- SHOP MANUAL $90. CLoOL £90 CL90 CD90 CT90FOREWORD “Wis shop moval is a reference ond @ guide book for the proper seivieng of the Honda $0 series motorcycle “he information contained herein is based on the 590 with equal applcatilty 10 the C90, CL90L, CD90, C90 and C190. When no reference is mado to ary specific medi, the tformation shall bo conen to oll del, Infermaton pertinent fo ony specie mocel will be note! The morucl is prepared in soveral diferent pers for converiones ond easo in oectng the pari calor information All servicing infouion including dsaserbly, vacssenély cd inspection procedtres 0 Contained In the respective sections for quick rofornce AI HONDA pretels ore precisonly erginmered with precise tolecree for optimum perfomance, therefore, the proceckros outlined should bo followed very closely and any ropaie or replacements mote when the serviceable lint Ts excoaded. Furr, the spacial tools speciiad mnt be wna in exdor 1 perform tho ropa er toric ne coifactory manner. For profile service cpactin, oll work should be completed promptly ond to the salsfeticn of the customer, this requires © complete line of anticipated replocenent parts realy available, HONDA MOTOR CO., LTD. SERVICE DIVISION ALL INFORMATION, ILLUSTRATIONS, DIREC: TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT 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.1, FEATURES. ...... , i 1 2 2. 2, 2. PERFORMANCES, 3 Cie tie Of he «ue 1 2 SPECIFICATIONS AND PERFORMANCES... 1 ENGINE... PrReVNPre9NrrvD CONTENTS ENGINE... FRAME SPECIFICATIONS . 20 ENGINE DESCRIPTION. .... POWER TRANSMISSION SYSTEM... ENGINE REMOVAL . .. ENGINE INSTALLATION CYUNDER HEAD . CConswction . : — agendas Disossombly (Cylinder Hood Bloc... saneaoncesi a Inspection ond Repatr...esees e242 Roossomby. CYLINDER, Constructions +sseees Disossombly « 23 ap Ae 35 Disossomby . Inspection. Rocesombly QUTCH . Constetion Disossembly . Inspection . Recssembly. OL PU Constvetion . Discrsembly .‘CONTENTS Inspection... eee Be Reomanblyssesvvidccccesbussuivsare 3.10. GEAR SHIFT MECHANISM... .0+s0se05 A. Concetion 8. Obassonbly C_Irspection D. Roossonbly..... 3.11 CRANKSHAFT... AL Constction . : con @ B Disossembly 2... Ga bnmpectlon vu vis cai sauusaseeresoe lest eros 53 ® Geo ecmerbly oda csveyisvesssesecersdieo ce 54 S512 TRAMBMESION: indervensereerenestaesar ents 55 AL Construction... mamma ot 7 55 PSE eee cneveatnoess sence te 58 C._ Inspecticn Ree 9 DL Reassembly : aaceenyercasst80 2.13 CRANKCASE eee eee él Corstnetion. ees : él Discssombly Inspection. Roossently. ceeueseia tae) cir Oe KICK STARTER AND GEAR INTELOCK MECHANISM... POSLTORQUE MECHANISM (CT 90) . Corstrction Disossambly CARBURETOR . Corstnction se. seceecere Firction of Esch Component Adjusiment 2. Adjusimest for High Spee Adjusinest for Intermediate Speed... ‘Adjusinest for Slow Speed Adjusting the Fuel Level OmmoOera erate ne> 4. FRAME ‘ STEERNG HANDLE Fos CONC ras 254 a che Uae cee B, DikossoMbly 6. ses esseeee C. Inspection (steering handel... Dy Reassonbly.-. see ceneesnen niCPP RP eo BPN ED RH DNPH aN PH REN EH EON EP p> CONTENTS: ‘STEERING STEM. - 80 Construction . - 80 Disassembly . 81 Inspection. - 82 Recssenbly. = 82 FRONT FOR. 83 Construction . 83 Disassembly . 86 Inspection. 88 Roossembly 9 FUEL TANK 89 Constsction . 89 Disassembly « 89 Inspection 90 Recssombly.. a FRAME BODY. n Constuction . 31 Disassembly . ol Inspection. ma easterly. = 92 SEAT... 92 Constnction Reiners 92 Disassembly... = 92 Inspection. «+ 93 Reassombly. 93 BRAKE SYSTEM 94 Construction. : Disossembly « ianas 94 MUFFLER, 7 Construction . 97 Disossomby ean Inspection. ..++++ Le Reossombly. es. 7 AIR CLEANER, . 2 98 Construction . 2298 Disossombly « +98 Inepection...+e++e++ 29, Recesembly. ee seeeveeee Te REAR FORK AND CUSHION DAMPER . = 100 Construction « = 100 Disossombly « oe 10010. 6. 8 BRAKE SYSTEM 6 9 DRIVE CHAIN. . WIRING DIAGRAM SUPPLEMENT TO $90 ZK1 SUPPLEMENT TO CT90K2~K6 SUPPLEMENT TO CT90K8 (77) CONTENTS 143 144 us 153 159 m1, FEATURES 11 ENGINE ‘Tho engines wed on tho HONDA 90 sees co bases idonical wih the mor ference in thet tho $90, CL80, CL90L and CD90 cre equpped wih « monslly cporoted clutch ond tho C90 ord C790 having on cvrematic dich. ‘A. Chain driven overhead comshoft The comshalt ts ctiven by 6 cersion torsion chin, casing let operation and proce voho Tining. Further, it enables grecter power cu'put che to aveiblily of higher oporarng RFA. 8. OHV and semispherical combustion chamber The overhead volve design provides gracter oi incke into the cylinder ond a consequent Fighor vyokmetic efeerey The seri-schericel conbustion camber assis snacth Nome propagation which Is futher enbonced by the reerpertion of espacial squish area. €. Double oil fter Tho oll system incorporates a fee mesh screen fit ond @ centifigal Mer Jo apply the engine with highly closn oll. This minimizes the woor 10 tho engine componins, reducing maintenance ond cextonsing the life of tha encina DL Clutch Fight ction ckich lever & employed on the $90. CL90, CL9OL end CD9O, with cutemotic lich drive plate —> clich outer —> Friction disc — chich center —> primary drive gaor—> Primary driven gocr—> trensmission main shaft — inain shaft gear —> counter shot gsor—> counter shaft —> criva sprocket —> dive. chain — dhiven sprocket — to the rear wheel, pro- gressively in succession, (Fig. 3.2) 3.9. ENGINE REMOVAL $90, CL%, CL9DL, CD90 1. Remove the step ber 2. Remove the muffler. 