;-2'
_' .. " CONE RACES
F.--~. -,' ' --- - _
"PI I3-ALL nieces
.
I
l|
I
._ _ I
.
I'
-it ..-
" .._ "

‘ J’
,
_, - ‘ '__ *' STEEL BELLS

! I .- *'
,'
' I
- - '
~fi
BFI-MZE ceiii
I 1
' ._1
“ I
-1-

I-"'\t
i ,1

. — I __. __|-'

‘I-5 r I
. ,I' .»'
-"l |i' .1‘
. Ill If ii

.-'
_. .'
- sine STAND ’
F“ PIVOT é
ee.-ti-:5 Peeet SPEEDDMETEH
Pivot GEAR
El‘~i-GIHE

Ll.ti‘iierif Issue: Mn~|'_ FE]-Bl] ts 2_?

'-EHUNDA MDTCIFI C11, LTD.
 I-Iowan.
cw ~eé.~ —
MEMU

20 Deteeflsseie Mai,-.1530
-Ie‘JHEi-rtirm M{}TUFi EU, LTD.
 %?\I-ION‘DJL III 2 =
|
s
_,._
C70 Oil ==-EEm ifIlI'l'l= Z2‘E2 —i
qfi

_,.¢—.

SERVICE INFORMATION 3-1 <.‘_DHASSlSl‘-=-

<_'ENGlNE.‘1=- DRIVE CHAIN 3-11
’_,_
FUEL LINES 3-3 BATTERY 3-13
THRDTTLE DPEHATIDN 3-3 BRAKE SHOE WERR 3-13
CARBURETUR CHOKE 3-4 BRAKE SYSTEM 3-1-Ill
ii-IR CLEANER 3-4 BRAKE LIGHT SWITCH 3-15
FF“ CRANKCASE BFIEATHEH ILISAi:irtl'i,rI 3-5 HEADLIGHT MM 3-15
SFRHK PLUG 3-5 CLUTCH 3-15

In
VALVE DLEARHNCE 3-5 SIDE STAND 3-16
CDNTPET BREAKER POINTS 3-Tl‘ SUSPENSI ON 3-1?
IGNITIDN TIMING 3-H NUTS. BOLTS, FASTENERS 3-13
SPARK ADVANCER 3-H WHE E LSJSFDK ES 3-13
CAM CHAIN TENSION 3-S STEERING HEAD BEARING 3-13

CARBURETDR IDLE WEED 3-H]

f""~.
CYLINDER CDNIPRESSIDN S--1!}

SEIWIEE II'IFlllIlili\TIUl'l
eemeeet INSTRUCTIONS
n En-glee erl Bee elite 1‘-1
I Engine nil Hirer sicreen 589 Dfltifl 3-?

!""‘~. TDD LS
Ccimmen
iv-‘W! ndiumng wmMh_ B I Q mm gflggmjntm qr mmmpgiqiiy eueliiitile iii it El mm effitet hex end
wrench
,i"""-. Ugly; qdjuflflf H
smite fllpplte $|:ii|.ni'i:r E, 1.5 at 5.1 mm BITE!-0020200

SPECIFICATIONS
-1' Engine l‘=-
|{""'~. Ti-vhttiu grip free play: 3-"5 mm ll-"3 " lIl"l' I"I'
5‘,_pgi-ii; piu;|_ Fiemmneended speri PILIQ l I c"""*dl'" t""p'B
For WM :|i|.mm 5* rd d Fur lptteittilleiiil hlgh
IB-elciw s°c, -ir‘i=i “ '“ !iJB'BEI ri="r-e
— u r-re Meat HI] ' i~iei=: ND ' NGK
u1n|=5 ci‘sH LlL':?F5 CTHS ue4-FE CHI-I
IF-
IUZDFSFI-L] [ceei-isi iu21'F$H-Li I ici=|rHs1 [1-ii=4F5R-Ll | [CHBHSI |
ping 5,1, Q55 _. 0,1 |'|"i|‘i'i ii:i.iI.t2-t - 0.0213 irii
I
.|—u 'I|"g|-tin qieiarertcez Ci:ilcl- lBe'ii:iw 35.13. S5fiFJ
lnh|ltie|"EiIil'\8u5t U.LI§ 1'l1-1'l1- lfl-D02 I'll

Deteef issue: May, 1930

IDHUNDA MDTDFI CCL, LTD.
=1 3-1
 I-ICIIUDJL '
INSPECTION AND ADJUSTMENT Q1" ~-
-j I _|_
;_-‘L

Cnntact hrlititnr point gee: 0.3 - 0.4 rrrr'rtlU.Cl1I — CD18 lrll

Ignition timing:
ii-min, "F " nurk ts’ etec
Ftlltifiritiit flirt 'l,H?B rpm
Full l€l'li'l'l'Il.‘.I 30" etee at 2.900 rpm
Idle speed: 1,500 :i: IUD r|:irn
Cell nder eempresele n.' 12.5 1 i:i.5 kgfmi‘ ltttit zi psi]
N ‘C Chlesla I-1'
Drive chain tieeit: 15-25mm I§5i'B—1 in]
Fl'iIi'lI hnice IE\lEi“ TFII |;il.|y; 20- il1mmI3.¢'4—1Ii'4iri]
Rear brake peclel free play: 2lIi—EI.l'rnm[3.i'il-—T1,|'iillnJ
Tire:
___.‘ __ __

Frqrlt Re-itr -
Tire sire - 2-25-1?-ll-P R 2.5m 1-een
Up tn vehicle mpacity l:i-acl ‘ an ma,
Enid tire pressure ":5 kg‘ am ml 2.5 moi T‘
Iiiiii’t:i-it‘ lefii
up ta ee lie teen l :i] ieeq I _1{.e_ igei ' . =?.-.P. <.=:e
TCJFIOUE VALUES
Rear axle iile-eve nut; IJU - ED I'D!-fit HS — 35 ll:-lI:il
Rear axle nut‘ IJIJ — 5.0 I'iifi—lI'! [EB — 38 T1-lhl
.1‘-,

ff“.

a-‘Iq-

."'

_,_

22
3-2 Detecrf Issue‘ May, IQBC
en-iciitieit. MOTOR i:D., t.Ti;i.
 ‘-5.
I-Inn:na.
[flu INSFECTICIN AND ADJUSTMENT

(ENGINE)
Flll-1 LINES
Check the fuel lit‘-es for deterioration. tieirnegfl or - '
ieeiteige. Replace if necessary

FUEL LINES

THRIITTLE IIFEMTIIIIH
Check for em-ooth thrniile grip it--ll eeeriirle end
I..IIDi'I1l!llII1'. full closing in iiii steering positions.
Check the throttle enhle arid reeieee ll ii it it
tllttrirlrirateri. Itinltetl oir damaged

I.-I.lhrF|‘:.:'il: the throttle i:ii.tile lpage 2-FJ ii throttle

operation il riot tmooflt.

Meaiulg thrnttle grip free plav at the throttle grip

flange.

FREE PLAT: I-5 i'nm'I‘ll'3—1Mii'iI'

Adliuetment can tie r'itai:Ie itt either end of the

thrnitlei -ciehle.

Minor atliustmerrts nrie ITIIIIIE -mm Ilte Upper Eti-

|u:iter.

Adjust be loosening the loeit riiit and turrilitg the

adjullige. Tlghleri lI’ii°: lflflli i‘|lJ!'..

|'i.lajr.ir etljtutrtte-rtts are ma-tie et the It-rwirr ildlustrrf ori

the carburetor iifter removing the It-ont -cover.

Remove the oerhiirntnr rl-rhbrr C-Bp.

Turn the ailiueoer to ol:it:iin the speciliod frttrr plott-

RecI'iiecit' the throttle operation.

_ I-

D-ate of lseuii: Mei,-, THEN‘!

@i"lDND.A MDTDR CU. ITD
 Hanna. fife-.
INSPECTION AND ADJUSTMENT
cm KE1; ~
BAIIBIIRETDR BIIIIIIE CAB LE’ CLAMP
Chflflh For rrnunrh dtnitn knob operating lrlriilrt-1'1,
The i1I"lOKB Itnoiei rriust move 5i1'!'I-EiD1I'tI"' and guy
w‘-‘tare poaitiorieel.

Arllutt ow turriirig ihe lrli;1iri-n adj|_|I_r:i_Eir l1.|_|1 |_|fl-flpt

the rubber t:e|.1_
Pull the rh-eke ltnob all the iivav our intl matte eure
the flholte valve la einaeti Irv moving the carhurntm
choice lever.
Adjustment:

Ffflrnovfl the front i'.1r.i-tree lpqgg 5-2|-_

Looseii thr. cable clarnp and pull the i'.'IblE ca-$i|'|g iup
it-I" EH "1! Choke valve is fulli,-' clotted. Pugh the ADJUSTER CHDKE LEVER -_
¢l'|‘i-‘IKE’ I‘-"01! I" II'IiII IJB llllr the choice valve 15 t-i,i||-,.-
even he checking for t—-em-m |1.'1a._i_r|=l |_-,| “D15
tiii-r:It

Install the front cover.

f/' Eterliient are oteervee covert
Alli BLEIIIIIEII . at pr ~,
Rernovri the air cleaner -cover tap nut nntl cover. ._ '- I __
Remove the air cleaner ulament nut and element,
. ---"'-
_f__ L;
I, _
| . -|' ' .--ax
.
I. .L -If_ _I I | _ {E-jrffi
.e
. ._,.- I , L I.
ll I ll-In -‘:5. I‘!
I ' . I
l' ‘ I‘ ‘all

J.
.'I I-'| I {ll CAP NUT
I
| I NUT

ELEMENT *-
CIHBI1 the li"lEl‘f\l‘ii'1Ii by tapping It lightly hp roman
DUEL Blow Iv.-err the remaining duet he app-tying
oernprciaeri .elr from inside the element
REF!-fBflB the Elurnerrl II it is eitceialvely ttlriy, turn gr
|'|_-tl. .
ti-iimeged.
Il'IB’¢_B|I the Hflmlnr iinicl air cleaner cover.

3.4 F =~ EIEIIE Ell I5!.'i.ia! May, TQELI

$'HDNDA MDTDR CU. LTD
KHONDA
J; [:10 INSPECTION AND emuwmsur

BIMHIBISE BRELTHEII IIISA only!

I BHAHKC-Fl-EE BFIEATHEH
Ha-rnmrq t-he plug hnm the drain tube to drain , --“Deana TUBE
deposits.
' 0
lrlstrlll the drain plug. -._\_____

NOTE ax {'
' Snr-ric:-u mflrn Trfieluenth,-' when ridden in rain _-
nr at full throttle, Ur if the dupotil lnunl I-um .-
l he nun In the drnln tube transparent section.
.

"-_;-\_
| I -_

||l
DH-NH PLUG

SPMIK Flllli
Glam mw dlrt frern around the sunk ping hue.
D4a|:e||1n§e|:rr ma iperl-r ptuq pep. fl.6—D.?mm - I
IU'.fl24—O.fl2B|n| f
Harnurve and diird the ipurk plug-
Me-murl: the new tperh plug gap using e wrre-type
feeler gauge.
SPARK PLUG GAP: 0.!-0.? mm {D.flf2l-—fl.D1'B irll
Adjust by bending ihe tide eiactrude carefully.
With the plug washer attached, thrubd Th: new spark
plug In by hand tn prevent crussthleadlnq.
Tighten the apart: |:iL|g lnmhur Hi lJ.rh'i wllh u
snark p\Iug~,w|'anch tn compress the plug washer.
G-:mne|:t the spark Mug Clp.

HEBDHHIIENDED BP|l.RlIl'. PLUG:

L '| Clnldian ND!
F Smpnderd ueucm-ls 1t:Ft1'H5!|
rm uzers 1U22FiH-L'|'
For nuld elimlte uni tau tenant
re-1“ s“c. 5:1“ Fl NU UIBFS IUZUF-ER-L1
Fur mar: can in-mar-ml ‘
L
lrlghql-lull rldlnq } unuz-we {LII-I-FER-Li

25:
Due ntiuue: May, 19511
EHUHDA HDTCIH £10.. LTD-
3-5
 rrtsmsc-rrutu mu ADJUSTMENT
I-ICl1\'l'ID.B..
[III]
F”-?;.~>~. ~—~
.-_-

VALVE |}LEllUiHBE MARK

I
NOTE i __i_
lntpeet and in-dlut-t valve eleatanne whiltr mu
;
uflglrhu it mid [below :i5"::. 9-Fri J
Flumtwrr thn manta-ct l:i-reeiter mini mover and value
lfliliflli-1'.iIIiI‘l cape.

"fine Ihfl fliflrihhll! wuntercdu-trktvise and align

thn "T" l1‘|.iF|'l. with the lncln: merit 0|‘: the left
crankcase uui.rer,

F-lake sure 1110 urttun in nr T.D.C. cm the t!OdflIZrl‘El-

slun strnite.

IITIJ
_""'.

LUCK. NUT
i'-lit:-ck the valve uleasan-|:i.u by inserting 5 ieeler
gauge helwticn the adjusting ternv and valve tttrm
'i|I'.i. LVE GLE.ltFUlNC.‘ES
INTAKE: U15 mm [0.DU2 I'll
EXHAUST. D.lJ5 mm [H.002 hill -—"-.

FEE LEH GAUGE RDJUSTING 1-.

VALV E ADJUSTING
,_,_

-Pvcliust by louse-ring the Iruzk nut and turning the

niiiustirtg anmii until there is e slight tun; un ttw
feel-er gauge.

Hold the m:i§u='ting mew and fight:-n Iha Inrti, nut,

_I-
Henhenk the valve uluurunce.

Install the I-‘¢l'iTi1CI hrttel-ter point web and Iraluu

lruncctinn cups.

.3‘
VALVE M1] LRSTEFI B “\-

3-6 =6 Data Of Issue. Meir, T930

r-

Ifl'H{}i'tll2i.\1 HIUTCIR CD, LTD.

 ‘H %;\I-I(J1\lI).Bt
J [III] INSPECTION AND ADJUSTMENT
1-=~
BIINTABT unmet l'l]lllTS _
Ftemuu-| the cuntuet hweeiter pnint never.

Clean the izireel-tar |1IUirr'l turleues with an tile-ctrurll

content |:lrniner tn r|:i‘nCi'n'E any uli film ctr riirl.
1’-"""

KT‘

r'“‘"

If the eunuut turfauu are la-wl hut pr:-,rl4h in r.:-uior

’@
or are 5|ighl1'|I |.tit1ed_ file tl-rem lightly.

ll the paints have a nutiuulhie tritnrler nf mm-ll

irurn une surface tu the other, hm evidence u'l
___ “—' F ie liqntly
(""1 heavy arcing. u-r are worn tit an angle, the paint set
U 1.0 rnrnute |ililIlIll'l§
thuuld he rnnlltbd.
Egon ___\\. SED and cnrreuun

QEJQ
UHSEFIVIEEABLE REPLACE ll wen-i IT. an angle ur int!‘-,r pitted
1'-‘\

,r"""‘\.
Flcitete the crnnlcshaft uounttemiottlcvuitta. and malt!
sure tluit maximum pnint gap is |:|i_3_fl_4 mm
lD_ElI2-13,1116 fnl with a feelnr fill-1'98.

if the point nap lrt irir.-r.i.rrer:t, iueeen the uuntnct

lreelter ntete locking -wrrtw! mitt adjust the point
F“ Q59-

Tight-rtn the lurking screws and ruuheult the point

Q39-

Inaiiutl the euntect breaker aciint emitrr.

.-""‘

If-\.

Detauf issue. Mat. IBBD

‘EIHDNDA MUTGH 00., LTD.
 HONDA 1"”.
INSPECTION AND ADJUSTIHEHT .-..
.—e_

IGNITIIIII TIIIIIHE LIGHT '

i"-IGTE
Puritufil lhn eonttitrt breaker point gilp brtliecre I
this iIIZfi'ilI1I'I'lT‘t inane 3-?f|_

STATIC METHCID

H-Brriovlt th= contact breaker point cotter.

Diiuflnliéri the Bit,"l."|.' breaker IBrmir'\a1wire_

Connect it 1:=orrtir\uit'qr light tn the contact hrearter

termini! wire .ettr'i to the positive it-l tetrninal of it
l'\:ll'|,-' charger! but-tart.-.

Connect the negative Ii-1 better»; terminal to an

' i‘ - ' -=1-!!'_;l
I 1 -‘

it .-at-.
-.

|_
engine ground. BREAK EH WIF-iE *'~.

Hotaiing the hate ptate counterclockwise will

retard the ignition tirnintt.
INDEH MARK
TF1-E !ii|'i'i|'n|t| I5 correct if the light qua-5 nut u-,rt-|.g|1 both
mrarita align

ADJ U STME NT

-F’-diust he loosening the twu eentact breaker bate

plate screws anti rtJIB1|1'i|]thl plate.
Fintatinq the ueae pint-n ciockwise will a-dt.-attca the
iq.|1]1'iCii1 timing.
F" MAHH .-".
F1-mating the base plate countarciocitwiee will
retard the -grtiliort tirr||n|],

Tighten the base plate screw and meheek the BASE "'
ignition timing and point gap, P -__ "
aouartee --' t-T-Q3
Disconnect the light and iuttertr.

Connerrt the Bit.-W hr-aaitur terminal wire,

In rteli the contact breaittit point ccruer,

ei1o_

BASE

3-e T
1|-
28 i3ete'-trf issue; May, IBEJ
EHUND-¢\ HUTDH C'»U., LTD.
“* 3-. [}‘][| INSPECTION AND ADJUSTMENT
N -1
.
-_"-.
D"r"NAMlC METHDCI
iWiTH A TIMING L|GHTi
NOTE
Adina: ma contact hrfliker point gap -licfuns I
mqklng this a|:iiu.1trnu_I_1f-_

..i
|r_\'
Hemm-e the tic-ntact lxaakar paint wwr.

Connect i tachumete-.r and timing light-

Srm ma Efl-EIFIB and in it idle 2-3 min-urn

1"“-
f|'\
,A_d|u=|.t the ldlq iflflfld if nacassarv.

IDLE -SPEED: 1,5!!! :l: III] rpm

Aim the rirning light at the timing mark.

u""'-. Thg fimlng is; current If thn "F" mask nlipu with T|1,||~G |_]||3l-r1‘
1h|1 index n'|-BHL
Acljust an. demcrlbad iur thr ilillnt math|:|U. ll "BIB-
airy, INDEX MAFIK
imtill the mntlmi |JD5ni cunm.

SFAIIH RIIIVAIIBEII
Kl

Rumuvu thu uuntuct point muar.

."*'i
Gunnunl. u tlmi-rq light and ta|:h|:l-mater.

Start thu angina.

Hr‘-ng Enqlflfl spec-d In 3,1lJC| rpm Ind =l'1BI=l\ 1l'Ii1 Th"

indml marl: is tletwn-art the iull aclvanci mama.

R¢|:_ifl¢|J' my nju-ancar aasembiy ii IT is nfli fi-ll'lII-

Tluninq prnnnrly. \ 1
lnqull lzhu mnuct bwal¢=r [J-Dllfl WWI‘-

Elili iiiiilll TEilSll]il ADJUSTING '.

;""'* Start the angina nnd ll-.1! il mil!- in

Lanmn Ll-in mm |;|-mun tel-uiciner luck nul: an-cl lmiit

imit.

Thu ‘I.Eh5lDI"li?|' will automatically‘ position its-all‘ TU

1"“- prmuglq zhq cnrrelti ulnai-::|n.

If 1-he 1.-.|-min I5 :l.'l“ l"iCii5'|' rumcwn this mnainner plug.

Gradually acre-w in lhl: inrlqinner odiusting acrnw
until 1h|:r cum chairl :5 rm longer "Biw-
lnstali tin tansinnur plug.
.-I“ '|'|gh:5r| tha tuniinnnf lnilk l:n:Ht and nut.
.--'
TENSLDNEH PLUG LDGK NUT
F“,

l_
Dam u|1"1i5u':: May, ‘IQ-BB
QIHDHDA MCITDH El.'J., LTD.
H 3-9
 FNSPECTIDN mu ADJU5‘|'l'i'lEi'iIT
HONDA.
[flu .-F‘-.

BQRBURETIIR ll]l.E SPEED

NOTE
' irdperl and -ndiust E-1Eli'iJLlfl:l.I.1r iijln spit-gt: aimi-
ilii 1:i1|'l|:l' BflfliflE E||"|;||1::1mi£!|1t|3r£ wqhln mg |
cifimliu-n.
' The :i1gli-ii: must he waii-ri in-r i}D;Ll|'I1_'E i :l.li=_-
iriiipa-i:tii:in ant: ailjuslrnitirrt Ten riiiiii-i.it<i:. ti-|'
atop an-i.l gu ti-dint; is siifiiciit-iit.

I‘?-=£1nr'»ai:t a tai::hr.ii'r1i_-tier.

Il‘i'i1n-i-i ii|:i the Eng-Iiie. :hii1 mi: trarimiiiaémi to "

l‘\lElJTFi'-°ii_. ind lwiltl ihr motorcycle upr-i|j1t

i|"'.5PfllIiI un|.i aciluat iilii: sprint-rl witli Iii: thmnln §L|Jp

icrmiv, '1l'Il'-£lI'EIi.‘lHl’\|'. THROTTLE fig? SCREW
“'1
IDLE SPEED. i_5i:iu :1i:iiJit>i1i '

CYLINDER BUIIPRESSIIIH _ i:iiii.iiaE

‘i"il'irm up thii l!f1[Ii|‘H!i.
Strap thii i?l't|:|iI'l-B Ill‘!-ii rr:m|.1'-m mt: iparii; pig;-Q.
lnriu-"r The cnmprassinn qaugé. -

Pull" the nhnlta liiitlb in. “'3

D|Ji:|'| thri thruttiu grip hilly,
Drank the eriginrt with the I[fli'TE|' mutur.

l'FE§_ _ ________... __ mi
'3rI1"|¢ ll’?-B Wflin: i.intli 111|1 DBUIIH raadirig i|ti:i|ii;
rising, The l'|'li-iIiil'l'H.|I'l'1 reading ii iimglly '
l iEBl3i'lHIIIi within -II-I seconds. I

COMPRESSION PFIESBUHE: 12-5 ii1;tiiii;ii=-iiil -

I171! : 7 Piii ___

Low i:i:ii-npriiuiun can he I:-tlutnd lay."

- lmnrupiar 'i.'i1l|.re ilriiustmtini
' '\."si-iii: lnakaqu __
' Biwirirn -::windai' heaii 1_|-iaiiluii I
‘ Wrnn uiztmii ring i:ii cirlindiar
Hiflt uni-nprnsaiizii-i cnn hi: aunt! by;
' C1Iii'hrIn i:i»a|:ii:mts in Dflmiiitfillflfl rhiirribar ur on
1+": pistrin c-rrrir-1'-

.i-—i,‘_

3_ 1 0 35 Date of Issue: May, IEIBU

'E.'HDNCI.i5i MUTUH C'U._. LTD.
 Eh HONDA
.~""' C10 INSPECTION AND ADJUSTMENT
.i---
€iIili\SS|S>
DRIVE Bilfllil
INSPECTION
F“ F'l:iii:e the iiehiule on its side Bland and Ihlft ll‘-E
ttarlsrnieaio-ni itttu neutral. |5-35'|“"‘l

Tuin the -ignition switch OFF.

Hi:i-i-ii:i-.ie the lLil"i\'E' chein inspection h-ole mp.

.i-'*~ Move the lIi!"i'li'I' -ehiiiin up and tlown by hnntl imrl
iiiieasure the amount of :-lat:-in

SLAGK: IE-E mm i5i'B-'1 in]

.I-H Adjust if nuoeeearv

ADJUSTMENT
H-.=.mi;m the rear iiitli; |'iiI'l ootti:-r p-in and loosen tlhu NUT INDEX MARK
||:i,l5 alrirl :ii:|:'|'t: l'|Ul;l.

Turn the iiiiliutiting nuts on both aides en equal

number i;i'|' turn; to obtain the specified oiitain slant.

.|I""I|i.\|i
CAUTION:
“lei-'i?T.-.ii.-mriiiii iii: M lmm fli
3;I|f1!.;.f;|'g-r meg“: with the urrrtr gr1ei'1rm{i'r-W 0-I'll
riorii iiiilirt iii: the :wl.ri.iriirm.
Tighten thir sleew iinio eiiile nuts Ind innlll I new
cotter pin.

ton ouei
steeve NUT: 4.0 - e.o tum tee - as mill
.-“H
AXLE nut: no - E.D iiiiii-iii lee - es ti-ll:-l CDTTER PIN AXLE NUT ADJUETIHG NUT

Tigjiti,-,-|-i the a,i3;||uetirii; nuts

Rent-iei:;lc drive ~l!i‘l3lfl slack iir-ii:l |'I'\i‘ll." wheui iotatlon. LEFT SIDE COVER ELEE‘-"
i""‘\i
Check hrnitg pad:-I lr|:i: plat; lI‘lt.i BCi|1..l51‘ ii l'li.\l;B!iiilI"li'.
Lulairli:-ate the drive chitin wilh B Eflmflwfiieily
iivflilihi-H rlrivr i1i'i:ii|1 iui.|ri:e.l'l! through i-‘PH iflliI!I=-
[Eflfi

CLEANING
.-*""'*»
Whg-|-| the driiii; iahtiiti h¢i:.~i:iri-lei EI‘i'.I'-El'l"lE|'|' dirty, il
5i'lfli_'.iEi hit rv:|'|1'||;wu11 g|'|i:t i'.|I;\;t'im:i' print In Fl.ll3i'r'ilI'E1ifll"1
ea followi-
Flt-ii-itrwu the frame lett side cover-
Remove the drive riorocirllrl DIWEF.
Fit:n1i.wi: the two tower chair: r-air: tin-lie as-iii lower
/"'“ oheiin case.
Flemt:-we the upper ohein oase-
Hemcwe the .-nilq nut i.-.tl|:teI pin end loo:-on the iiiailii-i
hut, eleeire irut and atiiurting nutt- ‘SFHDCKET LCIWEH CUTTER Fihl!
it"- CCNEH CHAIN CASE

Date nit is-.|m:5 Mlitf, iiifl-U

@HliI'iNDF\ MDTUH Cl'J._ LTD.
 I-ICl1\'lIIJ.H.
ll'ilfi"ECTiDN AND ADJIJSTMENT
urn '~§.r_..J .--I-t_
I

Remove thrl rnetter linii ieluinlritt clip and mesh: .1’ I \

i|rik_. DFH'u'E EHAIN MASTER LINK II i\5iiHl?-H3 CLIP

HE'l'|'hU'|i'E the drive chain.

Clean the drive ohein iI1 non-flammable cir him -

flesh point atihiant witli iii l||‘|.l5i'| and iiluw rt ti; dry.
lneoect the i:lrh-it ch'eii1 fer tr,-|ar er dfl'r|'tqg|_ Hiphgg
anti i=l"-iiin that is iixcimivaitr worn or damaged.

‘i

__,r"'
-HI
I

lnipeot the i:i-rniir and driven tpii-ecket teeth for

excessive wear or damage.

Flepieitit ii nccaiaery. “IEAH

!‘!‘.3lE___ L
Never ifliiili a new cirivi: chitin on wot?
sprockets ti-r e liviiirn chain on new strrttcitctl.
DAMAGE 1*»
Both chain ii-id apvoclte-tii mutt hri in goo-d
condition, or the replacement i:J1aln or
torookets will wear rluldlv.

NORMAL
"i

---i'1
Luhirl-i:at.e the drive i;hiaii-|, NHEUTIDN OF __ -|-__; |
'*!§'TE __ _____ FIDTATICIN . fl ":.'.
i Coiinmercltill nrrrotoi woe drive chain lubricant '-".
iii rocnmmnndad. '---___‘:

instill the -rirlva chain.

.-.- .-.-'j
l
'_ - 4-— - i
.'
'
.I
“UTE - a — ——. it lwistea -"
Note the direction of the meetier iii-iii; ttttuii-ting
oil P~ L __ t
.
- "ll!
-I
-

"
F]
. F‘
-_. '1 -"
LINK

ill-lA'lN
Q. '- ,__
.
".

Install the upper and lnuiicr chain cases. drive RETAINING CLIP '-
sprocket rm-er arid liitt aide oover. I
_r—\_
---. I
r5it!]i.ist drive izhiiin ii.liiii:lt lllhrqe 3- I 1 |_

liihlflit brfliw FIF-'l'i|Ili lrire olatr and 3L'i|Ll5IT, ii iteizizsettry. ' '
d_l-

3., 1 2 32 Date of Iiatia: Matt. TQBD

QHDNDH MUTUH [5i:i.. LTD.
 _I—\.
1
1%) HONDA
INSPECTION AND ADJUSTMENT

BQTTERY am:-um: CABLE Pusmvs r:.ns|_£

Rerfifl-W thtr rlght HUB ucwer
Drs-connect the gr-r:um;| mbiu at fiw frame
D|sc:nrmH:T thu pusutlw cable at thu buttery tnr
1-‘-.

Flummle the l.1u:1|-ry hold-nr plate

Ham-nun the buttery
Inspfltt ll":-E hi!-lrry fluid lgvpl
Whrrl thu fiuuzl level nears uh‘-_ |uuI.|H' lnl-I'l:|| rqfill w|t|-1
dlsflllad, vmar tn flu uupr-r Irv-al
1"“

-"1-]:|d uni? d|itliTBd want Tap matar wll

-""*. | fihurtan the 12-mes I-ll‘: ul‘ thu ba’rlaI"\I'
BAFERY HDLUEH PLATE

The mmerv dn."I‘rrHy.l'£ mnmtru mrjurnr arid

Frurmrynur eye: skin, and r\|’fll|Eu‘n';.
In cu-we 1|-I‘ rmrmw flush rimrougidv ma
mm and 1-mum-r a dorm‘ If den Iroiyre gen
in your emu.

F“
Replace ma ha"‘ter'y |fsui1at|¢n1 hqrnfl qr $ed|mant5
acu.|-mulata on the bntlnm

Li
H" LEVEL LOWER LEVER

BRIHE SIIIIE HEM!

F“ Hapiace Lhe bruku ah-01:1 I1 lhn anuw nn the
Induntor plaza ahgni wflh the mark on lhl
brake panel when the he-at-cu |: nppllcd

f'-.

f""‘~.

Dataof lama Ma-,~,1HBU 3

F-‘-i-HCIHDA mmun cu urn 13
 H0NnA(,T;Eg=%.'
INSPECTION AND ADJUSTMENT ETD -1-
/,»'--
‘*1.

BRMIE SYSTEM
FRONT BFIAKE LEVER FFIEE PLAY
Hiuuiura Ihq: Irurlr hrukea |::u|:r 11:1: ||lH|1;' Bl 111E [||J Elf
the brak-I: lcwr.

FHEE PLAY: zu-an mm ::m—1 11411-1!

lfl '- 1!-Urn:
1;!-1"'§lnl

£1. _‘"1

ll ad]-.utm|.=nt is necessary, turn mu adlultlng nu!

u|'|1*i1 the c:|;|rr|:\C't1'r:E play is obtained.

B215. _ . _ __ ___. _
Make sure the :uT-uut un tin: adiusnng nut is
‘ mum rm 11-m brakfl irrrl pin nH|,~r making flrul .»-3
free pia-v adjuitmant. _
I-._",___

HUT -'1

HEAH BRAKE PEDAL FREE PLAY

Chick lh-n hralu pedal free phay. "N

FHE-E F'L.P\"I': Z9-EU mm (EH-1 1M-in}
* I

-'"'--.

_"--|\-ZIK‘ ‘_\.
E ._-1'4"

3__1 4 31 um“: lnue: Maw, man

IEEHDNDA moron £10., LTD.
 ' - Hanna.
.-—--
/_.“~ BTU INSPECTION AND AD..iL|'5Tl'l"i ENT

.-I-r-t
r

if atljurtrirerir is r-.u:r:eseary, turn the Bdjuiling hut

until the currnrrt free play is obtain-ed

l‘-HJTE
.-P‘
Marita iurr: tHE| r:|Jt-r.n.lt i..li'l the Brliuiilng 1\l.rl l5
seated cln the brake arm |Jll‘i after milting the
1in;|l free alav adiuttment.

BRAKE LINKAGE
Check the beirk-5 cable, brake ru-ii, brake perhl and
__r-\-
hraite lever for louse connections. tnrcustivn play, ur
|
damage.

Repiam ur rrrplit il Fl-EG'B5i-ilnr.

1'-IL

BRAKE l.lE|iT SHITBH

HRH!-CE LIGI-lT SWITCH ADJUSTING NUT
£912.- _.... . . ___.._ i_
Perlurrn this arilusti-nent alter uidlusting brake
. .r?=1=.'=' "r".P‘-='r -
rldilrxt hhn trait: light iwitth bu that lhrr Ltrlite lnght
will ‘light when the bruit-I pedal I: |:le|:|rnsw|:l nr1rr.iIi‘w!
.1"""'* i:||ai<e tmgins engagement.

NOTE
' DD l|C|‘l turn the switch t|r;||;l'|r, .,_
- Thu front brake light 5-witch tic-es not require
n|J||.u'[r|'|i!*t‘|t.

Adguit by I:umirI;| the swit|:.h acllirstln-g nut.

_ 3
|.f"'\.

HEADLIGHT lllil
.'5\r.l]L|.lt '.ni:r'll|:.!I|1|r !:|I|r lLl'|'|'lI|'i§ thn |mrt_r'|;.al adiuiting
.--'_"- HITHW.
HORIZONTAL SCREW
|
Turn the lt.l]|.ul.ing 5f:r|:w cluckwiw tn dlnjrt thl
helm up.

P-flll-I51 hlltih-'.|nt||.l|'|' by tuming the hciriztrntil aci-

lur-ting screw.
Tum the Hrllusring rcrrrw clue-lw.n'ne tn direct the
lrfi beam Iowa-rd the teft aide oi ‘litre rldr-ll,

HOT_E_ _____
I -fidiwt the headlight beam as epecilted try i
i1:-ual laws anti regulatlnurz.
F-

' .-‘Ill frflprrrph-'r'i'_v rr-n',l'r-tvrtrd l'rau:i'fl'g1'r.r nwmr Mrhd Fl"

trncrrming r.|'nI'r'er:, or Ir nun; ftrri In Ir};-hr the = I

if-I. ruau‘ fur i: mfe rilnu-are _ VERTICAL ADJUSTENG SCREW

D;tl'|.1|1l inure: Mu‘-,1‘, 195D

EHCIHDA MOTOR CCL, LTD‘.
35 3-15
_‘___
INSPECTION me nimusmenir [‘,']l] @i®
' '
.-._

"'1
1
I

BLIJTBH II===-"Le=-r rwr

Stop the engine.

Lciizriien the iidlur-ter lock nut and tum the i:ii.rLi:li

aeliut-'l:er rtlri-eiiiwiee tine turn;::ii:i iint iuri-i excessively. L
5|BWi\-' l!l.lfi1 the ii-iiili-irtcir i:ruiintei'i:lu-clririile and step ‘I
vrlien I'B!liIB1!|2£I is-felt_
Frein-1 this pi:rin-‘t, turn the ed'puirter i:ili:i-i:i;wiee 1i'H to
U4 tum; and tighten ti-i-ii led; nut.
Check ti:i see -that the elutieh I: not slipping and is
iIi'l'-tDi!F|"i" dlr-engauirig. ' 1|

ADJUSTEH I, -1

Sill! STMIII
Cheek the rubber pad for dewrloretim -nr wear, ‘Il l | _ _
Hriiflece il' env imiiiir exceeds tci the were line er ' l
i|'i't'.IWi‘|.

.NDTE
'i'i'i'ifln repieclng, u-re a rubber 15511 with the - .-—-1‘

r~"L'“ELE’5"i1’.59_'l2' 9ii, W _

O -='.'-.

Check the eidir etenci spring I-er image and inn cit
_-.,_i ""1.
teniicin, and the side Fund I58‘-I'll-lJl'|‘ fur treiidum tit
muiierrientiind bH'iriil|l'lg- .. .
NOTE
l Spring tension it eni-res‘! if the measurement’!
fail -iiiithin 1.5-1.5 ke [13-5.5 ihi Wl'lllI'f -\“-

pulling the side stand |D'WI' -end with I :r;I'|l'lg

[Lain
ti Li. ""
'J|'i|i ifliq Ib

, _.
‘r.

SPRING SCALE

3_1 6 35 Dlteul In-ue: rim. ieee

EIHDNDA riiciren GD.-, LTD.
 HONDA
i""" .
@. can INSPECTION AND ADJUSTMENT

siisrtiisiiiii ‘
.52.. .,..i i-i. .r.t~ .. t'£*.i7i '.:‘.'§it it-hit rm.-rry =........-.....€.=... I
Loose, worn or uimrmiri-i iurprnnmr purl!
lrnpitlir veiiiioiie .ri*it11ii’i:ji' anti’ control.
F‘
FFlCil‘-.|T
Check the action of the Front Torin-
Fiepiaur. demeptl cuitipiareents which eanni::1 he
repaired-
.r'*- Tightan all nuts end bcittt

i"""*

. 713-1
L.uhirIoireri the 5i.|1Bt!l15ii'll'i li'l‘l'i pi-'r.i1L

_/'-.
____— f. .1 _ .
-_-

oeeriee ITTINGE
_.-""'~.

HEAR
r"\ Plan; flee |'|1:iti;ir|;yi;:liJ un i: iupptilt hii raise thE fill‘
wheel eff the ground.
Mow the rear wheel Hizieeirriirl -mih few: in HEB iii .
the ewingeirm huehingis are worn.
Review ii‘ eitonssieelv wtrri-. i
e ‘L _
Chqiflt the sheieit lteiorlsere for ieaiu or damage.
F‘- 'l'"i.@'ri:en all rear eueeieneion niitii rind hutlu. -'- '

F“

_.-"-.
Dill: I'll‘ Iniue! Meg, ‘IQBD 3? 3- 1 7
'EIIHCiiNEI'Fi MUTUH C'D._ LTD.

E4
 Hanna. T
iiiisieerrriciiii mo ADJUSTM ENT [:10 ,--.

NUTS, BIILTS. FASTENERS GAUGE

"\-

Ehiitrit I-hei iiii chassis nuts and hiallrt in-1: tiglrtgi-mu 1.;
fitlrreret toeque ireluee.
Uhflttit Hii flutter pins and safety dips.
,_
WHEELS.’ SPDIEES
more
‘ ‘Fire pressure shoiilcl be cl-ieiriied when tim:'|mJ
COLD.

RECOMMENDED TIRE FHE5$I.lRE AND -

__-

TIRE SIZE:
_|-- -"'
Fru-nt Rear
Tire site 2.25-T?-4PR 2.50-1?-EPFI .--u.

Cu-ld tire Lip in

preesuge uehiidq
imam tflffiw 1.0 ital 2.9 mi; SPO-HE NIPPLE Ii, 4-5 Ii 5.1|'i\i'!1-
iiae i-cg,
ane ii:-l
Up to
eehuiznn 2.iJi1Eii 21: izai
N | ibilelrl
'""\
Ch-srilt the tires for cuts, imbedded nails, or uflmr
dserp ohlects.
Cher:-it the front end rear wheels for trueneu,
Meesum the tread depth at the oanter i:if the tire-Q
Rfilfilflflrii the tiriu if the tread depth regal“; the
following limit. i

MINIMUM THEAD l.'.IEP'l'I-I: "F-,

FHDNT: 1.5 mml'li"1E in!
HEAR: 1,9 |'|'||1-| 131331“;
Fletlghtim the Wl1lIl1'il tpeiltes pmriodieaiitr. -‘r-.

STEEIIIIIE i'|El[l BEARINGS . - -i -\_

NPTE . I-._,__ i‘_i “In

[ Cheek thlt the ountrnl -eiihlns do not interfere l
with handlebar rotati-i:in. -4-H,‘

Raise the front wheel off me gr-uunrl,

Ch-i:i::it that the heniiletiar rotates freely.
if ti-‘ii! handlutnr metres unri-ertitr, binds, or hm
vertical movement, ediust the steering heed betting
be turning the :i.tiIi.tring heed edlurtirig nut (page
12-IHI.
tfjvg
¢ -I‘
HEAD BEARINGS

3... 1 B 3'5 Date of issue: htay, 1_QEi£ii

EIHDHDA MUTDH tre-., LTl'.!i.
 /T HONDA
@ Qi) cm
_ MEMU

.-"_'\-.

‘r"""--»

I .|-'—-.

.|-I-

ljlqm nf lame: May, 1980 35

EIHDNDA MDTCIH £26., LTD_
 Hanna.
FUEL 5"|"STEM cm K » -\
Q; -3,-I
)-
.,.-

If

I /W, ;
»
I
_ *-._ ==:...
-__.| .*1,0 *~_=~_";-
"--T:--. -. "
-" 1
3|. -5-.
% %%'\
I 'I'
|-‘I I!
.___?
\_&
_"\-\_

@_;7j/I)
O@
\§=5@~j E
-a 0'“ %
a

4_0 no Dnlq: -:1! lmm: M;|'y'_ 1BBl,'_;

ETHCINEIA MOTDFE C'O., LTD.
,I""‘*. 4. FUEL SYSTEM
Tm‘

SERVICE INFORMATION 4-1 THROTTLE VALVE ASSEMBLY -1-5

THDUBLESHCIUTING 4-1 UAFIBUHETDH INSTALLATION 4-6

F“-. tmneuneton nemowu -1-2 FUEL STFIAINEFI III--E»

THFIDTTLE vnwe DISASSEMBLY 4-2 PILOT SCFIEW 4»-T
FLOAT END JETS 4-3 HIGH ALTITUDE ADJUSTMENT 4-8
BAH B UR ETCIH ASSEMBLY I-4 FUEL TENN 4-El
(‘TN FLOAT LEVEL I-5

SEIWIEE IIIFIIIIIIIITIIIII
r"“' GENERAL INSTRUCTIONS
I Use caution when working with gasoline. Always work In I will-vlmllntfld mun nrtl um? Ifl-In‘-I tpflrili DI‘ Opflrl f|il'I‘HI!-
I- '|".I'h-on dlnsmmhling Iunl Ilfsllrlfl nl;||'l:_ n-mu lho loonllunu of me D-rlnqa. Fieoluoa them with new onui on rnaisefnbly.
I The float howl has a drain ol-u|] that I:-an be lo-oennod to clrlirl rcslcbunl qnmlirln.
TDD L
Common
Float ga-up UT-I-I11-IHIIEIIEHII

$.l§§LEI§+‘l\T|D"5 -
.1-"'\ ‘.F§."1 __ 1§§1._-
Venmrl die. 14 mm IEIL55 inl ‘hi

_"=.‘fF'.'!‘lI.'F?3'il“_‘!"' N 9:- P'B-‘E211 PEIIIEC

Float level 1Iil.T mm {EH2 inl ‘ii
Maln iet _ ___ IE‘ *3“
5-low put #35_ -___
-i-
_
_
Throttle valve #15 .

