oF HONDA ~SHOP MANUAL ATC70IMPORTANT SAFETY NOTICE Ter ear ost a ere Personal er or los of Kf atirscsru fotired CAUTION] Indicates a possibility of personal injury or equipment damage if instructions are not followed. Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand ‘that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda might bbe done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anyone using service procedutes or tools, whether or not recommended by Honda must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service method or tools selected.HONDA ATC70 HOW TO USE THIS MANUAL This shop manual describes the technical features and servicing procedures for the Honda ATC70. Since this model uses the same basic engine as the CT70, this shop manual should be used with the ST50+70/CT70¢70H manuals for complete infor- mation and procedures. Refer to the Addendums beginning on page 35 for servicing of 1978 and later ATC70's. Note that addendums were not issued between 1979 and 1981. ‘ALL INFORMATION, ILLUSTRATIONS, DIREC: TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PROD- UCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER, NO PART OF THIS PUBLICATION MAY BE REPRO- DUCED WITHOUT WRITTEN PERMISSION. HONDA MOTOR CO., LTD. Service Publications Office 1 " vi CONTENTS SERVICE PRECAUTIONS . INSPECTION AND ADJUSTMENT 1. Tappet 2. Contact breaker point gap and ignition timing 3. Carburetor. . 4. Cluten, 5. Cam chain 6 7 a 9. Engine oil Brake . . Air cleaner Drive chain... . 10. Drive chain lubrication 11, Spark plug 12. Throttle cable 13, Fuel filter ENGINE k 1. Engine removal and installation - 2. Major difference between ATC70 and CT70 engines eee 9 FRAME, . 1, Front wheel nia seat 2, Rear wheel and brake. . ose eeia 3. Handlebar cases oe 4. Front fork. 2 5. Frame body SERVICE DATA. 1. Special tools Wiring diagram . Maintenance schedule, . Torque specifications. Service data Troubleshooting 7. Specifications... MAJOR MODIFIED POINTS OF ATC7OK1. 1978 ADDENDUM 1982 ADDENDUM . 1983—1984 ADDENDUM Sekeeeseaeers Date of issue: August, 1983, © American Honda Motor Co, ne. 1983 All Rights ReservedI, SERVICE PRECAUTIONS 1 I. SERVICE PRECAUTIONS 1. Always use new gaskets, O-rings and cotter pins whenever reassembling 2. When tightening bolts or nuts for which sequence is not specified, begin on center or larger diameter bolts, and tighten them in a crisscross pattern to specified torque in two or more steps if necessary. 8, Use genuine HONDA PARTS and LUBRICANTS or those recommended by HONDA. 4, Use special service tool where use of such a tool is specified 5, Clean engine parts in or with cleaning solvent upon disassembly. Apply lubricant to their sliding surfaces when reastembling 6, Coat or fill parts with grease where specified a: 7. Upon assembling, check every possible part for proper installation and movement or operation 8, When working with others, try to give a signal or communicate for safety. NOTES 1, The procedures for reassembling the engine and frame parts are not deseribed when these are performed by reversing the disassembling procedures. All the service data for each component are compiled on the last pages of this manual,2 11, INSPECTION AND ADJUSTMENT I. INSPECTION AND ADJUSTMENT ‘The services set forth in this section are those which are important of all listed in the MAINTENANCE SCHEDULE ‘on page 25. Those not listed in the Schedule are covered in procedures under “INSPECTION ” in each section. 1. TAPPET ‘The tappet clearance adjustment should be made while the engine is cold. 1, Remove the recoil starter and tappet adjusting hole caps 2, Rotate the generator rotor counterclockwise until de mark “TT” on the rotor aligns with the index mark on the stator. Fig. 24 Qo gia at In this position, the piston may either be on the com- pression or the exhaust stroke. The adjustment must ‘be made when the piston is at the top dead center on its compression stroke when the intake and exhaust valves are closed. ‘This can be determined by moving the tappets with the fingers. If the tappets are free, it is an indication that the valves are closed and that the piston is on the com. pression stroke. If the tappets are tight and the valves are open, rotate the generator rotor 360° and realign the “T” mark with the index mark. 3. Check the clearance of both valves by inserting the 0.05 mm (0.002in.) gauge between the valve stem and the adjusting screw. To adjust, loosen the adjusting screw lock nut and turn, the adjusting screw either in or out to allow the gauge to pose through the clearance with alight reciatance 4. After completing the adjustment, tighten the lock nut firmly to secure the adjustment. Recheck the clearance to make sure that the adjustment has not been disturbed Fig. 2-2 @ Adjusting screw lock mut) Fecler gauge @ Adjusting screw 5, Install the tappet adjusting hole caps and recoil starter.11, INSPECTION AND ADJUSTMENT 3 2. CONTACT BREAKER POINT GAP AND. FF IGNITION TIMING Ignition timing is adjusted by altering the contact breaker point gap. 1. Remove the recoil starter located on the left side of the engine. 2, Rotate the generator rotor counterclockwise until the mark “F” aligns with the index mark, Ignition timing. is correct if the contact breaker points begins to open fas the marks align. 3. If ignition timing is incorrect, loosen the contact breaker locking screw and adjust the gap to specification, Increasing the gap will advance timing. Decreasing the gap will retard the timing 4, Retighten the contact breaker locking screw and recheck the ignition timing. NOTE: Point gap must remain within limits of 0.3 to 0.4mm (0.012 to 0.016 in.) after ignition timing has been set. If correct timing results in a point gap which is outside these limits, replace the breaker points. Fig. 24 @ Contac breaker ARBURETOR ® Contact breaker locking @ Contact breaker point base a The carburetor should be adjusted with the engine at operat- ing temperature and the choke fully open 1, Turn in the idle screw until the engine idles at approxi mately 1500rpm. Turn the idle screw in to increase engine speed and out to decrease engine speed. Turn the air screw in until you hear engine missing or engine rpm begins to drop; then, turn it out until the engine again misses or decreases in speed. Set screw midway between these two extreme positions, Turn this serew in to make the mixture richer for out to make it leaner. Correct setting will be usually obtained when the screw is turned out 1% to 1)4 turns from its fully closed position he ai Fir. 25 3. If the idle speed changes after adjusting the mixture, PMS aie screw readjust the idle serew as required. 4, CLUTCH The automatic clutch should be adjusted with the engine stopped. 1. Remove the clutch adjuster rubl 1 cap. 2 Loosen the lock nut and turn out the clutch adjuster until resistance is felt; turn in the adjuster 1/8 to 1/4 turn. Tighten the lock nut firmly to secure the adjust 3. After adjustment, start the engine and test ride the ATC70 to be sure that the clutch is operating, properly. Fig. 26 @ lack ont4 Ml, INSPECTION AND ADJUSTMENT 5. CAM CHAIN Tension adjustment should be made while the engine is running at idle speed, if unusual noise is heard. 1. To adjust, with the lock nut loosened, turn out the ten: sioner adjusting bolt approximately one-half turn. Pig. 2 | Lock mat @ Seating bolt @ Tensioner adjusting bolt If the chain is still noisy even after the above adjustment, loosen off the 14mm seuling boli, sind sewew iit the ten sioner bolt gradually until noise is minimized. The sealing bolt will be found on the left bottom side of the engine crankcase 3. After completing the adjustment, tighten 1 adjusting bolt, lock nut, and 14 mm sealing bolt securely. Fig. 28 @ Tensioner bolt 6. ENGINE OIL, Oil level check 1, Place the ATC; 2. Insert the oil level gauge into the oil filler hole to check the oil level. (Do not screw it in, 0 on @ level ground. Oil level should be anywhere between the upper and Tower level marks on the dipstick. 3, If necessary, refill the crankease with specified ol API classification: SE Specified viscosity Tn all seasons AE 10W-30 AE 10W-40 or S Above 15°C (69°F) SAE 20 O°-15°C (92°-5°F) SAE 20 or 20W Below 0°C ( SAE 10W Oil change 1. Remove the oil filler cap from the right crankease cover. 