HOW TO USE THIS MANUAL Follow the Maintenance Schedule (Section 3) recommendations to ensure that the scooter is in peak operating condition and the emis sion levels are within the standards set by the U.S. Environmental Protection Agency and the California Air Resources Board. Perform ing the first scheduled maintenance is very im- portant. It compensates for the initial wear that occurs during the break-in period. Sections 1 through 3 apply to the whole scooter, while sections 4 through 17 describe parts of the scooter, grouped according to lo cation Find the section you want on this page, then turn to the table of contents on page 1 of that section, Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subse: quent pages give detailed procedures. If you don't know the source of the trouble, go to section 18, TROUBLESHOOTING. Allinformation, illustration, directions and sp cations 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 ineurri obligation whatever. No part of this publi ‘may be reproduced without written permission, HONDA MOTOR CO., LTD. Service Publications Office ENGINE CHassiS ELEC- _TRICAL, CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVES CYLINDER/PISTON DRIVE PULLEY/CLUTCH/DRIVEN PULLEY FINAL REDUCTION ALTERNATOR/STARTER CLUTCH CRANKCASE/CRANKSHAFT COOLING SYSTEM FRAME COVERS ‘STEERING/FRONT WHEEL/BRAKE/ ‘SUSPENSION REAR WHEEL/BRAKE/SUSPENSION ELECTRICAL EQUIPMENT WIRING DIAGRAM ‘TROUBLESHOOTING TECHNICAL FEATURES INDEX ay ~ Date of Issuer March, 1986 © HONDA MOTOR CO. LTD1, GENERAL INFORMATION GENERAL SAFETY oe SERVICE RULES WW MODEL IDENTIFICATION 1:2 SPECIFICATIONS 1:3 TORQUE VALUES 16 TOOLS 16 CABLE & HARNESS ROUTING 17 EMISSION CONTROL SYSTEM 112 EMISSION CONTROL INFORMATION LABEL 114 GENERAL SAFETY Ifthe engine must be running 10 do some work, make sure the ‘area is well-ventilated. Never run the engine in a closed ared. The exhaust contains poisonous carbon monoxide gas. Gasoline is extremely flammable and is explosive under certain conditions, Do not smoke or allow lames or sparks in your working area. SERVICE RULES The battery generates hydrogen gas which can be highly explo= sive. Do not smoke or allow flames or sparks near the battery especially while charging it 1. Use genuine Honda or Honde-recommended parts and lubricants or their equivelents. Parts that do not meet Honda’ design 9 specifications may damage the scooter. 2. Use the special tools designed for this product. 3. Use only metric tools when servicing this scooter. Metric bolts, nuts, and screws are not interchangeable with English fas toners. The use of incorrect tools and fasteners may damage the scooter. Unless a particular sequence is specified Install new gaskets. O-rings, cotter pins, lack plates, etc. when reassembling When tightening botts or nuts, begin with larger-diameter or inner bolts fist, and tighten to the specified torque diagonally, 6. Clean parts in cleaning solvent upon disassembly, Lubricate any sliding surfaces before reassembly. After reassembly, check all parts for proper installation and operation, 8. Route all electrical wires as shown beginning on page 1-7, Cable & Harness Routing, 1-1GENERAL INFORMATION MODEL IDENTIFICATION TI) FRAME SERIAL NUMBER 7 The frame serial number is stamped on the right side of the frame body. (1) VIN NUMBER ‘The VIN (Vehicle Identification Number) is attached to the left side of the inner box. (1) ENGINE SERIAL NUMBER & y (1) CARBURETOR IDENTIFICATION B NUMBER. The carburetor identification number is stamped on the Fight side of the carburetor (1) COLOR ea The color label is attached to the fuel tank below the seat 1-2GENERAL INFORMATION SPECIFICATIONS TEM (Overall length (Overall width Overall height Wheel base Ground clearance Dry weight DIMENSIONS. Type Front suspension, travel Rear suspension, travel Vehicle capacity load Front tie size Rear tire size Front tire pressu Rear tire pressure Front brake Rear brake Fuel capacity Caster angle Teail length Type Cylinder arrangement Bore and stroke Displacement Compression ratio Engine oil capacity ENGINE Lubrication system Coolant capacity Ar fitration Cylinder compression Intake valve Opens Closes Exhaust valve Opens closes Valve clearance (Cold) Engine weight Idle speed <__>:CH1500 ‘SPECIFICATION 1,925 mm (75.8 ini (645 mm (28.4 in} < 655 mm (25.79 inl> 41,125 mm (44,3 in) <1,165 mm (45.87 ini> 1,200 mm (47.2 in) 125 mm (4.9 in) 105 kg (232 Ib} <107 kg 1236 IbI> Back bone Bottom link 76 mm (3.0 in} Power unit swing arm 96 mm (3.8 in) 149 kg (330 1b} 3.50-10 (-4PRI, tubeless 3.50—10 (~4PR), tubeless 150 kPa (1.5 kg/em®, 21 psid 200 kPa (2.0 kglcm?, 29 psi Up to 90 kg {200 Ibs} load 260 kPa (2.5 kgicm?, 36 psi) Up to vehicle capacity load Internal expanding shoes Internal expanding shoes 8.0 liters (2.1 Us gal, 1.8 Imp gal) 27° 00! | 78 mmm (3.1 ind Water cooled 4stroke, OHC engine Single cylinder 58.0 x 57.8 mm (2.283 x 2.275 in} 183 cm? (8.3 cu in) 10.0: 1 1.0 liter (1.1 Us qt, 0.9 Imp qq) at disassembly 0.8 liter (0.8 US at, 0.7 Imt qt) at draining Forced pressure and wet sump 1.0 liters (1.1 US at, 0.9 Imp qt) Paper filter 1,300 kPa (13.0 kgiem?, 184 psi) 0° (eT0C) 30° (ABDC 35° (88DC) 0° (ATDCI INJEX: 0.1mm (0.004 in} 26.5 kg (58 tb) 4,500 = 100 rpm at 1.1 mm liftGENERAL INFORMATION CARBURETION DRIVE TRAIN ELECTRICAL | | = | | | tice eM Ieentification number 85 After '85 Float level Pilot screw initial opening Main jot Slow jet Cluteh type | Primary reduction Final reduction | Ignition Starting system Alternator Spark plug Spark plug gap Jgnition timing “"F"" mark full advance Battery capacity Fuse cepacity Headlight, LowiHtigh Brake/Tail light ‘Turn signal/Position light (front) (rear) Instrument light Turn signal indicator tight High beam indicator ate light SPECIFICATION VEO3A |VEO4A, California model) VEO3E (VE04B, California model) 18.8 mm (0.73 in} See page 4-11 #100 (#95, High altitude type #35 ‘Automatic centrifugal clutch, dry type 2.2-0.9 7318: 1 i Condenser capacitive discharge ignition (CDI) Starting motor 12V 203 W/ 5,000 rpm IND) X22EPR-U9, X20EPR-US (NGK) DPR7EA-9, OPREEA-9 0.80.8 mm (0.032—0.035 mm} 10° BTDC/ 1800 rpm 27° BTDC/ 4000 rpm 12V9AH 20 A (Main) 10 A (Turn signal light, Brake light! 10 A (Headlight, Instruments light! 10 A (Horn, license plate light, position light) 12 V-85/60 W 1227/0 w {90/9 66) SEAN. 1157 12-208 [30/3cp) SEAN. 1084 12.V—23 Wee ep) SaeNe 1073 | 12V-a4Wx ion SaENO Tee | oe VVaaweaten) — SaeNo tee | | 12. V-8W [4 phGENERAL INFORMATION TORQUE VALUES ENGINE vem ary] GIRPEAD, T ToRaue nim haem fib) | REMARKS Oil bolt 1 12 18—22 (1.8—2.2, 13—16) T oie 2) "8 | le Bes tee! | Cpr eas cap ut a) 8 | ab aS ba a8 | Water fae eee Pf 8 | FRSC TS ria” | cotenana trcoss Cynse ea teen 5] 8 | 'stes12 68 ollie secee cop | ab | sSo30 nS 88: $1 be Sencha seating bor | 4] 8 eee Gam shan tens: bo >| 8 | stots 48-73 Eur dive pte fut i} 28 | s5-e0(g0-00: $e yee et 1} 38 | $565 \g0-e0: sea) Eee 5] "8 | eta $s aa Brive foe seal cover bot 3) 8 3151 3-08 22°30) Bre fe aut 112 | so%eo(ed-e0, 36-85) Guten ote ut 14 S80 S888 28-35, Traehon Sxe cover bot Mee ee enewscneieeciah Starr th cokes bo a ee eee eee Siansmason oftvalchack von | 1 | 16 | tntemoche, 7o1m FRAME rrew ary] IuREA® | romaue tem kom, fit REMARKS Engin Fangerstappe boll i é 2430. 17-20) Ein Ranger teste ot 1) 38 R528 20-88, Enghe tanger bo i/o B38 Engine rein bon | se—8 Front axle nut a 12 | 50-70 (5.0-7. foe aa 1 18 | ee s0t8o-4 cuceaeeer mere |) | ce leetes eset Renrsteck sbeerar anpereckma| 2 | 8 | aecagirgnzed Aon locking ent | Top cane tac ; vee | 822303081 | | Sito tee rut 1 | Ba fro Ago Sooke | Seeing eter ok ut 1) BBS Poo 22 are 2 | 8 | 08-12(008-0.12,06-0.8 | iret Be | LENSE GI | Capermome bor | 2 | | $0-36 6-88, 22—26) | Apply ot | Tiere [2 |B | SRR ETE e TTH Te, | A Clan noon | Brake aim st ae precismesiaiess Freat sm bat 5) & | acaeeree tacin heel hee 8 8 | 23812833. 25-28) | Anny ot Kecr bate pode sty $ | 83208 $28 ar Spendomere cope set sow | 4 Bo) Peete deh tan Reaaigntmowranccene =| | 8 | weaawos gata | Ce sen rete ' B | 1b He 7-8 Head stor Se ut i) 8 | 838-13 6-8) etal utr bok Pee eee Exhaust pie la ut ee ee STANDARD TORQUE VALUES Tyee TORQUE fe tam, Fb) Wee [TOROUE hem em) Sam pot, mut | 45-6,0(048-06,53-43) | S mm screw F 3s-s1035-05, 25-361 ginm por mit | “StS owas eee) | Sim sew, and 8mm) Tea ett 58) Simm boh Mik | Bb S55 G5 he) | Baal’ atnod Gin bot: nut | 30-40 20-40, 22-29) | Srimometaren | 10-1411.0-14, 7-10 Vammm fat nut | $060 (a0 80, 26-43) | Smmnane to nat | 24-3022, 17-90 l 10 mm flange bolt, nut 35—45 (3.5—4.5, 25-32) 1-5GENERAL INFORMATION TOOLS ‘SPECIAL eScRITION Too.numaen | ALTERNATE Too. | roounuween | EE \ecuinipessue pone | ASEIXGAI~ | Voeuum pump USA oa | STANZEOMET 4 Re Peswrcoumpsaom | Sranaesmer |2 Lnersl being puter 76310010000. Eau commer 3 weet nose tock nut wench, 38 mm [78161870002 lack mt month 38mm | 079161870001 | 8 Keng ccer cmt menen |B7sie=e70t01 | Eeavoentcmmersaly wala ness 4 Stetng stam wrench 07916-cx00000-|cstabe ns sanner | 077020020001 | 12 Shot ete Great 1990000 3 acerca Brass—Ke70000 *o sername, 12mm | resem tseon 312 ten ee a (07936_Noso10) 313 (Romer igs (e774) -G0t0200 | Remover woth 07936-s710200 [3:12 Becitgiemoshanae | 7440s r0100 3 Bearing remover, 17 mm | 07936-3710300 |9 Remover weight 077410010201 | Remover weight 07936-3710200 |9 ake coe Ser, 80mm 97842 nn600D é tocar orose- 9950800 : ST ve Sree aieeaos onanoos—ais [13 senetenee |orete—ececeno Bie cannes Grose Cesc | mace emover ora40-s7io4oo | a Cinch nett covessor | B/960-RMTOOGD | Sorngtsumessoratachment | 97860 KANON | 8 Sing Compress enh" | 6796090000 | 8 Seal and cose assembly toot | 07968 1480010 3 ‘BSc cota (0700886100) 3 (ascent Saf |\oraesta80200 | 3 Spring holder attachment |07967— 1180100 | 15 Beers tsi’ techment |07967—GATCOO! | Shock absorber atchment | 07867—GA7000% | 15,15 Sect Seotsorancatent | 7367—xMtOrO it cee ramet” — (87309 ~KiaNSS [Nox aval in USA 5 wee eoeeTeSne Sn | 87888 No600 é COMMON, eScRIPTION ToouNumsen | ALTERNATE TOOL | TooLnuMeen | ee : [ans [ace mel ane 373010010000 a ToS eeeAEeNE, 5032 mm [03710 -0000%00. [equate conmeriay ts sai aS Extension 07716-0020500 |Eeerstin eonmcay “4 cea eae Uriarse ole 07725--0030000 8 en 18772870020000_|eond avon wench commer to amy Staaten Si auecwment 32x38mm [07746 -o0r0100 esi Atscrmen S7aomm [977460016200 : ancenment #2%47 mm [07748 -cor0300 ba Atccwment s2xesim | o7nae 0016400 | ta oot tS nm SrrasgosoaeD Bia es Oras eososep 5 plot 20 0m Srrae—aososeo Bo Belay over sot 87745~ 0080100 -fEguvalen commercly ta Besingemover tess, 12m | 973460080900 Jacaate'n OS “ Bree Sires ooesee8 Take guide eve Si7a3—gossee. ¢ VaNe Sit Sompresor (| 7787010000 | $ Shock Sostor compressor [07969980008 fats 1-6GENERAL INFORMATION CABLE & HARNESS ROUTING Note the following when routing cables and wire harnesses: © A loose wire, harness or cable can be safety hazerd. After clamping, check each wire to be sure itis secure. © Do not squeeze wires against the weld or its clamp. © Secure wires and wire harnesses to the frame with their re- spective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires oF wire harnesses, © Route harnesses so they are neither pulled tight nor have excessive slack © Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. Clean the attaching surface thoroughly before applying tape. © Do not use a wire or harness with a broken insulator. Repair bby wrapping them with protective tape or replace them. © Route wire harnesses to avoid sharp edges or corners. © Avoid the projected ends of bolts and screws. © Keep wire harnesses away from the exhaust pipes and other hot parts. © Be sure grommets are seated in their grooves properly © After clamping, check each harness to be certain that itis rot interferring with any moving or sliding part, © After routing, check that the wire harnesses are not twisted or kinked. © Wire harnesses routed along the handlebars should not be pulled taut, have excessive slack, be pinched by or interfere with adjacent or surrounding parts in all steering positions, © After routing, check that the wire harnesses are not twisted or kinked. © Do not bend or twist contro! cables. Damaged control cables will not operate smoothly and may stick or bind, (©: CORRECT X: INCORRECT 1-7GENERAL INFORMATION (1) THROTTLE CABLE (3) SPEEDOMETER CABLE (6 wine | HARNESS (6) OVER FLOW TUBE (7) NEGATIVE (—) CABLE 1-8GENERAL INFORMATION (8) RIGHT HANDLEBAR ‘SWITCH CONNECTORS. (4) THERMOSTATIC SWTICH (5) RADIATOR AIR veNTaTUBE) (7) LEFT HANDLEBAR SWITCH CONNECTORS (9) BATTERY (10) WATER HOSE (11) REAR BRAKE CABLE (13) BREATHER SEPARATOR (12) cor‘unit 1-9GENERAL INFORMATION (2) SPEEDOMETER CABLE (3) THROTTLE CABLE (1) FRONT BRAKE CABLE (1) FRONT BRAKE CABLE (4) BRAKE LOCK CABLE (2) SPEEDOMETER CABLE (5) WIRE HARNESS (3) THROTTLE CABLE (6) STARTER RELAY (5) WIRE HARNESS (2) IGNITION con. (8) REAR GRAKE CABLE 1-10GENERAL INFORMATION cH150D: (2) TURN SIGNAL RELAY (3) suzzeR (4) MULTI COUPLER, (5) WIRE HARNESS, (9) HEADLIGHT MOTOR (10) HEADLIGHT/ (11) HEADLIGHT MOTOR uimir swircH “'" CoupLen COUPLER, (8) LIMIT SWITCH (121 IGNITION switcH COUPLER. (13) HEADLIGHT, RELAY (17) col UNIT (14) FUSE BOX — (15) TIMER UNIT (16) REGULATOR) RECTIFIER (18) RETRACTABLE HEADLIGHT INDICATOR RELAY 1-11GENERAL INFORMATION EMISSION CONTROL SYSTEMS The U.S. Environmental Protection Agency and California Air Resources Board (CARB) require manufactures to certify that their motor scooters comply with applicable exhaust emissions standards during theit useful life, when operated and main: tained according to the instructions provided, and that motor scooters built after January 1, 1983 comply with applicable noise emission standards for one year or 6,000 km (3,730 miles) after the time of sale to the ultimate purchaser, when oper ‘ated and maintained according to the instructions provided. Compliance with the terms of the Distributor's Warranty for Honda Motor Scooter Emission Control Systems is necessary in order to keep the emissions system warranty in effect. SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important becouse, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but itis toxic. Honda Motor Co., Lid. utilizes lean carburetor settings as wall as other systems, to reduce carbon monoxide and hydro carbons. EXHAUST EMISSION CONTROL SYSTEM. The exhaust emission control system is composed of a lean carburetor setting, and no adjustments should be mat the idle speed adjustment with the throttle stop screw, except CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system which routes crankcase emissions through the air cleaner and into the combustion chamber. Condensed crankcase vapors are accumulated in a storage tank which must be emptied periodically, ‘See the Maintenance Schedule in section 3. (1) AIR CLEANER: (2) CARBURETOR ofe=> (6) BREATHER ‘SEPARATOR A (4) DRAIN PLUG (3) CATCH TANK FPF) ce : can ; za i] as | 3 ee &i | | 88 |B | om L EVERY Se [se | oe | XY to poge FUEL LINE 1 1] | 2 | THROTTLE OPERATION fo 1 ial AIR CLEANER, NOTE (1) R B|_|_enanccase onearien NOTE a epee BT | spank puua R R a! |” |_vatve cueaRance 1 1 o 1 3 ENGINE OIL, R aoe eone rd 3) | exawve oi Acren Screen : ne | 22 &) - | cansunerorpLe SPEED H 1 i ' 37 | RADIATOR.COOLANT 2 YEARS "R 1 37 =) coouNns system 1 37 . | eurorae anssion | yore ree TRANSMISSION OIL eee |e ee a | 26 1: EVERY 5,000 mi (6,000 km) |_| eeur case aincieanen | rc | ¢ | c | 38 BC[eaey Toh a0 |__| BRAKE SHOE WEAR Ey 1 1 is ea 5 BRAKE SYSTEM 1 1 L 1 3.10 Bl | epaxe uct switce ieee rf 32 3” | STARTER Limit switcH ae aa anna To | 32 3] = | snake Lock vever Toto pant 31> [HEADLIGHT Aim 1 1 1] sta Zi*| CLUTCH SHOE WEAR 312 27 |” swe stano - 7 313 | suspension, - 1 a3 + | Nor, aOLT, FASTENER 1 314 =] weet t a4 ++] STEERING HEAD BEARING 1 fsa * Should be serviced by an authorized HONDA Scooter Dealer, unless the owner has proper tools and service data and is mechanically qualified ‘+ In the interest of safety, we recommend these items be serviced ONLY by an authorized HONDA Scooter Dealer. NOTE: 1 Service more frequently when riding in dusty areas. 2 Service more frequently when riding in rain or at full throttle 3 California type only. 4 For higher odometer readings, repeat at the frequency interval established here,MAINTENANCE FUEL LINE Remove the right rear cover (page 13-2) Romove the fuel valve cover (page 4-13) CCheck the fuel ines and replace any parts which show signs of deterioration, damage or leakage. nh + Gasoline is flammable and is explosive under certain condi- tions. Do not smoke or allow flames or sparks in your working THROTTLE OPERATION Cheek for smooth throttle grip movement, full opening and au- ‘tomatic full closing in all steering positions. Check the throttle cable and replace it, if it is deteriorated, kinked or damaged. Lubricate the throttle cable (Page 2-7), if throttle operation is not smooth, Mesure the throttle grip free play at the throttle grip lange. FREE PLAY : 2—6 mm (1/8~1/4 in ‘Adjustment can be made at either end of the throttle cable, Minor adjustments are made with the upper adjuster, Slide the rubber cover out and adjust by loosening the lock nut and turning the adjuster Major adjustments are made with the lower adjusting nut. Remove the right and left rear covers and the frame center cover (page 13:2) and then adjust by loosening the lock nut and turning the adjusting nut Tighten the lock nut and recheck throttle operation. (178—1/4 in}MAINTENACE AIR CLEANER 11) COVER. Remove the left rear cover (page 13-2) Romove the thrae air cleaner case cover screws and the cover. Remove the air cleaner element and discard it in accordance with the maintenance schedule. Also, replace the element any time it is excessively dirty or damaged, NOTE + The air cleaner element has a viscous type paper element. do not try to clean. Install the element and air cleaner case cover, and tighten the three screws Install the left rear cover, CRANKCASE BREATHER Remove the plug from the drain tube to empty any deposits, NoTE + Service more frequently when ridden in rain or at full theot tle or ifthe deposit level can be seen in the transparent sec tion of the drain tube. SPARK PLUG RECOMMENDED SPARK PLUGS: NGK_ ND ‘Stendard DPR7EA-9 | X22EPR—US For cold climent | 7 tooiomsec ater) | OPREEA-9 | X20EPR—u9 Remove the left rear cover (page 13-2) ae Disconnect the spark plug cap. 08-0.9mm | Clean any dit from around the spark plug base. (0,030.04 im) “Ff Remove the discard the spark plug Measure the new spark plug gap using a wire-type fecler | (3) GAP gauge. WEAR FOULING ‘SPARK PLUG GAP: 0.80.9 mm (0.03—0.04 in) DEPOSITS Adjust by bending the side electrode carefully With the plug washer attached, thread the spark plug in by hand to prevent cross:threading. Tighten the spark plug anoth er 1/2 turn with a spark plug wrench to compress the plug washer (2) CRACKS | | Re | 5 “Then connect the spark plug cap.MAINTENANCE VALVE CLEARANCE NOTE + Inspect and adjust valve clearance while the engine is cold (below 35°C) 95°F} Remove the right and left rear covers and frame center cover (page 13-2) Remove