3. Remove the loft crankcase rear cover ond un hook the drive chain from the sprocket (Fie, 3.3) NOTE® Tie a ploce of wire fo both erds of the chain Yo prevent the encs from boing drawn into the coin case. Ths will focltate the work ding ‘engi inctalation, ($ 90, CD90) 3.3. Remove the chive chon © Drive cain2“ 3. ENGINE Diseornect the clutch enble @ from the clutch (Fig. 3.4) 5. Disconnect the cir inlet pipe at the cylinder hood end also remove the high tension cord from the spark plug 6. Remove the battery cover ond dlecornact the bottery lear from the battery. ig. 3.4 © Cites cole @ Chich lover 7 Unhcok tho broke pedal spring. Remove the Tuts mounting the engine (3 for $90, CL90, CLPOL, 2 for CD90) ond the root engine inder bot. Pull cut the two 10 mm hex bolt ord the engire can be separated from the frane. (Fig. 3.5) 90, cr90 1. Ramove front cover (C90), remove gure (CT90). Remove the main pipe cover (CT 90 tnodel from fare No, 000001) 2. Remove the step bor, 8, otrowe tho left crorkcote rear cover end ro ‘rove tho chin joi clip to dscermact tho crivo Note: Tie ¢ pleco of who to both ends of the chan to proven tho ards from being drawn into tho Fig. 3.8 tose th be! po ‘hain caso, This will foeltto the work ding @ et pe @ Fg» nev ba ‘nghe retaltion (C90). 4 Remove the mur. 5. Diconnact tho air inlet pipe ot the cylinder hood. (Fig. 3.6) Discomect the elecical loads ot the com rectors Remave the High tension cord from the spark rho 8 Unock the bake pedal spring 9. Renove the 2 engine mounting nts ard then pullout the roar engine under bolt ond rear engine hanger bel. fig, 3.7 fegee canny (7 10. The engine con be removed. (Fig 3.7) -3.4 ENGINE INSTALLATION Gores, the enge Fataltion i perormed ia the reverse order of serve 1. Set the engine cn 0 block ond so B under the trove Route the engine wire heress sp to the batlery box whore tho engine ond frame, ond temporary Ivert_@ scrowstver ot @ rad of ‘pgroprito © tover @ Rotor paler3.5 CUNO HEAD 4 Romave the rockor am sido cover. Remove tho contact breskor ossombly @ ond isconneet tho lood wire @. (Fig. 3.14) Fig. 3.14 femovig ta eorac tester erty © Contact eter onertty @ Leod wire 6. Remove the spark advoncer by removing the hax bolt and renove the 3% 5.2 dowel pin 7. Remove the point bose @) by taking off tho tives mounting serous. (Fig. 3.15) 8 Rotate tho crankshaft so that wondhu key ig oligned with tte 3x 5.2 dowel pin hole in the canehaft and then remove tho camshaft by Urzcrewing tho wo bolts. (Fig. 3. 16) CAUTION: Perform tho canshalt dlossombly and esserbly wih the cylinder stud bolt ruts tightened, Fig. 2.18 Romoveg ho coma 9. Remove the cylinder head cover ond tho cylinder hood. IF the head's Night, top around the parting sxfoce of the cylinder head lightly with a seft tose harmee 10. Disassonbie the valves using @ veh lifter D (Toot No. 07031-20001). (Fig. 3.17) Fig. 2.17 Dansenbirg te vlees © Volee Mer2 Fig. 3.18 Chacteg cylinder od wong! © Cynder toot ang tod bod Fig. 3.19 kepoking warooe eyladae heed @ Cyindar too @ Sad pope valva gv siete D cyander gon 3. ENGINE Inspection ond Reps The cylinder heed @ is exposed to the high presse ond tonperctxe resting from the combus- tion of the fuel mixture futher. when the eyiinder heed is unevenly torqued, it may develop cracks oF worpoge crd wil be the cause of defective sealing between the head and the cylinder ond result in (25 Jock, cir sucking, with consequent drop in com preston. ‘The warpage of the cylinder heed does not velop sixdenly and it may be overlooked, there- fore, coution should be exerciced curing reassonbly Since the uneven toraving of the cylindar head ie @ very common faut To inicect for werpage of tho eylindor hood @, epply 0 thin coor of blving or rod lead @ on surface plote and work the moting surface of the cylinder head on the suface plate; the warpage cn bo dotorminad by tho transfer of the bling on to tho cylinder head. (Fig. 3. 18) To cowoct tho wornage, lop the cylinder heed fon the surface plate with o #200 semipaper, Fray frich by using a $400 sendpaper ond thn inspect ogcin with the bling. (Fig. 3. 19) 1. Inspect the conbustion chorber, inlet ard exhoast ports for cod. 2. Cylinder head conbution chamber, Stoned valve Heed vetore We~teee ‘ah tw spa pig ited | 11,0981.122 eu) 3. Inspect the valve guido ond vole stom, Valve cerenee| Standard vie | Scene goimccane | 0.06 Inet | cosooe~s.ooravn | soc0z8' 2.93—005e | Ow Etout | conaramo.ooabin | c.003eh0 Check the volve guide diameter at the top, center ond bsttom in both the X ond ¥ aves, wing 2 precision cylinder gauge ©. Check the velo i © micrometer. (Fig. 3. 20) a4. Impact volvo guide We de, Wet | Sead vo Onsise Dia | i'gpgara.3966 nt) o.st0~0.65 Ierferenco Ft |g nent ies a Feploce over 5528 575~5.485 bide Oe, If the valve guide inside lometer Is beyond sovvicedbla linits, it may be repaited by using & rearer @ (Tool No. 07008-00101) end replacing the vaWo with ore of an oversize. (Fig, 3.21) 5. When eplacenent ef the valve guide becomes rnocossory, romove ond roploce with an oversize 9.80, we tho vave ide remover (Tool No. 07047-04001 ord tho valve guide criver (Too No, 07046-21601) for replacement operation. ‘ior insoling the volvo gue, use reamor to cbicin the proper valve clecence. (Fig: 3. 