~ SHOP MANUAL HONDA. $90 CL9OL C90 CL90 CD90 CT90FOREWORD This stop monal is a reference end a ide book for the proper servicing of the Honda 90 series motoreyle, The Infomation contained horin i based on the 590 with equal opelicabilly to the CL.90, CLPOLL, clutch ceive plato —> clch ouler—> friction dise —S chitch contr —> primary drive gear —> pinery driven qoor—> trensmission main. shalt — main shaft coor —> eaunter shft geor 3.1. ENGINE ofscuPTON a counter shalt —> dive sprocket —> drive chain — thiven sprocket —> 10 the rear wheel, pro rosivaly in succession. (Fig, 3.2) 3.3. ENGINE REMOVAL $90, CL90, CL 901, CD90 1. Remove the stp bo: 2. Ronove the muffer 3. Remove the loft crorkease rear cover ond un hook the dive chin from tho sprocket, (Fig. 3.3) NOTE: Tie © piece of wie fo both ends of the chain 10 provort tho ends fem being draw nto the Gain cose. This wil foeltore the work ding exgine instaltion. (8 90, €0 90) Fig. 3.3 Hovering he ave ca @ Baie eta,a 2. ENGINE 4, Discomect the clutch cable ) from the elutch lover @. (Fig, 3.4) 5. Discomect tho ir inlet pige at the cylinder had and clko romavo the hig tension cord fe tho spark pl 4. Remove the battery cover ond clsconnect the battery lead from the battery. © Gives esto ¢ 7 Ushook the brake podal spring. Remove: the nuts mounting the engine (3 for $90, CL.90, €LPOL, 2 for CD 90) ond the roar encine under bolt. Pull cut tho two 10-mm hex bolt, ond the ‘ongine can bo separated from the frame, (Fig. 9.5) @ Citeh tovor Fig. 3.5 Enya cuenbiy €99, cT90 Remove front cover (C90), romove mudguard {CT 90}. Remove the main pipe cover (CT 70 model from free No, 000001A) 2. Remove the step bar 3. Remove the let cr move the chain font clip 10 disconnect the dive Note Tie @ piece of wite to both ends of the chain % 10 proven! the ends from being crown into the Fig. 3.6 tonorng the inlet pee chain cose. This will facitote the work ding @Wist pipe @) Fong» mowing bot ‘engi iatliation (C90). 4, Remove the miler 5. Disconnect the cir inlet pipe ot the cylinder hood. (Fig. 3. 6) - 6. Disconnect the eleciical loads ot the con 7. Fenowe the high tenon cord fom the spo coe 8. Utock the broke pada sping. 9. Remave the 2 eng wine urder tolt ond reor engine re moviting nite and then Fig. 3.7 gre cusnbly (C50) 10. The engine con be rencved. (Fig. 3.7)3.4 ENGINE INSTALLATION Genoraly, the engine instalation is performed in the reverse order of removal 1. Set the engine on 2 black ond lide i under ‘he frome. Route the engine wire hamess up into the bottery box whore the engine ard frome, ord femporarly insert a screwdiver or a tod of ‘expropriate diameter fo suspend the engine. 2. Insert the engine mounting bells from the lft side, ols0 replace the scrowcriver and Iestal ord torque the nuts. Hock the broke arm retun spring on tho lower mounting belt. 3. Conc al electra! laods fo tho wire harness. 4. Comect the battery leads to the battory termina’, pxsh tho wire bundlo up into the top ff the otter box where it will not Interfere with battery. insalation. —Ins'ollbottory ond check '0 make swe that the wires are not being pinched, 5. Route the battery vent hbo though the floor of the battery comperiment ond mie swe that the tube is not pinched or kinked, preventing proper venting. 6. Reconnect the clutch cable to the clutch lover 7. Install the inet pipe on the carburetor and bolt 10 the cylinder toad. Install the high tersicn cable hold down clip under the right inet pipe mounting bot. Mako sire that the © ring is Festollod batwoon the cylinder head and inlet pipe. 8. Install the muffer. 9. Loop the drive chabn over the drive sprocket ‘ond comect the chain, The open end of the choin jolet clip must be lestollad focing in the oppesite direction of the chain movement. (Fig. 3.8) 10, stall the chain cow, the rear crarkcase cover ond the footrest ba. 11, Adust the choin with the chain oxiustor ruts fon both sides of tho roar wheel so that there Js a slock of 1~Zem (0.4~0.8 ini when checked with fingers on the bottom loop ot mid- point betwoon the sprockets. (Fig. 3.9) 3.4 ENGINE INSTAILATION ae =O) Fig 3.8 Sating drecton of chan clip © Direction of rotton © Deve chan © Gn jo © Chain fit sina pote © Chain jin et Fig. 3.9 Adjusting the cainFig, 3.11 Saath a Fig. 2:12. Ronoveg the neler exendiy 3.12. Benovrg te rior Dtoer @ feter euler ENGINE 3.5. CYLINDER HEAD AL Construction, ‘The cylinder head is made of lgrtwoight cast lurinm clloy for good heat ditipction ond in- corporates the camshaft, com sprocket, valve, valve rocker rns, spatk edvancer ond breaker arserty oveihoc! canshaft is diiven by the cam chain through the cam sprocket, Combustion chamber ls of semi spherical design for better cooling ond Increased combustion effcioncy. (Fig. 9.10) (Squish Arec) This is an ares provided between the piston ond cylinder head to futher compress pert of the fuel (Ok mixture at the end of the compression srcke to create « krbvlence of the mein fuel mixtire The switlng fuel mixtue i dected toword tho spark plag whoro itis ignited. The fame propags- tion is accelerated, allowing the leanet than nema! fuel air ratio or the slowor buming fuel mixture to bun smothy, futher, decrecsing the tendency for rocking. (Fig. 3.11) 8. Disassembly (Cylinder Head Block) |. Remove the point cover ond then the loft cronkcose cover CAUTION: il may flow out when renewing tho left crankcase cover. 2. Remove tha stator ossenbly (D, (Fig. 9.12) 3 Remove the rotor @ using a dynamo roter pallor @ (Tool No. 07011-20001), (Fig. 3.13) CAUTION: When romovieg the rotor, caution not 10 apply excessive force so as to bend the eranicha,8.5 CYUNDER HEAD 4, Romove tho rocker arm side cover. 5. Remove the contact breckor ossonby D ord disconnect the leod wie ©, (Fig. 3.14) Remove tho spark edvareer by removing the hex belt and renove the 3%5.2 dows pi, Romove tho point base ( by Icking off the tives mounting scrows. (Fig. 3.15) 8. Rotate the crankshaft so thal woodkuff key 's aligned with the 3%5.2 dowel pia hole in the cambalt ond then remove the camshaft by inscrewieg the two boli. (Fig. 3. 16) ‘CAUTION: Pecfor# with the cylinder shud caruhalt dsossonbly and assonély rue tiahvered, 9. Remove the cylinder heod cover ond ti cylinder head. IF the heod is tight, op around the patting sxface of the cylinder head lightly with © soft foco hammer, 0, Disoxomblo the valves ccng o valve liter (Tool Ne. 07031-20011. (Fig. 3.17) Fig 3.14 Samovig te coroct be (© Conic Beaker stony Fla, 3:15 fenoving the poit bose Fig, 3.18 Renova tte combolt @Wooint ter 1 Fie. 2.17 Discaenbtoa the voles (@) teod wo fot ave Dowsl ia Hale ©) Valve thee 2Fig, 3.18 Checking evince bead warpoge ig. 2.19 Repotieg worpou cre Heod @ Cynder tod @ Sand pons 3.20 Chasing eo ude clneter 1D opiate goes ENGINE Inspection ond Rep: The cylinder head @ is exposed to. tho ich pressure ond temporature resulting from the combus- tion of the fuel mist ; futher, when the eyliner hod is unevenly torqued, It may dovelop cracks or warpage ard will be the casse of defective seating between the tect ond the cylinder ord rest in 965 eck, cir sucking. with consequent drop in com pression, Tro warpage of the eylinder head does not dovelop susdorly ond it may be overlooked, there- fore, coution thould bo exercised during reassembly since the uneven torquing of tho cylinder hood is 0 very commen fault To inspect for werpage of the cylinder hood copply a thin cont of blung or red lead @ on surface plate nd work the maing surface of the erlirder head on the suface ploie ; the warpage can be determined by the transfer of the bluing en to the cylinder heed. (Fig. 3.18) To comect the warpage, kop the cylinder head fon the sufoce plate with a #200 sandpaper, finally finish by using @ $400 sandpaper ond then inspect ‘ogc with the bling. (Fig. 3. 19) 1, Inspect the combustion chonber, inlet and extoust ports for race 2. Cylinder head combustion chamber, aod store re~t8, Ith he spor lag estsieat |] 11.0761. 122 cx 3. Inspect the valve guide ond volve stem. Valve ceroncn| Sted vive | Scnbie vee coi~a03me | O08 wodaoemcctrid | iS00z6in) wo 03~0.05mn | Oi mm o0or2~2.0020 eu | .0082tm) Chock the valve guido dianster ot the top, center ond bottom in both tho X ond Y cxes, ing «precision cylinder gauge ©. Check the voive stom with @ micrometer. (Fig. 3. 20) a3.5 CYUNDER HEAD 4, Inspect valve guide vee aiwne] lacy wan peneese Soeeen [os i To0850048 eee 10.3762~0.3966 inl Interference Fit SHo-aae - ; soon or fiesta : suemsas_| Be fle De. | gsr |e S28 IF the valve guide inside diameter is. beyond servicesble limits, may be repaired by using @ reane (@ (Tool No, 07008-00101) ond replacing the valve with ove of on oversize, (Fig. 3.21) 5. When raplacement of the valve guide bocoros necessary, remove and replace with on oversize guide, use the valve guide remover (Too! No. (07047-04001) end the valve guide diver (Too! No, 07046-21601) for replacement cparaticn. ‘After instling the valve guide, wsa rearrer to cobtcin the proper valve clearance. (Fig. 3.22) 6 Yoo Seat “Tho concition of the volvo sect plays o ‘prominent roll in dorermining the performance of the engine, further, Ir serves at a means for ssipating the heat from the valves. A valve seot in good condition shoul have full sxface conlact with the valve face Standard valve D—07~1.2 rm (0.028~0.048 in) Senvicecble linii—in excess of 2mm 10.08 i The valve soot contact can be checked by ‘applying a thn coating ‘of buing or rod lead ‘evenly on the entire surlace of the valve face ord rotote the valve while holding It femly against the valve seat. A good valve seating condition sill show @ uniform and continous width of bluing on the valve seat. Roworking of the valve, seat is performed by @ se! of treo cutters @. The 90° cutter is ‘used for facing tho valve contect aro@, ond tho location ond width of the seat contact area is ‘acconplished with the 60° and the SO" cutters. Finally, the valve lopoing opertion is performed by lapping tho ground valve face to the valve seat using. lberal amount of lapping compound on the volve face ond work the valve back and forth ving a svetion cup lapping tool. Wash off the compound congletely befere mcking the test x before cssembly. (Fig. 3.24) Fig, 2.21 @ Yoive gud reome —@) Cyeder teas 22D Valve ido srver Gnd hes Tig 25 voles ot covast aa Valve soot conact wih Fig. 2.24 Revolig the yale sat Valve vor erFig. 