2, Place a drip pan under the engine to catch the oil, and then remove the drain plug. 8. After the oil stops draining from the erankcase, operate the recoil starter rope several times to drain any oil which may be left in the engine 4. When the oil has been completely drained, reinstall. the drain plug. Be sure the washer which seals the drain plug is in good condition. cate through the oil filler opening. with approximately 0.8 liter (0.8U.S.at.) of specified grade of motor oil, Make sure that the oil level is up to. the pper level mark. If the level is low, add oil, 5. Fill the Fig. 210 ® Drain plugIL. INSPECTION AND ADJUSTMENT 7. BRAKE es L. Correct free play is 15 to 20mm (06 to 0.8 in.) os measured at the tip of the brake lever Pig. 2.11 Brake lever - 2. Free play can be adjusted by turning the adjusting nut on the brake rod. Turn this nut in direction @® to eerease the play and in direction @) to increase it 8. AIR CLEANER 1. Remove the cap bolt and take out thi case together with the gasket. Lover from. the 2. Pull out the element from the ¢ plate and inner pipe from the element. separate the set 3. Wash the element in clean stoddard solvent and allow to dry thoroughly 4. Soak the clement in clean gear oil (SAF. 80-90) until saturated, then squeeze out excess oil Assemble the cleaner in the reverse order of the dis assembly WARNING Gasoline or low flash point solvents are highly flammable ‘and must not be used to clean the element. Fig. 214 Filter clement Sot plate6 U1. INSPECTION AND ADJUSTMENT. Fig. 2.15 @ Lock bolt @ Tensioner shat Fig. 2:16 @ Drive chain @ Inepection window Fig. 2.17 Spark plog cap @ Spark plug ) { 0.6~ 0.7mm (0.024~0.028in) Fig. 2-18 Tending side electrode to adjust plog. ap 9. DRIVE CHAIN 1. Loosen the tensioner lock bolt just enough to permit movement of the tensioner shaft 2. Rotate the tensioner shaft all the way up by hand until it will no longer go; tighten the lock bolt. 3. Apply thumb pressure to the chain through the inspec- tion window. Proper tension is obtained when the chain deflection is 10 to 20mm (04-08 in, 10. DRIVE CHAIN LUBRICATION 1. Remove the rubber window. 2, Working through the window, lubricate the chain with clean engine oil p from the drive chain inspection 8. After lubricating the chain, be sure to install the rubber exp. 11. SPARK PLUG 1, Remove the spark plug cap from the spark plug. Un serew the plug, using spark plug wrench, and remove the plug. 2. Cheek the firing ends of the spark plug for deposits and electrode erosion, A fouled spark plug indicates too cold a plug, too rich a fuel mixture or otherwise excessive oil coming up into the combustion chamber. 3. A spark plug with burned electrodes and a glazed or biistered insulator nose indicates too hot a plug, t00 lean ‘fuel mixture or too early ignition timing. NOTE: ‘The use of spark plugs of incorrect size or heat range ‘can cause serious damage to the engine. 4. Check to be sure that the gap is 0.6-0.7 mm (0.024- 0.028 in.). If not, correct the gap by bending the side cleetrode only. If the electrodes are pitted or roughened, clean and dress the electrodes with a file, keeping the surfaces of both center and side electrodes parallel 5. Place a new gasket on the spark plug and screw the plug into the threaded hole in the cylinder head in two steps; first, finger tight, and then to the specified torque using, a wrench. Install the spark plug cap on the spark plug.U1, INSPECTION ND ADJUSTMENT 7 12, THROTTLE CABLE 1, Examine the condition and operation of the throttle cable The cable should not bind or impair smooth operation of the throttle lever in any steering position. Re-route the cable if it is improperly installed. Replace the cable if it has become worn or kinked. Eree play, measured at the tip of the throttle lever, should be maintained at § mm (0.2 in.) The adjusting nut is located at the top of the carburetor against the end of the throttle cable sheath, Slide back the rubber sleeve to expose the throttle cable adjuster, Replace the sleeve after adjustment Fig. 219 © Rubber sleeve 13, FUEL FILTER 1. Turn the fuel valve to the “S" position Remove the two screws a remove the cover, ching fuel filter cover in place Remove the neoprene O-ring and the filter screen, ‘Wash the filter aercen in solvent Reassemble by reversing the disassembly procedures. Turn the fuel valve to the “ON” position, and check for leaks at the fuel filter cover, iter cover @ O-ring @ Filer screen MEMO8 Ul. ENGINE 1. ENGINE REMOVAL AND INSTALLATIO! Remove the engine in the order given below. To instal 8. Muller reverse the removal procedure 7. Wire harness 1, Seat 6 Drive chain coupler FD) a | | NOTE: When connecting the drive chain, mote the direction of the joint clip. Fig. 341ll. ENGINE 2, MAJOR DIFFERENCE BETWEEN ATCT0 ‘AND CT70 ENGINES ATC70 engines use a recoil starter in place of the kick starter. The carburetor is also new for ATC70 engines Recoil starter Fig. 32 ring 2 Washer Fretion plate @ Friction spring & Set spring @ Washer ® Starcer ratchet ® Recoil starter pulley @ Starter return spring (@ Recoil sence rope { Recoil starter case 1@ Starter knob |@ Rope stopper &@ Knob tape @ Screw Carburetor Specifications Unit: mm Main jet 260 ABL 09 dia. x 2 Air jet 2150 Slow jet Ape | 35 09 dia. x 2 | ap 05 dia. x 4 | ‘ABB 09 dia. x 2 | ape 05 dia. x 4 | Vaive 10 dia, Air bleed | — 2 i 08 dia ABA Needle jet Setting mark Air screw opening Fuel level Cataway10 V. FRAME 44 Cotter pia Castle nat Plain washer Front collar Oil seal Radial ball bearing Front center collar Front ghee! hub Soap ring Front wheel axe ® Wheel bole Rim valve Wheel O-ring Wheel tire (168 0-7) © Cone pin @ Cascle nut Fig. 3 @ Feont shee! hub 1, FRONT WHEEL Disassembly 1, Reise the front wheel off the ground and position a suit: able stand under the engine. Remove the coer pin from he casile mut snd loosen of the nut from the front wheel axle. 3. Remove the front axle and take out the front wheel. 4, Take out the front collars from the whee! 5, Remove the bolts securing the front wheel hub in posi tion ; take out the hub, 6, Remove the oil seals, snap ring, ball bearings and center collar from the wheel hub. NOTE: Always replace the oil seal whenever removed.W. FRAME u After complete deflation, break the tire beads loose from the inner and outer rim flanges by means of a tire tool ‘as shown, NOTE Do not use tire irons to force the heads away from the rim flanges; this could damage the rim seals on the beads fand cause an air leak. 8. After the tire is loosened, remove the wheel bolts and then, remove the inner and outer rims from the ti Inspection and repair Examine if the whool axle is aot bent Check the oil seal for worn or damaged sealing lip. Check for signs of air leak through the rim valve. Check if the rim and wheel O-ring is not deformed or damaged. 5. Cheek the tire pressure using a commercial tire pressure gauge. Correct tire pressure is 0.2 kg/em* 2.8 psi). If Such a gauge is not immediately available, using a linen or steel tape, measure the length around the circumference fand in the center of the tire. It should read 1,200- 1,320 mm (50 to Fig. 1-9. 6. Check the tire for cut, tear, wear or any other defects. Puncture repair. 1, First examine the tire tread carefully for nails or other puncturing objects Remove the tire from the rims 3. Remove dirt and roughen the punctured area with sandpaper or wire brush, Clean the area with solvent. “4. Apply cubber cement around the torn area and allow itdry. -Kemove the lining from the patch end center it over the injury. Press the patch against the injury using a special roller as shown. NOTE: ‘Apply the patch after rubber cement is dried sufficiently ‘Do not touch with dirty fingers after applying the rubber Assembly 1, Make sure that the Leads aze up on the bead seats snd are uniformly seated all around, 2. Applying water on the rim flanges, bead seats and bead base makes the mounting procedure easier. NOTE Use only clean water. Make sure that the seal surface of the rim flange is clean. If necessary, wipe it clean with a clean, lint-free cloth. Fig. 46 @'Patch — @ Roller Fig. 72B WV. FRAME Set up the tire in place om the outer rim (on rim valve side); seat the O-ring in the groove in the im. NOTE: Exami before the O-ring carefully for presence of dust and dirt stallation. 