22) 6. Valve Soot ‘he condtion of tho vole soar plays a onirert lin doting tho perfomance of tho engine, futbor, B sores ot 0 moons for Gisipoteg tho heat from tho valves. ‘A volvo seat in good condition shoud have @ ful sxfoce conlast with the vaive fore Senda volo @—0.7~1.2 nm (0,028~0,048 ia Servcecble lint—in excess of 2: (0.08 i) ‘Tha valve soo! contoct con be checked by cpalvng 0 thin coating of bing or ro lod evorly on the entire sixfcee of the valve faco «2d rate the valve whil hole it femly against tho valve soar, A good valve coating condtion wil show @ uniform nd continous width oF bling on tho valve seo! Rewatting of the vale, sect is porfermed by © sat of thee caters D. The 90° cuter is sed for facig tho volve contact roa, and tho location ard wih of tho seat cortoct roa Is ceconplthad with tho 60° ard tho 30° cutters. Finally, the valve lopoing opuraton is performed by lopplng the grad val foes tis wave seat Using a literal enaun of laping compound ‘on the valve feco ond watk the valve back and forth uing @ wetion cup lapping tool. Wesh off the conpeund cenpletly before king the fost ‘oF boforo assembly. (Fl. 9.24) 3.5 cunpR HAO Fa 2.21 (D Valve guide seaner — ) Cleder hod Fis .22 @ Yar B Satie 23 Vales wat cack awe Yet seo cone wd Fig. 3.26 towoirg sh vole te (Valve wat Geer» 3. ENGINE Fig. 3.25 pacing te valve wo! covet ig. 3.28 feaw and ile woken rey Fig. 2.27 Mocauioa vlve @ Olt gone @ V Heck Inspection of valve sealing Assanble tho valve into the cylinder head o# shown in Fig. 3.25 20 thot the valves ae well sted ond fil the cylinder bead combustion char ber with ol, inject 0 blast of cir 2ks/em? (28.4psi1 ih from the int ard exhasst paris ond if ony bibbies sould oppor tis a Indication that the valve sects are not completely sealed. (Fig. 3.25) (o)_Eshou (Fig. 3.26, 27) Sina ole | ean ] ieee cree sion do @ | 9 £435— 5445. | tela. war Semae® | piaicoaiasin | Sate aziaets eos 04~08 | teploce i eder Mees @| ac2scoasew | “ES 10.171 Cenconnicty| G.2TR | enlace i over freee] $3.495~59,985 2.103~2.108 in) Servicestle linit —> foplace if under 53,00 (2.09 in)3._ ENGINE 4. Rocker arm (Fig. 2.34) oer spe) 03 1o013ia 1o.wd~I0.018 | keleca fone State tore |e aparaapdia | 101 14d Hla 9.96 Reet om @ Sipom toce — @ Seatt bre NEE. fects com sti ig. 9.97) yar | sentia eae | seve ua Salt 49 | i aeze~oanaam | 9920 13934 m shot eo1s~eo1a ‘Gowen | 0.c005~.0017 apace if over Fig. 4.37 Race oro shit D. Res bly 1. Apply engice oil 2. the wove ston before exzonbly into tho eyndor hood. 2. Asontle reelar am ond recor am shalt to the cylinder toad cr instal rocter am side cove. 3. Imo the cylhcor heod. (Fg. 3.38) NOTE: Exacta caro to rako sue that the cyllador teod gost, cylndor stud goslel end can chin gaskets insfoled properly to prover cil leaks. 2.38 Asonbing No cylinder head © Cyngor os @) Com ipaclor @ Com chon install tho cylider head cover and tighten the ruts hagoeally and unfomly 10 180~200kg-em (14.5~18.11b+f1), Improper toexing will owe oil look. (Fig. 3.39) Fig. 2.29 Torro cine of ender Deed5, Position the crarksholt 20. that the woodutt ey D is on the cylinder conterine ond in the dliociion of the cylivier head. Align the "O! snok @ on the cam sprockat to he Irdex mark on the cylinder heod he soracket menting bolt holae will bo in line withthe cylinder centerino) and thon connect the cam chain (D. (Fig, 3. 40) 6. Slide the canthaft @ into the eylindor bod through the sprocket @ withthe ph bole toward ‘he hace cover The volve end the piston are in the top-dood canter pcition of tho comgression stroke. [Fhge 4.41) 7. Assontle the point tose @ on the. carmhaft fxtonsion using en ol seal guide tae! (Teol Np 07087-039011. (Fig. 9. 42) Darege fo the oll soci may vest if tool is tel 20d, reautng ln ol loc, & instal the 2% 5.2 ido pin ond assemble tho spork exvance. 9 Aswonble the conact breckor assonbly and comect the lens 10, Assemble tho A.C. guneratos en the ranks, + Ferferm toppet clearance djustmort and ign ion fining 2. leslall the point cover and the loft ererkzave corer 3.6 CYLINDER A. Consirvetion Tho cyledor is mada of spacial cost ren, The Inside ejlindor wall Is expoxed 1p high lonperatue ‘and presse ‘ogether with tho wearing ection of the reciprocating piston operating ef high spoed 10 Froduce o great woaring efloct, Added to this, tha dust in tho oir ced tho foreign object ond the rmovalic dust contaminating the oll will estan the fote of weer therefore. exaquate otlartien should te given 10 tho clecning of the air fitor and the cil change, (Fig. 3.43) The piston rocsives the combustion energy. ond hharsnits tho high reciprocating motion 10 tha cran- shalt where iis converted to the rotienal motion, Due 0 the high sped friction berwoon the piston ‘end cylinder, the selection of the materials end the tolerance of the moving patls must be selected with ‘get core, 3.6 CYLINDER 3s Fig. 2.40. Comaaing te con chin 1D Wood ley @ “0” mak @ Con chan 3.41 Aisoing the conta @ Condit @ Cam sprocier 4.42 tales he pont bow) fos bow Fig 3.43. Cylinder3 3 ENGINE The. pton is on abminum casing made from Soloc! maroriol. (Fig. 3.