3.25 apecng the va svat earast Fig 3.26 Ertaat ond he vohes @ Leroi @ Stem saneter @ Hood tebe Fig. 3.27 Mecurea valve @ Dial gace @ V wiect ENGINE Inspection of valve sealing Assemble the valve into tha cylinder heod os shown In Fig. 325 90 tha! the valves are wall seated crd fil he cylinder head combustion cham 8.4 i in from the inlet ord exhast ports ond iF ony bubbles should cppeor, it is a indication that the valve coats we ro! conpletely sealed. (Fig. 3. 25) (ol_Exoust volvo (Fig, 3.26, 27) ber withoil, ject a blast of oir 2kg/em? 658-660 | Rea if ure sdoin | ‘esa W577 i fectace free eeloce if wncer Crane ts) ooesin | a's woora; (G1 nlet valve (Fig. 3.26, 27) amis | te eer torcth @| iagaomaasein | “daa tesa Sem dla @) (q.2147—0.2153 ni | 6.495 0.2141 H) 0608 | tepoce i ce rae @| woor—ous2 | “Us WOIzK Concearcny| 00278 | Replace f ovr etvolalacn| —Oa0tziy | Ou3 W0iZ Velve Mechanism Both the inlet and eshaust valves ore incarported inthe combustion chanter. The inlet volvo Is de- signed larger thon the exaust valve to afford groaree volumetric efficiency. The exhaust valve is constantly exposed to extanaly hich terperaixe; therefore, It is made oF speciol high hea! vesistig mexeral to withstand the high tengerature as well asthe weer Tho com chain rovolves at © very high speed Within tho cam chain chamber which is located on the loft sido oF the cylinder, making it necessary YO use a hoot rosstant os wll os a wear resistant twsber on the com chain guido sprocket and com Chain tensioner roller to proven! chain noe. Further. in contrast 10 the conventional puth rod type of mechanism, this system has less roclerocating mov- ing par's to coxse hitting noes, making the operationsuch sebotter ond qubte Is vary igh spaee to erble the increase In power ou. (Fie, 3.28) 1. Valve: Spring Dual veve singe 0 uted for oda sheng ard to prover? valve fading at High enon (a) Oar vole sping (Fig. 3.29) 3.5 CHNOC HeAD siteble foe24.942 0.973in 2 Comat In a four ks cycle age, the cot mates cre’ rvaln for avery to revcltlrs cf tho clans. The power to cive te com shaft ie teach the cam chan ckven by tho sprocket The: beating cl is pes it th ight side of tho capil and fore cut of the holes the cam to Licata the com alas, he rocker arnt ord the slopes. The corset 5 rnade of spacil ast tel wih the can and the bocing crea tel precisnly gard cher far teainert. Ippon ot bot en ey the becince i tho cyledar bea. A com sock! fe lntoed on th left ends ofthe corsa wih em bots on Is ver at ore ta conch ‘peed by th tien pocat prosited fo the crorksoft end, though the Ikkt welghe endless dar. (Fg. 8.30, 31) The sero loppatcleaonces macared cold ere .05mm (0.00219) fer beth the let and exh The it tho clearance yeaed when ste rocker ‘1m 1s agpbw tha hee of the eam lobo herder Yo cbloin this concticn, the craft must ba roleed so thatthe "7" tet rat a the dyrom rotor Ie aligned wit th Hing rik on th stair ceri, te ocker am ray been the itng sep of th cam, The coering ard cosing oF the vale ke deter rived by thm ison stroke ord ie td tothe carlo rain. Ding the inet cycle the ret velve is cpunad end closd. Owing the exit yee, the tome opening end closing sean foles lace wilh the esha wala. Tho open ange between th opening an clos ig the camo ce the ielon travel, however. shee i Ib the sane os the cristal roan, fle epresed in tome of angio novels ‘When pciat "3" nth Fig. 2.32 pases beyond the racer erm, th vetical movement ct vale erases, ord ots corti pen whe the com Ibe cones 10 © pea, the novaran’ of the vols owe doyn ond. comos to a batt at gin! "b'™ on tae “he toppet cesanco is eduted when he socher fm is ot the expceed section of the heel oF the cor between porte "e" end "92.5 Cuno HAD » 1. Vole fini Fg. 9.99) ea Moe a wn (io 3.34, 35) alee © coe @ berm Feiee fom speecat tol iano facade —> £9.45-~59.385 (7103~2.108 9 Serviesala Unit —> Reploce i ender i a 5300 1207 te is al daa © Cantait @ Msenae@ Slt bo (ci Fie, 287 Tong wamice f onde 4 Rocke rm (Fig. 3.36) (oe 5, feca cam shel ip. 8.971 Sat qp1a-ape D. Reattenbly 1. Apely engine sil oto vale stows before ortly ito te eyes bee, 2, Auomtle reler em or recor orm call fo the cyl: haar ord ial ocr ers ake cover, 3, Into she cylncsr ba (Fh. 3.38) NOTE: Beeche cow Jo mate sth! the che ood gost’, cylnser a gait) and cam choin tle! i hited merely t2 prove ol leas 4 Intl the cylinder ed cove" ond then the ‘ute agora ond wim 10 1S0~200grem (14.5~ 1811-11, nercper eraing nl case ol leok. (Fg. 3.39)woodtt ey © ie on the cylinder carts ord inthe civcton of the eytinde teat Alp the “O Ink © on to cam spac to the redox mak cn the cya food (he seracdat mountig bot 5. Poston te crntthatt 20. thet oles wil be in lne wih the evinsercentene) cad en cornet the exe chin). Fig. 3.40) 6 Sica the coma D ro the cplndee teed Weg the sprocket to pi le toward tho tend cove The volve rd the piston oven the Yop da corto poston of the canorstionshcke. (Fig. 2.41) 7. Asana the post bone (on the camshaft eatersion using an cil sed pide 40! (Tool No 07057-08801. (Fg. 5.42) anege fo tha ol eel rey real if tack is rot wed, weairg in all ck & real te 3x ext otvence, 2% Asie tom contoct brealer anQly ond 10, Atsunbi he A.C. gicerice on ths cal, Perfor tape! coaronce oxhtnert a anh fen tink. 2, alll te pale cover ce the elt crmbenee 2 ayide in ond asa te 3.6 CYLINDER A. Consrstion The cythaor i made of pci cast honk The imide eyidar wal 5 expoved to Fgh temperate cad prose ‘ogether wth the wearing estion cf tha reciprocating piten opsctina ot high speed ace a giect woul alae. Added 10th Tho duct In 15 0 end tha lovee cboct ad tte neta dst ccterinang te oll wil basen the (0 of wear, tele, eugcte comin shuld te geno the eearing of the of Fler ad the ii cionar, (Fg. 3.49) Toe peter reeshee tho conbutin enerzy and vensals the igh recprocairg maton to the cork ‘tal wero econeited tothe rotaband tion Due to the high spoad fiction betwen th ton rd ofeder, the seicton of the moti ond th teleanco of the evieg pails est ba selected with ect caw. 4 cvinves 2:40. Couette en Sn Dvisthe ey "O" nok @) Can edn Gerth Gon aren) @ fobs be Fie 243 Cyne3 ENGINE ‘Ho pion i ai clurinm casting edo fem select ratoial. (Fig. 3.44) This motel ie ght ax etahle or oh speed, in axon to haves good heot conduc propery to disipae the heat aptly. Turhamor, the co offclont af bea expansion ic nel, ts mninizng the warpage a elowied lorpsrohze end peiizg tal piston to cyledee ceoronca doch The s2cp0 of the piton isn lista oper. The heed GF the piste, composed Io the skit, 1s expoed 19 gtr erporotra or ence the econo got Ih topered amdler toward the fon. The toner ing of th piston dso fads to lesen the plten stop when the thot eighty sagped without! tho roe being loaied. The pisten erploys 0 thea sap ‘ope, The bon pa Eee ce is edo Whicker, theatre ing in ger expansion ot High terperanre. for ‘hs rear the danetr of the pat abit & mae role inthe diecion of the pen pi 30 ha a ‘he igh cperetng terperakza, tha psien wi orcard io 9 tue ceelor supe, Tho at is ‘xray provided with Maiy Yo cise that no chfertion wil real evn from aended con'nscut asia. “he pivon pin is offset {rm 104m fom the pllen cenerta in tha drocton of the Inet edo 10 that when fhe lion appronrhes the tepdox- cantor ofthe compression sete, he £do loa fon the eylior moves from the ah side 10. tho la. Wiha "O° oft, the point wall move 10 ain with tepead-cator of tha comerasion stake, (Fig, 9.45) ‘As own In Fig. 3.45, tho port of axinun conbustion presse occ afer the Lapclad coir, turelere, ti papoie of the Ofte! Yo nove the pot foward tte poit of weaker presare which is befor tepckadcerer, and by 30 dag, capes tte poveru presre revonent ord nck i) polo 10 ininwe te ptr 2p. “The pion seg price 9 Wit! ition of a bho prceer contusion ond Hansson oF the ro ala force ‘he lop ond second tna sore ote sal forthe ‘eitaston charter, the ol cont tng topes to ‘rent oll from the cyiindor wel 12 cartal te cylinder wall Mbzofion Father, thoy era? ‘he hgh temcerenra of the sion 19 the eyledar wall where it fe clitpated cut trough the cylinder cxaing fine.as cyuNoER 2 Fer the reoton @ spec ally of cotter ie tod to provide sroncth, wear restonce, oat ve o_o Tr since, ond gore heat contig properion crt yd furber it ghee pasieieng Yeatnen cr ‘rex ang. ® va top th erpaclly le pred on the over sufoco with had cone ard fhited by wot Te prove’ iter, to Wikre of tho rns 16 rode rerower aed ices. nets mode seller | Se Sy to hen te presse aarst the c/nder wal Father a lop and second rot oe mado at ong Nan TENURE sig taper wae it concts he eyindor weil 50 Ye compen ta Thar the tna regurad for wearin ie lator, oa (Fie. 2.46, 2.47) pe a“ g ats © @ top cmp ng B Sd Cepensn a 1) Song tenon 3. Disosterbly 1. fain he eh section 308-8 dre wih 2. Remove the an esis ® fom the tink sprechot ond rareve the cylinder D tageter With the chon. (Fig. 3.48) on i yaaa Fe: 248 toro te ep © Gira @ Gm denig 349 meen te pit (Cre ba ee ran le, 3,30 tenoviog be sso, Bion Pac Pen a Cyto ou eS hase |S Meroe 3. The cam chan aide ralor ean be removed from the cylin by rowodng o.com chan 9800 raler ph 4, emave the piston pin clip (ond ask os the psten pis to chan tito fr the comoctng tod. (Fig. 3.49) CATION: ‘When renuing he piston ia cp, core eave bee © tho ht lp dome ret depo S. Fenoie she petor nae) fen the son by weg a sing removing tool tpecil Yoo. no too) Is otal, the enge ay ao bo 10 roved by tend, by spectra the tng ot te ‘opening wih Roth Hn, the ng sal rat be ‘weet. (Fig. 3.50) Inspection 1, Macau the ejleder bor, taper, extol rar ‘wih prechion cyler gnige @. Toke the rrecaromant af th top, mile ond boom in both he X ond Y ones, (Fig. 3.51) The cesonca betwean to patos ca evince will peal ale! te ervine perfomance. Bo. Cait of to ton bole elped, te ceca in convoled vary covey. The clcrrees aa ot te save, however, cty crea fe gretar thon O.lnm 0.0049, the eer sok be Iokoted ord filed wth on eveses piston Ovevtue pare a'e ovale in 0.25, 08, 0.78 ond 1.00 rm 1.0), 0.02, 003 od 0.08 3 Winn emouing cot deco from te piston oe ond ins coves, oo stood be onercsed 228 ot t9 cose aly scothas ce daroges ‘0 the piston 4 Wests tel dhit Weipa perth to he pston pr tow. (Ha 4.32)5. Meaiie tho pistn rng sido cleormea with 2 ‘Niches ome. (fia, 8 $3) © toe 1 heen sp © Toco ores 6, Paton ona r3oH6 (ima Fon vgs Mecane tho sng ent gop by intra the piston ting Dino tbe eylade 20 that the Sa igh mgs le te Glee ok tha. 3.53) Ning [Ee] ttn | Paar Notes 1. Ovesize pit segs av ovale in for ‘izes, 0.28, 0.59, 075 ond 1.007 100, 0.02, 003° ond 0.04 in.