-.|It needle TEA 1'26

F“ Thmttla -grip from plw 1"—Bn1rnI‘l.l'El—‘Il'-IIIHI ‘T
Plim mrew |n|1|.l;|l' u|:eni|1g Seepuge-L II -I-i—

(1 TRIIIIBLESIIIIIITIIIII
En-pin: uranlu but won't run Ftnunh HI: Llln milturl
1. No fuel In tank 1. Ignifiorn mlllunotlun I. Clogged fuel iuti
2. No fuel to carburetor 2. Idle speed innorr-not 2. Faulty flout value
3. Ertgifll IICIDGHBI 'I\I'i'II"l Full] 3. Carlzurfltur rnalfunctloo 3, Float level low
4. No spark at olug 4. Funlconlirnlmrted -I. Fuel up vent |.1lm-.Iu:=!
Ilgnition m-alfunotlonl l|'i|firin| dturlng mobliurnicn Er. Fuel etrainer screw.-n clogged
/"“ E. Air oleaner clogged
I. lqnltlnn malluncrlon
B. Flestrlotocl fuel line
B. Intake al-r hank 7. Intake olr leak
7'. I-m12Il'fl|Jfll‘ dtoltn opnratlon Bldtllring B. Air 1-unttuhn nlomnd
B. lrnrlropur throttle on-erntlon I. lgoltlnn madfunotlon
2. Carhurntor nt-ulfuottiorl Rich rnhttllrl ,
Hard Illrtlng II llailinq liter nuflrq 1. Clrnggtd alrleti
1. Improper chain operation "'5' |!"'“l"'""'3'I* I'H""*u“"I'I 1 Faulty float veliue
2. lgnilion maliunotion I'll P""l"I|1l| l°""|"5""\" 3. Flr;-.111 value tun lugh
3. C-arbu-retor rnalfumtlun 1- Fuel witel" M9986 4. chum mm: closed
4. Fuel oontmuirumd 2- |El"i|5|1" ""|"""|'=""'" 5-. Dirty air odeaner
5. I|1I.BIt1& alr leak
Fl. It-He speed incorrect
F“
Date of Issue: May, 195] 41 4- 11
I3!-I€.lP-IIII-'5. MDTDFI GU . LTD
 .- —._‘_

HONDA I.--"
FUE L SYSTEM BTU ~.?;E,x,.-
I_

BIIIBIIHIETIIII III-II|Il]\'lll Toe ao|_Ts

|.:rr' |l1e iuel ~.'al'.'e DFF. T
Dr; in rg5i|;I||.:I Iunl Into a oont.a5rIer bv l<=I1=1=fi|r'r9 11‘-B
d|fl||‘| iCfE"|.'\1.
HBITIIJ-'\'|] thn hml val-II! I'1'|2|J'l'l ‘ITIE tT?ll"I‘JUh1h‘-"f-

Inn-n;-r| the choke o-abln clflmn H-or-I I-|i5fl\I~11flE4;1 Tl'""

oholu: |:al|Ie.
Loosen the air cleaner cr.I|1n|rrr1i-‘*9 !ulJB band.
H|5||'m'_;I.|e [h-3 |;||;|I15 5r_';<:urI.||g lI1E |3=&l'IJUI'E|IIIII' ll'l ‘lhlf
irltnh: piou-
Llngergw the ca'rl]|,|rI:T-:.1| t1J|.‘|- BIILI |JL||| the 11I‘IFII|'lIr-'
vol‘-re out.
Hemmle The oarburutor rnc:-urltiug lmlti B1'||:I ear-
I_1|_||'l"?'\t'ZIl. //
CHUKE C-ABLE E-END '

T|'IR|]TTlE IIIILIIE II|5l$5£IlIB|.‘I

Flélrnrrw The fiarhurl.-1or top and throtllu waive.

_,_

SPRING -
Compress lhe tltronle valve sorlnu. and mm-we 1I'|e ' J
throttlo cabin Itnrn the lltrtltlle '.rBI\|E gro-zwe.

cT\aLE END

4_2 52 Daqnul lsaue. May, 1950

-El HIJND.-5. HIITITDR CU., LTD.
 /' I-Ionrna.
If-\_ ~;§.:.j,»l cm FUEL SYSTEM

.-Ft--I

TI-FFI-OTTL E VAL ‘q"E NEEDLE CIJF

I'Iarr'oI.'r~ the ncaoln alio Petr-I"-er. I
Fl emoue the iet needle anrl ciip. I
I
lr‘.5CE|3t the Ihnzrllle value al1r;l jel "‘IEElIIH' l1:|r rI|rl_ I
I
H"-r-ntchn-r.~ or weer. I

IF
£-
‘I -—’—_
.-.;-gt’
-_ . r."
P-
,r"'f l I
M"-" JET NEEDLE
/ |
NEEDLE our
' RETAINER

FLICIAT F LCt:\T P"|I~l

FI.IIl\'I' MID JETS
Remove the float |:I|ernt:ar am-I null |;;-ut the flgat pi;-|_
Fh'Imrwa the float and -‘Ioa: valve.

.r"~

"JP-L

lot:-aot the float vulva and 'iE‘=El1 For r|roo~aa. nicks or

elepuaita.
Ins-pact the float t'al'.'e ooeration. J I.
I
1+] -"I1-I

1'-‘\ ir.-" 1'

ft‘-fi.I ._'1'J."

. I 1' erg?"
~f- ‘ti
" I '.
I I‘!
,,_ FI.DP1.T ‘I.-‘P-.l.".1'E
. FLUPIT

Date of lsaua; Ma-v I I93 D I13 _

'-EHDNDA MDTCIH L'l'U.. LTD. 4-3
 I-Ionana. F--"=-.“~ |.L'|-'-

FUEL evetem CTU -\-PI‘ ___

I_ _

.—.

NEEDLE JET H-OLDEFI MAIN JET Sl.C|'\II' JET

Remove the main jet. needle jet holder and needle
jet. I /
I
The stow air get eannot. be remoued- It is a
ores: fit.

Blow nil Iete end buoy omflflgflfi with camera-wed alr- 1.

.---,

1""-I

NEED L E JET
FLOAT MAIN JET

BARBURETIIII IISSEIIIBLY
Install the |'||:l:|:lI: |et_ needle jet holder and fl'lBil'I FET-
Ineiitll the float and line: I-naive ta-getl'|er-
NOTE
r it '\.
Tel-te care not to damage the ieti when
inetalling.

PIN

N Date of Issue" Mev, IBBCI

4-4 IEHDNDA MOTOR CCL. LTD.
 I-:t:::%n.a.
FU E L SYSTEM

FLINT LEVEL
Flemcrve the floltt tilfllniilfl
Measure the float level 'n'itI'l the flan! Illa II-Lit
:|;||'|tI|;.'H|1g the Iluat ualve_

FLOAT LEVEL: 10.1‘ rnrn Ilhti lnl

flgplglx the fleet, if lhe Iloat Laval Ia not wifltirl
lpEGII‘Il'.'.B1II0l'I.

FLOAT LEVEL
III '?n'll'l‘l I042 Inl

Cl?-ll-CI1 DUIMIIIIIII

TIIRIITTLE HUIE ISSEIIBLY

Install the olilp on the jet neelrie.
lnmlll the lot nlmlla lnm the throttle valve and
demo It vvlth the rl-eedl-a clip FI'lIiIi"lIl’.

NOTE
Install 1-he huadl: ellp retalnul to lt mt: an I
i the throttle valve bottom. I

NEEDLE CLIP

E‘:ol-npresi the 1:I'lrot:tIa vellra-toting and lnltall the

l:lll'.|Ie lnta the valve.

Date of lame: May, IEIBIJ _ _

!E'HONOA MOTOFI C11. LTD.
 1-Iotstna.
FUEL evetem BTU '-_ _-
1,-
THFIOTTLE 'u'.\!IlI.‘u'E T
OI-IO-O'v'E
Illllfili lI'|u 1|1rr!l|[I|: valve with 1Ifll! lttr-::|t||ef: ‘rnlvtt
oroove all-;|ne-cl wittl the tllrottle stop so-revv.

THFIOTTL E STOP
SC HEW

IIIIIPIBIIIIETIIII IIISTIILUITIIIII
The lrateiletion sequence ls essantlallv the reverse
of rel-noual.
o-.,

I‘-IOTE
lo __
"\'ii’*Bfl -Itfitnli-rlg the throttle l|'IIve_ QIFHT-l the
li'lr'nItl: valve l}I'|I|O't'E' with the throttle $!||:|p-
I|CI'LI'|I‘| .
- Cramp the 1-.l-I-ollre oe-ble and on the ca ble clamp,

Perform the lullmvlrlg Ihepnfllldfls and arlgualrneltu.

- Throttle operation ll:-age 3-3|

.-"I-.
' E&rI':|.lre'lr:lr |:hltI-te l:tJ.ng: 3--‘III CHOKE CABLE I
' Carburetor Idle soeed -loaqll I3 IIJI

_,.|-|_
Cl-H I‘-IE FUEL STFIAINEFI
FIIEI. STRMIIEII
Turn the Iuel valve OFF.
Dlalrl the l;iIl‘L'l.IfI-“IIDT hv lrloetrnlng the rirelrl sl:re\v-
Hemove the fuel value, O-ring erltl seralnar.
Clean the strainer
Install Ihr: olmlrver, If]-rirllg Illl Iu|:I valve.

4_6 as Date of Issuer Mav. IHEIU

l'l5.l PIUNDA IJIOTOI-I CO., LTD.
 I-IcE%na.
|I"lI-t F Ll E L SYSTEM

r-L
Ir
Fll.ll'l' SCREW PILDT SCFIEW WITH LIMITEH CAP

HEMUVALi'lN5TALLATlDN
NOTE
The |J=i|DT ecnuw ls lento": on W1 ="r-F fl1fl'Hlfl
not lg rqrnmlud unrest the oathurttflf ll UNIT-
I’-‘~.
_ hau lod- _ L
Remove the carburetor.
Remove the flout chamber-
Torn the pilot screw in ind lawfully mount the
numkpr -;tl turn! hniluré it wea'r_s1ight1~,~.
Hal-to i nut: nf this l|.'| ul-E -11- 1 relererioe when
installing the pilot 5|:-raw.
F“
CAUTION:
Darnoge to the pillor screw and roorwlllooetor I
if the pillar :‘:'NW ts rlglarmed mrbut the marl.
FLOAT Cl-{AME E H
F“ Hemflvfl i|‘|E lilil-U1 screw \n'lt|'| the lin1:t1|r mp it-
inched-
C.»\'\UTlU'N:
I Any fomgole ortnmtlr Jo remote the p1'l=r.|I
| """"" “""""" "P “ii i”T“"i‘Fi‘.@‘i*.3“""“""
Inspect thl pilot Ioruw for -I-lint and rnplflne ll
neoessarv.
In-rtall tho pilot sum Ind return it to It-1 origlnn-I
potltlon u noted nlutlng re-rn-oval.
F‘ Purfonn pilots-or-aw edluttrnlntif anuw pilot |I:rl=‘w
limstallecl.
HDTE
DD HUI il'|!-‘till El iimitpr i;p|;| un | |1q-w pllut
Htruw until aftlr idiustmont ha: been mid:
lie-a helowl.

ADJUSTMENT
NQKTE .
'i=l'|o nilot new it hiztorv pro-sol and no
r-. 5d|u5‘|;|'r||nl is nEtEl5Bl"|' unlos the pilot scruw
I: replaced,
Tum the pilot suew olooltwise until it teat; llghtlv
and hick it uul to the specification given. Thin I: in
f"‘~.
Initial setting prior to Th: llnai pilot screw ndiuw
mont-
l|\IlTl.|l|.L DFENING: ‘IBGD — I turns out
‘EH31 — 2 ‘H2 turn! out
C|fl|.'i:lTiONI _ __ __
|%['!flr;q;;|§\; ml H31," p|'I|'_rt .\1",|'£l|\* flifl MEI ‘l-\-‘I11. O\£'£1l!‘—‘
F‘ if the pilot screw is riekrencki opmlnir N41‘ mt.
Warm the |:ng.|.l‘1E up to operafino lnmperflmtil.
Stop and go riding for IEI minute: ii s1|llicHirl-T-
Connect u to|:-'l1I:|n'|I=tI=r-
.I'4.|:Iiult 1he IIIHE speed with the lhlottle flop www-
|,.v""_ . IULE SPEED: 1,5!!!‘ iflflrpm
Tom the pilot arxew |n or out to obtain the hiuhflll
nnglne =pn-url
Ha-adjust the '~|;ll|::pBEI1 to 1,511! i HID r|.-rm, uemg
1"“-
the tltrottle stop -so-rew.

Doteof issue: Mn, THBD

IEHOI“-IDA MDTUR El.'l.. LTD-
 HONDA [/
FUEL svstem fl]l[| /»'-~.

LiMiTEH CAP l|"~iSTfl\Li_o'J\TiUN Lli'|iITEFl: CAP

if the |J-iiflt sore-at ii&5 beeit li:|'_|lei:ir:d_ 3 new limiter
-BB1‘-‘I rI1~=ll |-1|r installed utter pliot screw soiluetment it
completed-
After atliustmerit, tzment lhrr limiter eeo over the
Diiu-I !n’:tr:w. using LDGTITE FEI #501 or equiunlent.
The limiter |:=ep shouitl Lt: pinned isgeirm 51;; 5t|;|p,
ore».-enring further udiuetment that would e-nrioi-i mi:
fuel mi rtture ilimiter mp position pqri-him |;I|J{;ii;wi55
rt-I1-Btl~::n mti prevents counterclockwise rotetionl.

MUTE
' A pilol strew iimiier cep Inuit be installed. It J
i prevents misseilustment that eoulti |:lLl5e pour
, peiforrmnci: Bod |rlttrt:t|H: emissions.

-|—._

HIGH .\i.'i'iTl.|l]E IiI1iliSTllEliT

For suetsined high altitude operation [above 2,000
I‘I'|."E.5lIi i'I|' lmtn-ll s I535 main let an-r.i reridiuttlsiie
speed.
RHH-flu‘! the fllrifiiunetiir irtaln the Iinqme sntl rrrni-eve
the flout I;i1smi:|er-
Fliepisce the standard tnsin int with the high B11i’rlJEiB
#35 rnsin ist.
Assemble tH‘|lLi imtsii the oar iJLlr!trJt.
-'\I:i,|l-1:! Idle spurt 1|! 1.500 1 IUD rpm, Lrtinp the
throttle itoo screw

CAi..i_TiC_il'Nr
' Stilt-rn'irrcti' anterior: or eir1!r.w.fe.i' in-war rim: J ET ..-_
T-55!?‘ HI |'-i.Ut?i'-' fh v-iltil riir Irtgii erl't‘|'i‘rm‘e
mil-bi In .I'rt.'i'i‘.-r-li5rtri' me'_v reuse elrgirie ¢.|ver.||.rer-
rieg om! oiermrge, For .-ru-rr.e.|'r1eo‘ r:-_|-,\er¢m'|;i-,1-,1
below I.56'i.1 m |'.?.rh'J-‘.1 _i"r_.l_ roiettofl rim !'I.e'.re:l'-
ertl win fr: strrd nsro',|iu'ir mu»: speed.

i smneaie High i=|mue= t'|'DtI

. 3 MO rn 1.500 rn (5,000 tri~
i i6.5Elfl ftil max. min.
Main iet man. .u-en #35
' 1981- was
ilctl:-toned 1.5001 l0ETr1=rn -e
he ..=...;;.' ' Faittuqg pt:-not
- oi -_ _-
iupening
i

Date of imm: H-iv. ‘I990

4-B fiH[IlT\ilIiA MDTDH G-‘DH LTD.
 HONDA
_,p— I
re» urn F UE L SYSTEM

Flllil. TANK
Turn ti-is fuel valve to HES.
Loosen the firain 5t:r|-.w uni-l rirmn the fuel thu-r|;|uqh-
ll,-.
ll?
R-:mr.w-=1 the rioht title cover and the il3l|lH",'.
D-.5130:".t‘iEttt’l the iuel i-|1r:: iiti-rn the Fuel t_a,r,l-;_

Du rsrrr -irillrm _fIs'm¢'; rrr .-'ajl'lIIl"il'4i'—f!i:t:4i'ii-' ,pr.tr.ri'i'm'

e
ltiipr up spilicdeesolrnr or I-'fl"CI'.
1'"-

FUEL
.-""‘

SEAT
Remove the s-eat_
Flrmmie the terew and hnlt tewrinq] the fuel link.
rheii rente-.re the lusi Téltiit.
Ir-.5.ta|| ihe Fug; tinl-q rn 111-e i'|':\|fl|':il’: DH]-El’ :31‘ removal.
J{""-. |'t-‘loin! sure Them: ore |'||.1 Tu|:i leaks.
i3-r:-eel: the uent noiei of the tilier can ifl-I lJl!fltl'-BI;|&-

|¢""“.
Thi-
SCHEW
‘Q1’;
./_'

.="""

Dateo-f Issue: M-:n,-', 1':'-MD

EHUMDA MCITDH 'CE'J., LTD.
4-9
_ _i_
 1-Ioeena.
ENGINE eEMovn|_.'|nstni.|_At|on C10 $1/i ~.
-I Ti

.—i.'

.-"""-

.-'-._

.--.._

2.5-3.5 he-n1
lI1B—1‘5 ft-lhl

5-O Date-pl‘ lawn; MW, 1QBfl

IEIHUHDA MOTOR CD., LTD.
 /’ HONDA :: ::- f" _"'“‘--.
I
.r—.
cm § EEgm Em =-Fe='z'='i:=: -:
_.\,_

in eestiroe INFORMATION
seems nemowu.
5-1
5-1‘
K“
ENGINE INSTALLATION 5-4

SEIWIIIE ii'iFi]|i|||lT|l||l
GENERAL iNSTRUC.TlDl~i
F“ The following pa-rt; or component: oil-i1 be !iEt'\'iE1!t1 WI-II1 T.i'tB Bl'l§ifl8 initeiiltl iI'l THE Tt-‘It'I‘lE-
I Ctutch I ¢.y|||-1;)" I i:'.r|.ri:|ur|:!r.rt
I Gearshift linkage I Pieto-n
I Di-ipomp i .¢i.¢.gIrnHatnt
I Cviinderhceci I Starter motor
F‘

SPECIFICATIONS
Engine tlr-|r wright 1B kg i39.? lit]
Dil eapecit-,r I11‘ lit i{|J,?4 LIE qt, 0.52 Imp qt] et en|;|ins sesemtiy
0.5 lit (0.55 U5 qt, 0.53 Imp qti at chine:

TUFIGUE VALUES
F"
Engine hsnqtw IJDIT5 2.5 -3.5 lug-m he - 2!-1'1-lbi
i'-'nutpeg:."xid-s stsnti arts“-I 2.0 -15 leg-rn I14 --19.1:-Iui

'1'"-.

./H"

K“

rm.

‘Dots of iesue: Mai-,ll=1filJ

IEHt'Iii"-EDP. MDTDH CCL. LTD
5‘ 5-1
_
 HONDA fleet.
ENGINE FIEMDVALHNSTALLATIDN [flu .-.
_.—e

ENGINE REiili]Wti. me ct
Drttin the nnoinn oil.
Heme-tie the tlir oi1te'1’1n-r etwet err-t1 Irnrtt cmler bend,
Flemotw the front cover.

'-;.;*@‘*:
PI_I'1}

Frtortt covet: ___

STAHTEH CABLE
LDDIGI1 the ettheust pipe letting nuts
Ftentoue the muffler mounting |'|u1.l and remote.-e tite
muffler assembler-
Dieoonneot the starter cable.

MOUNTING Mute NUTS |""""\

Sui:-port the tent:-|1.:-tale up-right with a I‘iIBI‘ll2i. 1

Remove the footpegs.-‘tide ttenti sssembiy.

Linhoolt the brake pedal return firing from rhe
engine hanger butt.

.1--.

FIETUHH SPRING STAND _

ASSEMBL
7___._r.
52
52 Detu of isms: Mere, 1980
'9 HDHDA HDTCIH CCL, LTD.
Fl HONDA
J ENGINE FIEMDVALJIHSTALLATEDN

;"_‘ Hen-nva the hhh terrsiun win: "mm l|'|E fipflrh Dluq IN
and clamp.
D]5{:|r||1E|;'[ thn |I"il'aH'.I: plpu |rn|‘I'I IHE :r\l_]|flE.

.-a-Hv
ugh‘
/_‘
i.

I-

F“ - n u
HI

ii.’-.
w='*.-6‘ HIGH '|'I.|l|1E
F“

AXLE HUT SLEEVE NUT

Rama-'|'! qm mg-t1,~|:r pin and |D'U'l'BI'l HM! Elli! E-l'|d
slwvl-11!-Ill
l_g.3¢5_5|'| {ha |;|ri\1l' Ch-li|'l .ir.||uiI|flQ RIG.
q-
Ham-we the iaft aid! 1:01'wr_ nngirll mrodkti C-flvflr
and Iuwar chain case.
If-\.

|||F"~.
LUWEFI CHAIN
CASE
CUTTER PIN >;.—*-*1UT

LINIC HETJHHIHG CLIP _ -.

fa" . . -1' '
Hflmmln ihe rn-aster link ¥EE3lf‘llTlfl rim ind \‘"*'=|!-IBF .-Ii‘-'

link 31 fhi drluc :p1l2|G|iB11.

_.-1""

|
.-F

1""
J-_
.9
55 _
Date of léiuar May, 193-CI
QHUHDA MOTOR CCL. LTD.
5-3
 HONDA F
ENGINE HEMDVALIINSTALLATIDH [:'].|‘] '\%j' .-.
.'-|
RC. GENERATOR
THEE HOSE
|J'i5DlJI1l'1-BCt 'lhE FLC. gE|'1E'r.llu|' nuuplur
Hlrflm-‘I: 1hr: hl'Bi'|L‘hEl' hose frum Th: faupnritflf and
clump».
Rerncml 1hr: two sngirne hangar bnlu and mmm-4; the
englnu.

ENGINE Fl BDLTS __,

ENGINE IHSTALLETIUN
IMI-Bll Thu Ehglfil: |1\ lh-0 r-wars: order 0! remove-I. FTFFAINING CLIP

NDTE

"fl-'hBl1 |l'|1bI1lln|1 thl! dfiuu chnlrl rnastlr iink,

main: sum 1-hat the retaining clip open and
@ ""1
Faces um npnmltn uirucninn of nurmal chain
rmnlin-n.
| * Huute the wire: and cabin prpperly ljpggg 1-B1
' ' Flll the crankcase to ma pm-pur leual -with tha
D I Fl ECTICI N D F Fl DTATIEI-M
fanom rwandad oil {page 2-2'].
' Miiusf thrr Izlriw ch-afn tension luaqu 3-1' 1 I.

TOHCIUE VA LUE5:
Fllfliilllllflldi Itifid lnnmhhr: "h"
2.0--2.5 in-m I1-4-18 ft-lhi
Engine hangs hdu:
2.5-3.5 lug-m lI1B—25 H-lb! .-“"1

_.r~ .

15- 3.5 'kg~rr1

"B-25 H-|bI

5-4 5‘ Datuoflsuua: h'lau.19BD

fin-cur-inn MUTDH :1u.. LTD.
 .d"_“-\-

HONna ‘.1’ _.
_,-r cw ~;%,J
’“ MEMO

K
1"‘

f“

J,-.

F‘-\-

I-_.

-55 flats r|-f Issue: M31), ‘IHHH

EIHD1‘-IDA MCITDH CD-., LTD
 HONDA
CYLINDER HEADNALVE C70 ___._|
Z

—"\

€l
§
,-

_ -—-
I
r =-

|-

$1’
.-H
- |

'\--
In

fi y..
4!-E’-2%’
a _ J.

%
Q1;
P" ‘Q‘F’ r - »""-

I19-1.2k;Bm _
(?—Qf1-lb] W
I
"
n ‘Ii
f‘-@.._;;s
l
‘Z
.| nu. '1; P_____
XI‘?
. R _ kjI. |

|
I ‘Q; .
0.9 - 1.2 kg-m
I? - Bit-lb]

1*-'1
K‘-Q“ Q? K’ . ,.-
|¢

|
.'
_.'l- *- .

.-| _ J

.-""~.

\Fa
.-

I15 —- I19 kg-m

' H -- 1 E1-lb!
.1-""1-._

--

-\|

E-0 5“ Data |:|f Issue: May. 1930

@'HCIND.I‘-"| MDTCIH CG, LTD.
 F‘

.r.-=~
E9“‘f=1“B““ BJIYLINIJER HEI-ID VIII.\IE
SERVICE INFDHIIIIATIDN S-1 VALVE SEAT INSF ECTIDNI
RE FACING E-111]
TRUUBLESHCIDTING B-2

rJ""\.
CYLINIJEFI HEAD REMOVAL
CYLINDER HEAD DISASSEMBLY
H?
B--4
CYLINDER HEAD ASSEMBLY
C"|"I.!NDEFl HEAD INSTALLATION B-13
E--11

VALVE GUIDE REPLACEMENT B--9

SEIIIIIIIE IIIFIIIIIIRTIIIII
‘("“-. GENERAL INSTRUCTIONS
I TI1-'| =0w:1Iun CIJ\'l?|'i rnainlcnancn and In':r-rumlun uf1hr 0'|'IIn|:Iur head, values, I:-in\:l1:|1‘t il1l'I mcknr lI'lT1i. Them ilrrvicu-i can I10
dune wilih the engine ins1aIIO|:I.
i Clmihuft m1rI r0-01-wr arm Iuhriclrlrrg 0iI is fwd thrnuqh 0II passages. B0 mm tho I‘-Ii55i.1§lll an: nut |:I0g'gnrI.
f""'*.
I During as00n1bI\I, appiy Inn-IyI;u:I0|1um dlsulflda grease '.-0 rha carmhafi baarlnm :0 prurvlde InItiaI1ul.1rI|:arI0n.

TCICI LS
5|1¢:0inI Cnmmun
'u'0II.rE Guide FIE&l'|'h!f Q1554-UBBDIIIU '|.||';1]yg fluid; |:|5mm.E.,_ 55 mm fl.;;,u,umfl-mum m942_32Bfl.|m
WW Bu‘-'10 Brim 0:002-1100100 Wvv E-W00 5*-I'"lIJFE5|=0-r 00:01-0010000 0| 01051-0200001
TDFIUIJE VALUES
CI.rIInd0r hnad I13 -1.2 kg-m I? E ft-lb}
P. 'E‘é1I'|‘| -CI'I|1|.r| :'prn|:Ic|:l ‘I15 — I15 IHH11 I4 — T F1-'|hI

SPECI FICATIUNS
_¥.'.'.'IIII‘f'I?i°‘_II.'?_ _ ..5'EH."""3E LIMIT. _
Cnmpressln-n pressure 10.0 + 0.0 |¢g.r=m= ms I 1 pm A
Cami"-:|1'1 Cam h-eiqm K IN. 26.1]? mm 'l1:I;1_2lE|_|nI 25.59 mm I'I.CI'I In_I
EX] £6.-1"‘ "~".~_i!."1fi..i"I -___? _._..___‘E§i_7-iB'%‘e":'1r11 'II';.5.I.Ti"1
Dil |:I-earlnc-e £1,010 — 0.1125 mm IIIUDM — IJIIIJID In) CLUE rnrn [D.I'.'.IIJ1' In)
IEII-dc :1I:I|'|-nm "_ 0.004 - 0.035-hm 10.0002 - 5.0014101
r'~ R-:x:I=0r arm shaft 0.1]. 0010- 0.000 mm 10.3020 - 0.3-00:2 am
0.01155 r0'.§0Fir-0
R0-cker arm LEI. 10.000—10.010mq110.aa:r-0.30431:-I 10.10 mm Iriaéa InI__
__
"-"aI'.rn spring Free Iangth Inner 15.1 mm I'D. In] 1's1..r*.-. ~ [DB4 |nI
F‘ I Dr-I'n|r 118.1 mm
_
I1.1T in] 25.9 mm
i
I1.DB|nI
Praluadllennlh lnmrr 2.45 — 2.75 1952.? mm 2.3 k§."2?.? mrn
I511-B1 —__G.DE3 Ihi-'D.B5I inI _ I5.D'|" I-I:5_|'EI.B-Q |n:|
[I-IJIIE-'|' 5.55 — T.'I'5 IIiQ."2-FI.EI mm EL3 k;|.'2-1.9mm
II-'1-.551 - IT DEG I:IJs."U.SB ir|I (13.53 lb0"IJ.EI8inI
KT‘. Valvu maids! 'l."aII.ra stam IN. 5.-I155 — 5.1155 mm 10.1145 — 41.21152 in) E.-\1=DC| mm Ifl.1"l2B In||
u-mu D.D. Ex 5135- 5.145 mm ID.2‘IAIII — 'Il2'1-'1--I In] 5.1100 mm Ifl.211'BIr||
' va'rIq0|0a—" m. 5.400 5.-100 rmn 10.2150 - 0.2150 an: 0.500 mm 10.210510}
LEI. Ex. 5175- 5-‘I435 "'.'“ ..I."?'.-?.I_5.5..- "P3159 "*1 5!-'.5F1'9!"_’.'1 ..I9;3I55.I"_I-
Srnrn-In-guide I 0010 - 0000 mm 00.0004 -0.001201; 0.0a mrn 10.000 gq|__
cluranua I BL
I
I.-\
“E59 "i15_'P_""'L_I"-"'l13.;‘!.I.I.'?EI.'.'3I I110 mm ICLIJU4 inl
I '\-"aI'.r0 seat wldth 1-0 rnrn ID.EI-II InI _ I.El mm IIIl.'l1E| in)
Cylinder head Wtrppgt -A . -
ELD5 mm IIII.II|l12-in]
F1

51' '
Dana 0| Is.-sue: May, IEIBIIZI
IIEIHCIHIJA MDTDFI I‘.'2C1._ LTD.
6-1
 HONDA
CYLINDER HEADNALVE CTII
I i _ —l 1-

‘_-

TIIIIIIBIISI-IIIIITIIIE
P0 rforrnence nrc IJI-ems related In the cylinder head can l.l:Ll.tlII'|r he diuanaeed by n |:t.'|l'I‘|I‘Jl'£:e:Ir.N'| tie-.1, nr nnice |'Jrul:|In-rn-i which
can he traced to the 1:0-p end with a saundlng red er i‘I1EfI'||:|»:-¢m'.I|:,
Law Camnretsicn Celrmnrusiun too I-Hgh
1. Valve: 1. Excessive carbon bt.|IId-up an pluten head er uflrltbusliurl
— Incorrect valve adiustrnent r:I'1.eml:-er
— Burned or cent uflI‘|'£: Eula“. "DI"
_ gt:-.|;rl'l-:I?I Tulve liilming 1' ltmtkmcr w|_“__’diuumEm
B I1
_ _ no En V W Em u 2. Sticking valve or bra-Itun valve sprint]
2‘ Clflgndur "Md 3. Damaged 0r warn camlh-aft
_ 'lIL;.aaInn|] cnr damagsd head qaattet 4_ Linn Dr “mm cam chain
_ amid Dr “ache ':""H“d'T ‘mm 5. Warn er damaged cert! chain tanelc-ner
3. C1-' Iihdflr and piston {Refer to S-lctinn TI BI Wm,“ mm zpmckfl math

_,_

.-"*1

;-_

6_ 2 58 Date cf Issue: Mrw, ‘I530

IE-'IH'DNEIA MIJTDH CI}. LTD.
 Fnorcna.
.|-'— CYLINDER HEADIVALVE

.=""
CYLINDER IIEIIII IIEIIIWIIL INDEIII MARK

Hem-zrue the Front mover

[Ji:nur|net':1 the intake pi-pa from the cylinder Mad-
'FI|rr'ri;|;ri.ra the |:ur|'|nr_'I |1|:||'l'l1 CDHEI in-DI TUH1 12I1B
F rzcanlcshaft cnun'tercI0cIn'rir-0 in align the "T" fl'lil'Ii
-m1h the I11|;Iex mark.

’,r'_‘\.

1-’
FI-
-L
f""'~
'1' MARK

Rqtnnvr the l1'|UI'IIBI'

Rarn-due the Fault plug HP.

Rerneue the cylinder hcn-I-I Ielt aide cover he
removing the through halt from the rlghl !|IIIB.

|p"“\. .-A

.
l¢- _

r""" CYLINDER HEAD

LEFT SIDE COVER

Ramaue the camshaft sprocket-

1"‘

....nll\
If '-

l".I
,e—.
SPFIDCKET

55
IJ-ate'0f Issue: May, IEISD
IIIHDNDJI MOTOR C11, LTD.
6-3
q-_
 HONDA .~"'.T
0v|.|rv0ee HEADNALVE [flu J
__:-"

CYLINDER
LODBBII II1: (:1.-lllrder I5 mm bnlt.
Remove the cylinder heed E n'||'|'| halt and r;-,-llndgr
head cover.
Fiarnave the |:r-,rIIn.elet heed.

CYLINDER HEAD CYLINDER ._._

E-mrnBl'JL1' Blnm BOLT

IJCIWE L PINS
Remove the D-rinqi. cvlintlet heed gasket. and rrlnlugl
pins.

_.-_

‘I .
‘II

'5'
st
GASKET O-RINGS -I‘-I.

v.».|_ve INSPECTION cams

[IYLINDEII IEIIIII DISIISSEIIBLY
Rnmuvl: the I:-pllndat head right aide eeuer 00.;-I
gasket.
Flume’-1|: the valve Inspection cape and D-nnga.

CYLINDER HEAD
FIIGHT SIDE -.',‘JI]'lJ'EH

ED
6-4 D-110 01 lawn: Mav, T!-Ail]
I-DHDNDA MOTOR £20.. LTD.
 r’-.-Eh!-Io1\tn.a.
|
_|—.
$5,» 010 CTLINDEH HEADIVALVE

I:Imrn HOLT
Sgrgw an E rr|rn Ia::iIl |rr!t‘: 1'I‘|E IDEIIZE-I’ il'|TI 5I13"I'l' i1l'll'I
pull me ihafi out Qf the I:','II|1rIEr I‘rEIB.|EI.
FI|.7rr|u'.r1} the r-ackel arma.

'1-I-.

f,|—.

ROCKEn AFIM5 ROCKER AFII1-I’

F‘

Remuve lllc camshaft aitgr-lnq the um IOI0e-.1. vvlth

the cvllnder head cutcnts

ra-

CAMSHAFT
'3".

.I"_‘*- gemmn ._h|_. 1,-.,|\.,-I gpriq] 11u|1'1:cri_ retainers. inrinpt

and valvea.

CAUTION: _ _ ___ ___ _ i

“fa pm-ma luvs 0|’ rvrlsinn. dv Hr“ IWPIPFFH I!!!‘
M-_r1.E 55.-;',¢35 fl1I[_|}‘£' f.l':|¢|':.I r|er:-es.sa'r_|-' I-‘r rearmvel
ll/"'.'*~.
| f|Ile'_lEElfI-!I‘.'I.

Hm-|1|1|\|g\ \|I3|q'E spring 50.01:, shim I.E|.BJ caps and !1El"lI

seals.

.-

VALVE SPRING CO MPFIESSOR

If“-.

Date ef Issue: Mav, IEIHO

IEHOHDA MOTOR CO. LTD.
B-5
 I-Iowna./’
CYLINDE R HEADIVALVE
cm E13.»
_,__

Flam-1:00 r.arb0n deposits from the DIJ|'I‘|I.Il.'tlI|:|n

chamber.
CIEHH eff the head gaslrart surface-.

NOTE
|—_
‘ - Aueid damegirrg the gasket mrtnce.
-Gasket materiel will name c-ff easier if necked
in eelvant.

I-\.

ROCKER ARM INSPECTION

Iraap-a|:.t he r0l:Iter arms fer damage, wear ur clogecl

all helet.
Manure the I.D. of the rueltar lr1'n.
."'HH"'
BTAHDARD1 10.000-1D.fl1E IH|'II
III.393il'—II.H-I-I-3 InI
SERVICE I..I'II'ITi' 10.'IEI HIIH IIIJSB IIII

--._-

""'r
ROCKER ARM SHAFT INSPECTION

lnspa-r:r.tha maker arm ahalt fa-r wear 0r damage.

Measure the ELD. at the rucker an-m rI1:rl‘t.
STANDARD: H.371!-SSH mm
10.09.20-0.303: ml
SEIWICE LIMIT: 9,91 rnrnII1.2!II12|nl

-\__

6-5 O-ate cf Issue: May, IQIBIJ

e5}-IIOI‘-IDA MOTOR CO.. LTD.
 "-1;
I-Iomnn.
_;—\ IC10 CYLINDER HEADIVALVE
__,.¢—.
.4

CAMSHAFT INSPECTION

Using a micrometer. measure the cam Inn-aa.

Ch-|:|:k ldr wur ur r.'Hr|'|B=g|:.
F
STAN DAHD: 25.9? mm H.025 inl
SERVICE LIMIT: 25.55 mm I'I.fl"I1 IIII

A‘?

1"“-

F1

CHMSHAFT DIL CLEARANCE

Mnnum and rrrcmd tha camshaft iuurngl CID-

Measure and rennrd flan cams!-um hearing l.lJ. in the
cylinder baud.
'{""'\. Determine the -|:a.m:h|'l1 huurlng oil qlgimngg.
STANDARD: 0.01 0-0115 mm
[IJ.DIIJ3--0.11015 H1]
SERVICE LIMIT: DJD5 l'I1Il1 IIl.IIIlZinI

1""-

f"" VALVE SPFIING FREE LENGTH

INSPECTIUN

H-uaiurg tha lgnglh Q‘! lhq lnnur and cuter \|'.ihIE-

5-prlhgi
‘,4--.
ETANDQRDI
lrmur: 25.1 mm {D39 In!
Uuur: 25.1 rr|mI'l.11inI
SERVICE LIMIT:
lnnlr: 23.9 mm [U34 InI
Dutar: 25.9 mm I‘I.l.'IE HI]

‘I;--.

Date of Issue". Mn-, IBM 53 6- 7

E-HUI‘-IDA MDTDH CCL, LTD.
CY Ll ND E Fl H EA DFVALVE
‘I'\'.

-
VA L"u"E STEM--TD-GU I DE CLEA Fifl\i"aiCE

lru|.1:|:r finch value for i:|=enr.lln-g, 1.1|.|ming, wmdqqq |J|'

Msurmal i‘iIE*fl'| wear.
Chuck vnlvn muvnmant in the guitin
Measure and re-::urd path vdluq stum C|,|]_
STAN DAFID:
IN: E.i455—5.#B5 mm [H.211-8-0.2-152 ini
EX: 5.1-35-54145 mm ED.21-W-iJ.i14-l in]
SEFIVIBE LIMIT:
IIWEK: E.-40 mm [H.213 ini

.-—:.
|

NOTE _ _ ' ___ I

I Fi-Ham tha |pi-cia tn remnue an-,' cm-bun build- \|"|§L'|i'E GUIDE HEAMEFI _

up before Ghflfliing ulnranm. mesa-uasoum I

* K
"-IIBBII-IF! and record ca-ch tr-ltiul guide i.l'.i'. using a
Bfflfiil hula gauge cw inrlida micrumatar.
STli"IDAH D:
IN,|'E}i'.: 5.115--E.-GE mm - {J * -
. . '- Hi -._ _
IU'.Z15B-0.2159 irll
El '\___..-'i_T ___._#:- III .-7-%'._I| L__’_,__. ll‘
SEHMIIGE I.'IMiT:
INIEH: 5.50 mm IDJIB5 lni || 1' ‘I’ -I‘ I
_. 1'. ._ _| '
. ._ -" I __
V
IIQT-I _ _..-'
_. -' =13-1:
_.- -- -I
III‘...
I
ll

Ufllnrrminu the I-tam-t|:|-puida daamnm.

STJUIIDA Fl D:
IN; lJ.II‘iII—O.fl3fl mrn ID.IHID4—D.iIl1ZIr1i-
1
R.
. $33‘ §;“. ».:*fi."-3
_- __—— ', . '_| - -. .
EX: Il.D3D—Iii.UElJ mm IEi'.III12—-<D.iII.I1U i|'|i
*3
-EEFIVIGE LIMIT: IN: IJJB-B l'l'lI1'l {II-flflflini
EX: fl.'IUmm iII.'DiiHir|-I
r
If the iIEl'\'1-‘ED-QJICIE BIBIFBFICE B_.K|3HI'di- the wrvim:
lirnill. thllen-min-a it I mm‘ guide with standard
ciimaniiona wuulci bring thu uiuarmcl within
tolerance. If so, replace lira guidas as rhacarr-I-ary and
rfifim tu Fit-
if the stem-ta-guide uinaranca Eiliiilllldl thn mrvuzu
—\_
limits with naw guidaa. rapiana the Inivns arhd
guldus-

§~iDTE__
Fiafana ma valve _aaats_ when-uavmr Thu vulva
, guides-Ir: tupimad ipql B-'l1]i.
_-|_

a—H-

Bi
6-B Date uf luuei May, IDEIJ
-DHDNDA MGTDH LTD.
 HONDA
1"‘ géé CT [I CYLINDER HEADIVFI LVE

'11-“.
'H.l.VE EIIIIJE REFLIIIIEIIEIIT VALVE -REi".I'|I'J‘u'EFI

Support the cyllndar head and drive the g|.|lcla- out

from fin} purl iirih.

MUTE U_ _
F L vmm driving out the u-aha guide. do not I
IIHFl'|I:tQ! Ii'H'.l I'll!-IIIII

K“

1""
VALVE G UIDE DRIVER
D7912-‘l TCID
Install a new uuanfza vulva quilzln from liw In-P HI
the head.

r'~

F‘ Flpim lhu haw viii‘! guide altar lnllnlltl-I DH-

VALVE GUIDE FIEAMEFI
NOTE _ mas-maanuou E43
QM

/
1 Uaa milling nil on 11-we reumar dur"'Ia1|1il 0'11"" \ . '
tlnn.
- Flmnu ma rsamc-r whflfl |I'I5IH‘TiI"-I Md i9|'"'5"""§_l
F‘ :- I.

FInI“u|;\5 Iht: vEIl'nE SBBI llllflgi 5-Tm. -*"'-- -:_"-- I I "

Illa-an tha cr-,r|i-\d=w mead flwumuuhlv tn rufl1fl'*! iflv _ L.-=""-..'='.-F X
I‘-J
- I ' . -- I
I
maul particles _ -. In I
I

_|—\.,__‘
— IJ‘.___. e---1
r-:~_. _'-\_,__
_
."'-'
".| \-.,_
=1-
_F.-IT|_
I'._l

"1".
1'7 ~.__‘.-
--‘,1’
,-
-.’-'-"—"2I"'-J
..___ _
<1--*~-.:_-._ "'."- ._____‘P;
.I___ ' ~.-~\
_ _.5 _ {J-"_" ___--I _.—\.

