SA5O ee eeHOW TO USE THIS MANUAL Follow the Maintenance Schedule recommen- dations to ensure that the vehicle is in peak operating condition. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period, Sections 1 through 3 apply to the whole motor scooter, while sections 4 through 18 describe parts of the motor scooter, grouped according to location Find the section you want on this page, then tum to the table of contents on page 1 of that section, Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subse- quent pages give detailed procedures. It you don’t know what the source of the trou: ble is, refer to section 19, Troubleshooting Allinformation, illustrations, directions and speci- fications included in this publication are based on the latest product information available at the time of approval for printing. Honda Motor Co. Ltd. resarves the right to make changes at any time without notice and without incurring any ob: Iigetion whatever ‘No part of this publication may be reproduced without written permission, HONDA MOTOR CO., LTD. Service Publications Office te of Issue: Novernber, 1987 HONDA MOTOR CO.” LTD. ENGINE Sat ELECTRICAL CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM |__ ENGINE REMOVAL/INSTALLATION [ CYLINDER HEAD/CYLINDER/PISTON KE ALTERNATOR DRIVE AND DRIVEN PULLEYS) KICKSTARTER/CLUTCH FINAL REDUCTION |_ CRANKCASE/CRANKSHAFT FRAME COVERS ~~ STEERING/FRONT WHEEL/BRAKE/ __ SUSPENSION REAR WHEEL/BRAKE/SUSPENSION E ER BATTERY/CHARGING SYSTEM "Ignition system “ELECTRIC STARTER ia LIGHTS/METERS/SWITCHES WIRING DIAGRAM is TROUBLESHOOTING __—«< [no1. GENERAL INFORMATION GENERAL SAFETY 1 SERVICE RULES oa MODEL IDENTIFICATION 12 SPECIFICATIONS 13 TORQUE VALUES 15 TOOLS 16 CABLE & HARNESS ROUTING 17 NOISE EMISSION CONTROL SYSTEMS (U.S.A. only) 11 GENERAL SAFETY rom U the engine must be running to do some work, make sure the laea is well-ventitared. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that ‘may cause toss of consciousness and lead 10 death. Gasoline is extremels flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in sour working area or where gasoline is stored. Inhaled asbestos fibers have been found co cause respiratory disease and cancer. Never use an airhose or dry brush to clean brake assersbies. SERVICE RULES The battery electrolyte contains sulfurle acid. Protect your ‘ees, shin and clothing. In case of contact, flush thoroughly with water and call a doctor if electrolyte gets in your exes. Te bry ii in i nN con No it pecbaceesprc bor 1, Use genuine HONDA o HONDA-recommended parts and lubricants or their equivalents. Parts that do not meet HONDA’s design specifications may damage the scooter. 2. Use the special tools designed for this scooter. 3, Use only metric tools when servicing this scooter, Metric bolte, nute, and screws ere not interchengeable with English fas teners. The use of incorrect tools and fasteners may damage the scooter. 4, lstall now gaskots, O-rings, cotter pine, lack plates, ete. when reesaembling. 5, When tightening bolts or nuts, begin with larger-diameter or inner bolts first, and tighten to the specified torque ciegonally in 2 or 3 stops, urlese a particular eaquance ie specif 6. Clean parts in non-flammable or high flash point solvent upon disassembly. Lubsicate any shina surfaces betore re: ssternbiy 7. After reassembly, check all parts for proper installation and operation, & Route al electrical wires as shown on pages 1-7 thru. 1-11, Cable and Harmeas Routing, and sway from sharp edges anc ‘reas where they might be pinched between moving parts. 1-1GENERAL INFORMATION MODEL IDENTIFICATION Ss Cf |9) VEHICLE IDENTIFICATION NUMBER The vehicle identificetion number is attached to the left side of the frame body (1) FRAME SERIAL NUMBER) 4) CARSURETOR IDENTIFICATION NOVBEDE The frame seriat number is stamped on the left sido of the “The engine serial number is stamped on the left side of the | frame. engine case, [ay COLOR CODETABEL ‘The corburetor identification number is on the left side of The color code label js attached to the ‘uel tank below the the carburetor body, seat, When ordering a color coded parts. always specify its designated color 1-2‘ GENERAL INFORMATION rem SPECIFICATIONS ‘Overall longth 1,850 mm (68.0 in) (Overall width 850 mm (25.6 in) Overall height 1,010 mm (38.8 in} Wheel base 1,160 mm (48.7 in} Ground clearance 100 rue (3.9 in Dry weight 62.4 kg (138 Ib) Tye Under bone Front suspension, travel Rear suspension, travel Vehicle capacity load ze, pressure Trailing link, 73. men (2.9 fn) Final drive unit’swingarm, 60 mm (2.4 in) 81 kg (200 tn) 3.00— 10—4PR, 125 kPa (1.25 kg/om:, 18 psi 3.00. 10-4PR, 226 kPa (2.25 kg/em’, 33 psi) SPECIFICATIONS | DIMENSIONS: FRAME Front brake Internal expanding shoe Foor brake Internal expanding choo Fuel capacity 4,6 liter (1.22 US. ga. 1.01 imp, gal.) Coster angle 27° Trail 77 mm (3.0 in| ENGINE Tyee ‘Air cooled 2-stroko Cylinder arrangement Single cylinder inclined 15° from vertical | Bore and stioke 41x 37.6 mm (1.81 x 1.47 in) Displacement 49.4 em (3.0 cu, in) Compression ratio 69:1 Transmission of capacity 90 ce (3.0 U.S. a2, 2.6 Imp. cz) Oil tank capacity 0.8 iter. (0.85 U.S. at, 0.70 Imp. at) Lubrication 5} Oil automatically mixed with gasoline Port timing Intake Open Rood valve controlled Close Reed valve controlled Exhaust Open 80° (geDC) p Close 80° (BOC) Scavenge Open 6° (BB0C) Close 56° (ABDC) Engine dey wi 14.7 ke (32-4 Ib) Idle speed 1,800 = 100 rpm. e CARBURETION Carburetor type Piston valve Identification number PAgIM Air screw initial setting Float level 1-3/8 turns out 12.2 mm (0.48 in|GENERAL INFORMATION GENERAL INE CROAT OR re SPECIRCATIONS DRIVE TRAIN | Gutchiype Ftc ir cole catch — Prmery reduction var Goor mls 2as-oe61 Final reduction trosrt : HLECTRICAL liven Condonna capcive dchorae tation (CDi Storing systom Suesor ect rt Kiet ateonsie 42 96W15.000 rom | spark [ee ne! | [Stenderd BPROHSA WaoFPn-t For old inate PRAHA [wiaren For extended Ie PRaHSA warn ‘Spark plug gop. | 0.6—0.7 mm (0.024—0.028 in) ignition tring" mark 17" Bre at 1.200 = 100 pm are copay i2vsan Fuse eapachy 10a ueHTs Headignt Lowtiah 1av-25/25W Tailetotigh iavezew Tur sana!” FromRear tav7w Secor tg 1av19W x2 High beam ndeator iva Tun snr lator iavaawGENERAL INFORMATION TORQUE VALUES ENGINE tem yty | Thread Dia (mm) | Torque Nem (ka-m, #10) Remarks Gylinder head bolt 4 6 1011.0, 7 Flywheel nut 1 10 38 (3.8, 271 Clutch outer nut 1 10 38 (3.8, 27) Clutch lack nut 1 28 38 (3.8, 27) Movable drive face seal bolt 3 5 4.5 (0.48, 3.3) Drive pulley nut 1 10 38 (3.8, 27) 1 il check bolt 1 8 1311.3, 8) Exhaust pipe joint nut 2 6 1211.2, 9) Muiflor mount bolt 2 8 27 (2.7, 20) Spark plug 1 16 14.(1.4, 10) | Grankease bolt 8 6 10110, 2) Engine mount bolt 1 8 35 (3.5, 25) FRAME om ity | Thread Dia (mm) | Torque Nem tko-m, fb) Remarks: ‘Steering stem lock nut | 25.4 9 (0.9, 6.5) Steering stem nut 1 25.4 100 (10.0, 72) Front axle nut 1 10 45 (4.6, 33) Front brake arm bolt 1 | 5 6 0.6, 4.3) ‘Speedometer attaching screw 1 4 2102, 1.4) Front shack absorber upper mount bolt 2 8 27 (2.7, 20) Front shock absorber lower mount nut 2 8 18.1.8, 13) Front shack absorber lower mount bolt 2 8 1010.7) Pivot arm nut 2 8 27 (2.7, 20) Front shock absorber damper lock nut 2 8 20 (2.0, 14) lear axle nut 1 4 110 (11.0, 80) Rear brake atm bolt 1 5 60.6, 4.3) Rear shock absorber upper mount bolt 1 10 40 (4.0, 29) Rear shock absorber lower mount bolt 1 | 8 25 (2.5, 18) Rear shock absorber damper lack nut 1 8 20 2.0, 14) Auto fuel valve 1 16 2312.3, 17) Engine bracket bolt at a 3313.3, 24) “Torque specifications listed above are for specific fasteners. Others should be tightened to the standard torque values below, STANDARD TORQUE VALUES Torque Values Torque Valu tom Nem (ka-m, flo) ie Nem (kgm f mm bolt and nut 5 (0.6, 3.5) 5mm screw 410.4, 3) 6 mm bolt and nut 1011.0, 7) 6 mm screw 9 (0.9, 7) 6 mm bolt with mm head 90.9.7) 8 mm bolt and nut 22 (2.2, 16) 6 mm flange bolt end nut 12.1.2. 9) 10 mm bolt and nut 36 (3.5, 25) 8 mm flange bolt and nut 27(2.7. 20) 12 mm bolt and nut 55 (5.5, 40) 10 mm flange bolt and nut 40 (4.0, 29) 1-5GENERAL INFORMATION TOOLS ‘SPECIAL Descipton | _Too Number ‘anemate Too [Tool number |e See | Vacuum pump | A997X—041 — ‘Vacuum pump (U.S.A. | ST—AH—260—MC7 (U.S.A. only) | XXXAK only: Included in turbo: 07916—KS40100 07936—KM10000 07945—GC80000 07936--KC10000 07336~ 1660100 (077410010201 97936— 1660001 (07936 1660100 97741—0010201, (07965—GM00100 07965-00300 Lock rut wrench, 39 mm Clutch spring comprossor Bearing diver Boaring remover eet, 15 mm —ramover handle romover weight Bearing remover tomover handle remover weight Assembly collar ‘Assembly shatt 5%, 12 mm Cave puller 07935-Gk80000 Case puller 07935—-KG80000 Univereal bearing puller | 076310010000 “Thvead protector Lock nut wrench Lock nut wrench 07931— 1870000 (079161870000 07916—KM10000 Attachment, 28 x 30mm | 079461870100 Ball race remover Shock absorber compressor ettachment Spring attachment Digital muttimeter 07348-GA70000 07967—GA70101 (07967—-GM90100 9360~277— 91774 39 mm socket wit) | Clutch spring compressor Remover weight Remover weight cama conmeriaty | svalable in U.S.A Equivalent commercial available in U.S.A. | Digital mutimeter (07960—KM1000A (07936-3710200 079363710200 KS—AHM~22—003 “Theee toole are not avalabl ‘COMMON the U.S.A. Equivalent tools are recommended, Refer to tha altemate tool column. ally available in the U.S.A, or other methods Description Tool Number ‘Aitemate Too! | Tool number Rot Sec Float level gouge Universal holder Flywheel puller Attachment, 32 x 36 mm Attechment, 37 x 40 mm Attachment, 42 x 47 mm 07250030000 (07733 0010000 07746-0010100 (077460010200 07748-0010300 Pilot, 10 mmm (07746--0040100 Pilot, 12 mm 077460030200 Pilot, 15 mm 077460040300 Pilot. 17 mm 07746--0040400 Pilot, 20 mm 07746 0040500 Bearing criver 07748-0010000 Bearing remover shaft (07746 0050100 Boaring remover head, 10 mn 07746-0050200 ‘Shock absorber comprossor | O7GME~0010000 Lock nut wrench, 30% 32 mm 07716 0020400 Extension bar 077160020500 (074016010000 | Flywheol pullor Equivalent commercially avatabie in USA, Equivalent commercially lable in USA (07933--0230000GENERAL INFORMATION CABLE & HARNESS ROUTING New te folowing when rutig eaten ane wie heeneses «A bose wit hernos or cable canbe a aaety hat str x dlarping, Suck each vite tobe sire stcue esearserpemmereceesieeet B ca = — spective wire bends at the designated locations. Tighten the bands £0 that only the insulated surfaces contact the wires oF wire harnesses, ‘© Route harnesses so they are not pulled tight or have exces: sive alack, © Protect wires and harnesses with oloctiicat tape or tubes i oO they eommect a sharp ee 1 corte. Oe Clem the attaching surface thoroughly Setore xpi tape © Do not use wires oF harmesses with broken insulation. Repair by wrapping them with a protective tape or replace them, © Foute wire hamasses to avold sharp edges and comers. Also avoid the projected ends of bolts and scrows: © Koop wits harnesses away from the exhaust pipet and ‘other hot parts © Be sure grommets are seated in their grooves properly © Atier clamping, check each harness to be certain thet itis not interfering with any moving or sliding parts © Wire harnocsas routed along the handlebars should not be pulled taut, have excessive slack, be pinched, or intertere with adjacent or surrounding parts in all stearing positions © After routing, check that the wire harnesses are not twisted or kinked. Do not bend or twist control cables, Dameged control cables wil not operate emoathly and may stick ar bind, ©: CORRECT x INCORRECT 1-7GENERAL INFORMATION (1) FRONT BRAKE CABLE 1 coreowmcreR CABLE (9) REAR BRAKE CABLE (4) INSTRUMENT WIRE (8) THROTTLE CABLE (7) IGNITION SWITCH WIRE- NS celeron (6) REGULATOR/RECTIFIER (14) B. HANDLEBAR SWITCH WIRE (9) L. HANDLEBAR SWITCH WIRE (12) R. TURN SIGNAL WIRE - [11] LL TURN SIGNAL WIRE 1-8GENERAL INFORMATION (2) CRANKCASE BREATHER TUBE ff 7) cor unit f, / if I U wosvaren tiny (4) REAR BRAKE CABLE (5) ALTERNATOR WIRE 1-9GENERAL INFORMATION (7) FUEL SENSOR WIRE 1) AUTO FUEL VALVE VACUUM TUBE (5) FUEL TUBE (4) SPARK PLUG WIREGENERAL INFORMATION 1-11LUBRICATION2. LUBRICATION SERVICE INFORMATION 2-1 OILSTRAINER 28 ‘TROUBLESHOOTING 2-1 OILTANK 25 Ol PUMP. 2-2 LUBRICATION POINTS 26 OIL LINES/PUMP BLEEDING 23 OIL PUMP CONTROL CABLE ADJUSTMENT 24 SERVICE INFORMATION GENERAL ‘¢ When removing and installing the ail pump, use core not to allow dust or drt t0 enter the engine and cil line. © Do not attempt to disassemble the oll pump 1 Bleed air from the oil pump if there is wir in the oil inlet ‘been disconnected. {© Bloed air from the oil outlet line (from the oll pump to the carburoton whenever the line has been disconnected (page 2-3) © Use HONDA 2-stroke injactor oil or equivalent. TROUBLESHOOTING Excessive smoke and/or carbon on spark plug » Faulty oil pump + Low quaity engine of + 01 pump not properly adjusted (excessive oll ne {from the oil tank to the oil purnp) or whenever the ol ine has Overheating + Faulty oil pump. + Low quality oll + 01 pump not property adjusted (insufficient oil) Seized piston + No oil in tank of clogged cil line + Air in ail tines + Fauity oil pump + Clogged oll strainer + 01 pump not properly adjusted (insufficient oi) Oil not flowing out of tank + Clogged ol tank cap breather hole + Clogged oil stranerLUBRICATION OIL PUMP (V) OUTLET UNE REMOVAL (2) INLET LINE Flemove the canter trunk (page 11-51 NOTE + Before removing the oll pump, clean the oi pump and crank- Remove the oll contral cable from the eable stay and oil pump control lever. lamp the oil lines so oll does net flaw out; then diseonnect | the oil fines from the oil pump. Disconnect the alternator wire from ghe clamp. Remove the oil pump control cable stay attaching bolts. ( Ramove the cl pump. INSPECTION (1) O-RING (2) MATING SURFACE (2) BOLTS ‘CAUTION + Do nov disassemble the oil pump. Inspect for the Following: Damaged or weak O-ring Damage to crankcase rating surface Damage to pump body Control lever operation Worn or damaged pump