the timing hole cap trom the right side of the cylinder head cover. Remove the four screws attaching the drive belt air cleaner cover to the left crankcase cover. Rotate the drive pulley counterclockwise so that the index mark on the cam sprocket is aligned with the cylinder head mating surface as shown to bring the piston to TOC (Top Dead Center) on the compression stroke. Loosen fully the valve adjuster lock bolts, located on the left side of the cylinder head. Move the intake and exhaust adjusters outward (away from each other) fully, until resistance is fet. ‘Then move them inwards (towards each other) the equeivalent of one graduation. Tighten the adjuster lock bolts Note + One graduation on the adjusters equals 0.10 mm (0.004 in}, which is the specified clearance. Install the removed parts in the reverse order of removal (3) EXHAUST ADJUSTER 3-6MAINTENACE RADIATOR COOLANT Place the scooter on its center stand. Remove the radiator grille (Section 13), Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the ““F"" and “L” level lines. HW necessary, remove the resorve tank cap and fill to the “F" level line with a 60/50 mixture of distilled water and ant freeze. Reinstall the cap, RADIATOR CORE Remove the radiator grille (Section 13) Remove the air duct, Check the air passages for clogging or damage. Straighten bent fins and collapsed core tubes, Remove insects, mud or any obstruction with compressed air of low pressure water Replace the radiator ifthe airflow is restricted over more than, 20% of the radiating surface. COOLING SYSTEM HOSES & CONNECTIONS Inspect the hoses for cracks or deterioration, and replace if necessary, Check the tightness of all hose clamps. CARBURETOR—IDLE SPEED NOTE + Inspect and adjust idle speed afterall other engine adjust ments are within specifications, + The engine must be warm for accurate idle inspection and adjustment, Ten minutes of stop and go riding is sufficient Remove the inspection cover from the center cover. Warm up the engine and place the motorcycle on its center stand. Connect a tachometer ‘Turn the throttle stop screw to obtain the specified idle speed. IDLE SPEED: 1,500 + 100 rpmMAINTENANCE EVAPORATIVE EMSSION CONTROL SYSTEM (California model only) Check the hoses between the breather separator, fuel tank, ‘charcoal canister, and air cleaner for damage or loose connec: tions. Replace as necessary IGNITION TIMING NOTE +The Capactive Discharge Ignition system is factory pre-set land cannot be adjusted. Ignition timing inspection proce: ‘dures are given to inspect the function of the CDI compo. nents, Remove the right rear cover (page 13.2) Remove the timing hole cap. Connect @ tachometer and timing light to the engine. Start the engine The ignition timing at idle is correct if the index notch aligns with the “E°" mark at idle of 1,500 pm. To check the advance, raise the engine speed to 4,000 rom; the index notch should be between the advance marks. If the ignition timing is incorrect, check the CDI unit, pulse rotor and pulse generator, and replace faulty parts. Refer to Section 16, Electrical Equipment. “TW ADVANCE MARKSMAINTENACE CYLINDER COMPRESSION i Warm up the engine Stop the engine, then remove the left rear cover. Disconnect. the spark plug cap and remove the spark plug. Insert the compression guage q Open the throttle all the way and crank the engine with the starter motor. NOTE + Crank the engine untill the gauge reading stops rising. The maximum reading is usually reached within 4~7 seconds ‘COMPRESSION PRESSURE: 1,300 = 200 kPa (1322 kg/em? 184 = 28 psi) If compression is low, check for the following. Improper valve clearance Leaky valves — Leaking cylinder head gasket Worn pistoniringieylinder If compression is high, it indicates that carbon deposits have ‘accumulated on the combustion chamber and/or the piston DRIVE BELT Remove the following: left rear cover and side rail page 19-2) — left crankcase cover (page 8-3} Inspect the drive belt for cracks, or abnormal or excessive Replace the drive belt (page 8-4) with a new one if necessary ‘and in accordance with the maintenance schedule (pages 3-2 and 3-3), DRIVE BELT AIR CLEANER Remove the left rear cover (page 13-2) Remove the four drive belt air cleaner cover screws and the Remove the element from the cover and wash the element in ‘non-flamable or high-point solvent, squeeze out the solvent thoroughly, and let it dry. CAUTION + Do not oil the element. + Dry the element before installing. Install the following: — the element, = the element cover with its four serews. — the left rear cover (page 12-2) (2) COVERMAINTENANCE BATTERY (i) UPPER LeveL Open the seat and remove the battery cover by removing the band Inspect the battery fluid level When the fluid level nears the lower level, remove the filler cap and add distilled water to the upper level line. NOTE + Add only distilled water. Tap water will shorten the service lite of the battery, ao + The battery electrolyte contains sulphuric acid. Protect your ‘eves, shin, and clothing. + Uf electrotyte gets in your exes, flush them thoroughly. with water and get prompt medical attention. (FRONT Ss Tener a9 \ [2) REAR se A (81 MARK, “{4) WEAR INDICATOR, BRAKE SHOE WEAR oP Replace the brake shoes if the arrow on the wear indicator ‘aligns with the reference mark “A” when the brake is fully @p- Sh aR plied, a opi “ , ~ a i" PLATE SP ars marcy May BRAKE SYSTEM FRONT BRAKE ‘Measure the front brake lover free play at the tip of the brake lever. FREE PLAY : 10-20 mm (3/8~3/4 in) Uf adjustment is necessary, turn the front brake adjusting nut BAO TSN T_T (GLINCREASE PLAY (2) DECREASE PLAY. 3-10MAINTENACE REAR BRAKE 20-30 mm Measure the rear brake pedal free play at the top of the pedal aera FREE PLAY : 2030 mm (3/4—1-1/8 in} NOTE + The normal distance between the top of the brake pedal and the floor board is 30-40 mm (1-1/8—1-1/2 in) with the pedal depressed, '30—40 mm. (1-1/81-1/2 in) I austment is necessary, turn the rear brake adusting nut. f BRAKE LOCK LEVER Check the brake lock lever for smooth operation, Ifthe lock lever does not return smoothly when the lock is released, remove the pivot bolt cover and pivot bolt, and apply grease to the pivot BRAKE LOCK CABLE ADJUSTMENT (2) LOCK NUTS (1) ADJUSTER /\ | \ Lock the rear brake. Check if there is clearance between the lock lever and the stopper. If there is clearance, loosen the lock nut and turn the adjuster ulate Until the clearance is zero. cou (6) ZERO CLEARANCE 4 : ——— | (a) Lock Lever (5) STOPPERMAINTENANCE BRAKE LIGHT SWITCH/ STARTER LIMITER - SWITCH : NOTE “ww + Perform the brake light switch adjustment after adjusting the brake pedal play. Adjust the brake light switch so that the brake light will come fon when brake engegement begins. ‘Adjust by holding the switch body and turning the adjusting rut. Do not turn the switch body. Make sure that the electric starter will only work when the rear brake is locked. I not, readjust the brake light switch HEADLIGHT AIM Turn the ignition switch ON. ‘Adjust horizontally by turning the horizontal adjusting screw. ‘Adjust vertically by turning the vertical adjusting screw. + Adjust the headl regulations. ow + Am improperly adjusted headlight may blind oncoming drivers, (or I may fail t0 light the road for a safe distance. {88 specified by local laws and _12) VERTICAL ADJUSTING SCERW, (1) VERTICAL ADJUSTING SCREW CLUTCH SHOE WEAR Start the engine and check the clutch operation by revving up the engine gradually, If the scooter tends to creep, oF the engine stalls, check the clutch shoes for wear and replace if necessary (page 8-9), 3-12MAINTENACE SIDE STAND e RUBBER PAD Place the scooter on its center stand. Check the eubber pad on the side stand for deterioration and Replace the rubber pad if wear extends to the wear line. (2) WEAR LINE Check the side stand spring for damage or loss of tension. Spring tension is correct if the measurements fall within 2-3 kg (4.4—1.6 Ibs), when pulling the side stand lower end with a spring scale. Check the side stand assembly for freedom of movement Make sure the side stand is not bent SUSPENSION coo + Do not ride a scooter with faulty suspension. Loose, worn or damaged suspension paris impair scaoter stability and control. FRONT Check the action of the front fork/shocks by compressing thom several times, Check the entire fork assembly for damage, Replace damaged components which cannot be repaired. Tighten all nuts and bolts, REAR Check the action of the rear shock absorbers by compressing ‘them several times. Check the entire shock absorber assembly for damage and re place sny damaged components which cannot be repaired Place the scooter on its center stand. Move the rear wheel sideways with force to see if the engine hanger bushings are warn, Replace the engine hangar bushings if there is any looseness. Tighten all suspension fasteners, 3-13MAINTENANCE NUT, BOLT, FASTENERE Check that all chassis nuts and bolts are tightened to their cor rect torque values (Section 1) at the intervals shown in the Maintenance Schedules (Pages 3-2 and 3-3) Check all cotter pins, safety clips, hose clamps and cable stays WHEEL NOTE + Tite pressure should be checked when ties are COLD. Check the tires for cuts, imbedded nails, or other sharp ob: jects. RECOMMENDED TIRES AND AIR PRESSURES FRONT 3.50_10—4PR REAR 3.50.10 4PR Tue size Cold tie | Up to fee |e 150 200 te | Gown | aan | eo troen?, | toed | pelt Up to | vehicle | 150 | 250 Seeocty | san | 2636) foes Tive erince- | ona |srone | Mee murz ouncor | Fi ona 627 | | ster '85 model en78 ‘Check the front and rear wheels for trueness. Measure the tread depth at the center of the ties. Replace the tires if the tread depth reaches the following lente Minimum tread depth Front: 1.5 mm (0.06 in) Rear: 2.0 mm (0.08 in} STEERING HEAD BEARING NoTe + Check that the control cables do not interfere with handle bar rotation, Raise the front wheel off the ground and check that the handlebar rotates freely If the handlebar moves unevenly, binds, or has vertical move: ment, adjust the steering head bearing (page 14-17). 