I-""“'~

Data nf Isaac: May, IQECI

IIIHCINDA MCITUH CU-., LTD.

‘I
 HONna. K
cirurueee HEADNALVE [:10 -'1-\.
_ _ _i I I

IIIIIVE SEIIT IHSPEBTIUIUIIEFABIHE

Clmdh Ii-nth intake mid m-ch-ans! '-l'IIi'lJB=S- themuqhiv tu
rum-we earhun deposits Apply e light eeatirig 0|‘
value lapping erampnund 1|; 1_'!I,lI2|'1 vglvu fem, Lap
B-lfih '-‘alum and suat using I rui:|i:|er here or d-ther
hand-lapping tout.

NOTE
Take mere net. lu allow lh: mmpwnd It! enter I
ilirlwflm the valve-stem and guide.
ll-lter lapping, wash ciut the itmnpnund enm-
IJIETBW mil apply a edit of engine ail tu the --_\-
waiira flue an-d seat. I

Humova the value and imnact the flee.

CAUTION: .—|._
I
The 1‘i|h'I'£'.'.l‘ mrmm be I-ruiinii. If mr 1'a'1‘ve_|"m:'e
Lt r|:.I|:,ei1, P.-r.vr.1 :.:rre1'mI_1r_ .'.Il' er.1rrJ'u'::.'. riise .aea'.|‘
rmurnp-er£_:', rile 1-u:t.|‘ve muxr he rep&:|rer1'
Inspect the velve se-at. '
I1‘ the aim in rue wide, tee narr-mu, er has luv: spots.
the wilt mu:-1 be gruum:i- I

more
I Fulluw the refaeer rnenuIu|:turer's -p|:nerat.inq Ii HH , VALVE sen WIDTH .*""‘
iI'iII"\I-I:‘IiD|'|5.
r‘

‘ff
.

-I’

ST-'5-ND-ll-RD: I.Clmm-iD.El-Iini
SERVICE LIIIIITI T.5I'I'|I'I'|
iilEl&ini

--I.

Alter nuttlnq the seat, apply lapping eumpuui-|:l tn PEI.’ |

the value feee, and lap the value using light pressure.
-lll'l|:r lapping. wish any residual Dfll'l'I|IlIJUI'IIi nI'l' the
cylinder heed end value.

‘T1.

. “\-

6_-I U 55 [J-.;|1u I'_lI IQI-{IE M1-,=, 1980

€-HONDA MDTCIFI GEL, LTD.
 ft HONnn.
,—. Ikfij,-' [:11] cvtluuee HEADNALVE
VALVE INi"-IEFI seem.-e 51-em
‘T BILIHUIER nun tsstmatt calm =.~=-qt; seer seal.
i|t5IaiI ||:t\' iiulv: sI|t'n s:::l:..

Luhrit:-ate E-at-I'i valve i1.£|‘|'| '-\'|1J1 rnul'g|-l.trle|1um

|Ii|5-uiEiti|: |3|'I:'.?ISl! :trt|;| int-:|;:r1 the value intlj 1,115 I,|.3|';1|3
taiida.
I _."
III

If’ II 1
NCITE ‘O
Tu uuuid damage tn the item |.r_ti|I, tut-|1 rhe_i
O.
-.¢. %I
valve sitv-vlt,| vmen irvsertinp. _ %_,_
I‘-‘tililll the ‘valve sprinpt and retainers.
if-'-~.

I l
EPRING OUTER STEM SEAL UALVE
1"“
HETP-INEFI SPFIING CAP

lnetell the valve cutters.

CAUTION:
l
TH prr'1'E"JrI |‘r.‘rt,I.fij.'r1 |i'.i3'.g,_ |;J|'-'_.I flur [r_1m'|r:Irfl.,\' {hf
uttivr r,t:Ir1'r|,z.Ir|-urr than nt-ct'.t.tt:'r_t- ru m.trei.|‘ the
re mire t.Tr{.l' err.

VAL '-."E SPRING’ ceueeesson

1-

1"" Tap the vei't-E !I'.n|11l pltllv with |t I-pit ltanlm-er In

firrnltr seat the valve cutter‘!-

NOTE _____ ___ _

|_ '5u|-ipurl |l1'e_t:-gilrttler ha-ad abuue the we-ri
bench eurteue to prevent tn-udfill-11¢ vflivé
I durtlagc.

. —'-.

1'“

Deteo Elisttttz Hm,-', i‘!31Bl'J 6? 6'1 1

IZIHUHDA "i'i':IlTDFt Cll, LTD.

._i
 HONDA r"
tI:vurteee nen.erwt|.ve C-III . -.

INDEK MARK
lnutall the ceneqrteft aligning the cam igbui wifl1 the
cvlihder heed cuinutq.
Align the camshaft huie with the qliind-qr head I’; .
5l'i|:lB:-I l'l'1B-tit 1'1-tr ease tnrrulwfl _aprecJt'at installation.

. -\-
' |

Fl ARM
Apply a thin cu-It of engine pil tci the rucher arm
ti-nifu. . _,_--

lnt-tell the rucl-ter etml and trltnll-I with lite Illfflflilltl

ands facing cut.
r"'_"‘\,

l_

CYLINDER HEAD
RIGHT CDVE R -" -
II‘il.i{l'|Ii the t:i,'ilntler head tight sidia ctrver using e new
Qltiiifl.

._"\".

-1.

6_-| 2 5* Deteoflaeue: Me-,-', teen

‘E-"llUl"-ID.fl. IIICITITIFI |::0., |.l'u.
-ii
 _r- -fig’ CH] CYLINDER HEAD.-VALVE
.1»

‘_.-.
i
IIYLIIIIJEII IIHII IIISTILLIITIUII eewei Pies
lngtgil is nnw E'fI'IfllIIEF heed geeiret end new nil \ I’ t
uaesage D-rinpe

F“

F‘
F1
\%\\\\-
- T-In
092';
I
GASKET BRINGS
r'*~

CAP
Install the evllritier heed.
install the cylinder heed ttlvet WI1-‘ll Th! WOW ft"-1i"iJ
down IEIII !ti!IE'i.

NOTE . '
F“ Be e-ure to inst-lii 'I.I"iIi sea-'l|il1§ Il’l'i5Il|"- MP9”
WM]-H.-I tap "U5 |u'|-Q] nut nn the cylinder hllfl
I i=e'r'£5e.=.I1?1"- _
Tighten the nuts.
TDFICIUE: 0.9-1.2 irp-In iT—E ft-Hal
Tighten tha t;'gt|i|rlI.:i|:r and head El mm bolti-

r"- WASHEFI NUT HEAD E-mm BDLT i3\I'Lll‘~iflEFi

Bmm BOLT

INDEX MARK
(“R
Turn the trrehllul-utt eounterclucitwise ant! align the
"T" and lnde:-t marks.
Lumen Ih|t;| mam ti"n'|i|1 [E‘I"I11I‘.I-I'll! innit H.111 and
adiusting butt.

If“-.

1""-

fl.

em tri irsue: May. ieee 55' 6-13

1111:-|C|r-me. MCITDH ce, tre.
 HONDA
BY’ L I ND E R H EADIVALVE cm a%;,»%
-..b_

__\

INDEX MARK "D" MARK

Pllwr: rhu I:-am chain over mg carruhaf: 1prqq;|r,g1,
aligning the fiprnnknt n-rruqrk with 1|-19 gylindgr |-mad
Index mark.
Install lhl namihaft lprnckei an mu qmmafi: ind
tiqhtan ma spruclr.-a1 l,1ul1s._
TEIHDUE: :15-0.9 am 11-1n~|u}

.--1 1

|l1P-tflll I-Hi! tvllnchr hind lufi ii-da cmral aligning th:

T-lng with tha uvlindar hand nut-uh.

I.»-'--.

TANG ..-_-\-_

I2-\-.

111:-tall the mufiier.

1I=lH|| thu spark plug cap.
Connect the lntaka pipq,
-filillult H19 vmlvfl CH-1rinl:1: Ipqu 3-Bi.
I .
In-ital the 1:I:rr'r€a|::t |:Iu-|nt towr. ___‘
-Rxlluxit the cam chain tanalun 1p1u_:|¢ 3'-B},
lrmrall thu final. cuwr.

,_

6-1 4 To Date 1:‘! |!zn.l:‘ Hay, IQHD

@HDHD-5| MUTDH C11. LTD.
In
 /’ HONDA
~- _ mu
,_

M-EMU

3’? -

'-I-\.
I

,1‘-'\-.

Ir.-\-

If-_-\-

.--.,_
|

.'I_‘

[I353 Q‘? |5iUqI Muqr, '|QHD

Tl
@1‘|UHDP|. MUTUR CU, LT D.
 1
FIrd“ Nm
:3“
_%lFm"
Jig
_% _H_ Hjfilk
_ _ ?_ _ H_‘ xi
Q
Q
WQW
I“?

C
_Y _ EMmH_]_|_ __J__m:_ h_ _ :© BL___
____;
_i___‘_|\ _______’__
p
______
A I_ _|

if \_I__-__II___HHI_ I

T,“
EH
_|)_h_x_i
_______H|HW\__‘
f
1A
fiA_Qx
If f__
_A
_m__
ii
Q_ ____
____ I|
____
____

_
___ IIIIII

_ ___‘
_ hp.
_ __
_ |_ |_ _ ‘F
_
TWIHHIL
II

_ ___
I-5__ ll
__L

__

mgmmmm M
A
wm
LTD
 Kéyll:-1::E1?=I|rT]n1=|..
. ‘
7. CYLINDER PISTON
SE FIVI GE IN FD H HATI D-N 7-1 PISTON HEIVIDVAL 7-3

TFICILIEILESHDDTING 7-‘I PISTON INSTALLATICIIII 7-6

CYLINDER HEMDVAL T--I CYLINDER INSTALLATION 'i"—B
ll’. -I

SERVIBE IIIFIIIIIIIITIIIII
GENERAL INSTRUCTIONS
u C\rIindnr_-‘|,1i:.tnn malnivananua and lnsn-action can be purfm-ned with tha anaim inita!Iu=I-
IF- -I Canuhaft and rnckar arm lubricating n|'| I: IBIII lI‘|fflHI;I'I1 t-‘I-‘II HIIIF UII Flliiiflifil 3'9 ‘I-"E Th? 955533" 5"" ""'-IT ¢"'3'9!"'-I-

SPECIFICATIONS
IF. "E1 s"r:-mn mo I _ SEFWICE LIMIT
-11.005 -- -u.u1s mm _1_;.a5qa_i:a51u I": _ -I-HIE n_1g|____t_1_.a52 inl
Cylinder I.D'.
Piltun. U I*I.1;:n rinq-to-ring TOP I Mun -11.0-ya-_5=gn_ 10.000-I - u._ua1a i_['1_Il___III.1 2 n'|rn i_§J.q!I!\_5_'qL
|;lIl1jUl“\ TITIQI QTUIZIIHE flfllrlltfl
0.010 — D D-45 mm mun-n-1 - n.u01_a In] _ 0.12 mm _IggI15_inl _
n-cl I 1 A-=
|_ _ I H.15--[L351-mm 0.5 mm __It|.I5|? InI
zin P 1 D" FII11-q and nan TOP IU.U§filI:I_.D‘I"I-_IflI

I 5EClJN_D__|_g.'_l5-Ilflfimrn IIZIIDE — U.I:I'Il'I- InI I15 rmn 'IEI.D‘i.‘ in]

. __ _ __|1;5_|1__ I t'l.31'J-U.BDmm '¢é|.Ii'1'i - nLi:i:;€|}»: -A-
fr"-. Plstqm 'D,|II, 45.93 - 47.0? l'|'| rh _II.BE'IJ' — I.BR5fl-II inl -II-6.9-III mm H.847 In)
PI5Ifll'l pin bore _ 11501 — ‘J3. DOB mm 10.5119 — El."-51 TI IHI 13.055 mm IEI.‘.it¢D inI
11I.1|'nrn IEI.52|nI-
._E'1'1=.=."1a12*!:!?!=_"!=t"!*_‘-F?-_ "’+F"?.— 1=’:9f’:?*:!11..!'i?:.5i1i15*=’-5‘"I
Rig,-tg;|_|-_|_t:|i|-| up, _ IIQQI 13 rnrn IIl511G—U§I'IBI_nI 1293mm ID511 In]

I ..P:-»<=~-u=-pm».-=|~@.-1=@==¢r=n= I"£'IE'.@_—_9-!I!1.'?».""" 1+1.-war-21 - I5‘-'.1.'E'9§..'.'i ‘ fl-'|J,15rr|rn

1?"=~~=~1 <11-"HP-'='~*
IIJ.IJDGinI‘
I Cvllndar-to-piston clearance DJII5 — U-D35 ITII11 IU-Um: - U-5914]" ..I.

4""
'I'II'I]I.IBI.E5IIIIIIT|IIE
Cumpraallnn low
T. Warn wllndar clr niittln FIfl!'_|'l
Eamasslma imoka
F/_*.
1. Wmn c-pllndar nr plstnn urn;-|
2. I|'n|J'rn|:lIIr lmt-allutlfl-H at piston rims
3. Scored or a|:.1at|:!'-ad |:.\i1t1:|r| or mrlindflr I-\'$I|
Dtrarha-atin-Q
1 Eacas.-r.Iua cub-an huHrI-up nn the nl-H011 ul flflI'flIJLl!l‘IDIl ahamI'l:Ir will
F- Knncidnq or IIlI'Il'lI'Il1II min
1. Warn piston and tn-'lIndet
9‘, Ett|.*:E551I'Iv‘E carbon build-up

1"“

Date of Issue: May, 1950

IEIHDNDA MCl'l'DH BEL, LTD.
-‘I!
7-1
 I-ID1‘\TD1!..(/
E"|"L1NDEFI_i‘F'|STUN C-III “--

IIILINIIEII IIEIIIWAL LLEFI PIN

pr.-1 -.—. . 1-

Hem-m.=e the c~,-Iin-.ie|' head [Salmon GI.

Flamcr-'a the 6 mm halt
Flumm-u Ihn gun-it: |uII|!-1 pm aru.I guide roller.
Fiammle the cvlind-er.

.T

-I‘
PI-eirnrwtr tho D-rir111,qaiI-re‘! and |:Iuw|:l |.mu_

|-"'_"-\.

PINS /1"‘.

CY Ll NDEFI INSPECTIUN
__4—|.,_
Inspect the c-,-Ilmtur burn rnr umar ur |:Ii||m:l;|u
Meat-urn thn wlindar |.D. at thraa laueli In III an-cl '1"
mcia.
STANDARD: 41005-4?.u1|s rnrn
|1.II5BB—1.B51DInI _ _ _ _
SE HUICE LIMIT: 47.05 mm H.552 InI _.-\.,_

_ _ L _1__ TOP
‘ " ' : ' r- .
'_ ~:--"P!I°‘T' =._':__I__:)-—-}--...l SEGCIHD
1. 'r|-nan

7H2 I T-I Dal: ul issue: May, IQIBD

'53 HDNDA MDTCIH F-U-, ITD.
 F
-I HON’nae.
"" \-M-J L
BTU cv LINDEHIPISTDN

“T PISTIIII atunm
|"Eacc I anon lrowai lI‘I crenl-main to I-':r:r1 dirt and
peruout.
Hem-one the piston pm dip with nE|£r.IIu nuee piieu.
r-—- I'I'€I$i ‘I111: pitta-n |'.|in out.
Hemmle the 1.1I1mn_

ii
III‘-_"'|.

’__\ PISTDH PIN c:.1P

ea‘
_

PIETDNIPISTUN HING INSPECTIUN

hhmurp II'||: piston rI|1g-to-gro-we olaararfl.

STAN DAFID! 0.0 'lfl—I.'I'.III~lI-5 n'|n1
III.l}IJDII-*-CI'.III1l- inI
SERVICE LIMIT: 0.12 mm ID.MBInI

-I Remove lha |J-IEEOI1 rin|;|-5..

NCITE _
Do not damage the piston rlnga during re-
rnmrul.

Inlipact tlw pinnn ion riu-n-am: and mranka. rina

gramraa for waar

r-

rw Insert each piston ring into the wllndw. and

maaaure the arid gap.
STANDARD:
TDFISECOND: III.15—IJ.35mm
III.lIIl~B—fl.'I!I1#InI
I,-5 OIL: fl.30—0.Bfln1InIfl.fl-12—D.D35in]
SERVICE LIMIT:
TOFFEE BOND: 11.5 mm IILBZ in]

If-

Dan; qf lwue: May, I981] T5 7-3

EIHCINDA MCITGFI CD., I-TI“-l
_
 HONDA f
GYLINDEHIPISTGN CTII .131

In'|B::aur1.: the piston OD. 10 rnrn IO.-I I-nl above

the aI=:|rt': hdrttum,
STANDARD: 48.88-47.00 mm
l1.a5::|-:.ae:u| InI
-I.
SERVICE LIMIT: 415.50 mm 'II.B|l-Tinl
Cflicuiate 131a r_",'I|:1:.Ier-1|:|-|::i:|:|-:m ttieai-1|-||::¢_
STANDARD: D.|IIE-IHI35 mm
Ill.DIZlIi—II.IIfl14 InI
SERVICE LIMIT: 0,15 rnrn I(I.BMl|':I

-L

I|$E.B!I.1rl lhl piemn pin hull I,D.

s'rmoano= 13.002-13.000 mm
II1.511a-11.5121 ml
SERVIIIE LIMIT: 13.055 l'l'I'l'I I'U=-51-I Il'lI

.-“""‘~

_.-

1""'*~.
Ramoua 1.'h:: Iu'It ::r:lI':I€|:nB IT-\'3'-fI!"I'.
Measure tI1e connecting rod small and I.D. with I
lrmili hole gauge.
STANDARD: ‘I3-fl‘I3—13.fl-I13 mm
Io.e1:a-41.515 ‘mi
ae|=w:::e :_m|'r= 111 rm: In.ea:n| '—_‘I.

53:; nation II} for rauieoerrrarvl prneédurfl. -

Inatall the I01’! ermkeuae never. -

.I .I.

_|-._
|

?_4 ‘re ' Date of Issue: May, ‘I950

E‘-‘IHDNDA MUTDH C-IJ.. LID.
 :""‘
J,-_--.
@a"‘:1:5":: CTLINDE FUFISTDN

Mun-sun: the piston pin Cl.D.

STAN DAFID; 1 2_.BB1l-—I3»MG mm
IILE1 15-15118 InI
SERVICE LIMIT: 11$ mm ID.I5'I"I I'I\I
’;""\.

C-almtete the pistorr-to-piston: pl:-I ::Iearan¢':e_

STANDARD: II.II‘EI2-IIIIJIIII mm
IILI-'lI3D'I —I'J.EIIlS InI
SERVICE LIMIT: B.IIIT5mm 'II].II‘II1IJ- InI

F7

r:
PISTON FIING INSTALLATION
lr|.11;|I| the pinnn rinqa -mm we marilinei hrfina He-
% TDP ewe
-After Imtaliatiun, the rings ll1:uLII::I to-'I;IIl gggqyqg. mmg
I'reaI'§'. .___
(.___ I . [1-o not :1:-_I|:_::_th| rap and sauaind rinqa. OIL mug

"r
——1“::.<\

-=1""-i==:-
' an: '
f"‘- . ‘ "~. —TDP

F" Space the piston ring and gap: 130° degree: HDBFL
Die not ellqn the papa In ‘I115 fill l'II\-I}i-
I
”"I
I _
SECOND

SIDE HAIL

._ _.|—I|
- SPACER
"1,
mm_gB
J
MOE aloe amt.
f'\.. in l'I'lI1'lD'H III -ii T‘-—-_ GAP
_"Ir.I-.___

-
.-' T“
~.
____
.'“-»-

r"'* _ __:-

-'-\

Dal:-U:-::|'I luu-a: May, 1956 T? T-5

EIHDNDA HDTDH CCL. LID.

“I
 HONDA
GYLINDEHTPISTDN ETD .-~.

PISTIIII lIlSTll.LlII'IIIlI
Afinlv moi‘,-b-danum LIILLLIIIIIII: qr-use to the nonmet-
ing rod email amt.
lrdtali the piston, piston pin and clip.

I‘-IDTE
' lnetall TJIE platen with lhr: "IN" r:n.;|rIc facing
H1!‘ ir|I;||Io:e ;irIc_
' Do not align the mater: pm clip end gap w|th
the plslitm 1:uI!nut_

.---—.

I.iI'|.IIIIIEl-'I lI'ISTll.LlII'il]II
%_
II151-ill 1.I'|E' |1€ILl.IE-I pafll, Cl-ring and gitiqqt,

.-"'

o-nine PINS Z‘!-

I

.-I""'\.
Apolv a thin coat of engine oil to the |:|I|1|;1.-r| ring;
and cylinder wall-
I-rutail ll-in cyiinehr, oumprnstinq the piste-11 rings.

~'=.=When
.IE the cylinder is half“-e-,: |:Iu'|f|' the_ |,'|i1-fljunl
r-IJLIT-I: '01: tum chain through ti’:-a ctrlin-dar.

7-e E Date of Inue: Hay, ‘IQBEI

EJHONDA IIIICITGFI C‘-D-. I-TD.
"“ j’ CYLINDEFHPISTEJN

Install ‘mu :;n.|'n chain QLIILIE rol-ler and 1I|_1h1+:r| ml!

guide loller pin

TORQUE! LI.5—'l .4 liq-rrl IE-.5—‘III It-IIII

-"H Loosely: install the El mm belt.

ins-tell the 1:1.-Ii-:rIer hes-1: [Section Bl. Q

'.§.
I

-"'1
In G Ul|_‘I E

F-.

-'-‘~.

f.._.

Ir.

..-I-'

|F'—-

Date of Iii-L=lZN Ma:-'. I-'=I’3l1 Ti 7_ T

-§-lii.'i-NBA MUTCIFI E3]-., I TTJ
 HONDA
c|.u'r::|-|_ C70 -F-“h

-.9
.-1,

"II:Qllli

3.8 — 4.5 kg-m

tee-33::-Ia: I Q
.,__ .'l. - ':
E’ - ---.__.___k
"-_
Q;-‘>0 I
1
"E:-___“-_ II _ ‘:21-

._~.

at J, . ______
»-—:. '\\._ ""'~._"-.
K ._:.l =:~ 1?
3.
-.
"'~.
I-" "-. ~.

:1: I . M
- .. ___ .
-*"~.
-\:\.

@%_
'\._.»' ‘H.

r"-T.‘
f
_t". ;—
.-I‘ .

B0
BO Dateof lesue: I|I-egr, 1950
E;1H::||'-Ililn. Motoa 1313.. LTD.
I": 8. CLUTCH
F‘
' SERVICE IHFDHNIATIDN B— I‘ CLUTCH DISASSEMBLY B--3
TRDUBLESHDDTING B-1 CLUTCH ASSEMBLY B-6

F,-.. FIIGHT GFIANKCASE COVER CLUTCH INSTALLATION B-5

HEMDVAL B-2‘
FI IG HT ERA NKCA-S E IIDVE Fl
C LUTCI-I HEMEWA I. B-2 INSTALLATION B-TI’
-L-_:—--|—

(“-. SEIITICE IIIFIIIINITIIIII

GENEFIAL INSTRUCTION
Clutch BElI‘\'II'I'lI- can be done with the engine In me ‘I1-ama,

rw
TDDLS
Cernlnun
Univareel holder DTTZEQDIDTDI — H..A. IN LI.$,.A,, U5! ¢|.'|r|1n1:|11i||!I'y' ivillihla
hand alrap wrench
l_n:;l: not wrenqtt, 20 1: 9-I mrn UTTIB-LKIEDIDD
Exllentiu-n, 1:’? in rlrlw 2-: 3 in ITS mm}: ClTI'IEi-IIIEDEDO — Commercially available

TDFIDLIE VALUE
F‘ Clutch lock nu: 3.8 —- I-.5 Itg-n1 I23 - 33 I1 lhl

SPECIFICATIONS

I
ITE M STANDARD §EFI":."ICE LIIIIHT _
_...,

Clutch Spring free length 15-DB rflrrl IELSH? inl E3T11'1rn II],E'I inl:
l
_
Dim rh leicneu A
B
I 2.55 - aee rnrn _|o.:oo_—__::._1o4 : 1_: =e_-~:. “.1.-Q: In
3.35 -3.-'I5n1l'n H1135 —CI.I3fiinl ILD mm l[l.12 in]
1"":
_ . Plate warnage DJ" n1rn |iII.El1 inl
I
i
Clutch <:a1'=tIr nui-cia DD-
Drive pear l.D,
anaan - ::n.ae:: rnrn :u.aa:u - u.a:4a inl
2‘I.'lIl|Jfl — 21.021 mrn IIILBQBB — 'lIl.H2?B inl '
*5-9° -~11 J:-ta:-I
21.05 nlm Inseam:
I”
TIIIIIIBLESIIIIIITIIIC
Clutch lllpi Blunrh cine: not tlkmlleu
1. ND fraa nlav 1. Flat: wamnge
F“ 2. Diane we-rn
3_ spring‘ “Wk Glued: chug! when tllaangqul
1. Lifter rnuchanien liarnmmul

IT"

_P'7"'\.

Data of lasua: Mat-', ISB-D B1 — 8_i

@'HDI\'-DA l'|ID"l'DFI IZCI-. LTD-

1-A
 HONDA
cu.rn':H ETD LEE,-’ "
I _

IIIEIIT CIIAIIIICIISE CIIIIER :»::t::< sTaeT En PEDAL FHDNT couee

NJ" -
IIIEIIIIIVAL
I‘ ‘I 1'
Drain :l1e ermine oi: thorough‘-5' 'I _ I. H"
_.- .. . . _,;'=?
_
5:.-ppurt the |n\'Jl1|.‘|-:'I2'\rI2‘lE U]flIIgI1T with a stand
' L-_.' " _.-‘ “.1
Remove ‘III'HI riqht cr:|nl=:;::== rrrrrm Itmgu 1-El. ::- ' '

4 ; 7* it’
T I.

.-’ I

STAND FIIGH T 1-:.,_

ASSEMH I. "t' CDUEH

CLLITIQI-l LIFTER HEMUVAL

ADJUSTING BU LT
F'IE!I1tJt'E 1l'|E Elutth l|'lI::: urIr.I clu1t‘:l'| odiutting bull

|' "1'

r:LuTI:H LIFTEH .-:—~._

CLIITCII IIIEIIIIWIL
llnmv-‘Mr the rlutch luwr and clutch r:::In.
»"~.
Hemoue the elutch -outer co-tar.

1"’;

L CLLF mu _

2 e2 Date.-of l5:~1.m Muir. IIJBEI

HCINDAuotoe co., LTD.
 HONDA.
..- cm .5“...
r""‘ LOCI-=1 TAB
Etraightafl the In-ck vr--1-=1‘-Hr I-ah. _
{Q},

F D ql Q,

l"“\..

F“

LIN IVE HEAL HULDE H

HEHIUHE zhg lcruk nur, was.har and Ir;-ck washnr.
The clutch can nnw ho rumuvud as a -nflll.
Hgmqw 11111 rlrivr: gear and r:lu!L:|| GEMEF guide.
*1» |

I,“ EHTEP-|SiD|'-l LUCK NUT WHENLH.

II] :< 24mm

BLUTBH DISHSSEIIIBLY E ms
fr-E Remove the IE‘! ring using a 5l:n:wdri'n~ur. S T fig
Rumuvn rhu r-IuI¢h plates, dis-I:-5, I:-nnicrr, drive gear
cuter and rollers. _?

F‘

‘F-.

If-I"I-.

om D1 mun: my, man "3 B_ 3

IEIHDNDA MGTDH [JD-, LTD.
 HONDA.
CLUTCH _ C70 J‘I -

HEFHDIW ill! |‘.’ll.|[|:h dampm ipringg.

Flaw i w|:||:|d blank under the dr in ptate.
Remove the 5 mm-5-cr'ew.=., |flu3|!|'|ir|g II‘-3 turn: gr i
1Iifl'\E ‘|'|'|1||E -|.'|L|5|'||r|g dnwn nn ‘l'h|_: |:|ulf'|;h gutgr,

1-._

CLUTCH SPFHNG INSPECTICIN

Measure I|‘||: spring mm Inn-qlh,

STANDARD: 25.UB'mlI'| IIJBBT inl‘
SEHVHZE LIHIT; 23.1 ml'l'l {DB1 In}
_F__/"""-..,____: .-
.- J.
.-
l"__\__L _ J
‘___. "“'-\._H_\_ -' |_.|I-\-.
.-_.
I-C g _
___’. _$________-‘ER

~&_ .. - :1. -
-\-‘.___ _ _ -\-.

. . ‘H -- .
I
'1 Jr ~._._ |

."""\

CLUTCH DISC INSPECTION

J-H
Heptace ma ulurch diam if lh-5'9‘ ghnw ,4;-,4 U4
Btclrinq or cilrnulorannn
Maaaura mu din: Ihicknnss.
STANDARD:
DISC A: 2.55 --2.55 mm 1fl.1fl0—D.‘HN inl
DISC B: 3.35-3.15 mm {fl.13fl—fl-.136 lnl
- -.
SEFIVICE |.|n.n|r= nlsc A: 2.3 mm mun mi
DISC B: 3.1! mm 10.12 ini

B-4 "“ Daiaclflssusz Haw. IQHCI

EHUHIJA MOTOR Gil, LTD.
‘T BTU CLUTCH
Ir“ l—

Ch-rerti. the [r.'|II|:|5 and plates for exuassiuu w|1ur-

Hanlam if nacau-arv.
Elruck fun -plate warpage on a surfanu plutu using a
f~.:r:~Iur pug!-
,/'_ SERVICE LIMIT: fl.2mmiD.D1inI

JF-

.|"""“

DFIIVE GEAR INSPECTIUN

.-L.
'Bhar.:lr for waar nr damage.
Mtrifiule the rfiiwe gur |,D,
QTANDAHD: 2-.“l.0fl0—21.Dfl1 mm
tunes-o.n2tfl ml
P SERVICE LIMIT! 21.5 nun IDJZE lrll

CLUTCH CENTER GUIDE INSPECTION

rihflflk ill!’ WEI!‘ U1‘ :1-smug:

Manure tha niutd-| cantwar quid: CI‘-I1
STAH DARE: 2I}.BI|—Z'lI|.'B5ll l'IIl'l'l
1fl.B2lU—D..Bl|l3 lI'lI'
senvrcz LIMIT: 20.30111-mI'D-B23 Inl
K"

K“

FT‘.

Data uf _Iw-":1 Mir, 19311 B5 B-5

IBHQNDA MDTQH CG, LTD.
 HONDA .-5
c|_u'rc|-| BTU " “'

BLIITBH ASSEMBLY _ _
Plane thE £IL|t|2h sprlnga un lhu drive: plqtr: and inflall CLUTCH PLATE A
- |.'|Ifl1r: 1t: the cI|.|t|:h 1:|ut|r.
the drama FRICTION
DHWE GFA_fl man B ELIJTEH
PLATE B
''"I____I3ITE ‘ serum:
I'l|_=|htur\ the " E"
In 2-5 !1.1:pl in i r;rl:5r;r1;|5q
H'u'"'-EH
I DUTEI|:‘¢LuTGr|
|-CENTER
SE‘
ems
-
.
uettnern. I _ I I L H J
IP15-Til-II the cIut|:h damper -sprtngs. _;I “ E I‘ 'i'_34;'_, I‘ |' "iii ‘H
tnsteel the rulleht. drive gear outer, <:lt.rt1:h center, Fl
K~:Y-_=.+"'
_ _.;€[;-,__fl_|i_“,’ :1. H" -
dim and plate: and secure with the set rlng. ..j| -
~.».;.r,
_;; -3~'-G. i|
lt Q "-
~_. .@?§ ', -,-'_:*——""' __.1-‘

I
IJFINE PLATE
CLUTCH
THING
'/
'|
FRICTION DISC A
|-,_

BLUTBII |NSTlI.l.flTI[II'I
PLM N INFIEH E Fl
|FI FIEIII I|"lE' fllulflh Hunter quid-5 and drive gem
Ihstnll the clutulr asmrr|taIy.
Irl:Il'|II the luck washer, plain H‘-r-udrn-r ind lqqlq m_||_ I. 1| . ‘__
NOTE
_ .-"'“'\._
lrrmrll the plain washer wlth thq "tJ|__IT5I£|E"
marl: Ia-::i|1g nut. |

.-

LOOK HUT WRENCH, ‘___

. ED rt 2-Imm
TIQTIIBI1 the luck n_=ut_ ...
TDFIQLIE: 3.B—l-5 kg-m l2B—33 fl-lb] _
Band The! lent was-her ml-t,

_.r—--

-I ."“'

UNIVERSAL HOLDEFI TOH DUE WRENCH

8_6 as Dare of Issue‘ l'~'I-a~,r, IEIBU

'€JHt'.JND.fi. MCITDH t:n., LTD.
 Huntnn
lg; cm CLUTCH
OUTER
lnetall the ciuteh outer cch.'e='.
Irmnlr rhe <:luu:l'\ cam and lever.
Install Uta flaring. oil tl'1ru-ugh, eluteh cam spring and
bell retamer.

EL.
CLUTCH LEVEFI CAM

RIGHT BIIIIIIIBISIE BUYER ADJUSTING

IIISTALLATIIIH
lrr51',;||| 11-"1 rzlutdh adjultlflg belt end llftut.

CLUTCH LIFTEH

lmmll the D-ring, washer and leek nut

lnetall the riqht clan-linen: wret-
lngtall thg kick itartnr |2|:dl|__ 'I'|;|t:-!;n!Q1.|‘hLI|!' 5'F.B|'||II
fl!5emI:|I'-,-', muffler and front cover.
Fill thn qrqnlume tu the proper level Imfl-| lhl:
|E=t:|2rfl'1m€-|'ldBd= e-'|l Ipam 9-2]-
Adiur-t the |:1|-Itch In-B99 3-‘IEIH

/ R.
CI‘-HING WASHER LOOK NUT

Date nf leer: Met-', 1931]

~'fiHDNDA MOTOR CO.. LTD.
I1 B-7
 H On““1’0D _’
G EA H 5H WT L W KAG E __ H

f
_____r
_ _

J
M
A
X /:Hm____
‘T
____fiH"_\______._

V
3
_

_ __‘__U__

X“X fix
m
__

_ _ _§_ _ _
mm
J’
W
__\
aw
HI“INNER‘___ if
______

%
9w n_ _ _H_HN“_I

QI

fig“HMD HmWA mm Wm_HHE mu

HO
ET D
I"
F“
9. GEARSHIFT LINKAGE
SERVICE INFORMATION 9-1 GEARSHIFT LINKAGE
‘B-2
TROUBLESHOOTING B-1 ‘NSTALLA1-‘DH
{___
GEARSHIFT LINKAGE REMOVAL 9——1'

SERIIIIIE IIIFIIRIIIIITIIIH
GENERAL INSTRUCTIONS
r"'_“‘- 1 1 hr; Q33;-g|'||.f|_ gpin-dl|| arid r.m1:r|:rerr arm I:-an he serviced with the engine rrr ri-re tramrr.
I It the shit: tr.rr-kr., drum ar-rl transit-'Iie:ir.:|I‘i require serr-'lr:.ing_ ren-rcr-re the engine arid r-eperete thr: -llrnttitrifll-9.

r-*~
TiI[lI.IBLESIl[I[lTlNI.i
Herd lhiitinu
1 ll-npmc-er clutch ndiuettfleltl
IL Shift lurks bent
3, Shltr shaft l:re'P-'t
-1. Shift rlrum =1r-inner beet
Er, Shllr drum earn gruclve I-lee!

P Trnnermrei-en iumpl nut |:|1' gear

1, G-,-.rrr tleqs worn
1 Shin 5.I'1.3‘I'! hem
3, Shift drurn rrterpnnr urcrkern
-I_ Shit: Irrrit: be-nt

f""-.

fr-I.

F"

F.

.I"'“'

Drrrerri I|5_|J9I l'rIa'-r, I9-B0

DHOHDR MEIIDH 120., LTD.
R9 9-‘I
-‘O
 HONDA r’
GEAHSHIFT LINKAGE BTU ‘gr

IIEIIRSIIIFI LIIIIIMIE IIIEIIIIIWIL t‘=eAee|-||FT PEDAL

DI’-Hm the engine ml.
Remeve the gearshift |}flfl3I_

-
r.,__

__,_

R!-nmle the right trranlrtqasrr Queer and rflutrrri-| 35- B.

wmhl-r i5E¢='liur1 Bi.
I H-I]Fl'lO'lr'E' the snap rln-5| end driven gear, I

I .fl'_-l.r

_--,_|
SNAP RING

_.-Fl-I

Remove the drum stepper arm. ii-Iii

nrrurrr smeeen ARHI

BU‘
9-2 III-nleui Issue". Mrr~,r_ IRSO
GIHONDA H-DTOR CO., LTO
 HONDA
BTU GEARSHIFT LINKAGE

O R UM P LATE
Remove the drum stunner |iIh'lr: ehll pim-
l-'I.|1I the geerrei-ritt spindle out of thn rrrerriura-2:.

ISHIISIIIFT LIIIIIHBE lIISTi\I.l.i'i'l'lIilI

DRUM
lnstaii Lhrr q.uI|t1I'|III drum pine iI'l'li!I drum rtElDDIlT ' '
Piflie.

irretmi the gearshift spindle areemblrr.

GEARGHIFT

OFIUIII STOPPER ARM

Install the drum atnnper arm as shown. "Q11:-:
Tighten the pirrnt heir.

Fietate the gearshift spindle and check the linlrapr

fur am'e-crti-r onemierrr.
Ir-rr51;|| the r:lutr:l'r assembly and right eranitouse
cutter.
Install the qunrshift pedal.

El-ate of Issue: May. IEIBIJ 51 9- 3

EIIHEINDA MOTOR £20., l.Tfi.
 DA
I <_=f§=§_=§
THANSMISSIDHIGRANKSHAFT C70 -I’ "0...

—
I
-.

1.0 — 1.11 kgm

[T - 1{|f"t-lhl

@='“ V 5/
is in 1 ‘K-

..-
.-1-"ii ll . ‘in-1 - --‘I """.
.- ) | Ii ____';-_-q__:___-_5_j:q_‘
‘-1.

x_ ‘"’!1|-I‘ ,1’ ' I -~T--. *1"I ‘

QQ‘;/*"+¢
- i |IrI",,d . 1'-H.

2-.

.»' "'r‘--_
n
-=1’\\
*3‘ ' ~'~."..' -"
. ..;~ - 2;-El, ‘.
-r if
.-"-- ' i
E-'
-_1-.- . ' _ fir
-
--
.--

-'-'--‘

4;
_-J
-4'

‘I.9-J
. $ _
1 U. O 92 um -=-+ IHLIEII Hay. 1550
EIIHDNDA MUTD-H C-0., LTD.
 E U’)
,»-
I-"‘“
I-IiJ1\I'IlJ.B.
BTU
%
A p Z'—'l $3
III Z U1
=5 3 EH
II,1
ii -|-ill ‘1""’.
SERVICE INFORMATION 'ID—1 TRANSHISSION DISASSEMBL? 1D—E

TROUBLESHOOTING II]~—1' TRANSMISSION ASSEMBLY ID-9

CHANKGASE SEPARATION ‘ID—3 CHAHKCASE ASSEMBLY’ 1D—‘ID

1"“ ‘IIJ-4
CHAHICSHAFT REMOVAL

SERIIIBE IIIFIIIIIIIIITIIIII
("‘\ GENERAL INSTRUCTIONS
1 The crnnkcasa must be saparaud to -mrvim 111: maniuhaft -and transmission nnmpnnanu.
I» The f-allowing pm-L1 mun be rammed before aamrating H1: crlnl-mesa
Cvlindar head Section B
1"‘ I£';'gIl111:l:r and nlstun E:-lIu|1 T
Clutch Suction B
Gngrsh11'1llnIm-ga Sec-than 9
A.C.gnIr1url1:or Slctiun II

TDFICIUE VALUE
Finql d1-Iuu sp-|m:I¢a1 ‘I.Cl - 1.4 kg-m IT — ‘I-U it-lhI

SPECIFICATIONS
M nm mmnnnu SERVICE LIIIII-‘T
Tfihsmlislnn Gear LEI, I-II! . 17.013 — 11043 mm I9-5599 — QETIU i|'II _ I7-In ITIITI IU-573 |"'I
1:1 .___|i.______
I 11015-110-1:1mm11115699-:11:-11101111
_._'_ _
I110 rnrn Il1EI?3 In] _
1 - E3 1T.II|1B -- 11.1143 mm 10.65-QB — GEE? TU Ir1|| 17.10 mm [CI'.B?3 InI
10.5-E? I111

11
II1III|ImI'l EIT O.D. — 15.954- mm IIILBBBB — IZLBEQI |n|' 15.55 rnrn
I'M
Cr:I1.|nt:1:I1arH O.1l . 16.965 — 16.954 mm IIILGHBD — H.535? InI 15.95 mm [D.BS? in]
in
Shift drum DD. in“
33.’E|5fl ' -I-_i___—33.QG-r1'1.1I1—1
— 33.915 mm 11.33615 —- 1.3336 In}
_/-\_ sum rm 1.1:. 34.11615: 54.1125 rrlI1‘l II.3-335- 1.33% I1'_1I a4I1:TT:T1T.i3.lIIfl:
'— '51-.1111».-1: pawl Lm 413% 4 11.11’-1 n:|m 10.191 u.1E€'i}1'| 4.5 mm_1'1:1.'1a 1111
I "“""""“ 111.1111. ass 5.91 mm ID-Z31 — 0.234 InI an mrn 111.22 1111
C1-anI:1|I1;fi Connuct-ilng rod big i:m:I T _ 0.6 mm ID-D2 InI
side dgmmm CLID I135 mm IU.GU"l — D.D'I-II IHI

f‘ =‘~ Currnnctirlg rad big end

fadmfiqianfl fi
_ I].£l12 mm IIJ - EI.OC|D5 InI U115 111111 lD.IIl2 inl

Flunuut -- 13,10 mm lIO.IIIl in)

Journal hearing A2551 n-1u m'1+1 IU.IJE_I1I Ln]

,..i.._
__ D-In FI IIIIIII UJZE rnrn ID.1DD2in|
P-
1""“~
D11; nf Issue: May. 1930' 53 1 o_ 1
BHONOA MOTOR CO" LTD.