geat Oil leaks INSTALLATION Lubricate the O-ring with grease or oil Apply molybdenum disufide grease to the ail pump gear and in stall the oll pump, Make sure that the ol! pump is properly inserted into tho crankInotal the oil pump contro! cable stay and attaching bolts and tighten the attaching bolts securely. Connect the ol inlet and outlet lines. Connect the oil control cable to the control lever. Clamp the alternator wire Alter instalietion, adjust the oil control cable (page 2-4), bleed the oll pump and lines and check for leaks, OIL LINES/PUMP BLEEDING CAUTION + Alr in the olf system will block or resirct oll flow and may result in severe engine damage. + Bleed ais from the oll Unes whenever the ol ines or pump have been removed or there is air in the oil lines + Bleed air from the oil nter line frst then bleed air rom ihe ott cuter tin. OIL INLET LINE/OIL PUMP FU tne oll tank with the recommended oil (page 2-1). Place a shop towel around the oll pump and disconnect the oil Inlet line from the oil purnp, Fil the oll pump with the recommended ol at the oll pump intet Joint Let oll drip from the inlet line to bleed air in the line, Connect the all inet line to the oil pump, OUTLET LINE 1. Romove the outlet line from the intake pipe and oil pump: Fill the outlet fine with the recommended oll as shown. Install the outlet line to the olf pump, 2. Stort the engine and allow it to dle and make sure that ci is forced out from the intake pipe end of the olf outlet line. oil is not forced out within ene minute, stop the engine and repeat steps 1 and 2. Connect the oil outlet fine to the intat Pips. CAUTION + Perform this operation in well-ventilated area. Do not rev the ezine up. LUBRICATION (4) CONTROL CABLE (a) CABLE STAYLUBRICATION OIL PUMP CONTROL CABLE TH ALIGNING MARK INDEX MARK] ADJUSTMENT CS NoTe + The oll pump contiol cable should be adjusted after the throtile grip froe play adjustment. Remove the center trunk (page 11-5). Loosen tie fully ll pump control cable lock nut and open the throt Check that the aligning mark on the ail pump contro! lever is aligned with the index mark on the pump body. Adust If necessery by turning the adjusting nut cauTion + Am adpastraent wishin I mmm (0.04 in of the index rnark on the “open side is ecceptable. However, the aligning mark must never the on the closed side of the index mark, otherwive engine tdaniage will occur because of insufficient lubrication OIL STRAINER Remove the following: both frame eaar covers (page 11-3), ‘center trunk (page 11-5) Disconnect tha ail inlet line at the oil pump and allow the oil to drain into a clean container Loosen the tube clip and disconnect the oil tube joint under the ol tank Remove the oil strainer Clean the olf steiner with compressed air, Install the ol strainer in the reverse a! removal Fill the of tank with the recommended oll up to the proper level Bleed air from the oil pump and oll Ines: Gomect the ol! ines securely and check for leaksLUBRICATION 1 OIL TANK (1) OL TANK ) REMOVAL eo Remove the following = both frame rear covers |page 11-3) — canter trunk (page 11-5), : Clean the interior of the oil tank thoroughly . Clean the cil strainer (page 2-4) INSTALLATION Install the oil tank in the reverse order of removal Fefil tho tank to the proper level and chock for oll leaks. Bleed the oil fines (page 2-3) (1) Om TANK. fe f Ort LeveL SENSOR (4) O1L STRAINER (3) OIL INLET LINELUBRICATION LUBRICATION POINTS ENGINE [__WuaricaTion Powis LUBRIGANT | REMARKS | Pietonierankhaft Honda 2-stroke injector oll or equivalent - | Final reduction Honda 4-stroke oil ‘90cc (3.0 US o2., 2.5 Imp.02.) || sae 10W=40 oF equivatent Movable drive face Lithium Based Grease | Miteubiahi HO-3 | Nippon Sekivu Lpanox Deluxe & 10-155 ldemiteu Coronex 3 or equivalent (0.38083 0: sta-luve HP #3143 Bot Rey Holy Lube 126 EP #0 ~Brortor geor General purpose grease FRAME ‘Apply clean engine oil or grease to ¢ om D a icamewsnca) = (vn THROTTLE AND oo 7 BRAKE CABLES ~ _(1) BRAKE LEVER PIVOTS (9) STEERING < HEAD BEARINGS pwvor . ARM ' \ \ susNG Franake camssiart) / (ec i ANCHOR PIN | (2) BRAKE CAMSHAFT! \ / 1 OV ANCHOR PIN san (9) FIVAL REDUCTION orwnee = aa {Sat 10W- 40, 90, WHEc. 5. qharecbomercn «CENTER STAND «308-2. 2.5 mp. 021) DRIVE GEAR Pivot 2-63. MAINTENANCE ‘Theattle free play Ile speed 2-6 mm (1/8 1,800 = 100 om Brake lever free play 10-20 mm (0.04—0.80 in} in) Tire size Tuo pressure 125 kPa (1.95 kgiom?, 225 kPa (2.25 kag/e SERVICE INFORMATION 3-1 BRAKE SYSTEM 35 MAINTENANCE SCHEDULE 3-2. HEADLIGHT AIM 36 FUEL LINE 3-3. SUSPENSION 36 THROTTLE OPERATION 3-3 NUTS, BOLTS, FASTENERS 37 AIR CLEANER ELEMENT ‘3-3. WHEELS/TIRES 37 SPARK PLUGS: 3-4 STEERING HEAD BEARINGS 37 CARBURETOR IDLE SPEED 3-5 COMPRESSION TEST 37 BRAKE SHOE WEAR 3-5 TRANSMISSION CASE 38 SERVICE INFORMATION Spank pugs NGK NO Standard | SrreHsA worn | For eo cimare ra For extndea nih sped dng arrersa | waarrna | Spark po geo 0.6=0.7 mm (0.028-0.028in) | Cynder comoression 800~ 1.200 KPa (8,012.0 kolo’, 114171 pa) 3-1MAINTENANCE ‘ MAINTENANCE MAINTENANCE SCHEDULE | — Inspection and clean, adjust, lubricate or Wnecessory RM — Replace C — Clean = acaueNcy | WtGHEVER ODOMETER READING (NOTE 1) Se L FIRST | sc00mi [oe] 25] 5 | 75 every | x1000Km | 1 | 4 | 6 | 12 Rater to page = [poet une 1 i 3a > [nnorrue OFERATION i 1 33 OIL PUMP AND Ot LINE Te 22 ‘AIR CLEANER (NOTE 2) e fete 33 SPARK PLUG (NOTE 9) | EVERY 1,000 mif1.800 kr R = | pecanwonvzina (NOTE 3) EVERY 2,000 mi (6.600km1¢ | CARBURETOR IDLE SPEED I Lo in 1 BRAKE SHOE WEAR BRAKE SYSTEM i > [RAKE LIGHT siMTGH >] MAD. IGHT AIM t 1 1 1 +> | CLUTCH SHOE WEAR ‘ t t 1 + | susPension 1 + | NUTS, BOLTS. FASTENERS 1 | WHEELSTIRES L ++] STEERING HEAD BEARINGS 1 1 a7 132 + SHOULD BE SERVICED 8Y AN AUTHORIZED HONDA DEALER UNLESS THE OWNER HAS PROPER TOOLS AND SEF- VICE DATA, AND IS MECHANICALLY QUALIFIED. ++ IN THE INTEREST OF SAFETY, WE RECOMMENDED THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED HONDA DEALER. NOTES: 1 At higher odometer reading, topeat at the frequency tested in and recommended for this engine, 2 Service more frequentiy when riding in wet or dusty aree. 3HONDA 2 STROKE MOTORCYCLE OIL has been specifically tested in and exhaust system, resulting in loss power and possible engine damage. 3-2MAINTENANCE FUEL LINE Remove beth frame rear covers (page 11-3). Inspect the fuel line tor damage or deterioration, ‘Greck that the fuel line ie intact and hae clamps at each con: nection. @.7. Replace any parts thet are damaged, leaking or show signs of datorioration. [iy FUEL LINE THROTTLE OPERATION {check for smooth throttle grip full opening and automatic full closing in all steering positions. Moke eure there ig no deterioration, damage of kinking in the throttle cable. Replace any damaged parts Remove the front and rear handlebar covers (page 11-5) Disconnect the throttle cable upper end, Thoroughly lubricate the cable with a commercially available ‘able lubricont or grease. Install the throttle cable in the reverse order of romoval Measure the throttle grip tree play at the throttle grip flange. FREE PLA’ 6 ram (1/8—1/4 in) ‘Adjustments can be made by loosening the lock nut and turn ing the aust i Abfusrer (1) LOCK NUT 2 the throttle cable when the above procedure is no affective, Check the oil pump controt cable adjustment (page 2-4). AIR CLEANER ELEMENT Remove the five air cleaner case cover screws end remove «screws “WyMAINTENANCE (MAINTENANCE Remove the air cleaner element, Wash the element in non-flammable oF high flash point sol- vent, squeeze out and allow 10 dy. + Never use garoline or low flash point solvents for cleaning the air cleaner element, A fire or explosion could result, Soak the element in clean motor oll (SAE 10V/—40) or gear oil (#80 90} and squeoze out excess. Reinstall the slemont, and tho air cl SPARK PLUG RECOMMENDED SPARK PLUGS: | NGK ND Standard BPRGHSA W20FPRL For cold BPREHSA WI4EPRL Rorereel al’ BPREHSA W24FPRL sped riding Loosen the screw and open the maintenance lid Disconnect the soark plug cep and clean any dit from around the spark plug base, Remove and discard tho spark plug. Measure the new spark plug gap using 2 wire-type fooler gauge. ‘SPARK PLUG GAP: 0.6—0.7 mm (0,024~0.028 in} ‘Adjust the gap by bending the side electrode carefully. With the plug washer attached, thread the epark plug in by hand to prevent cross threading. Tighten the spark plug anoth ‘er 1/2 turn with a spark plug wrench to comprose the plug washer TORQUE: 14 Nem (1.4 kam, 10 ft4b) Connect the spark plug cap. 1) ELEMENT In) WASH (2) SQUEEZE OUT AND DRY o8-07mm A (©.024"-9.028 in) iceman / ELECTRODE (2) OWL (4) SQUEEZE OUT Excess om (1) SIDE ELECTRODE [9 SPARK PLUG CAP 3-4. Te MAINTENANCE CARBURETOR IDLE SPEED (ar THROTTLE STOP scREW Place the scooter on firm, level ground. \ Nem up the copie end ettach an engine tachometer Tes th ce ped with the tht atop aeraw IDLE SPEED: 1,800 = 100 rpm BRAKE SHOE WEAR Feploce the brake shoes if the atrow on the brake arm aligns withthe reference mark "4." on full application of the front or mar brake (pages 12-7, 19-3). < * al) ARROW MARK BRAKE SYSTEM Nossure the front ond rear brake lever free play at the end of the levers FREE PLAY: FRONT: 10-20 mm (0.40-0.80 in) REAR: 10-20 mm (0.40—0.80 in} Wodjustment is necessary, turn the brake adjusting nut ae (1) abSUSTING NUTMAINTENANCE HEADLIGHT AIM Place the scooter on firm, level ground and support it with the ‘center stand. Start tho angine and allow it to ial. Make sure that the headlight and tallight are on Check the operation of the headlight dimmer \Lo-Hi) switch Adjust the headlight beam by turning the horizontal adjusting CAUTION Adjust the headlight beum as specified by local laws and rewulations. SUSPENSION FRONT Check the action of the front suspension by compressing them several times. Check the ontire fork assembly for signs of damage Replace any components which cannat be repaired. Tighten all nuts and bolts to the specified torque values page 15) REAR Place the scocter on ite canter stand. Hold the reat cartier with one hand and move the loft crank case sideways with force 10 sae if the swingarm bushings ere worn. Replace if excessively worn Check the entire suspension assembly. Be sure itis securely ‘mounted and not damaged. ‘Tighton allnuts and bolts to tha specified tarque vals 8) (oage 1MAINTENANCE NUTS, BOLTS, FASTENERS Tighten bolts, nuts and fasteners at the regular intervals thown in the Maintenance Schedule (page 2-2), fe nuts and bolts are tightened to their cor feet torque values (page 1-5). Check that all cotter pins and safety clips ara in place WHEELS/TIRES ‘a Sa + Check the te prassures when the tres are COLD, ‘TRE PRESSURES: FRONT: 125 kPa (1.25 kg/em?, 18 psil REAR: 225 kPa (2.25 kg/em?, 39 pail TRE SIZES: FRONT: 3.00—10-—4PR REAR: 3.00—10—4PR (Check the thes for wear, damage or embedded objects. STEERING HEAD BEARINGS Nore © Check that the control cables do not interfere with the handlebar rotation, Faise the front wheel off the ground by placing a block or jack undar the floorboard. Check that the handlebar rotates freely. lithe handlebar moves unevenly, binds, or has vertical move ment, adjust the steering head bearings by turning the steering ead adjusting nut (page 12-14. COMPRESSION TEST false the coat ‘Open the spark plug maintenance lid Warm up the engine. Stop the engine and remove the spark plug. m ~~ GAUGE Iheert 8 compression gauge (Open the throttle grip fully and operate the starter moter sev: ara times. COMPRESSION: 800 1.200 kPa (8.0—12.0 kgiem?, 114-171 psi) Low compression can be caused by: * Leaking cylinder hosd gasket + Woin piston rings: + Woin cylinder igh compression can be caused by ben daposite in combustion chamber or on top of the piston.MAINTENANCE TRANSMISSION CASE NOTE + Place the scooter on firm, level ground end support it with the center stand. sod let it idle for a fow rninutas, remove the oil level check bolt and check thet the bottom edge of the oll level check bott Check the transmission case for olf leakage. 