3-144. FUEL SYSTEM SERVICE INFORMATION 4-1 PILOT SCREW ADJUSTMENT an | TROUBLESHOOTING 42 HIGH ALTITUDE ADJUSTMENT 412 AIR CUT-OFF VALVE 43 AUTOMATIC FUEL VALVE 413 | AUTO BYSTARTER 4-3 FUEL TANK a1 CARBURETOR REMOVAL 45 — AIRCLEANER 416 VACUUM CHAMBER 4-5 CRANKCASE BREATHER 417 PILOT SCREW 4-7 PURGE CONTROL VALVE | FLOAT/FLOAT VALVE/JETS 4.3 INSPECTION (California model) 418 CARBURETOR INSTALLATION an SERVICE INFORMATION GENERAL Gasoline is extremely flammable and is explosive under certain conditions. Work ina well ventilated area. Do not smoke or allow flames or sparks in the work area. CAUTION + Do not bend oF twist control cables. Dumaged control cables will not operate smoothly and stick or bind. ‘© hen disassembling tuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly, he float bowl has a drain screw that can be loosened to drain residual gasoline. © Do not try to disassemble the auto bystarter or air cut-off valve, SPECIFICATIONS 1 k:california model Tem AFTER “85 Venturi diameter — Identification number VEOSB IVEO4B] Float level — mainjer Sander ype — High altitude type — Slow jet | as - — ~ Idle speed “1,500 * 100 rpm —_——— | rote ate foe pay 2-6 mm (0.08-0.24 ny | —_ Pilot screw opening See page 4-11. TORQUE VALUE Fuel valve lock nut 15-20 Nem (1.52.0 kg—m, 1114 ft—1b) TOOL Special Vacuumipressure pump A937X-041-XXXXX or Vacuum pump ST-AH-260:MC7 (U.S.A. only) Pressure pump ST AH 255-MC7 (U.S.A. only) Common 07401 0010000 a1FUEL SYSTEM TROUBLESHOOTING Engine cranks but won't start + No fue! in tank + No fue! to carburetor + Engine flooded with fuel + No spark at plug (ignition system faulty) + Air cleaner clogged + Intake air leak + Improper auto bystarter operation + Improper throttle operation cd starting oF stalling after starting + Improper auto bystarter operation + Igoition matunction + Carburetor faulty + Fuel contaminated + Intake aie leak + Idle speed incorrect Rough idle + Ignition system faulty + Idle speed incorrect + Carburetor faulty + Fuel contaminated Misfiring during acceleration + Ignition system faulty Backfiring + Ignition system faulty + Carburetor faulty Poor performance (driveability) and poor fuel economy + Fuel system clogged + Ignition system faulty Lean mixture + Clogged fust jets + Vacuum piston stuck closed + Faulty float valve + Float level low + Fuel cap vent blocked + Fuel strainer screen clogged + Restricted fuel line + Ai vent tube clogged Intake air leak Rich mixture + Clogged air jets + Faulty float valve + Float level too high + Auto bystarter faulty + Dirty ait cleanerFUEL SYSTEM AIR CUT-OFF VALVE [vacuum PUMP A937X—O41 —XXXXX of ST—AH—260-MC7 INSPECTION (U.S.A only) Disconnect the vacuum and sir vent tubes from the air cut-off valve. Cap the one vacuum tube connector and connect the vacuum pump to the other vacuum tube connector, and then connect the pressure pump to the air vent tube connector Q ; (U.S.A. only) VACUUM: 420—600 mm Hg (16.5—19.7 in Hg) es While maintaining the specified vacuum, apply light pressure to the air cut-off valve with the pressure pump. (1) screw CAUTION + Do not exceed 600 mm Hg (23.6 in Hg) during this test or the air cut-off valve may be damaged. The air cut-off valve is normal if the air does not flow through the air cut-off valve. the air flows out of the air cut-off valve, replace the air cut- off valve. (2) AIR CUT-OFF VALVE REMOVAL Remove the carburetor (page 4-5) Remove the two air cut-off valve attaching screws and the air cut-off valve. INSTALLATION Install 2 new O-ring onto the valve body with it flat face toward the valve body side. Install the valve body on the carburetor with two screws. AUTO BYSTARTER INSPECTION Ti) AUTO BYSTARTER f Wire connectoRs Stop the engine and allow it to cool for 10 minutes or more. Disconnect the auto bystarter wite connectors and measure the resistance between the terminals. RESISTANCE: 10 ohm max. (10 minutes minimum after stop- 19 the engine) IH the reading is not within the limit, ceplace the auto bystarter with a new one Remove the carburetor and allow it to cool for 30 minutes.FUEL SYSTEM Remove the carburetor (page 4-5, Connect a pressure tester to the enrichening circuit. Apply pressure to the circuit, If the passage is blocked, replace the auto bystarter. Connect 2 12V battery to the auto bystarter wires and wait 5 ‘minutes. Connect a pressure tester to the fuel enrichening cir cuit and apply pressure to it. Replace the auto bystarter if there is no restriction to the applied pressure. REMOVAL Remove the set plate screws, set plate and auto bystarter from the carburetor VALVE INSPECTION Check the auto bystarter valve and needle for nicks, wear, seratches or other damage. INSTALLATION Insert the auto bystarter into the carburetor body until it bot toms. Position the set plate into the upper groove in the bystartar with its round face toward the carburetor body. Install and tighten the two screws. (1) VACUUM PUMP A937X—041—XXXXX oF ST—AH~260—MC7 (USA only) (1) AUTO BYSTARTER (BPSET PLATE (1) BYSTARTER VALVE (2) BYSTARTER NEEDLE (4) SeT PLATE \aiscrews (GI SET PLATE, 4-4FUEL SYSTEM CARBURETOR REMOVAL Ti VACUUM TUBE Remove the right and left rear covers, and body center cover (Section 13) Disconnect the fuel line at the carburetor Disconnect the vacuum line from the carburetor. Dissonnect the auto bystrter wire connactrs. AIR CLEANER ( HROPTLEEREE CONNECTING a robe ean Gao AdustInG NUT a eer Wil Loosen the throttle cable adjusting nut and lock nut, and dis connect the throttle cable from the carburetor. Loosen the air cleaner connecting tube band, { # (3) LOCK NUT] max Ge fa] AUTO BYSTARTER WIRE CONNECTORS i Loosen the carburetor insulator band and remove the carbure 7] [it] CARBURETOR INSULATOR. Ay VACUUM CHAMBER DISASSEMBLY Loosen the drain screw and drain the fuel from the float cham: ber. (1) DRAIN SCREW 4-5FUEL SYSTEM Remove the two vacuum chamber cover screws and cover. Remove the compression spring and vacuum pistion, Push the needle holdar in and turn it 60° with an 8 mm socket. Then remove the needle holder, spring and jet needle from the piston. Inspect the vacuum piston for wear, nicks scratches or other damage. Ingpect the needle for excessive wear at the tip and for bend ing, or other damage. Check the diaphragm for deterioration and tears. ASSEMBLY Install the jet needle, spring and needle holder into the vacuum piston, push the needle holder in and turn it 60°. (1) cover: (1) SPRING (2) VACUUM PISTON (1) JET NEEDLE > (2) NEEDLE an _- (3) SPRING (4) DIAPHRAGM (1) VACUUM PISTON (2) SPRING (4) JET NEEDLE (3) NEEDLE HOLDERFUEL SYSTEM Install the vacuum piston in the carburetor body and align the (1) SPRING hole in the diaphragm with the vacuum passage in the earbure- tor body, Install the compression spring, (2) VACUUM “Piston, (3) PASSAGE/DIAPHRAGM HOLE Install the vacuum chamber cover and tighten it with the two (1! COVER. (2) screws NOTE + Be careful not to let the digphragm slip. If the diaphragm cannot be positioned correctly because of its expansion, dry the diaphragm before instalation, PILOT SCREW aa REMOVAL | : NoTE + The pilot screw is factory pre-set and should not be re: moved unless the carburetors are overhauled. + Tho pilot screw plug is factory installed to prevent pilot screw misadjustment. Do not remove the plug unless the pilot screw is being removed. + Cover all openings with tape to keep metal particles out eieaineeis eeu — [nor screw ewe Center punch the pilot screw plug to center the dil point, Drill tough the plug with a 4 mrs (5/32 in) drill bit, being care: ful not to dill into the pilot screw. ‘CAUTION + Be careful not 10 drill into the pilot screw.FUEL SYSTEM Force a sell-tapping 4 mm screw (H/C 069399, PIN 93903— 35410) into the drilled plug and continue turning the screw nti the plug rotates with the screw. Pull on the screw head with pliers to remove the plug. Use compressed air to clean the pilot screw area and to remove metal shavings. ‘Turn the pilot serew in and carefully count the number of turns. before it seats lightly. Make a note of this to use as a reference when reinst pilot screw. ing the CAUTION + Damage to the pilot screw seat will occur ifthe pilot screw is lightened against the seat Remove the pilot screw and inspect it. Replace the pilot screw if itis worn or damaged. INSTALLATION Install the pilot screw and retuen it to the original position 3s. noted during removal Perform pilot screw adjustment if anew pilot screw is installed (page 4-11), NOTE + Do not install a new plug in the pilot screw hole until after adjustment has been made. FLOAT/FLOAT VALVE/JETS DISASSEMBLY \ Remove the four float chamber screws and the float chamber. (2) FLOAT CHAMBER 48FUEL SYSTEM Remove the float pin, float, and float valve. (1) FLOAT Inspect the float valve for grooves and nicks. Inspect the operation of the float valve. Remove the main jet, neadle jet holder and needle jt. Remove the slow jet (3) SLOW Ji rd. (2), NEEDLE JET HOLDER. Blow compressed air through all passages before assembly.FUEL SYSTEM ASSEMBLY ps (0) neeotE Jer Clean the main jet, neadle jet holder, needle jet and slow jet in Cleaning solvent and blow them open with compressed air. (2) MAIN JET ™~. ‘ (4) SLow set —————P WS, (2) NEEDLE JET HOLOER Install the needle jet and needle jet holder. (1) MAIN JET Install the main jet and slow jet. (2) NEEDLE JET HOLDER, Install the float valve, float and float pin (1) FLOAT VALVE (1) FLOAT LEVEL GAUGE FLOAT LEVEL INSPECTION (074010010000 Measure the flost level with the float tang just contacting the float valve, FLOAT LEVEL: 18.5 mm (0.73 in) Replace the float if the level is incorrect. > Reinstall the float chamber 4-10FUEL SYSTEM CARBURETOR INSTALLATION (i connecting TUBE BAND Connect the auto bystarter wire connectors to the wire har Connect the fuel and vacuum tubes to the carburetor. Perform the following inspections and adjustments: (3) AUTO BYSTARTER WIRE + Harness and cable routing (Page 1-7) connector iG + Throttle operation (Page 3.4, + Carburetor idle speed (Page 3-7) + Fue! leaks: Install the center cover and the right and left rear covers page 13-2). (2) VACUUM TUBE PILOT SCREW ADJUSTMENT IDLE DROP PROCEDURE (U.S.A. ONLY) (1) Ploy SCREW NoTe +The plot screw is factory pre-set and no adjustment is nec: essary unless the pilot screw is replaced (page 4-7) + Use a tachometer with graduations of 100 rom or smaller that will accurately indicate a 100 rpm change. 