© 8. ENGINE 2. When king pian ing end gop esse rent, ner the ing coe ito te ender to rover scoihes geusee 16 th eye Di Reastorly 1. etl the pls sirgs en the pido in the {ere rereor ei woe removes. Tha berom ol papepeniars Shuts: 149.56 ce met ‘en non stn a Ela «check om sea be ne ce fl feay slr or ‘in the groove, This can be cone by rolling the: fe ice fre! coca. nl pin goo dM 20) The ig tn So aed eo down the wil cnse ot papa. Te opt of he D (rr |S etched at tho ord with the bitist oF the rede’ ne. Ra 3.57) ie othe cn thy oo wi ite inition oper psy in eae. 2. Anes pe to ant ad he cies tr 24/ caKYe pecrs be rensied $9 Iter the nitan pa. Alnave as 267 Pang Inuell new piston pin cs D Now CAUTION: Tha. clon st be sont 30 tht the "nN stomped on the pasion head ie toword tho top tho fe engi isin ho rome. tt (Fig, 3.58) 3. Rsanbie tho con eho oud cam oi guide ral to the syle A ntl thee ‘CAUTION, Te tng gop of the trae piston rings shel fe stogotes 120° opor se of the piston ring conpresor fool (Tool Ns. O7032~03901) for Fataing the cyl Fig, 248 Avenblag te pan wil prevrt danas to the een ing of BUN" mat Tr ll pty he wok Check to mote sw thet te ear cronser 5. Inetal the syindor head br cccondoce with pergh 3:50,2.7 cm Cat Toone 3.7 CAM CHAIN TENSIONER AL Conattion The cambalt is dhiven of of the sive sociat cn the errkalh tragh the com eh wich 6 Tooele on the lft sce ard teazed win the com chon charter, (Fig. 3.58) @ cm aps @ Cen dete near @ com toh (@ Can ty ps att @ con den © Tove moat (© Gas dat wid rile (ener 0D Tee pda 2 ENGINE B. Dizcatembly Revove the A.C. generator fn acxdnce wih Frocede described iy encion 3. 58, 2 Rovave tho canal in frocediwe described it secon 3.58, 3. Revove th ean chon frm the tring pocket end thee the con cin tide spoctr by reno rove atlaceg the cx lain emir sting pote @) to fe Senne, (Fig. 2.60) ing the f90 Sm 5. Urcsw the 14am setng io @ tron the rd of the fonder astra! ond serene the srg D od od 8 (Fig. 3.61) Fin, 341 terovtg the lesa aa vo thes sang oe ‘3 Soto (8 Feerw po od Inspection Check the eit ht ne Tene aie sie DL Reasserly B fenton prot B tees ta ‘Asunbla the consonott carts i the vovese @ em ecg ate Frocedie ot dhassenby datcbed section tem stra 378a8 clUTcH A. Conrction ‘The Knction of the clveh i 19 tonpealy le ngage te erating ofthe rota rolin between the engine and the trnaniion chrag oor che oe then fier the gaor change, perit a. areotk ower froretion, The contin of the eluch wi hove o voryhe Fact en the ofcensy af the eee Tha etch en al of the models cre of the con veil wet te wuitiple dic. The C90 ord C190 medele reoppormes. 2 evanatc Foc to perce the chfch ergane ond desrgeae freon ‘whareos, the clter models ore provided: monal foretions Construction and Operation of Chch The ch Is Bomeen the engine body ert the om ahft tonne, It eomecte or ucomacts Foner teranion wen roqied, sch ex i 96a sitag, ce stxing she erg, ot. ‘Accardngly. ch gles ox the dosroe of ergago- nent cocrcy, tbe city to deronge carpet. ioctinas ord signage whan engyaed or die ‘engage, wfc. bocce ingot, ($90, 90, C1901, CD90) “Te ech of the ode! $70, CL70, CL7OL, CD50 ea wot mitipoe ype ASshown in Fig. 8.68 td Flos 9.64, when tho gh crakcosa cover I removed he dich exter potions axezsed. Id tho etch sping, sve late, ch ple, od chech ftefion dae ave cxenited Tho fefion dsc. mar teeth ait ne fer cicveixace, ts oven fing ‘he spe eatin the oxtrnal cheurforence of the hive goo, oe coupled ta © ut withthe hive ‘sox in tho Geecton of rotation. Tho crive. gasr Tnmcirte on he cial! Hough the ce carter (gid ond can ite feely onthe crerkchalt on the other hard, thero a0 gover cu in he intrer of the dive plot 1 F the apne ca! at the ip of eantstalt; ha ave pote i fasered 10 se crrk- shalt by 2 1Sran lok rt. fering 9 sale uit. ‘Sree, 09 the exterior of the ve poe end ehich Plat, teth engage the cover et inthe nore of the clch Ferg, the cuter hich, the cee lala, ord the cuts ploe fous gather wih he arkitol, Theale, whan the chic is eraaned ae cuuten q ZA Tig 5604 Clea melvin 590, L9H CLFOL COVEa © é \ inves, \ ey / £L&E- w § aaron ewe @ Die pw ory nin © Oae aleen ara ny Oth mr Gat ee @ One com slow ENGINE the dive pate, chich fiction ds, end tha ehh plcto oe held ky tho clutch sikg forming « sngle rth by mua Fon end cetiog the. ne pon f the rotation oF the eran tote eee The dive gier i ergasod with the tien goat rd the power & comeyed lo the ronan. When the mana lover i pzed the eter da- srgooe lover is roto by the ctch cxbla, The loch har om, ettzted 10. the cutch ver, rez the ctchIfter by a rteiond! noron the cutch der poses the cltch exer though tho chien over cover, rosiceg the free of the uch spire Jo 200, ond tech the ave pe dluich plow, ed fetion den. Theafors the ‘ataion of the dive plate ons cul plate i not onsite 1 ho Fiction dic to diva gaar saps end power trnuniston i rol povformed. In on, te lich dsnper sing is isle sex ways 10 prover noes coised by ding Inthe Giecton of tation of the dive clote axd the hich acer, pravertieg damage 10 tbe tah. (C90, Cr90} (Fig. 3.638) The each ind on the C90 or CT $0 ko wel type muele dss, ovonsticaly operated by canal force. + Chich carter @ ond dive gear ‘A screw spe Ie incorporated to ongige the etch tng sat and lta to maton te euch erooged wie weg the erabe canprenn foe ‘rab. + Chech weight @ ond elaase sping @ \Wihon the ctch rovotuen atone = erected speed, ho cenilgal force causes the chich \woigits 12 rove redaly cuword, ie begh com rosin the catch flea sorog ‘As tho chich speed weveles, greater fore | opped 9 tte raecr9 spine, overcng "no force of fe loose sping cr periting the uch ploto 10 engage wih. tha ton ass, that, peiting tho sewer frm tho engine to be exerted 10 the train a 10 he roar shoe Tho clutch rooms srngs contol fhe mirirum spoed ar which the ergie expat var tha roar haa = Chtch eit machin Te dive ple fice tothe carkhal i the lsc congonon cf the chich osanbly. Chechao cuurew “s bom lv lehich le auanbied to tte cive ete By tapping on the goer charge pods the teh con pote = ackntes, eaitea the pet fe 10 ba epee ops the chich outer ond bsengaing Ho chick. Siren the change pmsl 9 diocty comeciod fo the cutch com ple, the cltch ésergapes efor the cea change is aected. ening 9 Gerging 10 be perfoanad smoothly bot pond down wihow iiuty B. Discssembly 1. Renore tte chich cover, Fg, 2.65 anoint ey ar oe 2. Rerore the cht cerlare cover. © cary cor cover 8. Remove the chich over cover. (Fla. 9.65) Bcd ow4 Unlose he 16 9m lock har one urcrow the Ide tk mit the clutch eaerbly @ can be renowd ce 0 nit (Fig. 2 66) Use the chich over lier oct No. 07024 1103) 1 hold te eh ers omen he lock int wit te 14 mw bx wrench &) Cael Na. ‘ornee-03001 Flee .68 fener te ch enemy Cay ar Gn eho Tape @ Vern tek at @ Chae ct ble 5. The wok of duassybing the ich esseniy B can bo sirplifed by the uss of ececol too! © ool No, 07038-00000), (Fe. 3.67), Note: Wen wing the meet tool, ould the ae Fete, daspar sing rece, ceria th ive ate comct be compete! @ iva eaounting rd combing fe Bch camasy CInspection 1 Quick sire (Fig. 9.68) Oa @ ite Sener Use call eng favor (Tool Ne. 97134— 999011 for tesing the valve sing tion,2. Friction dec od elih plate eee Tiamat | 198207 8. Guteh ost and cre alata or eh pe Tara | soon | ieee Gatch conor ise (Fe, 9.70) ig: 309 pacing he sh poe @ ewe ese @) Del ce DL Reassanbly 1. othe hich str, ausentsthecteh ‘ping, diva pt, foci dec and dutch ells, cd then cengres the dkve pts fh accorderee ‘nth ie proced tn section 68.4 and inl tho 201 te; bo atl etch damper spin. 2. Assoblo te dive gear, lich canter ge together wth the ech auently on the eank shot. “angus thé lock nt 40 980~450 bg. om (54~64 ef] NoTes The lock washer (D must Ge locked by be deg the 18 afer toute the rut; it hw sn (of the rut doos rot len wih tha tab eben the ns fitter fo per locking, do m0} own. (Fig. 3.72) 9. ‘Ausenble the dutch oiler cover 4 oval the eghr corksoee cove, ‘5. Inv the chten cover fegrher withthe chick Wer end oll ida Fla 3.72. Bondo wb ofthe feck water toa naa 2. ENGINE Oyu 5 Fe, 37 foe @ hbretg ot @ cont © aren ec @ Twin cometh @ tater © Comnatt © Cm den @ =a9 OM rum AL Contttion ‘The Hondo $0ce morceyele wage exeloys a 02 type oll pune for to oxrier mods ond trocheld ype for the later meres fo furnish of dae presse 1 a novng pate “0 orsvert ee Gnd mrisze veo: Thee which has boon dean wp fom the sump ( pased theagh te sicher cond is dvored to siocon. Gre wie: he il & sent thous the eerle stelt © ord to the oranslon where the compos on pans of the rein delt D ord the. coitor sholt Were Levicated The ofr sovles ta ll 1 ped teach the povages Inthe Hight crease ord tho earicaro cover wie its hathr bean: 10 tht cee of tho foule lbrea'es tho crakha) ard conponart pork ord the cher is rxted 49 the alow the corsicf whe he mosig pas witin the cyte ood exh at tho rocker om 8, conchalt Sand Lents the ea hela @) on is way beck to fre seip. The moving pars ch os goat, Dears which ore not labicated by pretare ove keicted by all spash rd poy. (Fig. 8.78) B, Disassembly 1. Remove the ch osenbiy ct wrt in accor ‘once with asm 3,88. 2 Tho ol punp ea bo ronavod by anerowing ‘he tvee Gen eres (ard spi bex tol @. (a. 3.74) NOTE: All engines beonwoe tthe leone nanbor shown below aw exvkped wih a sage pleco ght cerkcore cover F. No § 90-476103 c1p0-120015 €201-166081 1cD 90, Fin 8764 Gown ot pe D Snr com sew (D Soul ae* 3. ENGINE €o> @ Fig, 875A. Gen apne 0 @ 6 et et ea sore 3. The rencval of the two Sm screws wil ie cssenble the of pap. (Fig. 2.78) C lepection |. Tha norma! copay of te opamp is 1200ce (79.22cuin/arue @ 4000%pm; 1 the expacy fale below 1000¢= 6,02, tore fe a dan- gr: of devekpig erin sciewe: therefor the Fp seul be ropored oF paces. (Trothd amp + 1400ce 185.43 evn @) 8000 pn) 2 Cheaarees of component pete Goer Type Gor iotonea econ aitaei HE ‘os Gen tou |S eel ‘reeked Type fae tal | gle in D. Recisenbly 1. Asenble the ll pump ond tated on 10 the figt crskeae, 2. sll the cltch casey cr to dh crake fen cover Ip occotdence wth precade. out ned in exci 3, 80.