3-8FUEL SYSTEM.4, FUEL SYSTEM SERVICE INFORMATION 4-1. CARBURETOR INSTALLATION 48 TROUBLESHOOTING 42 THROTTLE VALVE THROTTLE VALVE DISASSEMBLY ag INSTALLATION ae CARBURETOR REMOVAL 44 REED VALVE + AUTO BYSTARTER 44 AIR SCREW ADJUSTMENT 4am AUTO FUEL VALVE INSPECTION/ AOATIFLOAT VALVENETS ig MAINTENANCE an JETS/FLOAT VALVE/FLOAT FUEL STRAINER CLEANING 412 ASSEMBLY 47 FUEL TANK 412 FLOAT LEVEL INSPECTION 48 AIRCLEANER CASE 413 | SERVICE INFORMATION GENERAL a + Gasoline is extremely flammable and i explosive under certain conditions. Work ina well-ventiated area wlth the engine stopped. Do nat smoke or allow flames or sparks in the work area or where gasoline is stored. ‘CAUTION + Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind. (© The fue! tank is aauipped with an auto fuel valve that Is turned OFF automstic the engine Is stopped. Ise caution when working with gascline, Always work in a well-ventilated area and away from sparks or flames. nen disassembling fuel system parts, note the looations of the O-rings. Replace them with new ones during assembly leed air fram the oil outlet fino whonaver it ie dizcannactod. SPECIFICATIONS. Identification number PASIM | Type Piston valve Ventuil diameter 14 mm (0.58 in) 12.2 mm (0.48 in) 1-3/8 tums out 1,800 rpms 1 “8 635 Throttle grip {r00 play Jot resale men (1/8—1/4 in) 1d groove Fuel tank capacity TOOLS Special Vacuum pump Common Foat leval gouge 4.6 liter (1.22 US gal, 1.01 Imp. gal) A937X—041 —KXXAXX or ST—AH—260—MC7 (U.S.A. only, Included in Turbo kit.) (074010010000 4-1FUEL SYSTEM TROUBLESHOOTING Engine cranks but won't start + 'No fuel in ark + No fuel to carburetor + Too much fuel getting into evinder + No spark at plug (ignition malfunstion) + Alreleaner clogged + Faulty auto bystarer + Clogged fuel tine + Clogged fuel strainer + Stuck ful vaive diaphragm Engine ies roughly. stalls. or runs poorly + lle speed incorrect + Ignition maifunetion + Low compression + ich mixture + Lean mixture + Air cleaner clogged At leeking into inlet pipe + Fuel contaminated Leon mixture Carburetor fuel jets clogged Fuel cap vent clogged or blocked Fuel strainer clogged Fue! lino kinked or restricted Float valve faulty Float level too low Air vent tube clogged Rich mixture Disconnected auto bystartor wires Faulty tloat valve Float level too high Carburetor air jets cloggec Air cleaner dirtyFUEL SYSTEM THROTTLE VALVE DISASSEMBLY Leoten the air cleenar connecting tube band. Remove the two sir cleaner cose mounting bolts Remove the heat inauietor from the it cleenor ease, then emove the air cleaner case. Remove the corburet ap and pull out the throttle valve. Disconnect the throttle cable from the throttle valve. Remove the throttle valve spring. cauTION + The carburevor cap is an incegral part of the throttle cable as sembly. The cap cannot be separated from the assembly with us causing demage to the cable [THROTTLE VALVE SPRINGFUEL SYSTEM Pry out the retainer and remove the jet needte. (Cheek the jet needle anc throttle valve for wear or damage and reploce thom if necessary. CARBURETOR REMOVAL Remove the following: canter cover (page 11-2). left side cover (page 11-2) — left frame rear cover (page 11-3) — air cleaner case (page 4-13). Disconnect the auto bystarter wire connector. Remove the carburetor cap and pull out the throttle valve. Disconnect the fuel line from the carburetor body. Remove the carburetor mounting bolts and remove the cazbu- AUTO BYSTARTER INSPECTION If the engine has been running, lat it cool for 10 minutes or Measure the resistance between the auto bystarter wires. Re- pplace the auto bystarter with a new one if resistance is out of ‘specification or if there is no continuity RESISTANCE: 10.0 max. A (1) RETAINER ~~ (2) NEEDLE CLIP 3) SET NEEDLE ~~ a) _ THROTTLE VALVE (2) BOLTSFUEL SYSTEM Lit the carburetor sit for 30 minutes, Connect a pressure toster to the enrichening circuit and apply pressure to the crreust. [tthe passage is blocked, replace the auto bystarter with a ‘ew one. Cennact a 12°V battor nai tive minutes, between the auto bystarter ‘Connect a pressure tester to the fuel enrichening circuit and apply pressure to it. Aoplace the auto bystarter with a new one if thers is no roetric: tion to the pressure applied, REMOVAL/INSTALLATION Renovo the two screws, sot plete end auto by: ‘earburetor body, Inopect the auto byatertor valve for weer or damage, and the ‘ting for deterioration. (3 Ser PLATE (ny vatve 2) O-RING. 4-5FUEL SYSTEM. FUEL SYSTEM Insta the auto bystarter into the carburetor until itis fully seated, and sacure it with the set plate and two screws. FLOAT/FLOAT VALVE/JETS DISASSEMBLY Place a drain pan under the carburetor and loosen the carbure tor drain serew to allow fuel to drain into the drain pan, Romove the float chamber from the carburetor body. Remove the carburetor float and float valve by removing the attaching screw. Remove the O.ring irom the carburetor body. FLOAT/FLOAT VALVE INSPECTION Check the valve and seat for wear or demage. Replace the valve and seat as a set if either part is warn oF damaged (2) SCREWS (SET PLATE (1) DRAIN SCREW (1) FLOAT, (2) SCREW (1) O-RING. (1) FLOAT VALVE, 4-6FUEL SYSTEM ‘un in the throttle stop screw and record the number of turns (1) THROTTLE STOP SCREW ittakes before it seats lightly. CAUTION ‘Do noi force the screws against their seats fo prevent demaging ‘her Remove the throttle stop screw and air screw. a Fomova the auto-bystartor set plate and the by ‘moving the two screws. Check ali ports for weer or damage “el aie SCREW yn flow open all ots and bedy openings with compraseod JETS/FLOAT VALVE/FLOAT ASSEMBLY 7 MAIN JET {natal tho main jot. Install the air and throttle stop sorows to their original posi tions recorded during disassembly. (2) THROTTLE STOP SCREW Inotal the float valve, fleat and float pin 11) FLOAT, (2) FLOAT PIN Tighten the float scrow securely. Install the O-ring onto the carburetor body groove. Install the auto byatarter with the set plate and two screws,FUEL SYSTEM FLOAT LEVEL INSPECTION Remove the Oring trom the carburetor body. Meosure the float loval with the float lip just contacting the Neat valve. FLOAT LEVEL: 12.2 mm (0.48 in) TooL: Float level gouge 074010070000 Replace the Hoot if the Jovol is ineorract Reinstall the O-ring anto the carburetor body groove. Check the operation of the float and install the float chamber, CARBURETOR INSTALLATION cauTion + Do not allow foreign particles to enter the carburetor. Be sure the O-ring isin place on the carburetor. instal the heat Insulator ond corburator mounting belts. Install the carburetor cap (page 4-8) Gonnect the fuel ine and auto bystarter wires: s N bs Pe ts THROTTLE VALVE INSTALLATION hie A R Install the needle clip on the jet needle. (1) RETAINER STANDARD SETTING: 2nd groove (2) NEEDLE CLIP & 3h Instat the jet needle into the throttle valve and secure with the JET NEEDLE ‘ay P THROTTLE VALVE ie ges 4-8> FUEL SYSTEM Install tho epring on the throttle cable assembly. 1) THROTTLE VALVE SPRING. Connact the throttle valve to the cable 2) THROTTLE VALVE [THROTTLE CABLE Slide the throttle valve into the carburetor body (iGROovE nore + Nign the groove in the valve with the throttle stop screw on the carburetor body, Tighten the carburetor cap. Perform the following adjustments and operations: = throttle cable free play adjustment (page 3-3). = oil pump and tine bleeding (page 2-3). ~ idle speed acjustment (page 3-6) Install the left side cover page 11-2) REED VALVE REMOVAL Remove the following parts: carburetor {page 4-4), ~ eylinder head shroud (page 6-2), ‘vacuum tube. Remove the four inlet pipe mounting belts, the inlet pipe and askerFUEL SYSTEM Remove the read valve and gasket, ((2) GASKET ff INSPECTION (3) REED STOPPER, Chock the reed valve for dara Chock the valve seat for cracks, damage or clearance between the seat and reed. Replace the valve if necessary. CAUTION + Do not disassemble or bend the reed siopper. To do so can cause loss of power and engine damage. If the stopper, reed or valve seat s faulty, replace them as a unit Z (1) VALE SéaT (2) REED INSTALLATION ‘Tho instalation soquence is essentially tha reverse order of re moval NOTE * Align the tabs on the gasket and reed valve and install the rood valve, ‘After installation, check for secondary laaks. 4-10FUEL SYSTEM 1 AIR SCREW ADJUSTMENT (1) AiR SCREW NoTE + The engine must be warm for accurate air screw adjust- When the engine misses or runs erratically, proceed as fol lows: ‘Screw in the air screw until it ightly seats, then tuin it out es specified, [AIR SCREW OPENING: 1-9/8 turns out ‘CAUTION + Damage to the air serew seat will occur ifthe air serew is tight- ‘one aainst the seat Reset the idle speed with the thrattle stop screw. IDLE SPEED: 1,800 + 100 rpm ‘Make sura that the engine does not miss or run erratically by lightly enapping tho throttle grip. necessary, turn the air screw 1/4 tum (maximum) in either digction te find the best performance. It the engine cannot be adjusted within 1/4 turn, refer 10 Troubloshooting, POOR PERFORMANCE AT LOW AND IDLE SPEEDS (page 19:2) AUTO FUEL VALVE INSPECTION/MAINTENANCE Gm Gasoline is extremely flammable and ts explosive under certain conditions. Perform this operation ina well-ventilated areaand «do not smoke or allow sparks in the area. 1, Disconnect the fuel line from the carburetor and chack if {uel is flowing out of the fuel ina. ‘The fuel valve is normal it fuel ceases to flow out of the aftar the fuel valve and fuel line have been drained. Should fuel continus to flow out of the fue Ine, pertarm the follow. ing operation: + Clear the vacuum tube of any obstruction. + Direct a jet of compressed air to the fuel valve from the top. 2, Disconnect the vacuum tuba trom the intake pine and apply vacuum to the vacuum tube. The fuel valve is normal if fuel flows out of the fuel tine when vacuum is applied. 11 fuel does not flow out of the fuel line when negative pres: ‘sure is applied: do the following: + Clean the vacuum tube with compressed ait. + Giean the fuel strainer with compressed sir. + Loosen a stuck disphragm by directing a jet of cam: pressed air to the fuel valve {ror tha bottom, Held tho air ‘nozzle about 3 inches from the inlet, | RR Ee 4-11FUEL SYSTEM FUEL STRAINER CLEANING co Gasoline ls extremely flammable and is explosive under eeriain conditions, Work in a well ventilated area with the engine Mopped. Do not smoke or allow flames or sparks in the work ‘area or where gasoline is stored. Remove the fuel tank | Remove the lock nut and ramova the fuel valve, | Drain the gasoline into @ suitable containe'. Remove the fol strainer and clean it with compressed ai (1) Lock nut——* | Install the parts in the reverse order of removal Refll the fuel tank end check for leaks 1) FUEL VALVE NOTE i _ Ad Da not evertighten the lock nut TORQUE: 23 Hem (2.3 kgm, 17 8h € / / (2) STRAINER FUEL TANK (1) SEAT LOCK, REMOVAL + Gatoline is exiremely flammable and is explosive under certain r conditions, Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the work be ‘area or where gasoline is stored. Remove the following: — bath frame rear covers (page 11-3), = center trunk (page 11-5) =~ — seat lock. Remove the fuel line and vacuum tube from the suto fusl valve, (2) Bout Disconnect the fuel unit wire connector Remove the fuel tank mounting bolt and the fuel tank. DISASSEMBLY Drain the fuel Remave the fuel unit retainer with slip joint pliers. Remove the auto fuel valve and cleen the fuel strainer. 4-12 CONNECTORFUEL SYSTEM ASSEMBLY iaveeee yan (2) FUL LeveL Senso ‘Assembly 's the reverse order of disassembly. (6) SEAT Lock (5) FUEL TUBE INSTALLATION Installation is essentially the reverse of removal Note * Align the arrow on the fual unit retainer with the atrow on the fuel tonk, AIR CLEANER CASE (2) AIR CLEANER CASE] Remove the left side cover (page 11-2). Loosen the air claaner connecting tube band Remove the two air cleaner casa mounting bolts. Remove the heat insulator from the ar cleaner case, then remove the air cleaner case 1) BOLTS]FUEL SYSTEM INSTALLATION Installation is (3) AIR CLEANER CASE ——_{2) AIR CLEANER CASE COVER 4-14ENGINE REMOVAL/INSTALLA TION 12 Nem (1.2 keen, 9 FLD) 93 Non (3.3 kgomn, 24 frlb) if 9 oud ( 35 Nery (3.5 kgm, 25 feb) 5-05. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION 5-1 ENGINE INSTALLATION 53 ENGINE REMOVAL 52 SERVICE INFORMATION GENERAL ‘© The engine must be removed to service the crankshatt. SPECIFICATION Engine dry weight 14.7 kg (92.4 Ib) TORQUE VALUES Engine mount bolt 35 Nom 13.5 kgm, 25 fb) Engine bracket bok 33 Nem (3.3 kgm, 24 feb) Rear shock absorber unper mount bolt 25 Nem (2.5 kg-m. 18 It.lb) Exhaust pipe joint nut 42 Nem (1.2 kg-m, 9 fe4D) Mutfier mount bolt 27 Nom (2.7 kg-m, 20 fb)ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Remove the following: = beth frame rear covers (page 11-3) — canter trunk (page 11-5), — air cleaner case (page 4-19), Disconnect the elternator, starter moter end auto bystarter wire connsctors. Remove the exhaust muffler jpage 13-2), Remove the spark phig cap, Remove the carbureter cap from the carburetor (2) Ou TURE (a) VACUUM TUBE Disconnect the oil, fuel, and vacuum tubes from the carburetor pi Fe ‘and Inteke pipe Disconnect the rear shock ebsorbor upper mount bolt Remove the rear brake adjusting nut, then remove the rear brake cable from the clamp on the left crankcase cover (1) ADJUSTING NUTENGINE REMOVAL/INSTALLATION Plsco.a workstand undor the engine to support it. Femeve the engine mounting bolt and nut and separate the ‘engine from the frame, Remove the following parte when the crankcase is to be sepa: rated, ~ Carburetor [page 4:4) ~ Intake pipe and reed valve (page 4-9). = Oil pump (page 2-2. — Rear whee! (page 13-2), — Alternator (page 7-2) = Starter motor {page 16:2), Driveldrivan pulleys (page 8:5, 8) — Cylinder head/cyinder (page 6-2, 4). ENGINE MOUNTING BRACKET REMOVAL = Remove the engine mounting bracket bolt and ramove the bracket, ENGINE INSTALLATION The installation sequence is essentially the reverse order of ro ql Tighten the following bolt to the specified torque. TORQUE, ENGINE BRACKET BOLT: 93 Nem (3.3 kgm, 24 fFelb) ENGINE MOUNT BOLT: ee 35 Nem (3.5 kgm, 25 flb) REAR SHOCK ABSORBER LOWER MOUNT BOLT: 25 Nem (2.5 kgm, 18 feb) EXHAUST PIPE JOINT NUT: 12. Nem (1.2 kgm, 9 fib) MUFFLER MOUNT BOLT: 27 Nem (2.7 kg-m, 20 Feb)ENGINE REMOVAL/INSTALLATION Inspect and/or adjust the following: = Wiro and cable routing (page 1-7) = Carpuretor adjustment (page 4-1 1) — Rear brake adjustmont (page 3:5) — Oil pump bieeding/priming (page 2-3) ~ Oi control cable (page 2-4)CYLINDER HEAD/CYLINDER/PISTON6. CYLINDER HEAD/CYLINDER/PISTON ‘SERVICE INFORMATION 6-1 TROUBLESHOOTING 64 CYLINDER HEAD CYLINDER/PISTON 6-2 oa SERVICE INFORMATION GENERAL, @ All cylinder head, cylinder and piston service can be done with the engine installed in the frame. © Betore disassembly, clean the engine ta prevent dirt and dust from entering the cylinder and crankcase, # Remove all gasket material from the mating surfaces of the cylinder and crankcase, ise coution when disassembling and assembling the cylinder head, cylinder and piston to avoid damaging them. © Cleon all cisacsombled parts thoroughly before inspection. Cost al sliding surfaces with clean 2:stroke injector oil before assembly, SPECIFICATIONS Units rm fi Tren STANDARD SERVICE LT janie feed wreaae = 0.100.004) Fevindor Ji. inca | 9,000=41 005 116142—1 6148) | 40,900 (7.0121 B (No mark) ‘41.008—41.010 (1.6144— 1.6146) 40.900 (1.612) [Toner 10:10 (0.004) _| foseeround 010 (0.008) [ Wormege — “010 06.008 | Reon [pee OF = fiacn'éng, | Farm am the boom, 40.988-40.908 1.6124-1.6128) | 40,800 1.0101 cee | Slot ete) Piston rin_| Paton vn le LO 19106216008 03898-03610) | 10.0810.388) | Piston ia 0. 