‘Oi _ _ - _
 HONDA |- -=’|
TRANSMISSION.-'CRANKSHAFT ""

TIIIIIIBLESHIIEITIIIG
Hard tn ihifl
1. |m|:1r|:11‘-J-=11 -::I1..|'t<:h aijjugrmgnt
2. 5I1IIl* fnri-: hunt
3. Shift ihafi hem
4. 5I’1If'[ drum an-||.'r|.'.1+|1r arm banl

Trlrllmiisinn jumps nut 1:1!‘ qnr

‘I. G-Ear Irloqsworn
1 Shifi shah In-.-n1
3. Slhft drum ltnppar L11 uh:-n
-I. S1'1if1fc1rI-1.: L‘|-B11!

Exclilivl l‘llZI~Ill
1. EJ¢1:!|e.Iii'|'~H crrrnl-cshaftju-ur11al Lu-m-Ing play
1‘ Excaaslve Gl'Bf:1I€|i3|'I|| h1:a|'ir|g play _ ..._

|"'

.1‘-

-"1.

1| D 2— 5" Dateof Issue: 1.131,, 1950

QIIONDA MOTOR GO. LTD.
 ' F\I-ICII\'I'Il.B.
K:-"I11.

,--_ C70 "r1=tAnsm1ss|onI<=FteNK$Hfl~FT

'IIIIAIIIIIJIISE SEPFIRITIUII _ ENE"
Hr,-1mm-1-. lhp cnglmr §Ser.'I'.ir.1n HI.
- tamrtt
‘ “-Ail
Remove the t:\rIit1|:Ier head ifieetion EI-II. ¢_
Homm-1: fhl: l!yI|1'||;I_r.'l' anti piltfllt [SHEER T]. —l J! e
Hemcrre the clutch I5n'ot1icII1 B].
rm Hgmgue thu ga-ir.$I'1-II! IIHIEBQE [5BD1I~Dl1 9|.
' Remove the flirting rnotor I5udi-::r| IBI.
Hem-we the A.C. generator [Section Id-I.
Remove the 1:-ranitsluft one-Ir.
Remove tI1e drive sprocket.

|r""\.

_.,____

1"‘
CAM CHAIN SHIFT DRUM SHIFT DRUM
RUBBER CAP H-OI T
Remove the elm ohein temioner red lflti tiflliflfl-El‘.
Ren-||;|-.r|| the ruhher up and 1hiI‘t drum m-otarrting 5
rnrn bolt. 1- -____
Home-re the crankcase 6- mm eerevm. ‘“--.___‘

("""~ ‘"1:

r1 CAM CHAIN TEN5lONER PUSH ROD

RETAINER
f ‘- Pb“, 1|-1; gnqlng wim 11-1|; l|:I1I termitoei-e down- \
Hammva flw Quip ring thB|1 |'Elml;l'\I'fl 1155 |'\E'IIlI|'ll?I' iI"I?I
II.l1:I\t starter I-Brine.

F‘- I}

f"'-.

Date of iuuet May, teen 95 1 °_ 3

ezunowen. motes co, 1.111.
i —
 HONna. ./T
TRANSMISSIONFCRAHIILSHAFT ' It

Seperaee the right orenireeee from the Ieit 1:re:1Itr:ae'e.

Remove the dowet pins and gmrkm,
I

_-—I-—
_-__1|—||:1I

- .3

-H1

IIRMIKSIIIIFT IIEIIIIIIHII.
Rome-ve the orani‘-rehait .1-5.5 _
CFIANKSHAFT INSPECTION
56! the tit-Ihltahaft on I 1t.|n-d or 'u' bioolu.
E’-at I diel Indioetur as ehowr1.
/T‘-_
FIIII-rite the crankshaft two rwoiutinns end reed the I
r1.Irrr.n.1t.
Actual runeut I: 11'?! of Tut-II Ir-dleatnr Reading-
SERVICE LIMIT: 'D.1fl mm [D.IIII.'|l InI

mm mm
1BinI II.£I2ihI .--.

Measure the I-IIIII eieennoe ut the Itonnoctlng rod bio -""\

end wiflt a feei-er gauge.
STANDARD: I§I.'IIII'—fl.35 mm {'iI.'l3Dl\—IJ.B1l I‘rI|I'
SERVICE LIMIT: 0.! mm I152 InI

_"‘~.

.-

1 O-4 96 Date _r.Il lento: MW, 19%

'QI'ICINI:h'51 IIICITDFI COL, LTD
 HONDA
.:—.
C1 U TRANSNIISSIONICFIANKSHAFT

1-
I

II.'IE1fl5=..r|i: The: :Bt:II3I ttlreuzeirfrr at the |.:r::|||r1er|':Ii||g rurl

hig end, at two points In the direction in-dieeted by
the arrowe.
STANDARD: U-0.012 mm IC|—LI'.DOI'.IE InI
ii.
’,--- SERVICE LIMIT: [I115 mm IIJDJIIE‘ iI'.lI
I ‘I’
'-\,__\_\__ .

|‘r'_'.

.I“"'“

5pi1'| thejournal trearinq try hund and rlmleoe it If

noisy.
Cheek the 1o..rr'-et heeriou pdey.
$ER'uI'ICE LIMIT: '
AXIAL: e.rrr rrtrn mum-1 1|-.1 .1
5-». e.n.om1.I one mm 1e.un21n1

F“

TIMING SPROCIICET INSTALLATION

1' I I|1s1‘eII tlnn epru-r:I1ter, ehgnirrg any tooth Ia-ortom 1I'r‘iII'I

the Ituyway-t:H:re nirpi.-I cunlur Iinn.

1"“

/T‘

I.--.

Date of lseue May, '1'.-IIIBI] 57 1 D_5

-E1 HONDA MOTOR CH1, LTD

-,.,i_
 HONDA ‘.5’
TR ANEMIEHONICRANKSHAFT -e__ T‘

TIIIIISMISSIIIII DISASSEHBLY KICK eme-ren SPINDLE centre IIZSHAFT

Rerntr-'1: the erenirehaft and ltieit starter spindle.

Q.

l1.l=- 4.

Remuyn The !!'ilI15I!1-.lIlI_'Il'I nod :I1|!t I.1ru|11 as an "Ir

aseenthly.

."“\|

. I _
-_|

..I.__; .1 —_lT
.-P.-.

—--.

KICK STARTER SPINDLE DISASSEMBLY

SPINDLE --N
Rernoye the snap 1'II‘r|;| an-rl r.‘l|sa:rI.:mI1le l.I\e Itiels |' -'
i*l..l|' IE1‘ L12|II1|.IIE_
Che-eh the driven r;11r;h|:|!I_ pirai-mi and epiin-die for
exeeeaiye weer.

~-

II Q

I ‘KO
1%
PINIIDN em»? ems emizner some ems -

10-6 B8 D3151]! Iosuee: MBY, IQBCI

HONDA MOTOR Cl:-II., LTIJ.
 _/—;;§\.I-IOBIDA.
J?-
Qéi CT" THANSMISSIDNIBHANKSHAFT

..___/
_/"'"‘ TRANSMISSION GEAR OISASEEMBLY C-GUI‘-ITER<I;IAFT FIRST FEAR SECOND GEAR THIRD.‘ GEAR
|'
Dieareemtie the rrui11ehnr| .1111: eountermeft. |

Inspect eeeh gear for weer or damage-

1*“
41., ,1.
rf"‘-.

'I\Ivt» "°
MAINSHAFT SECOND GEAR THIRD GEAR

Meaeure eeoh gear's I.D.

STA NOAFID! 'I?'.fl 'l'E- 'l?,l}rI3 mm
IIJ.IBB5—D.B7'ID inl
SERVICE LIMIT: 11.10 mtn IU.B'.I3InI

/“*

in

I/H
I|1g@1,||'rp ‘II-‘lfl 'O'.D, |;rI 1111: miinillkll lfld counter-
ahaft.
KTANO-ARO1
MAINSHAFTI 1E.flB3—'I=B.B9lI- mm
ID..EBBB—'IJ.II|IH1 inl
DOUHTERSHAFT: 1fi.9i-Ii- 15.581 rnm
1"" [D5550-0.65? |n'I
een1.r1ee LIMIT: 1e.ee r11IflIII.BE?InI

I-"'-'-.

I,-.

Date of Issue: Ir'Ie'y, 1950

EIHDHEIA MCITDFI CI1, LTD.
10-?
_
 HONDA E.
TR ANSM I55 ION I'C RAN IILSHAFT cm 11-’
_,__‘

SHIFT DRUM DISASSEMBLY GUIDE PIN CLIP

RBITIDVB ‘I116 QLIIEIB |:|It| dips, pull nut tho guide pir|5
and rernut-1e the 1.1-M1 fqrlqe.

NOTE
Hlerlr. the right and left shift forks to ensure
eorreet assernhfy.

Chisel-: the iluide oin for weer or rlernmge.

GUIDE PIN --I—L

-Check the iI'|I'Il Iurlr. ler weer, he-ndIrn;| or other

Amman‘ ..1'2‘_%_:
Memure the shift forlt LO.
STANDAFI IJ: 34.000-34.1315 mm
11.3:-tee-1 eeee InI
- .|-I’-H.~.
SERVICE LIMIT: 311.0? mm H.341 InI

_,,h

-+~._\_
"'-D.

A-ht".

Memun: the shift 'Itj:rIt Ellw I1'!ICIILnE1i5.

ETANDARDI
LEFT; l».HB—-llsflil mm 'IIJ.‘IB-1-CI'.‘I!I‘5 InI
RIGHT: E.BG—5.'5-II mm IIIJ.23'I--D.31'ld InI
SERVICE LIMIT!
LEFT: 4.8 mm IIIJI5 InI
RIEHT15.B l'I'll'I1 {URI irll

I10-e Date of IIEIHI May, I930

HONDAMOTOR CO., LTD.
 T FIANSMI SSI DNHIRA N KS HA FT

Check the shift drum fur wuur ur d:n'n-aw.

MBELITE the sl1|f't drum D-D.
STANDARD: 33.950-aa.e?§ mm
11.3355-133m nnl
SERWCE LIMIT: 3333 Ir|mH.33BinI

TRMISHISSIUH ASSEMBLY SECDND THIRD

GDUHTERSHAFT Fl FIST GEAR GEAR
Assemble the malnihrft and uuumerlhift qairi and If
secure wi'lh the map ring.

F-lDT'E _
I
Lubncate ear:-h gear_\;-;i¥h_-Film all afier I \ I X
asnumhly.

‘L i °~\';‘~ LO '

SHIFT DRUM ASSEMBLY

/ / ”1'~
MP-INSHAFT EECDND GEAR THIRD GEAR

lnrmlr thu 11-nfl furl-u urn mu mlf-1 drum-

Instill 1M fluid: plm art] nmuru wlth the clip. RIGHT SHIFT FUR!
LEFT SHIFT FORK.

r r
|\~ !
9/
I.-" " ___‘
EHEFT DHLIH

'~‘ if
;=+=-“" '- _'_“_’
A
/ii;-' -_—-_—_-_'—-|'r: __

GUIDE PINS

_—

um cf Issue: May. 1950 “*1 1 0_ 9

EHUNDA MCITDH CCL, LTD.
 HONDA /‘----:=\
“H.

TH AN5l'|ll$lDNl"CFlAN KSHAFT cm -5%)‘ ~-

.-1_‘-._.
KICH ETAHTER SPINDLE ASSEMBLY
Amlmlele the Fciclc .sta.rter aw. shmvn. HICK F.Fl'|I4.HT_EFl SFINDLE
NOTE ., S_
P0‘!-iHUl'lthB Ir|Gt|O|1 lpring in the driven I —.1 ,--|.
.-
ret1:hat qrnmre-
FRICTION SPRING
cg: i

—-.3‘; .

KICK. STARTER SNAP HWG I SNAP HMG

FINIDN 51,“;-p|5p|
HATCH FT
| .1 ‘I-. |
| .

TRANSMISSION INETP-LLATIDN

|l‘lE!€i|| the drum end tran-im-ulnn 1n me left

crank-cane as m assemble-
MAINS-HAFT
NOTE lIDl.ll'lTEFl5H#|l-'l'~\‘_F """ .
,..»r'-
.-

- Alqpt the neutral twitch rotor wlth the J..' J I 3' _‘Ie.*_
Hfi'Jtr|11wil1:h.
' After lnetlllinq, rntltn the milrreh-all 111 In-ll:
yure that the gear; rntata freely.
twee »
|'Ill‘.
.-' - Il' i kit‘
_,__ I . "fax"
|._' JP‘
__ I r U,
"1-A-I :'_
__.___l"lEl.ITFlAL
__1-_ -- '"_,€,|.fiI§fifl
‘ --
__-_-,-: ' _;_¢_____:.
"' 3w1"rcH HCITCIFI
, _.-— .-
&._ _ . -'=i=
("17:
F.
-;_l__ I ‘F--.~ meutem.
"":;~ ';___._- - _sw|"rcu
1-:_-__\
-iqt-=°'.Z'7
“" ‘J - " HFIUST wnsl-use
-I L

.1-.,‘
Instill the tuck l-’EH"lIfl|' spindle in that the frltrtiun
sprlnq mete in the nunhnuu grvcwc.

.-"_"~.q~

EFHIHG ---

1 0-1 0 ““ §"lB1l$Tfi@"?5'&'§'5'§'.
 I-Iowan
tr‘
gj TRANSMISS IONICH AH K5 HAF T

F‘ lIRll||lBlSE HSSEHBLY nuwtt PW

lrmtllll 1h|r tranltehett lfilfi the lefi ttrant-mate.
lrlttall the dowel nuts and gasket-
Plaee the rlghl t':rur|kt:a|e: -:1r‘|Tt|- 1hB lE11 crankcase end :F'
turn the clanitcase assemble |:wer.
F‘
lfistall and tighten the eratnltceste t-1:r1:'lI'lfI-

If“.
l I h

F"

GEM CHAIN SHIFT DRUM EHIFT DRUM

TENSIDNER RUBBER CAP BOLT
lrtetell the uem chair-, tensinn-er and tnrrtiurutr red.
Ir-_1.u¢ll the thlft |'.l|lJrl'l E ltl|l1l| met.-ntlng bolt and
rubber cup. _ ___ “Eh
lnflafll [ha l'lr|.:|l titlufl 5|Il|tn-Cltfll.
P. TORQUE: 1.1)-1.-\'l l-cg-m [?—1Dl't-Fh] --..____
‘ _'I-|_
__\_

CAM CHAIN TE HSIDN E R PUSH HUD

r"""

F.
lnitell the ttielt starter 5p-ring =lr|tl rttfllrlcr
. ', , .'
Hunk the 5p| In-t1 end: --n the retelner |]r-ntlvtl and mar _ .| t
the r_tran|-t-:15: |,|r|:|l,EC1'|t':-r1. '-. I J '
I
Install the snap ring. _ |'
I

lnt-telt the A.C. gnrtutalfll lSe=|:tlon ‘I-ll. ;“"- it | | _- KICK STARTER

. . I " ' | %Fl1hlG
/-\-. Install the ftarter mntrrt l$||l:ti=H115lI-
-. Li '.\'
1n5ta|l the geurqhilt llnlteqe I5-eetiun Bl. '—
‘ F"I’_' . _ at
lnetell the clull-.h [5el.t1|1JI'I Bl-
lnstall the wlinder and pittrm lfiefrllflfl Fl- -t-.
|n:i:a|| ‘lhn |:\,|'llfl1:lEl'1‘|E1id |Sectlt:|n Bl. ‘:-
'-'iI5'l'1 -

lnsmll the engine (5uI.1li|1rI 51.

F‘ senses ‘L u '
nemtmee "
"
f"‘~.
i_

Date u-F lseue; Mae, 1950 103

EJHCII-IDA MUTDH Ct}, LTD.
10-11
-1
 HONnn ff
cm
MEMO

-\._

.1-‘H

.--t,

-F'_-L-

ma Date of Italic: M-Iv. 1!-lBl'J

-D HONDA MUTCIFI C-13.. LTD.
 /'1-ztomnnt
Ft
cm it i I F-EZ 2:Z15Z22---2H52
I,-.
ll‘

‘ SERVICE INFORMATION 11-1 CAM CHAIN TENSIDNER

1_|_1 PUSH HOD 11-2
TR DUB L EBHOUT I NG
CAM CHAIN TENSIONEFI 11-3
J__

SERVICE IHFIIIIIMTIIJN
G ENE HAL FNETHUCTION
if-.
F
The can |;hai|11;|trt.;i|;|nltl' nl|tI|'.£I1m1't rad can he sereibetl with the ungihfi in the heme-

T|i[ll.lBl.ESllB[lT|llB
F“ Elm uhlin flbltl
1 In-cu-:ru|:l tenelbner eeliuetment
2. Dame-aetl st:-ring
3_ \'1|'|'||'r| ur dan'|agE*d 1-1.It'Ol:|'t£|T
-ll. Wern or damaged chain

r-

1""

F-.

FF

.-'“
_ _ .___

Date u-f issue: Mme. I931]

TQHUNDA MOTOR CU-, L'|'|l'|.
‘"5 11-1
ti - _ -
 HDNDA K
CAM CHAIN TENSION EFI
R —i_ .3
cto i
.--.
--»,_
. |

CHM llllllll TEHSIIIIIER PIISH fill] . _

It .u-| ,3‘ h
", |.-
_|
..|| _‘
Drain the e--rg='t||t -;:|i|. | -'32‘. . :5: |_:_I

|-|-1I='**" T118 |-D-Eh HI-I1 and remul.-e the Ind; 11-|||_ _|'
l.-:3" -tag ‘W-
-r
|’4r=rne'-‘B the inflllnq he-It and wufl1rt-I,
RENO‘-rl the adjusting belt, spri-ngi and [en-|-inner '
“H.-___
.-"II-‘rIII. It I-t'=.I.—
1:
r
.-'1-""f‘l€(_t"'l:
1. ---,¢:~,. - I

rt:||.‘|. i._ Pi" '-"''\-.. :-'#53":

'\--\. '--* -' '_|;.'::"|‘|'
'-_:--.-"":"'
-' .- n
LIST -::I\.:\-i'| ':.;_:-.iH|:_:E-J‘__. i__
1"-__ .-' lll|
Chéflil lhn teneic-net md and -,-pm-|g rm 41;“.-|_mE_ AD-1 I-:-.; :1 F-F‘ 4‘ .'__.___-H ‘E - ' ~:
__ - is --=.__‘--0* >2-
t.~ .-' -._}-' ._
I1 ____I-I _-'.

, L
LUCK BOLT
i
SEALING BO LT LOOK NUT

Install the tuntiuner push |-ml with 1-he tap-er factnvg ' | .__\-E K
' I
_ ll -
' -.. '| ll
Incl: btt-It. I I F I’ '1‘-L 1+ |'|'

|
.
Illt
|
I
.
-
|
.;_..
.-._
-.‘_ _ _-
-|__?._H_‘I|-.\"'\-II
-F
.1 ' "' ": _.
' In xi--£9? LQCK f-H‘
|__ .-_.-.,_ -I,
._|_ .-:_|I— J |
':---,-:51: _,. BU L T I
-1 .'..:'- H I" | u- '~'+ _;=‘' I
T’.1" ,1!‘- '1-L |.'_-;l I.
.-"-Ll
ll
".\-_ _.- . __*-._I LOO K NUT
I
eus net: __.r"
I fl.’
I'.I 1;". __.-'— - _-
_.»-' . §_-__- w
____..I" l .-"' '- .__|-‘I-'._

.-"ff: I

-I‘ K‘

.--.---

lnttall thn anrlngt.

.-"'_"'t_
Straw adiueting bb!t ‘mm the |:npnlt¢|:-e
lflfitflll the maliraq Wi-l'i|'lPl and bolt.

NOTE
I The eeeiing bolt end must hm \'_:|J'I113|3‘[ T119 J7...
bflllurn -:1! the adjusting bolt. | '|

lnetall luck bolt and lock nut. -5., "- -_1_;_=:_-.-5;.-_.: _ ‘___..--ADJUSTING entt
Ttghien thtt luck nut,
T‘?
senutue - - ."'
BOLT -_Q
,

" |
|

' we
11-2 Date bf Issue. Hey, ‘IQBII
'@HOND.A. MOTOR C-U.;. LTD.
/__”_I-IONDA
tfg/=' C11] CAM CHAIN TEHSIDNEH

BAH UIIMII TEIISIUIIER

Remg-re the .A,O. -;]c:|'|r:|.~.|tI.-.-l and llywhe-El [5E|.tIur'-

H|rn\|.w=: '!".:: :.:l.a||.1t.' l:|‘t;ti|‘| t|u|dE_

Flernmra the stattur ch-:i=\ ::Ir~11u|!h-H.
F|t:1r||.|'.It: the 51Br1LEl sprockets and nhilm H: e rrnfl
Re-|1'lu'.|e lhe craltltlhaft CD-.|Br.

CHANPZSHAFT GOV E Fl

. . .. _.._... an-1|-1.-4-1-||-|-|

Fl_e|'|1|:|';n the: teltttlurlel push rc:-cl. i

Renlme the earn than tnlltmuul
C-|tIr;h, 1l"||t ||:|".5|l1l"t!l :'.|.llDt:|¢|!'. fill lfli‘-BI DI‘ l$l1Fl'lI1I=|E-

lmtullatie-n It the reverse nf |=:rntnrul.

NOTE _ _
Be sure to Install G-r-up: cm the erankeheft
c'cn--Jr it-rew |'lEl|HFr.

0-nfile TEHSIUNEH PUSH nee

[lite Q! |i'5.lJI!. Hay, 1QBO 1“? 1 1 _ 3

IEHCINEIA MCI-TOR EIU., LTD.
 HONDA
FHDHT WHEEUSUSFENSIDN BIB -'“~
.-:-"l.

‘Kl -I-bl

l‘\\“‘“-:E?=’_-='-""-'=:|-'=t-

e
'1-.r'='"‘
_ _-5 " - _ -"1

It
6.0 — 9.0 Item 5
I43 - as ft-lbl 1'

It ‘Y’! E-:'E'.il !¢-‘*3-

an — 3.0 lqrn-. ___

I14 - 22 h:-lhl
._fi.
I- KT
5
Q‘ '1?“
|
$111
, G2 _
B- — -G‘ Q
_____...- .

I13 — 1.3 *5-m _,--"""'HrQ I1‘

l4 - ID rt-ml
. ' _. -
‘-.—..
- _----
ll
“___
I .
h I.
‘gt.
_H F I
'. ,4‘-7':
__r- 11 . I

II - " I'I.I"_ -_ ' ,7;'.,

J
O

2.-=i._. erF
I

'I.- F-
. -1‘ | ‘I-51
| m Hd_,
_ __‘_—|_::I_'
J..--"'_ _\

3.0 - 4.11 ltu-m T'

t— *
I I
I21‘ — 291!-IIJI

'l.D — 2.0 kg-m 2.5 — 3.5 liq-In 2.0 —-1D kg-In "'"'h
I'I'—1¢IIt-Ihjl [15-25ft-lbll I1-I-221‘!-lb}

-‘T 5.
I

.,||

#_'_

1 2-D 1'3 Date ullnue: Ma-r,'lHlBEl u

@'HUHDA MUTCIFI C11. LTD.
 tarena.
B10 M hi I E5 'II==:2-' E5 11
110"?!
l./

SE R'Il"I OE IN FO RMATI ON
T R OUB LESHOOTI NE
H EAD LI GI-I T
12-1
12-2
12-3
12-3
HANDLEBAFI
FRONT WHEEL
FRONT SHOCK ABSORBER
FRONT FORIUSTEERING STEM
J 1Z——E
12

12-12
I2-1E
INST R U ME HTS

SEIIVIIJE IIIFIIIIIMTIIIII
GENERAL INSTRUCTIONS
- A jeelt or cl‘I‘I'|r;||1' mppurt it required to autleert Th: meter:-rein.
~ Flnute all nab-Iee arrd wires ptetrerltr [D396 ‘I-51-

TDU L5
Special
Pln 1|.1ann-er 0190!-0010000
Bail race t|:rnt;wet ITH-IIB-1150000 — M5310-1??-01774, U.5.A. Uni‘;

Ebmmen
Bearlng drhrer handle A DTTJB-IIIIDBEIJ — EITQ-45*-51104110
Bearinq driver outer, 31‘ it 35 mm DTHB-DIJIDICIJ _ ?g¢5_g3?mm
1 u
Bearing dtluer pilclt, TU mm 01715-0010100
Le-elt nut wrench, 25 rt 30 mm 01110-B33525?
EJ¢'|'.p11;Ifle'_\ |_15_r_ 1_-'1' in driue at 3 In [T5 mm! 071' 16-0620500 — cemmemlallv available

TO FIOU E VA LU E5
Sm;-ring ttl.‘El‘l't nut 5.0 — 9.0 Itq-rn ma -- as H-lhl
Harvdlebar eettlng nut 10 — 3-I1 IHJ-"1 I14 - 22 rt-rel
Steering Ir:-tilt I15 - ‘I.-3 Iifl-I’I'1 r 4 - ten-lul
Front axle nut 3-D - 4-I1‘ IIE-l"'I lee - 2e fl.-lbl
Frflrrt 51;,.1pttrtli|:|r5pI't'lII1I bult 1.0 — 1.0 R9-I1‘! l I-' -11Ilt-ll-11
Frunt :1-.|t|:|a=a|-iun stopper bell 10 — 3.0 It!-"1 11-: - :2 ft-lb]
Frcl-nt ehclclt rrhr-tlrber upper belt 2.5 - 3-5 F"!-"1 l1e- 2".if1lL'rI

Crete at Iesue: I|Ia\r.1BEl/0 In l ‘I 2-1

EHONDA. MOTOR CO.. LTD.

--
 I-Iontnn. -
F FIOHT WH EE LFBUSFE N5 ION C10 ' /"'1
-J

geelrleetloms
i ii _STAhlDAFI[J ' EERVIOE LIMIT
Wheel bearing play ‘ 0.03 mm [D-001 i-11
Frflnl wheel runcrut H£t|2I'I|;|I 2.0 mm 10.03 Inl
I
Axial , _;_ mm inl -'1"-. |
Fl’-unt umtle l'Ufl-lJLl'I. - i 0.2 mm I-0.01 inl
fI"='I'I1 bfftife rlnlrn I-D: _ 1010- 110.2 mm I-1.32 - I.-'34 in|' .
111 mm I4-I1-inI'
I:l'|21'T'lI IJI'BIi|?.'I|I'|il'lg1I1II|:Ir|'|55.5 3_9 _ .|_fl mm [g._'|5q'_ U155 in) g_|].mm wfia |n:|
Ftr.\|"rt shtrcit abtttrber !pti|'|_|i1 tree le_r|g'd1 ‘ 1te.a mm tee: my ‘IE-5.5 mnt [I152 ir|I
_ _E§He-Bn1j1qn__=|1n nlr-Ft‘! bughina El-I1 ; 13.96 - ta.ae mm [0,E-50 - 0.551 InI 13-55 mm 10.533 Itll .‘ \

; '51-ilipentlun rlrn-I piutrt mullet I.D. _ 14.00 - 14.10 rnm 10.551 — H.555 ll'1I' 14.1? l'nrn 10.570 InI G;
Shnelt Icrwer mfluflt buehing D,|:l, I-L95 _ -H53 mm IE|.Il'.I1 - C|_1‘I1'.2 lflll 11.51 mm Inl-
Shcrttit lewet mbunt miter l.lJ. 110:1 _ 11m mm 10.1?! — 11.1175 Irtll 12'.4l rnrn 10.11-HE inl I I‘-\.
g‘|

TIIIIIIBLESIIIIIITIIIE
Herd |te|rIn|
1- Biélflriflfl flflrn bearing aeliuetinu nut run tight
1 FlLlI1"|\' eteurlntt ITEII1 beer-inns
3. Damaged tteer.I|tr,| Hem bguringi
4. Ineufflelent tirtr presaure

Eileen tn eme tide er den net tredt etreiglrt r"""‘t.

1. Faulnr rlqht er left ahoelt ebeclrbe-.t
2. Bent Irtmt ferlt etm
El. B-a-nt frtt-n1 H1115: whee! lnatall-nu incbrreethr
U Frent wheel wobble
1. Oieterta-cl rim
2. Worn Trent wheel bearing:
3. Faulty tire
4. Axilt nut tightened prupethr
5. 1'r'clrn Irclnt suspenslun m-m I:t|,|5hir|g
E. Laure er bent lpeltes
-'-“*.+
Seft luepemlm-|
1. Weak shutit eI:l\le'rbur wring ./“ts
Stiff luepemiun
‘I. Lecil t:I e-reaae In 1-U!pE'l1lI-ilh errn buihirrea

Freni Iuneermnn nmile

1. 'I.'l‘crrn t-ulflentitm arm bushing:
2'. Damaged rub-uund stepper
3. I.lJIIl'iI? BIT-Erllill -l|!flBI.'.lI'IJB'I' Iagtgeqgfg
4. I-8I1|'€~n1‘ greaaa in msperteien inn h1g1-ring;
5. Lair-It tr! grease in tpeurlemeter gear I‘|¢||,|5[l1g

.---\_

1 2- 2 rfu Del: nf _I15|.t:: lfley, 1531]

emcrraur. eaten ed- ttcr.
 --'-%_HnNn1-L
.'
/ff“ C7 U F HUNT WHEE LJSUSPENSIUN
r__
|
HEIIILIHHT
REMOVAL a
F|El"|'|G‘|'|: the headlight muuntirl-:1 scrum.
D'|su:r.\|'|r|I::|:t thn |‘\|1.1|d|ig|1t 5'-'|r|: |:|J||r|ECn.H'1 and {E- _--I- " '_
.-"' _ ' .0-'."
i _p
. - ||_ ‘I!
rr-cw-5 tha HEHCH-—§P'-‘L
I

1""

JIM»
.-"""'

D I SASS E M B L"r";'.\'-'\SS E M B LY
SEALED BEAM FIIETAINING SCFIEW
Ham-we ms hur-mural and \'nr1|I:'-a1ar|iI.rstir\-[iscrnwa
frnm she |=m.
Hfl|'|1|;-‘Fl: lh-I: clip ,:|':rJ Imalud [mum |.ln|l |E|.zi:rl-Hg
\r:rmr-', and uaele-rJ beam unit
Assembly ls Thr- l'I'-W\?|"ii' ml disasaemulv Aln=r
_r""‘ as-sun-|ul\,'_ adjun the 'r=aa|:Hiqh: beam {page 3-1.51,

.|"""
r-|o|=uzc|n'rm. VERTICAL
|N5TR|.|H[|"5 ADJUSTING scnew _ADJu5‘I'|Mt'J scnew
HEMUVAL
F“ Hnmrwn rm: ||r'.l||.|.||gh1.

F‘|I‘:|1'lO'\'E 1he handlelzual m|:~.mt|n!: nu 15.

‘.-"

Data uf issucri May. 19-BU "1 1 2-3

EHDNDA MCITDFI CU, LTD.
 HONDA
FRONT wusztrsusremsrom Cm /IH.

RHISE 13!! I'li_l.l'Il_II[!tIi|‘ flfifi ||3r|1¢_y.l|: -iDBQfl|_';_!|||,g1u|-

5:L'|!i|'|g 5;]-"|'|'||'p,

Diiflflllrwcl thu $1III!E|CIC1lI1o¢t|.rt:ahl|1.

NOTE
DH not allow the nnulg rt-1;: 19 [an ||-||'q. 1-ha
5IEE'rIr;-g l|H.'1'l.

I-7"-Bl10l""IEfl'E lhl: =t1u-uni:-mete: and Irtr.It|;.it0r bulb -,1-|||,

DC|l'|l1Et:ttt-rs. --
Ffnm nus the 5pEEdufl1:1:r, -

SPEEDUMETEH CABLE SE I IING EFHING

Rum“ M bum BPEEEFOMETEFI Llfil-IT HIGH BEAM INCIIEJATDH

NOTE
If 1 replacement sulb LIt.r|=:1 nqt light, chad;
I1I1E| v-|r'ing '-:Jr t-1 |I'|nrr |;|r qpgn girguétl |_t|' fflr
Ink?-I1: cnnnn-:ti'.‘-nt-. F

INSTALLATION

I Install the spelt-:tc|mete| w|th the lelllrtg. I-|;|r|rt-g.

II1.-!ta'| TI‘||': rlnredlenpr.

TURN SIGNAL INDICATOR HEUTFIAL IHDICATUR -

_I-».,_\_
~.

_’I-I.

1 2-4 In Datanf luua: Ma'|r,19BD

I3 HCINIIIA MCIFDH £30., LTD.
 f HONDA
-1--
~$“Y>-Q
' H;,- cm FRONT wHEELmusPEmmum
___

I'|lII|]I.EBlII
REMOVAL
FIBFHC-‘|'! Ihe Il:.'r..I||g||1'
3 l

L?'ir-crtnn-':ttt the :;:|eed0It1e||:|-'-'r|~-mt. ‘

‘___ ___ ..-|-
i
_ I‘ I

-I ii

_.-'--. /I’! I
FM’-r\'r:'»'|.1 the I-pr-1 fli|r'I-l2IIEI\iIl EW.i=II'l r-.1t:|ur|t.-|'|g
1‘tCFI!'l'l'$.

.r"""

_,-"'“ TH RUTTLL CABLE END

D15-cu-nnF.-|:1 the TI'l-'|'.I‘IIIE liib-E term nflrl -*|Irt1I:|'.|-I the
rh-nttle gr-p.

_.-’

If‘-.

D:gtt:t|-I‘ I5.1:t||:: Hay, IHHD 11:

z-Human-. moron cc--. nu. 1 2'5
 HONDA
FHDN T WHE E LISUSPENSIDN "'\-.- .
"

H-2-|1|r.w|.' lllr lull I|n||uluI}.:n e.-'1.-|t|.I| ntuulll-ltgt-;|:lewL

l1nn1cv-.'e The "'Ii-'n:|r=-

"'IIr

l-"]|;|I'|'|-',:u,Irt H1r l||'r| r.||_;|||.si5.

Flemu-.-e the left t|r||:l-.

fiun-mum lh-.-. l'|itr||J|l:E|ul :11 |:|u|1r. rn;| Hutt
Ha|5|1 ';I't-5| h|'mt'I|uk.1:|| u|‘||JI u|‘|F:I|‘||'|1|IlI 'I"II'l WIf'l‘ll3 I‘Ulf' ‘lg
-=e-siee. ,_
_-'—I'\-
"1

Fle|11tw.-|- 1'“|r! 'i.lIH!E‘ljt'.2I|"l'l-E1Il!I' t-ettirh] in-ring -1r|ri$rJEEEl‘fl- " -_ T“--n"

r"1r_t1{1'

FI!|1|-:>'-Jr: tI'||.- l"HIH1I=|I}3I fl'iFrBI'l'|'lI'I‘g.'.

1!; . .
HANDLES-"».Fl FHIDUHTING NUT --'-

IHISTALIATIUN
.1-I-t
In':1.1|l 1'I1|t l1:|t gnp.

In':r.aI| the 5DCIEllZIG~Il'l£'iIBl -ntn 1"w ha.n|1lnhar with the

:t:t|II=g mrillg.

Clamp 1"-u w--rlrtq harnesses |"t|:- placn. -Ii;

I"‘|."|r-1 t'|'||1 hnr:-|.I|t1t;u1r nrl >11 I'1'||:ur|t ||r||I I::urI|1e1t‘|I [HE
ipeuclnmeter cab-‘e.
II'li1i|II 1I‘mI|urt1:||t:I::~ur |1'|I::|.|||t||1g |||.|.|,:.

TQHUI.-IE1 LU-3.U HQ-I11 I14-E2 H-"II

it ha.
ihitall the "l'IIl'lO1'i.
{'_ .
l "
1'
I
.1. I-
H Al‘-iUI.. EBAH MOUNTING NUT _

1 2-6 "II Ltateof Issue: Maw l5i*EllIl

1’-?Ill'lLIlhlD.|'t MOT-DH C11, LTD.
 _'_1_

HONDA
»- cm FHUNT WHEELISUSPENSIDH

‘.-'

THFICIITT LE CABLE El"-IIJ

lr|staI' the leh' hancrle her 5'--.'ite'r' rrluufltlng -acre--t-5. I
.-5-.t:;.|||,r gt ::.::|.- It: lI||.~ |hru|- ||: gr||-. alitlirlq !l.i|'IF|l'.-I!
Connect the throttle c=1l':-l-_- euzl te t-"-e thre1:'=e gnu.
.-
r

| I

IF
|

‘___

Jan
Fl ec
F. E55
Ptllgu I ft t;._ .. "|:|||tItt"-I1:||
lG"" . :;w|1t:|'| Idlllj '|‘-'I|I| t?'--
hn -.t|I||::u- r|g|;r_:*-',r.g|n|1 Il't';i1_JII thrt nw-tljh
1"

F’.-'

1|:-|

_I—.
‘F
D UST CO1; E Fl
I- I|1t|:|I.' lI1|; hr_-;||_1l||'r.1 ' I|;|,=q|_
' ' ‘IQ-3-I urIt.I uur|I1tt|:1 tI'.|'
spur.-rle-"121-.1-r -.r.r-I ee.
P-.d|u-.-". |I|rr1l* t' |';||‘.\-vfr-1|:-j |-_|l3-I. [page 3-El},

t,-5.!
J-

ee
_.F'

,
__.f ’ 1"
,- HUT

Dntcetar I|;.5|_m: |'|'|n\,-_ IQBD

F§lHClI'-IIIIFI -"||'ICI?DH CU, LTIJ.
‘I1
5 T T T 12-?
 HDNDA %\
I370 I 1"»-.
F HUNT WH E E LFSUSFENEIDN

'—'\.

FHUHTIHHHH
nemovet M-
name me lrent wheel off rhn gmuml W plamrq a
lu r.I|:|nr1 hl u|:lt- ut‘|t:IE|' the enl;|lntr-
F " -_. ._

fr’
r
.-'
_.-

' I-

Lut.'m:l1 the st:-as-dumtttnr mbln nut and remtw-B the Q _

inaetlla-mutter eehle.
‘Fliemnve the front brake atliusling nut itm-1 Elilnfllr ' H,
net-,1 1]-H; bruke |;:|I:|Iu tnnm the brake arm. //I

.-l-I-. || I
|

CABLE BRAKE ADJUSTING NUT .-"~.

Remove tree eq-ttnr pin and It:-nn:n the .1:-tlq nut, T

Remove the tmnt axle.
Hen‘-nun the !.'rnr=-t wheel.

,t'""‘t

AXLE NUT CD'I'I"EFI FIN

' .1

WHEEL BEARING INSPECTION

.-"“'-H
Cheek u\|n||uI lgturlng play by planing the wh-unl in a ' 4

truing mnu and eplnnlnq the wheat by hantt.

FIIrEpIi,(:|j: the bearing-trwitit new on-ea if they Ira nuiw
er have eltlteesiw play. | FLA?
SERVICE ILll'tllT: fl.D31t'tl'l'l IUJHI1 H11
.~""\

1 2-8 "5 Dleeef Ieeula: Hn\r,19-BI?

@HUNDe'\ HCITCIFI Ell, LTD
 . -’- IIQ1“II-H
B-ll] FRONT wneeuausretuateal

WHEEL BEAFIING REPLACEMENT

Flamtwa the seal.

Ham-nue the bigrlltgl and 1.'l-i!.I|'rat|': eullar ‘item the
huL|,
K5?‘-.

9 -
pea} SEAL

MI‘ II“ I'“"""" “M """“-" I BEARING nrtlveh HANDLE A - lIl?9iH»61'lDCllJU

Drift! lfl thtt right Lltl-ll'|l"tg brat. BE_A§|~,G DRtI||rER GU-|'E|:|__ 3;: I 35 mm
Pre-.et'thu diltlnce t:|:|llar lm lalIat|- BEARING DHWEH PILOT, la mm I T DI“ mm
r--I‘ Hate .
Be lh!FlI!l'l the lzfiattanca collar Ia I11 petition
. . -
liflluru lnlttulllng the Inf! Haring. ___-:-'__“'Z_

Dtlue In the left hearing.

Met; E -_ , \
.1 . 'I I I

it
* Drlva thlr blaring! aql-|ll'll'||'. _
1 Drlva the bearing intn ltlttaitlun, l'fllII.Il'l'§ Ii-ll‘!-! -' --' ' '
\ ehm; I1 [1 fully |g51;||d ind {I111 fill! lflilllil I-‘HI '
is facing nu t
lmtall the 1aal.

I I WHEEL IHSPEUHDN
C:-melt the ri'n'I rur|ut.ll! by planing the wheel in a
tluinq atancli. Spin tha When! rlulllllli and read Th! \
runelut using a tlial indlcetur. r‘ -
l . '
fr" senvtne LIMIT: It 9 _; _
RADIAL nut-luut-= Ln mm tttoe llll 1\ I.“
A:-tl.e.L BLINDUT: 2.1! mm ll'.\.l:la inl F, __ _ _ nl

FF
I
Data vi Issue: Maw, ‘I950. 1" 1 2-9
“@l+DNDA MUTUH CD“ LTD.
 HON D ‘
FRONT wneauaueaerusluru CHI I/"2
I-1

AH LE INEPECTIUN

5&1 the axle tn V bInr'.It‘: and mttrnure the ttrtanut.

The actual runcrut is I."2 t:-f the tntal -nclictater
r-earling,
Ii". I
aenvrce LIMIT: a.: mm lam an .' _"_. '
. ‘___ d__. fl

/.""‘* _
xi
I .-'
I-l-

BHAK.-E DRUM I.D. INSPECTION

Measure the hralte drum imicle diameter. ‘

SERVICE LIMIT: III mm MA I-111

___':i,_\__\_

‘
‘h
_r-

-.;l\
1?
ii

inn.

"'at I"-"I 1 ,
‘:.\‘=T"v—"-E;
i --/>l
—r_

I er-_
BHAKE LINING THICKNE55 INSPECTION

IIIBEUFE Ihl: IJIlI'll.l linlnu thtel-cnes:.. I’

#1.
SERVICE LIMIT: 2.0 mm [Elam ll'rI
"___.-‘;_~_,,.|-—_

ti" ' -. .
|l'|‘ ‘ f _"f- .1 '-.
.-, .'- I ,-
-- " I |
I | ' I.‘ _|'

ll.

.- I"
.