4. Press the inner rim into place in the tite, being sure that the bolt holes align, Install the wheel bolts through the holes and tighten to proper torque. Fig, 48 @ Rim O-ring @ Outer rim 5. Inflate the tie to 08 kee NOTE: lf tire gauge is not available, inflate the tire until the circumferential length is 1,520 mm (60 in © Use care so that the clearance between the rim flange ‘and tire is held within 5mm 0. 6. Inflate the tire to specifi © pone a Nei 2. Hand pack cavities of the wheel bearing and wheel hub ion. The specified tire pai). Check for air leaks with grease. Drive the bearing into position in the hub. aA Do not angle the bearing while driving. Be sure to install Fie. 9 the center collar at this point of assembly @ Linen (or stel) tape 3. Coat the sealing lip of the new oil seals with a small = amount of grease ; press the oil seals into the hub only Fi gies far enough to make them flush with the hub end. 4 4. Slide the front collar into the hub, being sure to avoid damaging the oil seal lip. After installation, make sure that the sealing lip is properly positioned Fig. 4-10 @ Rim fange —@ Clearance berween flange and tire 5. Line up the hole in the w fork; without dis el hub with those in the front 1¢ above setup, install the axle with the end through these holes. Install the axle with the end through these holes. Install the axle from the z side as shown in Fig. 4-11, Bend the ends of the cotter ee pin against the sides of the nut, Tighten the castle nut to specification and if the cotter pin hole does not align, with the slot of the nut, back off the castle nut until the hole aligns with the next slot NOTE Do not force the front collar out of position while insert- ing the axle. @ Front collar @ Wheel hubWV. FRAME 2. REAR WHEEL AND BRAKE Fig. 12 © Drive chain jaine @ Drive chain @ Saap ring @ Final driven sprocket & Dumper cover @ Rear wheel damper @ Rear wheel axle @ Rear wheel hub @ Panel collar 6@ Radial ball bearing 4 R. panel spacer @ Brake shoe @ Brake shoe spring 4 Rear brake cam 8K panel 8 Panel cushion @ Oil seal @ Rear axle pipe @ Adjusting not @ Brake arm joint 4 Rear brake arm @ Return spring {Dust seal @ Tensioner shalt Disassembly 1. Raise the rear wheel off the ground and place a stand under the rear of the frame. Pull off the cotter pin and remove the wheel castle nut Remove the rear wheels and rear axle pipes from the rear axle shaft Remove the left rear fender. 5. Remove the rear cover Remove the step bar, Remove the undercover, ner Remove the left crankease cover, © Castle nut @ Rear axle shaft Loosen the tensioner lock bolt 10. Remove the chain clip and disconnect the drive chain. 11, Remove the lock bolt ond separate the chain tensioner from the shaft, remove the shaft from the frame. Fig. 214 @ Chain tensioner Lock bolt @ Tensioner shaftu W. FRAME 12, Loosen off the brake adjusting nut; disconnect the brake cable from the rear brake arm. 13, Remove the rear brake arm locking bolt, and pull the rear brake arm off the brake camshaft together with the brake arm return spring. 14. Disconnect the brake cable from the right panel clamp. ‘Brake adjusting nut @ Brake return spring ke cable ® Brake cam 15. Remove the bolts aud pull vut the lef ysnel snd panet collars. 16. In the same manner as above, remove bolts securing the right panel and collars in position. The panel and collars, can then be taken out. Fig. 416 | © @L panel @ Pane collar 17. While holding the rear wheel hub by hand, drive out the axle. Use a wooden or soft-faced hammer and give care ful hammer blows from the side as shown in Fig. 4-17, NOTE: Be sure that the axle is not bent or damaged on its threads and bearing journal when removed. Fig. 417 @ Wooden hammer @ Rear whee! hub @ Rear wheel axle 18. Disassemble the left panel. <1. Remove the oil seal from the left panel. NOTE: Always replace the oil seal whenever removed. 2. Remove the snap ring, and press the bearing out of position from the inside, using both hands as shown. Fig. 4-18, @ Ball bearing @ 1. panel7 ae W. FRAME 5 19, Disassemble the right pane! 1. Take out the cushions from the right panel a “2. Remove the brake arm dust seal fron the pane r Fig. 4-19 OR panel SF ietie exe det vel | Peat cation c 8. Detach the brake shoe springs,” ‘The shoes can thes be taken out from the right panel. 4, Pull the rear brake cam out of the right panel. -B, Remove the oil seals from the right panel. NOTE: Always replace the oil seal whenever removed. 6, Press the bearings out of place together with the panel spacer. 20, Disassemble the rear wheel hub. “1, Remove the snap ring from the ring groove in the hhub, Remove the final driven sprocket while tapping it around with a wooden or softfaced hammer. -2, Remove the rear wheel dumpers from the rear wheel bub. 3. Take out the dumper cover from the sprocket, Fle, 4-21 ee @ Shap ring @ Rear wheel hub @ Final driven sprocket 21, Disassemble the wheel. “1. Applying @ suitable wrench, loosen the nuts on the outer rim side; remove the fear wheel flange, 2, Separate the stud bolts from the flange. “8. Refer to page 11 for procedures to be followed in disassembling tire. Pig. 4-22 @ Outer rim — @ Rear whee! flange16 W. FRAME Inspection and repair 1, Make sure that the rear wheel axle is not bent 2. Inspect the lip of the oil seal for wear or damage. 3, Examine the final driven sprocket for wear, damage or any other defects which might interfere with proper sprocket operation. 4. Cheek the drive chain for wear, damage or elongation, 5. The brake shoes should be in good condition and not worn excessively. Observe the brake drum for excessive wear. ‘Make sure that the right and left panels were not damaged cor cracked ; that the rear wheel hub is not damaged nor 8. Make sure that there is no evidence of sir leakage around the area just past the rim valve. 9%. Make sure that the rim and wheel O-rings are not deformed or damaged 10. Using @ commercial tire pressure gauge, test if the tire is inflated to the correct pressure. The specified tire pressure is 0.2 kg/em* (3.0 psi). If such a gauge is not immediately available, use a linen or steel tape to measure the length around the cireumference and in the center of, the tire, It should be 1,290-1,820 mm (50-52 in.) 11. Cheek the tire for cut, wear or any other defects, 12. For tire repair, refer to page 11. Assembly 1. Assemble the wheel. “1. Refer to page 11 for the procedures to be followed in assembling tire Tstall and tighten the rear wheel fange reachin from ianer rim side i “ Install the dampers in the rear wheel hub. If necessary, coat the hub with a soap end water to facilitate installation Fig, 4-24 @ Rear wheel damper @ Rear wheel ub 3. Assemble the right panel. “1. Coat the sealing lip of the oil seal with # small amount of grease ; press the seal into position until it is flush swith the end of the wheel hub. Hand pack ell cavities in the ball bearings with grease. With the sesl end facing out, install the bearings in the right panel with the panel spacer sandwitched in between - Coat the sesling lip of the other side oil seal with a small amount of grease ; press the seal into position until it is dush with the end of the wheel hub.WV. FRAME Ww 4, Position the brake shoes on the brake cam and anchor pin and secure the assembly with the springs. 4 ight coating of grease to the anchor pin before installing the shoes. Be very careful not to allow grease getting on the linings; otherwise the brake will not func- tion properly. Fig. 426 @ Rear brake spring @ Anchor pin a 4. Assemble the left panel “1. Lubricate ball bearing with grease. With the seal end facing toward inside, press the bearing into place in the left panel. “2. Apply a light coating of grease to the sealing lip of the oil seal, and tap it squarely until itis flush with the end of the left panel. 