1. Turn the pilot screw clockwise until it seats tightly and back it out to the specification given. This is an intial setting prior to the final pilot screw adjustment. INITIAL OPENING: "85: 2 turn out After ‘85: 1-3/8 turns out CAUTION + Damage to the pilor screw seat will occur if the pilot serew is Aightened against she sea 2. Waren up the engine to operating temperature. Stop and go driving for 10 minutes is sufficient 3. Attach a tachometer according to the manufacturer's in structions, 4. Adjust the idle speed with the throttla stop screw. IDLE SPEED: 1.500 = 100 rpm 4-11FUEL SYSTEM 5, Tuen the pilot screw in or out slowly to obtain the highest engine speed. 6. Readjust the idle speed with the throttle stop screw. 7. Turn the pilot screw in gradually unitl the engine speed drops 100 rpm 8. Turn the pilot screw 1 turn out from the position obtained in step 7. Roadjust the idle speed with the throttle stop screw 10. Drive a new pilot screw plug into the bore of the pilot screw with a valve guide driver (P/N 078428320000) When fully seated, the plug surface willbe recessed 1 mm (0.04 in} into the pilot screw bore. HIGH ALTITUDE ADJUSTMENT oMaNser (U.S.A. ONLY) ‘When the vehicle is to be operated continuously above 2,000 'm (6,500 feet}, the carburetor main jet must be replaced with 2 bigh altitude type main jet to improve driveability and de- crease exhaust emissions, Drain the fuel from the float chambar Remove the carburetor (page 4-5) + Do not smoke or allow flames or sparks in the work area. Remove the float chamber, Replace the main jet (standard # 100) with ahigh altitude type main jet (# 95), | STANDARO SIZE [HIGH ALTITUDE SIZE Wane #10088 late speed Reinstall the float chamber and install the carburetor page anny 1,500 + 100 «pm Attach @ Vehicle Emission Control Information Update Label fonto the fuel tank as shown. Refer to Service Bulletin No. SL 132 for information on obraining the label on (1) VEHICLE EMISSION CONTROL Do not attach the label to any part that can be easily re ICaMATION UDA TE LAE moved from the vehicle, ‘CAUTION Operation at an alvide lower than 1,500 m (3,000 feet) with ‘he curburetors udjusted for high altitude may eause the engine tele rough and stall. When the vehicle is to be operated continously below 1,500 m (5,000 feet), remove the carburetor and replace the main jet with a standard size (# 100). 4-12FUEL SYSTEM AUTOMATIC FUEL VALVE INSPECTION = i | + Do not allow flames or sparks near gasoline. + Wipe up spilled gasoline at once. Remove the right rear cover Remove the two screws and fuel valve hest insulator Disconnect the fuel tube from the carburetor and drain the re maining fuel in the fuel tube and valve (approx. 510 cc, If the fuel flow stops, the fuel valve is operating normally, if the fuel flow does not stop, clean the vacuum tube, Disconnect the vacuum tube from the air cut-off valve and connect the vacuum pump to the vacuum tube and apply vac: The valve is operating normally if fuel tlows out of the fuel tube when the vacuum is appliad and fuel stop following out when the vacuum pump is disconnected. IH the fuel valve does not operate normally Inspect the fuel valve for clogging and clean. Blow air through the valve inlet side to check the flat dia phragm in its original position. FUEL STRAINER CLEANING Do nor allow flames or sparks near gasoline. + Wipe up spilled gasoline at once. Remove the tight rear cover. Remove the fuel valve heat ins ‘Stop the engine and disconnect the fuel tube from the carbure- Disconnect the vacuum tube from the air cut-off valve, sulator by removing the two To drain the fuel from the fuel tank, draw vacuum at the dis connected vacuum tube connector Remove the fuel valve. Remove the fuel strainer and clean it with compressed air, Reinstall the strainer and automatic fuel valve in the reverse order of removal Hold the fuel valve as angle shown and tighten the lock nut while holding the fuel valve. TORQUE: 15—20 Nem (1.5—2.0 kgm, 1114 ftlb) (1) VACUUM PUMP ST—AH— 260—MC7 (U.S.A. only) or __VACUUM/PRESSURE PUMP A937X_—041—XXXX (2)LOck NUT F «1 conwaro 4-13FUEL SYSTEM FUEL TANK FUEL UNIT REMOVAL (Open the seat and remove the left rear cover (page 13-2), Disconnect the fusl unit wire connectors. ‘Turn the fuel unit retainer counterclockwise and remove the fuel unit CAUTION + Do not bent the fuel unit float arm. FUEL UNIT INSTALLATION Set the fuel unit gasket onto the fuel tank. Install the fue! unit by aligning the groove of the fuel unit base With the tab on the fuel tank, Install the fuel unit retainer and turn the retainer clockwise f(T) FUELUNTT while holding the fuel unit. Make sure that the arrows are aligned. Reinstall the fuel unit terminal cover properly and connect the fuel unit wire connectors. Refer to page 16-18 for fuel unit inspection FUEL TANK REMOVAL (1) SEAT (Open the seat and remove the two nuts, helmet holders and Remove the right and left rear covers and frame center cover (page 13-2), (2) Nurs 4-14FUEL SYSTEM Disconnect the fuel and vacuum tubes from the fuel valve (page 4-13), Remove the right or left rear grip mounting bolts and rear grip Remove the four fuel tank mounting bolts and fuel tank INSTALLATION Install the fuel tank in the reverse order of removal 15—20N-m (1.52.0 kam 11-14 tea)FUEL SYSTEM. AIR CLEANER m Remove the right and left rear covers and frame center cover tpage 13-2) Loosen the air cleaner connecting tube band. Disconnect the crankcase and transmission case breather tubes from the air cleaner case. Remove the threa bolts and air cleaner case,CRANKCASE BREATHER Route the breather tubes as shown, See page 3-4 for crankcase breather service, Remove the right rear cover Disconnect the breather tubes from the breather separator. Remove the separator mounting bolts and separator, Pull the separator chamber out of the oi pipe. Disassemble the separator and clean the filter element. Reassemble and install the separator in the reverse order of removal FUEL SYSTEM (1) FILTER ELEMENT (2) BREATHER SEPARATOR 4-17FUEL SYSTEM. PURGE CONTROL VALVE INSPECTION (California model) NOTE ‘The purge contral valve should be inspected if hot restart is difficult (Check all fuel tank, Purge Control Valve PCV), and charcoal ‘canister hoses to be sure they are not kinked and are securely connected, Replace any hose that shows signs of darnage or deterioration, NOTE + The PCV is located on the rear side of the left rear shock ab: sorber Disconnect the PCV hoses from their connections and remove the PCV from its mount, Refer to the routing label on the fuel tank for hose connections. Connect a vacuum pump to the 8 mm ILD. hose that goes to the air cleaner. Apply the specified vacuum to the PCV. ‘SPECIFIED VACUUM: 250 mm (9.8 in) Hg ‘The specified vacuum should be maintained Replace the PCV if vacuum is not maintained, Remove the vacuum pump and connect it to the hose that {goes to the carburetor. Apply the specified vacuum to the PCV. ‘SPECIFIED VACUUM: 250 mm (9.8 in) Hg ‘The specified vacuum should be maintained. Replace the PCY if vacuum is not maintained, Connect a pressure pump to the 8 mm I.D. hose that goes to the charcoal canister. While applying the specified vacuum to the PCV hose that goes to the carburetor, pump air through the canister hose. Air should flow through the PCV and out the hose that goes to the air cleaner. Replace the PCV if air does not flow out. cAUTION + To prevent damage 10 the purge control valve, do not use high air pressure sources. Use a hand operated air pump onls. Remove the pumps, install the PCV on its mount, route and re connect the hoses according to the routing label. 4-18 (VACUUM PUMP ST—AH—260- MCT (U.S.A. or A937X—041 —XXXXX (61 T0 CARBURETOR (2) TO AR, only)” CLEANER: (3) TO CHARCOAL CANISTER (4) PURGE CONTROL, VALVE of A9S7X— (2) PRESSURE PI ST—AH—25 937X041 (1) VACUUM PUMP: ‘ST—AH~ 260--MC7 U.S.A. only) () vacuum pum ST_AH—260—MC7, (U.S.A. only! or AQ37X—041 TOK (041 —XXXXX UMP 55—MC7 (U.S.A. only) of XXXKX,FUEL SYSTEM Route the vacuum tubes as described on the Vacuum Hose ee Routing Label ‘VACUUM HOSE ROUTING DIAGRAM. NOTE EVAPORATIVE FAMILY 58 XE "fe cael not 0 band fist orknk the tubes when install cau voc Koy ie + Side the end of each tube ful onto its iting orm cox . "Secure tho tbe withthe hose camps whenever spect, sow / Check that the hoses are nat cantacting sharp edges or cor ey g ‘ AFTER ‘85: ‘VACUUM HOSE ROUTING DIAGRAM Yo FURL COCK m manor | 4-19ENGINE REMOVAL/INSTALLATION 24—30 Nem (2,4~3.0 kom, 17-22 to) J) 24-30 Nem (2.4-3.0 kgm, 17~22 feb} FON a5 5 nen _13.5-4.5 kgm, 25-32 feb) 35—45 New (3.54.5 kgm, 25-32 fetb) 38-45 Nem (3.5—4.5 kgm, 25-32 feb}5. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION 5-1 ENGINE INSTALLATION 56 L ENGINE REMOVAL 5-2 SERVICE INFORMATION GENERAL, © A tloo: jack or other adjustable support is required to support and maneuver the engine © The following parts or components can be serviced with the engine installed in the frame. + Carburetor (Section 4), Cylinder head, cylinder, piston (Section 6 and 71 Drive pulley, clutch, driven pulley (Section a) + Final reduction (Section 9) SPECIFICATIONS TEM SPECIFICATION Engine dry weight — |___ 26.5 ko (58.42 th) Sa ai change Fo ter 0.86 US 0.70 inp a at disassembly 1.0 liter (1.06 US at, 0.88 Imp at) Transmission oil capacity at change (0.15 liter 10.16 US at, 0.13 Imp at) at disassembly 0.18 liter (0.19 US at, 0.16 Imp att Coolant capacity engine and radiator 10.78 titer 10.83 US at. 0.68 Imp at) reserve tank 0.33 liter (0.35 US at, 0.29 Imp at) total capacity 1.11 Titer (1.17 US at, 0.98 Imp atl TORQUE VALUES Engine hanger bolt 35—45 Nem (3.64.5 kg-m, 25-32 feb} Engine mounting bolt 35-45 Nem (3.54.5 kg-m, 25-32 feb} Rear shock absorber mounting bolt 24—30 Nem (2.4—3.0 kg-m, 17-22 ted} Engine hanger stopper nut 24 30.Nem (2.4 3.0kg-m, 17-22 feb} Engine hanger bracket bolt 3545 Nem (3.54.5 kg-m, 25-32 ft-lb} TOOL Speci Engine hanger setting too! (07973 -KJ90000 Not available in U.S. A 5-1ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL (1) EXHAUST MUpFLER Place the scooter on its center stand. Disconnect the battery negative cable at the battery negative terminal Drain the engine oil and coolant. Remove the exhaust mutfier (page 15-2 Disconnect the thermosensor wire connector from the thermo: stat housing. Disconnect the fuel tube at the carburetor sida, Disconnect the vacuum tube at the fuel valve side (2) THERMOSENSOR WIE] Disconnect the water hose from the thermostat housing and the water pump. Disconnect the alternator, pulse generator, and auto bystarter wire couplers and connectors.ENGINE REMOVAL/INSTALLATION Loosen the throttle cable lock nut and adjusting nut, and dis connect the throttle cable from the carburetor. Remove the screw and battery megative cable from the starter Remove the spark plug cap, Remove the bolts attaching the brake cable clamps and remove the rear brake adjusting nut, (CLAMPS 5-3ENGINE REMOVAL/INSTALLATION Remove the rear shock absorber mount bolts and remove the rear shock absorbers. Remove the engine mounting bolt and nut. / (1) ENGINE MOUNTING BOLT/NUT Disconnect the starter motor positive cable from the starter motor. Remove the engine from the frame.ENGINE REMOVAL/INSTALLATION ENGINE HANGER BRACKET REMOVAL Disconnect the CDI unit wire couplers and remove the CDI unit, Remove the stopper nut, washer, and stopper rubbers. Inspect the stopper rubbers for damage and replace if neces sary. Remove the engine hanger bracket bolt, nut, and engine hanger bracket. Inspect the engine hanger bracket and engine hanger for wear ‘or damage. Check the rubber bushing for damage and replace any parts it necessary, 4 (2) ENGINE HANGER ENGINE HANGER BRACKET INSTALLATION ‘Assemble the engine hanger and engine hanger bracket with the bolt and nur. NOTE +o not tighten the nut at this time (2) STOPPER NUT 2430 Nem (2.4~3.0 ko-m, 17-22 felb) ie HANGER, (3) ENGIN \I (1) ENGINE HANGER BRACKET 35—45 Nem (3.5-4.5 kom, 25-92 fro) 5-5ENGINE REMOVAL/INSTALLATION Install the engine hanger setting toa! as shown and tighten the TORQUE: 3545 Nem (3.54.5 kg-m, 25-32 ft-lb) Remove the tool and install the engine henger assembly on the frame with the engine hanger bracket bolt and nut and tempo: ranly tighten the nut Install the stopper rubbers, washer, and stopper aut and tight: fen the stopper nut. TORQUE: 2430 Nim (2.43.0 kgm, 17—22 ft-lb) Tighten the engine hanger bracket bolt and mut TORQUE: 35—45 Nem (3.5~4.5 kg-m, 25—32 ft-lb) ENGINE INSTALLATION Lubricate the engine pivot bushings with grease and make sure the O-rings are in good condition and in place. Install the engine in the reverse order of removal NOTE Route the wires and cables properly (Page 1-7) + Fill the crankcase and final reduction case to the proper levet with the recommended oil (Section 2) + Fil the cooling system (Page 12-2) Perform the following inspection and adjustment: Throttle operation (Page 3-4) Rear brake adjustment (Page 3-11) TORQUE VALUES. Engine mounting bolt: ‘3545 Nem (3.5- 4.5 kgm, 25~ 32 feb) Rear shock absorber mounting bolt: 24-30 Nem (2.83.0 kg-m, 1722 feb} [ITDENGINE HANGER SETTING TOOL 07993 KJ80000 (Not available in U.S.A. (1) ENGINE HANGER BRACKET BOLT Oe (2) PIVOT BUSHING,CYLINDER HEAD/VALVES (0.8-1.2 kgm, 6~9 feo) t 1 (0.81.2 kgm, 6—9 feb} 18-22 Nem (1.82.2 kgm, 13—16 feb)SERVICE INFORMATION TROUBLESHOOTING CYLINDER HEAD COVER REMOVAL CYLINDER HEAD COVER DISASSEMBLY CAMSHAFT REMOVAL CYLINDER HEAD REMOVAL CYLINDER HEAD DISASSEMBLY VALVE GUIDE REPLACEMENT 6. CYLINDER HEAD/VALVES VALVE SEAT INSPECTION AND REFACING CYLINDER HEAD ASSEMBLY CYLINDER HEAD INSTALLATION CAMSHAFT INSTALLATION CYLINDER HEAD COVER ASSEMBLY CYLINDER HEAD COVER INSTALLATION 6-10 6-12 6-13 6-14 6-15 6-15 SERVICE INFORMATION GENERAL This section covers maintenance of the cylinder head, valves, camshaft and rocker arms. © The cylinder head can be serviced with the engine installed in the frame. SPECIFICATIONS ie [ ‘STANDARD min a) SERVICE LIWAIT ram Onn Compression pressure 7 1,300 = 200 kPa (13 + 3 kg/cm, 184 + 28 psi) =- Camshaft | Cam height — | 30.80 }0.920 (1.2126 1.2173), 30.75 (1 211) ex | s0.411~30.531 (1.9726-1.2020) | 90.26 (1.191) Rocker am | Rocker erm .D._—*|_—_—12.000-12.01810.4724-0.4732) | _12.10.0.476 | Shaft 8 “71.966 -11.984 (0.4711-0.4718) 11.91 (0.469) Valve | Vavestem.b. [iN | 4.978-a.990(0.1958-0.1985) | _-4.2010.193) | [__ 4.955=4.970 (0.1951-0.1957) 4.90 10.19) Voive guide 1B. ~~ 5.000-.012 (0.1969-0.1973) 5.030.196) Stemsto-gude [IN| _0.010=0.037 (0,0008-0.0015) | 0.08 (0.008) clearance ex | __0.030~¢ 0.057 (0.0012. 0.0022) | 0.10 (0.004) | | | Vaive spring [Inner [ 32.30.27) 91.16 free length Outer 38.0 (1.38) 31.5 (1.24) [Valve seotwith sf SSC«t OA “18000 | Cylinder head warpage = 0.05 10.002) TORQUE VALUES Cylinder head cover bolt Cylinder head cap nut Gil bolt (8 mm) 8 Cam chain tensioner sealing bolt Cam chain tensioner bolt Camshaft holder bolt 812 Nem (0.8—1.2 kg-m, 6-9 feb) 20-24 Nem (2.0-2.4 kg-m, 15—17 feb) 12 Nem (0.81.2 kg-m, 6-9 ft-lb} 4—6 Nem (40-60 kg-cm, 35—52 in-tb) 6-10 Nem (0.61.0 kg-m, 4.37.2 feb) 8-12 Nem (0.8- 1.2 kg-mm, 6-9 ftlb) 6-1CYLINDER HEAD/VALVES TOOLS Special Valve guide reamer, 6.0 mm 07984—MA60000 Valve guide driver, 6.0 mm 07942 MA60000 Common Valve guide driver 07743--0020000 Valve spring compressor 077870010000 TROUBLESHOOTING Engine top-end problems usually affect engine performance. These can be diagnosed by 8 compression test, or by tracing noises with a sounding rod or stethoscope. Low compression + Valves = Incorrect valve adjustment Burned or bend valves — Incorrect valve timing — Broken valve spring + Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head + Cylinder and piston (Section 7) Compression too high + Excessive carbon build-up on piston or combustion chamber Excessive noise + Incorrect valve adjustment + Sticking valve or broken valve spring + Damaged or worn camshaft + Loose or worn eam chain + Worn or damages cam chain tensioner + Worn cam sprocket teeth + Worn rocker arm and or shaft 6-2CYLINDER HEAD/VALVES CYLINDER HEAD COVER REMOVAL (Lervacuowrose Remove the following parts: — seat, — Fight and left rear cover and frame center cover (page 13-21 right and left side rail (page 13-5). Disconnect the fuel and vacuum tubes and remove the fuel tank (page 4-14) Remove the two oil bolts and the oil pipe bolt. Slide the oil pipe to right side so that the eylinder head cover ‘can be removed CAUTION + Do not bend the oil pipe to remove the cylinder head cover or the oil pipe will be damaged. Remove the five cylinder head cover bolts and the air cleaner stay bolt, and then remove the cylinder head cover, Remove the dowel pinscyt DER HEAD/VALVES CYLINDER HEAD COVER DISASSEMBLY (4) 0-RING (1) ROCKER ARMS Remove the O-ring from the cylinder head cover. Remove the valve adjuster lock bolts. Remove the rocker arm shafts and rocker arms from the head J (2) ROCKER (3) ADJUSTER BOLTS ARM SHAFT INSPECTION (3) ROCKER ARM SHAFT (1) ROCKER ARM, / / ROCKER ARM Inspect the rocker arms for wear or damage to the camshaft contact surface or for a clogged cil hole. Measure the |.D. of each rocker arm. SERVICE LIMIT: 12.10 mm (0.476 in) ROCKER ARM SHAFT Inspect the shaft for wear or damage Measure each rocker arm shaft 0.0, SERVICE LIMIT: 11.91 mm (0.469 in) CAMSHAFT REMOVAL Remove the exhaust muffler (page 18-2). Remove the cam chain tensioner sealing bolt and spring. Remove the two bolts attaching the cam chain tensioner and the tensioner, Remove the drive belt air cleaner cover by removing the four (2) cover 6-4Remove the timing hole cap and turn the drive pulley so that the “"T” mark on the flywheel aligns with the index mark Remove the two camshaft bearing holder bolts and the bearing holder. Remove