-44) The materol is light are suitable foc high speed, bn odtition to ving good heat conducting property 10 diisixxe tho heat reply. cffcint of hoot exporsion ' small, hus misinizing a ‘he warpage a! elevated temperature ond per «@ tna piston 10 eylnder cleoroncodsign. Tho shepe of the piston {s.0n elliptical toper. The heoe of tho piston, compared to the skit. is exposed lo Aigher tonparance ond shoe the exparvicn is greater, Fig. 3.44 Paton 11 ' fopored smaller tonerd tho tep. The tape a ing ef the piston eso torde to lestan the piston slop when the thot Is Ighily sropped without the engine being loaded. The piten enploys a tres stop taper. The piston pin bo8s area is ado thicler, thoveby,cesu- ing in greater expansion at high temporatre. Foe hs ea%on, the eianetor of the paton skit is made smaller in the direction of the piston piso that ot tne igh operating terporctue, the plsion wil expard into c true circular shope, Tho skit is ‘corstanty provided with Nexbilty 10 cssue tha! ro oforncien wil result even from extended corrinvoss a, 34S Cynder chew ving. @ ofr “The plson pin i oftiet Im (.04i0 from the piston contetina ie ho direction of the hlet side £0 that won the piston appreaches the top-doad- cortor of tho compression stroke, tho side load from the cylinder moves from tho right ido to tho lot. Wih oO" offse, the pont will move to elgn wlth top-deod:canter of tha comprastion stoke, (Fig. 9.45) ‘As shown In Fig, 9.45, tho point of mexisum conbieton presto occus after the topdeai-conter, therefore, the pursese of the ofiet is to move tke polet tonerd the point of wacker prosnue whichis before top-doat-certor, ord by 10 doing, eicapes @ the powerful pressure rovernnt and cts it posible to lininata the piston slop. The piston rng perfoms a vial fncten of au Ita proper combustion ond trosnision of the re aunt fore, ‘The top end second ng vive os « zol forthe @ ‘contusion chonbar, the oil conel tng trap05 the ‘excess oll fom the cylior wall to. contol the cylinder wo vication. Farher, thoy tranmt tho high temporatire of the piston Io tho eylcer wall whore I i dissipated cut through the cylinder cooling fn. @4.5 CYLINDER a For this wcson, 0 epociol lly of ost iron fz sed 10 provide strergth, wear ‘etistance, heat 10. sislonee, and godd hact condieting properties end futher it is given parlerizhg reamert or forrox coating. Tho top ring especially ts ploted on the oer surface with hord chrome and Mrished by wot honing, To prevent fktter, the thickness of the tgs are mode raxiower end thickos. Inetlo fr made snalier to Increate the pressure agaist the cylieder wl, Fusther the top and second rings are made ot 0 slight toper where it contacts the eylinder well £0 that the time required for woarsn Is lessened. (Fig. 3.46, 3.47) 3. Disorsembly 1. Remove the cylinder hon! cecerdonee with section 3-5-8, 2 Remove the com chan @ from the timing sprocket ond remove the cylinder ( togetter with tho chair. (Fig. 3.48) Fig, 8.48 Poor © Ten compresion reo @ Sect competion tg © Osho Figs 247 Fister veg Sealed ad et song ton © Ton competion sea ) Secord Compson tha @ Ol rho © Seay forctin © 21 seorng Fig. 2.49. tomomng tw ede © Gyineer @ Gam adn28 3. ENGINE ig. 2.47 samovig Ho psten bi Graton pi ete @ ran 2 Fig, 2.50 Renoving be pie sing @Pisen vag” GD Paten” (Pon ving vamevng toot 4. 3.51 Mesurng the vier ove © Gpieder gone @ Cyn 19.42 Meaning ple st dowste @ Paton | @ Miconaer 3) The com chain guide rllor can be removed from the eylieder by reneving the cam chain vide raller al 4, Ronave te piston pn clip Gand pxsh ost the piston pin to cisseanblo. ho piston from the comecting 1d (Fig. 3.49) CAUTION» When remaveg the piston pin clip, core shoud be exercised 9 thot the clip Goes not drop iio tho erenbeata, 5. Reneve the piston sings @) trom tho pion by using ting removing Joo! special tool. If no too! Te ovellebla, the rings may dso be ro roved by ford, ky spreading the ring ot the ‘pening with both hove, the rng ehould nt be twisted, (Fig. 3. 50) Inspection 1, Meowro the cylincor bore, taper, ourol-rourd with @ precision eylindor oxugo @). Tako the rreatirement o the top, middle ced bottom in both the X and Y ans, (Fig. 3.51) 901 caoeodin | Resor if over cow | Tbs inode ~400) | Repiose ome 2, The clearance between tho psion cra cylinder will geatly afr the ercina performance. Bo- caso oF the piston being elliptical, the cleeranco is contolled vory closely. The cloences are rot the some, however, if eny area ie greater thor O.lmm (0.004 in), the eylinder should be robored ond Fited with on overs piston, Oversize plo aie ovalltle in 0.25, 0.60, 0.75 ond 1.00 my (0,01, 0.02, 0.03 ord 0104 in) 4, Whan removing carbon daposts from the puten top and cing @-oaues, eres should ba exercised © ashe 10 cause any scrotehas or camoyes 10 the piston 4. Measie the att ef the piston perpandicutr to the piston pin hole. _¢5, Meawre the pitton rng #de cleorance with a teress gage. (Fa. 9,93) [ten | tercne vane | Seven me oei~o0s | tee on 6, Pitn reg groove. (Fig, 3.54) ‘ordad veiw [Sericaatle bit ‘wim gl] aaa ameter ©) g.zavincn ration Groove it! nami.22 | torloce over 0.0472 ~0.84e0%n |" 1.0512 Gleave wid | ogo on ro") opens oot W082 Ferloce 34 oto: 2. Plsten siege Mocsxo the reg end gop by Ineortng the pton ring (into the eylnder so hat the rng is a right ongle to the cylinder ovis. (Fig 3.93) [item || Srmdard elon) Servioabe Unt | piace i uae hs 10.048 n find) niremt.i90 2rd | c0n6460. 