3.994 10.000,0.3935~0.3037) | 9.880.383 [Fiver patrp dronce @1002-0.614 (6.0001 -0.0006) | 0.08 (.00a1 ati ea as 0:10--0.2610.9040-0.0100) | 0.60 0.0201 coonealigradenese {arbos—14.015 0.5614=0.6516) | 14.09 0.88 TORQUE VALUE Cylinder head bor Exhaust pipe joint nut TROUBLESHOOTING Compression too low, hard starting or poor performance at low speed Leaking cylinder head gasket Loose spark plug Worn, stuck oF broken piston rings: Worn or damaged cylinder and piston Faulty reed valve ‘Compression too high, overheating or knocking + Exceasive carbon build-up in cylinder head or on 109 of piston 10 Nem (1.0 kgem, 7 feb) 32 Nem (1-2 kgom. 9 feb) Abnormal noise:piston + Worn eylinder and piston + Worn piston pin or piston pin hol + Worn connecting rod small end besring ‘Abnormal noise + Warn, stuck or broken piston rings, + Worn’ or damaged evlinder 6-1CYLINDER HEAD/CYLINDER/PISTON CYLINDER HEAD REMOVAL Remove the folowing — reat carton (poge 11-6 ~ bath side cover (page 17-2) = both frame roar cover (page 11-2). center trunk (page 11-5). Remove the fan cover by removing the two mounting bolts Remove the at cleaner case (nage 4-13), Disconnect the spark plug cap, Remove the cylinder head shroud by removing the two mount- ing bolts Remove the exhaust muffler (page 13-2). Remove the spark plug, the cylindar head bolts and the eyiin- der head. Remove the cylinder head gasket (1) GASKET.CYLINDER HEAD/CYLINDER/PISTON INSPECTION am ges, Remove the carbon deposits from the combustion chamber, ‘and the piston head. Clean the head gasket surface. CAUTION + Avoid damaging the combustion chamber wail and gasket sur- faces. Remove the carbon deposits from the head pipe of the exhaust muffler CAUTION © Do nor scraich or score the head pipe. NOTE + Ifthe engine stil has poor performance after decarborizing, rapl muffler assembly, Check tha cylinder head for warpage with a straight adge and ‘ feeler gauge in the directions shown. SERVICE LIMIT: 0.10 mm (0.004 in) INSTALLATION (1) GasKeT Inetall a new eylinder head gasket. a(CYLINDER HEAD/CYLINDER/PISTON Install the eylinder head on the cylinder (2) BOLTS. Install and tighten the four cylinder head bolts in a crisscross pattern, in 2 to 3 stops, TORQUE: 10 Nom (1.0 kgm, 7 ft-lb) Install the spark plug Insta the cylinder head shroud and tighten the mounting bolts Inetal the spark plug cap. Install the air cleaner case (page 4-14) Install the fan cover and tighten the mounting bolts, [EAN COVER (2) BOLTS Install the following parte: ‘center trunk (page 11-8) — both frame rear cover (page 11-3), — both side covers (page 1 1-21 rear carnior (page 11-6) CYLINDER/PISTON (1) CYLINDER. CYLINDER REMOVAL Remove the cylinder head (page 6-2) Remove the cylinder being careful not 10 damage the piston, cAUTION + Do not pry between the cylinder and crankcase or strike the Sins Place a shep towel into the crankcase around the piston 6-4CYLINDER HEAD/CYLINDER/PISTON PISTON REMOVAL Romeve the piston pin clip ueing a pair of pliors. Plats the pleton pin out of the piston. nore + Do not damage or scratch the piston. + Do not apply side force to the connecting rod. + Do not let the clip fall into the crankcase, (1) PISTON PIN CLIP PISTON RING/EXPANDER REMOVAL Remove tha piston rings. Clean carbon deposits fiom the piston head and piston ring arooves. Note + Spread each piston ring and remove it by lifting It up at 2 point just opposite the gan, + Do not damage the piston rings by spreading the onds too far. + Use care not to scratch the piston head or ring grooves. CYLINDER/PISTON INSPECTION Chock the cylinder and piston for wear or damage Clean carbon deposite from the exhaust port area. cAuTION + Do nor seraich or score the eylinder liner, Inspect the eylinder wails for scratches and wear Measure and racord the cylinder 1.0. at three levels in both an X and Y exis, Use the maximum reading to determine the amount of cylinder wear SERVICE LIMIT: Cylinder A (Mark A}: 40,900 mm (1.612 in) Cylinder 8 (No mark): 40.900 mm (1.612 in) caution + Some evlinder are marked with the letter ‘shown, and some cylinders are not marked. Wf the cylinder is replace be sure to use the matching replace ‘ment parts. 4°” in the location \ Coleuiate the piston-to-cylinder clearance. SERVICE LIMIT: 0.10 mm (0.004 in)CYLINDER HEAD/CYLINDER/PISTO! Check the cylinder for warpage with a straight edge and a {eeler gauge in the directions shown, SERVICE LIMIT: 0.10 mm (0.004 in) Measure and record the piston 0.0. at a point 4.0 mm (0.16 in) fram the boxtom, and 80° to the piston pin hole ‘SERVICE LIMIT: Piston 40.900 mm (1.610 in) Compare this measurement against the service limit and calcu: late piston-to-cylinder clearance. Measure the piston pin hole LD. SERVICE LIMIT: 10.03 mm (0.395 in) Measure the piston pin 0.0. ‘SERVICE LIMIT: 9.98 mm (0.393 in) Calculate the piston to-piston pin clearance. SERVICE LIMIT: 0.03 mm (0.001 in) PISTON RING INSPECTION Set each piston ring squarely into the cylinder 30mm (1-14 {nj from the bottom using the piston and measure the end gap with a fester gauge, SERVICE LIMIT: 0.50 mm (0.0197 in)= CYLINDER HEAD/CYLINDER/PISTON CONNECTING ROD INSPECTION {eotall the bearing end piston pin in the connecting rod amall ‘ond and check for excessive play. Measure the connecting tod small end 1.0, ‘SERVICE LIMIT: 14.03 mm (0.552 in) PISTON/CYLINDER INSTALLATION Clean the piston ring grooves. Lulvicate the piston rings and piston ring grooves with clean 2stroke oi) Install the piston rings on the piston with the marks facing up. NOTE + After installation, check that the rings rotate freely in the ring grooves, Cost the needle beering and piston pin with 2-stroke oil. Inatall the needle bearing in the connecting rod, and install the piston with the ““EX’’ matk facing the exhaust side. Install new piston pin clips. Remove all gasket material from the oylinder and crankcase ‘mating surface (1) MARK C\ =. TIE” MARK (2) PISTON PIN CLIP ell a ¥i eCYLINDER HEAD/CYLINDER/PISTON Be sure the ring end gaps are aligned with the piston ring pins: Inthe ring grooves caurion Be sure the rings do not rotate in their grooves over the locating to prevent ring breakage and piston and cylinder damage. Install a new cylinder gasket onto the cylinder Remove the shop towel from the crankcase. Lubricete the piston and cylinder with 2-stroke oil end install the cylinder aver the piston while compressing the piston rings. CAUTION + Avotd damaging the siding surface of the piston. Install the cylinder head (page 6-3) After assembly is complete, perform a compression test (Sec- tion 3) ‘Chock for any abnormal engine noise or air leakage past the cylin 6-8 TW aSTROKE oNALTERNATOR7. ALTERNATOR SERVICE INFORMATION 7-1 ALTERNATOR 72 SERVICE INFORMATION GENERAL This section covers alternator removel only. # See Sections 14 and 15 for alternator inspection. TORQUE VALUE Fiwheet nut 38 Nem (3.8 ko-m, 27 feb) TooLs common Fiywheo! puller 07783 -0010000 or 07933 0230000 Unversal hotcer 07725-0030000 7-1ALTERNATOR ALTERNATOR REMOVAL Remove the both side covers (page 11-2), Remove the fan cover by removing the twe mounting bolts. Remove the two bolts attaching the cooling fan and remove the cooling fan, Hold the flywhe wheel tlange nut | with the universal helder and remove the fly: Too! Universal holdor 07725--0030000 Romave the flywheel with the flywhee! pulla. oot: Fiywhee! puller 077330010000 Remove and retain the woodrutt key. 7-2CC OOOO OG . =F ALTERNATOR ator wire connectors. and ground wires from the starter Remove the pulse generator mounting bolts Remove the stator mounting bolts, then remove and the stator with the pulse generator INSTALLATION Install the alternator wire grommet in the case groove: Install the stator and pulse generator and tighten their bolt. o ‘SE GENERATOR 7-3ALTERNATOR Connoct the sltornator wire connectors, and the starter and ground wires: NoTE + Cleon the taper hole in the flywheel of any burrs and dirt. Install the woodruff key onto the crankshaft Install the flywheel onto the crankshatt. NOTE + Make sure that there are no foreign particles inside the fly wheel. Hold the flywheel with the universal holder and tighten the fy: wheal flange nut TORQUE: 38 Nom (3.8 kg-m, 27 fib) Toou: Universal holder 07725—0030000DRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH 3-08. DRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH SERVICE INFORMATION 8-1 DRIVE PULLEY 85 TROUBLESHOOTING 8-1 CLUTCH/DRIVEN PULLEY 88 KICKSTARTER 8-2 STARTER PINION B13 SERVICE INFORMATION GENERAL SPECIFICATIONS Ut mnin Te STANDARD | seavice ui [_bave bor wih a 166 061) [sos Movable dive face | Biahing LD 20.038 20.008 ©.7888 0.701) | 20.130793) | Boss 0.0, 20.005 20.025 (0.7876 0.7884) | 19.97 (6786) Weight olor 0.8, 16.92 16.08 ©.627-0698) | 16.40 10606) hich Outer LD. | tone-ronawat-azer | rors) Shon ticenes 40-41 0157-0167) | 201008) Divan pally Driven tacs spring oe engi | —_—=—i88.1 2.601 92.6 (065) "Driven face 0. 38.805 —94.026 (1.072-1,9980) 90.94 1.936) Movable even face 1 34.000—34.026 (1,3986-1.3980) 96.06 1.941) TORQUE VALUES apo cee 38 Nem @.Bkgm, 27 fib) hah ure mut 38 Nim (3.8 kgm, 27 Hb) hatch fock nuk 38 Nem @ kgm, 27 fb) ovate ave face sea bok 18 Nom (akg, 9 feb) TOOLS ‘Special ibck ut wench, 89 mm 97816--1870002 or Commercity avaiable 29 rm socket Gish song compressor 07960-KM10000 oF 07980 -KN10008 (8.A. ony Aachen 20°630 mm 07946 1870100 Besnng aver o7eas—Ge80000 fron rivers noir 077280030000 Bearng diver 077486030000, Sidon care; bun mon suse wot nore Poor performance at high speed a lak of power Worn arve belt Worn ive bak + Broan ramp pate + Week teen food alg + Worn or damaged sito ting «Wom weight roller sere iver fee ang «Faulty ven face «Damaged driven play shat splines + Wom or seized driven puley bearing Engine sls or motor sooter moves suddenly Ccutch nots or mal Broken dash eta sping OT er renee om crve bok or play * Bameged etch fring + Wom eve bok + Wook driven face spring + Worn or seized driven pulley bearingDRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH KICKSTARTER LEFT CRANKCASE COVER REMOVAL Remove the following: — Left side cover (oage 11-2). ~ Kickstarter pedal. the starter motor with the left crankcase cover removed KICKSTARTER REMOVAL (1) SNAP RING Remove the snop ring and washor from the kickstarter spindleDRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH Romove the kickstarter spindle, spindle bushing and return spring trom the left crankcase cover, WETURN SPRING ML KICKSTARTER INSPECTION (1) SPINDLE: (3) RETURN SPRING Check the kickatarter spindle, bushing ond return spring for wear or damage, t (2) ausHING Chock the kiekstarter driven gear and friction spring tor waar (1) DRIVEN GEAR = ‘or damage. (2) FRICTION SPRING Check the spindle and driven gear bearings for wear or dam- age.DRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH KICKSTARTER INSTALLATION Install the kickstarter bushing, spindle end return spring onto the teft cranksase cover NOTE + Pry the inner end of the pring out of way with the end of a screwdriver, if difficulty is encountered in inserting the spinde thraugh the spring. Install the kickstarcer driven gear and friction spring onto the crankcase cover as shown m2) FRICTION SPRING Install tne washer and snap sing, (2) SNAP RING (1) WASHERS Install @ new gasket and dowel pins. (1) GASKET, 8-4DRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH Install the left crankcase cover and tighten the mounting bolts securely. histall the kickstorter peda. DRIVE PULLEY MOVABLE DRIVE FACE REMOVAL Remove the fan caver and the fan. Holo the flywheel with the universal notder. Remove the nut, then remove the starter driven gear and drive bet. Remove the drive face. Tool Universal holder 07725-0030000 DRIVE BELT INSPECTION CCheck the dtive belt for cracks, separation or abnormal or ex: cescive woar, Measure the width of the belt at its widest point, SERVICE LIMIT: 14.5 mm (0.87 in) Replace the belt i itis narrower than the service limit. NOTE + Use only a genuine Honda replacement drive belt MOVABLE DRIVE FACE DISASSEMBLY Remove the three boits attaching the movable drive face seal and remove the seal (2) FACE SEAL 8-5DRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH Romove the ramp plate (1) RAMP PLATE Remove the weight rollers. (1) WEIGHT ROLLER MOVABLE DRIVE FACE INSPECTION Check each roller for wear oF damage. Measure each roller 0.0. SERVICE LIMIT: 15.40 mm (0.606 in} ‘Measure the movable drive f bushing 1.0. SERVICE LIMIT: 20.13 me (0.793 in} Replace the drive face if the I,D, exceeds the service limitDRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH Inapoct the drive face boss for wear or damage: Measure the 0.0. of the bace at the drive face contacting sur face. SERVICE LIMIT: 19.97 mm (0.786 In) Replace the boss if the O.D. is less than the service lini MOVABLE DRIVE FACE ASSEMBLY (1) WEIGHT ROLLER Lubricate the inside of the drive face with 10—15g (0.35— (0.53 02) of grease, then install the weight rollers. ‘SPECIFIED GREASE: Lithium Based Grease Miteubishi HD-3 ‘Nippon Sekiyu Lipanox Deluxe 3 Idemiteu Coronex 3 Sta-Lube MP #3141 Bol-Rey Moly Lube 126 EPO. Inotal tho ramp plate and movable faco eval, (1) RAMP PLATE: (3) BOLTS Tighten the seal bolts to the specified torque, ‘ TORQUE: 13 Nem (1.3 kg-m, 9 fe4b) NOTE + Make sure that the O-ring is in position. Install the drive face boss in the moveble drive face, MOVABLE DRIVE FACE INSTALLATION Install the thrust washer onte the crankshaft, thon install the hive face assembly. Insta the arive bot nore + Clean the hole in the movable drive face, drive face boss and crankshaftDRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH Install the starter driven gear and nut. Hold the flywheel with the universal holder, then tighten the TORQUE: 38 Nem (3.8 kg-m, 27 fttb) Tool: Universal holder (07725—0030000 NOTE + Do not get oil or grease on the drive belt or pulleys. t the following: fan and fan cover. — left crankcase cover, the air cleener case and both side cov- — kickstarter pedel. CLUTCH/DRIVEN PULLEY REMOVAL Ramaye the following: — both side covers (page 11-2). — kickstarter pedal ~ left crankcase cover (page 8-2). Hold the clutch outer with the universal holder. Remove the nut, then remove the clutch outer. TooL: Universal holder 0725~0030000 Remove the driven pulley trom the drive shaft. CLUTCH DISASSEMBLY Install the clutch spring compressor and remove the 28 mm ‘Toows: Cluteh spring