Honda Mopeds MOTORCYCLE

HONDA
AMERICAN HONDA MOTOR CO., INC.
100 West Al on dra Blvd.
Gardena , Calif. 90247

HONDA MOPEOS
MO DEL P50 PC50 Fuel level on early models with type
Displacement-cc ......... . ....... ........... . 49 49 A carburetor should he set as follows:
Bore-M M ...... . .... . . . ....... . .... .. . ..... . 42 42 Remove carburetor and cover (15). In-
Stroke---MM ............ . ................... . 35.6 35.6 vert the carburetor. Clearance (H-
Number of cylinders ............ . ..... . ...... . 1 1
Plug gap-inch ......... . .. . .. .. .......... ... . 0.024-0.028 0.024-0.028 F ig. HN1-2) between fuel bowl and
Point gap-inch ............................. . 0.012-0.016 0.012-0.016 float with the inlet valve closed should
lgnition timing ...................... . ....... . Automatic Fixed he 3.4-3.6MM (0. 1378 inch ). Adjust-
Degrees BTDC below 4500 RPM ... ... .... .. . 28 28 men t is accomplished by bending float
Degrees BTDC at 5200 RPM ........ . ....... . 10 28
Valve clearance (cold)-inch arm.
lnlet and Exhaust ........... . .............. . 0.002 0.002 On P50 models with type B carbure-
Electrical systcm voltage ....... . .... ......... . 6 6 tor, float setting can be checked after
Battery terminal grounded .. . .... . . . ......... . Negative Negative removing the float valve cover. Fuel
Tire size-Front ............................. . 2.00 x 17 2.00 x 19
Rear ........ ..... ... ....... . ....... . ..... . . 2.25 x 17 2.25 x 19 in let valve and float are inside cover as
Tire pressure psi-Front ...... . ............... . 18.5 18.5 sh own in Fig. HNl-3. With inlet valve
Rear ..... . ... . .... .... ... . . ..... . ....... .. . 24 24 closed (cover inverted), distance (H)
Weight-lbs. (approx.) ........................ . 99 110 between floa t and bowl should he 4.9-
Illu strations courtesy of Am e rican H o nda Motor C o., Inc. 5.1MM (0.1969 inch). Ifincorrect, bend
the float arm as required.
HN1-1 and the following specifications. On PC50 models. float level is ad-
MAINTENANCE NOTE: Type A & B carburetors are used justed by removing the float bowl and
SP ARK PLUG. Spark plug elec- on PSO only. positioning carburetor with the air in-
trQde gap should be 0.024-0.028 inch on Type 50A Carburetor take down. Distance from gasket sur-
all mode Is. Recommended spark plug is Befare frame serial number A148608 face to float arm should he 5.0MM
NGK type C6HB for P50 models and Mainjet (18) ..................... 55 (0.197 inch) as shownat H-Fig. HN1-
type C-7HS for PC50 models. Idlejet(21 ) ........... . .......... 35 3A.
CARBURETOR. The variabie ven- Needie jet (24) ................ 2.6x2
turi type carburetor is s hown in Fig.
HN1-1. The idle mixture is adjusted at
Clip (6) in third groove from top of
needie (7).
H
needie (11). Idle speed s hould be 1500 Type 50B Car b u retor
RPM and is changed by turning stop After frame serial number A148607
screw (10). Normal setting for needie Mainjet (18) ..................... 62
( 11) is 11/s turns open. Refer to Fig. Idlejet (21 ) ...................... 35
Needie jet (24) .............. 2.6x1.55
1 2 ~
~~11
Clip (6) in second groove from top of
8...... needie (7).

6--.L....J..J PC50
Ma in jet (18) ..................... 62

::~~ c"
Idle jet (21) ...................... 35
Neediejet (24) ............... 2.1x2.8 Fig. HN1-3-0n type 8 ca rb uretors, float clear-

~~\ Clip (6) in third groove from top of ance ( H) with cover inverted should be 0.1969

12~10
needie (7). inch.