5. Drive the rear wheel axle into place in the wheel hub from the brake side toward the sprocket side Fig. 4-21 @L- panel @ Oil seal driver -~ 6, With the return spring installed, slide the brake arm over the brake cam shaft, being careful that the serrations are align properly. Fig. 4-28 a © Brake cam —@ Brake arm — @ Return spring 7. Install the tensioner. Position the tensioner on the shaft, being careful that the punched marks are lined up properly. stallation, coat the shaft with grease. Fig. 29 @ Punched mark —@ Chain tensioner18, Fig. 4-30 @ Chain clip FRAME, 8 9 0. With the close end toward the direction of rotation, install the drive chain, To install the wheels, start with the left wheel, finishing with the right wheel After the above steps have been completed, inspect the Grive chain for deflection and the brake lever for free fey MEMO:W. FRAME 19 3. HANDLEBAR Fig. a1 @ Handle grip @ Levee case stopper @ Handlebar @ Upper holder ® Brake lever ® Rear brake cable © Lower holder @ Fork top bridge plate @ Ignition switch (@ Throw lever cover ® Throtle case seat @ Soap ring @ Throule lever @ Throtle lever spring Throtle lever ease Throtle cable Disassembly 1. Loosen the brake adjusting nut 2, Remove the brake lever from the handlebar ; disconnect the brake cable at the lever. 3. Disconnect the throttle cable at the catburetor, and the ignition switch wires from the coupler 4. Uusesew he bolts which hold the upper holders in posi tion; take out the handlebar. 5. Turn off the steering stem nut and fork bolts. The fork top bridge plate will then be removed. Fig. 32 @ Steering stem nut @ Fork bol @ Fork top bridge plate 6. Remove the screws securing the throtile lever case and cover on the handlebar. 7. Remove the throttle ease seat 8. Remove the snap ring and take out the throttle lever from the case. 9. Disconnect the throttle cable at the throttle lever, Fig. 4-33 © Snap ring @ Throtle lever case @ Throtle lever20 WV. FRAME Inspection 1, Observe whether or not the handlebar is bent or damaged 2, Examine the electrical wires for broken insulator or cut 3. Cheek the cables for damage or other defects Assembly 1, Apply a light coat of grease to the end fitting of the throttle cable; connect the cable to the throttle lever. 2, Position the throttle lever on the lever case and secure with the snap ring. Attach the assembly horizontally to the handlebar. Fig. 4-94 @'Throtle lever case @ Throttle lever @ Throule cable end —@ Throtle lever spring 2. Position the handlebar in the lower holders. Be certsin that the punched marks on the handlebar are flush with the rear top edge of the holders. yportant that the upper holders be installed with the punched marks facing the front of the motorcycle. ‘Tightening should be made starting with the front toward the rear. 4. Connecting of the cables and wires should be done in fa way to avoid interference or undue stresses when the hhandlebar is turned to either of two extreme positions 5, Adjust the brake lever free play to specification. See page 5. Make sure that the throttle lever operates freely; that the free play is held within the prescribed limits,” See page 7. Fig: 4-35 6 @ Punched marks MEMOW. FRAME a1 4. FRONT FORK Pig. 4-36 @ Lower holder @ Fork top bridge plate @ From fork @ Front cover retaining washer (® Front fender @ Steering stem not © Stem nur washer ® Steering top thread © Top cone race (@ Steel ball @ Steering ball race @ Bottom cone race @ Steering head dust seal @ Dust seal washer Disassembly 1, Remove the front wheel, See page 10. 2. Remove the handlebar. See page 19. 3. Remove the fork top bridge plate. See page 19. 4. To remove the front fork, unscrew the stecsimg wp thread NOTE: Keep steel balls in a part container so that they are not scattered and lost, Inspection. 1. Inspect the front fork to see that it is not bent or damaged Pig. 4-97 Steering top thre 2. Be sure that the top and bottom cones are not damaged, pe worn or otherwise dented 3. Observe whether oF not the steering head dust seal is in ‘good condition and not worn, Assembly. 1. Install a total of 21 steel balls on top and bottom. ‘Turn in the steering top thread all the way until it will no longer go; then, turn it out 2/3 turn. Be sure that the fork rotates frecly without binding. NOTE: Before assembly, clean the cone and ball races and all steel balls in solvent and lubricate with grease, Pig. 4-38 @ Steel ball @ Top cone race22 WV. FRAME Fig. 4.38 () Rear handle pipe Spark log wrench fandle lever @ Rubber retainer @ Seat seing rubber tank rear exshion el tank Fuel tank cap @ Packing ipe gasket sat pibe joint collar @ Exhaust mufler G) Exhaust cover @ Exhaust cover seting band {Mutter lid packing Mu @ Connecting tube band @ Air cleaner ease & Air cleaner element eH plate @ Air cleaner inner pipe Dinwenbly i pacer 7 TE MEM re olf Fei tht tacking bol 2 Li she sear ofthe sat lighly aod pl owas no Fig. 4-40 @ Seat 2. Remove the fuel tank “1. Disconnect the fuel hoses at the carburetor. Crush the sections of the fuel hoses while disconnecting to prevent spilling of fuel on the floor. “2, Remove the fuel tank from the rear cushion and pall it toward the rear. Fig. 41 @ Rear fvel tk cushion — @ Fuel tankV. FRAME 3. Remove the step bar, 4. Remove the under cover. 5. Remove the rear cover. 6. Remove the mutter. 1. Unscrew the nuts securing the exhaust pipe to the engine. 2, Remove the bolt which holds the muffler to the side of the frame. Remove the nut holding the muller at the rear, The rmufiier will be taken out Remove the front wheel. Remove the handlebar, Remove the front fork. 10. Remove the engine, 11, Remove the earhuretor 12, Remove the rear wheel 18. Take out the sir cleaner cose. 14, Disconnect the brake cable 15. Remove the rear fe 16, Take out the ignition coil 17. Remove the upper and lower ball races. Inspection 1. Cheek the entire frame for freedom from damage, distor: tion or otherwise crack. ‘xamine the head pipe for incorrect angle ot defossativu 3. Check to determine that the ball race is not worn, dented or otherwise damaged. 4. Be sure that the muffler and exhaust pipe are not damaged or cracked, 5. See that the fuel tank is not leaking or corroded. 6. Check all fuel tubes for deterioration or damage. Assembly: 1. When install the upper and lower ball races, do not angle the race, 2. Clean the air cleaner before installation. See page 5. Allow sufficient space around the muller, Be sure that the mufller is not leaking. 4. Check to see that the fuel hoses are put over the fittings all the way and secure with clips, Install the hoses in such a way a5 to avoid interference with adjacent oF surrounding. parts, Pig a Fig. 43 Fig a © Ball race Fie, 45 © Ball race @ Ball race remover @ Ball race driver1. SPECIAL TOOLS V. SERVICE DATA SERVICE DATA Ttem Tool No. | Description Remarks 9 07949-6110000 Handle, driver Use with item No, 8 2, WIRING DIAGRAM |HEADLIGHT CONTROL SwiTCh 24 sy {HEADLIGHT 6V15W, HEADLIGHT CONTROL fs c (eb Gps NITION SWITCH oy ¢ IGNITION, swiTcH SWITCH ARRANGEMENT ARRANGEMENT . riS's ia go re [OFF OO} siatelaiale ite NOTE: sre IGNITION COWL i ao | Wesco Blck pane cere or ee vemstaton — LGe--Lih een - Go Green TAIL UGHT 613 ‘To NEUTRAL SWITCH it ‘AC GENERATOR me INDICATES OPTIONAL PARTS On units equipped with an optional head and tail lights, the yellow cord of the harness is connected to the engine green cord.V. SERVICE DATA Ey 3, MAINTENANCE SCHEDULE ‘The maintenance intervals shown in the following schedule based upon average riding conditions. Vehicles sub- jected to severe use, or ridden in unusually dusty areas, Items marked * should be serviced by Honda dealer, unless the owner hes proper tools and is mechanically proficient, Other maintenance items are simple to perform and may require more frequent servicing be serviced by the owner. ‘© ENGINE OIL — Change. ‘@*CONTACT POINTS AND IGNITION © DRIVE CHAIN—Check, lubricate, and adjust if necessary. “InTiaL TIMING Clean, check, and adjust or | @ BRAKE CONTROL LINKAGE - Check DenTTAL ees eee seRvic e*VALVE. TAPPEP cteamance- | » TiktS-Tromt tol duit ae peemure : hed esd aed acc o ALL NURS Sorts, AND OnIER sex. | 2CARDURBTOR Chere ond Mijae x | ttcn d necemory vimst weex | *7CARBUR or @ THROTTLE OPERATION - Inspect OPERATION cable. Check and adjust free play o-CLUTCH™ Check operation na jt peice Ee 5 ranrruc cat as sje pny | pie cumkecse ie oe nap See o-GLUTCH Check option a eka SERVICE PERIOD | Contact POINTS AND IGNITION | ° if accccay TUNG Ges cack