compressor (07960~KM10000 or (07960-KM10000A (U.S.A. only) Lock nut wrench, 39 mm (07916- 1870002 or equivalent commercially SPRING COMPRESSOR available in U.S.A. es NOTE + 1f 07960—KM1000A is used, place the special screws in the holes marked “A” Remove the compressor and remove the clutch and driven a8 spring from the driven pulley CAUTION Do noi T cxoara ireDRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH CLUTCH INSPECTION Inspect the clutch cuter for waar or damage. Mesure the clutch outer 1D, SERVICE LIMIT: 107.5 mm (4.23 in) ‘Measure the criven face spring free length. ‘SERVICE LIMIT: 92.8 mm (3.66 in) Inapect the clutch shoes for wear or damage. Moacura the thickness of each shoe. [SERVICE LIMIT: 2.0 rm (0.08 in} CLUTCH SHOE REPLACEMENT (ny erRcuPs 2 IRSHER. Remove the circlipe and washers. Remove the clutch shoes and shoe springs. Install the clutch springs on the new clutch shoes, Apply grease to the pivot shafts. CChack the dampor rubbots and replace them if they ara dam- eed. Install the clutch shoes onto the drive plate and secure them with the washers and ciestips (3) CLUTCH SHOE (4) SHOE SPRING eee 8-9DRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH a <= ey (5) CIRCLIPS = 1G ; 1s / * omer fo i. SPRING "RUBBER. Install the cluteh springs on the new clutch shoo. Apply orease to the pivot shatt. Check the damper rubbers and replace them if they are dam. aged. Install the clutch shoos onte the drive plate and secure them with the washers and circlips. DRIVEN PULLEY DISASSEMBLY (1) SEAL COLLAR Remove the gui ping, then remove the movable driven face. (2) o-RINGS. Remove the oll seals and O-rings (1) DRIVEN FACE UNGAR J GUIDE PIN 15) vi RINGS PA (6) SEAL COLLAR a) OIL SEAL,DRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH Inspect tha driven face assembly for wear or damage. Measure the drivan face 0.9. at tha paint indicated, SEAVICE LIMIT: 33.94 mm (1.336 in) a ms (it I i Ny hit i RHE tiLuial a Inspect the mavable driven face for wear or damage. Measure the movable driven face 1.0. SERVICE LIMIT: 34.06 mm (1.341 in) CChack the guide groove for wear. DRIVEN FACE BEARING INSPECTION/ REPLACEMENT ‘Tum the inner race of both besrings with your tinger. ‘The beatings should turn smoothly and quiotly ‘Also check that the bearing outer raca has not been spinning in the driven face ascombly. Discard the bearings if the races do not tui smoothly and ‘quietly, or if they have been spinning in the driven face as: ‘sombly, Remove the snap ring, and then the outer bearing. (2) OUTER BEARING 8-11DRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH er Drive in a new outer bearing with its sealed side facing down, (1) BEARING DRIVER Install the snap ring. TOOL: ‘Bearing driver 07945—Gc80000 ‘Apply grease to the inside of the driven face. 5.0 6.6g (0.17 -0.20 or) Drive in the new inner bearing with its marked side facing up. (1) BEARING OFIVER | Toous: Boaring driver 077490010000 Attachment, 28 x 30 mm 07946~ 1870100 (2) ATTACHMENT. 28 x 30 mmny CLUTCH/DRIVEN PULLEY ASSEMBLY (1) O-RINGS (2) O1L SEAL Lubricate the inside of the movable driven face with 3.54.09 then install O-rings and oil seals, ddiven face on the driven face assemb- ly, then install the guide pins. Install the seal colar. (1) SEAL COLLARDRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH (1) LOCK NUT WRENCH Position the driven face aszembiy, spring and drive plate as- sembly in the clutch spring compressor TOOLS: Clutch spring compressor (07946—kM10000 or (07960—KM1000A (U.S.A. only) Lock nut wrench, 38 mm 107316— 1870002 or equivalent commercially ‘available in U.S.A, Nore \ + 1107960—KM10004 is used. be sure the special screws: IF (2) SPRING COMPRESSOR tare located in the holes marked Compress the spring by turning the handle Install and tighten the 28 mm special nut. TORQUE: 38 Nem (3.8 kgm, 27 ft-lb) CLUTCH/DRIVEN PULLEY INSTALLATION Install the driven pulley onto the drive shaft Install the clutch cuter and hold it with the universal holder, Install and tighten the lock nut, TORQUE: 38 Nem (3.8 kg-m, 27 ft-lb) TOOL: Univereal holder 077250030000 Inetall the remaining parte in the raverse order of removal STARTER PINION Remove the following parts ~ both frame rear covers Ipage 11-3), left crankease cover (page 8-2) — starter criven gear (page 8-2) — starter pinion holder = sxarter pinionDRIVE AND DRIVEN PULLEYS/KICKSTARTER/CLUTCH ‘ Check the starter pinion goar and sliding surfaces for wear or (1 PINION GEAR damage, (Check the starter pinion for smaoth operation. Apply grease to oach sliding por reverse order of removi 8-14FINAL REDUCTION 19. Nem (1.3 kgm. 9 feb) 9-09. FINAL REDUCTION SERVICE INFORMATION 9-1 FINAL REDUCTION INSPECTION 9-2 TROUBLESHOOTING 9-1 FINAL REDUCTION ASSEMBLY 95 FINAL REDUCTION DISASSEMBLY 9-2 SERVICE INFORMATION SPECIFICATIONS Specitig of) Honda 4-stroke oll SAE TOW 40 or equivalent il quentity 80 c¢ (3.0 US oz, 2.6 Imp. 02.) Toos Special Thiead protector 079311870000 Bearing temover, 18 mm 07938—KC10500 Remover handle 079383710100 Bearing temover, 12 mm 07938~1660100 Boating remover waight 077410010201 or 079363710200 Assembly collar 07965—GMo00100 Assembly shaft (07985 -GM00300 Common Bearing driver 07749--0010000 Attachmant, 32.4 35 mm 077480010100 Pot, 12 mm 077480040200 Attachmant, 37 x 40 mm 077480010200 Plot, 15 mm 077480040300 Plot, 17 mm 077480040200 TROUBLESHOOTING Engine starts, but scooter won't move + Damaged transmission + Seized or burnt belt Abnormal noise + Wor, seized or chipped gears + Wor bearing Olteaks + Oil level too high + Worn or domaged oil sealFINAL FINAL REDUCTION DISASSEMBLY Remove the riven pulley (page 8-8) Remove the rear whee! (page 13-2) UCTION Place an oil drain pan uncer the final reduction case to catch the ail, than temove the transmission cover bolts and cover, Remove the two dowel pins and the gasket Remove the following: the thrust washer from the countershaft and the cilia from the final shaft the final gear and final shaft the countershaft. counter gear and inner thrust washer FINAL REDUCTION INSPECTION Inspect the driveshaft and gear for excessive wear or damage. Check the countershatt and gear for excessive wear or dam: age Chock the final gear for wear, damage or signs of seizure 9-2 (1) DRIVESHAFT i ceaR 3 pee GEAR oR” (1) COUNTER SHAFTFINAL REDUCTION DRIVESHAFT REMOVAL (1) THREAD PROTECTOR Use a hydraurie press to remove the driveshaft from the trans: mission cover TooL: Thread protector 07931 1870000 TRANSMISSION BEARING REPLACEMENT. (1) BEARING REMOVER your finger The bearings should turn smoothly and quietly Inspect the bearings by turning the inner rece of each with \ 2 Also cheek that the outer races fit gril in place Remove and ciscard the bearings if the inner races do not turn smoothly and quitly, or if the outer races have beon spinning in place. Check the transmission cover final shaft beating, drivachatt bearing and oll seal for damage, Remove and discard the bearings YooLs: Beering remover, 15 mm 07936-KC10500 Remover weight (077410010201 or 07936~3710200 Chock the left crankcase driveshaft bearing, oll eal and final shaft bearing for damage. 4 \2) OL SEAL (3) FINALSHAFT BEARING HW necessary, remove the driveshalt bearing from the left crankease: roots: Booting remover, 12 mmm 079361660001 Remover weight 97741—0010201 or 079363710200FINAL REDUCTION Drive a new driveshaft beating into the lalt crankeate. roots: Bearing driver 977430010000 Attachment, 32 « 35 mm (077460010100 Pliot, 12 mm (07746 -0040200 Drivn a new final shaft beasing into the left crankeaes, then in stall the oll sel ‘Toots: Bearing driver 077490010000 Driver attachment, 37 x40 mm 07746~-0010200 lot. 17 mam. 077460040400 Drive a new final shaft beating into the transmission cover Toots: Bearing driver 07743-0010000 Driver attachment, 37 x40 mm 077460010200 Pilot, 15 mm 07746~-0040300 Drive a new driveshaft beating it 0 the transmission cover TooLs: Bearing driver 97743~0010000 Driver attachment. 37x 40 mm 077460010200 Pilot, 17 mm 07746—0040400 IT) BEARING ORIVER cs pw. \ (2) ATTACHMENT, 37 40 mm Ee BEARING DRIVER (2) ATTACHMENT, 37 « 40 mm (1) BEARING DRIVER (2) ATTACHMENT, 37 x 40 mmFINAL REDUCTION _ FINAL REDUCTION ASSEMBLY (1) ASSEMALY SHAFT Insert the diiveshalt through the cover beoring from the loft side Toots: Assembly shaft 97965—GM00300 Assembly collar 07965—GM00100 Install the olf sea ‘Assemble the inner thrust washer ond counter gear onto the ccountershaft, then install them in the left crankcase, Install the final shaft and final gear in the case. Install tha thrust washer onto the countershaft and the citi ‘onto the final shaft, as shown, Install o new gosket and dowel pins uy casket 9-5FINAL REDUCTION Install the following — transmission cover, = driven pullayichiteh (page 8-12) — drive pulley, drive belt page 8-7) and left crankcase cover (page 8-5) — rear wheel (page 13-2) Pour the specified amount of olf through the fila opening, ‘SPECIFIED OIL: HONDA 4 STROKE OIL 10W-40 oF equivalent QUANTITY: — 90 c¢ (3.0 U.S. 02,, 2.5 Imp. 02.) (2) BOLTS Start the engine and check for teaks.CRANKCASE/CRANKSHAFT 10 Nem (1.0 kom, 7 ft-lb) 10-010. CRANKCASE/CRANKSHAFT SERVICE INFORMATION 10-1 CRANKSHAFT BEARINGS 10-3 ‘TROUBLESHOOTING 10-1 CRANKSHAFT ASSEMBLY 10-4 CRANKCASE SEPARATION 10-2 CRANKCASE ASSEMBLY 10-5 CRANKSHAFT 10-2 SERVICE INFORMATION GENERAL © This section covers crankcese separation to service the cronkshott. ‘© The folowing parts must be removed before separating the crankcase + Engine (Section 5) Reed valve (Section 4) — Mounting bracket + Alternator (Section 7) + Corburetor (Section 4) Cylinder head, cylinder (Section 6) + Oil pump (Section 2) + Starter motor {Section 16) © In.addtion to the above, remove the following perts when the left crankcese helf must be removed: + Rear whee! (Section 13) + Finel reduction (Section 8) SPECIFICATIONS Unite mm tnd TEM [STANDARD SERVICE LIMIT Cranksher [Connecting rod big end side cleerance 0.6 (0.02) ‘Connecting rod big end radial clearance — 0.04 (0.002) Funout A — 0.15 (0.006) 5 — 0.10 (0.004) TOOLS Special Universal bearing puller (079310010009 oF commercially avaiable in U.S.A Case puller 07935 kG80000 ‘Assembly collar (07965—GMO01 00 ‘Assembly shatt (07965—GM00300 ‘Thread protector 079311870000 ‘common Bearing driver 07749--0010000 ‘Attachment, 37 x 40 mm 07746-0010200 Pilot, 17 mm 077460040400 Attachment, 42 x 47 mm 07746—0010300 Filo, 20 mm 07748.-0040800 TORQUE VALUES Crankcase bolt TROUBLESHOOTING Abnormal engine noise + Worn main journal bearing + Worn erankpin bearing + Worn transmicsion bearing 1O Nem (1.0 kgm, 7 Feb) 10-1CRANKCASE/CRANKSHAFT ‘ CRANKCASE SEPARATION Remove the crankcase mounting belts. (1) BOLTS: Attach the spacial tools on the erankeate as shown, separate the right crankcase from the left half. roots: r Case pallor 07935—Gxa0000 ‘Thread provector 07931~ 1870000 j 4 " 0) cast PULLERS MPU raReAD ProvEcron CRANKSHAFT i) THREAD PROTECTOR REMOVAL sshatt from the crankcase, TooLs: Case pullor 07935 —K680000 ‘Thread protector 07931 ~ 1870000 INSPECTION Mescure the connecting rod big and side cl feeler gauge. SERVICE LIMIT: 0.6 mm (0.02 in| 10-2Measure the connecting red big end radial clearance at two points in the X and ¥ directions. SERVICE LIMIT: 0.04 mm (0.0016 in) ‘Support the erankshalt on @ stand oF V: blocks end rend runout Using a ial gauge. SERVICE LIMITS: ‘A: 0.15 mm (0.006 in) 8: 0.10 mm (0.004 in) CRANKSHAFT BEARINGS INSPECTION/REPLACEMENT Turn tha inner race of each beating with your finger. The bear Ings should turn smoothly and quietly. Also check that the jaring outer race has not been spinning in the crankcase. Discard the besrings if the races de not tun smoothly and ‘quiewy, or if they have been spinning in the crankcase. When the bearing stays on the crankshaft spin the bearing outer and check for emaoth and quiet spinning. NOTE + Roplace crankshatt ball bearings in pairs. I necessary, remove the crankshaft bearing from the crank: shaft Toot: Univareal tearing puller 076310010000 or equivalent commercially available in U.S.A. fl CRANKCASE/CRANKSHAFT 56 mm (2.2 i) 20 mm (0.8 in) (1) BEARING PULER 10-3CRANKCASE/CRANKSHAFT a Drive @ new crankshaft bearing into the left crankcase (1) BEARING DRIVER Too! Bearing driver 077490010000 Driver attachment, 37 x 40mm 07748-0010200 Plot, 17 mm 077460040400 Drive a new crankshaft bearing into the right crankcase. roous: Bearing driver 977490010000 ‘Attachment, 42 x47 mm 07748-0010300 Pilot. 20 mm 077480040500 CRANKSHAFT ASSEMBLY Wash the crankcase in solvent and blow cry with compressed air. Chock for cracks or other faults Apply clean 2-strake injector oil to all moving and sliding sur- faces. Remove all gasket material from the crankcase mating sur- faces, Dress any roughnoss or irregularities with an oll stone. Position the assembly collar’s small 0.0. against the crank: ‘shaft bearing, Thread the assembly bolt onta the crankshaft Hold the bolt and turn the nut to install the crankshaft into the left crankcase, Toots: Assombly shaft (07965—GM00300 ‘Assembly colar (07965—GM00100 4 ‘Lubricate the crankshaft main and journat bearings with Honda oF) 2-stroke oll or squivalont ¥ 10-4“ q CRANKCASE/CRANKSHAFT Install 2 now left crankshaft oil seal using tho acsambly st ‘and the opposite side of the assembly collar as shown, Too.s: Assembly shaft '07966—GM00300 Assembly colar (07965—GM00100 CRANKCASE ASSEMBLY Ingtall a new gatket and the dowal ping onto the crankcaes ‘mating surface, ‘Assemble the crankcase halves; place the collar with the small ©.D. against the right crankshaft beating Thvead the bolt through the collar onto the crankshaft, Hold the bolt and turn the nut clockwise to draw the crankessa halves together. Toots: Assembly shatt 07965—GM00300 Assembly collar (07965—GMo00100 Install a naw right crankshaft oll seal using the same tool unt itis 9mm (0.38 in} below the surface of the right crankcase as shown. Toots: Assembly shatt Assembly collar 07965—GMo0300 (07965—GM00100 [aren Seay] Ee (00.08 inyfid (y) ASSEMBLY SHAFT 9 mm (0.35 in) (1) O1L SEAL 10-5(CRANKCASE/CRANKSHAFT. : Install end tighten the crankcase attaching bolts in a crisscross pattern, in 2-3 steps. TORQUE: 10 Nem (1.0 ko-m, 7 fb) Install the removed parts in the reverse order of removal. 