@ 3.10 GEAR SHIFT MECHANISM ‘AL Consition The gear shit fest is moved tram'y by the Wen toeo of the padol i copreccd. The shift forks ‘0 fited over the shift che an cided in ts lesar newenart by tha cam groove en the soca of the hit dum into wich tho fork edo pine ‘re fred. Rotation of the dum bis the fos to the rght or lat wich in nen pevonae the geor ahting, A gear sift eeten pring veers the or crge pedal 10 Hs nano pstion aier each peor charge stole. (Fig. 3.75) 5. Dizoseombly 37 aig pny Sm oe 1. Remove the ele) osenbly In oxcordance oe ith section 8136, 2 Rorow the peery diver gpor @ by, soem. hg the 20 rn excip, (Fig. 3.77) 2. Remove the: ahft doen stipe Pil out the guar ahr sala wth the ond of te ah am orga tho abit dem held the deecton of arom. (Fig. 3.78) @ soem le CImpection 1. spec! the opor shit spine, gear tm ‘ord gear shit fers foe tit ce bond 2 inspect the gearshift um ord ido pin fr ercetdin wer. as 2.78 beoweg 8 oe i pe 3. Check the sing for bieakoge ond proper ton. ers e, D. Reassenbly Asinble the gser sit spade in the rove acer of the soqurce cecrba ia the cuncem- Ly ion B stove, Afar antenty, mole sre tho the cpertion is proper ond ob ose thot the sft venenccing pln Is not bow 2 tll tho shit due stoppor ond ‘bon ‘orbs the ker gear (Fig. 3.79) 3. etal ho elich wierd tho val errtento ‘ener in ccoordce wit section 3. 8D. @ Sit da noe Dit du spoe etre @ a3.11 CRANKSHAFT ‘AL Cootirtion The cenkolt i coretmcted of Sigh seh catban wool ad tegeor wth the earmecting 104, conics the secbrocaieg noilon of the ion 10 tho ‘olay motion ar iy asction, pelos tho furction ofthe Aywhaal by abicrieg tho fuchar tg tor ho rai! end left crkift eanporerts oro poss fied to the aldol come neoyicorue rk Ph withthe correcting ros exoréled. Tho tiring sprclet wich des the cart cola 1s stint ted 4 the ll crete Crorishatt caanbly is sepoed et two poms by beau dy. toll beats “ho ra carlena reopporeet & conor ci pastooe trough which il wear grease poses 12 fhe crantgin 0 Msicte te Lage el ef The con ecteg vod. (Fig. 3.80) 3, Disassembly 1. Romavo the chtch exnbly In occordnce wth 88 ad the gas wilt indir occordnee sh 108, 2. Renae the leit cose, 5. Remove ita cyl ped in codon Ah 5B avs to cylinder m accordance with 68, 4, Renave ite 616 box bolt ond seat te left cocose. he ciriaalt ord trowrinice wil be core ppeiey expoast 5. Tre cenietaht auonbly © can bo removed from the loft crrkcowe, © (Fig. 2,81} Inspection ae pec the cxrisatt @) on V blocks 8) ot both Seance ond rsca2s the enoutt of nos. (Fa. 9.82) an cnsawr 2 Cresta8 ENGINE 2. The came iy te booting fe meonied by fag th (io. 2.23) risk on cents and Jozcrce In the sii rection becomes opcenive, Me cnkahull wif move fom soto sp when eri ie raving ond proces vacerercle cis: as walle cag unevon wea: 10 the cylinder, piston ord ha tira oe Ill ho stevtan the fe of the cc, IF ho elorence fe Yeo small it wll ease @ ocrease In the power cutpt ond svt the Recent He of te crotha! opsincetin | 3. Comecting rod swal nd bore. (Fig. 9. 84) Serdaid vole 140012-14,028 (0.85)7-0,5825 Servloebie nt —Roplaca if aver 14.05 10.5891 in) 2. Reossenbly 1. Avtertie tno conkshlt ain it th Jolt eroteat 2. Ascorble the eight exnlema D 10 the let errheate, ©) (Fig. 3.85) (Ceon Do, Forget to pe (ig. 3.85) | to can chain evide 4. Assenble cylinder #0 the cronnue i eecor once with scion $60. ord the evinger nex end cover in accordanca with socion 3.50. he to dons che On eesves 5. Assemile th goor evtt spite In cordance Di concn With secten 5.100, Ausertfe the chlch ont Sowa pre Ino the corkossa ond ins! the Fight croskenee cover i eszordance with section 280,2.12, TUASMISSION 3.12 TRANSMISSION AL Constetion The ronanixion recover the eotary power from Whe ceriselt al troush @ seis f go, changes IF 10 te dates speed. ond tar resis 10 ho dive chin socal to ave the rear wheal The sorsnedon on she $90, C.90, CL 901, €D90 ond C190 tos four woods. C90 ha roe speeds: Al the sos orecralnd meshed, sg smooth gear chonga, The lor sere ronan onthe CT90 is eaipood ith o abtreunision Which bas @ low sceed verge ‘electcbily, soo feclin 3.15 The primary reduce vaio for Occ 3.722 (Fo. 3.86) 1. Operation ($99, CL50, cL¥OL, CD90 cr) Lows (Fig. 3.88) Tho power fer to certaall lb honitad ‘howgh the ch ote spe fos civen goo 7 the treson msn chal The poner fom the teri in shalt te sermiied fem the an ech Give gear 10 holy stain canter sc low oar However, hs comer sf cord gear which le plod 10 the corte Bait ond it moved og! the law gear D by the eit (oR and locks by means of 2 deo, fomieg cn itegal unt wit ‘ho counoubalt to tanent the ang oreo to ‘he dive socket routed on the lait ond of te counter ea @ Shen cor Bomar ~ 3H 2 ah 83 SB rones 0 1B low per ‘D Tourn cortwest {© Coto low or courte send ger2.89 Seed gem Siete roman Beas So @ teeutten sarah B adc so oe @ eminen eooramats @ to ew Seconds (Fig. 2.89) Tho rein shaft ti gocr @ which tre std Fites 1 the rein ski Dis moved by the ait 0 look with the tseond gecr ©) by macrs rom the ma sia 19 tho comer shalt @ by nose tha mn ska acced goo wih th sped comer th to dive tho Thirds (Fig. 3.90) ‘The power on the woranean eh shaft D Is envied 10 ths costes st hrs opor @ by rosina with We Wain salt thed goa The courte tol escerd gn © which is spe do Fite is 14 by the abit fork 10 look wth thm fee folding thd gear @ by mecrs of «dog, this caer the ceaier sft GD 10 110% ord in en chives the wrk Tons (Fg. 3.91) The main shit thd goa) is moved by the Aft Fok to lock wih the fi rotting top goo D by means of e ag. ts pening He tr sision of poner fom tne roin taft D 10 tho cauter soft by niing the woln elt fep oo wth te Hees eure ah ose th sprocket,2.12 THNENISSON Neviral: (Fe, 3.92) “The gears ove rot lacked. The ncn shaft lowe ge © ie nested wth the ener shalt low guor cre the mein set ed goer (D & meshed wih comer that this gear (@), nouover, the cotter tholt goa tocto fesly and threre no fewer 1s delved 10 the dive sprocter 2. Operation (C901 Lows (Fg. 5.93) The poner fron tte crnisalt ts tonne Atrugh te clich to the spine fed den gear fon he tarencion mon ett ©. Tho power from the tsrison in shalt is torrid fom the ron thot dive gan ta the fealy counter taft low gear @. However, the counter shait second ‘oe D whieh is spina 10 th cote soft ond Ik maved gaint ho low gery tho shift frk ond bb locked by mors of 9 dog. Foriegn intl ut wih the counter stot © to rane he diving force 10 the dive epoclet © noured cn ‘he eft ‘end of che counter sta Second: (Fig. 2.94) man salt top gooe Ge moved bythe eft {oi fo lock with he Tee rlciee second gear by moons of ¢ dog, tur pointe ranaisten of power fom tho min sit @D tothe caurer shalt @ by resting the main shaft second gor ‘vith the counter sal tocons gear © 10 ara te sprocket. Top: fig. 9.95) “The canter stl second gaar @ ix moved by the shit fork to engage ste top gow ® by meas ‘of 0 doa. The poner is taniied fiom the wain shalt tp gear @ andthe cower Salt top gece © end to tho dive recat.a a. enemne 8. Dinossenbly Rorore te cyledr hood azsordonee with ocr Rel rane e eenane ae Se rents will be exosed. 7, Remove he main atoft D, comer sha @ rd the gear shit day fom the let cork cane at invita) asexbles. (ig. 3.97) @ Tommie way lt @ onrmas comsr tel 2) Geo at dm 1, Remove the Guar shift ge pin clip, D ore! Pull xt the goor eit lok pide in, the gear AI fork con be dexsentied fom the peat shift dum lg, 3.98) @ Gee her gee os @ cr ant orG.Inspection 1, Main dat 19 main shaft geor ceoorco (Be. 2.99) ont | BtLE=ROtaen | pm toe np en cea | fo in Tee wre | ictod~occadin) | Oa tbe) Coane stot 19 counter soft once clearance (Fig. 3 100) wm wa | due SREeT, “a ger, | 298608880 | ee co | eaten | Mw ts 3. Terwrisier peor bash Sortie vahe. .084~0.170 ‘0.0034~0.0068 4 Senfescle lis Fepica aor 2 (0.008 is 4. Saft 16 beorg cence isonet oo 5. Silt Fak % stilt dun clornce Sterdad vole 0.025~0.075 mm (0.0010~0.0030 7) Servceble t= 0.15 mn 10.0040, eploce 6 Bera ahi fore sunoussicn o 2 12) Met all tp ber B Cental ed ‘Stara vole 0.05 ne (0.0020 ir) Sericeable Unity 02 (0.008 1, rpioca 7, Sift um groove (Fa. 3.101) Stereo vale: 61~4.2 an ‘9.2201~9.2481 1 Senvcacle lit: opie if over 6.4 nn (0.258 ino 3. ENGINE D. Rocstembly tho gicr Sift forts @ on the gaoe hilt dom @. Inert tho goar eit cudo pies ard fe b pace by sotihg te CAUTION: When cisonbing the gear sift fs, cas rot to tera the LH rd the MH fos, The goo aut fork nated "2", Alter He cscenbly, check for cperaion (Fig, 3.102) 2, Ine oxsrely of th anension goat, those i fot goat which ae fed 10 rlute wih te bait Qer oat Srl be ite fo he splice wth core ond we Ges wt don wich ore foo tolaing ml bo riled with the rat waders, Air the cxealy, cack for prepa pact 4. lata hanrien rine, carer sa, ‘00 shh cum senbly onthe ll crkese @ tg. 2.109) 4 lll te ck shor sph 5 Asante th LM on cnc in cco rep vith ection 3.10. (6 stl the gear i pice cd the tien por 1 occertor jon 10.0 end the ct cenbly the RH crenkcaw cover in ocoxdonce o vith eectlon 3.80, Fig, 3109. eset te ramon 7. Ireall te eyliner fo accordnce with section tan oot 2.50 and te eylnder hoa In occonce wih Poe seclon 360. 8. Insta the gaor sf pnd oto averse xe of tection 3.128, ‘CAUTION: When csenyng, check fr area "a" opera. fon ord lea chock the for bend. (Fig. 3.104) 9, etal tha ehit dian stopase ond tho hivon totum sexing pin 0 the el pure. tll fe Sch cst Ly in aeconionco wth sction 3.8 D.. ta he lock waste, lock mt ord lock the nu by. bene fing the vetor 1b brutal he ehtch cuter cover ord the ight Fig, 3164 Outta te ger st am3.13 CRANKCASE AL Construction The crathcasa is en bregal pot ol the em rrsion rode in the ig) and elt aver from deri ley: dhe cin. (Fig. 9 105) Thm cyinder Ie mesos of he fens ard cre held in place by the cyldor hood she bobs seroned into the cralear: ‘A bicater conparnt ond © Bremer panage 129 Incrpcated tthe upper scton of bath cronk- cose alias 1 disipae tha prose tultap inthe even, ‘A-com din foskrer & tcopawied ito te Int crankcase Fal. Ia the forwod loner section of the ‘igh rnkerse is incided an ot shiner ‘nd bien togator with te comfy Mio prfas tho lieaten oll wich Is proxare fed to the veviow conperents the erg weAtre The lok of the crerkcae i contnnlly inde vexying pestnes, butt up by the recpocotrg Biter. In edition, the cronoze fr fled with the (ges fram the blow ef th pen ad the gues Ta 100 Goon Leck Rawk — OL eelaee comeFie: 3 107 ecurrg te cence fovae nih © Ret tes once Gh certeme Onan oo fa ser ove Ge ott pis @ Conte hl low proces by he hect of the erorkeate, For she eaten, the decsrerenson of the cl looks of the ie pating oes heres The bvsstor ¢ segres ond incorpocted othe ate to etka the gates to th oui er cls fo mirtin o coment presve wih the enh aie: (Fig: 3.106) 8. Disostenbly 1, Remove cylinder bao, rer to secten 3.58 2. Remove cle, tof section 2.6 & 3. Renove lich cxsently os © uit, refer to section 3.88, 4. Remove goer Sit spindle, roles to section 3.108, S. Seporte the Seth crarkeate tom the lt refer 10 section 3.116 6, Remove tte woh Shaft ond couver sat fer fo section 3.128, ‘he gee shh tok cuenbly ard the bik slorer ean be ravovec. The ceratot can be ranoved oF © wit for dase 7. The right crrkcave wit hove the ol sare: ithe Tet conkeoe