MINI-BIKE Model ATC9O, US9O VEHICLE MAINTENANCE Air cleaner should be removed and cleaned periodically. Clean filter in a suitable solvent then allow to dry Lubricate filter with a light oil being careful not to over-lubricate filter as a richer air-fuel mixture may result. Do not run engine without air leaner or with air cleaner that is punctured as engine may be damaged. Fig, t-Adjust cluteh by loosening lock aut (2) and turning adjusung serew (1) a¢ outined in ire pressure should be 2 psi in all tires. Tires should be inflated using a manually operated tire pump. damage may result due to overinfla- tion if a high pressure system is used. Pressure must be equal in all tires or vehicle may have tendency to pull to one side during operation. Drive chain and cables should be lubricated periodically as dictated by riding conditions VEHICLE ADJUSTMENTS. CLUTCH. The ATC90 and US90 are equipped with an automatic cluteh, Cluteh action is adjusted by turning clutch adjustment. screw shown in Fig. 1. Adjust as follows: Loosen lock nut (2) and turn adjusting serew (1) elockwise approximately one turn. Slowly turn screw counter-elock- wise and stop when serew becomes hard to turn, Back off screw clockwise to % turn and tighten lock nut (2), When shifting gears, cluteh should engage and disengage freely without excessive slippage, Refer to engine section for servicing. ‘Stroke 456mm Honda Disp. 89.6e¢ CHAIN. A drive chain tensioner is used to keep chain under tension. To adjust chain tensioner, remove frame body cover and refer to Fig. 2. Loosen lock nut (N) and force tensioner lock arm (A) up so that drive chain is taut Retighten lock nut (N). Fig. 2-Adjust chain tension by laosening lock ‘aut (W) and pusning lock arm (A) up to tighten chain. Turn cable adjuster (8) to adjust roar rake. 77Honda Fig. 3-Exploded view of front whee! assembly. 2 Lecwestor ia sat” 10, Bae THROTTLE. Throttle lever free play should be ‘s-\-inch measured at end of throttle lever. Adjust throttle cable by pulling back boot and turning adjuster at top of carburetor: BRAKES. The rear brake may be actuated with either the foot pedal the brake lever mounted on the han dlebars. Adjust the foot pedal first. by turning the adjusting nut at end of brake rod. Free play of foot pedal should be 5/8-19/16-inch. After ad- justing foot pedal, brake lever may be adjusted by turning brake cable ad- juster (B—Fig. 2). Brake lever free play should be 19/16-1 1/4 inch mea- sured at end of brake lever VEHICLE OVERHAUL FRONT WHEEL. To remove front wheel, remove cotter pin and unscrew axle nut. Remove axle collar and re- move wheel from front fork. Remove spacer (4—Fig. 3) und pull axle from wheel. Remove retaining bolts and separate wheel hub and wheel cente Drive seals and bearings out of whee hub if necessary. Inspect bearings and axle for wear. If axle is bent more than 8mm (0.31 inch), then it must be renewed. Beur- ings should be packed with a good quality wheel bearing grease. To reas- semble, reverse disassembly proce- dure, Bearings must be driven into hub so that marking on bearing is on outside. Tighten wheel center-to-wheel hub capserews to a torque of 15-17 ft. Ibs, 78 10, Lackwasher it Mer 12 Bearing 13. Bearing Fig. 5 Exploded viow of rear whee! as mbt. 4 op & What tie Eine f Ser STEERING HEAD. To remove the steering head assembly, proceed as fol- lows: Remove the front wheel as pre- viously outlined. Disconnect throttle cable at carburetor and brake cable at brake lever. Remove handle bars, Flip back handle clamp lever (9—Fig. 4), Fig. 6-Exploded view of rear hub and brake ‘atbomby. # Take backing aus 1 Reanne as 9. Brakes Bh Bee bts remove cotter pin, unscrew enstle nut (11) and remove handle clamp lever. Unserow steering stem nut (2) with a suitable tool and remove washer, Un- sere ining capscrews and remove upper fork