061% ve Die 07st iacraci | dei iaanien Q7~12ka | Repece oder nmzedion | Beialdszn arsmoss (woeredia in 4:38)01 | wyopirceaisrin | ‘Os 1eot0 NOTE: 1, Oversize piston rings ore ovolitle in four sees; 0.25, 0.50, 0.75 ond 1.00 mm (0.01, 0.02, 0.03 and 0.04 in, 26 CYLINDER 2 Fig. 3.49 Alacuing the piso sig sew eloronce @ Paton @) Pion sag $2. Pat 1p ed cap Paton © tenes ign* 3, ENGINE 2. When mckirg pbten ving end gap eoser °) ment, insert the tng carefully into the cylinder to proven scratches or govgos to the cylinder wall, D. Recssenbly SS 1s Feel ie dan GE GH tHe pion’ ‘hs % ‘aro moma os wo rene, Th ton tro mtb Ist Ti CAUTION: 3.56 cng te ng oor Wes few ston tig ttle 9 check Pw tee shold bo ma 10 ttre that the sing fe Fey F ine grove This can ko done y ring to the ptr hg etal et pen aeow Gh 3.58) The tings must not be Wastalied upside down; ths il sa ol poping Th pa fhe ! ‘tng Is etched at the end with the intiol of the nefaczn's rane. (Bi 3.57 Un of opin tg 10 wil fetta intone revert posit of nobel 21, Ant te io 16 old of he comeing only sgt tr pro sos fe elec to hu he tn aA ®m Ma N87 aor wo at @ fw pin pte @ Mat CAUTION: The pion ma te vena 20 tet the “IN (sang on th pene over theo nh age tenon th (Fig. 3.58) 2 Arto he cam chon on en a tale 1 fc 4 tel he ec, cAmION: Th sin oop of te thee pon te seed 120" cpr Uke ofthe piton ing conpreivor feo {Toot ® No. 07032~03301) fo icin th cyider Avanti wil prevent doncge to te piston rg od fh, Q enn it wil snolty the wad. ae ‘Chect to moke sue that the cam chanber gases prop sot. 5. Install the cylinder head in accordance with aD pexagiph 9. 50.7 CAM CHAN TENSIONEE 3.7 CAM CHAIN TENSIONER AL Construction Tho camshalt is driven off of tho drive serocket ‘on the crankshaft through the com hain which is located oF the elt sido an reused within the: com choin chamber. (Fig. 3. 59) Fig. 8.39 Con cian wenioner axa logon © Con seve @ Con dow enioner @ Com sto @ Can dian pide specter @ Gon cir © tig wrote @ Cam cain cic rot tonne @ Tersonr pth vod2 ENGINE B. Disoss bly 1. flenove the A.C. ganercter in cecordance with Frocode descibed in section 3, 58, 2. fenave the camtieft in a:cordonce with the prozedte daveribed in section 3. 58. = 3. fenove the com chain from the tinirg sprocket ‘ond thon the cam ebsin gua sprocket, 4. fonove te com chan tersionor D by rem ing the thioe Simm screws (@) attaching the cam chain tonzionercoting plote (Fig. 3.60) othe tenlones, ig. 9,40 Removing te com eren Yelner Com cay weiner @ Erm cron poht ser @ Tenioror etieg pla 5. Uncerow the 14 0m soaiog pleg ( from the end of the tensioner uitwod ord remove tho spring ® ond rod @ (Fig. 3.61) Fig. 2.41 Renoring te tetera pth od @ Mm slg og @ Seg © Tesoro pw cod Inspection 1. Check tho com chat tensioner for any damage Tien | Sendo ve tr 70m Replace If ued ‘amnjcs~8i g | teplece it under feng J agstmazrs~ | “atmm/Og Pinon) | (1.994 al 408 ocd Fla, 2:42. Component pars of the com chin teninar a @ Tenderer eubion bow D, Recssonbly @ Teniorer pu rod @ Tentorer sing 1. Asomblo the companant parts In the roverse @ Ver sot woah Game Frocedue ot dizassenbly cescribed In. soction 3.78,8 CLUTCH 3.8 CLUTCH A. Construction The function of tne cutch is 10. tenporaily ci ‘roage the tranamitting a the coir mcticn between the engine cid the ‘renanislon ding geor change ‘ord then after the csar change, permit a smooth power treition. The condition of the clutch wil have a vorying effect on the ficiency of the power trorenission. “The clutch on all of the models are of the cor ‘ventional wet type multicle dsc. The C90 ond C790 nodes incorporaies:cn avonctic footre to opecale the clitch engoge ond diseigage function, whereas, the otter adele are provided anol functions Construction end Operation of Clutch The clich fs betwee tha engine body ond the ocr sh tronenision. I eormects ox discomects ower torsion when reared, ach as in goor Siting, 6 tating the angio, 0 ‘Accordingly, sich pois 0s the degree of engage- rect cccurcy, the abitly 40 deengnge coneletely. sneotinass ond slippage wien engeged cr cl enoond, otc. bacoma impotent. (890, CL 99, CL70L, CD90) “he cich of the model $90, CL90, CL7CL, CD90 ts wot muliplote typo. At shown in Fig 3.63.4 cas Fig, 3.64 when tho right erento cover Is romovee, the clitch ower portion I exposed. sie. tho clutch sping, deve ple, cltchplro, ond catch fiction dic ero estonbied. The friction dic. has tooth cu ini ner clcunforenee, is prion fing tho spl cut in the extandl circunfernce of the dive geer, ond it seupie eto aunt wth th drive ear In tho drecien of roretien. The ceive. gear is mounted on tho ersishat theugh the dutch conor ide cd car rotate fealy on the ernshaft en the ciher fend, the cre grooves cu in tho intern of the do pte tof the spiro eat tho tip of cronkhelt tho dive plate is fastered to tho crake ‘bait by 018mm lock nut, fering a segle nt Sica, «x tho extacor of th chive plate end cbich poe, teeth engage the grooves ou. ithe interior of the chich hoisieg, the cuter ebtch, the erive plate, end the cutch plate rotate together with the crerkialt, Therefore, hon tho elich is engaged, Fig, 868A. Cluich mchonim 570, 0.90, CL9EL, C40“ Tig 3.49 Giteh nochanin €99, C190 © Cluch emer D Gee peor @ Chien wei © Cheb tlt apron @ Dri ola @ Cch cote @ heh aig @ Chich com pro 3 ENGINE the gre plate, clich ftion dsc, ond the clich plate cro hald by the cltch spring foring a single unit by mutual Fiction ond roauting in the trons: mission of the rtetion of the ereniahat fo the drive ear. ‘The dive gear is engaged with tho Tho carburetor produces fel mixture which is a Fig. 3.114 Grnraonind vow of aber © ine se of eo Ae sow & foe ehorter {8 Ope of th ae cw oO @ Nese ot oder & Sow jt © Nel o © Art © Wels robe @ oe rae © bi © fos (Outer ado of etree © Fat om © i Bnd hen @ Orr how Fre —_ @ Woh ioited to the thotle opening end engine speed. However, for “hot pupese, i & necessary to hoep fuol level censiont in the cabuetor. This is per- forred by