wil have the com eka torsonar ond ignition cll reset Tho ol ter szreen con be roroves Hom to sgh errheeo Inspection 1 Chock for anager epeclly cin the we- nad ening axles since even 2 eral cefoct wl cae of ls. The mating aslacur should bo fat fo witin 0.05 10.002 i Mocexe sath tele: gauge. (Fg. 3.107) ©. Reostenly 1. Axle in he vvere oder of section 3.13 B3.14 KICK STARTER AND GEAR INTERLOCK MECHANISM bn ths systems where the Kk sere lion @ Is ‘ogg 10 tte low gear @, ho ek or tang 1s litt ond ccey, and he we of the harisin (90% reas the posilty of robe, ‘As shown in Fig. 3.108, when tho bis ster spindle is rtated by oc. the ick stort at Aarge ie rotted storey Tho shal of He bck sor etch Hage ees ‘down fom tha Hick rar ratchet gide er pressed 10 the tooth oF tho lick slater pinion by ‘the stot sing ©, Power is txunited to te couvertalt low gor @ fom tte lick saver rion. @ ‘When the kick ster sine retin fier Leking fo stown in Fig. 3.109 th lick ster ratchet fonge is pressed tock by the Hidstoter srg ‘ho tholt det on the lick #arter riche) ido cd the ick trorsinon is Fig. 3.110 sions the guar inelock om the Tan 10 Gem ech one ary dives eo Ninoy dive 20 © Man satFig, 2111 Eater ann ner pec ler 9 C170 @ Fiol dive ywecioe 8 cranial, tem which the pastons of hats tion diecten ord be soon 5.15. POSITORGUE MECHANISM [CT 90} AL Construction “The CT9D mode's from rons No, 122551 ax VA are eqeped with © postorae to atwean the Nigh nd low speed rorge. lou ct repacra te srclet or tte atl seis, 10 provide geet ising power in the eal dive oF recused speed, The incoparcten of the posorqe ceases cnly the cperation of the lighlow speed ange twister 10 cherge the ting seed. 5 ret tne ring over the ster sores whet rami te remening of te lage Sracket ax! ching the length of tho chor. (Fig. 3.112, 3.112) TOWER THAN! MECHAM Lew s08d songs. (Fie 3.113) In the low spood range. tha selec stiles te splines postcorqn high gear @ to sh win the diven gaor of the pos-lonue counter @) The power from th cantor eit D fe tae rite to the positorew confor thlt ©) and ON INTHE POSL-TORGLE Hen 10 the free ating spoctet ckve guar ant @ where the speac recicon tele eloce, The cyan ©) aiven oy te specie which ottas et © sped loss tha tha cower shat216 CaRsuRETOR @ + H30h ced rxge (ig. 2.114) th th gh epod rnc, th ecto elder tho ‘tod paittome hh osx Dt ck wth the fea rong acelet ihe gear nt ©. Te power tam te conte sat & hernted fom em the postion Neh or acy he rn ral rrodat dine oor eit @ to dive th spoct oF the sane speed tthe cowie si Disassembly 1. Fomove tho fou, 6m scone ard lake off @ the posionge core: 2. Romewe the posclorqe low gear ond tte counter gear anenbly tether with the couver shot 3, To dsauorele tte positoreve ch gee remove the 20 me cic ond th spo! wat 4. The Inf crorkcoes cover mst be reroved ond the chain urooled fiom the saociet Io decsanble the d 3.16 CARBURETOR A. Govatrtion The ok Ion is fr the ok claorer tas the ‘lt edo U1) of the cabrotor a: 9 mn ct ow poxss urder the tote vale (6! and tn lee te carburetor Heaigh pag (Ito 98 token no tho engina. This fow of er costes a negate presire crand the needle jet (Al ond caves the ue nthe Meet charter 12) 19 ve crown up trough he cin jot 10), te nile Het Hotler wee 1 is mee with the oh that tlen in a ar [at ‘Sl ond ono tru the ci bled hos 1 foates oaand the nocd ja Hote IS), ox ie thon a cretgod botwoon the aoa fl Al er el role 71 cated drscly below the thotle vate (8 The cicharges fel = med wits tho mano Fw 1 olorized below bebg tate ino te eagne bh etion, to rule the fs! miaue at see ‘hots opening, the oF elon in fron eabuerer 111 pases by te opering (12) of te oe screw 11, omer the Bow [or (13) by the way of tre Blood hole, nd thon is mine with the foal cged fom he Hole lected Under the trotle Yair 0 prodize rc ee mish, Ts echo fool wixtwe te wised th the main ‘lat ot flow @ ‘nd token nt tho ongro. Tho ful aisha edu. le“ 3 ENGINE meee of the sow syste is ode by repustng the fr seo (10. Turing the of screw clockwise wil posce © ‘leh mite, Toning the or screw cower clack wise wil podce 2 leon mix (2) Foot Crorter a The corueter prosicee fs! mare which ©ais carsusrroe ital 10 ste trots opening ond engine spond. Howover, fe thr pupozo, 1 & necomory to kop fu level cortant in tho cobieoton, THs is por formed by the foot chamber Te fel fon the fufonk poses throw the zane (14), Botween eve seat 18) ar! the vane (16%, ard han ertrs ‘he oat chanbar (Zl, Tha dest 171 baconae voyant oe fuel enti, sits the Foot yoke (16) ings a! te Poo! am and whic seats the float ole ito te valve sect to top the Bow of the fal. When fil in the ot charbe:'s conned ro tha ful love hep, the Naat 17), lower org With the fol level Cecrance botween te Valve (el and the vale sect (18, allot foe! fener tno foot chanbar. 8/ repeatiag thy tho level Ie ovoyseeinkined const, sping fed nto ta tation of tha vave (16) whch contects the foot om i, ond proverts the valve tenia tg. ‘Whee tho Vebilo ie on a grade er when dit «lodged between the valve cr set, goalie wil ‘ver Now ond enters the eyleser. Theofo, fox rotating th foal from ing above a consi lve cn ern fe is istalod, (Fig, 3.116) (3) Cre Whee an engiva Is cold ox the tenporctne ts lou ding earing, 0 rh fel mb is torpocoly reauled. Ths canbe hd by to uo ofthe choke. ‘When the chats lover ie led wp, the ctabe 20) is fully closed. The opening (Za is rormly closed by th sole! vce 2, ower, cg sxtto ‘hon the thotle ic opored aproxinaraly 1/4 ond Iho Kick starter oparted: the noma cresixe cmcte! nthe cylidar wil caso the reef vale (21 to open by tho preger anos ited tection 24) ord port or to pas Hoi the cabreor ths fw of ar crane the fol ct of the readin ie! ll Yo provide a a fuk mira dot for tot Ing. Alor he ergo sis. the ie! rogarve ome increaeas, ans cts tho raat va (2) a open couespondagly wider to ese © alabie rwocuxo. Th, the pang of re ralaf valve (21 ctorges occardag t2 the cperiea of tho tte ‘ole (), scion 25). (Fg. 3.117) 8, Functions of Each Component U1 Main Jot Its min opone iso cin a proper fl mine rate by comraing th fw of fue whan te thea Eee Netto @ Mi nse a Is fly opored lnorting ct the maximen sped. However, the fel rato Is rfuence don to ound fone hl that paring, (Fig. 3.118) (2 Air Jot To prevart he mised gos trom becoming rich ot igh speed, on Jean ot lon speed, ui feed to tho need jot foliar The futon of the oF [ot Ik to comrale he enort of cin Al 6 corcknt Tote epenig. the xan th cir, the soa wil be the diference tn fuel fow between high rt low speed, a a conseaert roccton in fil Fv. (Fige 3.119) (3) Noodle J) Tha rood [ot ontce the fel which had been ttered by sho nai jel tate the inert 28 fl hota, The conta le paren by vary Ing the cloxenco between the seeds fet rd jo! ntl descibed in to folowieg seein. Hele the needle fot re with hgh donree oF prec slot to cate accwote foe cor. Hfg. 2.120) 14) Je needle Tho fet needa, In conwncion with the cbove rrentioned noes jl, conte the fel trio © internadave tecale oping ely betweon 1/4 Yo 1/2. Tho long topsred ict nonla ' fite fn the contr hole othe it vv with ha rare end Inte nto the pede et. The vertoa move ret of the Hecte. vahe carespendagy roves ihe topos jet neasle within Pe paca fat, vary lng tho clearance between tho nosci cr the jo. nd i ths way. te proper Ft mire He oiod fn roforoxce 10 th portion of tho thatle vive. Thurs oe five ckp aicove gains on the bead cf the iat saa, Tha fel ance t-te cle is moved trom the fist grove top) toverd tre fh goove. [flg. 3.121) (9) Twila vave Tie thetle voNe rogutes te eneurt of et taken ito the ein, tis exert contcls he fergie spood os wall os tha power ouput, in ai dion, the toile vase perfore otter imran conte fonction: Tre set of the vote valve it ot on ania on the itt side tho size of this cataway Is do Srerod by tho cuaway rnber wich ie dsesbed in suscoodiea section 2.8) charging the vohe with @ dif sia sAawoy, the nego prose In tho veinty of tha needle jet is charged oft Ing the fol Tow ord consoguily charging tha fo!rire robo, The change te effective in the sow pee ronge between idling and 1/4 tote cpen- hg ond has no efect anore 1/2 theta opening, (Fin. 9.122) 16! Slow jet ho slow ot mater te ow o! he fuel ot ang ‘nd the slow speod range, rd cases the fel 10 be clonized by misrg with te oF than in from the ar bleed hls, (Fig. 9.123) 1 Ae sew The cir sxow rents the arcu of ct entering ‘he slow spood system. The ar which paises by "Yo ak sew mee ith tho fel from tha low set ‘nd is dichaged ie the proper mine, pring fe sry s0 cree voncroen, Fig. 3.124) CAclustment bn oréer forthe cakuetor to prsicn the mnie ‘um poromarce cf the orgies copapity it matt be afisted 10 that proper fuel intro f eval fe over te conplate spoed rong fron idlag 12 the rake speed, and Khor, b2 ole to rain tot this codon, This coer tos been signed cra nonulozwed to eotiy thee exer: by the preciéon nomslociwe of the comperen's ono specoly inthe tea oF appeler quay wear ctttant moti, Tho jt noodle, ned je trot eva ord the oat valve being. etcepte to ‘woot, Fas been nado of rates postosing aoc weaving chores, precisely ranfoctved a sufoco veaed 19 ge exende salactory sence without charge 10 patloraree The adistve's cre azxuctely wade on pa fomence eteciod by Seth te nonufotier ans iactoy persrnel loi tha the seting oF the vereous pore x proc, Theefaxe, whan rahi ory odusinen, peers ensine repir or replee- ‘rg wom pars. give patclr aemion 0 the fle ‘owing points @D Moke sre thot He erghe is odjisted to cexxorance with the mecfeators ® Chock to 220 tot there exe 00 or locks ot the cabueler mouning fonge. @ Wren the conteing component tecore wor, replace wi neers eB Aras oo oe eeens Oita OD ante @ thee rhe eS Sete me @ Ar scow enoine D. Adjustment for High Spee The contol of the fuel mitre between 1/2 thotie % ful rotte oparing = the frelon of the mein jet (a, 3.125), “The dalominsicn of the fal mitre ratio i rade by the folowing mehed. 