10-611-0 2 & 2 3 S = 2 &11. FRAME COVERS ‘SERVICE INFORMATION 11-1 FLOOR BOARDILEG SHIELD 14 FRAME CENTER COVER 11-2 HANDLEBAR COVER 115 FRAME SIDE COVER 11-2 CENTER TRUNK 15 FRAME REAR COVER 11.3 FRONT FENDER 16 FRONT COVER 4 SERVICE INFORMATION GENERAL ‘© This section covers the removal and installation of the frame covers. ‘© When installing the covers, align each locking tab properly and be careful not to pinch the wires, 1-1FRAME COVERS : FRAME CENTER COVER (1) SCREW i REMOVAL, Raico the seat and remove the frame center cover mounting screw. Remove the irae contor cover by releasing the tabs from the Noor board and the frame covers grooves. INSTALLATION ae Installation is the reverse ot removal \ Za) pRAME CENTER (2) GROOVE COVER FRAME SIDE COVER REMOVAL Remove tho frame center cover Remove the twa tapping screws, trim clip screw and the trim clip Remove the frame side cover by detaching the tabs from the ‘ear frame cover grooves, INSTALLATION instatiaion is the reverse of removal. {| FRAME REAR COVER 15) GROOVE (2) TRIM CRIP in) SCREWS (3) FRAME SIDE covER 11-2FRAME COVERS: REMOVAL Remove the following: ~ frame center cover (page 11-2). frome side covers (page 11-2) Remove the tear cartier by removing four mounting nuts. 2)REAR CARRIER Remove the mounting bolt and the trim clip screw and the trim lp, Remove the right and left reer cover assembly by detaching tha tabs from the grooves. Separate the right and left frame rear cavers by removing the ‘two self tapping screw. 5) NUT (7) REAR CARRIER (3) FRAME REAR COVER Ye) NuT (4) SCREWS J FRAME REAR COVER At ~ a 7" (3) FRAME REAR oS TRIM CRIP (1) BOLT INSTALLATION Inetallation is the reverse of removal. 11-3FRAME COVERS: FRONT COVER (2) FRONT cover (1) CAP NUTS REMOVAL Remove the thee front cover cap nuts, the two tapping a serews and the front cover. 4 (4) Le@ SHIELD INSTALLATION Installation is the reverse of eomoval (3) FRONT. FENDER cover (2) TAPPING SCREWS FLOOR BOARD/LEG SHIELD Remove the following: ~ trame center cover — frame side covers battery (page 14-2), 14) LEG SHIELD ‘Open the front trunk using the ignition key. move the five floor board mounting bolts. Remove the leg shield mounting bolt and the four self tapping Femove the leg shield with the loot board. Separate them. Installation isin the reverse of removal 11-4FRAME COVERS HANDLEBAR COVER Femave the rear view mitrors, Femave the two self tapping screws and the screw, Separate the rear handiabar cover from the front handlebar Disconnect the speedometer cable, the handlebar switch wire and the connectors. Disconnoct the headlight and turn signal wires and connec: tors. Remove the two self tapping screws, the center mounting screw and the front hanclebar cover CENTER TRUNK REMOVAL Remove the {rame center cover, and the reer carer (2) ser Ta) REAR TAPPING 7 7e HANDLEBAR SCREWS “(31 SCREW’ COVER sar TAPPING (3) FRONT HANDLEBAR COVER, (1) REAR CARRIERFRAME COVERS Romove the seat by removing the two mounting nuts ty sear Remove the eil tank cap and the seal rubber. Remove the center trunk by removing the two mounting nuts, INSTALLATION Installation Is the reverse of removal FRONT FENDER Remove the following front cover. frame center cover floor board, leg shiei Remove the mounting nut and the frent fender, NOTE + In cose that the front fender is connected, cut the fender 08 shown {Installation is the raverse of removal 11-6STEERING/FRONT WHEEL/BRAKE/SUSPENSION 100 Nem (10.0 kgm, 72 fttb} pa ~ A = Ss 27 Nem (2.7 kay, 20 ff) 12-012. STEERING/FRONT WHEEL/BRAKE/SUSPENSION ‘SERVICE INFORMATION 121 FRONT BRAKE 12.7 TROUBLESHOOTING 122 PIVOTARMS 12-40 HANDLEBAR 12.3. FRONT SHOCK ABSORBERS 12411 SERVICE INFORMATION GENERAL + Inhated axbestos fibers have been fourd to cause respiratory disease and cancer. . + Newer use an air hose or dry brush to clean brake assemblies. Use a vacuum with asealed collecior. Wear a protective face rash and thoroughly wash your hands when finished. FRONT WHEEL 12-5 STEERINGSTEM 12-43 SPECIFICATIONS Unit: mm find ITEM ‘STANDARD ‘SERVICE LIMIT Front axle runout == | Front wheel rim runout [Racist = 2.0 (0.08) Axial [ = (0.08) . Front brake Deum 1B. 80 (3.15) 80.5 (3.17) Lining thickness I 4.0 (0.18) ~ 2.010, Front shock absorber spring free length 172.5 (6.79) 167.3 (6.59) TORQUE VALUE Steering stem nut 100 Nem (10.0 kg-m, 72 ft-lb) 9Nem (0.9 kgrm, 6.6 fib) Front axla put 45 Nom (4.5 kg-mn, 33 fib) Pivot arm nut 27 Nem (2.7 kg-en, 20 ft-b) Shock absorbar upper mount bolt 27 Nem (2.7 kg-m, 20 ttlb) Shock absorber lower mount rut 48 Nem (1.8 kgm, 13 fttb) ‘Shock absorbar lower mount bolt FNer (0.9 kg-m, 6.5 ft-lb) ‘Shock absorber damper lock nut 20 Nem (2,0 kg-m, 14 ftlb) Apply a locking agent to the nut threads Broke arm bolt 6 Nerv (0.6 kgm, 4.9 feb) TOOLS Special attachment GNHT-54, Attachment, 28 x 30 mm (079461870100 or equivalent commercially avaiable in U.S.A. Lock nut wrench 07916—KM10000 or equivalent commercially available in U.S.A, Shock absorber comprastor attachment _07967—GA70101 (Not available in U.S.A.| or 07967—GA70001 Shock absorber compressor Spring attachment 07967—KM10100 Bearing remover attachment M9360-277~91774 Bal race remover 07946--GA70000 12-1STEERING/FRONT WHEEL/BRAKE/SUSPENSION ' Damaged steering balls and races Insufficient tire pressure Common Pot, 10 mm 077460040100 Bearing drvar 077490010000 Bearing remover shatt (07740 -0050100—F-or equivalent cormecialy avatale in U.S.A Bearing remover head, 10 ram 077480050200. Attachment, 42 47 mm 077450010300 Shock absorbar compressor (079593290001 Lack aut wrench, 30 » 32 mm (07716 -0020400—r-or equivalent commercially avatable in U.S.A Extansion bar 1077160020500 TROUBLESHOOTING Hard steoting + Steoring stem nut too tight + Steering top cone raceinut too tight ‘Steers to one side or does not track straight + Bent fork + Bent front axte + Bent spoke plate Front wheal wobbling Bent rim Axle not tightened properly Bent spoke plate Excascive wheel bearing play Faulty or unevenly worn tire Soft suspension + Weak shock absorber springs Front suspension noise + Shock absorber spring binding + Loose shock fastenors 12:2STEERING/FRONT WHEEL/BRAKE/SUSPENSION HANDLEBAR (1) SCREW REMOVAL Ramove the handlebor caver {page 1-8) Romove the throttle housing screw and the throttle grip. Romova the front and roar brake lever brackat by removing the Pivot lock nuts and bolts and disconnecting the brake cables. Romove the steoring stem nut and the handlabar. TooLs: Lock nut wrench 30 x 32mm 07716~-0020400 Extonsion bar 07716--0020500 or ‘equivalent commorciaty ‘available in U.S.A. (1) Lock NuT WRENCH INSTALLATION ‘Align the tabs on the handlebar with the groover in the steer {ing stem and install the handleber.STEERING/FRONT WHEEL/BRAKE/SUSPENSION Tah th stoeiog ster ct 2) EXTENSION AAR iia TORQUE; 100 Nem (10.0 ky, 72 F416) d 2 sn if roots , at {ook nut wrench 20 x32 mm 07716—-0020400 Extension bor 077160020500 or equivalent commercially avaliable in U.S.A. In) Lock NUT WRENCH] Connect the brake cables to the lovers and install the levers on the brackets using the pivot bolts and lock nuts. Apply Honda Bond A or Honda Hand Grip Cement (U.S.A. ‘nly) to the inside surfaces of the grips and to the cloan sur. face of the let handlebar and throttle pipe. Wait 3—§ minutes and install the grips. Rotate the grips for even applicetion of the adhesive. NOTE + Allow the adhesive to dry far an hour before using: Apply grense to the throttle grip cable end and insert the thot cman tle grip and connect the throttle cable end to the crip, (1) THROTTLE HAUSING Align the locating pin on the lower throttle housing with the hole in the handle Install the upper throttle housing end tighten the screw. install the heaeight and instruments (section 17). al 12-4STEERING FRONT WHEEL/BRAKE/SUSPENSION FRONT WHEEL EERIE AO REMOVAL Raiae the frant wheel off the ground by placing jack or block Under the floor board. - Femove the speedometer cable set screw and disconnect the speedometer cable from the brake panel, Remove the front brake adjusting nut and disconnect the brake cable trom the brake arm and penel Remove the axle nut, 3) ADJUSTING NUT] Pull out the axle and ramove the front wheel INSPECTION AXLE Set the axle in V blocks and measure the runout ‘SERVICE LIMIT: 0.2 mm (0.01 in} | BEARING INSPECTION Turn the inner race of each bearing with your finger, The bear ngs should turn smoothly and quietly. Also check that the besring outer race has not been spinning in the hub, Discard the beerings if the races do not twin smoothly and Quietly. or if they have been spinning in the crankcase (page 126. Nore + Replace wheel bearings in pairs WHEEL RIM Check the rim runout by placing the wheel in 9 truing stand, Then spin the whee! by hand and read the runout using a dial indicator, SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 3204.0 mm (0.08 in} 12-5STEERING/FRONT WHEEL/BRAKE/SUSPENSION DISASSEMBLY r (1) SIDE COLLAR ™ Remove the brake panel, axle side collar and dust seal from the wheat hub. (2) DUST SEAL Drive cut the whee! bearings and remave the distence collar, (hy REMOVER SHAFT IN Toots: Bearing remover shatt 07748-0050100 or equivalent commercially available in U.S.A. Boaring remover head, 10mm 077460050200 or equivalant commercially available in U.S.A. (2) REMOVER HEAD ASSEMBLY |}) BEARING DRIVER Pack oll bearing eavitios with grease, Drive in a new right bearing and install the distance collar Drive in a new left bearing: Nore + Install the bearings with their sealed ands facing out + Contaminared brake Unings reduce stopping power. Keap grease off the linings and brake drum. Toois: Bearing driver 07749~0070000 Driver attachment, 28 x 30mm 07848- 1870100 Plot. 10 mm 07748—0040100 Instal a new dust seal (2) DUST SEAL 12-6STEERING/FRONT WHEEL/BRAKE/SUSPENSION INSTALLATION Install the breke pene! into the whee! hub. Position the frant wheal between the fork and align the tongue of the left pivot arm with the groove in the brake panel Insort the axle from the right side Inetall and tighten the axle nut TORQUE: 45 Nem (4.6 kgm, 23 fb) Connect the spaedamater cable to the brake panel and tighten the set screw, Connect the brake cable to the brake panol and brake arm and install the adjusting nut ‘Adjuet the front brake free play (page 3-5) FRONT BRAKE REMOVAL Remove the front whsol (page 12:6) Remove the brake panel from the whe! hub. INSPECTION BRAKE ORUM Measure tho brake drurn 1.0. SERVICE LIMIT: 80.5 rm (3.17 in} BRAKE LINING Measure the brake lining thickness SERVICE LIMIT: 2.0 mm (0.08 in} 4(2) SCREW " “ 12-7STEERING/FRONT WHEEL/BRAKE/SUSPENSION BRAKE PANEL DISASSEMBLY ‘Turn the brake arm and expand the broke shoes. Pry the shoe spring off the anchor pin and remove the spring and brake shoes, Remove tha biake arm and cam, dust drive gear 1 and speedometer (2) SPEEDOMETER (9) BRaKe (1) BRAKE PANEL" DRIVE GEAR SHOE) suor (s) Dust SPRING SEAL (ret . rem (0.0-kam, & 43 ftib) @ Q oO (6) BRAKE 4\’ cam (9) RETURN SPRING (9) BRAKE anim BRAKE PANEL ASSEMBLY cs ouer sou ‘Apoly grease to the speedometer drive gear and install the drive gear into the brake panel Install a naw dust seal and apply grease to the seal lins. (1) SPEEDOMETER DRIVE GEAR 12-8STEERING/FRONT WHEEL/BRAKE/SUSPENSION Apply greace to the anchor pin and brake cam and install the broke cam into the brake panel. ‘+ Avold getting grease on the side of the brake drum or braking ‘power will be reduced. Clean the inside of the broke panel rhor- oughly Inetell the brake arm return spring aligning its end with the hols nthe brake panel ‘Apply clean oil to the felt seal and install itinto the brake pane’. Install the wear incicator plate onto the brake cem sligning its wide tooth with the wide groove on the cam. é (2) FELT SEAT J.) (1) RETOAN SPRING Inetell the brake arm onto tho brake cam, aligning the punch . UY PUNCH MARK ‘mark on the atm with the index mark on the cam. Install and tighten the brake arm bolt and nut. TORQUE: 6 Nem (0.6 kg-m, 4.3 ftb) Install the brake shoes and cho spring onto the brake pane! (1) SHOE SPRING) ‘Turn the brake orm 2 that the brake shoes are expanded and press the spring over the anchor pin. J INSTALLATION f Install the brake panel into the whee! hud. Install the front whee! (page 12-7) 12-9STEERING/FRONT WHEEL/BRAKE/SUSPENSION PIVOT ARMS REMOVAL Remove the frent wheel (page 12-51 Remove the pivot arm covers by removing the bolts, Remove the shock lower mount nuts and bolts. Remove the pivot arms by removing the pivot arm bolts and DISASSEMBLY Remove the cust cavers, felt seals and shock lower mount col lar, Remove the pivot collars and discard the O-rings. INSPECTION Check the pivot and shock lower mount collars, the folt seals ‘and the bushing for wear or damage. ASSEMBLY Install new O-rings onto the pivot collars, then grease the col {ars and instoll them in the pivot arm. Grease and install the shock lower mount collar, then instell ‘the folt seals and dust covers. INSTALLATION {ngtall the pivot arms, bolts and nuts. Tighten the nuts. TORQUE: 27 Nem (2.7 kg-m, 20 ft-1b) Install ad tighten the shock absorber lower mount bolts. ‘TORQUE: Nem (0.9 kg-m, 6.5 Feb) Tighten the ehoek absorber lower mount nuts TORQUE: 18 Nem (1.8 kg-m, 13 fb) Install the pivot arm covers and tighten the bolts. 