the camshaft Suspend the cam chain with a piece of wire to keep it from fall ing into the crankcase. NOTE + Be careful not to drop the bolts into the crankcase. CAMSHAFT INSPECTION Check each cam lobe for wear or damage. Measure the cam lobe height. ‘SERVICE LIMIT: INTAKE: 30.75 mm (1.211 ind EXHAUST: 30.26 mm (1.191 in) Check each camshaft bearing for play or damage. Replace the camshaft assembly with @ new one if the bearings are noisy or have excessive play. TU ORIVE PULLY CYLINDER HEAD/VALVES 72) INDEX MARC (1) CAMSHAFT BEARING 6-5CYLINDER HEAD/VALVES CYLINDER HEAD REMOVAL ee Bai 0 TeenvostaT HousING Remove the thermostat housing from the cylinder head by re moving the batt Loosen the carburetor bands and disconnect the vacuum tube from the carburetor insulator. Remove the crankcase breather separator attaching bolts and the breather separator. Remove the four cylinder head cap nuts and washers Remove the cylinder head, (1) CARBURETOR, INSULATOR, Remove the carburetor insulator by removing the two bolts 6-6CYLINDER HEAD/VALVES Remove the cylinder head gasket and two dowel pins. TH DOWEL PINS. Remove the cam chain guide from the cylinder. Remove all gasket material from the cylinder head mating sur face. NOTE + Avoid damaging the gasket surface. + Be careful not to drop gasket material into the crankcase CYLINDER HEAD DISASSEMBLY Rlomove the valve spring cotters, retainers, springs, spring seats and valves. CAUTION To prevent loss of tension, do not compress the valve springs _more than necessary t0 remove the cotter. NoTE (1) VALVE SPRING COMPRESSOR + Mark all disassembled parts to ensure correct reassembly. a : = 07757 -0010000 Remove the valve stem seals. Remove carbon deposits from the combustion chamber: Clean off any gasket material from the cylinder head gasket surface. NOTE + Avoid damaging the gasket surfaces + Gaskets will come off easier if soaked in solvent.CYLINDER HEAD/VALVES INSPECTION CYLINDER HEAD Check the spark plug hole and valve areas for cracks. ‘Check the cylinder head for warpage with a straight edge and feeler gauge. SERVICE LIMIT: 0.05 mm (0.002 in) VALVE SPRING FREE LENGTH ‘Measure the free length of the inner and outer valve springs. ‘SERVICE LIMITS: INNER (IN, EX): 29.1 mm (1.16 in) OUTER (IN, EX}: 31.6 mm (1.24 in) VALVE STEM Inspect each valve for bending, burning, scratches or abnormal stem wear, ‘Check valve movement in the guide and measure and record each valve stem 0.0. ‘SERVICE LIMITS: IN : 4.90 mm (0.193 in) EX: 4.90 mm (0.193 in) VALVE GUIDE NOTE + Ream the guides to remove any carbon build-up before checking clearances, (1) VALVE GUIDE REAMER, 5.0 mm 4 (07984 —MA60000 Measure and record each valve guide I.D. using a ball gauge or inside micrometer. SERVICE LIMIT: 5.03 mm (0.198 in) Subtract each valve stem 0.D. from the corresponding guide LD. to obtain the stem-to-guide clearance. \ SERVICE LIMITS: IN : 0.08 mm (0.003 in) “ EX: 0.10 mm (0.004 in} 6-8NOTE + If the stem-to-guide clearance exceeds the service limits, determine if a now guide with standard dimensions would bring the clearance within tolerance. If 80, replace any guide as necessary and ream to fit. If the stem-to-guide clearance exceeds the service limits with new guides, replage the valves also. NOTE Reface the valve seats whenever the valve guides are re- placed. VALVE GUIDE REPLACEMENT Heat the cylinder head to 100°C (212°F} with a hot plate or CAUTION + Do not wse a torch (0 heat the cylinder head it may cause warping. + To avoud burns, wear heavy gloves when handling the heated evlinder head ‘Support the cylinder head and drive out the old guides from the combustion chamber side of the cylinder head. NOTE + Alter driving the guides in, check them for damage. + The cylinder head shoul stil be at 100°C (212°F} for in- stallation of @ new guide. ‘Adjust the valve guide driver so that the valve guide height is 13 mm (0.51 in). Drive a new guides into the cylinder head from the rocker arm side, Let the cylinder head cool to room temperature and ream the new valve guides, NoTE + Use cutting oil on the reamer during this operation, + Rotate the reamer in the same ditection when inserting and removing it Reface the valve seat and clean the cylinder head thoroughly to remove any metal particles. CYLINDER HEAD/VALVES (1) VALVE GUIDE DRIVER, 5.0 mm 0794260000 1) VALVE GUIDE DRIVER 07743-00200 fy 13mm ost “rep cL (1) VALVE GUIDE REAMER, 5.0 mm (07984~MA60000 6-9CYLINDER HEAD/VALVES VALVE SEAT INSPECTION AND REFACING Clean all intake and exhaust valves thoroughly to remove carbon deposits. ‘Apply a light coating of valve lapping compound to each valve face, Lap each valve and seat using @ rubber hose or other hhandlapping tool NOTE + Take care not to allow the compound to enter between the valve stem and guide. After lapping, wash out the com: pound completely and apply a coat of engine oll tothe valve face and seat. Remove the valve and inspect the face. ‘CAUTION +The valves cannot be ground. If the valve face is rough, worn unevenly, or contacts the seat improperly, the valve must bere placed. Inspect the valve seat If the seat is 100 wide, too narrow, or has low spots, the seat must be ground. SEAT WIDTH: ‘Service limit: 1.6 mm (0.06 in) Check the valve face for even contact VALVE SEAT GRINDING Honda Valve Seat Cutters, grinder or equivalent valve seat refacing equipment are recommended to correct @ worn valve Follow the instructions supplied with the Valve Seat Refacing Equipment Using a 45 degree cutter, remove any roughness or itegular ties from the seat. NoTE + Reface the seat with a 45 degree cutter when the valve uide is replaced, Use 2 32 degree cutter to remove 1/4 of the existing valve seat material (1) SEAT WIDTH | (1) ROUGHNESS (1) OLD SEAT WIDTH 6-10CYLINDER HEAD/VALVES Use a 60 degree cutter to remove the lower 1/4 of the old sea. Remove the cutter and inspect the area you have just cut. (17 OLD SEAT WIDTH Install a 45 degree finish cutter and cut the seat to the proper width, 1.0 mm (0.04 in) NoTE + Make sure that all pitting and irregularities are removed. Refinish if necessary. Zs | Apply a thin coating of Prussian Blue to the valve seat. (1) CONTACT TOO HIGH Press the valve through the valve guide and onto the seat with | a mn Gut rotating tt rake a Glow peter, Ye ovo sear oe ator Nore we + The location of the valve seat in relation to the valve face is 329. very important for good sealing mom If the contact area is too high on the valve, the seat must be lowered using a 32 degree flat cutter Refinish the seat to specifications using 2 48 degree seat cut- L——_— ter (1) CONTACT TOO Low If the contact area is too low on the valve, the seat must be raised using @ 60 degree Inner cutter. | | LD SEAT: Rlinsh the sat 1 specctons using 045 degre set cu eae o | | | / wor | 6-11CYLINDER HEAD/VALVES After cutting the seat, apply lapping compound to the valve face and lap the valve using light pressure ‘After lapping, wash all residual compound off the cylinder head and valve, CYLINDER HEAD ASSEMBLY (6) INNER (7) SPRING SEAT Seas the vate gues ws) ouren Intl ne wel stem seas Seni Int tho ve oping seat sping and rete The song’ thy wound cols shuld fce In toward the combust chenbe Ld Oo vauve ee (2) stew seat S14) COTTERS (2) SPRING RETAINER Compress the vaive springs using the valve spring compres- sor, then install the valve cotters. CAUTION + To prevent loss of tension, ‘more than necessary. (1) VALVE SPRING COMPRESSOR 077870010000 ‘Tap the vaive stems gently with a plastic hammer as shown to ficmiy seat the cotters CAUTION + Support the cylinder head above the working bench surface 10 prevent possible valve damage. 6-12CYLINDER HEAD/VALVES CYLINDER HEAD INSTALLATION Install a new O-ring in the carburetor insulator groove and then install the insulator with two bolts (1) O-RING. Install the dowel pins and new gasket, Install the cylinder head 4 py, WT) CAP NUTSIWASHERS Install the cylinder head cap outs and washers and tighten E them in a crisscross pattern in two or more steps. TORQUE: 20~24 Nem (2,0—2.4 kg-m, 15-17 fib) Install the spark plug and cap, Install « new O-ring in the thermostat housing and install the Af) THERMOSTAT] (2) BREATHER SEPARATOR hhousing with the bot. HOUSING MM 1 Install the breather separator with two bolts.CYLINDER HEAD/VALVES CAMSHAFT INSTALLATION cu cain Seno ai (3) CAM CHAIN (4) INDEX MARK, Lubricate the camshaft bearings with clean engine cil Remove the timing mark hole cap. ‘Turn the drive pulley and align the “"T"” mark on the flywheel with the index notch on the right crankcase. Position the intake and exhaust cam lobes down. Align the punch mark on the cam sprocket with the cylinder head surface and install the cam chain over the cam sprocket. Install the camshaft bearing holder and tighten the holder bolts NOTE + Be careful not to drop the bolts into the orankcase Install # new cam chain tensioner gasket. Release the fock pawl and push the push rod all the way in. (3) TENSIONER Install the tensioner using the two bolts TSO RING ‘TORQUE: 610 Nem (0.6—1.0 kg-m, 4.3—7.2 feb} Install the tensioner spring, O-ring and sealing bolt. ‘TORQUE: 4—6 N-m (40—60 kg-om, 35—52 in.) (1) SPRING 6-14CYLINDER HEAD/VALVES CYLINDER HEAD COVER ASSEMBLY (1) O-RING Install new O-rings onto each rocker arm shaft Apply engine oil to the rocker arm shafts Install the rocker arms and shafts onto the cylinder head cover. Install the valve adjuster lock bolts loosely CYLINDER HEAD COVER INSTALLATION Fill the olf pocket in the cylinder head with clean engine oil to provide initial lubrication