15 16 17

Fig. HN1-1-Exploded view of type A carburetor

used on early modeIs.
I. Cable adjuster 15. Float cover
2. Cover 16. "0" ring
3. Washer 17. Float
4. Spring 18. Mainjet
5. Retainer 19. Gasket
~: ~~fve needie
20. Cover
21. !die jet
8. Throttle slide 22. Plug
9. "O"ring 23. ''O" ring
10. ldle stopscrew 24. Needie jet
I I. !die mixture needie 25. Fuel i niet needie Fig. HN1-2-0n type A carburetor, float clearance Fig. HN1-3A- Honda float level gage shoutd be
12. Choke plate 26. Fiber washer
I 3. Choke shafl 27. "O"ring (H) with ca rbure tor lnverted should be 0.1378 used to set float height at 5 MM (3/16 inch) on
14. Choke spring 28. !niet valve seat in ch. PC50 mode Is.

34
SERVICE
IGNITION AND ELECTRICAL.
The ignition system is of the energy
transfer type with the low tension (gen-
erating) coil and breaker points located
under the flywheel. The high tension
coil and condenser are located inside
the frame above the engine. The
breaker cam is inside the flywheel. An
automatic ignition retard is used on
P50 models to keep the maximum en-
gine rpm at approximately 4500.
Ereaker point gap should be adjusted
so that points just open when the "F"
mark on flywheel is aligned with the
mark on crankcase as shown at CF-
Fig. HN1-4). Ereaker point maximum
gap should be within limits of 0.012-
0.016 in. when timing is correctly set.
The ignition low tension coil (1-Fig.
HN1-5) is located toward rear and
lighting coil (3) toward front. Flywheel
retaining nut should be tightened to
13-18 Ft.-Lbs. torque.
V AL VE SYSTEM. The val ves are
actuated by a chain driven camshaft
located in the cylinder head via rocker
arms (cam followers). Valve clearance
should be set when engine is cold and
piston is at TDC on compression stroke.
The flywheel has a mark "T" indicating
top dead center when aligned with
crankcase mark (M- Fig. HN1-5 ).
Clearance should he 0.05MM (0.002
inch) for both valves. Make certai.
that the end of decompression lever has
0.2-0.4 inch free play. Adjustment is
accomplished at rear of cable housing.
Fig. HN1-4-The breaker points shou/d justopen
when " F" mark is aligned with mark on crank-
case as shown.
Fig . HN1-5-View of generating system wlth f/y-
wheel removed. The crankcase mark (M) is used
fortimlng.
M . Mark 2. Breaker points
l. Ignition low lension 3. Lighting coil
coil
Honda Mopeds
~21 six hearing halls (26) are used in lower
race of steering he ad and twenty-one in
the top race (21). When servicing the
front suspension, renew rubber parts if
deteriorated. Check all parts for wear,
or damage and renew as necessary. Fit-
tings {12) should be greased every 1000
mi les.
~\
REPAIRS
TIGHTENING TORQUES. The
26 following lists the r ecommended t ight-
ening torques.
Clutch nut .......... 27.5-32 Ft.-Lbs.
Crankcase ........... 5.8-8 .0 Ft.-Lbs.
Cylinder head .
(4 nuts & 1 screw) .. 6.5-8.7 Ft.-Lbs.
Cylinder he ad cover
{4 screws) ......... 5.8-8.1 Ft.-Lbs.
Flywheel . .......... .. . 13-18 Ft.-Lbs.
Rear Axle ............. 29-43 Ft.-Lbs.
Spark plug ......... 8.0-f0.8 Ft.-Lbs.
ENGINE REMOV AL. Most service
to the engine and drive system requires
removal of the engine.
D isconneet spark plug wir e a nd
Fig. HN1-7-Exploded view of the front fork and
other (four) electrical wires. Remove
suspension. the carburetor and disconneet the de-
I. t'ront fork 9. Pivot bushings compression cable, rear brake cable
2. Upper spring mount JO. Scals
3. Rubber cushion 11. Collar and the exhaust pipe. On P50 models,
4. Spring 12. Grease fittings remove the torque a rm screw (2-Fig.
5. Lower spring mount 13. Rebound bumper
6. Suspension arm 21 . Upper race halls HNl-8) and nut (3). Loosen t he rear
7. Bushings 26. Lowcr race halls
8. Seals axle nut and r aise the frame until the
engine and rear whecl are clear. Be
careful to prevent oil from running
Ifthe lever doesnothave free play, the onto the brake shoes. On PC50 models,
exhaust valve may he held open. remove drive chain and engine
LUBRICATION. The engine is lu- mounting bolts.
bricated by 1 v2 pints of high detergent When reassembling, the chain
motor oil. SAE 30 motor oil should he master link clip should be installed
used above 60 degrees F., SAE 20 or with closed end toward direction of
20W from 32 to 60 F. , SAE 10W below move ment. Make certain that oil is not
32 degrees F. , multi-grade 10W-30 oil leaking around the rear axle collar and
can he used for all season s. Oil should " 0" ring is in good condition.
he maintained at upper mark on fiBer P50 CYLINDER HEAD &
plug dipstick. NOTE: Do not screw V ALVES. Remove the cylinder head
fill e r plug into crankcase when cover (with rocker arms ). Remove
checking oillevel. dowel pin {1-Fig. HN1-9), withdraw
Engine oil should be changed every the camshaft center shaft (3) and re-
2000 miles or every three months. move camshaft. Remove the four stud
Front suspension sho uld he greased at nuts and one screw then lift off the cyl-
fittings {12-Fig. HN1-7) every 1000 inder head. Cylinder head gasket sur-
miles. faces must he perfectly flat. Refer to
SUSPENSION. The front suspen- the following specifications for cylinder
sion is shown in Fig. HN1-}. Twenty-
liig.. HN-1•'9-fo remave the eamshaft; remove
do wel (1) and center shaft (3). End of center
Fig . HN1-8-The torque arm (1) Is attached with shaft is threaded and screw (2) can be used to
screw (2) and nut (3). withdráw the shaft.
35
Honda Mopeds MOTORCYCLE
head and associated parts.
Gombustion chamber volume .... . 5cc
Valve face and seat an gle
Both valves ............. 45 degrees
Valve stem diameter
Both valves ....... 0.188-0.189 inch
Wear limit-minimum .. 0.187 inch
Valve guide inside diameter
In let ............ 0.189-0.1894 inch
Exha ust ........ 0.1898-0.1902 inch
Valve seat width
Both valves ....... 0.028-0.039 inch
Valve head minimum t hickness
Both valves ............. 0.008 inch
Valve spring free length
Inlet & Exhaust .. ....... 0.764 inch
Wear limit ....... 18MM (0.708 in.)
When assembling, hollow dowels
should be installed around studs (1&2
-Fig. HN 1-10) between t he cylinder
and cylinder head. Tighten cylinder
h ead retaining nuts and screw to 78-
104 inch-pounds torque in the order
shown in Fig. HN 1-1 0. Make certain Fig. HN1-14-Exploded view of the clutch and reduction assembly used in P50. Chain (13) is trom
that all are tightened evenly. Turn the sprocket (12 to 14); chain (17) is trom (16 to 18); chain (26) trom (21 to 27).
flywhee l unt il the "T" mark is aligned I. Crankshaft 10. Steel ba lis (3 uscd) 17. Chain 24. Spring
2. Spaeer 11. Bali retainer 18. Secondary drive n 25. Snap ring
3. Bushing 12. Clutch drum & sprocket 26. Chain
4. Clutch hub and shoes sprocket 19. Th rust washer 27. Final driven sprockct
5. Loek washer 13. Chain (22MM) 28. Sprocket ball hearing
6. Nut 14. Prima ry driven 20. Snap r ing 29. Oi l seal
7. Cluteh springs (3 sprockct 21 . Final driveshaft 30. Reduction cover
used ) 15. Damperrings 22. Engaging lug (18 to 31. Rear ax le
8. Cluteh dampers (3 16. Secondary drive 21) 32. Free wheeling
used) sprocket 23. Guidc (engaging) plunger
9. Friction plate