1) ANT thot i he ergo speod heroes when the chche is sgitly closed, it i on in icstion of loan wittue. Pogessvaly replace the a fet on ata the serorreren. no ot ‘re roresred in segue of 5) (21. If te orciae spond chops whan the che is oily closes, Ir ideatos het tte nin jet ith of the prope size cr that # mey be 190 lage, a wed ema, parton te folow'rg check 19 naka the detention, (al the man ot hd bow of « proper size, tho engi ss0ed wil drop when the main Jot roplaced with one of « snr soe; he sped wil erate IF he cha shy loses. In ch cote, fe exigal fet wes OF the proper slae ond thrfore stall be ronttcled, [bf the nein Ft Fo been t20 lige, replace ‘ho rsa Jot fs saqarce wih thot of 0 tally #20 unt tha conor lol above Is fou ond then eis the reper ze o E Adhatment for lntermeciote Speed Tho fel mivtre oxsinert a the stem ‘peed rong borwoon 18 19 1/2 tema cpeng |S mode by ralocating the ot resco pasting cin 76 replechg the thoi vale wi thr of @ cf feve! sz0 cpowoy. However, changing the tretio valve will oko efiect the opasing cation bolaw the speed range of 1/8 sheila cpering. therfore, |t ie very aifeuh ro edt for terete opens by replcenent of the thoitle valve only. IIs rocotmarced sha tha cline forte keerredicte ‘peed bo mace by the je! needle, and say within fhe rong of ocenplatle occlartig pone hee the would gio. a fol centurion that ie smh lower, (Fig, 9.126) (1 Jot osc (a) Blk encke emitted fom the esha! os ff lnernesiate speed on Indewien of 1 rich fiol mitra ond is eorected by aCatto the et meade to a lower pation Je) Flot spot tener 10 engine ising cing ‘ecolsotin oF at lleiedioto speed i ‘oles chat the foal sire fs to loon and ic covscted by odutag th jet reedie 10 8 hiher poston (2) hots woke. cutaway! Tho thotte woe rimbsred 2 thot the longer the stmped runter ee, loner the ful rbewe wil bo. Whan chong te roto vole, it mim be conidered that dow speed wil bo faced ot wall of the ntermacore seed F. Adjuriment for Slow Speed The ccfwtnet of the fash ice betweon 1/8 trata cpenro nd Hing ise by he i er cond the cutaway of thotle wove. (is, 3.127) (1 Ai sew Tho fuel metro osixinont ot ing spoos ie nod by the cr scew. Turing the screw the elodite cteton wil podice a rich > tire @ Joan mare can ke had by ‘ing the screw inthe comer dockuise deccion. Moms fever, the Ide screw Je not ony 40 odie th Iing sce atenton shnk abo be giv to the tration peos fom icing Ye tate cpenrs. in other words, the feel mintue to provide tho snoath cperaten ot the polt whore hota ‘pened tly beyond the Eels speed. G. Adjusting the Fuel Level Sree its dial! 10 mesure the abl Seg of th Leal ove, the mactrament of te height of ‘he Neat valve is made which, will eavempond to ‘ho height of the Fleet reoswing motos \6) Top the float Tgty from loft 10 ditt wih the Mhgee and locate to postion whore the tie ef the fea! vee las! basly coms in Faen contact with a clearnce of 0.1 nn (0.008 erie Eetwaen the Naat am. (In tt potion, the conse between the bose of the foot cei thn etretr body @) shoud 21.0 rw (0.827 i, dat rowed, carly berd the Hoar am by the proper enc CAUTION 1 sung I incorporated inthe base of ho float vole, terafors IF tho oa am ie precio’ agate the velre, the seieg will recede ito the vaie rd tue icction wil tet be obihed. Cael cbsrvtion rust be moda 16 osseataly cetet te point of contact between the fa crm enc the feo! wave (CT 90 Modal Fram Frame Ne, 000001) ‘An aide selec'os no inccrovoed inthe court ofthe CT20 made satog wih fre seri No, CT90-00000% Ajengre sural No. CTSOE-OQ0001A, Ths moles ovata fox romal er heh abide rcterycle oceration. Pil he knob out fer riding ot clive of 6,000 fet stove sea level, This will rovide ccdtional apply Cf ar 10 the peacte jet fom the main cfr spply passage. At th some tine, osdPiond Ie aso sipled to dow [et fron the dow syten air posone to lex out the ful mie Peg In tha knob wil cose off the ar suply to both ta slow ord malt sysens in cotutor pefermance 1B mone ctie osier @ sin it & Wane 1B Toete oreo Aesoww Btw role se vere fit an on (@ Neel cp late Gre tae whe Bom 1 Top mater @ hile eo are tase & Goat sae Db evele 1 eel © Gol wg @sove Ome & Sens lp (© Foot Cantar bole Oi etcanner ser HH vem or I aw cry ya Fee einen oth “Tyiase =H wr FI8VL ONILLBS YOUN4. FRAME Toole Necestery for Disassenbly ond Reossembly ® ® ® ® TOOL Ne. DESCRIFTION |D 07045-0930) Rotem gin sole! wrench {07035-05301 Rew cishion dowendlrg & oxening too 07083-03001 Stem rit scot wrench © 07048-09001 eaieg ner @ 07072-00101 Fin Seaver. 34m © 07071-2500) Mn swith ein sperrar © 07782-99925 Swap tng pls ks) © 07054-02801 Fert fet ol eal iver ® 07790-02001 Teal case4.1) STEBRING HANDLE AL Convection “he storing teres of all he mae! 90 nator exces wih the eopien cf C50 ore wad formes stel ppc They ore naried to the font fok by being coeed betwaen the urper and lows: hand rips ldo ard bolts’ 19 fe Fork t9p bridge pte The serrg tarde of te 90 male of rested shes! steel wih a cortinoxe Yes! pine gp wal dec or einfrcener 90 Fig 4-1 | Sen crm ie) | Upto Fig 4.11 $90 sng hese 1.5. C190 sin torte ‘4 FRAME B. Discssenbly 1899, cL 90, c.90L) 1. Hold the fort rake am @ back ond arscrew coating na. © {Fig 4.2 2. Decomect the cltch cable @ lover end from the chich lever @. (Fig. 4.2) caution: 2 Fence cow rot to dhrmge the cylinder ent cylrder teod fhe when ronoviag. the b. Tha tsk can be sired by loscening the xlesing ceow of to hoe lover end ced 3. Decorrect tho thotle catle ot te ‘hole whe D by wscreweg the cxbureter cap, pilieg ct the otto vahe ard then tooling the tote cable @ (Pig. 4.) vegeta gure 4. Reno lee D by loosing the seus of a Front of tho poosicht cote, and dscomecig the comactors win he heoigh ewe, (Fig. 4.5) te hom, tum sanl end dene swith& 5. fonovo tho tout box belie movnting tho harslo pe beiween the upper ord lower Fokiers ond anova ho steering hala D togttor ath tho conta cables. (Fig. 4.6) 6. The foak op bridge @ is reroved ogeter With tho um sgl lich by removing he fot fak bols @ au te slowing stem mit @ (Fe 4.7) Uke stam rut socket wrench) (Tost No, (07083-030011 to fosen the ster rt 6 bar te wend GS Sen et ioe tare Gia 7. In exer to amore the etch and bro exbioe fio th hore love. laoson the colo easttg bots ©, din tho lek rat D to tho groove ford separate rom the harile Iver. Renowe the cable end fom the lava (Fig. 4.8) Remove the two Sram screws #2 separate the fight harclo gulp bracket, ten High ewlich ig) 44 neg tm nd oth cole oe cezertly, twos aio pee ord then daccreect SE St Sa the trot cable @ from the trom cable roe ©. (Fie 4.9) D 9. Renee the hax sem nit to dkasible te DG. honde sips lower telor, tere action wppo! ‘nd lower siters ond tarde aolon sect from @ mies waa nore. We ng the herd pipe lamer holder from tho top bridgs, laccon the 10 er Fox me before rencving ‘he handle, This wil prevent tho feller end nut from fuming end focrres Sg Oo removel (Twos cab” Tarte cate toe(€90, cr90) 1. Ramove the fot cover. (C90) 2. Ucaiple the specdanater cable @ art di correct the ren! brota cable @. (Fig. 4.10) The ft hae ker of the CT 90k the lke lave forthe wer broke. Fomeve tho cable ord fren the hn lver Lecering the asa ett ho ror wheel al slapify tho to. 3. Dicorract tha thot cable ot the thotte velve by ft mecowing he extarator op palleg cut the thotle save ord then unho- (Fe. 4.11) 4. Remove th hoadisht nounihy sew ond pl Off the heap nl, iscornect che hom, tn slop ond the diwrar sven leads @ ot the seem as ete comectas within he hoaight cote. Ig. 4.12) 5. Unscrew the two top bige setieg bole ‘tem win the hoods cose and remove the two Brun exile sain mvs ©. (C90) (Fi 4.13) ond it 0 tho handle ‘ogathar with he cates a lo, 6, Famave tte fa én tox bots te sacacte tte hordle pipe user kohler, Then. pall oot Pe steady hore @ together with the cables and sles lois (Fa. 4 14) (CO 90 & CT9O) [C190 Model from Frame No. 0000014) fo} 1. Ranowe the Fw eke ontt rt ond front take cable fron the frat om Gront bike tmoy be diccnmectod fio te bake lever 2 Remove tho rox broke cable from the roar rake lve 2 Remove he the Hrotle va from the court 4 Remove te hoodigt ord azcmnact the ce sects leds 5. Urscaw tha four bale meuming tolls and Ree renova te hance bor C_Inapecton (steering endo} 1 repect the tote, euch, font brake ond fox erko [CT 90) cabes for voor od daar 28, elo check for ochre of operon. 2 Gieck th fondle levers fer sraathcpevtion 3. lepect the handle Fp lor dlornation and 4. Check all the switches for proper apration Ma. 413 Romie Hea eg ts ru irpect te slectical oor for danages ‘B enn nt at” Sm fox batB. Rootsembly 1. Assent cithion sper and lower ube, tun sgl baits ond handle cision sct 10 the Yop beget, @ 2. Auserkie te tote ond tent txche exes, fect gp and switch catanby tothe stenieg NOTE: ‘0. Apply grease on bash she ds and oust Cf te flpe wher the trot gin i to be om insoles, Ts to Mbxcte the novenen! of the thotie giip @ cmd is conponem pas (Fig. 4.15) b. Chock the proper castoten of al cables, 3. Axcetle the for tcp ridge plate on te from ok cre inal tte row foik Eo ord stoorig ton ni 4 Potan te cles el eel eas th pope locaten an clowp he seorng hand 1h Bs proper poston betneen the rer a! tower tonde pe hlér wih the for mew ing ots Note: eC Teer to to fond balls ft, ere oi be @ dese of 02 f6 O3ren {©008~0010 i chacece between te tell at ite rear Eel te roar bas tne 1 The saatins on fe hate pe shoud be lect ot th contr of th hats Fetion tho pach eligren ram cn tho tonde sige to te pot alee of fe 4. Tome the bots to BO~H1Ckg.on 6 8~ eof a 5% Comec ol te electical od 1 the las of te toro color win fe hoclgh oa & sil rd conc th tho ctl 10 the Troe vahe erd sce on te exbueor xp ‘Adjust tho cable for proper amount of play. 7, Ceansct the elseh eale 0 the cich om @ ‘ad ofiat te ploy aioe tatlfon to 10— 201m 040~0.80 in of toe ro ott on of th ekichleve (59,90, C. POL, cD 90) NOTE: Tie axbuinert of te ch lve fee rare conto made ct both ch colo wear aajier@ Pg. 418A) onda he etch ede o@ coher (Fig 4168) 3 rig sing ede OE © Mande tor Tote wp Fin 4 16h Cush cable appr eine Ha 4 148 @ Caen catia otter tee msoa ete itm 8. Comes: tha frat beste cabo ord male the tient wih the jing mi Oot the brake Adjat 2 tot tere (040~D.80 in) of tee om fore (la. 4.17) 4.2. STEERING stem Av Constrstion ing ton i tha pio! poit from wheel o witsond the Seck imposed by seugh toate ered ‘to the boh requney vEvaton which nde to fag tho ta (© Ft Tok eto bsB. Disessenbly (590, cL.99, cL 90) 1. Dissen plore © in accordance wih 4 the hand ond he top diigo Fie. 4.19), as 419. ene fi op Bd pm 2. Dicssertl the ‘ral actin Dn axcondoren with 43.8. (Fg. 4.20) 3. The fom cuionbly ic emeved fram te fark bottom riige by renaving the two 6x12 hex (tho han nay be rerowed ether belre fier te resort of the eterng ston) © tet fo A, Femove the seareg hood top trod D who © 26m hock sporner @ tock No, O7072~ 00101) cre put ten. (Fie. 4.21) CAUTION: Do robcop out tho $6 steak bale ang the seen ston remove footing stm ot(99, €90, cr 90) 1. for destortly, rfer to te ispectve fron! fork removal for COP, C90 and CT9O in 438, caumions When rercvag to font fork, exon wot fo op steel bale tld fe the steering heal Fig, 4.22) (c790 Made! From Frome No. CO0001A) 1. Remove the tarde evs" Ia eezarcarce with Ha, 22. out tew section 4.1.8 (CT 1B ae sel tts 2, Uneron he two front fork balisan he stearrg sleet and temave the fer top bridge. 