the faa! chamber. The fuel from the fuel tonk passes through the passage (14), between volvo eat (1) one! th valve (14), and than enters the flct chanber (2. Tre float 1171 becomes uoyent oi fuel anlees, raze the float valve (15) hinged at the Toa! aim and which seats he oat valve into the valve seat to siop the fow of the fol. When fuel in the foot chamber is coneaned (nd the fuel level chops, tre float (173, lower along ‘with the fual laval. Clacrance between the vale (16. ond the valve seat 115i, allows fual to entor the float chamber, By repeating this. the level lways maintained constont. A soriag ts filed ino the section of the volve (16) which contacts the fect orm (181, ond prevents the valve fronoscile tra. Whor ‘he veticle is on a grade or when dit is bdjed betwoer the valve ard seat, govoline will cover flow and enters the cylinder, Therefore, for Frovonting the fuel from rising above @ certain level ‘cn overlow ine Is instoled. (Fig. 3.116) (3). Choke ‘When en engine Is cold or the tonperaure Is low during starting, a ich fuel miéure is temporary required. This can be had by the use of the cho. When the ctoke lover % pulled wp, the choke [201 le filly cletod. The opening (28) it normally closed by the relief valve (21), however, curhg stating when the thotle is cpened aparaximstely 1/4 and Ie Hick starter operated, the negative presue created in the cylinder will couse the roliof valve (21) 1© open ky the preper amount (dotted section 24) end permit oir 10 pass though tte carburetor; this flow of air deowe the fuel out ef the readia jet 41 10 provide on cir fuel mixture Keo! for stor jeg. Aftor the engine stars, the inlet negctivo ressve increares, ond eaizer the relief valvo (21) to open coxependingly wider 10 ossire ¢ stable nist, Thus, the opening of the raiaf valve (21) changes cording 10 the opering of the motte valve (6), section (25). (Fig. 3.117) B, Functions of Each Compons U1 Mein Jot Its main purpose is to obtain a proper fuel mintve ratio by contaling the flaw of fuel wan tho theotia 2.16 CaRaureor 's Tig 217 Chaleo Fig 3.120, Nevals jot Fig 2121 oy a ENGINE ts fully opened (eperating ot the maximum speed, Howeter, the ful rato is inuenced down to exoue Cone half thottle opening, [Fig. 3. 118) (a Air Jet ‘To provent the mixed ga: tram becoming rich ot high speed, ond loon ot low spved, ai Is fead to tho needle jet holier. The furctin of the cle jet is to controle the amount of cir. At @ constant throttle epeniag, the larger the ai fet, tho smaler will be the difermnce in fuel Now botwoon igh ‘rd low speeds, one! a consequent redition in fue flow. (Fig. 3.119) ( Neealo Jot Tho noodle jet contol, the fuel which had boon ‘metered by the main jet betweon tho inermadiate ford full throttle. The control is performed by vary Ing tho clearance between tho neodle jet ard jot neadie descrited in tho folowirg section. Hole in the noedlo jot is meso with high degree of prec sion to esse czoyate ye! contol. (Fig, 3.120) 4) Jot needle Tho jet nescle, in connctien with the cbove mentiorad needa jot, controle the fuel mixta retio ot intemediate tvottlo oporing (nally between 1/4 10 1/21, The long tapered jot needle is fitted in ‘he confor hole of the three valve with the tapered lend ingried into the neac jot, Tho vertical nove- ent of the theolle. valve correspondingly moves the tapered jet noodle within the needle jet, vory ing the cloarence between the nescia and the jot, and in tis way, the proper fuel mixture Ie ebtainod in relerence to the position of the tattle van Thore are five clip rcove postions on the head (of the [ot raedia, The fue! ixuxe becomes richer 5 the clip is moved irom tho fist g-oove (top) ‘owad tte fiih groove, (Fig. 3.121) ‘S) Thole valve The throtile waive regulates the amount of ir taken into the engine, this estetilly contols the engina spied oe well cs the power culpa, in cok dition, the totte valve performs other lmpertont contol funtion. The skit of the thotie valve is cu ot an angle fn tho inlot sido, the sizo of this evtoway Is do- signated by the culaway sunber which is described fn succeeding section F.2. By changing the valve with « diferert size cviewoy, the negative preswre in the vicintty of the needle jet is changed, affect. Ing the Fuel flew ord consequently changing th fuel3.16 CARBURETOR nite roto. This change ‘s effective in the slow speed range ketweon idling and 1/4 throttle open- 'pg ond has no effect abot 1/2 throtile opening. (Fig, 3.122) 161 Slow jor Tho slew [ot meter the Now ef tho fuel et ling ‘nd in tho slow speed rengo, ond cowes the fuel to be otomized by mixing it with the air token in from the air Hloed holes. (Fig. 2.123) 7) Ab scrow Tho ole serow roquitos tho amount of ci entering the slow spoed system, The clr which pawes by ‘he cir scrow mixes with the fuel from the slow jot ‘nd is discharged in the propor miktuo, predvcng ‘0 spray 1D asst vaporization, (Fig. 3.124) Adjustment In oder for the carburetor to produce the mex: ‘mum performance of tho ergia's copoly it mist be adjzted £0 that @ proper fuel miso tt vail: Clo over tho cemplate speed rnge from ieling to the rxtinum speed, and futher, te oble to. mon. Jan this condtion, Ths carbteter hos bean ee- siowed and manufoctred 10 selify theso conditions by the prociton menfoctue of the components ond specially in the wwe of aporior qusity weor vosstant materi. The jet reed, noodle jo, hot ie valve ord the Noat valve being susceptible