Fig. HN1-10-Tighten the stud nuts (1, 2, 3 & 4)
and screw (5) in the order shown.
Fig . HN1-11-Aiign the " T" mark on flywheel with
mark on crankcase , then insta/I camshaft with
holes (T) parallel to gasket surface of head.
Fig. HN1-12-Cil gulde (3) is at sprocket end of
camshaft and washer (4) is at other end. Make
sure "0" ring (2) is nol damaged when installing
the center shaft.
with mark (M-Fig. HN 1-5) on crank-
case and install camshaft with holes in
sprocket paralle l to gasket surface as
shown in Fig. HN 1-11. When the cam-
shaft centershaft is installed, oil guide
(3-Fig. HN 1-12) should beat sprocket
end of camshaft and washer (4) at other
end. Make sure "0" ring (2) is correctly
installe d. Align hole in center shaft
and install dowel pin U-Fig. HN 1-9).
Valve clearance and de com pression
linkage must be adjusted after assem-
bling.
PC50 CYLINDER HEAD AND
V AL VES. Push rods may be removed
after dismounting head cover and four
h ead holding bolts . Remove rocker
arms. Valves may b e remov ed by
pressing down on spring retainers a nd
shifting them to one side to clear end of
valve. Head should be lapped on sur-
face plate to insure flatness. Use the
following s pecifications:
Valve stem diameter-
Standard .. .. .. ...... ... 0.217 inch
Limit .................. 0.213 inch
Valve h ead thickness-
Standard ............... 0.020 inch
Limit ........... . .. .... 0.007 inch
Valve seat width .... 0.019-0.027 inch
Valve spring free length-
Standard ............ .. . 0.965inch
Limit .................. 0.906 inch
Torque head bolts to 6.5-8.6 foot
pounds using an "X" pattem to prevent
h ead warpage.
PISTON, RINGS AND CYL-
INDER. To remove the cylinder, first
remove the cylinder head as in the pre-
vious paragraphs, then withdraw t h e
cylinder . R ings sh ould be installed
with marked side toward top of piston.
Arrow on top of piston should point
down. Piston and rings are available in
standard size only. Piston pin retaining
snap rings should not be installed with
open part of sna p ring aligned with cut-
out in piston. Piston ring end gaps
should he 0.004-0.012 inch and cyl-
inder and/or rings should be renewed if
end gap exceeds 0.024 inch.
CRANKSHAFT AND CON -
NECTING ROD. The crankshaft and
connecting rod are available only as an
assembly and sh ould not be disassem-
bled. Removal is accomplished after
r emoving t he clutch and reduction as-
sembly, cylinder , piston , flywheel and
Fig. HN1-15-View of P50 reduct/on assembly
with cover removed . Refer to Fig. HN1 -14 tor ex-
ploded view.