plate (4). Unscrew steering stem nut (5) with a suitable tool and remove steering stem and fork as sembly from frame being careful not to lose bearing balls (12), To reassemble, reverse disassembly procedure. Lubricate stecring bearing balls with a good quality grease. Both the upper and lower bearings have 21 balls. Tighten steering head nut (5) so that steering stem will turn freely without looseness. Tighten upper triple clamp retaining nut to a torque of 29-35 ft-Ibs REAR WHEELS AND AXLE. To remove each rear wheel, remove cotter pin, axle nut (2—Fig. 5) and washer. Remove pipe shaft (4) from wheel. Remove axle spacer (7) on right end of axle, With both rear wheels removed, remove drive chain case and pull axle out left side of rear hub. To reinstall axle and wheels, reverse disassembly procedure. Tighten pipe shaft bolts to fa torque of 15-17 ft-lbs. Be sure that axle spacer is installed on right axle hefore installing right wheel REAR HUB AND BRAKE. To remove rear hub and brake assembly, disconneet brake cable at rear end of cable. Remove rear wheels and rear axle as previously outlined and discon-ie Abe UF Flos: pin neet drive chain. Remove brake drum nut (1-Fig, 6) and seal washer (2). Withdraw drive assembly (14 thru 21) and remove brake cover (3), drum (5) and shoes (7). Slide brake lever off brake cam (11) and remove cam. Re- move serews securing chain inner cover to left side of frame and brake backing plate (8) to right side of frame. Rear hub (12) may now be re- moved by rotating top of hub so it is on hottom, then remove hub from frame. Drive bearings (10) out of hub. Inspect all components for excessive wear or damage. If inside diameter of brake drum exceeds 5.54 inch (140.6mm), renew drum. Brake lining thickness should not be less than 0.06 inch (1.5mm). Apply a small amount of grease on area of brake cam that contacts end of brake shoes. When reassembling drive sprocket, be sure rubber dampers are fully seated ‘Tighten sprocket bolts to a torque of 5- 7 ftelbs, Tighten drive bolts (21) to a torque of 29-86 ft-Ibs. and stake nuts Drive rear hub bearings into hub with markings on bearings to outside. Tighten rear hub thru bolts to 2 torque of 15-17 ft-lbs, Tighten brake drum nut to a torque of 29-22 ft-lbs Adjust chain tension as outlined in ADJUSTMENT section, at (H, Bend tow ENGINE MAINTENANCE SPARK PLUG. Recommended spark plug is an NGK D-SHS. Elec- trode gap should be 0.024-0.028 inch (06-07), CARBURETOR. Refer to Fig. 7 dle speed is adjusted by turning idle stop screw (8), Adjust idle mixture by turning idle mixture screw (5), Initial setting of idle mixture screw is 1% turns open. Jet needle clip (1) should be installed in center groove of jet needle (2). Float level (H—Fig. 8) should be 0.925 inch (23.5 mm). Do not compress spring in fuel inlet valve needle when measuring float level. The altitude compensating valve (4 Fig. 7) is used to supply additional air when operating at altitudes over 6000 feet. IGNITION AND ELECTRICAL. Ignition breaker points are loeated at left end of eamshafl, Ignition point gap should be 0.012-0.016 inch (0.3- 0.4mm). Ignition timing is adjusted by moving the ignition breaker point base plate after loosening the two clamp screws (B_Fig. 9). Static igni- tion timing should occur at 5 degrees BTDC on compression as shown in Fig. 10 Advanced ignition timing should occur at 45° degrees BIDC and can be checked with a timing light using the two lines on generator rotor and stator reference mark. fer loosening clamp ‘crows (8) tang to adjust float mark (¥4) on stator. Piston Is at TBC when (1) ‘mark is aligned with mark (M4) VALVE SYSTEM. The valves are actuated by rocker arms which ride on a chain driven camshaft located in the cylinder head. Valve clearance should be set with engine cold and piston at TDC on compression stroke. Refer to