nad pour ok |» DHRIVE CHAIN Ghali ch OEBEATING: replace if necessary. adjust if necessary. a e@*VALVE ‘TAPPET CLEARANCE- @ BRAKE CONTROL LINKAGE- Check an Chee tal ine H wea Fee CON oe Nace Change oil every 30 operating days for every 3 months, whichever occurs first. @°CAM CHAIN TENSION ~ Adjust. @ POLYURETHANE FOAM AIR FIL- ‘TER ELEMENT Clean and oil. Ser. vice more frequently if operated in dusty areas @CARBURETOR- Check and adjust if necessary © TIRES=Inspect and check air pressure © ALL NUTS, BOLTS, AND OTHER FASTENERS ~ Check security and tighten if necessary. EVERY YEAR (@°CENTRIFUGAL OIL. FILTER - Clean. @°OIL FILTER SCREEN - Clean, © FUEL FILTER SCREEN - Clean ‘© FUEL LINES - Check. @°STEERING HEAD BEARINGS - Adjust. "BRAKE SHOES ~Inspect snd replace if worn,26 V. SERVICE DATA 4, TIGHTENING TORQUE Tae [ile reais Tread a : = A Tia cn 5 cam ae Co a il : 2139 a Cnr ea oa : Sum ace Cnr sie ta ‘ im ma Chine aid : sons tes Cale : on a at Colne et econ é recbmerd |= cian | Cyiacs bad as cover ‘ rs sent | Tappet lock nut = 70~100, Bl~ 72 ea aeans ad 3 1-20 sos | ot pam ° eee) eae Be hea tees : me seuins ua wl ope pie : asa ae oad cc oe ‘ seo tos Gch nt “ ons acs ee es : mois are foe ‘ ain tear Flywheel - | 330~380 B9~275 Dee . coos ee : fo sien Dan cost to | aces ee = ner tps | coe $ maw | esuans ale : nite aes ea ee 5 od 2a 48 aia ape tas ‘ 0 iss fie haber ° cosine] ahonate eager 2 soo deanm0s Pont op be sa ° ‘to-0 0-38 Fo ot : sr sic ta Wn bh i vscire naeieiae a tars pac aua i faces Frame L. panel 8 M5~174 i pel ; site cee t sa 0 ee ; suite Tove ee ; wscina Sop tr : uetta Coe acpetaas ‘ Sta mca ‘ sion alge ; usta | Rear fender | 6 70~100 5i~ 72 | ‘Under cover | 6 ‘7o~100 Bl~ 72 eeV. SERVICE DATA 5. SERVICE DATA mm (0) ries ‘Ameniy sawiard Service limit Coen 210 (oR 28 (a9) Com it Gocuding the tae ere) 25079 (a) [28 ci Vale eo 10-18 @o0=0081) | 20 (ame Valve w wake guide ckarnce nae | ton omant~acoi | 0.08 (ano) Exhaust | odo o0012—an) | 010 (oto Valve sem OD. Tniake | §456~546s @2u8—oaisr) | 5.40 @2125 Exhaunt | 5496~5.46 (02070~02300) | 5.38 (02048) ‘Valve spring free length nner | 251 (0988) 289 (0941) Ouer | 251 (1106) 269.058) nee a mo] SESE T a TTT a aloe oping compres Ea Sey OU ny Saran) Oune | 86507 Simp ote on Ao 1g/2t8 mm Teen Eseoiny | “MOA Soeoiny ree ons ~ 17015 (18806~ 11610) | Wa C884) Pasion skin OD. 1698~1700 (L402~18%0) | 469 Ge) ion pin side havaace Top and vcond | @015~0ows (oapos—000i8) | 042 (adouT ° 0100. (agnns~o0n8) | 012 (0047) se al "Top and cond | 018=038 (0ms9—a0138) | 08 (aD1a) oi oas=o40 (omes9~a01575) | 05 (ani) ae 010=018 (eaoi~0a6) | 020 (0079) age = ~ S Rotor end clearance 0,02~0.07 (0.0008 ~0.0027), 0.12 (0.0047), | Prieion disc ‘Thickness: 3.50 (0.138) 3.10 (0.122) eee = 45 (0005) Chachepring fre Teng 214 @8) 204 (38) ‘Crankshaft runout iS 0.015 (0.0006) 0,05 (0.002) Connecting wed ide pay 01095 (0@04-001H 0 (mR) <—ero 1 (0208) 206 (00) | Gear shift fork thickness R. 55~6.3 (0.217 ~0.248) 5.3 (0.209) tL. _| 45-83 (0177-02) 42 (0109) | Gear shift fork hole dia, 34.0~ 34.08 (1,9985~ 1.3395) (34.2 (1.347) | Gear tit dram OD. SH oe | 9 AH) Gear backlash — 0.09~0.18 (0.0035 ~0,0070) 0.25 (0.010) Gear to aba clarence Miata vo wer | 02008 (oomi—omes) | 0a (0000 Counters to ear | oax2-0077 on013~aoc0) | 01 (0004) cae Mia je | 880 aij | 0 stow pe | 25 Ain screw | 1961 Fuel keel | 20 (0787 Sis peal acer 2 02 (0008) max : (peers Ss 06 (002) max. eae bib tooo iio (sesame) | Lo 37) ae aes 40 (03575 2.0 (0m) *?28 6, TROUBLE SHOOTING V. SERVICE DATA ‘Trouble Probable cause Remedies Engine does not start Excessive wear on piston ring or cylinder. Seized valve in valve guide ‘Seized piston. Faulty valve timing. Low oF lack of compression pressure Blown out cylinder head gasket Warped gasketing surface of cylinder and opine bet Replace. Replace. Replace. Adjust. Lap valve against seat replace Replace. Repair of replace, if necessary, Poor engine idling Incorrect tappet clearance Low oF lack of compresion pressure Excessive valve stem clearance ‘Adj Rep Replace valve and guide. 1 speciation Engine Loss of power Valve stuck open, Incorrect seating of valve Weak or broken valve spring Faully valve tinsing Blown out cylinder head gasket Excessive wear on eylinder and piston. Worn, weak or broken piston ring Loose spark plug, Replace Lap valve Replace Check valve timing and adjust if necessary. Replace Repltce Replace Retighten, 2 Ad 5 Aj Airset Weekes dba gpa (05~01 mm) 0.004~0.008n Eee lege ee ga ich SS wea ollie eae 2 Ol evel wo teh Adj bevel Biot pe ek ier 1 Peer gall Ripe Wi cod uly ot Black exhaust 1. Too rich a fuel mixture. ee Adjust carburetor. ae | acs eer | cae meee T naa ch ohting Ae eet esc” | eee ee siceeni cents eee eUNRe eepe ate diam, | wane or ee ae | OMAR at alrite ae © High of vnc. Change ol TeeaiaG! | keaton Gatal aaa | camera al es ya etic ecdeumiel| noice elas ae slo | rr agen mm pl Replied |\swesee eee mae 3 Worn spline fayhen [resceapsias [ciao aaa aac AWA oee Re alleR AGL iag, | tenes Senin, Sitter etree eats ae nayY. SERVICE DATA ‘Trouble Probable cause Kemedies Engine does not | Cerburetor start 1. Choke fully open Close choke. 2. Carburetor air screw improperly set Adjust air serew. ‘3. Air letking into eylinder head. Retighten carburetor connecting tube 4. Clogged carburetor slow jet ‘Check, clean and retighten, 5. Clogged fuel valve oF piping Disassemble and clean, 6. Clogged vent hole in the fuel tank esp. Disassemble and clean. 7. Fuel tank empty. Fl tank full. Poor engine Carburetor idling 1, Clogged oF Ioose carburetor slow jet ‘Check, clean and retighten 2. Improper float level Adjust. 3. Incorrect aie screw adjustment. Adjust. 4. Air leaks Tigiten all ai connections or joints Poor engine Catuinor performance 1. Jet size too small Replace with lager sie jt. 2, Improper float level Adjust 3. Clogged carburetor main jet. Clean and retighten, 4. Ae Tea, Tighten all air passage connection. Heavy steering | 1. Sicering stem excessively sightened “Loosen steering sem nat 2. Damaged steering stem steel balls. Replace 5. Low front tire pressure. Inflate to L2kg/sqrem (17 psi). ‘Front and rear | 1. Worn front and rear wheel bearings. Replace bearing. ‘wheel wobble | 2. Front or rear wheel runout or distored. | Repair or replace ae _ 3. Deeatve te Replace. Defective brake | 1. Worn brake lining. Replace 2, Worn brake shoe or poor shoctodrum | Replace, 8, Worn brake cam, Replace 4, Water of oil geting on lining Clean 5, Worn brake shaft Replace. 6. Brake lever out of adjustment. Readjust30. V. SERVICE DATA 7. SPECIFICATIONS Tem US. measure Metric Dimension | Overall length Si.tin, 130mm, (Overall width ‘Sin 800 mm ‘Overall eight 09m, 785 me Wheelbase 5.2m. 29 ma Turning crcl 46h. Lam ‘Seat height ain, 570 mm Foot peg height 79in, 200 mm Ground clearance 38in, mm Dey weight 168.1 1b, Take | ‘Weigh distibation dry F/R 595 /108.81b, Ema ‘Curb weight 170i, Tg Frame Type z Back-bor: Front tire size, ype, pressure 16x8-7, ATV tire, 28 psi (O2kg/em') Rear tne size, type, pressure 15x8-7, ATV tire, 28 psi @2kg/em") Brake type, lining ara Internal expanding shoes, $09. jn. (247 em®) | Fuel capacity 0.65 US. gal 25h i Fuel reserve capacity 013 US. gal 05 ti. ‘Gaster angle a ‘Teal length 1.26in, 2mm Engine ‘Type Air cooled 4stroke OH.G. engine Grinder arrangement ‘Single cylinder 80" inclined from vertical = [Bore and stroke LAS. 470x414 mm Displacement ‘dd enin ; Tee Compression ratio 15: | Valve eran Chain driven overhead camshaft Maximum horsepower 6 BHIP/6,500 rpm (SAB) Maximum torque 04 b-F/8,500 rpm 042k /5,00 rom | Oil eapaciyy asus. ost, Lubrication system ~__Foreed and wet sump Valve tappet clearance IN, EX: 002i, IN, EX: 005mm Engine weight (ry) “ai 1895 egV. SERVICE DATA 31 Drive train tem ‘hutch ‘Transmission Final reduction Ignition Starting system Alternator ‘Metric pte automatic centrifugal type ‘S-apeed constant mesh 4058 aura Lia 190 2500, drive sprocket LAT, driven sprocket 35T Flywheel magneto Recoil starter AG. generator Spark plog NGK CiHS, ND UZFS32. ___M. MAJOR MODIFIED POINTS OF ATC70K1 | I. MAJOR MODIFIED POINTS OF ATC70K1 1. EXHAUST MUFFLER ATC70K1 comes up with a new exhaust system spark arrestor and consequent exhaust muffler modification in shape. For the new type spark arrestor, the removal and instal procedures of the muffler have changed as follows to allow Spark Arresor Maintenance The exam spark even ist he eed re rom ‘ecole Cibo peroly ey 39 opsaieg a 1 She gear cna pd to ple te Sennaion i aa 2. Remove the dif pipe mowming Yo ed side othe Site mite @ Avan mata a ees Setace’ 9 bias fe Ebel eel pge ese te oe ee spark arrestor by momentarily revving up the engine. deem es 5. Rel he dies pipe wih the mounting bol © Diffuser pipe mounting bolt @ Diffuser pipe ® Spark erresior Removal Turn off the screws and take out the rear cover, Remove the rear wheels, Disconnect the brake cable at the rear brake arm. Remove the bolt; take out the right brake panel. While holding the rear wheel hub by hand, drive out the rear wheel axle from the left side, Use suitable wooden hammer to drive the axle. 6, Remove the bolts securing the muffler to the rear of the frame, 7. Wrap the carry pipe with rug to avoid damaging the pipe while operation, Place the machine so that it is on the carry pipe and rear frame through a block ss shown, 8. Remove the bolts and take out the step bar 9. Remove the bolts and remove the undercover. 