36
SERVICE Honda Mopeds

T18
9 l5
Fig. HN1-16-Exploded view
of P50 rear wheel drive as-
sembly. Inner end of drum
(17) spilnes into the final
driven sprocket (27 - Fig.
HN1 -14).

1 Snapring
2. Th rust washer
3. Snap ring
4. Thru!:il washer
5. Frcc wh eel spring Fig. HN1-17-l>C50 camtiming shaft. Align timing
6. Peda I sprocket
7. Th rust washt'r marks on timing sprocket (1) and cam sprocket
!1. Loek platc (2) and in stalt cam chaln.
9 Hub
I 0 Scal co llar
11. Nut (5uscd)
1~. Oilscal
13. Snap ring
14. Bali b<'aring
1:1 Paw l s p ring
16. Ratchct paw l 12 uscd>
17 Drum
18. Screw (.5 uscd)
19. Axle nut

t he left cra nkcase ha lf. Ecce ntricity at installing t he le ft crankcase ha lf.

ma in hea r ings whe n supported at ends
in lat h e cen t e rs s ho ul d not e xceed
0 .00 2 in ch . Co n nec tin g rod hea rin g
cleara nce on cra nk pin should not ex-
ceed 0.0019 inch . Maxim um clea ra nce
between pisto n pin a nd co nnecting rod
(sma l! e nd) is 0.0032 inch.
Whe n assembling, ma ke certain t hat
crankcase ha l ves are clean a nd free
from n icks a nd burrs. Make su re t ha t
cngine dise ngag in g lever a nd the two
h o llow dowe ls a r e positio ned befo r e
P50 CLUTCH AND REDUCTION.
Re move t he e ngine asse mbly and se pa-
rate from t he rear wheel. Remove t he
br ake cam and shoes, then re move the
reductio n cover. Refer to Figs. H N l -14
and H Nl -15. Ma ke ce rtain t hat rcar
ax le is notbent more t ha n 0.020 inch
throug hout its len gth.
P50 REAR WHEEL DRIVE. Re-
move thc engine and rear wheel asse m-
bly, re move th e ax le n u t (19- Fig.
HN1-16) a nd withdraw t he rear whee l
Fig. HN1-18-PC50 cy linde r head . To re m o ve
valve (1), depress va lve retaine r(2) a nd shift it to
one si de t o allow va tve to re lease.
assembly. Be careful when disassem-
bling t hat thrust washers are not inter-
c h a n ge d. Cup on th ru st was h er (7)
should be toward sprocket (6). Care-
fully inspeet ratchet pawls (16), spring
(15) a nd ratchet teeth inside sprocket
(6).

37