3. Unicow the two headlight moxtig bls ond ‘eove the beast ond then ‘te left ond i from for cover. 4, Fens tha fro fend: 5. Raise the low wheal ord pee send vedo the engho oreciew the rot axle nt pil oat the cala and rencve the font wee. {6 Loosen the Fron cision movcting elt on the front fork koitom kridge and drop the feet Fork cmonbly Looeen the snarrg bead top thvead wing the berm hook spotter and romove the ster ing stem cat the bottom Note Exarcke ex not fo dep festa balls when renovirg te soeing stom Ce Inspection + lrpoct he 6 steal als For crock and ocr rope! steering sor for bend. nd wil Insect te seorag Bolan re top core ‘es and boll ces for sich. weor and socks, 1D. Reassenbly 1. Wesh to cone ol ball voces ced the steal bole, ond pack with racommondes now for goc. NOTE: Theo: lef eft oll 21 of the sleel Galt ero indoled shovtd be between 1 to 2mm (.040~ 0.080) (ig. 4.23) 2, Perform the yecxenby in to roveto arocode @f dcsonbly xercis easton on the Fellows pols. i) Dp not dap sto so0| bal dung the inerion of He Heer stm. (% Steorng sion shoul be ohaned so that only 0 alGht presi ls requed t's Ihe wheel nove to ether edo onder ie own woigh nile rag th whl ff the gsm, however, F shell not be leote to the extent shat excamive clewnes 1 even tho vacs! sido, cna foro ond oft dlscton ‘when checked with the wheel vlsed off the grou4.3, tone Fou a 4.3 FRONT FORK A. Construction Te function of the trot cishion is to provide oc stocring charoeertice and tageter with tke ‘or euthen ford confortable sing. The font fork, in paticor, mst grovent tha vibration of the fro whee created ky the ro0oh rood cand tion fom being tonite’ to the rida Ih mat te nade tudy 12 witisand he teh lode impo: fk (Fig 4.24) Faas fe wan wale Gaon 00) © fn et pe 1D Pin eck {5 fet eto eer eer (© fer sin Sa 8 tet 2 © feet onion Gx {@ fare canon Sopa eer Ceo 1 tor aaeer at 1D fet omer er eo Biat See ol tos G@ fret Soe ee cai 18 totes need cot (fer oien © tet dana ts le Tie 4268 Fost cnn (896, FD, LOL C79 tem F No oOmD1 AN) tea foe st Go canto ane Fw son sa Se Danse {fr foe os 1 tr foe Spe tse @ fret fot en pe (G fro fore son 1B fr fre pn ep og @ tana wear reBL. Disensombly (550, cL 90, cL 904) 1. Daassaniie the steering hone i occorkrce wh 418 2. fareve the weodonster exile exp fom te broke pel remove the two 832? be bls @ fren bot sider of tho oadight and remove the Feadight body. (Fig. 4.25) Figs 425 tomo hadi @ 9362 en ta ‘3. Rarowe the lt ord atom Fork coves (Fig. 4.26) 4 Place on osequete ord below the engine 2 rate the Flow whee. Remove the fort het colo me @ ard pt othe fert axle. Thor, tho font wheel wil hon away. (Fe. 4.27) Gotan al hoe aban 5. fenone the fron! Faery renening 2 ox bate @ frow each sie, (Fig. 4,28)& Renove sta Iwo fen! exshion sting bols ct thant fork boom bridge ond remax, the front sation: @, (Fig, 4.29) CAUTION: Ssfora roroeng the fet cutie, rk the Ant fk pe Oren tok 7. Drain hao ote. ine by semen dian pag beers cinstenby ofthe ower 7 fede 8. Duauonble the fork axertly by renova CO - the lover cover sta prio, over ovr @ bot, cal spieg and epehg gud 9. Uso 5 sr0p tng ples 10 wenave the 37 ea Tew ct Spe theo pon ot nh NS ‘top trg om the for boom sine 5 @ ® Fig. 432 Cenpntt prof et fo (c090 & c190) Dre eee 1. arave the handle rd th fot tp EG as aes i eccrine wit scion 41.3 ‘Bm ony ee 2. Fecove to heedign com @ by renoveg ic a ‘he two 625 fox bits itn the Feo a season oso onl the 6340 cross scion. (Fg. 4.31) 0}2, lace a aiabe stort under the etna oe ronove te font bok tere le @ fro the fret bike pevel @ (Fig. 4.92) Fig 432 Chcwec ft ‘B ret tre er “Sho tte ant 4. Remove the font clo nu and the Ben bx ors @ et the front supaon om ord pull cut the fort ave 3 from tho opeesta edo the Fert heal wil cp ou, (Fig, 4.39) 08 Ee rw vi i 5 Renore te lnm fender © by renorig te ‘ro 8 rn hoe ruts @ (C190) (Fi 4.34] Raa the fw fener ky eanaving te > em hoe rts ond tho two carlo ma. (CD 90) {feet fot con be renore! without ting yl ee ne tnt torcen 4 i oe 1 5 Useg © sé em hook spanner Dot No. 707201011 tesove tho sloung bea top teed, (FG: 435) G'Serer ea spar Set fo tes @163 Mr fom o 7. Thm tert fock con be removed togeher with Re foe eshions by seg oat the oto, (Fie. 4.38) 8 To dostemblo the fret exsion, looten the nm sf locking rat ond ronove th ent am, ‘rat bot. Aud enave the front euthicn wpose ls by rancingtho 18 jam nt, the Bn hx bel fing the rbourd toppers Then, the front ucion Fig. 4.97) oo bo roroved together with the lt xapersion aims from fhe front fo. 2. Remove tho front cushion under bol by remem FA 36. Benoni ft fo veg the Bram hex ns. thea the font hier © enti ‘can be ditertles fon the eecension orm. (Fis. 4.38) CAUTION & Wher sepzcticg the fat spenion am from tho frat cation, ee shew be tehen Yo prover to font cuhon lower dst sect 0p, cst sal and dete col from dope 1 Reove the pot st seo by unlacing the sHcking end remove: the cist sa ee pio! call. 10. The front cuicn dsossently con be perfor Ped by renovng to fron ewhion lock nit rl then removig the fon) anton sng, ‘cAUTION, ‘he front doer Kottom med sho wot bo lacspbed os | roqsres spac tools adhe ‘component parts not sod indy, (C190 Model From Frame No. 0060014) 1. Remove the ar fore ately frm he frome in occordance with secon 4.2.8 (CT90, 2 Disasenble te Loot, spring ide, front cattion spi ond ote from the fron) fork xen 3. Remove tte 37rn cicip ard separate the frort fork pipe fom the front fork bottan cow, as Fe 28 i 1. Remove tho searing hart cxcononce Oreo wih A 2 Poca 0 aie oe eg Yo rte to rt hae Ierore te ent bls tors bt by smog idm Ecins mt. fonev be elo cpl Cut fo tort es ae he epost tartan he Fert vd il Son os, 2. Ung 0 86m tok gamer Fonts Set lod op the cd dew te ent Yok cof the reed Sr. 4 Tenor 1 brn ck pe OIE na, ct ton te fort coon ket wer cd lt ber apie mares Ned by forvig te feet om pct bt ow 0X42 ex bo te ot xen cnt te foe‘enpenion arn con be renoved together fom tho rent fo The frent om rebound stopper con tart bo removed. 5. 8) removig he Bram kot and th frm co “bion lower Lot, the fen ation ord the oa! ‘expartion oo con be seperfed ._bespection| 1. Chock tha frat euhion spe * ona so | sane 1697 m/0.24e (EBSA 1 ban 62588 19840 252081 Neer ienoezae 157430 wenn 1697 om/IO2g SBOE ts TIPanibka M6616.) fore |ledog 2. Damping carochy 3._Dinersios S| lenin errr ve Te ro 90 Fee To ee 9s0~90575 ).215~1 2 Pepe eer SDA 112 Fon fk boon can —SGO=910R9 ORLA Ta ow SUID ‘G0, GHOL feat iokpon 99 980~AFTE ANEMIA Fost Fo trom cn = AO~S197 .22I~1.25 68 Toptae ow O10 RE oe err S085 (12164. spect dist seal, bahinge ond sha or wor ‘ad donage solace oF neces) D. Reatsembly ecsonbie tho fmt Fork the reves one of dcsienby. (C70 Modal From Frome No, 0090014) Alter reasienbly of te front foik on C130, Ail with 130~140ce 16.0~8 6 ¢u.i\) of good 1gase SAEIQW-30 oll from the fert foi bol fete, 44 FU TANK AL Comsrvetion ho fal tank is mowed on the Fame and ‘ea oF the seat on he $90, €.90, CLIOL ond CD80. Oh to CHO and CIO, t located fon which te asst boi the oat ond is he sc Ts mounted (Fg. 4.394, 8) 8. Disassembly (850, cL 90, cL90L, cD 50) 1. Tun off the ful"coce @) at tho bolton of tok ord dieconsect tho fel Hoe. (Fig 4. 0) 2, Renowe te sect seteg rats @ and remove (Fis, 441) esata at sen3 Widow to fol fork D from the roar, sok Ht sigy. (Fi. 4.42) Fig 42 fing a ok fn Yok 4, To ronove the tak to cover @, the no screws on the enblem erd then unscrew the side cover bolt. Sida the cover Fowers to ranova, (Fig. 4. 43) ret vou To Wi coe 5. The foal cock con bo reriwed by fist un sero fe fel sane op, ronevirg the fier sere ond than the cre pont He! cock moi no sxow () (Fla. 4 44) (c90, e130) 1. Tun off the uel cack, correct th fst Ton eré cain the fist fo ‘he fork 2. Unicow tha tae nouning bate D locates foi side of the rk ord lft off the tok ie. 4.43) Ctnspection| 1. Fh he inie of the fork to remove ary cole or ear foreign mete. 2. Moko aie tht tara re mo lon i theta fig. 445 ey el Yak Gra ton tag mat folReonembly Perm tte reosenbly the reves order of duaserty. NOTE: (590, CL99, CL9OL, CD90) TI Woke swe that the fuel ose gait! isin 9084 cendton befor invalltion; clo that the fal seal poctig is on the fist ence rearing sou 2 Usp the proper size bot 16% 10nm hex bol to instal the side cover on the tae org bot wil botlom on the tonk oe esl a pancie. (Fig. 4.48) 4.5 FRAME BODY AL Conereton Tho frm is the backbone of the otreyce ite cbout Ine that tho meterycle desire. Furth it 13 the very fnpoton factor in dee. ring the notrcyco eying Tho most inportont freon of the fone poring the recesary sieht th ere mate Cycle. gpors Re ace, the re, eae ore thowph He Hes ord sation mst wt th shsis pears by tal over righ Yom Father, fon te soni oh stena. hech is wihin stood tlsrce, Too anal a Sosa wll ease he vows to ey open, casing passive eckoge cr citing in tard oting or n9 sang ot cb 15 Chock for Inpoper vohe tin, ‘& Check fr seth Inthe can cola, Chace for ary appage of ho tineg wscke Breaker point servicing ond gop odjustment 2. Reneve the dynamo cover and brea rxee! ito alas of the txecker points thay ose kunt or ped. cress the aefoce wih fn olttone ox © port dieteng fe 80 tat he pois cro ncking poral conte ‘alte tha points bovo ban creas, woth in 2:aine or tihloroehven fo ramove all race of ol. b. Tum the ganaator rotor counter slocito to the point whe the breaker ports cre t moximum opening, The roma g=p D 0.9 to Cee (0.012~0.016in. oxi. nore voces, Icosen the Imo brsckor ‘om cajzing srows © crd move th sation. cry brockr point by faering o sovdiver Ino the adusing ot to cktcin the prerer ‘cap and than ration te srows. (Fi. 5.5) Irion brocker pot gop (ol The seam tend Yo Inger, tet I he erouption of the inary ckeut 1s ot eongloted af the port, tevelore, te tamrday heh vetiope Duldap i rodeo (01 The cowed ran of tte points fs roe, prodiong hoot ant rsitirg in damage. tc) b conpocton with ‘Bl chore, the pots wil be Len open casivg daly th Ton fing, Me wil eauze © doo in powar expt. Exceasve becker pont 92 {el Tho duction that tho pobis © closed Is too short %2 aw for sufclert corart fo In the nary creuit with a conaquert Jew vetago Fee 54. Losrg ha ecto me @ Sinn nese @ Sea pene Figs 53 Aduti he pot cozane @ Gores eae pe @ beer aig tr ieee nsne 5 mai09 aDnTNANT 7 Lnistup in the socondare oF the hgh torsion voltage cial, This cxndion wil cas pce lrg stesing. spot mising ot High speed (7d 9 conosueet Ise of power, 1b) Engine overheats sory lel Tee ignition tng i grey advan. sheeted boon antag SS ae eee este ces eee ee Samos Sep sole Seo Sores See a. 2.7 Asura Ne gviee irs oe sevice tester opection, © Ba plat see Wen ing 0 soba tring Hot O 10 chock the tnag, We the engin at 1,200 om (Fig. 5.8) 1 ard oot of fining, foun the odiment in the tone mamar ‘ot dezcrbod above. esis of rloed igition tines 1 roo in powor cuts 2. Deatic retese i ful csrazmpin 3. Engine overheats with © pastaty of ken ote, owt of edvaced igi teh 1. Prodices Inorg and shop Ih power ouput bh severe cxtet, donage #2 pion, conrecting a5. he inn ng ea feo meter rod, corti oy rom, Werle, prod @ Tact Irpeeton shoul bo pofomes. 