10. Loosen the chain tensioner locking bolt. 11. Remove two bolts securing the mufilet to the side of the frame, 12, Remove the joints nuts holding the muffler and eylinder head together. 13, Move the rear wheel hub so that it will not interfere with the mufiler while the muffler is being removed ; take out the muffler toward the front of the mechine. Fig. 3 @ Mafler assembly @ Rear wheel hub @ Bol @ Wooden block Joint nut © Carry pipeWl. MAJOR MODIFIED POINTS OF ATC70K1 33. Installation To install, reverse the removal procedures. However, observe the following installation points 1. Make drive chain tension and brake adjustments after assembling. 2, To install a new mufiler (ATC70K1) on ATC70 (former), observe the following : Elongate mufller attaching holes (7mm (0.275 in)) in the frame side with a 10mm (0.394 in) drill , Install the muller on the frame side and the rear of the frame side with the following parts Part No. ‘Name of Part ov 2000-08012-0A | Bok, hex, 8 Boos | veten ab fae a a Rear Wheel Do not remove the rear wheel hub from the frame without first removing the muffler due to the installation of the new muffler MEMO. Fig 6s ( Muller mounting hole (ame side)SHOP MANUAL HONDA. ATC7O ADDENDUM SHEET 61937022 Date of Issue: Dec., 1977 ® A30007712 © HONDA MOTOR CO, LTD. PRINTED IN JAPANPREFACE This Service Manual has been prepared as a “SERVICE GUIDANCE” for the mechanics responsible for the upkeep of the HONDA ATC70. Since the model uses the same > basic engine as the CT70, it should be used in conjunction ‘with the manuals prepared for the STS0-70/CT70-H for ‘complete information, It is compiled into six sections and summarizes the procedures for disassembling, inspecting and reassembling the components of the machine. Strict adherence to the ‘nstructions given herein will result in better, safer service work. Al information, illustrations and specifications contained herein are based on units manufactured after March of 1973. HONDA reserves the right to make changes at any time without notice and obligation. - HONDA MOTOR CO., LTD. Service Publications Office ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PURLICATION ARF. RASED ON THE LATEST PROD. UCT INFORMATION AVAILABE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES: AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRO- DUCED WITHOUT WRITTEN PERMISSION. Date of Issue: Dec., 1977 © HONDA MOTOR CO., LTD, CONTENTS, 1, SERVICE PRECAUTIONS. oa IL. INSPECTION AND ADJUSTMENT ... 22 1, Tappet Raed 2. Contact breaker pont gap and ignition timing. 3 3. Carburetor 3 4, Cluich . 3 5. Cam chain 4 6. Engine oil , 4 7. Brake .. ee 8. Air cleaner s 9. Drive chain 6 10. Drive chain lubric: ne 11. Spark plug =e 12, Throttle cable Seas 13. Fuel filter... az UI. ENGINE a 8 1, Engine removal and installation ........226. 8 2. Major difference between ATC7O and CT70 engines . 9 IV. FRAME boas 10 1. Front wheel 10 2. Rear wheel and brake B 3. Handlebar . 19 4. Front fork 2 5. Frame body . 2 V. SERVICE DATA Bese 24 1. Special tools. ’ 24 2. Wiring diagram 4 3. Maintenance schedule 25 4, Torque specifications 26 S. Service data é Py 6. Trouble shooting. 28 7. Specifications _ 30 VI. MAJOR MODIFIED POINTS OF ATC7OK1 .... 32 ‘SUPPLEMENT TO ATC70°78 7 35SRA ARBAB SRS SE TUVAAE’ ym baying one sed Tuned lie aT pos 0 albaaget sabsonen we 10) "SMACAND ‘met dt eno Lsbeen ade sae OTUTA ACHADT wl ‘sotawyuen ad bawu 96 Divodla f JOTTD hae wore ined sah HOTA ORT et tt ane sles This addendum applies to ATC70 (’78). Engine No. ATC70E- 2000004 and subsequent Frame No. ATC70- 2000004 =~ and subsequent 1. INSPECTION AND ADJUSTMENT CARBURETOR IDLE ADJUSTMENT 1. Shift to NEUTRAL and warm the engine to operating temperature, 2. Tum the throttle stop screw as required to obtain an idle speed of 1,500 + 100 spm. CARBURETOR FUEL-AIR MIXTURE ADJUSTMENT. 1. Shift to NEUTRAL and warm up the engine 2. Tum the throttle stop screw to obtain the lowest practical fide speed, 3. Tum the pilot screw and obtain the highest idle speed possibe with it | 4. Repeat steps 2 and 3. NoTE: Fig 1 (1) Throttle stop ew Turning the pilot screw in produces a ean fuel mixture; “®" 3) oc serew turning it out produces a rich fuel mixture, 5. Tum the throttle stop screw as required to obtain the specified idle speed. . Operate the throttle slowly and check for smooth engine response, BRAKE ADJUSTMENT 1. Measure the brake lever free play. BRAKE LEVER FREE PLAY: 15-20 mm (5/8-3/4 in.) 2, Tum the brake adjusting nut, if adjustment is necessary Fig. 3 (1) Brake adjusting nut (B) Increase play Date of Issue: Dee, 1977 © HONDA MOTOR CO., LTD. 1 of 12Fig $ (1) Lock nuts (2) Adjuster (@) Drain stew G) Sezews Fig. 7 (1) Oxing (G) Carburetor (Q) Filter steen (4) Fuel valve 2of 12 ADDENDUM SHEET ATC70 "78 DRIVE CHAIN TENSION 1. Shift the transmission into neutral, 2. Remove the drive chain inspection cap. 3. Check the drive chain free play FREE PLAY: 10-20 mm (3/8-3/4 in.) 4. Adjust by looscning the two adjuster lock aut and moving the adjuster. ‘Tighten the lock nuts. ‘TORQUE: 2.53.3 kgm (18.1-23.8 ftbs) 5. Install the inspection cap. FUEL FILTER CLEANING 1. Tum the fuel valve to “OFF” 2. Loosen the drain screw to drain gasoline from the carbu- retor. 3. Remove the two fuel valve screws and fuel valve, 4, Remove the O-ring and filter screen. Check the filter screen and O-ring for damage. ‘5. Wash the filter screen in solvent. 6. Install the filter screen, O-ring and fuel valve. NOTE: Install the filter screen so that the cupped face is toward the carburetor body, as illustrated 7. Tighten the drain serew. Turn the fuel valve to “ON” and check for leakage. Date of Issue: Dec., 197 © HONDA MOTOR CO., LTD.ADDENDUM SHEET ATC70 ‘78 37 2, NEUTRAL INDICATOR ‘Anneutral indicator is installed on the left crankcase cover. 3. ENGINE REMOVAL AND INSTALLATION REMOVAL 1. Remove the two rear fender mounting nuts, two bolts and rear fender with seat. 2. Turn the fuel valve to “OFF” and drain the carburetor by loosening the drain screw. 3. Remove the fuel vave from the carburetor. 4. Remove the fuel tank 5. To aid engine removal, place the machine so that it rests on the rear carry pipe. NOTE: Use preventative measures to avoid damaging the pipe. Date of Isue: Dec., 197 © HONDA MOTOR CO, LTD. Fig. 9 (1) Rear fender Q)Seat ‘G) Nats (@) Botts =, be: Fig. 10 (1) Fuel vale (Q) Din screw @) Serows Fig. 11 () Bolt (2) Fuel tank 30f 1238 ADDENDUM SHEET ATC70 "78 Fig. 12. (1) Nuts (@) Mounting botts @)Mumer ig. 13 (1) Bolts (2) Footpes assembly Fig, 14 (1) Under plate (2) Chain case Fig. 15 (1) Clip ) Serews (@) Neatal indicator (G) Left crankcase cover 40f12 6. Remove the two exhaust pipe nuts, three muffler mounting bolts and muffler. 7. Remove the footpeg assembly 8, Remove the under plate and chain case by removing the seven mounting bolts 9. Shift the transmission into neutral and remove the neutral indicator retaining clip and indicator. 10, Remove the left crankcase cover. Date of Issue: Dee. 1977 © HONDA MOTOR CO., LTD.ADDENDUM SHEET ATC70 ‘78 LL, Loosen the drive chain tensioner. 