1 2-10 1“ Eheteul Intel. May, TQM

IEIHDNDA ll-IIJTCIH BU-. LTD.
F l§§;j_,.' 0% FHU-H T WHEELISUSPENSIDN
In BRAKE meter. DISASSEM HI."t"
. SPEEDUMETER GEAH
Herrteve the l:-ralee arm, In-:lit=attIr :=l=|Ir' =IH=!"E1I-lrl'l BRAKE p'9'IIIEI'
wring
' " ‘l SEAL
Flam-mtg the ljlrai-:9 5-hue-s nrrrl I1fiI:N.I1! t:u-n|.. LI:iI_|IF§ITD¥I ' j_ I

Ir -' Herr-.nue the sueeclnmeter gaar. - -I-I‘.-,-_' '

Fltlrhew th-tr wall. II‘ I‘ . I
€L_ *- .- .
cilfil -
5|
I

| I I -_ I‘ I‘ I

_,. t “~
' .. BRAKE cram I"-.lIt
t \ FE‘-T SE“ eemte er-lea.sI
‘ea M-IM seems
BRAKE .l'-‘IFIM

F‘

BRAKE PAN EL ASSEMBLY

Ag‘:-pl-,' -g*E.:|51L te the -ipeadclmeter [eta-r and lfllflflll 1l1I-* T
qaar
lrletall the seel

--' .-'-
SPEEDUNIEFEFI 'I'.IE.I'I.H EEIIIIL

SH-DE eenmes BHAKIE cm-1 -@

Apple grEa5E 1.; The elidmg mrlece elf thn hntlm eanl- ""--.._
lnetirll the brake cam.
Irhl-IBII the hralte eh-rm: and rite! 5lIll'lfi-l;l£-

fimramlmnzl-E-Ska l'|'ru'r-res reduw napping

]JD‘lR.!'I".
Keep greats ufi rirr fining;

SHAKE SI-IDES

Date of Ii:|.1.||:: May, IQHD

EIHDNDPI MDTDFI I35-I LID-
1‘5
‘I2-11
 Hanna.
FHDNT wH£ELrsusPEn|s|ou BTU -'"-"~
"—?'\.
BRAKE ARM PU NEH MARKS
I-rsflfll the felt usal-
lllmlll the wear i1'||:li|:a'm| plate.

fiEIE___ H
filiqn th-B indicator [rlhthe Ir1nr.\r tab wi-I11 the .4 5%,‘
l.'.!.I!D'L|t {JP this brakn |;|m_

In:-tali the |:||-‘aka efln and rmurn 1|'_Ir|ng,

FDTE
| Julian the r|ur".1:H rflurk;
1..
‘I
Tightr.-n rm: hn1J|:= rm hqn and |-\|_|1_ I

is-'~.,

INSTALLATION
SPEEDUMETE R C15-B LE AXLE NUT
lqstull 11--a hum mane-I b11h-we-n the furk legs.

NOTE
-1.
Mlilfl !|l.Il'I the ting an {hi |-jihf p;||p|q1';|q|-|
BFITI ll In-Izatad in the qrm-aw at mg huh‘
- Vi“ _
:""‘-1*,
lflltnll the a:-ela shaft In-um lhq right aid;
Tighten Ihu me rIu’r.
TDHDUE: 3.D—I.'B ill-I'll '|12—2B' H-IH
lfiilfllf I new cotter pin.
Burma-ct the frunt hraka an-cl Lp¢=c1|:mmmr.mb|g_;_
-'5L!3|,llJFtT|1Efl'-Dl1'|I lamina ipmgq 3-14}.

BRAKE CABLE Bil,-mi

HUT
1'"-"'
FIIUHT SHIICK ABSIIIIBER
HEMDVAL !“."“.\

Flemcruu aha ‘frunf. whaui inane 'l2~Bi-

Hu-nu_1u¢ lhn lrunl, 1|-mcl. mwrber and rebuunfl
i'u:|-pp-ar muuntlng bolts.-:1'n:l rluu,
Fhsmnvu lhu flancl-I: lhnafltnrs.

I-It-I"

1 2. 1 2 in Date of Luua: M-av, IQBD -

§1HI."JNDfi. MCITDFI C11, LTD-
 m lJ1\I'ID.-5.
BTU FFIDNT WHEELISUSPENSIDN

D'5'°‘55EMBL""' SUSPENSION AFIM EHUCK .A?'S0l=IE5EH

§=lmm_;|.-E the Imlmr 1hu|;|r. ubsprber mrnlflhrlg bflll __T |
and 5|r|‘|ur:||I|:' zhe -sui:-ur=.-iiI:|r' irrrfl Trflffl 11118 i|'I=J'-3“ ._
absnrhaf. -._ 3-_ '

_.-Ii

|¢_.
$- ____. 1-,. _-_. 1} -I" _-fllI ..\
_||l"

..r"-
_ F“?!-'
.

\-,-r.-.-.-
fi
-’-i-T-w‘F5.’-0-‘I

Fl-emu-an Wm dust cum and dilamrmhlc the :usbEfl-

‘i°" “F” DUST SEAL‘-5 BUSHING
\ must CAPS

\~ ‘I W
P .. @wfi@®'j
Q6‘ ' I
» ausnuwfi ‘

.1 GREASE FITTI .
SUSPENSION ARM N‘-
_i -i- til

EHDCK ABSORBER INSPECTION

FHEE LENGTH
Inspect the sh|:||:|-1 he-r|',' inl nil Ielli-t an -- --—;-
M-nz15u[|- |l1|= lreehr.~|1gl+| crf spr|rI|;|-
SERVICE LIMIT: 165-5 mm 16.52 in}

D t Hi: : h1ay,‘1BHD 121 — — _ I

EHHTZIDHDAHEADTDH 130., LTD. 1 2 1 3
 J-—'I-|
HONDA
FRONT WHEEL.-‘SUSPENSION ""‘

SUSPENSION ARM BUSHING NSFEGTIIJN AH“ FWD... SHOCK LOWER Mmmn.

“ERNIE tlw bushing nutilde |.tIume1;qr_

BE FIV ICE LIMIT:
SUSPENSION ARM PIVOT: 1155 mm IlI.533lnI' ..
SHOCK. LOW’-EH MDUNT1 11.51 H'll'Il IU.'l-'5? lr|I'
Maas.ur-nth: buuhlrq |1DI|Il' inside dtimsmr. --ii ' _ _ "'-._
ssmncs |.|m~r= ‘ "
SUBFENSIDH ARM FIVDT: 14.1-T mm {D510 In] -.3‘
SHOCK LOWER MOUNT: 11.41 II'lI"rI ID.-489 ITII

1""--..

.-\-.
|

ASSEMB LY
FE
Assemble the suspanason arm! EN
Pggn q.;||;'.". s;|,|5p|rnpi|;:|r| .|'|r||| p|u'fl'[ |2I1.|£II flip II'I l‘hI"Dl.'
plauaa as shown.

I'..-1-.,_

.IP-<.

SUEPENEIDH AH“ ."""‘\.

Il'l5I|Il|I the 5lJ5pE|'|i.irJ1‘| arm In the :|1r.:c;l:. ntasprbgr nnd
Iiqhlbfl filu I-In-It and nut.

'_“‘-.

SHOCK ABS-DH H-E H -

1 2-14 ‘H Dateuf Iuue: hI.a\r,19BIJ

ezwnouna MDT-DH cu, nu.
 if’;;§§*§‘~,IiDI\l'DJ\.
-""‘- BTU FFICINT WHEELISUSFENSIUN
-1

P I!"-ISTALL.ATIUN ARM PWQT

1. “"“' I
lnmnll |-hr: shack EIJ5GI'I2lI}‘-'$- /K
TORQUE:
LIPPEEFI MOUNT BDLT:
|,.»""‘ 2.5»-3.5 I1!-fit HI!-25 ft-lhI'
SUSPENSION ARM PIVOT HUT:
1.0-2-0 kg-m I7—1l fl-ll]
|:'|5t51I- thu rI!I.h'.:|u|1d stuppa-rs.
TDRDIJE1 2.fl—3.U hi-rt‘-I IIIIPZZ it-Ihl

re-.._ REBOUND STDFPEFI BCILT AND NUT

NDTE __ __ _ mi '_
PD|;|1i|;|n thn r|_:!:|nL|1'|lZI stepper ii shown. _]
_|I'

~Ill

neflouwu STDPFER
I
1""

F. Instalt the from whmal IDIBII ii-1?I' I“

I-.uhr|ci|-tr: rhn suaperlilflrl III11 Ifiwll :- _ %“
1' , _.
i I-
‘ .

I sr
'1 "--
|§- -‘iv 3 .’ gt
In
Y. 1 .- " = 4.‘
I |. '

P ‘I I, F ‘Ir

I 1 '

1,...‘ amuse FITTINGS-

|:>. r1 .=- Ma .1950 "3 _

EI1AT3|DHD:u:IUTEI?.H LTD. 12 15
 HONDA.
FFIDNT WHEE LISUSPENSIDN C70
FHDNT um-r=|-1 :_:mrE+;4__ . GAHHIEFI
.'
nE=-.1ew~ |_ Q \|\ if
FIEl'r||.:n'|: 1hr.\ F:u|'|dlBba|' {page I2-I:||.

Heme».-"e-the Ila‘.-|1| '.r.rI‘1r!nl ipggg 22-Bl.

U
...‘~.\
4- A

Herrtrwe '-I"-u ehuel-I: aI:-s-:-|'.:-er: Ipqgll 1? III.

Flum eve the ‘.-nvr i-::n.:Iu1.
Flernrrve the f|'|J|1I.1'.‘.-.|r|i1_!|,
FF"
Flem-m'|= I|1r' fr.-mt u|J::|er em-er. I
I
|
I
I
I
I
|
FHDHT FENUEH _._

DiIr.=e|1'1m:t the E'I‘|uI=.|! c.-|hI|_- ;-t :5-.5 ca. |J|Jrn|L1.'

Flertttlvr Hm cheie k|"_'Iti' ||'t1i:1§\ \;-|:r.5I\.r.| and Iernmm
the -"-heke ea IJ|r:.
4'.
REr1||.':-'.r|: the thrntllu. I.|ruIu: .|n-:1 1|;w|=_|E|:||;||'|-'||¢!|¢r |:.uhie-;_

I I-H‘

CHOICE CAB L E

_.d-I-..
FIen1r:wn rhr- ton IJr||Jqc rnn-..|nt|ng belts.

'_“-\-.

@>

12-16 "‘ Dame! Issue‘. Mm,-, 1950

EZIHOF-IDA F.-‘IDTOFI CEL, LTD.
/éfinomna
'\_/ C70 FRONT WHEEUSUSPENSIDH

Flame-we the eteefing stnrn nul. Lggqq Nu-y w|{£fl('_‘;|-|_ 15 3 3|] I|1z|1:
Humm-|_-. -rm: 1u1.| Lxidue. meunn nhd Ila|"IrJ|E'IJB| EXT_I§_I'-ISIDN HANDLE AND
Imvareever F

-liI_

Remove the Ieeernng a|:I]u'.itIr-9 nut.

H 1h_‘ ' R _ 6 ml PIN S1I='Ai'-II-IEH, 36 mm
h;|;neI-rn -1. rv.-I-nl ur ,u1.1per4:e-nelace nn s n n?gm_m1uDL:u
.- ER \l .

H‘ '“‘ x 1_ “*-.
e:~Q>l_ '~. r.'='r-._
___:“'_:,.':»'—' A “I '.'I-_'

-I“. "'1 ‘I ',

|l__I :'| 3| "'

LUWEH CUNE FIACE FIEPLACEMENT

Hem-we the In-.v.-er |:c-ne race, dust eeal and washer.

Inatall a new dart-t l\T.lil'| em] weehur. ‘
DI'l\|H-I B HHW ICI'\\'B'I' CGFIE -IBCE CIIWEI I'.I'l-El IITEIH.
_,_.

1'
II‘ 1
LDWEH cone RACE

D:_th'| 1.1-I Inue: Hay, ‘IQBD 125 _

BHUII-IDA MDTDR ED" LTD. 1 2 1 7
 .-*‘—' .
HONDA
FRONT wueetrsuseerrrsrerrr C70 ~
Ii ' _

er-'~r_|_ FIACE REPLACEMENT ?fg';‘é_P?”§§§D§F|5”;='2:”'¢§Q LV M931-I'.|-I I? ‘E-ll 77:1

"
HE!I‘I1iI"|‘! 1;lf‘|E =D'.i.iE|' Luirll l‘|]D!! with lhnr ;|'._:|;|gi.3| 1;gu.|_

_,__

Hrrmtr-'.rri the un|:rrrr hell rac-=- with the errmn tn-nl

NOTE
if the metcmzwele here been rriire-I'Ecl_in en—_]
nr:-::irlr:;|'|1, rrstnrnine the-r nrrre nruunrl ilhn steering
; head for -:rar:-Its. _ _ _.-Ii-\.
|

I'Jr-ire the u|IlDEl' ‘I:-ell race Into the iteeririq hrrnd with
the in-r:r:i.~rI 1uc_rls:.
Drive the Inwer bail race inte the steering hencl with
Il‘|e temr: Iuuls.

;-|-

.--\-.
Apply 3 eee: r.iT Iireerrreg green I:-::| the upper l:|i|-‘rl rage
Bi-1-d Ir'!r1.ei| Z1 |t|:<:I hallii.
Apple e truer crf hearing green Lu the 1:v¢-ertmll r.:|r,'.r| r
Ir-
and Inetell E1 nee-I tmtle.
in?-eri the steering item rntr: the steering heed em'.|
irtttuil thr: ripper l3Dl"‘=H race and beenrrg edluetirng
-—-.
rrut.

_‘._

1 2-1 B ‘E Date crf Issue: !i.rIe',r,1Q=B[I

$JI'l-DND.-A MUTUH CU-. LTD.
 HONDA
"“

I,-_
K7“ _ 0 FRONT WHEE LISUSPENSIDN

T“"“‘"'" "1" "'J"“"""=‘ "“‘ “"fi' “"5 “'*"""” 1"’

upper t:-:rne raee.
BE“-rtttt. rtmtrsrtue __
rttrr r=rr~r ETPAHHEII
,
urea:-trereetre
Then, Igqeteut rt 1.-re turn. -I . I/a

.t~‘
___. Clrech that tneie ti ne we-rertr-el rnrzhremerit rrr‘-rl that ' ' , , I
' 1h|_r stem |'i:_:-tr.tI'r:: ‘ltre-:!'.','. _ '' _ 1"‘ - - "

' - ' r ".

JP 11'
'| '- ".1.
i:_" . =t- \'I '_ E| II ','- ll "‘‘I
__- fr rl ~. r__r| _ I i,_ i-1| ,| |
. -L '-_ .. -.-,= I I

_r"'“"

tnttuil lllu handlebar lewtrr -never, mp nr-.r:Igu meunt! |_|'_}t:|{ t-.tt_;|T 'r,|.I‘HEHCH_ 26 :-t it} rnrn
are-LI tep Itrit-.I;|r.r. HM;
Tightull the eteurrnu stem nut.
TORQUE: H.D—-9.0 kl-I11 {il3—B'E H-lb]

III-.

In'»=1e|II 1+‘-u ‘tt:|| lr-rrtlge muurtl 12iD|'1t. \" ‘I... ‘ 3 I

\ -r
Fluute the up-eeclerrreter, crhnhrr and thrutlle 1-'-1|-lie!
lp-ettfl I-El.
F-

' lrrstull the Ir-zrnt upper i:.i.wiJr. firm! r-trrrrirr until lrflflt
I-rtrrdgrr,
lnllflll LITE fnlnwtn-g:
' Hunrilubm (tinge ti-El
- Frttint whrrr-I ||,-rqge I2-I2}
’__,__ - Headlight [page ‘I’? 3i

.-.-.

r:r -:r-fl ;r.r..reetr I-'5' _

eahhenftuhretge Ctl. ttn. 1 2 19
 Hnntnn. |r""_f§;e\.|
H EA H WHE E USUSPE NSIDN ."-"I

.- -K

{D — Ell kg-tn
129 — 36 ft-lb]

- _ ___ __ I

.11». . #931 /-”

t} --' "-El‘?-,
I- ___
:'—'~.
I

It‘ -Zr-. ‘A?-ili -. _.~*" if

:.tr-3.er= F ..i -- I I ‘ 1*-_~. I’-H‘

Pm ---"’ _

.. ' "Ii-'1" '"-.._ '

.-- - P‘ -. _ . - .

A " I‘//I
.1- ' .t ‘Tr -.
1! I’

1-0-2.0 he-in IN‘-J "‘-“K

li'—'t-lift-lbl

‘L.-I’ r’-7',
3.0 — 4.0 ltg-m
I22 — H ft-lh]

_. ,- .,_

1 3-0 m Date er Issue: rttw. teat:

errerreri-. meme ce.. tte.
 @"“t‘ti5”"‘ it GIJ I mfit: $2E5i'£=|= =l"'i=5
"“-..

[ ju SERVICE IN FORMATION ‘I3--1 DRIVEN FLANGE 13-?

trreuetesuoettrtre 12-2 st-tetzrt rteseneen 12-tn
E REAR wrreet 124 swrrueetem 13.12
l

SEIWIBE INFUIHATIUH
GENERAL INSTRUCTION
I A iitrlt ur ether ttrppurr In reqtrrrecl te supper! the motcrrctrele.

T DU L5
C-emmen _.
Béiitlng iI.ItI'.I-Er tun-Idle A U?T4B-IIJIIIIIDD — D'?91B-EIIIIDCIIIU
D?B45-‘DQBENFUU 3? l‘t1|'I'I
BEBFIW driver IJu[E'l'. 3? rt 4|} rnm
° T?““'"°‘°'"° _' urerreenntrocrtr,' 40 n1n'|
Heating rlrluer ptiet, I2 mm U??¢B-DQ407300
Bill-l'Il‘IQ driver nllctt, I? rr|r|1 0774518940100
She-t;|-r; trhuuttaer eempreuur 01955-31"9DClI|1

TOFIEILJE VALUES
Ftertr brake l|:t-ftitue lrrllit 1.r:r - 2.r;r rt;--1. t zr - 1-: rt-rtrr
Driveh flu-nga sleeve nut ¢.tr - e.tr Hg-fl'l t2e _.ee rt-rm
Fleur turtle rt-ut 4.0 -- E.IJ he-m tee - 2e rt-re:
Driven ip.r-zreltee 2.0 - 2.5 kg-m tr-t - rert-rel
Flt!-rtr ihrr-nk aheurher 211 - 3.11 he-m tr-r - 2211-Ital
Swingtr-rnt ptut-u ::r.r:r - 4.11 K9-n'| r22 - 2e rt-rut

SFECIFIEATIUNE
STANDARD serwrce t|r.r'r'T
Ruth iiJlI;UFIlItIJ-1I FL? rrirn 10.01 inl
Wheel t:|e|t:|hg pin- .j_1_-E-. III.D3 mm tlllillii |rr|r
Fiear whnnl runcrut Herein] .
2.0mm Ittee re)

i- tetra rt-.1
Axial ?_I'.ImrI1-
Fleflr l:rr-Ike ilrurri LD. I 1.5 - 110.2 mm 14.32 — 4.34 inl lit mm (r.t._t_t'Ir-rlr
Hear brake Iining thieltneet 3.B—4.£Irnm 10,15-—D.'IB|n| 2.0 mm [I105 irll
Fleer struck ulnurher spring free length E-‘1_9.3 mm In; I 1"ID.5 rnm teen rep — I

q'___._ _.__. ...

Date of Issue". Me-,-, IQIED "9 1 3- -g

WHUNDA HDTUR C11. LTD.
 _q_

HEAR WHEELISUSFENSIDN

TRUIIBLESIIUUTIHB
Dsmltlatlun
F. E.rrnt_ tim
Z, Wrfrtn rrerpr r.'rr1‘IE'r!I IIrE~iFIl'l-I3
3. Lr:-eee er i:rrrrr: epriirrre
4, F;1uI1‘-|r' titril
E. Lcrcrsa etrla
El, TI-rrr |1-ressur-Er rr'r£tJt='Bi3!
3'. Swingerni bushing '-r-rt'rr"-

Suit suspension
1. Weak muck trt:rsr:rrIeer sprlrrgs
2. Shock absorber leehnqfi

Harri atuperrslun
1. Hem r.lrr.rr:lr ulaenrber
2. Lack of grease irr swirrqarrtl |JLl11'iit=iflB H‘

Strrpenncrn neue
1. Sherri creee binding
2. Lu-use i'ertrrr~=rr
3. i.fr'r.rrn r.r.'tiir'rr]err1'i It.\;I55'r|nrr_:|=

.-"“i-.

-i-t

.~—i-t‘.

_|—\-_

-|_

3|}
1 3_2 1 Date r:t-f Iieeue: Maw. I950
EIIHDNDA MDTCIFI CD, LTD
 Hanna.
3"" HEAR WHEELISUSPENSIDN

-BRAKE DRIVF CHAIN-

El“ \'l'|'iE[|. AEIJLISTIING NUT
REMOVAL
HE'S-E [he I‘!-!|' wln:-1! n1I H1: gruurul Ir; pinning 1|
5-L||.||J|.1-rl L|||J|:|I. undclr lh-;'. mnrnrgynlg

Fiummrlz The :'B3|' brake adgusung nut and G|I~it0|‘|rv:|:1

H19 |Il|3|ICE IE-Ll fr|I||r| ||||: :11 [flue arm. —----in--_|

|JisI:-onnsct the brake torque link it-;.~m 1h: Drukie

panel.
Lnn-sr:"| thn driva c-hi'rI adjuaaing 1'|ul=_

BHAKF BRIWZE TDHUKJE LINK

qurfl-fa":-r lh|: culhir pin frnm 1h! rnnr mclu nut,

Flu-'r1-:~e the aaucie run and pull 0u1 fluzr axle

Hummn tho nlhuql.

J _.- ‘

.. _ 1 \._\""-
\“\"q.h_
~:
‘I-.:| ‘H I _' I .

CUTTER FIN MKLE HUT

AXLE |N5FECTTU'N

5513 '|li'1-'5 33¢|'!-'4 in "1' *!l|LhG5;S i1|.1 IEIU l|'m :|::.l|'. r\_|r|4;||_1L_ IHI

Tlw actual axle run-::-ul i; |."2 qr TIH Hma| 1

_.-.
lndicatm F|e:uJi|1g:|. J P.’-'_.-'

simflcz LIMIT: IJ.Z|'nm|lJ.flHnI 'qg_'-' if

_' I"; 1

I.{_—R
-“H

5.?»$9,»
/ J
___]

D12: ul |5-:-us: |'|kq\|r,1BH-D 13‘ 1 3_3

TEIHDNDA |'|-TUTOR CCL, LTD.
 :-Iomna.
REAR WHEEl.J5USPENSlD1'\| C70 J-

WHEEI. BEARING INSPECTION _ _

llhmgi-c '.r|11|!|_'|| |:e|:::I'|||g |;1la'|.' |.1',' |1 HCZIFIH the whael H 5 PLAY
|;'|_|ir||;| -51;3|'.{1 and spin [‘|||‘|!j 1h|_: w11r:|:| '.Jl|I' h:|r1|J. -
T-Iepl-ace the bearin-;|1 -with rwl.-v urI=.".- If thr.“.r n-"I! n-niw '
|:u -“LEM: :.~:=.¢:|'=:-me p-l;1',.- |
SEHVICE LIMIT-. n.n3mmi0.uu1in+ i

I-Q1
__

WHEE L BEARING HEPLACEMENT

BEARING
Hammwg mg |1e,1-'|n[_;'5 -Jn-.1 d|'=1r||||::1: collul l'rur|| THE
|'lL|lJ.
-q

‘In.

.1"-"\

1,

/'\_
. .-'“:

_ _.. _ _,__ I .--\._

|-‘mill; 1|“: l.|r:;:|||||='| w|ll'1|_;"|:ase
BEARING DRIVER HANDLE A - fl?El493f!1DflUD
I1ri\.-0 i"| 1'|'|-:\ I‘-ght hi:-:|r||1g ||'||. B-E.5|F||NG DH-|"|I'EH UUTEH- 3? - ""3 mm L-|?9i5_CflH_Du_Dfl
Pnm: 111: r.t|st.i|l|:e cellar I-“:1-J alum. HE’u‘H|N'D DRIVER P“-OT‘ 12 mm

more ‘
- Dril,-n kn-: hearing nquarfllyr, _.---' _ '-_-_ _ " _“
- Drive the bearing into r.I-:\si1in-I"-, rn--h~I1Q =ur= ,-*"'- __.--_-_:'-'-'--' ' _T_:_:-'
lha il -| fully seaaed and mat the seaiu-:t aid" ,._--¢.,,_._.—- ,-
'
|s facing uuf _ .-" __=-:j_ ",I_ - __--'_
L __-4-_.-__. __ __
.-' - '
I | -- ‘*-.-.
_ .___ Q .___‘, h."' I .-.-_.__
U,‘ ":3.-s'Z_|.._ __
_ _’.,_-. _ - _
"'|\_"'-.--"3 _'_7Jv
._ \ _ __.,__ _ _._
"- -~12.» - *

-|3_4 131 |].'|11J .1: |::ue |m~,»,1sso

HONDA mmor: r:c:., u n.
 /’ HONDA
s 0 FIEII-Fl WHEELISUSPENSIDN

WHEEL INSPECTION

EIhm:;_ um r.m rUr|L||J|. L1-,| placing the wheel Ln a /,*"' ’_____"f"-Kl

1:4-u:'|'|;-| 5-yang, Spin fhu wh|:e:| xluwly flr'I-Ll 1|!-nil 'l!‘1& ‘.-"
|-.muu'.us.-nua d|a| indiaatur. 3' __
.= _-,_H H
slzawce LIMIT: *’ -*».,_ g . ._\
an.nm4_ RIJNDLIT: 2.DI1'|n1'|'U-flB|II'l1' 3 _ , _f )
AXIAL Hum: u-r = an mm muainr
. - ~_ 3-H- I\-_,fsi
\ -.-,
.|| .
I i'£‘fi fi H
1.-' . .-
.1‘ I
|
TI
| I| *1 ‘ 1
'\_ 'x__ -‘

DNv1F'EFl FIUBBEFI INSPECTION

Heplann l|11e 1|!"-"1pu.l luhlrri If they ME dflmi-QB-d DI‘ -1 _

_.-
- .
d-ewri-:\ratu-rt I. ___-

__4— ' I

_..-_='

DAMPER

BRAKE DRUM |.D. INSPECTION

Measure :'='1E brskn drum irlsirlr: dinmrrhfl

SERVICE LIIMT: ‘I11 rnrn (4.11 inf

.-4"‘--_ __ E__
__.-;::-———-'_—_-_-

' <*"'T ‘H | I .~:i|=€!tn. L

'-. .

1"“
~
Elan: 1:1 I534: Mal,-,1QBO 133
E HUI"-IDA MDTUR CU, LTD.
1 3-5
 Hanna --

FIEAFI I|'IIHEELf5U$PEN$ICIN B70 _--\_

-1.

BRAKE LIHING THICKNEES INSPECTIUN

MI!flIJ.lrE li'|u hrahu lining thickneai,

EEHVICE LIMIT: 2.0 mm HLIJB inl -— .-

I
.— -1-I._

% .1’. ___‘: I ___ — \ ‘I _|'

-'

xiii;H Q; I J" E5

1-NI

BRAKE SHOE REPLACEMENT

BFIAKE CAM BHHKE ARM
Remuus the brake arm and Indicator |.1lnt=.
Fiumuw Eh! brake 5i1lIlE'i and brake cam.

,-"'5.

__‘
INDICA PLATE I

.*"-_
-5-Uni? grim-=: tr: thn iii-:iin|I mrfam oi the brake I:-am.
il1E1.l'I|i ihu brake shoes and shoe .'|{.'II'l|'I§5-.

Conlmwirwted .|'m':1i.'r I‘|'.r||Inp nature stopping

pa aw. ="""H
Heep gru.-me off rile Mk];

. '_'“\-
ll

SHOE svmmss same SHOES -'r

13" D-a:a of ism-Ir Miw, IEIBIII

1 3-6 E."HIEINDJ'I. MCITDF: 00., LTD.
 . =-ii” I-I(J1\TII.Il.
ii cm HEAR WHEELISUSPENSIDN
PUNCH MA FIIII.'5
Install the telt seal.
lmtnil the wear ir‘|t'.l:GiIt€|r Dli‘I.'B.

NOTE _ _
Align the Indicator plate inntrr tah with "H'-
|_w.r~1~* '-T" =t-."_L1'=#.e.m. J
Install rm trreire an'n.

f-ICITE
' Align the |.|uru:h merits. I

Tighten the hral-re arm belt and nut.

rnercmee r-tare BFIAKIE AHM

INSTA L L ATI ON
BRAKE nee AXLE HUT
Ir-retell the near wheel. '
Ir-Inert the re-er ercle and lrutell the axle nut,
lrrstnll the trreke terqu-e Iihlt end secure it with a
1'-aw c-rnruv pin.
TORQUE: 1.-l!I—2,fl ltg-In IT—1iI- ‘ft-lh-I "'I- 1- -..
[I|;||1ng|;r 1_I-1.5 ragr brake red tn tl'I|: tnhr Lrreke l-tI"l'I "
nn-;l |n:_r-!I||il the brake ediuitlrvg |'||Jt.
Lumen the sleeve nut end adjust drive chain slack
lpme 3- ‘I 1 I. Tighten ihe sieeve nut.
TORQUE: ll=.I}—5.0 kg-In I29-36 I-blhl
Tiqhte-n the axle nut urrrl ir-stirll a mrw I:-Ihtlnl pm-
TDRCIIJE: 4-0-5.0 It;-In {B-36 ft-Ihl I I
Tighten the |:lr|-re chain erljustinq nuts.
Adjust the rear hrnlie lent 3-iii.

IIRIIIEII FLMIGE LEFT SIDE COVER UPPER CHAIN C-11.55.

eemevnt
Remove the rear wheel {page I3-31.
Hnmrm the left aide :r:2nt|:t, drive sprocket never,
up;-:|r and lewer rlrwe -chain cu!-rrs.

‘I
J!

_ I
Fl I I I‘ l I E.‘

DRIVE SFRDIZKET COVER LCIWER CHJIIIN C-REE

Date ef Issue: May. I581] “E 1 3- 7

IEIHUNDA MDTCIR CCIE, LTD.
 1-Iontrna.
FIEAFI WHEEUSUEFENSION mu \__;

DFIl"I!'E CHAIN
Fiernoue the |:lrl1.'rr chain.
Rrtnoire the sleeve nut mo IIIIIIeII Ilursqe.
Qt
- It1
1*

Ie,:"

NUT o-I,
I
DRIVEN SPROCKET

' INSPECTION

REDIBEE Ht! sprucltet if worn, bent or I:leI"I1ug::i.

NOTE
ll '.hIe I:lrI'Ir=r| sprocket reI:|uIres rI,I|;|II;II;I|-IIrIq|-I;_ GOOD REPLACE l
5"tII'BflT Tl‘IE lIlFi'-1'8 eh-ain and drive sprocket
in-aesfi‘-III.
O >< .="\

__,J%§__§ EL

' REPLACEMENT
_l—ln.‘
S-'l1l'It§'l'l|l!l'l thn lock piate '|_1tsI. |‘l.l'1|’l my-II,I;II,I-II the
sprocket mouetlhg bolts,
Rt:-In ova the spr-cclret.
lnstslt e new sprocket, loci: otetes and bode,
-l'lQl'ITH'| the bDlt5 incl l:|er|-r.l the rock plate rehg.
against the bolt l1eIIItI_
TORQUE: 2.U—2.5 Itg-t'l"l 114-15 ft-lhil

—I.

13-B 135 Data cl‘ issue: May, ISBIII

DI-tOI‘-ILIA MOT-DH CD-,, LTD.
 I-ICI1\'Il'DB.
REAR WHEEUSUSPENSIDN

BEARING _tte.=1Intric
' INSPECTION

Check the IZII'l‘|‘IIF\ Flange bearing claw be srtlltninethe

bear-'|tg l:I-,1 hand. He-place the hearing with a new
rtnt; if it -I5 m:|l:i'y 4:|r l'I.:Il |:KEE!I1i\|'e 1llIl'|‘.

SERVICE LIMIT : D113 rrntt IlI.IIII‘t inl

- REPLACEMENT
BEARING DRIVER HANDLE A — CITBIIB-3lIIODl][.‘£|
FIIIIt-Inn-II tr-.II Ietel end l.tee.1-ino,
Peck the beating with grit-ttte.
Oritm lrI the bearing sottetew until it seats fulltr.
Install the seal.

BEARING I2lFIl"II'EFl ""“ }--- matte-aunareu

BEARING DRIVER PILOT. 1? mm

INSTALLATION

Q ‘:3?
Install the drttren tlenge and Ilenge sleeve.

NOTE
in ‘Ally: the Ilttu on the llct:'I'|: v.II.tl~I tr-Ie tII=lII lI'l
the swlngatm.

l|‘Is1,.:tll tlle lo'lt IIrl'I'e dtalrl tacliurttter atnrl slrurv-rt nut‘

Install the rear wheel [page I3-Till.
Ir-_ttIt.tl and ndl|.|.-It the drl-II: I:l~rII|It {page J-1 II,
Arllust thc rrrar hmlca [oage 3 14].
lrrstell the upper and lower chain case, I'.IlI"II'E'
i'DrO:El~tt:t cover ttrtd It:l'1 side prover,

SL E EVE NUT

Detect lesutt: Hey, 1950 13? 1 3_9

EIHONIJA MOTOR CO., LTD.
 ___ _._

I-ICIIUILB. r’ -I1.
_'\_fI"

REAR WHEELFSUSFENSION ctn -I.

SIIIIIIIII ABSIIIIIIEFI
REMOVAL

Rerrtrwt" '-'i"Ie unpe-* trod lower shock absorber‘ mount-

ihe I‘lI-IE5 Brtti l-tolls, and remove the slturtlc et;qI:IrbIgr-5,

'|_ ‘-‘I .-II

I-Ii-

-- - I

.—I._

DlSASSEI'I'IBL"r"
SHOE K ASSO RB E Fl COM P R ESSO R
Compress 1'1-B spl'l|1g lU.IT erto-tigh to ram-|;rtIo the Incl;
l'ILIl1.

I-IIICII-Bl'l Th-E loclt rhtt ant! remove tho upper" mI5It,r|t_

Dlsui.-;:-ttlrnlaln the unit, ./"Tn

LOCH NUT -.

SPRING FREE LENGTH INSPECTION

_. -I._

Measure the .tnrI|tgI tree length

SERVICE LIMIT: 210.5 n-Int lB.3iiIinI
Inspect zhe shock bode for oil leeks.

*1

lillgtlrm
__,

1 3. 1 0 133 Date of l|:I‘ut~: Inlay. 1950

i'£:'HU."IlI.ilI'7l-. NIUTDR CO-., LTD.
K_ C10 HEAR WHEELJSUSPENSIDM

ASSEMBLY

Inmn the s|J=ring with the light mu at lh-c mp. *f'?!-<_a~_..»gJmd__

' .| ll Ii"-
____._- nmwen

LDIEK uur 1.5-2.5 kg-m

W»
'
:11-1a 1'1-|n| RE
III |
“-STCJPPEH RUBBER
LCIWEH M0ur~|T-""'J ' ‘"@.=..,

Agpiy 3l|;||:|ci|'1l agent m1he1|:|ck nut and initall It.

Tighten thzrlnck nut. -’i~
|.-":_;-,
-r

'-\-. . .'
*1_»
»‘*-
' . .-" .|
u. .-

I J_/ 3| ..
= :'=

swocx ABSORBER '--if

COMPRESSOR H“ =-

INBTP-LLAT1DN

Tight-an thn shack absorber bull: Irlfl huts-

TDFIDLIE: i'_.l]—_3.D Iii-rn I14-22 H-lb!
'ER1r:-ck shock -lbiurhur upnerltlcun after |ns’r.i1li‘l:io|1.

u r n = Ma JBBG 135 _
@aH::5~:u5:l:|uTc:'n 00.. rru 13 1 1
 HONDA.
HEAR WH E E L.|"5USPEN51DN cm 1
QHMHWM PFVDT HLIT
HEMDVAL

F|1rr11m'r: rhu mufflar ipge E-21.

Ham-wt 111: nmr Whccl {page 13-3|,
HI q,, __.
Home-'5 the dnueu 1lang-e1|:rag!.= 13- 1'1.
Rumrn-n thu shu-ck absorber: (page 13-113].
REMOVE UM! I-_'|1 lntkinq wut and nivut bu-11. Flernnm:
11'"! nvingarm. ":-

'_‘\

.'-\.‘

INSPECTION
PWDT BUSHINES
FHSIJEI-‘I lhfl PH-‘I11 buflfii-H95 and hult Fur axcasaive
VIEIH. Flnplnnr if =|u|:Bn-ar\.r.
DrFUEt|1B bushing; |l'|T:r 1111;: with n iufi; hlmmflq,

MUTE:
I M3115‘ ILITI T115-I Eh! 1211.-llhlngi qr1| nu]; |j3|1'|5q¢.|;|L J r3
1!1lpB\'.'T the 1:‘.-|'|:|n gultln fur wuar,

PIVOT BDLT :I'\

INSTALLATIUN

Insult mu swlngarm -ltd pl-.rn1 bull,

Install 1hr- rnulflar hrankat aid pivot se|f'1n-ultinq
nl-II.
TORQUE: 2.5-3.5 kg-In 118-25 f1-1h]
1r:I’ql| the muck abuurrhnri lung: 13-111.
lrutall the driven flange [pipe 13-BI1. »r"-
lflstull thn rlzlr wheel [mp 13-7|.
Install The |'r'|u!f|1:r,

“'-|

13-12 Da.I'euf |5.5u:: Hay, 1551]

EIHUNDH. MUTDH C-I1, LTD.
 I-Iuntna.
-" A ,1 C70
.1-" MEMO

If”

‘pk

F“

1-'-.

1"-“

{...

|""‘

Dare of Issuer H-Mr, 1933 1'"

QQJHDHD-'1 MDTUR 1:13., |TD.
 HONDA
BATTERYIGHARGIHG SYSTEM »._

LIGHTING SWITCH

1* _.- MAIN FUSE

--
,. _.- —_-_—

_,'_‘.
___-I‘ ‘-:-__

.-I I I *"'"E" -
1 I—l.- '_| '|
r"""= I//,/“
.- t,
.-"- -

——— .-"_-
' ... 1’ 11”“
__/1 ‘-- —nm"ren~r
.-"
.-"-
----'—
1' 5-
“ =‘:""“-— IGNITION con.
IGNITION
.- _. - ;
Q;' '
,-
__.1' I’;
‘2
.-1:?‘
A.|:_ GENERATOR
swncn '~ - ‘*-

:_.<_ -
Z I
.-
_ |
:é-4::
I‘*1 “I-
‘___

.1-'f~:-_
.»’=2!-. ..». -
' -gt-~.,=>.
-.' |'“ -if-.'."»-"Ir-'----f=' :1
|;;I.::_ =-;'. -
| H :_, _'. ' __.
II || _'_,l| H -1 |

Ill III‘? II“. II ' '-

.
_
I\.' L

K ‘*»:.;~__]§ F
/4»
vi

um ‘HQ

'|4...Q "43 Diteoflssua nm,1nan

@~HoHuA Moron no LTD
 am: Y CHARGING
1‘
-I-1.
14. svstt /
F.

SE Fl VIC-E INFCIHMATI ON 14- 1 CHARGING SYSTEM 14-4

TFI DUB LESHUCITI N G 14-2 All. GENERATOR 14-5
BATTERY 14-3 RECTI FIEFI 14-S
| a'—

SEIWIIIE IIIFIIIIIMTIIIII
GENERAL INSTRUCTIONS
P Buttery 1'-1ui|‘I lmrul ihnulrl he 1:I‘|l:¢:1cflr.I rkgullrlyr. FIII l|'n1ltd|:tI|led water only.

F ' Quick clmrue the blttenr only m art e.-rm-rgenw. Slm'I'-charging is |.'|rI:fe|rr|':-1:|. Remove the battery Irum the moturcnrula fur
cltarginp. If the battery l'11lJ:1. he chained en the motorcycle, diam-nnect the huttnflr -I:ul1|E=-

I1" bum-qt gprtrmna .lI_|n-.fr|-Jp-pr 34:1 |-l.\l|:£rJ: mm be hlgilly e,\',|':l'u-,\II-e, flu nut‘ maul: or allow flnmn or iparkt near the
bafleqv, expeefalfy w|I|Fl'e charging fl'.

- All churning 5‘g'i1lIl'1‘l uamrrunlrntt can be tmud nn rhu rflutflrflynld.

TUE! LS
5|-'m1:|nl
Flvvfltflfll Hold“ W922-1190000, LI.5.A. unw use cummercialw
available hand strut‘- lrnrflflfllt
K" En-mmnn
Flomr Puller UTF33-flE|1'0EH]1 - Fliemevirm halt, 91113-IE-HEB-DUO

TU H D U E V A LU E
Generitur rotor-‘flywheel hnli 5.5 - 5.5 liq-m :40 _ -11 mul-

SPECIFICATIONS
f-‘I Bmmn; Bppqelw EV 1 1 AH
Specific qra\rit1,'_ 1.250 - 1-2euI2e“B I:BB“Fl
Bl-|||-ging rate 1.-1 iumzvzma minimum
P.
-151,13. gflrtnrutur Capacity {DOD rpm I 5,0511‘ mm
'l"""""'lPll"l '°“' “""" °"' ' rte A l‘l'llI'|. i 2.3 A mu. '
Fte1|1IIE-ar tyne i Slllcnn cllocle I
l
{.___

J;-—.

l""'*
Date ul‘ l:;|e: May, I5-Bl] "3 — 1 4- ‘I
QHDNDA MDTCIFI CU-. LTD-
 I-IONDA I-‘ft-§;'£;'3.1\~|
BATTE HYICHAHG I HG S vstem CHI /,»_,~..
_I

TIIIIIIBLESIIIHITIHB 1

Nu puwer — in-v ntrned mt

1- Heed hatterv
— LI-M‘ Iluirl level
— Luw 2|:|euil'l|; gravity
— Charging system Til-||.lr~e
1'. IJ-islcunnactad L1-attuw lT.DII_1Ifl
3. Il.'1Bl|'l Ium: hurngd nu:
-11- Faulty innltic-|| nvltuh
Lmll pnvvlr — key tu-med an
1. Wt-.ak hatter-.-'
— Ll1‘l'|'\|'fIuIt.1 |:w,:|
— Lu‘-'-‘ spI.I1:Efit: gravity
— Charging wttew I;1iIL|r1:
2. Lu-use hatter-,' ennneqiun
Lu-w power — engine running _. -=1
'1
1. I:l-nttnrv under|:l'|nr-ged
LD'Wf1L|I|;I Iflvel
— D119 ur rnq-re in‘-ggd Q3-llg
2- Chm-ging system f-BIII.|.[|:
Intermittent power
1'. Lee-we Iinttvnr izcrnnecliun
1*. Luuse chargllig :.1;:re|-n. qunntnuflun
3- 1-DH-SE !1|rtin|; svstem -EOi|\llE‘\':IItJ|1
‘I. Lnnse nunnactiurt qr phu.-1 i;i reuit In lgmI.lr;m fl'|1'g|T| ."""'“'~..
Bhnrllnq nuum hiluru
1- I-DDBB. IJI‘-fll<Er‘|_ or ahurtotl wire or Cflhltectid-n
9- Rflfitifévr faulty
3. -'5-_C_ qunerqtuv |'p|.|||'\I'

.»—\_

.1-"ft,

"H

1-1‘

14-2 *'" Date u-I lzsuec May, ‘I9-BU

*-‘EJHDNDA MDTOH C.£I.'l._, LTD.
 I-Inntnnt
C70 em-re HWCHAHGING svsrsm

ISHDUNIJ C.|"|ElLE POSITIVE CABLE

HEMUVFIL

I"ir.'n-I'M! thl: -"i-;|ht side ::t:'ver.