12) BIVOT ARM COVER contr 2) LOWER MOUNTING BOLT \4) PIVOT COLLARS (1) DUST covers oe (3) NuT (2) PIVOT ARM BOLT 12-10i STEERING/FRONT WHEEL/BRAKE/SUSPENSION FRONT SHOCK ABSORBERS REMOVAL Raise the front wheel off the ground by placing jack or block Lunder the floor board Romova the front whee! (page 12-5), Remove the pivot arm cover by removing the bolt (1) PIVOT ARM COVER’ Romove the shock absorbers by removing the upper mount bolts and lower mount nuts and bolts, 1 (2) LOWER MOUNT BOLT DISASSEMBLY [1) SHOCK ABSORBER COMPRESSOR Compress the shock absorber, loosen the lock mut and remove (2) SPRING ATTACHMENT the lower mount and lock nut. ‘TooLs: Shock absorber compressor 07959 -2290001 ‘Compressor attachment 07967—GA70101 ‘not available in U.S.A. ‘07 07967—GA70001 Spring attachment (07967—KM10100 5 (3) COMPRESSOR ATTACHMENT Remove the spring lower seat, spring, spring guide, spring (3) SPRING GUIDE upper seat and stop rubber from the damper unit 7 (2) SPRING @ /" SPRING LOWER, | SAS GDP ONT _ STOP RUBBER (4) SPRING UPPER SEAT 12-11STEERING/FRONT WHEEL/BRAKE/SUSPENSION STEERING ————e—errr SPRING FREE LENGTH INSPECTION Measure the shock absorber spring free length SERVICE LIMIT: 167.3 mm (6.59 in} Place the upper Spring seat, spring guide, spring, lower spring fat and stop rubber onta the damper unit. ' ASSEMBLY (1) SHOCK ABSORBER COMPRESSOR Install the spring with the tightly wound coils facing down. Apply a locking agent to the lock nut threads ané install he rut ‘Apply a locking agent to the damper od threads and screw the Tower mount on. Hold the lower mount in a vise and tighten the Jock nut securely, (2) SPRING ATTACHMENT ‘TORQUE: 20 Nem (2.0 ka-m, 14 feb) Toots: Shock absorber compressor (079593290001 (9) COMPRESSOR ATTACHMENT Compressor attachment 07967—GA70101 not available in U.S.A. ug aBcibiben eee aa NUT y (LUPPER MOUNT BOLT™ Check that the lock nut is seated agoinat the rods bottom thread. INSTALLATION Inst the shock absorbers and tighten the upper mount bolts. TORQUE: 27 Nem (2.7 kgm, 20 ftD) ‘Tighten the lower mount bolts and nuts. TORQUE: Bolt 9 Nem (0.9 kg-m, 6.5 feb) Nut 18 Nem (1.8 kg-m, 13 ftb) Install the pivot arm cover and tighten the bolt Install the front whee! (page 12-7) A 1) PlvoT ARM COVER a 12-12'STEERING/FRONT WHEEL/BRAKE/SUSPENSION STEERING STEM REMOVAL Remove the following: ~ leg shield (page 11-4). — front fender (page 11-6), speedometer and brake cable — front wheel ipage 12-5). = hendlebar (page 12-3). Remove the steering stem lock nut. TooLs: Lock ut wrench A Lock nut wrench B 07916-_kM10000 (07916— 1870100 Remove the top cone race and steel balls. NOTE + Be careful not to loose any of the steel balls. Ul the steering stem out of the steering head. Romove the following: — shock absorbers (page 12-11) ~ pivot arms {page 12-10). INSPECTION Check the ball races and stee! baile for wear or damege and te: place tham if necessary. (2) LOCK NUT WRENCH 8 (t-TOP CONE RACE (2) PIVOT ARMS ——_(1) SHOCK ABSORBERS | iW) LOCK NUT MP eSi=-12) Tor cone nace 7 2-13) STEEL BALLS (26) = “~ 1a) TOP BALL RACE Ab, =o BOTTOM BALL RACE AS) S101 srect satis 26 /fb (7) BOTTOM COME RACE 12-13STEERING/FRONT WHEEL/BRAKE/SUSPENSION ‘STEERING HEAD/BALL RACE REPLACEMENT Remove the top and bottom ball races from the steering head. TooL: Ball race remover (07946—Ga70000 Drive in naw top and bottom ball races. TooLs: Bearing driver 07749-0010000 Driver attachment, 42 » 47 mm 07746~0010300 (2) ATTACHMENT INSTALLATION 1 AT (1) SEAT RUBBER) Grease the top and buttom ball races and instal the steel balls. i Install the inner seat rubber ita the steering stem and insert the steering stem into the steering head Install the top cone race and hand-tighter it. Rotate the steering stem lock to lock several times to seat the bearings. ‘Moke sure that the stearing stem rotates freely without verti- cal play. 12-14STEERING/FRONT WHEEL/BRAKE/SUSPENSION Hold the top cons race and tighten the steering stem lock nut. (1) LOCK NUT WRENCH A. TORQUE: 9 Nem (0.9 kg-m, 6.5 feb) Toots: Lock nut wrench A 07916~KM10000 Lock nut wrench B (07916~ 1870100 Install the remaining removed ports in the reverse order of re: moval (2) LOCK NUT WRENCH 8. 12-15REAR WHEEL/BRAKE/SUSPENSION 12 Nem (1.2 kgm, 9 fttb) : Li _ 9 4h OY ol S 3 6 Nem (0.6 kgm, 4.3 ft) 110 Nem (11.0 gen, 80 feb) 40 Nem (4.0 v tab) 25 Nem (2.5 kg-m, 18 ft-lb) 13-013, REAR WHEEL/BRAKE/SUSPENSION | SERVICE INFORMATION 13-1 REAR BRAKE 13-3 | TROUBLESHOOTING 13-1 REAR SHOCK ABSORBER, 13-5 REAR WHEEL 13-2 SERVICE INFORMATION GENERAL + Inhated asbestos fibers have been found to cause respiratory disease and cancer. + Never use an air hose or dry brush to clean brake assemblies. Use a vacuum with asealed collector. Wear a protective face mask and thoroushly wash your hands when finished. SPECIFICATIONS Unit: rom (in) ITEM ‘STANDARD ‘SERVICE LIMIT Rear wheel rim runout [Radiat = _2.0 (0.08) Axial — 2.0 10.08) Rear brake | Drum 98,0 (9.74) 96.5 (3.76) a Lining thicknoss 4010.16) | 2.0 (0.08) Rear shock ebsorber spring free length 208.0 (8.19) 201.8 (7.94) TORQUE VALUES Reeor axte nut 110 Nom (11.0 kg-m, 80 Ft-1b) Shock absorber upper mount bolt 40 Nem (4.0 ka-m, 29 ft-lb} Shock absorber lower mount bolt 26 N-m (2.5 kgm, 18 fb Shock absorber damper lock nut 20 Nem (2.0 kg-m, 14 ftb) Apply a locking agent to the nut threads Broke arm bolt 6 Nem (0.6 kg-m, 4:3 ft-lb) Exhaust pipe joint nut 12 Nem (1.2 kag-m, 9 Feb) Muffler mount bolt 27 Nem (2.7 kgm, 20 fb) TOOLS Special Shock absorber compressor sttachment 07967 —GA70101 (Not available in U.S.A.) or 07967—GA70001 Spring attachment 07967—KM10100 Common ‘Shock absorber compressor 07959-3290001 Rear wheel wobbling Poor brake performance + Bent rim Broke not ousted proparly + Faulty tre + Contaminatee brake shoes. + Axle not tightened property + Worn brake shoes Soft suspension + Worn brake shoes at cam contacting = Weak shock absorber spring + Ween brake cam ‘Suspension noise + Worn brake drum + Shock apring binging + Improper engagement between brake arm and cam * Damages stop rubber ‘shat serrations Broke squeaks: + Worn brake shoes + Foreign matter on firing + Rough brake drum shoe contacting face + Brako shoos glazod 13-1REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL TL EMAUET MUFFLER, REMOVAL Remove both frame side covers (page 11-2). Femove the exhaust muffler by removing the mounting bolts and loosening the joint nuts Remove the axle nut, and the reer wheel INSPECTION WHEEL RIM RUNOUT Check the wheel rim for runout using a dial gauge as shown. SERVICE LIMITS: Radial: 2.0 mm (0.08 in} ‘Axial: 2.0 mm (0.08 in) Replace the whee! it runcut is beyond the service limit. INSTALLATION Install the rear wheel and tighten the axle nut TORQUE: 110 Nem (11.0 kgm, 80 feb) (a) AXTE NUT, 13-2REAR WHEEL/BRAKE/SUSPENSION Install the mutfier and tight urs ‘the mounting bolts and joint Install both frame rear covers (page 11-3) a 1) EXHAUST MUFFLER, REAR BRAKE 9 INSPECTION BRAKE DRUM Remove the rear wheel (page 13-2). Measure the rear brake drum LD. SERVICE LIMIT: 95.5 mm (3.76 in} LINING THICKNESS Measure the brake lining thickness, ‘SERVICE LIMIT: 2.0 mm (0.08 in) an “(8 ARM BOLT 5 picaTon GA! DISASSEMBLY ‘91 ARM BOLT 6) INDICATOR CAM Remove the brake shoes, shoe springs and stop tubbes. x (Z Remove the brake adjusting nut end disconnect the broke LTP RRBER, VK aa Seo a Pp ee Sue FO PNGQI cv snace ae gare PP NOR” gra ee aa / vex F € . | SHINS gy grax cam VA)REAR WHEEL/BRAKE/SUSPENSION ASSEMBLY ‘Apply grease to the anchor pin and brake cam and install the com. Install the two broke shoe spring step rubbors Install the felt seal onto the brake cam, Install the wear indicator plate on the cam aligning its wide tooth with the come wide groove. {Align the index mark on the brake arm with the wide groove in the brako cam and install the arm. Tighten the brake arm bolt TORQUE: 6 Nm (0.6 kg-m, 4.3 fttb) rm retuIn spring 13-4REAR WHEEL/BRAKE/SUSPENSION {Install the brake shoes and shoe springs. Con + Keep grease off the brake linings, Wipe off excess grease. Connect the brake cat justing rut, to the brake arm and install the ad: Install the wheel and adjust the rear brake Ipage 3-5) (2) SHOE SPRING REAR SHOCK ABSORBER (3) REAR SHOCK” ABSORBERTIT UPPER MOUNT BOLT) REMOVAL Remove the following: = left frame rear covers (page 17-3) — air cloaner case (page 4-13), hack absorber upper mount nut and lower mount bolt and the shock absorber DISASSEMBLY (1) SHOCK ABSORBER COMPRESSOR Compress the shock absorber spring, loosen the lock nut and remove the lower mount. Remove the rear shock absorber spring. (2) SPRING ATTACHMENT Too.s: ‘Shock absorber compressor 079593290001 Compressor attachment 07967—GA70101 ‘ot available in U.S.A, o 07967—GA70001 . Spring attachment 07967—KM10100 (3) COMPRESSOR ATTACHMENT Remove the spring lower seat, spring, spring upper seat and (3) SPRING UPPER SEAT. ‘stop rubber trom the damper unit. (2) SPRING (1) Lowen sear *.% (5) DAMPER UNIT 4) stop RudteR 13-5REAR WHEEL/BRAKE/SUSPENSION SPRING FREE LENGTH INSPECTION Measure the spring free length. [SERVICE LIMIT; 203.1 mm (B.00 in} Replace the spring if itis shorter than the service limit ASSEMBLY Install the spring with the tightly wound colls facing up @ Compress the spring with the compressor and attachments. (1) LoweR MOUNT Apply a locking agent to the lock nut threads and screw the lock nut all the way on the demper rod threads, Apply a locking agent to the damper rod threads and install the lower mount. Hold the lower mount and tighten the lock aut 7 TORQUE: 20 Nm (2.0 ko-m, 14 fi) { P Toots: f Shock absorber compressor 07959—3290001 - Caccea sine” “Siseraurecr acer ibook wun % STE UPPER MOUNT BOLT ® INSTALLATION Install the rear shock absorber and the upper mount nut and ower mount botts. TORQUE: Upper mount nut: 40 Nem (4.0 kg-m, 29 fel) ‘Lowar mount bolt: 25 Nem (2.5 kg-m, 18 ft-lb) case (page 4-14), covers (page 11-3)BATTERY/CHARGING SYSTEM. (1) IGNITION SWITCH (2) RESISTOR (3) REGULATOR) RECTIFIER (5) BATTERY 14) ALTERNATOR REGULATOR! RECTIFIER IGNITION SWITCH q ta 2. S RESISTOR MEADLIGHT | Tan ucHT fev 2625 w1 ol aw Tie | 1} BATTERY auto oo BYSTARTER D =| ALTERNATOR 14-0©) 14. BATTERY /CHARGING SYSTEM SERVICE INFORMATION 14-1 REGULATOR/RECTIFIER 144 TROUBLESHOOTING 14.1 ALTERNATOR INSPECTION 144 BATTERY 14-2 RESISTOR 144 SERVICE INFORMATION GENERAL © Quick charge a battery only in an emergency. Slow-charging is preferred. '® Romove the battery from the ecocter far charging, If the battery must be charged on the scooter, disconnect the battery cables. © The batiery on this scocter ie a sealed typa. Never ramave the fillng hole caps evan when the battery is being charaed. Use only a sealed type battery on this vehicle © Be sure te chatge the battary with tho amount of currant and for the time indicated on the battary label and on page 14-3, CCharaing with excessive current andjar too fast may cause battery failure. © For alternator removal, sv0 soetion 7. = Do not smoke around a charging battery, and keep sparks awey from it. The gs produced by a batiery wil explode fa flame or Spark ts brought near. STARRED Battery, Capacity [ 12V3AH econ cine | ____ SaA, aerTSOTA . a Austin stator ell Liahting eal 0.10.8 8 (20"c/68°F) = " Gajovsal [ans aorciserri TOOLS scat None Pe hate ae tO USA. colt suivomerusy oan ‘nosso powee chatdrd sane oer ; Hoeree sae Low power-engine running + Battery undercharged Charging system failure + Loose connection oF short circuit in lighting system 14-1BATTERY/CHARGING SYSTEM BATTERY (1) NEGATIVE TERMINAL JMMMLI2) POSITIVE TERMINAL REMOVAL flemove the center cover (page 17-21 Disconnsct the negative cable from the battery first, then remove the pasitive terminal Fomove the battory holder bolt and the battery, INSTALLATION erie 4) HOLDER BOLT (3) BATTERY Installation is the reverse of removal NOTE + Connect the positive terminal first. Route tho battery cablas properly INSPECTION ‘Measure the battery voltage using a digital voltmeter Fully charged: 13.0 13.2 V at 20°C/6a°F Undercharged: Below 12.3 V at 20°C/68°F 1f the battary fa undorcharged, perform a leak test (page 14-3) before recharging, CHARGING Connect the charger positive (+) torminal to the battery posi ‘ive |#) terminal and the charger negative (-) terminal 10 the battery negative (~) terminal CAUTION + Be sure 10 charge the betiery with the correct current and for the time listed on the top of the artery Quick charging should only be dome in on emergency: slow chargins is preferre + Wait for 30 minutes after charging, end check the voltae. Charging current Standard | OSA Maximum 30A Charging time Standard 5.0 hours _ Minirnur 30 minutes Voltage at (20°C/68°F) 12.3.V min After installing the battery, coat the terminals with clean arease, 14-2BATTERY /CHARGING SYSTEM CHARGING SYSTEM Leak test If the battery tested undercharged, disconnect the nogative (-1 cable fiom the battery and connect the voltmeter between the battery terminal and the geaund cable, There should be ro voltege with the ignition switch OFF. If there is voltage, check for damaged wie harnossee andioi loose connectors. ‘Tost the ignition switch (Seotion 17), REGULATED OUTPUT INSPECTION NOTE + Be sure that the battery is fully cherged betore performing this test Warm-up the engine to operating temperature. Stop the engine and remove the center cover (page 11-2) Connect the voltmeter across the battery terminals. NOTE + Avoid short cirouiting ta the tester during the test Start the engine, and gradually increase the engine speed: check that tha output voltage is regulated within the range specitieg REGULATED VOLTAGE: 13.8— 18.0 V/5,000 rpm Ifthe Voltage moves outside the range at any spaed, stop the fengine and test the regulatorirectifier (page 14-4) eo i seal LIGHTING VOLTAGE INSPECTION a Warm-up thé engine to operating temperature ‘Stop the engine remove hanclebar rear cover (page 11-5). Connoet the voltmeter actors the hesdight wires; positive probe to blue and negative prove to green ‘Stort the engine and raisa the engine speod gradually, chack to ‘sve if the voltage is regulated with AC range. nore ‘+ Hold the headlight securely to avoid damaging REGULATED VOLTAGE: 12.1~-13.6 V W the messurements are out af specification, stop the engine and check the regulator'rectitier 14-3BATTERY/CHARGING SYSTEM. REGULATOR/RECTIFIER Remove the front caver (page 11-4), Disconnect the 4P connecter from the regulatorirectifie, ‘Chack the charging system components at the connector ter ‘minal. Item | Measure at: Standard value pany wie | Abd Gren (1 charging et | Lighting coil_| Yetow—Green 01-089 meaner [Geenniec—cana [su ~Gieen | any of the radings are out of range, inspect the individual ‘component, all readings are good, remove and roplace the regulator! rectifier. ALTERNATOR INSPECTION Stator chargine coll Remove the center cover (page 1 1-2). Remove the right side cover (page 11-2) Disconnect the alternator and starter motor 6P-Black connec- tor ‘Measure the resistance between the white and green term pals, STANDARD: 0.21.0 0 at 20°C (68°F) Replace the stator coli the resistance is not within the speci fied ronge (see Section 7). ‘Stator chargine coll ‘Measure the rasistance batwoen the yellow and gr als, STANDARD: 0.1—0.8 0 at 20°C (68°F) Replace the stator coilif the resistance is not within the spec! fied range (se9 Section 7). RESISTOR INSPECTION Remove the front cover (page 11-4) Disconnect the green/black wire connector. Measure the ressstance of the resistor between the green! Black wire end grounds STANDARD: 5 0 at 20°C (69°F) Romove ond replace the resistor if necessary. 