12. Remove the drive chain master link retaining clip. Do not co bend or twist the clip. Remove the master link and drive chain. Fig. 16 (1) Drive chain tensioner @alip 13. Remave the intake pipe Remove the spark plug cap. Disconnect the wire harness leads. ig. 17 (1) Botts (@) Intake pipe 14. Remove the two engine mounting bolts. Remove the engine. INSTALLATION ‘The installation sequence is esentilly the reverse of removal NOTE: 1. Install the master link retaining clip so thatthe closed end of the clip will face the direction of forward wheel rotation 2, Tighten each bolt to specification TORQUE: ENGINE MOUNTING BOLTS: 1.9-2.5 kg-m (13.7:18.1 fetbs) DRIVE CHAIN TENSIONER: 2.53.3 kgm (481.239 fetbs) 3. After mounting the engine, adjust the drive chain, Fig. 19 (1) Retaining Date of Issue: Dec., 197 © HONDA MOTOR CO., LTD. Sof 1240 ADDENDUM SHEET ATC70 °78 4. REAR WHEEL AND BRAKE Fig. 20 a (1) Brake drum cover (2) Brake drum (3) Baake shoes (4) Brake shoe springs (S) Brake camshaft (6) Brake cam holder (7) Baake anchor m (8) Oiltet (3) Brake arm return spring (10) Beake arm (LD Brake arm joint (12) Adjusting at (13) Chain master (18) Deve chain (15) Chain tensioner rs (16) Driven sprocket (17) Damper cover (8) Sprocket damper (09) Damper ease (20) Chain ese QD) Rear axle pipe (22) Oilseal (23) Ball bearing (24 Rearaxle (Qs) Distance collar (26) Sprocket retainer G7) Aste nut (28) Washer (@9) Outer im (G0) Stem valve GD Wheel Oxing GD Tie G3) Inner sim (G4) Rear wheel Dange 1 DISASSEMBLY wheels. Fig 21 (1) Cotter pin (@) Axle nut axle, 10, Remove the rear axle. Fig. 22 (1) Sprocket assembly) Rear axle (2) rake drum 6of 12 1. Remove the rear fender with seat 2. Remove the cotter pins and loosen the axle nuts. 3. Place a suitable stand under the footpegs to raise the rear 4. Remove the axle nuts, rear wheels and axe pipes. 5. Remove the under cover, chain cover and drum cover. 6. Remove the neutral indicator and left crankcase cover. 7. Loosen the drive chain tensioner. 8, Remove the drive chain master link and drive chain. 9. Slide the sprocket assembly and brake drum off the rear Date of Issue: Dec., 1977 © HONDA MOTOR CO., LTD.ADDENDUM SHEET ATC70 "78 a 11. Remove the brake adjusting nut and brake cable. 12. Remove the brake arm locking bolt and nut. cc Remove the brake arm and retum spring from the brake camshaft. 13, Remove the cotter pin and retaining washer from the brake anchor 14. Remove the brake shoes, shoe springs and brake camshaft as an assembly. NOTE: Take care not to damage the oil felt when removing the brake camshaft. 15. Remove the brake anchor and brake cam holder. 16. Remove the axle ol seals and bearings from the frame. NOTE: Replace the oil seal with a new one if it is removed. Date of Issue: Dec., 1977 © HONDA MOTOR CO., LTD. Fig. 23 (I) Adjusting nut (4) Return sping (2) Lock mut G) Bot (4) Brake shoes (6) Brake shoe springs Fig. 25 (1) Brake cam holder (@) Brake anchor ig. 26 (1) Oil seal (2) Beatinga ADDENDUM SHEET ATC70 "78 17. Disassemble the driven sprocket assembly. Fig, 27 (1) Damper case (3) Dumper cover (2) Sprocket damper (4) Driven sprocket 18. Separate the brake shoe springs, camehaft, and brake those. Fig. 28. (1) Brake shoes {Q) Brake shoe springs (G) Brake camshart 19. Rear whesl disassembly Remove the rear wheel boss. Remove the three nuts and special bolts, Refer to page 11 for tire repair. Fig. 29 (1) Rear whos boss bots (@) Nuts for special botts INSPECTION 1. Check the rear wheel axle for runout, SERVICE LIMIT: 2.0 mm (0.079 in.) 2. Inspect the lip of the oi seal for wear or damage. &/ 3. Check the drive and driven sprockets for wear or damage. €/ 44. Check the drive chain for weat or damage. 8 5. Check the wheel bearings for excessive play. pe 6. Check the sprocket damper rubber for damage or deteriora tion. 7. Check the brake shoe spring for damage or weakness. Norm a\ Fig. 30 Sprocket conditions Date of Issue: Dec., 1977 8o0f 12 © HONDA MOTOR CO.,LTD.ADDENDUM SHEET ATC70 ‘78 4B 8, Measure the rear brake shoe lining thickness. STANDARD: 4.0 mm (0.158 in.) SERVICE LIMIT: 2.0 mm (0.079 in.) 9. Measure the brake drum LD. STANDARD: 130,00-130.02 mm (5.122-5.12S in.) SERVICE LIMIT: 131 mm (5.161 in.) ASSEMBLY The assembly sequence is essentially the reverse of disassembly, 1. Install the brake camshaft so that its punch mark is positioned upward (12 o'clock). 2. Install the brake anchor and brake cam holder using the correct bolts. NOTE: If a longer bolt is used, it will interfere with the brake shoe. TORQUE: 0.7.1.2 kg-m (S.1-8,7 ft-lbs) 3. Align the brake arm and brake camshaft punch marks and install the brake arm, Install the brake cable. Date of Issue: Dec. 1977 © HONDA MOTOR CO., LTD. Fig. 31 Measuring lining thickness ig. 32 Measuring brake drum LD. Fig. 33 (1) Camshatt (2) Punch mark Fig. 34 (1) Punch marks 90f12“4 ADDENDUM SHEET ATC70 "78 4. Install the drive chain. Install the master link retaining clip so that the closed end of the clip will fice the direction of forward rotation. 5. Install the rear wheels as follows: =1. Install the rear wheels, —2, Tighten the rear axle nut of one side to 1-2 kgm (72-145 fabs) and then loosen it 1/4 turn, 3. Torque the opposite rear axle nut to the specification. TORQUE: 6.0-8.0 kg-m (43.4-57.8 ft-lbs) 4. Tighten the remaining axle nut to the same torque. 6. After assembly, adjust the drive chain and brake. 4, SPEED LIMITER The tlyottle lever case is equipped with a speed limiter NOTE: When the machine is used without the speed limiter, plug the speed limiter screw hole to prevent dust and water from entering Fig. 36 (1) Speed limiter screw 5. TORQUE SPECIFICATIONS | Torque value Item Dia. (mm) Kem felbs Handlebar upper holder 6 o7-12 51-87 Handlebar lower holder 10 40-48 28.9-34.7 Steering stem nut 2 5.0-7.0 36.2-50.6 Fotk top bridge 10 40-48 289-347 Front wheel hub 8 19-25 137-18.1 Front wheel axle nut 4 | 60-80 434-578 Rear wheel axle nut 14 60-80 434-578 Rear wheel boss 8 19-25 13.7-18.1 Engine mounting bolt 8 19-25 137-1811 Footpeg bolt 8 137-1811 Step guard (outside) 10 28.9-34.7 Step guard (inside) 8 19-25 137-18. Change pedal 6 07-12 51-87 Seat 6 36- S.1 Rear fender bracket 6 36-31 Rear fender mounting nut (rear) 8 14-18 101-130 Drive chain tensioner 10 25-33 181-239 Brake cam holder 6 07-12 5. 87 Brake anchor 6 07-12 | 5. 8.7 Date of Issue: Dec., 1977 10 0f 12 © HONDA MOTOR CO., LTD.ADDENDUM SHEET ATC70 °78 45 6, SERVICE DATA o Ttem Rear brake shoe lining thickness - Drive chain length Standard mm (in) Service limit mm (in.) Front wheel hub runout —— 0.5 (0.020) Rear axle runout 0-1.0 (0-039) 2.0(0.079) Rear brake drum LD. 130,00-130.08 (5.122-$.125) | 131.00 5.161) 400.158) 2.0 (0.079) 914.4-915.9 (36.027-36.086) | 929.0 (36.603) 7. SPECIFICATIONS - Item Specifications (Overall length 1,305 mm (51-4 in.) Overall width ‘800 mm (31.5 in.) Overall height 805 mm (31.7 in.) Wheelbase 895 mm (35.2 in.) Tread 610 mm (24.0 in.) Ground clearance 85 mm( 3.4 in.) Minimum turning radius 1,420 mm (55.9 in.) Dry weight 74.0 kg (163.1 Ibs.) Caster 20° from vertical ‘Trail length 32 mm( 1.26 in.) Front tire size, pattern, pressure 16 x 8.0-7, B-901, 0.20 kg/em? (2.8 psi) Rear tre size, patter, pressure 16 x 80-7, B-901, 0.20 kglem? (2.8 psi.) cr Brake type, lining swept area Internal expanding shoes, 41.4 em? (6.42 sq. i Fuel tank capacity 400lit. (1.1 US. gal) Reserve fuel 8 lit. (0.2 US. gal) hutch ‘Semiautomatic Transmission 3.speed constant mesh Primary reduction 4.058 Gear ratio 1 3272 u 1.722 m 1.190 Final reduction 2.500 Date of Issue: Dec., 1977 ©HONDA MOTOR CO.,LTD. 1 of 1246 ADDENDUM SHEET ATC70 "78 8. WIRING DIAGRAM IGNITION SWITCH AND, ENGINE STOP SWITCH IGNITION COIL mit IGNTION SWITCH AND fl Gene sioe SwiTen By To NEUTRAL SWITCH IG] E Yalow OFF] O+O SPARK PLUG = Green Ba Black AC. GENERATOR OFF] OO W white WE] ac] 6 = eae Lo Light Green Date of Issue: Dec., 1977 120f 12 © HONDA MOTOR CO., LTD.