Dis-Guritieirl lh-_- gr uu|v.1- |.;||l:il|: ul 1I1r.I If.l1l'I‘1l:.
Discnnnuct the nos!-titre cable at the batten,-.
HE|1!||Il'.r~:-: 11'|r- I.u|1lrr-r‘-|r hnlrir_Ir pimp bolt,
Remove the Luntia-|~,-.

1'_—-'
PLIRTE

TESTING SPECIFIC GRAVITY

TE:1e|1|:I'| |.‘z:II w'.!I1 :1 I1'\vrIrq|T|qtt':r ,

SPECIFIC clmwrrv;
:20’; e-a”Fl
__
we-we -fvvWWfl.__ t Ige
Beimv I-250 1..i |'||:lert:he|‘ger_t ' J,-'
| .
____
IR-UT E
\
"L -TPHI barterv rnu1.1 be rggttarqgd |r -J“ ,pm;|f,c TI
Uri‘-'|I'v it I-1llID'J'v 1.230,
' TI'Ifl SEIGCIEIC |]r|ivi'l',' uariui with '|,|'|g 1:fl|T|pu|'a- /-’
_.r"
‘\-

\\
‘Y
luru as ahuwn In the table
. /,1’ I \
H9919“ II" hattvrv II ml"-Itir:-n is evident cu-
I "1" 517535‘ 5'9-'1-I‘-'-' "1" DB" DI-E|IE= il Iillud with HYDHDl'l|1I:'TEH ELECTHULYTE l
wrtiment.

The lIM‘l'.l'| *\"_1-' I.“-ml.-i=li~}l».'}ilT1uG-T-'fi_i

lmrd mmurr W-l'l"II thin, r-vrs er :-i'u-n'u'e;
I-In.r|in'r.rtr.' I"|'u:|'| nalrir I1-til‘!-‘I-fl‘.l'I11' get prump: I EAT‘i'EFI‘1" TEMPERATURE vi SPEBIFIIC GRAVITY
rrredfen-I atrermrm. 1:‘ILI'J'| EH“
""4-_
-23.?
.;_-:.-_,-;_-_r--..._'.-.\ _ ._
'“%$mfi$E§fij.
I-I---_‘__-E .;___-Ii: --_|:l.::_,1..'l;~ _:;__..__._-;,;»-___H__-I-'1']
ll 21-: ‘*~'-'r:_r,¢-.-T" $31."-':~'=.':;-‘i-:15331111-.,%::~ii=
- '
l 2l;vIi| I var "*-1 ' >5";-‘~35 -

ECIGGHAVT"|"
F
I I-1-I1
1 QED ‘=1’ 7:
...g 1 2:?”-
u I-'. -11-:I ti-3:}

SP

4: "~-fi!l- mcfirn zniaul auiaél q;.IiT

ELECTHDLYTE TEMPEFIATUHE 'C |"'FI

Dates-f Issue: May, ISBD "5

-D HUI‘-IDA moron t':i:a.. LTD. 14-3
 HONDA
aerrzewtzuaaema svstem C71] - H"-I

.1 _""“‘I. .

BATTERY CHAFIGI NG

Flam-ave tha battery t:ali1:at:-5. "

Cgnnggt 1-itu charger ptrlitilre [+1 tlflblfl lit.) lh-ll
Q,‘ I 1',
I’ all
battery p-ositi've'I+I terminal. ‘_‘_-.-.-

__, _
Connturt tho charger I1-|:l5!1I'-'= I—I ah]-‘lie I0 IHE
battew negative I-1 terminal.

CHIRFIGING IIUFIYFIEHTE 1.4iT'I\1II1'Ill‘l'liIl'~-

Chargq 111: battery until 5'|JEI,1Il!lI gravity II

1.260-1-2en at 2u“+: [El-B“Fi Ir -1

ea “T
- B-r_fiw are-T:E§'}.iT at. '
rap from-eoeh eeI'I'.
- Keep _|'Ivma.: and spark: vwuy from o I
I
.1.-I-.
I
I
¢'Jta1rgt'rtg.I|orrer_}'.
' 'I"|mv pallwr I‘.'-IN,"U.F'F or l‘-Itr it-Ileqmr. not
or eke balmy l'erm|‘mrI.t.
- Hmvntmur chvqihg 1')’ the ekvrrvlyte 1950 I991
\ ,
ternpemtmwa exeeedk 45°['|‘.|'I.i':'.F'II. " t It u I | u ll
FIFIIJI II Hill IELIII
1
CAQTIDN: _ ' _ _
Qu:'c.I:-clterigtog tFtrmr.|'d only be drmr In rm I -*_ -" __ ,»-
I en1i;!;_gE.»:;:*_|.-'_';l1't'v\-ti-|eI1nr.r'g:I_.t.i,§' 1': preferred‘. I

I'M-ter inmililng the battery, coat the tE‘I'I'I'1lI'I-BII» with

oiean gra-eea before oon nuoting the battery nublne -' n EJ9-
n -. - Lela
antmta - “I Q; '-L-:»'l_’=.‘1_"'¢
CAUTION!
| Route the breather lube rn lilrrwrl rm Th;
' I
_ -=- "§:i'f._;'fiC
53.3--_ -
_ T" 3--E
'_-.-;-,=‘-I
urstnr ms amm '|
* 22:12::
1.

_-better? eaunbri §1'

=’-Q1.5
a~;q,“'~;_
- '€TJ

IIIIIIIBIIIB STSTEII _v""|

I DUTF UT TEST
Winn up 1;I'1|;| eregine 1:|||'It'1r-E 118111115] l‘QidIl'!I§i.
r""*-.
Check charging witam output with n irultrhller Md I
en'n'net=:|r _ _

HDT_E _ _ b
| Uqa ;| lolly eltarge-cl batearv to chat-k the 1 I _
nhirqlng system -outpuL

TECHNICAL DATA: '

I!
ii!
J

1»-I
| -!"""*-
. .-

_rv:A|M svmcl-I _ orv E E.

FUSE
LIGHTING swrrol-| ON [Low beami |_| -
_ INITIAL CHARGING 1,550 rpm mix. .--.._I
_ at 4,000 rpm 119 arnperae min.
AT 3.1300 rpm ' 2.3
_ vo-its max. ~—._

|I$—

14-4 1'15 Datarof 1|-tub: May. 153311

EIHUHDA MUTDFI C0-I LTD.

j-Pi - - —
 1'"
HON
nee
,3 CHI eattaewcnaeomo svsrem
.-""'"
n.c. statnntnn _ -l‘-\..C. GENEFIATDH CUUPLEH

STATDFI HEMUVIIL '*.

H1:rr|-mm the gear 5hYIl pt;-d,-ti. _ | _.

I:I£t'I'|t'WI': IIII’: |‘2It|'|l'tt 54.'|l'i'.‘I|.‘-II.EI 11t‘l'|E1.

U|a|::onr'-not 1T|E AC. generator oottoler

FI|!|'|'|m'|'- lhn |o:_:=nl|t|:1 |'t-::||!1! t-,u‘|'|:r -::|.|ni..1|:| I:|||.1ttil.t.'r ' "PT T
be-ie oiate and spark advanter Ioaoa 15--1-I. j—-

’_.
Di:-t:nnr:-F:|:1 |It|: rv:u|r||| |wm:h 'J.|l.'u at the :‘|\'ll|.'Il.

Fler-nova the left t'ar.'-ltcasa cover

IELQ!
I‘

/’
LEFT CHQNKCASE CDVEFI UFIIVE SPHDCKET COVER

F'lnrn-wt: lite twu =tvto- tent-vv!-_ Wite prGliI:IC1IfII' ilflll

nttttu: Ir-:||1'| 1’n|;| I|tf1 ttrnltll.-::nr:e Cover. "'~._~

{___

I‘-H

STATCIFI CUIL CI:-INTINUTT TEST

{F-H
:-‘IICITE
'1' I5 I151: I1ECIEESEF'||' 11:‘ |'U."I'ICI"l|'|| TI"'I|I lI'I'lr|'-1| HI?‘ I
mnbn thin !1::.l._

Cheek |1D|'|IIf1uiIu' between the vellow, white, hlauki

'|'|'I'|il:|1 '.|:.;||-I»: and -itator grnunrl vv-1h an rtlttnmittet on
I-'-=. the Fl:-t'I scale. Rear-ace the stator if therrr is rm-
mntinuirv.

I(
r’

r‘ -.

om of Issue" Mav,1ElE!{l 147

ianorvu.-=1 moron co. |_"ro. 14 5
 HONDA I, .',5==
BATTEH"r'.-‘CHARGING strstem I270 ‘

GENEFIATIDR FIDTDH

' REMOVAL
Use the fl-.-"wheel holeet or ba-nd strep holder and
L|Iu|:I=. LII-_r Iiy-wletel tu meuertl lI|e t:turt1tfl'ta1l Hum
turning

FIe='n ove the geneiatar iotor bolt.

$5

FLVWHEEL ITBDDDD -.
U.I:-i.|l"II. ill?‘-lL"r" USE‘ CDI|.1I'v|EHfl|_At_I_"r'
AVAILABLE BAND STFIAP WFIEHICH

Flam-we the generator auto-.

"“‘\

HCITUR FULLER DFI .-.,

- U.5.A or-1|_\'. HEMDVING BOLT
- INSTALLATION 9°°l535°*3'"‘°
—I.
Align the rote! ltaw.-av 1n'l‘III'l the key on the eran'lt- I‘
qhqtr pr-.|-I inrtali the gt:-nenalnr rotor

___
‘\-

' >3 -|,|-911: _‘

GENEHQTUH FIUTDFI —._

1 4-6 “'3 Ltate of Issue: Mei. 1531]

'33 HUNDIA MDTCIH CCL, LTD.
j
 _"'-'_|\ HDNDB.
."" \.__/' BATEEFIYIGHAHGING SYSTEM

Ir‘ T |[_!'\7|:|'| the [|r:rI.t:r5|t|;ir rn-ttir Itnlt

TCIFI E11-IE1 5.5-8.5 ice-m 110-4? it-lbi

Ira F|_‘r"i1i'l-lEE|_ HEILDEFI 0353211-1TQtZlJD CIH

IJ.S..¢\. DNLY — CUMMEFICIALLY A1i'AlLAEILE
sratoe INSTALLATION B-“NU STRAP "IRENE"
In-trail the stator
|"loi|i’r.~ the gnr'er:ttor IF.!-'lGI'i orooorit,-'.

Connect thu I‘IULJI'.-‘III 1'-‘vit|:h load

lretali the iett ci.:iii-tizese c-ova.-, riiive apioeltet oovar
if“ and qE=|‘|I"iI1I‘I‘1 oeclal.
Corlhect the gttoerator wire t;r,tu |'lI11l'.
lrtttiil the right i:ti|'|I-c-::I:e cover, rmmegh-“fin
iliiirt-if:I mid ItIii:_:$€ !l'|J|'I'f!l' pt:'|'I.1I

Flli the crankcase with the reoommentieti oil {page

-llrljtiat the -tr-i ti on tirrii-'i|] ipatte 3-Bi.

r"'~»

F“

F.

r"'
||l"_"~i

Date t:-I |5$u|.-.1 May, IIIHIJ — 1'19 1 4- T

5:'HDI'IDPi. MCITUFI CU , LTD
 HONDA
BATTE RWGHAHGING SYSTEM cm
RECTIFIER HELTIIIFIEH
REMOVAL
H-=mrI'-"H 1""-E Tight iIE|E cnvm,
r':F.‘\'Fl DYE I?‘-.2 recl"rlir'r

INSPECTION

'3'-ack 1|1e |'m::51|e| [u- |_-un|inu||-,- i1ntwm':|'| the

term||'|als. Rewrzrzm 1hr; lrrads and nhgck again,
Cr;-n1i-1|:-W sh:-uld amsr m une |'.|irP_q:1i¢:-11 |1|1l\-
F"h:ulu|:u 1’r'-n rnntifler |’r there Is |:=on1|nu-Ly" in 1m1|1
dirucllu-":1.

J-I...‘

\.

1 4-3 15'] Dare of Inue: Mw, 1950

E51!-IUNDA MDTDFI ED. ITFJ.
F-
1"“ Haw“ GYLINDEHIFISTDN

MEMCI

‘|__

F.

, _-\. .
I

F“

F1
.-

F“

r"-

Date of I55-us" Maw, 1580 T51

vi: HONDA MOTOR CU, LTD.
 Hanna
IGNITION S"f'STEM cm ~
.' ¢,

_u-I-.
I

u,;g_- ~
_
§.,+_\-»-.--,-* __LT;»
I-a_>»----
I"-**-“‘».'-5-."-| BATTER? __~
I || r || I I I I |
.5",-
,.
‘_.- #5 |~:m|110n|
.-F.. -0-' ‘\- |" SWITCH _._-- -
_.;.~'=’ T“?-"T. ¢."~=‘~=—,-..F.‘
I _ __ - -\_"\-\.
I_1-__
|'—-I-_- n-':\_ _:--F _ _ __.-

= -I II 1
-I.
-. J-
—I-
I '|'I' || I L ._-2

%_.-;-
|_,_-|. _,_-n. _-_|— —'Pr ,_
.___--_"]"
.| _. -__,__

. R I r Tux‘

--4.-1- -I " J,/"nsc'rsnen

' SILICON ___
_\__-_—.\."-

"=_Tr:‘-—l—==-—_—L1-'-:I"| -‘ll- " I‘-l

_,_ -.-1'- ..n""'/-F
I
-H"'I'-I. "|L|
,,.- ""'-I’ _ _ ____\<1T_____4' R | .'_"\'
,'_,.__IGHlTlCIN
E’
'2' " COIL
-_ /____:RI:
RF, " hu."-av .I 31.;
i
.-‘ --. _.
.-""’- E--J--'.'l_:,_'— -2:4;
T-‘I'M
'- .' - "IQ. ., | ".-II: - -'_ |
. "
- -
I.
.-' | I- I‘. III". .1’, III I E‘-._ I.‘-u In I "I I -I I r-. II‘-I‘ I -II: -_ PC" HTS
5"‘ . ‘w |_ I
I
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‘I-
J.-—I-
ll.
--1;.

I
A.-C. GENE H ATDFI

III
SPARK
PLUG

ENGINE ETD? e"'\|,

.III.G. GEHERIITDH IGNITION SWITCH SWITCH

nar-||1'|u:u
mu. ET‘---5_
. . I 'l| RECTIFIER

I ;
- I/E
Ci 5 I I I =__/ BJITTEFW -P“-H

SFHFIIII PLU G-“I

i.-- $3 e
FIIIIIIEIII I
0-‘-it ,"_~
I

..»—|..
GDHDENSEFI POINTE-

15-0 ‘H USED-I Issue May IQSIIF -= . .

'1'-‘HONDA MCITCIFI Ell, LTD.
 /' HONDA
I
,-
@J can i5.IGNITIIIN SYSTEM
fI'“'-.

SE RV ICE IN FDFIIIIIIII-TI ON I5-1 CONTACT BFIEAIIIEFI POINTS 15-3

TROUBLESHOOTING 15-1 SPARK AEIVANOEH 15-4
IGNITION CO-I L 15-2
I'll-F -- _I

SERVICE IIIFIIRIIIIITIIJII
GENERAL INSTRUCTION
K,-I. Fur apari-: plug informatinn, ass pagn 3-5.

TCIHCIUE VALUE
Spark a-dyaitcei GL9 — FR Hg-H1 [II — Q ft-IIJI
{-
SPECIFICATIONS [ I I Canada MuI:i‘ul
Eparl: pi ug Standard u22|=a iU1'S'FSFi-L]
ND Fm unici nlirnptu i:|:Ir,\w EDD H11 FI- LFQOFS iu2uFsH-L1
, F5. aitizn-cIarI-I'IEI'I-sip-aiad riI:Iinq-_ U U211 FE ;ua4i=sH-L1
I— _ _ i _':-§§;L_EIQIr]_______ __ ETHS ICHTHSI
| NGK For pnhci climate: bi!-lnw EEC I\I1:'FI can ~'caa|-rs]
F“ I r;;;';;.1;.;;..;;; rl'a£|H"LI$é;§r]T|Ei1'1}— can rcaansl
Sp-aria plug pap I 0.6 - 0-1 mm 10.024 - u-u2a mi
Igniti-pn timing . P" "'2'. L5.” ETD‘?
E.~".¥9.*_%"~" =fl" BT92-2-1v9:.a_m
E‘-on-ciianaar capacity . I£?i‘N_..__.____i
Cnrtuci hr:-aic-ar pain: gap 13.3 -- 0.: mm i|:r.lJI2 - 0.016 inl '

Ft TIIIIIIBLESIIIIIITIIIII
Eriuinu wank: but will not nan: Enflna mm but rum puuriy
1. Enginu atnp lwitch OFF I. ignition primary circuit
1, Nu mark at |:|1u|;| - Faint; rIirt'y qr I~|:|L|I|!\'.I
f"r - incnrract point gap
3. Improper igniti-an timing
No lparir. at plug — Faulty ignitinn mi!
— Faulty mndemar
1. Enpina atop s-witth OFF
I, Fnirits EH11 ciptltiiig
— L|:u:ra=a' pr i:|-arir wire
— Irrtarmittenl shnrt circuit
3. Pu-ints burnu-ci, wet fuuiud u-r riirty
(-1 -II. Nu primary Eurtbltl lu pr:-inl: and coils 2. Ignitinn n:c0nr.iary l=i'fl:l-Ill
— Fmity piim
— Lc-uau I:r~' hruirun wlra
- Fguily high remiun wire
— Fauity lqnitiun switch
5. Pl-up fr.\ui:|I 3- improper ignition timing
B. Fa-uity plug wira Timing Iflllllflfl incnrrecl
1‘, Coil yr-aaic or inap-aratiira 1_ Cn|'|1riIugaII|.‘I'.rnru:E1‘ IflLllI"y'
{-1.
B, Faulty nuridunsur

F‘
Data 1::-I It-sun; Hay, IIJBU
EHDNDH MOTOR CU- LTD.
'5“ 15-1
 HONDA .-5
.-' '\-.

BATTEHWCHAHGIHG system CTI] .»"

;-"

IIIIIITIIIII IIIIIL
‘F tar -.1--i
REMOVAL _ ' |.
'
_
I-1‘-
, |
‘T '
I ' a
ITE-I‘i"|G‘v|'B I?‘-E right an-LI II.-1| ilrln qmyurs.
Firniuim 1!‘-1: I=~attI:'r1.- and 51&|‘IIEl rainy switch.
DI-iI;i.1l'iI1lII'3T‘II1E"'|'i|'iIi! I!3LI:1.
T'IE"-‘-Hi"-= l|1i= r-flii by rc'rnu+'in[; the atta-rzhrr-g nur
‘rum HIT? mrt —.irJ@

_-l--
--_ -ll?!“ __—4

IGNITION EICIIL p.1T,.\(;H||q-5 NUT

CONTINUITT TEST

C-I'IlH;I"i I'U|' cunr-nuiry as |.I"lu'n'|1.

THE DDII I5 good II lI1c'r-cl is -:,:|;'.nti|1|_|ir_'y'_
5E'30NE'»°~H‘I’= 1'-E5--9-35 H3 PRIMARY" 1.35-1.a51:
..-—= -
t_.» .--HT -
-wt- , "T: I
-x

E. 5;; I I
'
‘FILM. I E _
L'__ J. -
L I
NI
' _“i
FI R I Continuity H _-; '|__Dfl|] q , y
-w

PERFORMANCE TEST
_?__
PE'|'I|I|i'|'|‘| iII‘|e 3-|.1|::-Ir1: sniuiic t-n$1 yr-1'I'| 3 |:i_',iI| tugige-|'_ '
PRIMER? ELEUTFICIDE
SERVICE LIMIT: B mm I1.-'4 II‘II min. |

~.i?=.-11¢ <
IT I"'i';\III.I-W the CD-I lmmlr rnr|n||i'51:mr1~.'r"1 |r|51:n_|c-
Iiunt. I .-.‘_

E mm |
m.24 my SPAR“

SECONDARY EL ECTFIODE I

1 5- 2 15" Data ':|F isms: May, IEIBICI

El HONDA M-i‘J'l'EI|T t:i1._ LT|'J,
I
:"' "
%.g) cm IGNITION SMSTEM

F‘ BIIIITAIIT BIIEIIIIEII FIIIIITS , ‘#11::

REMOVAL

Hem-oue the zoom‘! I:|E'|-IIIEIF point emu:-r

illlli
Dir.;;nrmer:1 the point win: lead».
Flumnun 1I'|n c.or|t_a-ct breaker usslemiliy. If

For CI,‘l"-1|IC[ hre:oI<Ef points impaction, sen page 3-?

NOTE _ i It
K- I IIIREOIITBIEI-EII-"'1'.lqJ|'lI'||'CIEF\'EOl’1-"1'-I‘?-II"-IF'iI[l5I-'l? '
-e:In.u|1 u-'1§|iflE| CIII ‘ID IT.

CONDENSER CAPACITY TEST

Remoir-a thn rzcurrinnsei 1|o-m the hit-sr plate. ' _

Olerrharge the ooneinmer In grouncling itn tlirmirlki I"-—*'_“'-.
. . . -- F._1
iH3|I'lE-I I115 (IHl.'iII'|§- '

4"‘
Ii-F|ea5u|r,| rhn condenser eapalsity with a iehter.
CAPACITY: u.a2-on #F T
E -1 _
ii -1 in |.IuE oi spuoificqtirsir, iepiaee ihe crmricflher. ‘ 1-I-_ —— ___ __ _
" |t‘_Q|

F 4
P'H.

POINT REPLACEMENT
F.
SFITING SCI-IEW5
Fiemoye -:hn prylni setting screws -1n=l bolt.
Fiepiacr. the contact p-I:|in[,

NOTE i i F
Du not formt 1:; 1|'I!1IHII the bekoiite wwhers I
rt; insulflte the |t:IIml.‘IBI15'lIrr"|3E!'I»I!r'B‘[ClI' torrnin-'-‘I
F‘ '?|'|;|-'rr1 [|-r|;u,_|n|:I.

Install contact breaker assembly in the reverse order

qt rem-ouai
Adjust the 1;In|r|I gap an-|:i ignition =imiI1|;|- K il
fr.

r'“

Date of issue: I-Iay, IEIBI3 T55 _ 1 5_ 3

.271 HONDA MOTOR CO., LTD.
 HONDA FI
IGNITION system I:-III Itifisj -'“.

SPARK tnwrmzen
For alzivancer function nest, sue page 3-9. - ,- _.-
Removl the Irontact point cover or|tI' contact hreaI:- I
er aelsrlm-I:|I‘y. . /‘
- r
Check the ipflflg for |'C|Bs or run-slon and aduartcru - .' .-._|
Iii" ADI E'HlI'B5-$i~'E' weer if the aciuanser Iaits rr.i ramrn. .
Firzplase if I'iE|1'£5s.Itry. - B

- |
,1“--.

‘ ""h-.|—

_.-|.
|

ADVANCE FI Fl EP LACEM E NT

Hsrrlcm: the holt by hoiding ms satacur.

Remove the s|:i'.~'a|1cer.
-'3.

--.; er
K...

.""!\

Irt-stall thu nrivar-met", aligning the llot with II‘||: i / .--'-,

Ffywhuni DIn_ ~ '
Inetaii the s|:Itpl1|.'r onti tighten the Lm-It, .-
TOHBI-1E= n.e-1.2 ii-TI1 IT—9 met
.1‘ '\.
-‘.

"t
-1.

-|5_4 '5“ Eietaofissua: May.1DBfl

enemas Mcttnn so, LTD.
 ff““‘°&‘¥“i§i”" IB..ELECTRI[i STARTER
.r"'"
,.___ i _

SERVICE INFORMATION ta-1 steinten neuiv 1s_s '

TFIOLIB LESHOOTING ta-1 stisnten ctutsi-ironiye
1 -s
.-"F STARTER moron ts»: CHAIN B ii

SEIWIIIE IIIFIIIIIIIMIIJII
GENEFIAL INSTRUCTION
I.-M. The ;1q|-151 |-|'||'_'|~|;m can he rgrr-ii;;ur-,u;| with tho r:|ngInI! in the items.

SPECIFICATIONS
|TEg.1 Standard SurI.i'it:e Limit

.|—. I--§1:‘1.".-2| i"l'|D[D‘I' “flush spring tension _ *1-I’-l\I.'I Q I14-I CIII HOD q I1i].E ozi
. .. ..._

Hiusii sengrit 12 mm II].-47 ir-ii T mm I0. I5 l"I

_ . .. . — .___._ -1

Strtrt.-ttr i:iu1i:lt rir.ur.-n tor-octtet O.D. 37-900 It .-IE2! -ni 35.75 rnm IT.='i-Iii‘ I1;

ruse ILIA
nee-OP"-D-—neo—0"'
IGNITION SWITCH
BLACK
F. I :-
|'I'l Tl-
” "'7 STARTER
_-
- .. L _L _I_ FIELAY
.-.
5T.n.i=rTEFl MOTDH I
_ :- -= YELLDwmED LIOHT GHEEN.~'hED
"~. .r"
at- IIIIII,, |::Iil-
5

'‘IIIIIIOI‘
Z
-. '\'i
IOI’
l

‘Ir.’-

' '“*~-*” -vi

.5 {C}; ‘sit “‘°”"TEF' SWITCH NEUTRAL
ruitrer-w 5"""TF"'
fr“ _ ~.___ ___

TIIIIIIBLESIIIIIITIIIE
Sta-rtnr motor will not turn Surur motor turm arriigirio :I-uiuly
1. Battery i:i‘.sehsn;|ei:5 1. Low oottary specific gravity
2. Iiiuin lute burned nut 2. Excessive re-sistanm -Il'I i:ir|:r.rit
-II, Firuity starter relay 3. Binding in stutter motor
5. Faulty starter switch Starter moeur uni-is, but eriigii-in doe: not turn
H, F:.u.iIly ni:utreI :wlIrLI’t I. Faulty starter niutch
Ti‘. Loose or etisoonnetrted wire or cable I, Fllliy strlttet mntnr grutrs
IF’, B, Faulty sIIIrti:r mflttar 3. Faulty startar I1I"I.EII‘l and sprockets
Starter motor and engine to ms, but engine don not start
1. Faulty rgrilli-on system
I"-

Date of issue" May, Iiilil-IJ 15? 1 6-1

is-Horton MEITUH CD, LTO
 I-'1'-fi._-_. "E?-ix‘,

ELECTRIC stninten [III] P-

STAIITEII BIIITIIII
nemoyst

H'.|.|‘!t rfia rgnrnorr switch OFF, reniirre r.Iu- __-

ililrrirtitl‘ rt--ipilfilr r-tIi'1i-r .'.|.r r.i'|r frame before
.i.e.n'r'r.'1iItg the rrurrer mrirrtr.

FI:rt|'_tii'r:- lItr.' Ir.~.'1 i;ri|n I:|;.35r_i qi;t\.'|_tr,

FIBFI1-D't'E II'IE' hlitrre-| LI|.i.'i.- !.LI"IICI'I.I':'II snap ring_

5P-MP RING stsnren caste -..,

DI:-w:r:I1r|r:1.'.1 the starter sable at the starter motor.
I1ElI‘l'|IZt-'1'! II'iE II'||t'1t'-: st.-|rt|:r m|:|1||| n1t_:iur=!':ng bolts

R‘.1I'l1O'1II the starter I".TO]'I'Jl

HEAR COVER ARMATUHE 5H‘iM'5 FRONT BRACKET O-FII?-I-G

If It.-1,.‘

‘Ci
ii

"*_‘———~s|~isi= HINO
PLANETARY ..,
--—-——"-_'_ GEAH

-i~-_sn.irnien .-—-,

SHIMS “I

l% a‘\se.itarr~.|e
snusn
EPHING

U-RING BRUSH YDKE O-FIINO set 's1=n|ns

1 6- 2 ‘H Date of Issue: Iriay, IQBEI

E'Hi.IINL"J.i"i IIHIIITUFI CO . I T[I|_
 1-Ionirrm.
KT-§\ ELECTRIC STARTER

BFILISH INSPECTION B1;“_|§_-_,i| Bflr__|5,i.| r.;p|1|r-45

FIE-moi-9 t+|r;i ;.i:.-uiirr motor i:-see screws and ii==:i

rrovei.
In5pi:t:t IIii: 1JIl.i5I'l-E5 and l‘i"ilI-iii-i.iFD II‘IrI I-'lI'I-l‘!I| |l'=""flTh-

SERVICE LIMIT: -it mm I018 in]

Iiierr-iuri+ orush sprinit tension with ii ti-irifl-Q BBBIE
senyiitze LIMIT: anu gI‘lII.G ozl

COMMUTATOR INSPECTION
COMMUTATOR
Rf:-tn uyc II to iiir i‘il-BILHIL

FIUTE . .___
FI|:i:pri;I tl'iii Ini;i.i1it;iii IIFILI i'ii.Ifi1IJEI OT ihiI'n5.

irispi:-st II'|n- commutator hats for Ol5IIOIOl'i1l-i1li'I.

Bars i.l seraiurecl iri pairs inrliriaie grounded arniiirlur:
coils.

NOTE _ _ __ _____ ______________________

I Do i1-sit use i.-mary cloth or rant! pair!‘ Ian Eli! _‘
IIIIJ|11FI'lLlI‘i'I‘I.I.I'I

CI'|r_st;It ‘I'I1|' i:i1intiriui|y L‘iieL'.r.i'Ei:rI piliri OT i2flf'i'ii'i"iLHi'iOI‘

hers, and !oritii.'e-en commutator hurl iiml im-niiiturfi
theft-
Cerrimutator hat pain: Continuity
.it.i-rniir.urii to 1IieI1: No contlnuiw

Date of lseiis: Miiy. IQIECI ‘I 6 3

-f.-HONDA MOTOR CO., LTI'.'i.
 .; .;._.|'

ELECTRIC smmen C70 I-»

—._.-’

EIHUSH WIRE INSPECTION

CHEER Iu| rur|t|n|_,||1;5r f:'|:|-|'11 1_h|g- |_;1|_1|u h-"1-|||-|3| 1;|;| "Lg

IJILHII-8'! ‘I’-rITI'I I1IE£II'; W IE Jud l|.11hn momr |:-ass;
RI=|'.I-E-llr the I:lh.ri1"| |.\-I-r|, |I fin; w|rg |g bq-<;|lu|r|_ Q1‘ |f |1 |5
she-rte-.1 Tr: ch-P motur :33-59
Bahia tamulnml to m-umr can Nu uontlnuhy
Dhhln turrmnul to brulh Euntlnully

ASSEKIIHLWIIINSTALLATIUN

-'5-swmflu 1'11: starter motor

AI||;|n mu LE5-'.-! nulnh with 1hn IJl'lJiI'| h|:|I|:I|2-| pm

5-

Ins:-all ‘II’!-B hear ccwer lIIgn|ng :11 51-or wo:_h the Izlrush
SLUT
I
Ins-t.aII the 5..a|te-r mcnur by ruwxrilnq the re-maul

Data of Issue Ma"-,-', IBBIZI

EHDI-ID-fi. MOTOR (IE1. LTD.
 /HONDA
F‘ GTO ELECTRIC smnren

STARTER REI.l’f
If

SIAFIIEFII H.-|:LA"r"

I N SP ECT I U N

U-:=:;:-r|::;-z I"1I! 5!.'.|rI|:*. nu'|'1r_'I| !h.|'IuI'- WIIII III-e: igm |c:-I1

ON.
The OUII I5 II-.mn;1I I‘ we >L.=|1e- Id-lay‘ m'IIr:2Ir_I|v.Iu

3'"-

.r“~-
4!_'\..
I-7D|'I"-'.'.'I2II LIII uII|1'|lnE|r:' Iu [||.": |I||r:|:| rcII;w r'n.|1'r’h
I'.':dL1lc- Inrn1-n;|l~..
'€1|:|n|1=-ct i Ei'-4' Dfll'.IE-‘I -,-' r.u 1|-Ir; Ilflllfflh win‘: Ir;-.1111-;.
TH: :.-'|.'\'I||:I1 I’. |1r:-'rn.:I II II1n||:|'I l1lIlI1|'IfllJI1l|'.

.-*""

.-'~\
STIIIIITER [:LI.|TBI'|f'I]RI‘l'E EIIHIII
HEMDUAL
5"" SNAP HING CI-IAIN GUIDE
Ffnmuulr Ih-Q AL. Qarml at-Jr rntur I5-artiun I41.
FIIE-'1'1I:m:- The star:-an I:-hmu g|.,|-|.Ir: =r|c:I pm-|:=4:Iu|.
FI.n-'r|-'.1\1I.- IIII: :|;:-r|:r|::II.r:1 5-1:11-n-;| |'|Ia11||.

Flumuue the 5|‘!-EIIII ri-'1-;|.

FIErI"|u\'é IIII: 11B|Ir.'I |:hni|| .1|1rl :|'Ir|I|:I€1:1s..
If-I-I

I-'—I'.

lfl
PTIUTEL-TDFI SEWING PL ATE

Daze or Ir.:ue: May, IQEIII

$1 HUI‘-IDA HIUTDP Gil, LTD.
 .-i

Homnnf I '-.- I"

ELECTRIC srnnten CHI . _E“/*1’ dfl

».—\\
STA RTE FI C LIJTC H D I SASSEM I3 LY

HEN-‘lEl'JB ‘II’?! TI"lI'£E' S-EI'E"|'l"5.

PIl£'|'l'I=l'I'I|'-EI thn zlartur ~3I||tI;r: r.Iu'I9r.

Harncwa 1ha ralle-rs, nlungers a|1|:I sprm-gt.

STAFITEFI CLUTCH INSPECTION

II1:-|:IIJr:'.' 1I'Ii I|:|II=Iri fur imuuth u-perivnn.
CIIECII III: rt!-III.-r': Itlr I::\Ir;r::::Iva wunr,

.—’-.
I.

.I—I\._

Impact the drive and cirsuen spruckuti and chain fur

#Il:ljI$$II|lfl ‘||'I|'IIfl|' lflr HKHIF.

I|1~:a:|LIn: the unue -sp-rI:Ir:|-=.et U.IJ'.

SERVICE LIMIT: 35.71-mm I1.1HI?InI

In

jg. -|--—-

STAHTEH CLUTCH ASSEMBLY

.-"""I‘I
lnrtall thi rtartur r:JutI::h uutrr.

NQITE
Eta!-H: the arid 01 nnlrh 11:-rmv against Ihngruuvn
In thr clutch -:I-u'tl:\_r.__
.-*1-.,_
Irtstpll thu BDFIFIIIIB. |:|lurI-|1u-rs and ruIIur:-I

INSTIALLATIUN
-_
.-.,_
Rawrn mu rumcwal |:|rn|;~!:r.1|.I|'\:.

r'1

{S-6 — — 152 D-.1n_-u'I Iisue-: Ma-,1, I981]

-DHCINDA MOTOR CCL, LT I1-
 {HONDA
F.
oi,» cm IISWITCHES
SERVICE INFORMATION 1?—‘I HANDLEHAFI SWITCHEE 11-3
BRAKE SWITCHES 17-2 IGNITION SWITCH 1?--'-I
f NEUTRAL SWITCH 1 Tr‘ - 2

SERVICE IIIFIIRIIIITIIIII
GENE HAL INSTRUCTIONS
_J" - Sq|Tru wimi I'I.l|.'t* dliforent colorant IJIII1EI!- around them near the o-onn-uctnr Tings: wit no-rirletlfld ID G-II1E-I '-'-Iirflb wI'Iit-‘I'I
oorresn-ond with thn Ia-and uoinr.
' All |'.III:'|:II|t pIog1 I‘IB\'B Iooitiiig tabs that must be rolauiod bcfuru tllsconnflclirlg. IHII ml-ll! DH -iIll5II1I!"J'~\'I'IEfl I'B'I1-'I'I'll'IIE’tFl'lD-
- Thu fnllu-wing |;:;\II;|r curt“ qru un:I.I 1'IIruI.IgI"|uut 1I'|ii n!1:t|I:|I1 and IZIII the Wirifig dimrnm IHIIBIIIJI1 IBI.
.p- B — Blue G — Gwen LG — LIgl1tGr1HIn ‘W — White
Bi; - a|q-=I= Gr - G-Iv D — flmnun ‘r - ‘I’-lI'Im'r
Hr - Brown LB — l_nfl'|IBluI H — Hnl
- To IECIIBIB an Elgctriual fa|Iurn_ ch;-ca 1h: wntirioity o-I the electrical oath throuqh thn part. A oontim-|i11|-' check uurl
u|unII'|-' be mad! wi'J'It|ut removing Lhu pan from the mowrcvclu. Simply dim!-linen the wire»! and connect B wnfiflvlw
tIfi.1ji|! cur 'ItI|IIi-I;lI'iI‘l\I'I'I.1!I,I:|' In |I‘I! tE'1'I'flIfli_I! CIT III'DI‘lI'IB|IIII:I2II'Ii
~ A ngntinu-tlf I-i;51'ur i5 usniul |.\'h:r| izhmzking Lu find out whether orr not thorn is an uluotrical crmneclifiri I-IE!‘-':HEfl W-"II
points. Au ohmmatar is l1BBI2IB‘III to munsuria the roiistermu of II circuit, Ii: when ‘mute ‘rs a specific mil resiutlnui iI'I'1\=II'-‘HI.
nr Ir-|!|.|:n |1hE|,.1I|'-1] for high ronlataiiira I!n.|lBI.I by corroded connections-

1"“

1”‘

.="'“'-

r'““

r"~-.

Dato of Issue-'_ May _ _ II63‘___ —

-soiior-ion MUTIZIFI I::o., LTD 1 7'1
 .-'“ '--.

HONDA. if
SWITCHES C70 .- '-

.- -._

BIIIIKE SWITCHES FRONT BRAKE SWITCH E‘|i""r' LEAD

FRONT BRAKE SWITCH
FI=_-ni-owe the I1-satlli-ght.
I.II5I;Q|1fli_tI;‘Ij l'I‘|c Ct,-‘Y _1||tI Bit iieatti oi me front brake
twitch.
Clmizk fur i:uniIno.|-,- with mi: imnt brake app-Iiacl.
Eraka applied: Continuity
Bash not amaliciii: No continuity
I'Ic|:ilai:c II‘!-E switm I1 -Wee-aasarv.

1-_ w
BI: I.E-"IO _,_\_l

REAR BRAKE SWITCH

BRAKE SWITCH
Fem-we rh»: r-gm sicia cover.
Disconnect LI'H.l G.-"F oI||'.I Bk Ic|.i.|d1 [If 1h»; Igai hrukg
wiritch.
'3I'lE~E|I1'flr riflntinuitv with the ioar built: uppiiq-i;i,
Brain lppliad: Continuity
Brlitl not opp-Iinlt No corrtinuitlf ,‘ ".
Rflfllucc thc =iw'i1ch ii ricccssarah E3?

Bl LEAD G.""|" LEAD P».

NEIITRAL SWITCH
‘HE
IIEIITIIIIL SIUITIIII
FI:I1‘i|::Ni: thc IEII Li|:Ii: l:_:11u:|' ;|r|-|:I angina 5p|'g[.Ii:g1_
co‘-rot.
Ilhirck it‘-rr swilch tnr coctintiitv hctwccn the switch
turm‘-nol Iw-re romou-ed} and gr-oun-ii -mih I_hc
‘H.
I1l.EiI1SI‘i‘|-iiinn In rii:|.irrr|I qrirl with thn h'3n5411i55-I011 ||1
any goat.
Ih I'lIl!IuI‘IHI|I Cwrlfimity
In gait! Nu uominultlg
Rec-i=v=:i= lI1r' l"'tllII.I'UI wirI1':I'l if necessary.
'-.

_-.1,-"'
F

1 7-2 ‘H’ Don: oi Imm: May, IEISII

IE.-HIJNEIPI MOTOR ISO" LTD.
 /"T HONDA
{I'-'\
K _=_j GTII SWITCHES
Ji-"It

HIIIIIILEBIIII SWITCHES H EADL IGH1 H I -LO SWITCH

The |1flI‘||_'II|II1I1' -::Ii|:.t|=-I i'.|'|':tt!"|G'5 *II'l3"I‘-- EUI" 5IEII'l=I'-I

I"|:irI|, enigino atop, lt=1'1cII' I1!-1-I!-I I36‘ I"¢I‘tI-=¢'"I 35 3"
os-'ic'11hl',r-
. I‘-I
\._ I‘
_i-. I3."-r |||_||t-,- 1ni;:~. I-:1: ihe co-rri-|:|nr-itnlrl f-II the - e-
I-|.:n:in.-Imr cios:-or switchon i1=IIoW'

I:Il.'1"|lll‘il! tho hm|r:IIi5h1-

t',Qmin||-ty shot;-Ir] e:-mt hntwi-c|'I TIRE CHIC" ¢'=I'-Ifl!
ynryg gin i!:|i:?'i |.th.B|'I.

Ii-"'-

r TURN SIGNAL SWITCH HDFIN BUTTON

HEADLIGHT HI-LOW SWITCH

I-loadiighl Hi- Loni Switch
HI; Bu: ‘I’ I_— __Hl I |::| Ln-
|".i'I|DDLE INI1 Ii"toBtn‘I"|' IHI ' E.»-——C:
L-D: "I" toI|‘|'
CJi-—-CII~ -—-C5
p.l,§'__
IL" . -
K“ |l;qlurootI-a ti -1-"I1 ' W

TURN SIGNAL SWITCH Turn Signal S‘n'Itl=Il

LE FT: O to GI‘ -I IR W ..L_

QFF: No continuity LEFT | _ _-_t- _--I
FIIGI-IT: LB to Gr _'dF'i'= _ _ __
|"""'.
RIGHT E3“ "-ii-1'
_ Co-Ior coda LB GI‘ 0 _

Flu

HORN BUTTON
Hum Bi-mun
LG tn I3 with button dlprnnd.
‘No continuity with button r1iIhlld-
I iii E i
N
F.

T
. .
i Color Codi I
1-
I’
LG C

F.

,-t.
‘IE5
Date o-I Issue: May, I950
QIHUNUA "-IICITDH 130., LTD.
1 7-3
 HONDA
SWITCHES I‘-.%»,xI
-_ _—I_

STARTER BUTTON EN
NE ET-BF swircii
‘FIR to LGIFI with button denrnstcd.
No continuity with button released.