Fig. 10 for TDC mark. Clearance be- tween roeker arm and valve stem should be (1.002 inch (0.0mm) for both intake and exhaust valves. Camshaft chain tension is automati- cally adjusted by » camshaft chain tensioner, LUBRICATION. The engine is lubricated by a troichoid type pump located on the right side of the erank. case and driven by a sprocket and drive shaft from the camshaft drive chain. The engine and gear box are lubricated by high detergent motor oil contained in the crankease. SAE 10W should be used below 32 degrees F. SAE 20W/20 between 32 and 59 de- grees F. and SAF 80 above 59 degrees F. Oil should be changed every 1000 miles, Oil level is checked with dip- stick attached to oil filler plug. Do not serew plug in when checking oil level. Oil pump operation may be checked by loosening the lower, left hand eyl- inder head stud nut, Slow, steady flow of oil should come from around the loosened nut, After checking, tighten all cylinder head retaining nuts to a torque of 78-108 in.-Ibs. = Fig. 11-Bxploded viow of oll pump. Fain Inner rior oS © Geiet Gove B Gates chain of Spree sptalo 79Fig. 12-€xpioded view of ignition breaker points and ‘advance mochanism. Drive bin (8) tor advance should be removed before re- Serres Tetanus: = fl oe Ignition advance Sse SoA ( On oil panigy eloatanwe betwen Fi. 16-4ntal pst (2) wih 1" mark (1) outer surface of outer rotor (3—Fig. {towards intako valve. 11) and bore in pump body (2) should Riyhaust valve stem— not exceed 0.006 inch (0.5mm), Axial guide clearance ...0,0012-0.0020 in. Camshaft left bearing play of rotors (3 & 4) should be 0.0008- fi clearance ............0,003-0,004 in. 60,0027 inch (0.02-0.07mm) when cover Oo oan (7) and gasket (6) are installed. Clear- ance between tips of rotors (3 & 4) Outer valve spring— wear limit ........ Camshaft right bearing should be less than 0.006 inch : clearance... .0.0024-0,0036 in (O.1Smma}; renew rotors if over 0,008 "Teeleneth --.--. 0.062-0.091mm, inch (0.2inm). wearlimit .... Sitlleraren- shaftclearance . .0,0005-0.0017 in. Pressure (i 1.0945 in.—14.5-17.0 Ibs. avast Boise oem ENGINE OVERHAUL Pressure (« 0.874 in. —39.6-44.1 Ibs. svesnunssa HORE Inner valve spring— : VALVES. To remove eylinder heat, Tet PHB SPI IR Cam chain tension spring (26-—Fig. 1) first remove generator assembly and wear limit ..0.0..0000.0. 28in, ‘free length 3.228 in. intake and exhaust pipes. Remove the 52mm me ede risa wear limit 3.110in ignition breaker point stator plate (3 Ha Fig. 12), screw (4), ignition advance Pressure (@ 0,976 in.—6.7: unit (5), drive pin (8) and adaptor (7). Pressure (@ 0.76 in—18.7- When reassembling eylinder head, Remove screws attaching camshaft to Camshaft left bearing align valve timing mark as follows: sprocket und withdraw camshaft. journal diameter ... Turn crankshaft so that keyway (4— Remainder of removal and disas- Fig. 13) is towards cylinder and sembly procedure is evident. Refer to wear limit aligned with camshaft and crankshaft the following overhaul specifications centerlines as shown. Install camshaft Camshaft right bearing sprocket in chain so that “O” timing Valve seat and face angle ........ 45° journal diameter mark (2) is aligned with centerline Valve seat width 0.028.0.070 i and adjacent to notch mark (1) in cyl- O.7-1.8mm — wear limit inder head. Turn camshaft so that Intake valve stem— guide clearance . .,0.0004-0.0012 in. 0.01-0.03mm 0.0028 in, Fig. 14-View of valve, cam- O.07mm Thai and asocited pats guide pin hole (3) is toward notch (1); wear Hoc 32 Ginn sorbet By Glan wide eller 2 One Ge rller aha Fig. 19-View of camshalt timing marks aligned. ST unl All pointe should be aligned with centerline of ‘camshaft and crankshaft centers. Guide pin 32. thai train pat guides ‘note (3) 18 shown at (8H-Fig. 14). HE Chaat ll ‘atghom aide ot 24. Evan valve guise % Gadepinheto 