+5oor ‘82 ADDENDUM a7 INTRODUCTION This addendum describes the new technical features and servicing procedures for the 1982 Honda ATC70. Use this addendum with the base ATC70 and CT70 Shop Manuals for complete servicing proce dures. ALL INFORMATION AND ILLUSTRATIONS IN. CLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAIL- ABLE AT THE TIME OF APPROVAL FOR PRINT- ING. HONDA MOTOR CO,, LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITH- OUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE RE- PRODUCED WITHOUT WRITTEN PERMISSION. HONDA MOTOR cO., LTD. Service Publications Office CONTENTS SPECIFICATIONS ..... ll, INSPECTION AND ADJUSTMENT . TRANSMISSION ..... 248 ++ 49 51 Date of sue: July, 1981 © American Honda Motor Co, Inc. 1981 - All Rights Reserved48 "82 ADDENDUM |. SPECIFICATIONS DIMENSION. Overall length Overall width Overall height Wheelbase Turning circle Seat height Footpeg height 1,300 mm (51.2 in) ‘800 mm (31.6 in) £800 mm (31.6 in) £895 mm (36.2 in) 28m (9.3 0) 570 mm (22. in) 180 mm (7.1 in) Front tire size, type, pressure Rear tre size, type, pressure Brake type, lining are Ground clearance 85 mm (3.3 in) Dry weight 77 kg (1698 Ib) Weight distribution dry F/R. 30/47 kq (66.1/103.6 Ib) Curb weight 80 kg (176.4 Ib) FRAME Type Backbone 16x8-7, ATV tire, 0.15 ka/em? (2.2 psi) 16x8.7, ATV tire, 0.15 kg/om? (2.2 psi) Internal expanding shoes, 122 em? (19.0 sq in) Cylinder arrangement Bore and stroke | Displacement Compression ratio Valve train Maximum horsepower Maximum torque Oil capacity Lubrication system Valve tappet clearance Engine weight (dry) Fuel capacity 4.3 liters (1.1 U.S. gal) Fuol resorve capacity OB liters (0.2 U.S. gel) Caster angle 700 Trail ongth 32mm (1.26 in) ENGINE Type ‘Air cooled 4-stroke O.H.C. engine ‘Single cylinder 759 inclined from vertical 47.0 x 41.4 mm (1.85 x 1.63 in) 72. (4.4 cu in) 75:1 Chain driven overhead camshaft 3.4 BHP 9,000 rpm (SAE 245) (0.42 kg-m/3,000 rpm (3.04 Ib-t/3,000 rpm) 08 liters (0.8 U.S. gt Forced and wet sump INTAKE, EXHAUST: 0.05 mm (0.002 in) 18.2 ka (40.1 ib) DRIVE TRAIN Gluteh Wet, multi-plate centrifugal type Transmission 4speed constant mesh, semi-automatic Primary reduction 4.058 Gear ratio | 3273 Gear ratio It 11938 Gear ratio 111 1.350 Gear ratio 1V 1.043 Final reduction 2.769, drive sprocket 13T, driven sprocket 36T ELECTRICAL Ignition Flywheel magneto Starting system Recoil starter Alternator AC. generator Spark plug CR7HS NGK, U22FSR-L ND Date of Issue: July, 1981 © American Honda Motor Co, ne. 1981 - All Rights Reserved"82 ADDENDUM 49 INSPECTION & ADJUSTMENT SPARK PLUG REPLACEMENT AND ADJUSTMENT Spark plugs for 1982 are resistor-type plugs. Refer to the chart below for the proper spark plug heat range and gap. RECOMMENDED SPARK PLUG standard crmis (NGK) U22FSR-L (ND) For cold climate | CR6HS (NGK) below 419F (50C) | UZOFSR-L (ND) For extended high | CR8HS (NGK) speed riding U24FSR-L (ND) SPARK PLUG Gap: (0.80.7 mm (0.024-0.028 in) OIL RECOMMENDATION Use HONDA 4STROKE OIL or equivalent. APL SERVICE CLASSIFICATION: SE or SF VISCOSITY: SAE 10W-40 Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated. range VF o6-a7mm (0.024—0.028in) Date of lsuer July, 1987 © Americen Honda Motor Co, ne. 1981 - All Rights ResoredHONDA 50 82 ADDENDUM ATC70 4-SPEED TRANSMISSION "Ong O68 4th GEARS COUNTERSHAFT 3rd GEARS 2nd GEARS. Qogi, 4 1st GEARS MAINSHAFT Date of Issue: July, 1981 © 10F Coy Ine. 1981 - AlHONDA ATC70 Ill TRANSMISSION "82 ADDENDUM 51 GEARSHIFT LINKAGE DISASSEMBLY AND OIL PUMP REMOVAL. STATOR REMOVAL.........-++ CRANKCASE DISASSEMBLY. TRANSMISSION DISASSEMBLY INSPECTION . TRANSMISSION ASSEMBLY ........-.57 CRANKCASE ASSEMBLY. . 58 STATOR AND FLYWHEEL ASSEMBLY......... 58 GEARSHIFT LINKAGE AND OIL PUMP INSTALLATION. .......--. a) GENERAL INSTRUCTIONS: The ATC70's transmis hhas been changed from a 3-speed to a 4-speed. © To service the transmission, the following parts must be removed (refer to the CT70 Shop Manual on the pages indicated for the procedures) — flywheel (page 15) — cylinder head (page 16) = oylinder (page 16) Date of Issue: July, 1981 © American Honda Motor Co, ne. 1981 - All Rights Reserved52 “82 ADDENDUM GEARSHIFT LINKAGE DISASSEMBLY AND OIL PUMP REMOVAL Remove the clutch (page 24 CT70 Shop Manual). Romove the primary driven gear. Remove the gearshift spindle and gearshift return spring. Remove the stopper plate bolt. Remove the shift drum stopper arm. Remove the of! pump assembly. Remove the drum stopper plate and the pin retainer plate. STATOR REMOVAL Remove the final drive sprocket. Date of Issue: July, 1981 © American Honda Motor Co, Ine. 1981 - All Rights ReservedHONDA ATC70 “82 ADDENDUM 53 = Remove the wire from the neutral switch and the grommet from the crankcase. Remove the stator wire's grommet from the crankease. Remove the two serews and the stator assem- bly. CRANKCASE DISASSEMBLY Remove the cam chain, Remove the eight crankcase bolts. Date of Issue: July, 1981 © American Honda Motor Co, Ine. 1981 = Al) Rights Reserved54 “82 ADDENDUM Separate the left and right crankcase halves. Remove the dowel pins and gasket. Date of Issue: July, 1981 © American Honda Hotor Co, Inc. 1981 - All Rights ReservedHONDA ATC70 “82 ADDENDUM = TRANSMISSION DISASSEMBLY Remove and disassemble the transmission ‘assembly as shown. OB cage aaa 6 he Cog ole Obs Rotana oo SHIFT FORK puoyer Sarr FORK KB RyE wevtaat sure S vin ae Date of Issue: July, 1981 (© American Honds Motor Co,, In. 1981 - All Rights ReservedHONDA ATC70 INSPECTION in i) 56 "82 ADDENDUM ‘Check the gear dogs for excessive or abnormal Inspect the 1.D. of each gear: ~ Mainshatt ‘Second gear, fourth gear : 17.016~17.043 mm (0.6700-0.6710 in) Countershatt ; First gear, third gear: may 17.016--17.043 mm (0.6700-0.6710 in) Measure the 0.0. of the main and counter shaft with a micrometer. MAIN SHAFT [Standard Value |Serviesable Limit 16.983.-16.998 mm | Replace if under (0'6586-0.6601 Im) | 16.94 mm (Gee70m = Counter | 16.066 16.984 mm | Replace if under Shott | (0i5680~0.6687 In} | 16.92 mm (oie6e ie) COUNTER. SHAFT GEARSHIFT DRUM Measure the shitt drum 0.0. ae ‘STANDARD: 33.950~33.975 mm (1.3366—1.3376 in) SERVICE LIMIT: 33.99 (1.336 in} Date of Issue July, 1987 © American Honda Motor Co, Ine. 1981 ~All Rights Reserved"82 ADDENDUM 57 SHIFT FORK Measure the shift fork 1.D. STANDARD: 34,000-34.025 mm (1.3386—1.3396 in) SERVICE LIMIT: 34.14 mm (1.344 in) ‘Measure the shift fork claw thickness, STANDARD: 4.88-4.94 mm (0.191-0.195 in} SERVICE LIMIT: 4.6 mm (0.18 in} TRANSMISSION ASSEMBLY Reassemble the gears on their shafts. Install the gear and shaft assemblies with the shift drum in the lett crankcase half Apply oil to the gears. Make sure the gears rotate freely. Date of issue: July, 1981 © American Honda Motor Co, Ine. 1981 - All Rights Reserved58 “82 ADDENDUM CRANKCASE ASSEMBLY Install a new crankcase gasket and join the right crankcase to the left hat. Tighten the eight crankcase bolts in a crisscross pattern. Install the cam chain, STATOR AND FLYWHEEL ASSEMBLY ‘Assemble the stator and flywheel as shown. NOTE: Make sure that the woodruft key seats in the keyway properly. NEUTRAL SWITCH WIRE INSTALLATION Route the end of the wire through the hole in the switch while compressing the spring. STATOR FLYWHEEL NOTE: ‘© Make sure that no metal particles are inside the flywheel © Do not strike the flywheel with ‘hammer. Date of Issue: July, 1981 © American Honds Motor Co, Ine. 1981 - All Rights Resarved"82 ADDENDUM 50 GEARSHIFT LINKAGE AND OIL PUMP ASSEMBLY Reessemble the gearshift linkage and oil pump as shown. GEARSHIFT SPINDLE ‘Alter installing the lover. — ‘hock for operation, cuuteH ie rn ae at aK mle LIFTER cuuten CLUTCH BALL RETAINER Bo not fore to int) Be RIGHT CRANKCASE COVER Date of Issue: July, 1981 © American Honda Motor Co, ne. 1981 - All Rights ReservedHONDA ATC70 ‘83—'84 ADDENDUM 1 INTRODUCTION This addendum describes the new technical fea- tures and servicing procedures for the 1983 and 1984 Honda ATC7O. Use this addendum with the base ATC70 and CT70 Shop Manuals for complete servicing pro- cedures, ‘ALL INFORMATION, ILLUSTRATIONS, DIREC. TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PROD- UCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE RE- PRODUCED WITHOUT WRITTEN PERMISSION. HONDA MOTOR CO., LTD. ‘Service Publications Office CONTENTS |. CABLE AND HARNESS ROUTING ........... ll. INSPECTION & ADJUSTMENT.....63 Ill, HANDLEBAR ... 64 IV. WIRING DIAGRAM . Enso, Date of Issue: August, 1983 © American Honda Motor Co, Ine. 1983 All Rights Reserved