to eae, bas been modo oF moterils postasing goad wwearng chro, procsleny nenloctived cr surface toate 10 ave oxterded Saislactory sevice witht change Jo performance, Tho adjutnerts ore ocewciely made ord par. fomence checked by both the manufacturer ond Joclary prsorne 10 ase that tho setng of te vious pats are pris, Thorefoe, when making ony. adusimens, performing engine ropa or roploc= ‘ng wom pats, give particular cltertion to he fol ‘owing point. @ Nolo sxe that the engine is oxjuted in cxcorcance with the specifcotins @ Cwck to 26 thet there cre mo or looks the carburetor maurtig flonge. ® When the conlirg compenents bocone wom, replece with new parts. Fig. 3.122 Tote vole 2.123. Slew ee O hero© Main te Fig. 3.126 tt roote. Tonle ve © tern @ Thette vave ln soe. Ak sew © Trvtte waive © Airscen tNoINe Adjustment for High Speed The conic of the fuel mistwe between 1/2 throtle to full tote openina is the function of tho main jot. (Fig. 3. 125) The deterninction cf the fuel mixte ratio is mode by the following mated. 11) Ar fol trots, IF the ergine speed increazes wien the choke is slichty closed, it is on in- ication of lean mistve. Progesively replace the min jet ond note the performance, (rain fats ‘rs numbered in sequence of S1 [21 if the ergine speed drops when the choke is slighly closed, i indicates that the main jet ithe: of the proper size or that it my be 190 large, in wtich casa, perform the following check to mako the. determination. (a) If the moin jot hod beon of @ proper size, the engine speed wil drop when the main Jets replaced with ore of a smaier size ; the speed will increase iF the choke is slighly closed. In such cose, the original jot was Cf the proper sizo ond therefore should be reinwalod (bI IF tho mein jet hod been 100 large, replace tho mein jet in saquonce with thot of a smaller size ust the corsiion ih fa cbove ‘is found and then roistall tho proper size lew E._ Adjustment for Intermediate Speed The fuel micro cxstnent in the iternediove 000d range between 1/8 to 1/2 thettle qpening |& mate by relocating tho jo! neodle gostioning el ‘ond roplocing the trelte valve with that of @ of- ferent size extawoy. However, chorging the throtto vale will ako eect the operating cendition below the speed rengo of 1/8 thetle opening, therefore, it is vory dificult to aciust for intormodiore speed by replacement of the thotle valve only. I is recommended that the adustment forthe intermediate speed be mode by the jer neadle, ard stay within the rorge of occeptcble accoleathg performance ‘ince this would ove a fuel consumption tht is uch lower. (Fig. 9.126) (1) et noodle (a) Black snake emited from tho exhautt goe ‘of Intermediate speed Is cn Iniicaion of 10 tich o fuel mixture and is corrected byadjustig tho jt needle to a lower position (8 Flot spot (inilor to engine miisingl dng czcolerction or at internedicte speed i cates thot the fuel mixture it foo lean ond is conected by adjusting the jet needa to © hoter position (21 Throtla vave (cutaway) Tho thvttlo valve is numbered so that tho larger the stomped munbor size, loaner the fue mature willbe. When changing the thctle valve, 1 mutt be considered that love spaad wil be Coffected as wel a: the Invernodiate speed, F. Adjustment for Slow Speed The odjustaent of the fol mixture between 1/6 throttle opening and iding it mae by the or screw ford the cviawoy of thretilo valve. (Fig. 2.127) (1 Ale scow Tho feel mistore adjustment ot idling speod it made by the Gr screw. Turning the screw In the clockwise crecton will produce a fch mine ture; @ lean mixtre con be hed by wining the ser@W In the courter cleckwise direction. How: ‘ever, the idle screw is rot oly to ocfust the ‘ding sirce attention should clso be given to the frarition period trom iding to thovtle opening. in other words, the fuel mixure to provide the smooth operatin at the point where throttle is ‘opened slightly beyond tho idle speed. Adjusting the Fuel Level Sirce it's dificult to measire the acta! height of the fuel level, the mansiranent of the height of ‘he foot valve Is mode which, will correspond 10 ‘he belght cf the fuel. Float mocauing method \al Top the float lightly fron loft to right with tho finger ard lozate the position whore tho tip of the foct valve just barely comes. in RETOR ia 3.128 Whonremart oF Val in he fom cher @ Fox om @ Fost Ive wondard nrloce n” 3. ENGINE contact with or @ clecrarce of 0.1 mm (0.004 ind exist betwoon the foct arn. (Wn this position, the distonce betwoen the baie of the Meat and the carburetor body @) shovld measure 21,0 mn (0.827 al, IF adjustment is required, carefully bord the oat axm by. the proper enount CAUTION: 1 Spring incorporated in he base of the flea! volve, therefore if the oat arm is presied agait the valve, the serirg will ecade into the velve and tne indication will rot be-cbicinad. Careful cbuarvation rust be made 10 accuvctely detect the point of contact barween the foat arm ord the foot valve. (CT90 Model From Frome No, 0000014) Analitude selector knob Is Ircerpotated Inthe carbxrelor of the CT 90 model staring we frare sect No. CT 90-000001A/onaire seriol No, CTS0E-000001A. This males ovalldble optimum carbuetor performence for normal or high abide meloreyele operation, Pill the knob out for riding ot cltiute of 6,000 feet cbove seo level. This will provide adattional supply Cf it 1 the needle jst from the moin or wunply portage. At the tome tine, oddliiond it alto