Starter Hutton
*‘ I T ..'—
FiI"e'
.-05-‘ = Qi-
Ccint @955 wn u:I.Fi=i Y
-F

ENGINE STOP SWITCH

RUN: No co-ntinuity
CIFF; Bit.'\'i' to STARTER BUTTEIN -.
Engine Stop Switch

o|=F _— IfT.Ii-I-—:i:1'— _
nuiiii — '
tin" .-.___?~
Ifioiorcocie N BItNt' I G
_.iI-I-I.
.

-\_

IIIIIITIIIII SIIIITBII
COUPLER ""“\
FIltl1"I.Il.lE tlic II'I.1I'llt1|'.>'-‘E1’ E-"II'.I |.IiIi£i:|r||i|!c| Ihn r:|1|i|"|lci

Chock thc I:onti-'=|.i.|-,-' oi ii.-rmin.-ii-i ir-. 1‘I‘IFr iflrlitinn

5'.f|'II'|‘:I"| '-tiiI|: |:.it|||_1|r_ir

I OFF: HIti'\|'|IIJi:i-G
ON: Bltto-R

. , .2
____

‘___ st anti to _ _.-It.

grr i
'19.
_E2oIot ondn' B-It
Q -~H. Bttfllt Q

Rcplece Ii"'|B switch Ii itc-::|='t5;|ry

IG NITICI N SW ITC H _,_

1 7-4 we Onto r.-I italic: May. ISBEI

-D HONDA MUT-EIFI C11. LTD.
 _,-r I-.

IBIRIJUBLESHIIIITINE
|"rI_I-‘L

ENGINE '|'iIlLL NOT START OR DIFFICULT SHIFTIN-G 1 B-5

IS HARD TO START 13-2 ENGINE NOISE 1 B-5
ENGINE LACICS POWER 1B—3 MOTORCYCLE POLLS TO
—._-
ONE SIDE 13-?
POOR PERFORMANCE AT IDLE
AND LOW SPEED ‘IB--4 FAULTY FRONT Si REAR
POOR HIGH SPEED SHOCK AEISORBEFIS 18-?
PERFORMANCE I3-Ii FAULTY BRAKE IEI—i'
Ir"- SMOKING EXHAUST 13-5 ‘IS-T
ELONGATED DRIVE CHAIN
FAULTY CLUTCH 'I3—S

if-.

I-"'"

.-.
I’

IF

I.-.

_/F“

IF

Date of Issue: May, IHSIII IE? 1 8 1

HONDAMOTOR CO.. LTO.
 r"' =-i
tnoueteseoorrnro CTR --,
-'-t
EIIGIIIE I'Ill.I. IIIIT STIIIIT III! IS IIIIIIII Tl] START
PCISSIB LE CAU SE
I. CI‘IE|'.‘h. If Iu|:I rtt3[,I'|1J5 FUEL DOES NOT REACH A-p Err'i|:Ity' ‘Iufll tank
tattmmtqr CARBURETOR Clogged htel line ICIE-t'M=:ttt1 fuel tank 5;.
carhu reto-r
Clogged htul yelyn
F IJE L H EACHES Clogged Iuel tenit oep breeriinr hniri
CAR BU R I-TTOR

I‘
1'. Remove toerlt t:-lug Gr ten WEAK OR NO SPARK in Faulty ot fouled plug
tnerlt Fouled, burnt nr pitted cttntoet
brceitor It-ointt
II‘|i';'t'Jri‘t!-t'.'I. hruflkqr putnt gap
Faulty condenser
Brolterl or thnttecl hiqh tent-ton wire '-“t
Open or ehorteo ignition coil
Faulty iQtiItIIJl'l st-yi1:i;h
GOOD SPARK Irlcormct ionition timing

I‘
Ci. Tcet cyi Inder- comore-“inn
TORMAL CO III P R ESSION
LOW COI-IPRESSION—-i—-e-
Er-nine our tzrm-itienl
Nu unlyc clearance
"-I"-alirc rtucit open
Worn cylinder St oieton I"i|1g5_ -I
.-'"-
Blown cylinder hr.-.er:I gleitet
Flaw Irl -t:ylinr.Iirr he-ed‘
Incorrect yeltre timing

1'
-II. Start elnqi rte ENGINE Fines, trot??- Choke irelrie open
ooes r-rot st.-ant Ct_ltI.'Iun!l.ttr pilot egmw Qipen
Air ieeiirro t'I\rou|;h- It‘ttaItti tht|'nIfr,'.iI|:i'
ENGINE STARTS Incorrect Ignition ti mitrig
I .'-""‘\.
‘I’
S. Remove ioerlt plug WET FLUGHA ——b Fiooiclecl corboretor
DRY PLUG
Cerhrtrrrttr-r choke excessively
closed
-"~.
Thtottl! ‘relive crceetiireiy open

S. 5Hi'l engine with ettoite

clototl ""\

I-I_I-L

1 B-2 In Crete of Imtez Iiiiey; IEISII

'13- HONDA Mfi-TOR tICI., LTIII.
m
 [I THDUBLESHDDTING

l;""" .
EIIEIIIE LMIIIS Pl]'IIElI -
POSSIB LE CAUSE

1_ Halter '.ryI'tr:¢,rI5 r.rH gt|.rur'ir.I H WHEELS DO NOT SPIN __ __e- II] Dragging his-rlrr
spin FREELY III Faulty wh-eel bearing
I3I Osertightened drive chain
‘.-" WHEELS SPIN FREEL"i"

2, Check tire pressure INCORRECT TIRE F'RESSLIREi'- [III Puncturecl tire

III Faulty tire velvrr
TORMAL PRESSURE
|,..-.

3, Rapidly accelerate from DOES NOT ACCELERATE WITH -—e- III $II|:’!|pi.i'ifi If!IuII'l-
low no tr:-con-rl ENGINE SPEED RAISED IEI Worn or unrvcn -|‘.Iut1IIi Iltclritih

|.i"""\. ACi.'!EI.EFIATES

I
it, Rev up gr-eduelly ENGINE FEED DOES NOTA1-III Carburetor dhoite closed
INCREASE IE] Cfiogeecl air ulcan-it
rzti Ciogge-ti Iuel line
I-ti Clogged fuel l.|nIt up breather hole
ENGINE SPEED IBI Clogqetl muffler
INCREASES

1"" 5 Chuck ignition timing INDIIJFIFIECT tir.t:rioA- III Incorrect ignition timing
rti Ignition malfunction
CORRECT TIMING

E, Chectt yeiye clearance INCORRECT VALVEO III Incorrect yelye cleerenoe

CLEARANCE III’ Worn value mt
CORRECT VALVE
CLEARANCE
I-"_"~ ‘I’
T‘. Test cylinder compression LOSS OF COMFRESSIONih I‘-II \.r"e-Iue ttuclt open
III Worn cylinder Si piston rings
no RIIIAL cow-neserort I5] Btown cylinder heed oritlrer
K-P.-.
I-ti lncdsrect yelye timing
I
B, Ohecit carburetor for C-ARBURETOR -CLOGGED C-erburenor iets cloqgetl
clogging
CA RSIJ R ETO R NOT
TLOGG ED
F
5, Fierrrrwe sperrtr. plug PLUG FOULEO DH F poled plug
orscotoneo III Incorrect hcet rirnglt Dll-L9
PLLIG HUT FDULED
Tin III-ISCOLOHED
(W.

F“

Date of ltsuc: May, IEHIII 169. -1 B-3

-El HONDA MOTOR CO., LTD.
 1-t:r:;E%t:us. .-Pi

I‘ ‘I-
TROUBLESHOOTING
1
‘it

Chncir oil layrrl and condition OIL DIFIT"r' on LEVEL-— A in Lenrel too low or high
incorrnecr is] Co-nur|'nineter'i t:|iI
ODRFIECT ENGINE OIL
LEVEL

Remove cylrnder heed cover
and ctr-scit ItJI:rrit*.etit;in
SLIFFICIENTLK‘
LLIBFIICATED
INSUFFICIENTLY _ E... 11] Cboygnd oil has-sage
LUBHICATED ni Poor nil pump deiivery
i3I Low oil preeeure

Check If engine oyerheen. ENGINE oyeenerne --A In E1-rtcsrsivit carbon in combustion

chamber rq_|

IIII lnooi-rec-I I'LrcI

ENGINE DOES NOT rel Sfrppino clutcin
TUE R H EAT ill Mntrure too Ietrrr

Rapidly ictnrlerate or run er encrne r:nocrts——-_- III Worn psston or cylinder

hich speeds IEI Mixture too ieqn
I3] Incorrect IUII
ENGINE OOES NOT I-ti Excessive certr-on in combustion
KNOCK- chamber
i"5i Advanced ignition timing

FIIIIII FEIIRIIIIIAIIEE AT lIl.E AIIII LIIII SPEED ..E.._;,.-ME CAUSE

Checlt Ignition timing Sr rncorrnecr TIMING e A iii Incorrect rirning l:IjiIi;trn¢'tt1
yeiye clearance ctennnnce i.'.ti In-correct uelye claerenoe
CORRECT TIMING A .--s,_
CLEARANCE

Check. carburetor oiior rnooenectur no.ius"reo —- in Mixture too Iuen

screw srI;l,iI-rttnltnt rzi Mitrrtee ton rich "E
CORHECTLT ADJUSTED

I
Checi-t for err leeks me tear-zei in In Faulty iarburltor Qrrtltfil
ctr Carburetor not securely tightened -"d"\.\l

iai F.-rulry Intelrc pipe qrninn

ND AIR r_Erti<5 to Deterio-rated D-ring

I
Remoye resent plug Er wane on irrrennrrren-ri..r1i Faulty or fouled plug
rut spark WARN [El Fouled, rough. or pitted breaker
point sl-Irftlcl
GOOD EPAFIFI [SI Condenser shorted
I-II Faulty ignition coil
—-._
It

18-4 In D-stool ltauu: l'Ir1ay,TSE9[l

QOHONOA MOTOR LTD.
 1-Iowan.
F“ cm THUUB LESHDDTING

FE.

Fllllll HIGH SPEED FEIIFIIIIIIIAIIBE ’°55‘ELE “"55

'l_ [Ih||1;l-Q ignific-n timing B1 INCDHHEUF TIMING 31-i 1- lll Inna-rract timin-3 II‘-ll!-lFII’I'1ET1l
valw cluarancl CLEARANCE lIl' lr‘||‘:lj:|l'fE'£I value claaranca

CDHHEET TIMING E
I.’-I’-‘m
'1ILEAFl ANCE

1 Dlsuonmct lunr ti-ltlr at FIEETHIETED FUEL FLD'l'|I'—— a- ill Emmy luai tank
carhuratnr and check For l2l Clqggfltl furl 'rul1a
crng-gmg l3l -ljluggmgl furl 1..-mt cm braallier l’lDlE'
F-
UNRESTRICTED FUEL
FLOW
i
3, Chuck; fi.p:l‘li|tu1'_fl|nl h'alIm_ CLUGEED l1] Clqggfid jel
r""‘“ E: narburamr jet For cluqplnq ll] Clogged fuul Ii-ltflr
I3] Ciclgg-ed lual ualw
NUT CLDGGED

T
4 Huplmu |:arl;.|L|r!t|:|: mnin |u1
{EDNDITIDN IMPROVED
CDNDITIDN AGGHA'u'ATEDiI- [ll J91 sizu ‘IIDCI small
[El ll mncllricm ll‘I'I|JfrJ\FBl2l with small lIt!
all Cluggud air clluflflr
bl Chn-he nut opened fully

K“
E, Chuck v4|lu&1imin-g l-NC-U-HHECT ii‘ lill incorrect ualw timing idil-I$tl'I'1Efl1

CORRECT

l Faulty value snrlnn

B, Chggk vulva §|:|-n|1g*[5|'15i|;|-n WORN DH‘ BHDKEN SPRING-it ill

SFHING TENSION
CORRECT
1"‘-.
Slillillllllfi EXHAUST PDESIB LE CAUSE
F. ‘i Hun m0|::'rll'.'y'lI:lE a In-nq BLACK Ski-Gil-E EMITTEU iv ‘ill \|i'n|'r| |:','|i|1l',l:r Bl piflflh ring:
distzmm at hlqli weed lil -Dil lavll ton high
'l3l Pi;-run. ring: lncn-rm-:t.l\-' installud
lil Fault-¢ raimn cw cl»-llnder
THIN EIl(l"lA|-..l5T EMITTED l5] Flam in cylinder hnad

F,-.
2. Flururn thruflle grlpl qul-cklv WHlT'E SNIUKE EHI‘l'TElIli1I- lll ‘Worn lntal:-n ualvn lrulrln nr him
[2] Deusriurared vulva guide D-ring

ND WHITE BJDKE
EMITTED

I-'1-. T
3. Hun motoruvulu a lung WHITE SHI-DICE EMlT'l'ED-l—I- I1? Wum exhaust valve gnlidu S: rtuffl
rll-;1nn|:=e ul lnw spa-ad ll-ill E;+m|.|-51 v5l'n: guide lnen-rractllf aaatud
131 Worn exhaust valw strrri I-Bil
l""" uncumnen EXHAUST

Data of ls:-ms: MW, 1530

'3-HDNDA MDTUH CD- LTD.
In
1B-5
 Hanna. _
"rnuuetesuoetme C70 z-",1 1"-1.
\-

"‘=-.
|illllT'f BLUTIIII
PU5-SIB LE CAUSE

T. Preperlv ecllusr clutch CLUTCH 5|_|PPmt3 —i -lg. 11; wqik ggumh -§pf|n.n
{Ell Wr.'|H‘| ur ill!-tnrted clutch plate gr
frlctitrn dist:
J

BlFlilBl.I.T Si'llF'i'lliE
PUSSIH L E CEUSE

DIFFICULT sH|rr|r1ei- in Bremen geqr ehilr qrrtl 5|!lr|n||'

ill Hrrritltn shift furl:
E3} 5luqgirri1 movement of ehiit drum E
fork .-I-\.
I
Hi Bruit-tm shifting gear rlrcltrutiun
[5] Shift arm pawl tli.u:=ennet.1ed ir4:|fl'|
shift drum

FED-M. NUT |iiETUHHEDiI- [I] Br-niten shift return fltlflflg

TD NEUTRAL ii] Ehiil Bhrit lrrtlrfurrinq with tare tr-r
cmiur

GEARS .ll..Ilr.IlPlNG GUT OF -in H! Bent shifting near or we-rn $i1r-H lurk
POSITION iii Brfl-lr-H‘ ur weirir-entrl shift rlrurrr
stopper spnnu.
1"“

Eliiiilii IIUISE
PCi35l B L E CA USE

VALVE Hfilfiifi in Eartseslv-rl valve clearance

Hi Warn valve
PISTON -SLAP Worn nrunn He cvl-rrtler
Ertcleilvr CBFl'lD11 in nnmhurrien
chamber
[Bi Worn piston pin 81-rrtmneetinq re-cl
smell end
"N
CAM CHAIN r~|u:sE?—-_- rrl Worn eemehelt hearing
I21 Wurn camshaft spmuitat teeth
[3] Exeeselveiv elongated drive chain

CLUTCH cunrrieiiw 111 Excessive clearance between clutch .-I’-_'I-“Ll

pine Er r:l|.rt|:h uuter
12] Wlaltnnntl -clutch damp-er eprin-ii

NDIST D-FH\I'E 5 DHiVEH-er Hi Wtrtn or deteriorated tlriuen gear

GEARS deflq:-er
ii-?l Wflrfl gear teem
.'_'|,_

11$!
13-6 Date ul iuu-e." Mae, 195111
'§?HUND-5. MEITDH CD, LTD.
 I lgeeuflmna
F‘ ETI] TROUBLESHOOTING

F l|lIIT0lIII'IBLE PIILLS Ti] IIIIE SIIIIE FOSSIB LE CAUSE

DIFFICULT STEEHIHG uni» iii Dwrtigh1eru=ti steering head tore

eutn DIRECTIONS threetl nut
(‘Ii-\-
iii Brn-I-ten tteerrng rteel halls
i3i Bent steering Ir!!!"
WHEEL wr:lee1_es E-P ii] Eneeatrve uiiuv in wh-uni hearing
ll’! Bmrrl.‘ wheel rim
I3] Loose nzle-ire:
Ill Ere-£E'l5l'|II ti-lav in Iw-l'|gnrl'fl Divfli
if-‘I. hugfllttg
[El Frgrrr-I: l:|en1
IEI Drive ehiin acliusreu urwquellv
.u.Ilun:e|:i

ll;I"\.
MOTORCYCLE FULLSE» III Unhelanultfl frqnr E rear shtr-r:i~.
TO ONE SIDE aI!iHJl‘I'J€II"i
III Fr-gm it r|'-!-it wheel: nut alignncl
I31 Hem fr-:|nt I'|:|rl~; ur wringflm

lilII.lI.T'f FRIJIIT I‘: IIEMI Si-IIIIIII HBSIIIIBEIIS FOESIH LE CAUSE

SOFT FIlDE—i m“ III Weak !|Ill'lT‘|fl5

Iii Excessive lead
F‘ |-met: FHIJE Cir lri Feultv ire-fll fflrlt
III Fgultv rear sfhntllr iIIJ"llIlfI-IE!

NOISE IN SHOCK ABSOFIEEHE ill Faulrv stopper ruh-her

[El Faulty rqir |I'|l,1riCI=! lib!-DTIJIFF

FlI.iLTI' BIIIIIE PCIISSIB LE CAU SE

r"_"-
INEFFECTWE ADJUSTER E-h II} '|'l|l|}|'n brgl-tn lining, brelte shoe cum
qr in-rate tzem

.-I-5|‘ SOUEAKING -ii I- III Worn brake lining

III Fnreign ‘particles cm hrfli-ti lining
I31 Finugh brake |:ir|rrI1 1hr:-e ttantaetmg
lat:
ill Ihlurn imrltu |'.r-1|1E| huihinq

INEFFECTIVE BFIAKE Er III Fault-,r Irent brake table

iii E-riltrr shun pprtiallv contacted
I3l Mud ur water in hr-rlirl
HI Dii er grI:r|1E on brake lining
IEI were nrelee lining

ELIIII GHED IIIIIIIE Bllllil POSSIBLE CAUSE

iii Inutrrrerzt etljuitmums

III Hut lubringtetl guflileientlv ent:-ugh
.---1 I3! Wnm mrodrets

Date nf issue: l‘|-ltlv, I-HBO "3 _

E:-HONDA MOTOR CCL, LTD. 7
@522
,_ _| 9_O_DH|8__DamQ
_a_ _ "_€_N{_5% 5
E_=_ ’_m_H_>m_;_<_
_iE5
“ Ln‘
‘?5;
_‘%_‘un_:HU6:fl____I W
Yw
’_'____*__:_;_€_ W
I_§8VD__\EmWWI_m;“_ |UUH_N
AT’ u
,flfl
_'n_fi_l|V_UP_g|_§2'_ _ gm:'_9n:w__a_s
_’_"D|O_H0_TI_T_“
E‘“‘m___?ag
._ _F ___!
w§___g:
_ _ n_

__
1 35mg!3F;V"‘ I|
_%wv_q__M \aF
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‘_®|__ \_ _
 2D. ‘B2 ADDENDUM
.""‘-
INTRODUCTION CONTENTS

TI'I|s aII1;IencI1.Irn CO'I'II..E.lIl'lS rnfurmauun Iur IIIH ‘IHB2 I. GENERAL INFORMATION . . . . . . . . . . . 20-2
___ _ CTIII. Raf-er tr: the base shop manual for sewice
infurr11aliI.III nu-I. included In this addendum, 7. LUBRICATION . . . . . . . . . . . . . . . . . . . . 20-5

3. INSPECTION AND ADJUETHENT . . . . . EU-5

ALL INFORMATION, ILLUSTRATIONS, |J|I=IEc.- lI.FUEL5“I'STEM...-...... . . . . . . . . . H20-R

--~ TIONS ANIJ SPECIFICATIONB INCLUDED IN Tl-IIB
PUBLICATION ARE BASEDON THE LATEST PROD 5. CYLINDER HEADNALVE . . . . . . . . . . 2041
UCT INFORMATION AMIAILABLE AT TI-IE TIME OF
AFPFI-IIIIIAI. Fun PRINTING. HONDA MOTOR £10..
LTD. RESERVES THE RIGHT TO MAKE CHANGES Ii. CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . 2!]-‘I2
-""_' AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANT OBLIGATION WHATEVER. T. TRANSMISSION . . . . . . . . . . . . . . . . . . 2!]-‘I4
NO PART OF THIS PUBLICATION MAY B-E FIE-
R. CAM CHAIN TENSIONEFI . . . . . . . . . . . 2!}-14
|F‘ROOUOED WITHOUT WRITTEN

HONDA MOTOR 60., LTD. R. FRONT WHEELI'5IJSPEN$lON . . . . . . . 2!]-1?

Surwricl PuI:IIiu'I:In-I1: Office
‘I'D. HEAR WHEELISIJSPENSION . . . . . . . . 20-1?
.---.
‘I1. BATTERTICHARGING STSTEM . . . . . EU-TB

‘I2. IGNITION SYSTEM . . . . _ . . _ . . . . . . . . 2!]-22

‘I3. ELECTRIC STAFITEFI . . . . . . . . . . . . . . QC-EB

14. TECHNICAL FEATU RES . . . . . . . . . . . 2U-ET

,-._ I5. TROUBLESHOOTING . . . . . . . . . . . . . . 2U-23

‘I6. WIRING DIAGRAM . . . . . . . . . . . . . . .. 21]-3T

. ""\-

-\

r'_'\

|F'_\

-t _ _

Dane bf |;;u=: Nu-.-__19a1 "'9 2o_-I

‘ii-I-IONDA MOTOR CO-,LTO.
 HONDA -
'82 ADDENO UM ETD .---\_

—I.I.
I

I. IIEIIEIIIII. IIIFDRIATIIIII
SFEBIFIBITIIIIIS
ITEM
DIMENSIONS OIIBFBII IBfl§'ICI'I Lfiflfl mm I719 inI
Dvérull '|IIl'II.'I‘l!I'I Bflilmm (26.0 InI
Ouirall height 1,010 mrn (39.8 InI
Minrrnurn qrI:IunI;I tlgu-rant: 150mm I{5.5in1
.-' '!q_
_ EII_v wa_§qht E2kgIIBfl.IIII:I-I
FRAME Fmnt 1I.I1pIImiI:|rI, tnlvnl Bntlum link BB mm [23 InI
Rear u.|apem.IuI1, trnuel Swingiarm 51 mm IE'.:I- InI
Caster angle E3°3|II_' |' '-
TI'dIII 1-'5 rnrn I195 InI
ENGINE M-an-:|munI torque I16 kg-m I-II.3\I ‘II-Il:].I'E,EIII1 rprn
OH qplnhr IJ.-E Iltun IIILB5 U5 III. 0.71 Imp I:|t‘r after disasawmbly
IntiIc| valve O-pa-In 'I'.I5° ETDC
Cline: I15" ABDE:
lt‘I.U5mmIiIt
E III‘!-nu IT vulva ODBWI 22.5“ BBDC
Chases 2.5" ATDC
Englma welght 20 I-cu [=1-4.1 IIIII
.=-5} I
CAFI BU R ETION Curt. |I:I-unLiI|I:.atInn nunmer PEIEA
ELECTRICAL I|;|1iI»I:|n CDI
F uI| Ildulnipfl 23.5“ BTDC ut 3.100 rpm
I3a|1urau:|r FI~,m.~I-I:-¢I A.C. gBr|EI‘l‘I-Ur EIIWIEIIDIJ rpm
EIITIIT cauanitv IEV-EAH
Spud: plug
Standard u22I=sI=I:-u INIIII. cams INGKI
Fm‘ mid CIIITIIII III-‘IDW 5°C [l‘I°FI uzursn-u II‘-IDI. cnaus INGKI
For extendud hlgh speed r1I:Iin:g uznrsn-u INDI. =:HI='IHs INGKI
LIGHTS Headlight [high.I'|-aw beam] 1'5|'?1'EW *""I
Turn slqml 3332 ED EAE ND. IDT3
SIJBBEIOIWBTBT 15'!
NI:u1rIII Indicrrur 3.'IW SAE No. 158 "H
Turn slqnal Indrnamr 3.-I'l‘II‘ 5-PIE Nu. I53
High bum IIICIEDIIIUF ZN

"""-.

-HI

20_2 '3" Onlacrflssuui M=~.,1m?.1

-EIHONOA MOTOR COL, LTD,
 HONDA
f
I-H
% CT II 112 ADDENDUM
{T-'\.

TDIIIIIIE IIALIIES
ENGINE

Turque
U, Thread ‘
'11" “I r,I'|l. Irrmll kg-m ft-IIJ
,_

Elem-shaft sprocket 5 D-7' I-I 5-H

F'.|'|i| I;IrL'I,IrI 1prI:\CIe-E1 B I-I-15 B-I1
r‘ CI.'I'—I.‘I
12-15
5-H
'I.I'iI~.'u- .:|I;lj1.|$l1r‘II;1GrBIAI 5
OII drim ho-It ‘II 2-III'~-2.5 15-IB
Fuul III‘I.Ul' I5DIl -1-|yq|—lIJi,\.1 ._ I].IJ3—-IJ.D5 0.2-0.-I
I‘-‘_.-.

F FI RIM E

I _ I Torque
I
Thread -
It"“ GI“ din. Imml In;-rn It-1I:I

TOP bridge eiue I.IuII: I 2.5-3.5 13-25

5ue1-mg lock 0.8-1.2 B-9
I"-II‘ , Engine hunger I:-all 2.0-3.0 15-22
Hear ixle 5IEE‘|‘fl r1U'I ‘I 3-5-4.5 I3-33
Rear brake tn-r1:|ue IInI\I mmmmm 1.5-2.5 I T-18
Ree: .II1I:II::II ebs1:IrI:I-er 1U 2.5-3.5 ‘I8--25
Swlngerm ni-m1. hr:-I'£ TD as-3.5 13-25
Fmnt epspeneran pw I:It hull 5 2-0-15 I 1EI—IB
Frcmt |I'II:II:Ic absorber upper IJCIII R l\.Ih3-IFhI\-J‘H-'|I"\-17*-'| e en-2.5 ' 1E—‘IEI

“I” mots
SPECIAL
f‘ _"'I
I_ Tug‘ Mm-|'||§ TCIDI HO . CI'l'I' FIef- WW
I FI|,rwI'1 eel I'1CIIOIl' U‘-7915~I5I34mII:ID I 2'13-EIII
'l|"iI|'IIrII Id'|II!I‘LBI* D'I'HIIB-GB-I‘I»@CO I LID-B
_ ‘H Flutgr puligr IIIII'5-II-3"‘-ZIIIIIIIIII 1 I EC-1'0
__

r"'“"‘~ I
‘Pu

um er I15!-re: raw. Ieer II" 20 .. 3

fir HON CIA MOTOR CO-, LTD.

—I--
 I-‘I-LI
‘B2 ADDE NDLIM

_"'-.

BIBLE MID IIIIIIIESS IIDIITIIID

.33 -
.-
'\\\ FRONT eenrce CABLE /
_'|'-Q __ |;—;'Z:1:;_
L I II I --‘I -*'——_'J'_’I::._;-:"_——_~....'_‘
-I T: _ -. —
___—'__I II I
I
-I I
H‘. '-. '
._\ . ..: . _,..- __ __,,,J H _ -I“-H
A F It

— 15!; CHEIKECABLE
.-"_"H

THROTTLE CABLE
—I__\_
EFEEDCIIIETEFI CABLE

I
I

,-".-
.-
_,-"-:-I-FT“-:::I'_:-‘.‘I\I.__--,-E .-"
' M Ir ff ""I
‘I’ ‘-~:’.-*-=.__,_=-'1; I .r'_...
F -.' -. 1__ fl
_ .
.:" l- _-If
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I 1",‘:-I.‘
'..‘i|I?v-* “Q1-
II"-=.../23
i__:_?>
‘=1’-:. g_ IPl:-_ I
II TI'"'~‘"TTl-E .' ,.I_-¢' -'THROTTLE mete
mlueenuess -_ pr;-‘I " , °""“-E .@' .' II__ '|.:_H
_-"__.I ""\
II
.l
. I '|' I ' I --I | I ‘I. I
I. -1'._‘_i.- I ‘H. I I I .. In
NI III ‘~ 1 I JII1 .-
.__ .~.,II‘ '. _\,-._
IIIAIH HARNESS
'.' -= ‘__-
"‘\
'-;_ __ J - - F~r§'_.' II II-“*1:-.
LII 2: III-RI A..C. GEN EFIATOFI
AFINESS
~- -ix. -I».1.. -_' ...'.el1?T'R- _.
3:-=-—
_-9- I:
‘T-.___ ii.’
H“!-|__
_-,.- ‘"-___.--"
_.F'iI Iie-= ‘II IE3" 'I€,|'.| /
_ ‘Eif
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I‘_. @<. I I I". I 22:1‘:
“\1_. Id ""5.
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_":—:§-‘I--.
J}
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.
'- /I
Ir‘
K _
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hm
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'
It L-_

'4?.;‘*~@.;’/1'
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I. L_i_I- f‘
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-;/ ' . ' I ‘I- I2? . J

Y"’\%J
-:- -F I i ’ r‘ --— -:1?"--. '- Fla

*~.__':
-II-I"I_

2o_ 4 '31 Dale of I-uue; Hum, 1ee1

EIHONDA urcrrue ccI.. rm.
 II-I"-I ‘B2 ADDENDUM

r"'“\ IIIIIIITEIIIIIIDE SDIIEDIILE

pl rfm-m ‘ht p|qE-1:g|gE 1|'-,I5pE¢TIflfl In I11; IJIII-he-I'=_I'IIIenueI at e-euh ir;l1I':-dule-d Irteé-ntenancr: partied-
I; |,|-Igzpflclf and Gleam. II'IId[II|II1., Luhriurtn 0-1 Renlee-e If neea-Ir-0rrI'.
'. Clean
: Repleue
Adjufl
f;l§'1fll.'} Lu hrleete
: H Eu“ EHCY
'|'IlHICHE'II"ER ODOMETER READING II‘-IOTE Ell
COMES
EV E H Y FIRST :§In... In? ' ">1; .3;-I /
ITEM
"'l'.__!' 5“Q90
§,__,
M‘: Jr
.-' DHflhr I“
"5iq;b:I 5'1-IE
3-3
I
I.
__ ' FUEL LINES
S ‘ _I_=_I._I_I'iLI_.j§rI'1.r»II|~I*eI=r C I."II fll ['21 _20-0
EM " THROTTLE OPERATION
I; .| 00
-C ' caeeunetoe CHOKE . - .
EC-B
2“ _?'
OT
E " AIRCL.EAI'~IE_FI _ NOTE I‘II n I-I 5:0
NOTE [2]
CL emu even Y 35
ELPIT
C Fl AN IIICASE B R EATI-IE R 1___;§0 rni 12.000 kn-II T
R S-FA FI If. PLUG Ia‘ ' R R -.2013
N I _ I ________ ?_ I 10-B
_ '. var. v E r.:-I_E_fi_§I~T_.‘
A .'_]E ” _!
FIEPLAC E EV ERY 2-E. IDE-
SSO
.. ENGINE OIL YEAR R 1,200 mi I2,000_IIII-II
EIIII ' I: I 2-2 I
I THII
' ENGINE
_

IIIR l"II'
OIL

BFI_T_'_l'E R"\"
-
FILTER
CAREIURETOR IDLE SPEE D
N
_-I'I'I
BC SEEN

III0I§I'rH
I

I
I-—._

., Lweexiwm-I E.I: El
‘I-F
..
I -.- _
3-ID
I3 ‘U. _
I0-10
F

' I 335' '

'
D
TE
III
I I _R_R_IIIII'I'.E SHO E WE -"IR
I BRAEE 's~I*5'rerII
0H.rIr.:E |_|iiI'I-T? SWITCH
A I 3-H
0557:.
EL HEADLIGHT AIIII Y _
3-‘IE
EI-IE
~"'“I NR CLUTCH
3-IE
SIDE STAND _. ..-

__
SSO ' 5u5PEI\I?sIDIII _I. l_|'., I.L '
I,L. en
NLIT5. ROLT5. FASTENEIIIC _ I I__ _ I 3-H3
|-it-‘J

N-EM " 'I'I|'HEEL_5I"5PQlf.E5 _ I I I_ 3-IE

e_.rfeI=_I=Ir~I&' HEAD 0_e5e IN [3 ' I ' 3-‘IE
I00 . ._
I-P

I Shuum hi ‘Em |cB,d U... an Iu "1 |-3-I155 |-[mg]; 553“;-_ I;|-IE5; the gu.Ir||r I1.“ pruprer Hiflli fl'I‘II:I BBIVIDIJ date lI1I;I I1 l'I'1EI5I'liI'lIfllII"I"
queIifier:I.
H In II-M |,-,m";; n,f;q{I;1;I;_ M |1=|g;|r|-|r|15I|'1d'1_'hI:ia item: he 0erIIiI:ed r:InI\,r by en eumurized Honda drrnler.
F".
NOTES: [II Rewrite rrrure frequently when rirllng III-11'-P5‘-‘Ir HIRI-
rgt Min |-mm ff§q|_|gflfl-1'! when riding ‘n-I rem I-:Ir'et full throtflIr IU.5.-"I. mI'I'I-
qap |=I;II hiqhar I:IdI:-Inerer readings. rennet it the frImIIIr"='r ilrlflrfll Biiflblhhfld I'W"=

.-.. I
|J;I;I_II:I'IIw.Ie: Nu-u.,1-‘BB1 1”
EIFHONOA MOTOR CU’... LTD.
 ___1

HONDA I
'32 ADDENDUM |:'m —

2. LLIBRIBATIUN
BIL IIEBBIIIIEIIDITIIIIIIS
5:-Fl-L L-.'!_'l|.'h'— -1|} .'-"I1'|"J -"H1

U51: HUNUJ1 I1-STHUKE IIJIL or uquwal9n1_

API SERVICE CLF-SSIFFCATIDNI SE r.Ir SF S -1E 1l'J'J'L' 41]
'b"|5CO5|T‘I"'
SHE IEIW I1-U
!'5.IT1l'.1II}‘|'J -L1-El
Dthar '|'Is|:'.c|:-ities sh-zrwn |l'l 111: |:I-mr: rn.1-,.- |',||:
u5E-ll w|||:rI !h*_' uuerag: H:rrI|'_|n-raturu In I,':\q_.|r
rid-nI;| -1-rrr=| -L within the In-::lI-|:a.Iud wflgv. 20 CI 20 40 EIIJ BO 'lE|CI“ F
I I- I I I I I I
-In 0 ‘ID 20 an :0» L

3. INSPEIITIUII Illlll ADJUSTMENT

HIEL STRLIIIER
_‘l
'“—I_
Tum ‘ihe {u:| nruiuq DFF

.\E:=
Lnosnn thu Izarh-ur:I1'<:Ir drain screw a-n|.1 drain
THE fL|u| lru-Jrl Ihe c:arbI.|r|:tnr ir-flu ,1 iu|13bl|9
cuntainur. AxI--...:_':-"—I
_ _|A~‘\ Ir?I |' I 1
|l|'l|",""r /"J

15 ""11"-F"'~""G ‘Gal-ulina n flammable nnci in

J‘-===;;:_ 1-.. - ._ I |_‘I_ ,,J__»
- :_—_:- _ -_\_,.
upluulve undnr curtain |:n|'||:li1i1:||1|. Du nnl
imulsl ur allow flIIT‘lB'I ur rpariu near ihe ,F_.-.:_'e*
:qu'||:I|r'Ian1: 'l\'hl]E drllnin-Q lunl.
r.
P-I
Ham-we the fuel Iiltar bah and uuli nut I!h|:
fuel Illlzr and D-rings.
D-RINGS
Walh the fuel fill!-I In Ciearl rlnn-llamrnnhhe or ;""-I-_._ J .---...-
high I‘!-1-sh T-l:l|nt ml‘-runt

HI.-lI1Lta|I the luul h||.|:1' Ind ncw O ring img

“‘"——~FuEL FILTER
tho funl uahm. Hand ti|;l'11an ‘I?-a fuel fliter halt
making sure the new D-rmq: aw in |:|laI:a:
Thcrr Iurqun tn wucificatiun; .I—-\

"runnue; 0.3-0.5 kn-n1 I2--1 H:-I|:|J --—-—FUEL FILTER BOLT

Altar installinq, turn the fuel uaalva I.'JI'-.| Ind

"Ii
chuck Ilh-a1 thurn am nu iuei Iaaki-.

—I.

20-6 _ 1“ mm Uf|1!L|B—I I'-h:w_,19B1

@ HUNDFI Moran I:n.,1_Tc>.
 ‘H
11"- B2 ADDENDUM

-1

BIIIBIIRETUR UHUKE
C2’-|':¢_-It Inr etlncicitri I:|1.'JI<.B lever ntmrntlnlt
the Ievu-' shuulci szair wlwrs pnsitiunnd Mr‘-vn
the -',hr;-|c.I- |l!'||'fl' all thi: way‘ lu ‘.I'I-2 let: arid
n-.aiua aura ihe I:-7'-|:II-Ia -waive is closed by" rn-Iwinu
the chnlm law-::r at thi: I.-.;;rl1._re1o|.
|\!5U_'|,_|$TME.NT
Tl::I'I-nu-:1 ‘Jne if-Dl'I1 CDHEI.

l_un-mm l'r.I.- -::|hlI: -:l..1|n|1 ||'1|.] |.lu|l the CEIIJIE

uusi-I9 up 4.451 unr-I the cnciku val‘.-'1: II !uIh,r
6|-,‘j5£|d Hutightnn tl-II: I:iB|1'I|1. f'a'|<:-vi: the 1:lIr.|lI:E-
I!'||'lH irl 1l'u'=' 'n'-3'3,‘ 10 I'|‘I|'-I I'Ifl1'I1' flflfl bl! ’Il.II'I" 1I|'II-‘I
;h giqg -,-3'--,1-5 is; f|_||--,- l_'lfl|_!"'i by c?i"u:I::kaI'|g fur 1 -17
"'|rn I'I-‘IE I-‘B -ul |:.=I.|Ie slaci.
EHDKE LEVER CHOKE
l|I'|1u!| ll‘|r.-‘: lr|'.|."-K C1I:".'r'.'|

llll IILEIIIER
AIR E CAISE BHEA TU BE
Tum the Itan-:tI-2-I:I-at all thn v'-aw tn the r-gr‘!

|'_flO5.I'_.l|'l Th: \i::rr:',un .Itl1|c:h|r|g lhr: \‘.'t|!|II-Erl-IIT|I'I|]

cum: and uraathur tubu and tiituunnuct thfl
tu|;||:-1

II“
FI.-.|-nu-.--= the :|;t|:w!. attaching the an I:='u-annl
ca-5e_ P\,,lI out, :hn inst: wirth the nlr Iiieaiter
ll-l1"l'l|!|'1|.

CONNECTING

AIH CASE
=19-.11 305- tha r_|ir -:|e|:|n||| :i-E¢'r'I&|11I.

Iflieait zha element in taut-I-nr,I -I |iI5I'1'-T|'v TU ‘R

||J|:Iili|'I d|.|1t1, |':llI:>'|.'-|'3I.".'B1-' -E|I'1\r I'BI‘I1itflIl'\1] dl-I11 UM‘
appél,-iIIg GC|I'|'l‘|Ill'I3F-.‘iE-1] qt: trmri :I':a I!‘-54lZ|'EI -J!
1i'.r' I-“||i!|'l'lIHl1.

R;-;p|,;¢;|; 1|-1,; blgmant -F II; E: ||1:1:r|saiv|:l\| rlirlv

Ir:-rn or damagur!

||151;;|I| 1;hr~ |'.t|":l|'I'lE'I‘I| uI‘|C1 t:\C|I'h"|EIZ.'I 'I"'IlI I1flI'll"4!I'-I‘

ing 'l.ulJE.
_,‘__
|n5ta|| ti"-I: air cleanrr case.

Cnrlnmzii the breather tube

ELEMENT

1815
Dan: 01 |:t!:UBI |'\|U‘-'.. 1931
20-?
-TEIHDHDA MUTUH CCL, LTD-
 HONDA /’_
‘B2 ADD E NDLIM
crn
WINE CLEARANCE I-IDLE

NOTES:
I inspect and adjust valve clearance witrle Ill:
-engine is euitl lbeluw 35-"-"C. BEEF].
I ltt-eta the lne.e1lur| u‘l' the "T" mark.

Tu cheek the ualye clearance, tempyg thg

flrflltltahnlt. tlrninq marit hole and value mspec
titan cups.

I"-l|ri2ljlJ5‘l' tlfluflrfln-tr: IT n:r_'.955.a;'y train“ ualya ad-

iultnt IIITBIIIB-G B-HBDIII II:-ee page 3-E-I.

HE sure in relmtall thfl GED!

_’__4,-.1
CHAN HSHAF T

IGNITION Tllllllli
LIGHT
IIIDTE The C-;|pIiI2l1'l‘I|‘B Dlseh-arge Ignrtlnn 1-,-1
lIflI'l'I- I! f3I:‘.‘l10|'y are-set an-rl r;ann1;|t big gdju 5ted_
Tu inspect the f|.|nr:tic|n nf Llt: CD1 mumpu
reentr-. ignition timing tn!-pecfiun prqflgdtlffl-l
are r,||1.-en hern-
Fllnvnye the timing h-ale eeu. "x
Cenneezr II tlehnmr:-tar anti tmting lnghl
‘Start the engine and Hlflw ir m Idle |1,5[l]
rpati. Cheek the ign-riqn tirnine.
Timing it-eurrect if the -nder-r mark alight with
the "F" mark at -tl!=.
II the ignltiu-I1 tim-inn ie incorrect, erreclt lhn
CEJI unit, e.-Inter coil end nuiaq gq|-|;|m¢|;Ir_ and
"BI-tlflflfl Faulty parts. Flrrfer tI:| page 20-22 Igni-
tlun S-\.|'5‘tern.
-'-.
BITTER?
GAPS UPPER --at
HEIPUHE the right arr-rle cnyzr
Inspect the battery llu.-cl layer
Wihrn the fluid near: the luun.-r I:y:!_ lnumn
TI‘IB bfll! and tape:-I the battery bracket fur
unease to the battery.
HEI'l'lU'-fl‘-‘ thtr battery filler cam-.
--~.
Carefully acid distilled wat-er Ir; the |4|:||:Iur iatrvei
rntrir using a small syringe nr plastic fur-In-qt.
NOTE Acid only distilled water. Tap water
will em:-rtan the service Ir-in nf the battery.
The battery aIh:r=tn:Il'|rlI tinn-
teim mlturla aeitt. Protect your Wu. sltln. Q I
and clufltina.
In cue n-‘I II:nnta|r:t_ fiulh thoroughly with
mm: and eenur.-t 1 damn: il electrolyte am
In '|'GL|t -I1.-ii.