14-4IGNITION SYSTEM (1) IGHITION con. (2) col uni (3) PULSE GENERATOR GENERATOR PULSE 15-02 9 9 9 § 8 15. IGNITION SYSTEM SERVICE INFORMATION 15-1 ALTERNATOR EXCITER COIL 15-3 TROUBLESHOOTING 15-1 PULSE GENERATOR 15-3 IGNITION TIMING INSPECTION 16-2 CDIUNIT 15.4. IGNITION COIL 15-2 SERVICE INFORMATION © Be sure the battery is fully charged before diagnosing the ignition system. © ‘Igeition timing eannot be adjusted. HH the timing is incorrect, inspect the CDI unit and alternator and replace any faulty parts. SPECIFICATION ITEM STANDARD: | ‘Spark piug — NGK | Standard | senerisa [er coe imaig | ernavesa | waren —] | Forester nih soed ing ernersa ware. | Som aoa 75-07 mm 024-0020 | Ignition coil Primary coil 0.10.2 0 (20°/68°F) teen ai 7.4-11.0 ka (20°/68°F) Secondary coil a or (without spark plug cap) talon Ignition timing - 17° BTDC!1,800 rpm Pulse | 50—200 0 (20°768°F1 ‘Alternator exciter coil '500— $00 9 (20°/68°F) TOOL, Sanwa electrical tester 973080020000, or Kowa electrical teater TH-5H Kowa digital multimeter 074110020000, or Digital muttimotor KS—AHM—32—003 (USA only) No spark at plug Engine starts but runs poorty + Faulty spark plug + Ignition primary circuit + Pooily connected, broken oF shorted wire = Fauity ignition coll Botwoon alternator and CO! unit Loose or bara wire or connector — Between CDI unit and ignitioin cot = Poorly connected ignition switch — Between CDI unit and ignitioin switch + Ignition secondary ekcuit Between ignition coll and spark plug = Faulty ignition coil + Faulty ignition switch — Faulty spark plug + Faulty ignition coil — Faury spark plug wire + Faulty COL unit Poorly ineutated plug cap + Faulty alternator ‘+ Improper ignition timing — Faulty alternator — Stator not installed properly = Fauity CDI unit 15-1IGNITION SYSTEM IGNITION TIMING INSPECTION NoTE +The CDI ignition tining is not adjustable, Ifthe timing is not ccorreet, check the CDI unit and alternator and replace any faulty parts Ramove the tight side cover (page 11-2) Remove the fan cover Check the ignition timing with a timing light. Timing ie corroct i the index mark aligns with the "F mark at 1,800 rpm, IGNITION TIMING: 17° BTDC at 1,800 + 100 rpm. IGNITION COIL Remove the frame rear cover (page!1-3), Disconnect the ignition coll primary wires from the ignition coil Measure the primary coil resistance between the terminals. STANDARD: 0.1-0.2 0 at 20°C (68°F) Disconnect the spark plug cap from the plug and measure the Secondary coil resistance between the plug cap and the pri mary coil ground terminal (green) STANDARD: 7.4—11.0 0 at 20°C (68°F) I the rasietance ie not within the standard, unscrew the spark plug cap from the spark plug wire and measure the secondary ‘coil esietance without the spark plug cap. STANDARD: 3.74.6 k0 at 20°C (68°F) {tho resistance is within the etandard, roplace the plug esp ‘and re-test, the resistance is not within the atandard, replace the ign ton coil and re-test. 15-2IGNITION SYSTEM ALTERNATOR EXCITER COIL Remove the center cover and the right side cover (Section 11) Disconnect the alternator GP-black connector and blackired wire connector. Mesure the resistance between the black/red wire terrinsl arid the green terminal in the 6P-black connector on the engine side, STANDARD: 500-900 9 at 20°C (68°F) If tha resistance is not within the standard, reptace the at temator and re-test — It the resistance is within the standard, check the wiring be- ‘tween the CDI unit and alternator connector for an open or short citcuit, or loose connection. Repair or replace as nec: ‘essary and re-tast PULSE GENERATOR Femove the center cover and the right side cover (Section 11). Disconnect the alternator 6P-black wire connector and rea: ‘sure the resistance between the blue/yellow terminal and the green terminal on the engine side, STANDARD: 50-200 0 at 20°C (08°F) = if the resistance is not within the standard, replace the af: tornator and re-tost — V the resistance is within the standard, chock the wiring be. tween the CDI unit and alrnator coupler for an open oF short circuit ot a loose connection. Repair of replace as essesary and re-test 15-3 aesIGNITION SYSTEM CDI UNIT INSPECTION Remove the cantar cover (page 11-2) Remove the CDI unit from the rubber holder, and disconnect the connector, (Check continuity between the terminals according to the chart below. 3) cI unr} (2) CONNECTOR Ignition switch Exciter coll Pulse generator Ignition coil (primary) Secondary (with cep! Secondary (without cap) MW any reading ie ebnormel, check the faulty item, If all tests are satisfactory, replace the COI unit 15-4 Terminals Black/White Greon Black/Red.Green Blue/Vellow Green Block/Yellow-Greon Plug cop-Green High tension cord terminal-Green Standard result There ls no continuity with switch ON. 500 900 0 (20°/68°F) 50 200 0 (20°/68°F) 0.10.2 9 (20°/68°F) 7.A~11.0 kf (20°/68°F) 3.7—4.5 kf (20°/68°F)ELECTRIC STARTER (1) STARTER RELAY STARTER RELAY vA — os i. 12¥25W ES oar orl BRAKE LIGHT SWITCH 16-016. ELECTRIC STARTER ‘SERVICE INFORMATION 16-1 STARTER RELAY 16.2 TROUBLESHOOTING 16-1 STARTER MOTOR 16:2 SERVICE INFORMATION © The ota F moter can be removed without removing the engine, TROUBLESHOOTING Starter won't tun Lack of power + Fuse burned out + Week battery : + Faulty wiring or loose connection switen ‘+ Foreign matter stuck in startar or starter gear + Faulty starter switch + Faulty front or rear stop switch Engine does not crenk-starter rotates + Faulty starter ralay + Fauly starter pinion + Poorly connected, broken or shorted wire + Reverse rotation of starter + Faulty starter motor + Wesk battery 16-1ELECTRIC STARTER ‘STARTER RELAY Remove the center cover and the tight side cover (Section 11), Disconnect the starter relay connector and remove the relay. There should be continuity between the A end B terminals ‘only when the positive probe of a 12 V battery is attached to the D terminal and the negative probe is attached 10 the C terminal as shawn Roplace the relay if there is no continuity STARTER MOTOR REMOVAL + Perform ihis operation while the engine and exhaust muffler are COLD. amove the canter cover (page 1 1-2). Disconnect the negative cable trom the battery, Remove the center trunk (page 11-5). Remove the starter wire and the two motor mounting bolts, Loosen the cil pump cantiol cable stay mounting bolt end remove the starter motor NOTE +The ground wire is secured by the lower belt 16-2 (1) BOLTS (2) STARTER MOTOR© © ELECTRIC STARTER Wi Remove the O-ring rom the starter motor. Connect the battery to the starter motor and check its opera: ton. (Ge careful to observe polarity.) ‘The moto should turn clockwise (viewed from the shaft side) BATTERY INSTALLATION Install the O-ring onto the starter motor and apply grease to the O-ring. Apply molybdenum disuiide grease to the sterter motor pinion gear Connect the starter wire to the starter motor terial Install ths starter motor and tighten the two mounting bolts. Nore + Secure the ground wire with the lower mounting bolt Tighten the oll contral cable stay mouning bolt, 16-39. 17. LIGHT/METER/SWITCHES SERVICE INFORMATION 17-1 FUELLEVEL SENSOR 174 HANDLEBAR SWITCHES 17-2 HEADLIGHT REPLACEMENT 17-5 HORN 17-3. BULB REPLACEMENT 17-5 OIL LEVEL SENSOR 17-3. INSTRUMENTS 17-6 SERVICE INFORMATION GENERAL ‘© Some wires have different colored bands araund them near the connector. These are connected to other wires which cor- respond to the band color © All plastic pluge have locking tabs that must be released before disconnecting. and must be aligned when reconnecting, ‘© The following color codes are used throughout this section and on the wiring diagram. Bu = Blue Orange W = White BI = Biack Fink ¥ low Br = Brown R = Red Lb = Light Blue ‘© To isolate an electiical failure, check the continuity of the electrical path through the part. A continuity check can usually bbe made without removing the part from the motorcycle. Simply disconnect the wires and connect a continuity tester of volt-ohmmeter to the terminals. ar connections. © A continuity taster is useful when checking to find out whether oF not there is an electrical connection between the two points. An chmmeter is needed to measure the resistance of a circuit, such es when there is a specific coi resistence in- volved, of when chacking for high rocistance caused by corroded connections. 17-1LIGHT/METER/SWITCHES HANDLEBAR SWITCHES Remove the front cover (page 11-4), Check the continuity of each switch Continuity should exist between color coded wires indicated by interconnected circles on the following charts IGNITION SWITCH BLACK! couon | Back | SACK! | Green | RED BAT 1S e | eal Lock o—}—o OFF | o—}—o oN ——— }—o DIMMER SWITCH coton |_Yewow BLUE Waite HL 4 le lo o—t o_| iw [e¢ 0 4 o—}—o TURN SIGNAL SWITCH GREY | LIGHT BLUE | ORANGE coon Srey w RK t a ° ° N L ° ° HORN BUTTON coon FREE PUSH ENGINE STOP SWITCH coron |_BLACKIWHITE GREEN iG E oFF o——}——o RUN STARTER BUTTON YELLOW color ELLOW RED GREEN st E FREE Pus ° 17-2LIGHT/METER/SWITCHES FRONT/REAR BRAKE LIGHT SWITCH “Tho switch ia nomal if there ie continuity when the broke lever 's applied ® HORN ‘Tho horn ie good if it eounde when 12 V le appliad across the terminals, Feplace it necessary, OIL LEVEL SENSOR =— TURN SIGNAL LIGHT @> Remove the screw and the lens. Replace the tuin signal ight bulb with a new ono, o>LIGHT/METER/SWITCHES. INSTRUMENT BULB NOTE + If the instrument bulbs burn out frequently, check the ‘charging system resistor ipage 14-41. A faulty or poor'y, ‘grounded resistor cen be 2 cause of frequent instrument amp faiture Remove the handlebar ear cover (page 11-5) Pull out the bulb socket and replace the bulb with @ new one. INSTRUMENTS REMOVAL Remove the handabar rear cover (page 11-5) Disconnect the instrument connectors. Remove the three screws to separate the instrument case from the rear cover. Push the each switch tabs and remove the switch, DISASSEMBLY Remave the three sorews and the lans from the case Disassemble the instruments by removing the screws and bulb sockets Assemble the instruments and the case in the reverse order of removal Install the rear handlebar cover. 17-6 (7) ENGINE i (1) DIMMER SWITCH Z| TURN SIGNAL, SWITCH, K2) HORN SWITCH switch | ‘STOP | (2) STARTER SWITCH 6 e18. WIRING DIAGRAM 0029—ZS3—Z0800 18-1HARD TO START ENGINE LACKS POWER IDLE SPEEDS ENGINE DOES NOT START OR IS POOR PERFORMANCE AT LOW AND POOR PERFORMANCE AT HIGH SPEED 19. TROUBLESHOOTING ——<—<—<——_—wuwAH i ittomaEs®si rea 181 poor HANDLING 192 om Levet SENSOR tg2 FUELGaUGE 49.3 STARTERMOTOR CLUTCH AND DRIVE/DRIVEN PULLEYS 19-3 19-4 19-5 19-6 19-7 ENGINE DOES NOT START OR IS HARD TO START 1, Check if fuel is getting 19 carburetor by loosening drain screw GETTING TO CARBURETOR ' 2. Try spark test SPARK 3. Test €ylinder compression NORMAL COMPRESSION 4, Start by folowing normal storting procedure ENGINE DOES NOT FIRE 5. Remdve spark plug pry Probable cause. NOT GETTING TO “ay CARBURETOR 3) @ a WEAK OR NO SPARK —————»1) @ ci) a 6) 6) o Low compression ————»;1) @ a (ay (5) (6) ENGINE FIRES BUT) SOON STOPS (2) 3) Wer plug i (2) a No fuol in fuel tank Clogged fuel tube to carburetor, vacuum tube to intake pipe, oF fuel pipe Clogged tleat valve Clogged fuel tank cap breather hole Faulty spark plug Fouled spark piug Faulty CDI unit Faulty alternator Broken or shorted spark plug Broken or shorted ignition coil Faulty ignition switch Stuck piston rings: Faulty or deteriorated reed valve Worn cylinder and piston rings Faulty eyinder or eylindor head casting Comprassion leak post crank: Leaking cylinder head gasket Faulty auto bystertet Air leaking past intake pipe Improper ignition timing Carburetor flooded Faulty auto bysterter ‘Throitle valve excessively open 19-1TROUBLESHOOTING ENGINE LACKS POWER ENGINE SPEED INCREASES 2. Check ignition timing CORRECT 3. Tost cylinder compression NORMAL 4, Chack carburetor for clooging NoT.cLoGcen 5, Remove spark plug NOT FOULED OR DISCOLORED 6. Check if engine overheats NOT OVERHEATED 7. Tey rapid act high speed ENGINE DOES NOT KNOCK Probable cause ENGINE SPEED DOES NOT————+ 1) INCREASE SUFFICIENTLY 2) 3) 4 iNcoRREeT +1) 2) T00 Low +1) (2) (3) ‘a Clogged air cleaner Restuicted fuel low. Clogged fuel tank cap braathor hole Clogged muffior Faulty CDI writ Faulty alternator Worn evlinder oF piston rings Blown cylinder hood gaskot Flaws in cylinder or cylinder head Faulty or deteriorated reed valve cLoccep + Carburetor not serviced frequently FOULED OF DIScoLOREE—————+|1) @ OVERHEATED +1) (2) a (a) 8) ENGINE KNOCKS 1 (2. (3) 4) POOR PERFORMANCE AT LOW AND IDLE SPEEDS 1. Check ignition tii correct 2. Chack carhuretor air serew for proper adjustment correct ‘enough Plug not eorvieod frequently enough {Use of plug with improper heat range Worn eylinder oF piston Fuel-air mixture toa lean Use af improper grade of fuel Excessive carbon build-up in combustion chamber Ignition timing too advanced Excessive carbon build-up in combustion chamber Use of improper grade of fuel Cluteh slipping Fuel-air mixture 109 lean Probable cause INCORRECT. a (2) INCORRECT» (1) (2 (3) Faulty CDI unit Faulty alternator Fual ait mixture too rich (Gerew out to correct) Fuel air mixture too lean (Screw in to correct) Faulty auto bystarter A 19-2