3 Exhuant valve Sal 2 tiitekiekey 3 Saleen St Spring atalign with holes in camshaft sprocket and install retaining screws, PISTONS, RINGS AND CYL- INDER. To remove the cylinder, first remove cylinder head as previously outlined, and the chain guide roller shaft (25—Fig. 14). Rings should be installed with marked side of ring toward top of piston. Install piston so that “IN” mark in piston crown is towards intake side of eylinder. Standard cylinder bore diameter is 1.969-1.970 inches (50.02-50.03mm). Maximum allowable cylinder taper is 0,002 inch (0.05mm), Piston-to-cyl- inder clearance should not exceed 0.0047 inch (0.12mm) measured at right angle to piston pin at bottom of skirt, Piston to cylinder clearance should be 0-0.0004 inch (0-0.01mm) Fig. 17-Explodod view of 4-spead transmission. 1 Thrust waster sediaiey gor 1 Imp chat ets 5S Spite tener 12 Taleo 1 Sepa Fig. 18-Exploded view of centrifugal clutch ascombiy, Ghats paer Se we i Chath dram Lock anor eitiearng Bamger sing {ton iter 2 Cheha sre 2 Stop ring 2 athataaoe 2 Sipe piston, Ring end gap should be 0.0059-0.0138 inch (0.15-0.35mm) with « wear limit of 0.020 inch (0.5mm). Ring groove side clearance should be 0.0004-0.0018 inch (0.010- 0.045mm) with a wear limit of 0.004 inch (0.1mm). Piston pin clearaneo in piston should be 0.00008-0.00055 ine (0.002-0.014mm) with a wear limit of 01.0019 inch (0.0mm). Piston and rings are available in oversizes of 0.25mm, 0.50mm, 0.7mm and 10mm CRANKSHAFT AND CON- NECTING ROD. The crankcase halves must be separated to remove crankshaft. Connecting rod and crankpin bearing are removed by pressing crankshaft apart. Crankshaft should be disassembled only if tools are available to correctly check and align the reassembled crankshaft. Eccentricity at ends with crankshaft supported at main bearings should not exceed 0.0006 inch (0.015mm). Con- necting rod side clearance should be 0.004-0.012 ineh (0.10-0.35mm) with a wear limit of 0.0197 inch (0.5mm) Connecting rod diametral clearance on crankpin should be 0-0,0005 inch (0- 0.012mm) with a wear limit of 0.002 inch (0.05mm). Connecting rod small end bore should be 01.5517-0.5528 inch (14.012-14.028mm) and wear limit is 0.5831 inch (14.05mm). CLUTCH. ‘The cluteh is a multiple dise, automatic, centrifugal type which operates in oil. To remove, drain lubri- eant and remove engine right side Fig. 18-Exploded view of gear shift mechanism. 8 Shin frat Sinerkiowe cover, Remove cover (21—Rig. 16) and nut (24) then pull clutch from engine crankshaft. Clutch spring (14) free length should be 1.06 inch (27mm), Cluteh spring minimum pressure @ 0.47 inch should be 27.4 Ibs. Frietion disc (3) thickness should be 0.1102- 0.1141 inch (2.8-2.9mm); renew if less than 0.0944 inch (2.4mm), Tighten cluteh nut (24) to 54-64 ft.-lbs. and lock with tab washer (16) 15 18 19 17 Fig. 18-£xploded view of Pos-Torquo cub transmissionHonda/Kawasaki TRANSMISSION, Transmission components may be removed after separating erankcase halves. Refer to Fig. 17 for exploded view of transmis: sion. Gear shift forks are not inter changeable. Shift forks are identified by identifying letter cast on side of shift fork. SUB-TRANSMISSION. Torque high-low sub-transmis coupled to the transmission output shaft and may be removed by re- moving sub-transmission cover. Re- move snap ring (13—Fig. 19) to re- move driven gear (11) from transmis sion output shaft. Left side cover waust be removed and drive chain discon- nected to remove drive sprocket. Refer to Fig. 19 for exploded view of Posi- ‘Torque sub-transmission STARTER. A recoil type starter is, used on the US90. Starter is mounted on left side cover. Refer to Fig. 20 for exploded view of recoil starter. Fig. 20-Eyploded view of alternator and recoll starter Oi et Sncct eutatiniestr bate Noval inder aur Be aoe” Seine cs fig Spon Brive plate