20-3 '3“ Denenflsauai N0‘-'-,1QB_l

emewna MGTDH 00., ttn.
 E, egg) C?" eeaneeneum

Hep-In-::e the battery it euifati-an at sediment!

hlue lI.'_!l;lJ|'I"|1JIlI1'lH.I12lIl the brill-::||‘n.

CAUTION: When r:hedtlr||| the battery lilac»

trulytl lfiei ut ltllllng distilled ureter, nuke
T‘ nure ihe breather tuba in ea-nneratad tn the EMITIIIN INSERT THE BITT
hetllry hrnafliar r:n.|'I:Il:1 -ell:-aw as shown. BRERTHEN TUBE
SEEURELY UN
5l_IT_5"l'

I.-

II. FIIEL SYSTEM

| ‘l
SPEEIFICATIUNS

y--‘ml [care Identification nu. I PBIEA

Below I 500 m Above 2.000 m _
I.-lain |et (5,000 fri IE-.500 Itl
-HTS u tar Gig-av’
‘Throttle yalya 4‘ 3.0 '
I é
, J-at nn::r.lIe DA.-Ur _ _ _ .
-- -- ~i-‘ 1,";-F
I4
.-" J-
‘aha .

-I— eaea~. -HELFCJ

' ._ _ - _ an I.-_-

' -".-.---—.\
_¢5.- _' .

If

K - -;.

. at QI§§%%i%%
3"‘

e E5
fin]
@
/
_ . _____n.ua-u.na kg-n'|
I
--. re.2-0.1 rnal

em of Issue: 'I~Il=»._ teat "'7 T 2 O_ 9

IE HONDA MDTDH Cll. LTD.
 HONDA Ia
'e2 ADDENDUM [III] -5'

Hllil-I lLTlTI.|lJE
'|i'.Il1er- lrle vehicle =1 to big operated |;r_Ji|lir1u
uur-li.i mntrr E,-[I00 meters ll:i‘_iiDiIl It!l'!1| the
carburetor mus! be .'I|J_||.H]:|"|.I to i-‘l'l!IlI'D'|‘E' di ivo-
ill-ill W end -‘Ii-r-r-'ie5e eiilteuiit 'll‘fl‘liL'Sl'|',I|'l"|

I. FIE'r|"i|2|'|E HIE r_'z-rrI’1i..rrr1i;Iir

2. FII.?IT'-lJ'ii'B ‘H19 lI'ElllJlJ!l£1|Ill 1li;tiat_ [h3|||'_,3|;|_

3. l‘Il!I‘I'4.'l'i'i'-‘ tl'I-I! # T5 ma ll |El iiI'll.l iirnall 1+-ie

-1* T2 ntaiit jer
4i Filr:-lisaiir-‘ii-iiii and 'l'lH.iIl iliii i:iirt.ii.iri;-rm
5. 'I.'il'atl‘l'- i.i|.i the ier|§nr- tn operating 1ierr|r,:iura-
lute ISIZOI1 ifld Q0 driving I||r t|_:n rri.irti|_|t_g5
is eut‘Iir_~ieii|.fi
B i5'i.d['\J!-I '.I‘I-E Idle .rp~e:r:r_l lu 1,%l]i_' IDD mir-
wllh the ll-rnittln stop soi"ew.
WDTE. Iitiri atl||.|strnnn1 |Til,|!‘I IJE 'l'lJLIl: a!
l|I|]l1 IIIIITUGIJ =0 'E'l'I§iJY1! |.:-||.I|||:i' high altitude
Cl'ClE:l'flI.ll'Jll.

7 iI\IC1'i£l‘l 1.F‘il! '\4"I!PII;=r: Emrrsinn Crtntrri-! I|l-

loiinflr-iJi‘i Lliirilntii label as sihriwi-i.

I“-ICITE Du |‘ll.H attach 11"-is iaggi t|_| ,|ii-,- |i;;r1

that Bari be easily removed lrn.-ri 1iii- uiii-iiigile,

"t""""""n""""'3 Continuous oparariun at In

lltlludl lumr than 5,Dl2IiIJ Ieet ll,5-00 mereral
with the carburetor adp-rt-iirl for hruli altitude: E —-1—--—:i
may earn: the engine to Idle rciugliily and slell
and could muse angina diiirri-rig-Ii Item oner-
heating. When the vehicle ie to be operated
'- *—-"‘:I_::ii
raziritilriuiriuliy below 5,000 feel H.500
rr1atareI_ reinstall the I 75 rnein iet and adjust
l.I'nr idle lpned to 1,500 1100 r|1il1|i.

HE =i-HI: to mrltii there adiustriteiiiii I1! I|']lll|'i|,I1'I-

2;; “ ‘*
‘lg-
r-"'
1-.,

tullle.
‘-—_____— _ flu
‘i-—'=—i-r El

-I 0 Dull of lame l‘-Ioir. 1501

20 e:-uuuoit Iiiiotoe co LTt:i
 HONDA.
C70 '32 ADD E H DUM

5. CYLINDER HEAD/‘MLVE
EPEUFFEA1 HZIHS
- STANDARD SERVICE LIMIT
|
.-F‘-it.

Ca m mt I ct". mum z1_.g-g5__ mm

' |1.1t:t|: mt ggts mm _t_1_.t_r§§e rm
IE.'U?Etl'!l'|'l[1.l]'2BBiI1P 15.59111!" [1.UH'|I'I'l|

ETUHIIER HEM] IPIIJ-EEK M|l\Hl'-Z "O"

|" -
HEMDV AL

Hesnnua the front I:-uvtlr

I.»-PH. Dimnnnect the mtaltlt rltnr Truth Ihfl cvlinder

head.

Htlmcwv the murtlur an-|:I the up-ark pluu cap.

Hgrncmu Thn |,'.'|,r|i|'|-Eh-:1‘ ht-!:r|.'| ||!f'l titlfil Cm!!!‘

Hm-nave lh: crttrtkitaft can -Ind H-Irrt I11!

ctanitlhnfl |;.-uunmml-nckwtse to ilttlfl the "O"
mark on the GiI1'li|'lI|‘l lnrnlfii-ET with I'M Ifldflh
3""-. rn-urlt.
CAHBHA FT
Humutu: thu nzamthah anruttkst.

Remuuu thn t;'\rl-'nt‘l|&<r I12-ad lpaqe 5-11-'l

IN DE! MAR K
|N5TF\L|..fl|TiUN

lr|:ta=l the wlirtdut hunt! atsmtl-hltr {P6913 E-131

J,-_‘\. Hlmgvq the narrr qhuln Lemlu-rter Duih TDCI

-1r.|at1u 2'5-I-‘III.

Turn tha crankthatt cu-unmrcltt-flltwllé ind

aiiqn 1hr: "T" -1-utrlt wtth the mdntt mttri .,_-

».<
I

Ptm,-tr the cam chain outtr tht: tiun-uhatt sprock-

et, a||I|‘|I'lll'lfl the tptuckst "D" marl-t with 111!
cylinder h-aatl lndmt marit-

lnstall 111: t:i|m$hBfi mrumtnt on In-2 camshah .

-- 4
F‘-. and tlflrtten the inrncltt-t bolts.
_ II _---1-‘ _

TGIFICLUE: DJ—1.1 kt:-m |5—B ft-thin

tn-,-ml ti-|= rlemlintnq r:|nm'e-d parts {pa-gt: 5-

H1-_
r"‘"-
-*-*-

1- -1
‘I B‘!
Ditlufltauui N ., 1581 -
-D HONDA MDTUSH CO.,LTD. -I 1
 HONDA ’_
‘B2 ADD-E NIJUM cm _/ H
B.BLflTGH

— I
ITEM 1 STAN D AHD SERVICE LIMIT
Clutch gpri-ng tr N lanqm I 15-I mrrl [I175 in} I15 mm 10.39 in]

Q
fit it II
%~
.‘. -J G I T" ' _ -.
E!’ . _ __|'I :1 _.
., . '

git -.; *' L“ "x

3.5»-4.5 ittrm §
tan-as mar

—_“____ _ __L I‘ -'== 1.

- I-1‘. ____:r__r___:_ ._ In Q ' . _ _.
.E H‘
-.
~-__ _.--j"T-
wt: " It
I'll
. 'I:||
.-—-‘I-
|l
t ._\ I I ‘u '-.5 'III ||
k“'I— ' ,- |
._L .

Q _ -. .-'
| | ' __-"I I
I
" . -,

I 1"-t |

-\-t

20-12 1@* D ataoflsauw: r~|-:v.,1sta1 u

@:~ur.;n~mA mntun t:|::., |_'r|:+.
 HONDA
P‘-"h_
/i C70 ‘B2 It DDEN DU M

|r""‘-.
CLUTCH WEIGHT IJFIWEFLATE
NIJTE: For disassemble and lnitt-eI:tit:|rI =-H: | |CLUTCH
page B-3. I WEI HT

ASSEMBLY
,.|-ifi-.__
lr\.t.taII the -::|utc|| weights on me eluteh Gl‘l'|‘fl
plate at i‘I‘|O'|\'I1

Install ‘thl: |-.tL||.t .-lug and the eiutc-h springs.

STOP FI I HG

C LUTCH DU TE Fl
1|-11taII therdriue pkatu in the clutch outer Md I (1
tighturl the mre-.n: in 2-3 new in a crlesttrose J,"
iJflIIern- _ ® if.

|./"1
Install the eluteh damper spring:

@)
.
-J
DAMPER SPRING
scnew

en GEAR CLUTCH csrrren

I|1:.tt1II the dl'I'|'E' gear e-utsr and |:lult:I“l :I:r1lBt

I‘-ICITE: Airtyt the grown in the tlulflh DENIM

with the b-trues ti-n the drive utter.

I|'1$l_3_II the clutch pl-ates and tlitl"-5 IMI IEC1-IIE

r, with the set ring.

r"‘-
._\\

-!’ “

Date t1-I i55|.tE3 N0'.r., 1951 191 -

EHDNDA MDTDFI Gil. LTD. 1 3
 Hanna,-5'1
‘e2 ADDENDUM C10 /I_.-..

T. TIIIIIISIIIISSIIIII
5F'ECIF ICATIUII-IE
I
__ ITEM §rI§r~IeAHD seevice LIMIT _
|5h'n‘ttorIt |.t:». IH-.UT5—T.'I-lI.ILl:lmmII.3-415-1I-I425-trti 3'-1‘I.1flrr|n11l,I3-IH-ir|I

B. IIIIII BIIIIII TEIISIIIIIIEII

IE rnn1BflLT

_ ITEM ETANUMU 5 e|_?“'|'-|'?'E I PK‘

IT I M _I
Sr.Ir|nt| Ire! Ie-|t',|tI\ 2|-II -'r'.m I13 |r'.| 1'1‘ i'|‘.F| '
I'3.II In]
-- ._||
'Fu|I'r|:|t:ID.IJ. Itsee-Izneemtt-H11_gqm"-.
, ID.-1?1B--H.172‘-flrnl Itrrr.-nu ml
PIISI-I IIIIII
eerttewtl.
Dfiillfl the Engine \;|i|
“H
FIE-rI‘II=I'-II! the sealing he-It, was-tIrer, t-urmnner
eurlnu nn|:I push red.

Remeue tI1e E rnrn belt and sealing washer,

INEPECTIUN P-U5" HUD

Check the pttih red for wear er damage, anti

meaeure me CIJIJ. ,,._\I

STANDARD: 1 I.9B5—12.UCIO mm
IU.4?TB—O.1IT|'2II i|1I
SERVICE LIMIT: 11.91 I"l"|I'I"l IU.4iI'lJ in) A

Measure the sprint; free iength.

ETAIIIDARDI B3 mm I33 ||'||

SERVICE LIMIT: T? ITIITI I3.IIIinI

FIa|:|Ieee either part It it: rr:eay.tm|'nt;|r|t dtje-5 J-‘Kl

net fail within the limit.

TENSIDHEH SPRING

_‘I|

_ "95 Datecrf Issue; r~|=w-,.'|ee1 _

20 14 enemtm MDTCIH t:c:., LTD.
_—
 -H $2’)
HONDA.
c]'[] 112 ADDENDUM

JFK

CHANIILSHA FT CCIVEH

R E MDVAL

Renteve the tenelnner nI..I1~I=I rud [pine 29- IAI-

If"-‘\-

' Ftemeue the A.C. genereter nn-d Ilvwhflll

IPIBI I'D-IEI.
Fiemove the starter chain and mrocltets Ieege
1&5-II.

F Ftnmaue the ttrlniuthult c.|:w-ur ant! the I:IirI'I

chain teneinfler.

Cite-t:It the tenunner S-FIrUCIt|:1 ler wear or

_-—~ damage.

TEIISIIIIEI/I'II$I'I IIIII]
D-RING HJLT AM
INSTALLATION
lnltali the earn chain tenslunhr

||-malt 1|-|| D-rings un the i:renItehi‘It I:-Itwet

.-"-3 1|;-few I-tulee end e-mler.

Inetell the t:enItehe'It cetrttt anti Lighten it

with two ecre-we.

CHAIN GUIDE
truteil the tterter chain and seIreIi:Itet_t.

tnttell the flwmeel end A.C. generator IPIIIQI:

I'D-THI.

.--‘;
|I

8/_‘\.

‘Egg: 1:|f lnue: I‘-iI:w., IQBI 153 _

IEIHDHDA IHIUTUH CU.tLTCl.
A i _ A -
 Hanna.
‘B2 ADDENDUM
cm ,,»~-»
PUSH FIDD-
PUSH FIDIJ SPHIIIIG 1,!
IFIEIHII 'I‘II"IB IIIUSII I't'.‘t\Il.I_ 5|:|nrt_r,t_ |,i,|'fl5hEe flttgi 5|;Iq!I'|'||'|
I:It:I|t.

NCITE: MIIIIII sure tI‘|E pueh rtt-t:l '|';eih,Itt| i5 free

Irnrn rlutt before ||l5'lt|tIIa1Itjt-n

t /
- A",I'-'1' _
' 'I'73't .1§§5r;.
' - .'_t:I|.,

WASHER SEALING BDLT --I.

E rnrn EDLT I-IDLE

Ttarqtte the tealinq belt

TDl'-‘IEIIUE: 2.0--2.5 l-cg-in (TB tB1‘t-lhi

FIII the titer‘-ltI:-alae with the retrurnrnettctett tel

Ittaea 2D--'Ii- """'t
PIIII-Ir EIIIBI1 engine oil through 1I'|: 5 mm belt
ltttle ur=tIl nit flew: nut nl the hole.

lnttali the B It I8 I-1m lrttlt and seal-rig wmthn-r

NDTE, I..lu.- the prunnr length Ltulr A In-|'||]£|

hell mmr interfere with lI'Hl truth re-cl.

.-I-'-.

t--II-Ml

“I

-...

2o_1 6 1" Date ttt Ittttet rttttttt, 1-aet

Q HONDA MEIITDFI CCL. LTD.
 _ . -Jet I-Icutirnat
"-1.

tr"-'-, %7 [I1 I] ‘B2 ttttteetteutn

I“ 9. tnntr vrnttt/susrtnstnn

E11“? -'"_
1' e??? fir
_ _

(-- e.e-en kfrn _______,,_fl “ABLE

I11-3-H-5 ft-Ibl

F“
111-3.0 kg-In
I"_22 H'IhI '
e f
"II"
t I‘-t
NOTE: Flemcwe the dtelte cable
heItl:ItIt IttI tllltlettnlct the nl:|I|
I‘rtItt the ti-IHIIIII lever to 1'I|'I'llII'l'l
the Ieft hltulleblr ltulteh.
- e
t.t.-ttt... 3»
I1 II-—1I'2-ft-IIII . {Z1
,I5-g§gI;e=t-tttt~-
15-15 Ittrm -. | . _ I --..-,;,I.-;l-;-.--"-'-.- :-
rta-25 rt-ntl - "_'| ' ''
I—- tI.e-t.2tt "“’
I '= . .-
. _ E‘ 1- ,lit
' . -I I

FQE: "_.- — _ "

_’_,.-——-—- ‘I-. -. t'....._;..|_ —_
F. I‘
. . III‘
._ I . _ - _'- - _

at’ ' _ It I ' an-2.5 mug;

H,-' - _" '-I IIH—IB It-lh!
=-"=-=-I
1_D_2_5 ku_m___,_.--—-"""'
=\A
-G‘ "
I ,
t__52$?’
Ffiglgi-\;..
:_
SFHIIIIG FREE LENGTH:
‘I73-4 rnttt IEJ3 InI
SERVICE LIMIT:
II.
3
jw
-;I _ I.‘ .t _
I I - 5‘ - an-es Itg-In
‘If -|- ' ' I'lII—1B I1:-lbI
9' I

F .""I' 'I
"| %:.,tIt.._fl ~ 10-It.tI Itg-tn
III
I,t
|
I.‘ -
-L
" I22-29 it-lb]

“$
(*1.

III. IIEIIII IIIIEEI./SIISFEIISIIIII

SPECI FIDAT IDI"Il'S

ITEM _ STANDARD serwitze LIMIT

Sheek eheurber II|J=Iet| free Ienttlh -229.1 mm [9 D2 ttt; 1215 mm teed In]

um ttt Itttutt rtmt, teat 15 _

-ZZIHDHDA MDTUH CCL. LTD. 1 7
"B2 ADDENDUM ..~..

11. BAITEIII/BIIAIIBIIIB ststtrt _

SPECIF ICATIDNS

B-ttltertr II.‘-e|=ItI:lttr _T EAI-I

_§_|:_|e-cifie g1Iev||'¥ I210-1.290 IIUDG IB-FF]
_DtIttIng_rem ‘I.-II ampere: maximum

-III’_"3II-- HEAIJLIGHTSWITGH
. - - I///' I
BATTEFIY -
t
~ - - ' .
- .,'---.5 ‘______-'
,’=“-'iY_‘-1..
-._
:3’-""-t.,___L____l_| FUfl_.E___,..
.-- "_"'-t
_ . - |

-It , . ,- Lt t, t ._ 4
I | ' —
..
'- ' tI tI It - .t ‘- .
_ _ ____.-.J—-
_ "- :?_-____,_:____.. - [ sttrcette “— -- -
RECTIFIER "
-I-ii

_
Qjghit.
Iq " '-"!."'~I.-._ ‘t|| ' we‘\-
.-
‘\E'Ii&
t J__
ItI5.
'?*‘ "*-1-1.-.t~-e:'
.,_ u_ L_ ‘I’ i‘
.l
_FL
_ _‘t-"—.______
1-t. ___ _
__
‘ll 1

_' 5 --
|t_ . .

1"‘-—_-_
-..,,_
.‘I'll
_-
-!I—
-I . -
.

til tit-1-.5
;t--L._?_

.__;fj. .L___‘ _.
" .

LC- GENE FIATDFI

.I"'9"t

_.-f

/..-;' - .
r _ Ln‘:
‘Ht. I -
"'~I._ -- -'

e.tI-e_.e It!-III I I ' __ /"*~..

I22-zemei " _ __.._ _- _;;r -_ __._.- .5-*-'
—— ___ §

'-::-.:,l;t-l__l

-.| 4—-1
1

_ 195
\ Deteef lease: r~.|tttt_, teat
A
20 18 eheuue HIJTDFI CD.-.LTD.
 ,6 I-II)1\TD..Ht
r-- [:10 'ee ADDENDUM

D-B. LC. GEIIIEFIAT-DH GDUFLEFI

INSPECT I GIN

FIerflUit'E' the item e-i:II-Ier-

."’-I"-
t' Diseein neet the A-..I;. gnrierater counter
Mttatturq the reeismnee between the termi-
rials.

RESISTANCE:
fr" White-Green: til 3- -0.5 I’?-IIIIrI:I
't"e|li:iin—Green: El-.2-B-6 Dhm:

Fteeilaee the eta-tnr IIlt1.BI'I'|II|I'ItI IP eflhlf I'Bit¥l-

grtttie tt ntit withtn reriee.
t-"-\.

I"IEI|IEI'It'AL

Hem-ihre the frent curet-

Remove the gearshift pedal iirIt:l the drive

tttreeitut ecwer

;'"- GEAHSHIFT PEDAL LEFT GHAHKCASE

I_':t:I-tree

Dllettrineet the A.-C. eeheretur enupler.

Dieceitneet the neutral switch lead Ireim the

=wltI:h terminal il‘lEI remove the left i:te.nl:-
ease eetier.
‘I-t
If " FIItrI'I-I;IItIIt the wire nreteeter.

.—t ‘HIRE LEAD

Dete til‘ Ieeuit: I‘~tleiti., ‘I931 197 _

IEHDNDA MDTDH E‘.I£l,_ LTD. 1 9
 ___—__

HONDA. 5"
112 muzuuum [fig J,-

STA SCREWS
F|Efl1Cr|'|: ‘[wC| llfllui I|.'r|:w: :|n|_1 stator frnrrl the
|I-‘H C|'i||'||‘:€iil? CUYBT.

LEFT

Um the fil,-wheel l1|L||rJ|:r nr n hand mug huldgr

and mrur-u 'rh|| fh-who-el tn |'.-raw!"-1 ‘mu wank
shaft from :|.||n|r|g.

Humane the genenum rn1.q|' nu1_

.--t

FLYWHEEL HDLDEH Ii-L

D?§L'5-G84-UDOU bind strip hnlde-r

.-'--»,_
finmcwu the -utor

_,_~_

H DTU H
DT'H3-3-4-BDIUDOD

195 L'lal:-:;|1|1:u:: Ncr-'_ 198'] _

-EFHCIHD-I1 MDTDR CD., LTD.
F? _ _
 F“ HONDA
Iffi
tlklfyl
ctll ‘B2 ADDENDUM

fr’-‘-1.

F YWH EE L HDLDE F-

Align tha rl:-tor kuvv-at-' with thlr kflv lJr~ T|lE'

cnmkstlart and lrutall the gnneratur rI::-tur

Tghtqerl fl1E tflt-l.|t ."lLlt.

F“
T-DRDUE: 3.0-3.8 kg-ltl 122-213 ft lbil

I'-

WIRE FHIJTEIITUH STATDH

Irlstnll the BIHSCH an me left crankcase cnuuf
wlth the 5lJHJ'WI

Rn-my th-u |]|;l'||t|'tl.ltH leads |:sru:-u=|-,r an-cl install

1|-tr: -me prnmctur
fr-

Ll: -
Fl-

C.|:l|'l"\l1fl1' 1l-"tn l1:lllrq| swltch lal-L| lIl.'| I|‘lE W-l‘§"IG|'l

ll:-rl1l-mill

Install the left crankcase cull nr, tlliur: sl1r<>lr1l-H1

l_IlfIl|'-HT and HBfll’L|"lif'lI fllfldflll.

F1.
I2-:l."-l'lla~l:'t the -glaneritur wirr l:c=ul;:lt:r

|n:1,.l|'.| ll-la rrunr |!t2n.'E'l‘

r__

F“

El-ateuf mu-: |'~ll:rr.,19El1 1“ 2{]- 21

EIHDNDA MU-TDR cu, um,
 'a2 ADD ENDUM ___

12. IGIIITIBN SYSTEM

l_ l ‘ - ,_ ,4. _

| | __.¢ ‘\-
| I I l-*=- |'-. _
I .-IE-*?1"\_ -
_‘. \L’ I: ‘ .’ '
*1
'f3='-l._____J. J __________-" ,._--»--<51? _"-.___‘.

-3 ll-1 _ , “ I __________. --
|l_» _ .
ll
|| |'
CDILIHIT
I . . ,.
,- IGNIT [DH EDI
iilir I|_-ill‘
I _''-,__-_‘.I,
,{T.‘t _"' —i——“ _

._ Eh ..

'5' ' '-—.'L---':' l' ‘L lift. K '. _ ' __.- -

..
~. hi‘
I.
I‘ I 4;; ‘L-TL-‘.1-:- it
—
l
_
:1;-'1?
'?"""
_ -.
.
. a.
7"if
,=,l =--gift‘
_
I |_|'
I
‘\
-a.-1{E,-l »-T
f‘= F‘ "'
'=:'
| . _'___-—"l"__
_
,
I __--_
_,.
___ _
__ -
_.-
| ""'l-I.

"W
_,-l-'
I‘-
_n~,I ‘I \- I 5' -.I|

l§>;<3‘ '-¢.'_'_'_-‘H
‘*----:_-— _-
l ix?‘
‘-.

-._..-1;“? y___,
SPAFIK PLUG

""1
ll..C. GE HE H ATDR

_-'-~
IGl'lIIIT1DN SWITCH E1 GITER CD1 L

i _ ._ '| G .-F-._
SPARK ‘ii cu 1 - I "-

.1
lGl'|l'TlflH
I T T
l—TlTI f‘J. 4I CDIL
-:
FULE-E
GENERATOR -: -3

.-

20-22 Dal: of Isms-'. I‘-Ill:lv,, 1961

-DHDHDA MCITDH C11, LTD-

?-i '—‘ ‘ii “ -

 /T HONDA
C70 '32 AD DEN DUM

EPE CIFIEATIDNS
i

5;:-stilt: plug Standard __ _ L.l22FS¥_ll_LlE~lDl, stuns ll-ll3l<.

For mm climate ennw she |41°F I uzlzlesll-I.l lgltll. CHE-HS ltjleltl
For E1: randeel high weed riding u2-tl=sl=l-u ltlnl. I3l'li:IHS It-ll‘3tu
Spark plug gill Cl.E—D.]' m rr lEI.EiI~'-1- 43.028 tn I

lqnltimt tinting “F” tI1a_:|rlc 'l5'_J_B_]-ES;-Bil lditei

Fnlt ltdtlanult I'll?" B1iJCt'3,1DU rrlnl

TIlllllBLESl'lllilT|llI'i
Nu Snlult at Pine Engine S-tim but Hun: Fuel-I~|r
1. Englnll !-lIlZt|II iv-"itch “lIlFF" 1, Ignlt-urt lJf|l'l'lil‘y cirliu-l:
2. Pnnrw gnnnected, broken or shct-r:al:l w-res — Fauittr igrllllfitfl CD-l

Hem-een AC g-nnerutur and Il]I'l1l:ifl'1‘l -CD|| Lease or be-rn win.-

- Bntweert CD-I unit and or‘-glllfl filflt-‘r SWiliEl'I - fmzlre fJ\.|l!E' qan-eruter
Between CD1 nnit and ignition mil 2- E-euullclul-I l:-irl:t.lit
- Between lgl'llIllCll'l CD" Ind illlug — .|'3\C gen-t‘:r.:|'lul fllulllr
Between ptllee gerterator and CD! uml - CDI unit fellin-
3. Fi-.=l',-V tQl'll[:-l.l1'|C|III| — Faulty pulse l]I!l‘rt!1‘:l1.L|I'
4, Fnul1‘qI -EDI unit Fuulhr 5-lltilrllt FltTl.'irlr_'¢t|-
-E|_ AC g[ll'l::'|ttl:l-P l|lLlilI\l
-B, F.-mltt; pulae earl-erater

lEl'ilTl[lll BIJIL
HEMUVAL
F|fi|'I'|\'.l\|E the |Jti[tH‘!"|'

?-lt:*1'ttJtlt: t|'lE |Il|1Tt9'l|' l1l'.l:|l

I I
Date clflesua: NmI.,l'Elfl‘l H"
'E'I-IUNEIA MCJTEI-Fl CD..LTD.
 ‘B2 ADDENDUM HI‘
|_

Iii —

IGPHTIIJH COIL NUT

Flemeue the lett sitle eager.

Flertletre the relay hex .ITI{.'.t-l:hlt"|g |'lul'_:|-t1.d' halt,

Human-e the relay bet:

Hemetle the igltltlttll cull mount-ng nut incl

remttee the iqrliticln nail.

FIE LAY’
-t

lH5PECT|UN - - — 1

Measure the [E5-l51fll‘lCE ul :1-tu pl'lTl'|iI'\|' nnn til‘ llfi R l

sect:-nder‘; znll, ll‘ |t' |' all I i 'l

PHIMRHT: U 2-5 3 Dl‘Ir1" ‘ F Ill I liI_

‘ll
5ECO'|ll|DlFl't"l 3.11---11.2 K l:lltl-l -___ Qt, ___,‘

1 I ' ‘
r- t -| - ~——' | '-la _
REDIBGE !-:F‘EI' Cflll I1 11 rel:-stance ring; nu: ' _‘ r_ .-"'"-\
fa|Iw;i't.n-hr_' range, - __h - --
" I

F’ l‘ | '-I J
..

e Cl
' I

PRIMARY
ll I
'-J
SECONDARY
-*-I

Blll lJl'l|T
i‘
FIEMDVAL

Herntwn the batterq-and battery hex.

Hflmr-P-re the CDI unit.

""“-.

20-24 M filth! D1‘ Eeiutl: New-., I981

@ HUHIIIA MDTCIFI ECL, LTD.

__-
 F!
I "'“i:‘1“u”“ B2 ADDENDUM

F" INSPECTION "SK EXT

C-heelt the uelntinulttr nf the EDI utl-It termi-
net;

Hepteee the CDI unit if the readings are not

within the llrrlltsi I|"ll]Wh in the table.
/T"
NOTES:
I The CDI unit It fuIIt,- transirttlrized.
1' Fer ee-curate testlltg, it it neleeseety te uee
e ntecilled elnlttrll: teeter. Use elf en Irn-
nrntter te-ster may give false readings.
f" I Use a SAHWA ELECTRIC TESTER IF,-‘N
CITBUB-UDZEIDIJDI at KCIINA ELECTRIC
tester: ITH-5H]- '
_.l-"-

_ mm,+ Fruh-I aw ettt I IGH SANWA It. K ohm:

- KCIWFI. at ‘ILIIIII Dltrrte
sw I -=~= DICI

LIL!
EXT 01-20
F‘
| PC 4EI- IUD 2'IJ—B-‘IIIEII t_lJ

I
E I-51] Ill - Z0 .'.lfl—5'I]fl L '\

I |;r;| DI! l:I,'l

__\_

-.1
I

ff‘-. EIBITEII IIOI|.,/PULSE GEIIElIlTI]ll

INSPECTION J5.

l""‘ Ffltmteele ihe frunt t;t;rt.'tt-r.

Die:-eltltect the A12. generettsr emu cnuprel

Measure the ettc-ter eeil res-lst.a-nee between

LI'lt: I.'l'IBCIlI:'l'lllI wlte l|:rrl‘t|r"-BI and the gntmntl.
l("‘=.
EKCITER CDEL RESISTANCE:
‘I5lJ—i'DG Ohm

f-Iurte1.lrt- the pulse genenlter ecl-il resistance

between the Ll-‘il,lE_|I"|\i's:tl: intl lI't|l g't;|etn wit:
(_ terminals.

PULSE GEHEHH-TU-Fl HESISTIIHCE

ED 'IT{'I flhtrl

Date er! leave: I931

\§'I‘l|:|§'l-IDIIYII. MCITDFI CD., LTD.
20 25
 HONDA
112 ADDENDUM --fi_

I3. ELEBTRIB STARTER

STARTER IIIIITIIR
REMOVAL T

Renteu-e the mrter tlrive serecltet .t.nat.t ti-up

lpage 1EI-RI

Dleecnneet the stertnr cabal: et the mtl-tor

terminal. I
I

Flemnue t.ne starter nt-eter meunt-ltq IJ1.'l='I11i an-d

remflllt: the meter-
stenten cent: ___

.-Pea

I-"-L‘

.-—-,

_ 5'4 D tenll e: Nttth, leer

20 26 eaneeeiuunten ecl..LTtt.
_ _ _i __ Ti
 HONDA
' B] I] ea leettelteust
l>

It. rtcutlctt rtttutts I

The autprrlatle ehalrl ttlnslttne-r epneitl: pf it push rod, a pne-tleett valve and rt tettsipner sprlnp. The push red pesititetl is maln-
llilrtfld by‘ B lrtl-It-'l-tflrlt Inteunt cl-I r-em thltirr-sttlittshttel eil in the ts-il chamber. The amount elf ell present is determined by e
sore hine-cl action of the value anl:I the tattsiener spn ng.

When the tensiiener spring putltas the red up to I"E'I‘IHZlllB eltein sleek, the erle-wet; wet-t-e eperte ertel ttlluwu r.til t:t.ll.It:t:|.t:l:I in the
reel ID flew mm the all chernher.

WI'ltH'l BIIIEH IH1"l!-IHI1 11.!!!-‘I Id rfl-all: th= 1-1|-lsh l-tad dmtln, preswre from the elll In the t:h-aml:l-er ferret the traltle t:Iesel:I sl:l the
rttnitien uf the red is rtteintain=al:l.

TE"5l°"EFl--_ ' . -. _ tettslurten

nel.l.en ' ;j@._ K AH”
. _ .- - '-,1 .

1. _h_ .......
ti’
- ' PUSH net:

ea I *"*'
. . DNE-Wlt"l' VRLVE
" ‘I E :_:1"'
.____-I-____\l_
5- _ _
-l-I. _ _ __
. _~
__
i
.-.; elt cnenteea
:3

G mm EDLT E F
N-
+5
4';
-q-.
W-Y
_ 1;- ._-__'___
“I-.-t=I3'.3:'E-Iifi

-TENSIDNER SPRING
SEALING BDLT
'1‘. I

ll \|

E-i'&P..
-.

.l"-LT"
_t
I ll I _ -

.-v'=\": 53' I

it--_...j;
Dett ef lame: hIolr,, IE8] _
El HONDA HDTD-R CD- LTD-
 I-ICIIl!\iTIJ.!\..="'
"rs: ADDENDUM [:10 J;-..
__\_

I5. TRIIIIBLESIIIIIITIIIS
‘i

EIIEIIIE IIIIIES IIIIT STIIRT [IR I5 IIIRII TI] START

Pri:il;r=al:r!e Cause

I. Cheek -f ftl-ltl is glrltlrtg In NCIT GETTING ‘I'D - hlci fuel in fuel ta-nit
i:etI:iiuret.ei C-RITHUHETUR Cl-:i-ggetl lust tube er luiil f-‘lter
Clogged I'Ir:iat '-talee
GEITINGTD CARBURFTCR Clogged fuel tettl-:. i:iii|:i
hreether tube
ll.

‘J. Tnr sperlt test 'ii".IE-RR IJFI NU SPARK it-P Faulty tpitrlc |.l-ug
Fouled spark plug
GUDD SPARK. Faults; CDI un=|
Brerften er shorted high tension .-""1
wire
Faulty AC generator
Elrrllltért tlrir thrtrted ignitirgt-n cull
Faulty pulse generator
Fr.el.'ll"I'5r drlrflnrs-r:|.-et.I, brnliteth t:rr
shertetl wires

El. Test i:i,-llntlei ite-rnpreesinn LD'ri't' CDMPRESSIDN -er Fm-llttl reeelll starter
Value clearance teiu small
COMPRESSION I'iI-DFIIIIAL 'ri'|ltle stuck epen
tl'|'l:irn cylinder amt t.'ilst-i:iri rings
-'*~.
Damaged rztrllnder head gasket
Sell-Bl'.I value
Impreprtr iraltie timing

'1. 5ti'l"II IJ'|i' ‘Il2lI.Ir2ni'li'Iltg nt:rn'naI trtgrteng EHGINE FIRES BUT-in Choke excessively tit:-en
pre-eefluru SOC-IN STOPS Cerbureter pile-1: scisi-u excess-
rirulv closed
ENGINE DDESNDT FIRE A-r leaking pest carburetttir
lnsulatqr
J_‘i,|
Imprrrlper lttniti-en timing [EDI
rrnit err ptrlse gettereter fault-gl

5. Rernetie snarl: plug WET PLUG - Crtrhureteir fliaicitled

Carbureter i:I'li:il:e E'il(l‘l"ESlI'lEI'f ='-~.
Dir’ cl-used
Thrpttle rial-ire erteiessi-.ieItr eipen

6. Start with eltelte appil-ieict

.1,

EIIEIIIE LIIIIIS POWER

I

Preibaible Cause

1. Raise wheels eff greiuruel aiiitt spin WHEEL DOES NOT SPIHL-——r Elrelte draggire;
by hand FREELY Wetn rt-r damaged wheel bearing __,_
Wheel be-eelng needs lulzitliretiitii
WHEE L SPINS F REE LY DI'I'|'l! ehain ttr-l:ri tight
Rear axle nut exeesthielti
tlgltteti-etl

20-2B 2°“ Date elf Isaue: I'~[psi'., 1981

EIHGNDA MUTDR CD., LTD.

_——
 A HClE:I_;I"]DA
‘B2 ADDENDUM

{-1.
2. ljhaclt tim D-l‘B'55LlFI.= with Hr: [pogo FREE‘-BU FIE TDD LBW E-1- Punt.-mrutl lir‘:
Fl;-u|l:'5r tin: vulvn
PRESSURE NORMAL

r____| 2. Tiiv Fll|;Ji|'.i acoolemtioo from low to ENGINE S-FEED noes not?-* Clutch filpplrq
aeooncl CHANGE WHEN CLLFl'IIH I5 ‘Mom clutch disolnlate
HELEn5ED Warned clutch rJlsI.:-"r-ill!!!
ENGINE SPEED LDWEFIED WHEN
CLUTCH [S RELEASED

4. |_igl-|1l»,r lr_'€ElBl'S1;E anoma ENGlHE SPEED NOT lNl'.IFIEA.SED—#- E.‘-orl:|urP.~tur make-clmod

|f""". 5-UFFIBIEHTLY Clogged air ole-anar
ENGINE SPEED INCREASED Hemictant fuel fl-ow
Clu-ggod full tank hroittint tuba
filo-goat! muffler

f'-*- 5. C?i1la1:l: ignition I!-rrnhg |m:oHHEo1'-—_————-- Faulty CDI unit

Faulty pulse generator
CDHHEGT Faulty ionitioo Idvinoor

+1 Ciwock --nun |:lnnn|n:u- iHEflRflEm lmproom ualv: a-diusimont

'|."|'um valve squat
CFHHEGT

1. Ta-:1 cylinthlr cuntprflfllfln ul-Ing I 1-on Low -ii-_.-. Valve stool: open
nnmpraaslon pauqa Worn c~,-1m|:le|' and piston rings
r» ."\lDFllMAL
Lea-king h-oatl yulcot
In-iprmee ualvu llming

ljiiack carhutltnr lcr clo-gglng BLDGGED C-arhumtor nu! servlcod fru-

qufl-|'|t|'qr B|1|‘.'||JQl'|
HGT CLOGEED

Fri.-more spark nlug FDLILEDDH DISGULDHED ou- Plug not aorvlcocl frnquontlv
enough
NUT FUULED CIR DISC-‘ULCJFIEEJ Um oi n-‘mg with lmpropor hnat

F‘ l
H]. Fcemuma oil larval oaugo and chock DIL LEVEL IHUUFIFIECT-Ep-
ranp

-fill level loo hlgh

|;|-ll l|:vu| Di! lauol too low
C-firltlkfllrfltflfl -all
l'.L*l'JFl'RECT

11. Homo-vo ovllfldor hood cow-r -inl-1 '¥'AL"|"E THMN NOT Clo-ggad oi! passaqa
mapert lu hrleation LUBHIGETED PHDFEHLY Cl-ragged all cm-nml nrlflre

V ALVE TH AJN Ll-JB H lfi fl~.TEfi

F“ P'+HClPEFlL"|"

Che-cl: if oI1g|ou- ovnrhonts oi.-EH:-|E.r:rE|::-E- E.:tE£5\i:-1'9 oath-on l:|ul-|:l-uo in

combustion chamho-r
not DVEHHFATEU Use of |mpr|:||-oar quallw -of
fuol
(___ Clutch Llioniru
Fiml-pir mi:-:ILlrE tun :2-an

Data of ‘mull: Noun, ‘H351

'2 HONDA HDTQH 50., LTD-
=" 2o-29
 I-Iomna. "D
' ADD EN DUM cm ~_-1 -~
|-|.\_

13. Floaolarata or run at high speed
ENGINE DUES HGT KNDCK
ENGINE Bil‘-IOCIICS E |‘l] Warn piston amt! r.:'fl|r|rJr.'r
121 Fuel-a-Ir mixture too lean
13! Ur: of improper grade of luoi
Hi Excessive carbon build-up ln
rturrlhualrurr clrarnber
£5? Ignition timing loo advanoocl
[Faulry EDI urlil: or 3|'l'|'fln-|::1|'|-

Pflllll PEIFUIPIIHUE IT LBW lliiii IDLE SPEED

Probable E-auae _
1
Check i-an-lfi-on timing and valve IHCUH HE l:T____i,, lll lrrltlrooor valva claara-nos
clearance |2l improper rgnltion timing
{Faulty SDI unit -or eoarlr ad-
CE+l'Fl HECT eanoerl
-H
Chaolr oirbumtor 1ai1ol: screw lN%HHECT-Eh |‘II| Fuel-arr mncturo too lean
ocllrultrnent iii Fuel-air Il:'|i:|ll{l..H'B loo ri|:h
C-Cl-Fl Fl ECT
f
Chock if air iiiEBi\Ill1Q beet LEAKJNG (H Deterioraied |l"|:.Ll|a|!|.'1r {I--rirq]
carburetor -l‘|:Lllo1l:|r iii Loos: narburrrtrrr
H EJT LE Alfii HG

Tw ilflaril rm wear: on :uTEr=rm|TrEu'ri- ill Famw, carbon or wet fouled /_\_

SPARK eperlr plug
GCIIDD EPA Ff l-C [El Flulhl CDI unit
[El All generator faulty-
l¢'l Faolry ignirr-on coil
l5l Faulty oulla alzllraneel

Fllllli PEHFUIIIMHBE AT HIGH SPEEDS

Probable Cause
Chitk igoilio-I1 tlrning and lralaa INCORRECT ill Improper valve claerarroe “M'-
claarenoe liil Faulllr EDI unit
l3l Faulty nurse generator
C0 H Fl ECT HI For-llI'l1 arllranrrrrr
l
Dlaoonnocr fuel oube at eerburelor FUEL F1_El-“I RE5TF|t[_‘_TE|:|
.-" "\-.,_

l‘ll Lack of fuel ll'l tenlc '

i2'l Cloggflci fucl lino
FUEL FLOWS FFlEEL"r' 131 Clogged fuel tank .l:lr:la|!l'lu|' fllhn
iii-J Elflggori fool ireluo
Hornoae carburetor and check lul CLUGGEU E ill Clean
clogged jel: .---..
N illT BLDG GED

Check valve tlrrrrng ||'-JCUH HEIJT iii, ill GJH1 wroulrat not Inetallocl
Waverly
Cliilil Fl ECT

I5. Chfiok valllo spring tension WEAK I 1 I Faulw spring

-5-

HUT WEAKEN E U‘

1-

20-30 'DH'lIB Hf |::|.lE: H|;r¢__ ‘IQB1

QHDND-15¢ MUTDH Cflu, LTU.
bp
K
hp
[bAD
@
xgxArpg
HONW A D0
mo2 A D D _____ N D U M

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B5Gi ES
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