supplied 10 slow jet {rom the slow systen air passage, 10 lean cut the fuel mitre. Pushing in the knob will close off the lr sypely to both the slow end mai systems ® Wor @ Host Haat on pla @ Float vave @ hukber cop Onc vale @ Cal eeng Spec lp @ at nowdla Sow iet @ floc chante body @ O sing @ knob r(CARB.RETOR SETTING TARE ose. exer a [zxco || 1 |exco 3 |zxz0 2 waco] [exo || veueoynads Ones on oe 0—161—90014. FRAME Tools Necessary for Disassembly and Reassembly TOOL No. DESCRIPTION © 07045-03301 town pn soe! wrench @ 07035-03901 fear aahion dctsontng & ossenbing to 7083-03001 Stem nit acct wrench 07048-02001 Bening diver 07072-00101 Pin Spemrer, 36. © 7071-25001 Main swich pin spamer 7782-99925 Sap rng ples (cove) © 07054-02801 Front fork ol sel diver 7790-02801 Teal cate @ eee4.1 STEERING HANDLE A. Constrection The stooring handles of ail the mode! $0 moter. cycles wih the exception of C90 or made of formed steo! pipe. Thay oe mounted to the. frant fork by being cloned between the upper and lower handle pipe oldoss ard bolted to the fark top bridoe plato, The steering hand of the C90 ls mado of pressed shoot stool with a continous steel pipe ge wele ed for reinforcemont. es Typ ole SPR a4 1-2 | Unto 10 ti. 4. 1-9 | Senbap 50 fig 1-4) | Teed sh te 190 tn 41-9 | Uptonde Flas Astet $70 steorg here 4.1 STEERING HANDLE 7% Fig, 4. 1e2 CLIO. CLYDE soerng torso ia: Fig. 4.1.3. C090 vnoing hone Takao Fig, 165 C190 stewing fondoB. Disassembly (S90, CL90, CL90L) 1. Hold the front ako orn @ back end anscrow the aajusting nur. (Fig, 4,2) Be bas cheng at te on 2. Diecomect the cluich cable @ lower end from the citch lover @, (Fig. 4.3) CAUTION » @ Frercise care not fo danaye the cylinder ‘ond eyindor hood fas when removing the cable, he fost con bo shnalified by Icosening the ‘edveting screw ot the hordle lover end cred escomnecting the cable, 4.3. Diccmesig itm curd © Cinch ewe" @)'O 3. Disconrect the thiotle cable ot the thotle valve D by unscrewing the coruoter cop, pula ou the ttretie vaive and then unhooking the frotto cable 2. (Fig. 4) 4. Remeve the horn, tun signal ond dinner switch lead @ dy loosening tho screws ct tho front af the hacdlgh cote, ard dscomecting the comeciors wiihin the hcalight cose, (Fig. 4.5) 4.3. Dicoinacing 8% toca tact4.) STING HANOLE & 5. femove the four hex belts mountna the horde Fipe between the ypper end lower toldes ord remove tho steerng handle) together wih tho control ecbles (Fg. 4.8) © 6. The fark top bikge @ le removed togsher wy tho tun sign) Highs by removing the ent fot bas @ ard te. seeing ston rt Fie 4.7 Use stom rut socket wrorch (Tact No 07083-03001! to lesan ho sa Tig. 4.7. Renowrg Nh top Wide pate Shem mit sett wranch 3) Som rt © From fou sor For vey widse ® 7 In order to romove the ctch and brake exblos ‘rom the taro lover, looron tho cable adjusting bots @, atgn the lock rat D 10 the groove ‘ond sopo.ta fram the handle lever. Remove the cable end from the lever. (Fig. 4.8) B. Remove the two Simm scree to toparate the fight handle grip bracket, wen slgncl switch 4.4 Komoving tale and cy coos a assembly. throttle grip pipe ord then ciseornect Oe DORE em, ‘he theotle cable @ from the throtla. cable hiege @. (Fig. 4.9) i, Renda ts Gel ea ar disens s eee te ete eee ae co oa ok Rec @ Seer note. ‘ny anon Hs ee ee eon op een oer We TOES ba Nee ae cae eee Seikbe an al boa meng! aes oO removal @ Trorle cable @ Those cable noen ig. 4.10 ‘ont ote cate @ Spantomesr cable) Bree ease - Fig. 412 Dsconrect enctea lcd ICT 0, tlc” lots 18 Removes ole at bets ve D Sam nec wt — @ Gm hex bolt 4 PeAME (C90, cr90) 1, Remove the fiont cover, (C90) 2. Uncourle the spovdomater cable (D) ond ss connec! the front broke cable @. (Fig. 4.10) The left handle lover of tho CT 90 is the brake lover for the roor broke, Remove the catle end from the handle lover. Leatening tho ciuster mut et tho rear whoo! wil seth fe fa 3. Disconrect tho thotle cable ot the thistle valve by fist unscrewing the carburetor cop © Pulirg Out the thottio valve (2) and then unko- coking the thottlo cable. D (Fig. 4.11) 4. Remove ho headlighi mounting serew ond pul off the headlight unt. Disconnect the hom, torn signa ond tho diner switch leads @ ct tho contactors wihin the headlight case, (Fig. 4.12) 5. Ureciew the two fop bridge setting bolts @ from within the heoslight cose ard remove the 0 Bam handle setting mits ©. (€ 90) (Fig. 4.13) and lift of the hondlo together with tho cxtles ond laos, 6 Remove the four énm hex bolls ie separcte the hondle pipe upper holler, Then, ll cut the stoorng handle @ together with the eablos and electical loos (Fig. 4. 14) (CD90 & CT 90) (C190 Model from Frame No. 000601A) 1. Remove the front brake clus! nut and front broke cable from the front am lfiort brcke cable may be disconnected from tho broke lever. 2. Reneve the twor broke cable Trem the rear broke lover 3. Renove the corbueior cap and disassemble Ihe trotile volve together with the thottle cable from tha carburetor 4, Remove the headlight ond dscomect the re- spective leads 5. Unscrew the four handle mountieg bolts ard remoye the hande bor C.Inspection (steering handle) 1, Inspect the. throttle, elitch, fon) brake ond rear broke (CT 90) cables for wear ond dema- 905, ako chock for smoothness of operation 2. Chack the hordle lever for smooth enertion 3. Inepect the hande pipe lor deformaion ond 4. Check ll the switches for proper operation nd inspect the electrical leads for damages a