2. Usen cangloin of the point gop ond frien tiring ccheimert, check for proper operation ofthe epak odvarcer wih the sevice tester,5. Spark pha edlustment A ity oF damaged sea plz. oF pls electron det whieh ore eroded wil not predict 0. good stoma tpt, theetove, the spark lige steuld bo Inspactes! paredeally end cloning ad ochsinerts hose. Spore pce wih toy, wat loses, or locates covered with deposits will permit the High tenon voboge ro bypass the gop wit seccig 1 Chening © The ue of the spam plc cloner i the recanmended ratiod of cloning the phos, however, © sarfactoy cleonhg con be taferted by usirg © nesdle or asi wire fo remcxe the deposits ord then wash Ta Crone flowed by drying wih coreested ch. (Fa 5.9) b. Adut tte spot gap after eaering. Sot the gap to 06~07 mm [D021~ 0.628 n) by ardng the sleciode on the rend si. Fig. 5.10), 2 Seak Pla kspeton 1 Cinch te spot intently produ between tho gop of te ground and ho enror oct reset Bo pth snes, Good condition Fra 7 oo ove contin Cass die 13: 1. Lew apsy volloge 2. Defective igion cot 8 Defocive spare ply 4. No sparing my do be de fo con pression CAUTION: 1. Do rot semave the dass ty boning, 2. When eteling the spat pigs, cleon the sealing cea Hee of oll or forign ator ‘rd tell fg tight before txging wh 2 plug wrench 3. The spot plugs an bo tose oor as! ret, wit tke lag tser. With the igh terson votago naintcind content, vary the test caréar presi end Yspect ho cond tion of the spre@ tacos ne 1 fal tod ne O08 @ ® ® Fig 5.124. Cloaneg lsat (980,199, 1901, 0991 Boren D fl arse on 28 Sang al ar IED, 79 6. Fuel supply eysten Restretien ithe fook apply syctn vel) prevent saflciet fuel flow to te cotreto: ond enue rue 10 ‘puter dwg ecelecson othe exgio ray ta et ch pact 1 Chact fer scent sily of fol the tak b. Dicemect te lel food ke ® fom the co: tavetor and. check he fol ow with he ool cick Don te ON or te & poston (Fig 30) © I be eel Dow is incon, rove the oe ‘cock, cleo ord clas, ‘When the fow i ail inodervte, ronore the ‘uel tank fiom the fee bay ore claon tara caution. @ Toe inafcent fel fow may bo cased by tho plugged ven! hola tho Miler eap at well th retcton i the ful ie © The fool cock is suited 10 B (ete! From the ON potion hen the ful tok 7. Fuel strainer clsoning Tho fori abstereer eosin’ ia the kel poses thceo! the hel fr fom the fuel fork ond fees the tier em The fragn stones nd ‘water, if pot erased, wil rtor the evlher end causes ein fee Closing {Set the fool cock ve fo the S bb Remove the scar cap ore Mtr teen & Cher tte sisi op ord Mer sxroon (Fo. 5.12) Note C90, C190: Theft stine is rcorpoated ‘ho teor end ofthe corer 8. Oil Mier screen clacning The ercive ci) Miered trough © syst of ovbla fers bafera it spline to the vorout pris of the engine, When ipuiliee have aces rloted in the Titer to crovent ts prover frtion the of surely te the vvove ports ore stove ord evenvaly real seinro ard damage 10 the fergie. Ite there-xe incor thot thefts be eloanes paisa2.1 MANTENANGE PECTIN @ 1. Cheoneg 1 Hanne the Hck stator pada Perea the sight conten cover, pil ot fh all eaeen ord wae In goeshe, (Fig. $.131 @ cauTion: Insel tho ll er seen with the nao Aepeted side toward the ide and the fn on the fier screen toward the boron. % Air clooner servicing ‘An ot clearer domed with dut testels he Fla 12 foeoves of QO free passage of let ct and rewtt in power lous es ar) OL fare OF crop in occelorsen, thoefoo, to ai prcpor elerrerce, peiokc choriag of the or cone shoud te pafomed. Femeval. (Fig. 5.14) Fees to page 98~97. 2 Ceorrg © Ton tte clear elerert listly to Koken tho dhs cr then biow ry coneesse ci from she ido oF ws9 0 bth to vonove ‘to dat. Fig. 5.15) ‘CAUTION: Fig, 5.14 amoung 9 ceca @ 1. Air cloner elavent made of colle cco @D Ardheme @) tm tot OA dcr core rd deared ce dvoged, 3 wit peat diate ‘0 erter engine cylinder ord coxz0 xcoe- 1) Se eyieer wor 2. Oil or wots wl exe the ele? to econ oaged snd will ait in lonorsd onan rr 2 @ 5:16 fw par of eth trere & FRONC AON 10. Clutch adjustment “he function of the cléch & 10 nun of db ongace tho rary power podiced oy the ongina fo the Honimison, fhe goo: mange whet the circ korg completely dizegaoed, te: mor eyde wil tat moving with @ jl o¢ he ence hn tho citar ars, ifthe teh is sping, tho seed of the nolocice wil “eg vation the engive speed 1 Lever elay Fin S17 datas ih te @ cic otis ede © loa at There seid be 1 to 1Sem|04~06 1 of lay in tho clich lover before tho clrch atts 10 deengaxe, 1590, C170, CLPOL, D901 (Fig. 14) 2. Aajvoment ($90, CL99, 901, co90) he deh lov’ ploy can bo adsted ot ho lever by looting the lack nt nd roving it in or cu. Ch cre. mack 20. povsien te poten the adn othe ater coining loered radcnt on the shore ie Hore shoud be O4~06iN when (Fie. 5.17, easy EEE feces ot ord of the ee i cable Ueper ohsier 18) (C90 oni C150) Te C90 end CT90 ae eaieped wi on Cec rch Ga ers, ces bot he a ie The lich cst mi ot efuteg tor Wg. 5.19) Ty lecion te lock mt @ oo tom the etn eae re ach th tuning becomes bord ar then tn Ih the opposite distin chat end tigen the lack tu, The stout provide the prozer avionstic spon. (Fig 5 19) 2, By tng abt sew 1 sh che Ba ap ereprbostiratl aargagonart will be sowed and to loft it Olan ‘wt be eleteed tsoecton (899, €L.99, cL 901, co80) 1. Kk sot the ego ot it to lon gos ailing auld be scot iti ony jot or ‘cio sal ven te geo engaged 2, The mclrjle Bout move acco ote lsc lore ly rec5.1 MANITENANCE REPECTION m Qa (€ 90, CT 90} 1. When she tons i difted to low goat ‘while the engine iz ing, the engi shoud ro! sal or ph 2. As the tte i cpenad, to notoeyelo a sheuld sot 1 rove cody. 11, Cerbureter loaning end ediustnant A dey exbucior or cxburaor out of otis wert will coe foor erga peformance, A of fecrpe, © existe eat Yo 9 lan fil or ite Wl coue the engine fo ovebes wile © Hh fg, $20 twa tn caer ¢ vviewe will casa erga Yo nn suggich. An over thea sep acon ‘owing of fuel from tho cabicolor it © pombe B av fee hazeac, thle, prose ecrng od cat- wnt leuld bo pom 1. Cheoring ©. Disssanble the exurster ond woth the IDLING SPEED (RP) pats In gvolio. ee be Blow out the nozzles with ccrresind ie » cand olter chong ert reaxonbly, make the i, ocjatert, 2. lle ojurnert 1.400~1,600 Tho flo oduenow ic pofomes with both ha ei a thotle slp screw rd the dr sow by tho Felling proces (Fig. 5.20) Fie, S21, Mia seed ste tle ©. Set the theta sep sew Jo the spolfed lng spss. (Fig. 5.21) 1 Now, asi tho ie sea by ting slowly fon fo kts the Highs angina in both speed. Teg the srew in wil pradice sich fun nieve. Trenrg tho srw ot wil prodve © lan Foal ine & Rathco the engre speed whier har gore vp in fel fo tho spectfed HM by roguatng ( the tere stop screw At the tre Zep ser satire, recheck the cxbirelor aistrent by rerinlating tha © Mio the idling adnan! hos een com Pete, chack the estaetor by snoring the ‘roto oe ato check th thot rospoe The ce screw shoud beset 10 Ys tum of tho spucit eating. ale 10 page 73) NOTE: Al edstnen sell bo nats oer the engine hos alched oporting tempera,Fig. 5.28 Ot lel i/o © Ot eal om ® Weer 1D tae tt ne & RIOD sONETAENT SE curs #30 2 200r #200" 524 Sp ‘ours SE enperurine | craves ‘cry r 154 p60 #10030 ojmhse 5. Lubricating The parpore of ibizcton & 50 prevent ect turoce to axdace covtoct of the moving part by frvlcng ofl of il betweon she alocss ord fhorey, redehe Nolen ond povertng weer. io serves #9 cool the pais fron the bea! ro: cxcod by fe“en rier, the bicot perertes between the pion ond cylinder to form an ol fn ich oc: (8 a 290 fo prover lose CF hn eyiae presse 1. Ferts not requiring periodic cil chongs or Iobrication pats wlich io Wb fetlon whanever the pots oo ceixorbid for spol ce replacanent. Tie ore ise Bon eel ole end con voce Tote oie 2. Engine oil chonge Change of at 1, $00 1,000: ding. 1. OH dexpe Remove the oll cap end din the. engine corslotly of cll by urserwing the cin slag @ ot the beton of the enste, (Fie 5.72) NOTE: The oli shold bo ccinod wha tha engine ie sil wean, 1 Tho propor oil level Is Indeatad by she ol between the keel makes on the age when checked nihos scenkg. the oo own. (Fg. 5.23) (08 exgocty ‘ler overtaving the engoa, Al corto wih OP 11.9US pit, 1.58 mp pid of ol, onere, drrg of Gange, rfl accactng 10 fe ve! gane. Ol Bere ond Grove The Gee of ol forthe season ts shove en fhe & corkosse cover, Uso the oil caneepon dng to MS. 0G or DM in the A oriiostion (Fig. 5.24) Plow O° (3241 SAE 10W wise is2~s5 SAE 20~20 coove 18°C SAE 30 However, SAE giaup 10W-20 is on all Waother of ore say bo vod over tho noel renge of calside tonporaive,2) ManT@UNce NBMETON ua NOTE: 1 Ol doys @ cromient rie the tite ond tte cube feo perfomerce of cr engine. tterfcre, ti very ingen tat ste ol shorgns be performed parctely end refia from ving city oll over @ long. pied Tho mare froiott the ol change, the ber Bs for th engine bien rafting or axing ol it eeuld not be fled cbcve the specified lve. Over fiieg ‘nil couse al ariging ond lees of owe fia, 5.23 cna on Use only wccrended ol 3. Grearing Leorcation Aap gre late gree Hepes with grasa fam url re goa ie forced out ot te com roncos. [Fl 5.28) ‘Use mitjrpone NUGI No 2 grave. Nore. 19 Clean the dit tom the nile bofore gre sia. bh. fit te create aun vozzle seovely to the tipple whan gracing Fp. 5.26 tugectts die dfs tsk € Exatze cara ond co rot pemit the reate D leoecen bl ep to becane conasinaad with dit, dust or ried wih Drive Chain Adiustment Ao erczeevoly 202k ave chin wil ee ein Cis ‘eT EnE wa : i AN eer eee reise Ve ‘of the rear wheel. Always maintain the chain ee ys pees Tenion Gning Hotere Nee rer idea all faved on ech oer Sct to han tate 1~2en tO i Coes Glan e roamp oars on 1 olor odininset by leoate the ode 2 i ssi or sao at ord en et wh rel ‘he cciairg ovt.@ (Fig. 5.27) © haste mt Tum to the ret to decrease ctan sla, Tor 10 tha left to tnrcse chain shock.