for the cam shaft when the engine is started. Install two dowel pins in the cylinder head Install the seal rubber into the groove in the cylinder head Install the cylinder head cover Install the sir cleaner stay and five 6 mm flange bolts Tighten the 6 mm flange bolts in a crisscross pattern in two or more steps. TORQUE: 8—12 Nem (0.81.2 kg-m, 6-9 feb) [Attach the air cleaner case to the stay with the bolt j (2) CYLINDER HEAD COVER Install and tighten the two oil bolts and oil pipe bolt. ene eal NOTE + Make sure that the sealing washers are in good conditions. ‘TORQUE: OIL PIPE-TO-CYLINDER HEAD BOLT (BLACK) 8~12 Nem (0.8—1.2 kg-m, 6-9 feb) OIL-PIPE-TO-RIGHT CRANKCASE COVER BOLT (SILVER) 8-12 Nem (0.81.2 kg-m, 6-9 feb) (3) OL PIPE BOLT 6-15CYLINDER HEAD/VALVES Install the fuel tank (page 4-15) and connect the fuel tube and vacuum tube Install the right and left side rails, seat, frame center cover and Fight and left rear covers (section 13}, 6-16CYLINDER/PISTON B12. Nem {0.81.2 kgm, 6-9 fb) 7-0SERVICE INFORMATION ‘TROUBLESHOOTING |_ CYLINDER REMOVAL SERVICE INFORMATION GENERAL 7. CYLINDER/PISTON 7-1 PISTON REMOVAL 7-1 PISTON INSTALLATION 7-2 CYLINDER INSTALLATION ‘© The cylinder and piston can be serviced with the engine in the frame. SPECIFICATIONS 73 16 16 eM | Cylinder Werpage Piston, | Ring-to-groove Top Piston ting | clearance = Ring end gap Piston 0.0. | Piston-to-cylinder cl Piston pin bore Piston pin 0.0. Piston-to-piston pin clearance { Connecting rod smal end 0, STANDARD mm (ind SERVICE LIMIT mm (in) 58,000— 58.010 (2.2835 ~ 2.2839) | 0.015—0.080 (0.0006—0.0020) 0.018 0.050 (0.0006 - 0.0020) 0.15—0.80 (0,006-0.012) (0.15—0.80 (0.006-0.012) 0.20.9 (0.080.035) 57.975 57.995 (2.2825-2.2833) | (0.010--0.040 (0.0004 0.0016) (0.08 (0.004) 58.10 (2.287) 0.05 (0.002) 0.08 (0.004) 0.50 10.020) 0.50 (0.020) 87.90 (2.280) 0.10 10.008) 15.002 ~ 15.008 (0.5806 -0.5909) 14,994— 15.000 (0.5903—0.5908) _ 0,002 0.014 (0.0001 0.0008) 15.016 15.034 (0.5912-0.5919) 15.06 (0.583) 15.04 (0.582) 14.96 (0.589) 0.02 (0.001) TORQUE Cylinder base bolt TROUBLESHOOTING Low compression or uneven compression + Worn cylinder oF piston ring Excessive smoke Worn cylinder, piston or piston rings + Improperly installed piston rings + Damaged piston or cylinder Overheating + Excessive carbon build-up on piston head + Blocked of rastricted flow of coolant + Sticking thermostat Knocking or abnormal noise + Worn piston and cylinder + Excessive carbon build-up on piston head 8-12Nem (0.8 1.2 kg'm, 6-9 feb)CYLINDER/PISTON CYLINDER REMOVAL Remove the cylinder head (Section 6). Remove the water hose from the cylinder. Remove the cylinder base bolt and cylinder. » T~arcyunpen | “BASE BOLT! Remove the cylinder gasket and dowel pins. Clean any gasket material from the cylinder surface. NoTE + Gasket material will come off easier if it ie soaked in sol- vent. INSPECTION Inspect the cylinder bore for wear or damage Measure the cylinder 1.0. at three levels in both the X and Y ‘SERVICE LIMIT: 58.10 mm (2.287 in} (1) TOP, (2) MIDDLE (3) BOTTOM 7-2CYLINDER/PISTON Ingpect the top of the cylinder for warpage. SERVICE LIMIT: 0.05 mm (0.002 in} PISTON REMOVAL Place clean shop towels in the crankcase to keep the piston pin clips, of other parts from falling into the crankcase. Remove the piston pin clips with pliers Press the piston pin out of the piston (2) PISTON PIN CUP INSPECTION Measure the piston 0.0. NoTE + Take measurements at 10mm (0.4 in] from the bottom, and 20° to the piston pin hole. ‘SERVICE LIMIT: 57.90 mm (2.280 in} Calculate the piston to-eylinder clearance ‘SERVICE LIMIT: 0.10 mm (0.004 in} Measure the piston pin hole ID. SERVICE LIMIT: 15.04 mm (0.592 in)CYLINDER/PISTON Measure piston pin 0.0. SERVICE LIMIT: 14.96 mm (0.589 in} Calculate the piston pin-to-piston clearance. ‘SERVICE LIMIT: 0.02 mm (0.01 in} Measure the piston ring-to-groove clearance, SERVICE LIMITS: TOP 0.09 mm (0.004 in) 2nd 0.09 mm (0.004 in) Remove the piston rings. Inspect the piston for damage and the ring grooves for wear. ‘CAUTION + Piston rings are easily broken; take care not 10 damage them during removal. Insert each piston ring into the cylinder 20 mm (0.75 in) in from the bottom. To ensure that it’s square in the bore, use a piston to push it in, Measure the ring end gap. SERVICE LIMITS: ‘TOP 0.50 mm (0.020 in) 2nd 0.50mm (0.020 in)CYLINDER/PISTON Measure the connecting rod small end |.D. SERVICE LIMIT: 15.06 mm (0.593 in) PISTON RING INSTALLATION Clean the piston head, ring lands, and skirts. Carefully install the piston rings onto the piston, ‘Stagger the ring end gaps as shown. NOTE + Be careful not to damage the piston and piston rings during assembly + All rings should be installed with the markings facing up, + After installing the rings they should rotate freely, without sticking. (tor (2) SECOND (3) SIDE RAIL (4) SPACER (5) SIDE RAIL 20 mam (9% in) 20 mm (0.8 in)CYLINDER/PISTON PISTON INSTALLATION TiN" MARK Install the piston and piston pin. Position the piston "IN" mark fn the intake valve side. Install new piston pin clips NoTE + Do not align the piston pin clip end gap with the piston cut out. + Place a shop towel eround the piston skirt and in the crank: case to prevent the piston pin clips from falling into the crankcase. CYLINDER INSTALLATION Remove any gasket material from the crankcase surface being careful not to get any in the crankcase, NOTE + Gasket material will come off easier if itis soaked in sol Install the two dowel pins and a new cylinder gasket. Coat the cylinder bore, piston and piston sings with fresh engine oil Carefully lower the cylinder over the piston by compressing the piston rings, one at a time. cauTion + Do not force the eylinder over a ring; you may damage the piston and piston rings. Loosely install the cylinder base bolt. Connect the water hose to the cylinder Install the cam chain guide, NOTE + Push the guide in until it bottoms in the crankcase guide hole. {nstall the cylinder head (Section 6} Tighten the cylinder base bolt 11) CYLINDER BASE BOLT f TORQUE: 8—12 Nem (0.81.2 kgm, 6~9 feb) 7-6DRIVE PULLEY/CLUTCH/DRIVEN PULLEY 50-60 Nm og - (5.06.0 kgm, 36-43 feb) KPA F200, iss © aoe ©®S6/Z eee eel (ae ¢ 50-60Nem (5.0. 6.0 kgm, 36-43 feb) 8-08. DRIVE PULLEY/CLUTCH/DRIVEN PULLEY SERVICE INFORMATION 8-1 DRIVE PULLEY 83 TROUBLESHOOTING 8-2 CLUTCH/DRIVEN PULLEY 88 |_ LEFT CRANKCASE COVER 83 SERVICE INFORMATION GENERAL © The drive pulley. clutch and driven pulley can be serviced with the engine installed, © Avoid getting grease and oil on the drive belt and pulley feces. SPECIFICATIONS [ TEM STANDARD mm (in) ‘SERVICE LIMIT mm (in) Movable drive face bushing LO. __27.000~27.021 (1.0630— 1.0638) 27.06 (1.085) | 3] Drive face boss 0.0. _ | 26.870 26.990 11.0618- 1.0626) | 26,94 (7.061) Drive belt width _ 190078) 17.5 10.689) _ Clutch lining thickness _ _ = 2.0 10.08) Chitchouter\D. ___180.0- 130.2 (6.12~8.13)_ 130.5 (5.14) Driven face spring free length _ 88.3 13.476) 83.2 13.28) Driven face 0.0. [= 33.965— 35.985 (1.3372 1.4167) 33.94 (1.336) Movable driven face LD. iz 34,000~34.025 (1.3386-1.3396) | 4.061.362) “Weight roller 0.0. i 19.95—20.10 (0.785 0.791) 19.5 (0.77) TORQUE VALUES Clutch drive plate nut 50-60 Nem (5.0 6.0 kg-m, 36—43 ft-lb) Drive face seal covar bolt 3—5 Nem (30~50 kg-cm, 26-43 in-b) Clutch outer nut 35~40 Nem (3.5~ 4.0 kg-m, 2529 feb} Drive face nut 50-60 Nem (5.0 -6.0 kg-m, 36—43 fr-ib} TOOLS Special Lock nut wrench, 39 mm 07916~1870002 Clutch spring compressor 07360—KWw10000 Bearing driver 07945~GC80000 Common Universal holder 077250030000 Driver (077490010000 Pilot, 20 mm 07748 0040500 Attachment, 32 x 35 mm 07746-0010100DRIVE PULLEY/CLUTCH/DRIVEN PULLEY TROUBLESHOOTING Engine starts but scooter won't move + Worn deive belt + Damaged ramp plate + Worn or damaged clutch lining Engine stalls or scooter creeps + Broken clutch weight spring Poor performance at high speed or lack of power + Worn drive belt + Weak driven face spring + Faulty driven faceDRIVE PULLEY/CLUTCH/DRIVEN PULLEY LEFT CRANKCASE COVER REMOVAL Remove the left rear cover and left side sail (page 13-2) Remove the drive belt air cleaner cover screws and cover. Remove the rear brake cable clamps, Remove the left crankcase cover bolts and left crankcase (2) BOLTS, INSTALLATION Install the dowel pins. Saas garam mae Install the seal rubber on the left crankcase cover. net eet bolts, being careful that the rubber seal isin position. Install the brake cable clamp. DRIVE PULLEY TDAIVE FACE NUT Q REMOVAL S&S Remove the left crankcase cover Hold the drive pulley and remove the drive face nut, washer and drive pulley face. (3) UNIVERSAL HOLDER, (07725 --0030000DRIVE PULLEY/CLUTCH/DRIVEN PULLEY Pll out the drive belt from the drive pulley face collar and then. remove the drive belt from the driven pulley to avoid damaging the belt INSPECTION Check the drive belt for cracks, separation or abnormal or ex: Measure the drive belt width. SERVICE LIMIT: 17.5 mm (0.689 in) | Remove the moveable drive face assembly. NOTE + IF the spline fitting is tight, use a commercially avai bearing puller Remove the drive pulley collar. (2) DRIVE PULLEY COLLAR Pipes DISASSEMBLY (1) 80LTs, Remove the three bolts and remove the drive face seal cover. (2) DRIVE FACE SEAL COVERRemove the ramp plate and O-ring, Remove the weight rollers. INSPECTION Check each raller for wear or damage. Measure the weight rollers 0.0. ‘SERVICE LIMIT: 19.5 mm (0.77 in) Check the face seal for wear or damage Feplace the face seal with a new one if nicessary DRIVE PULLEY/CLUTCH/DRIVEN PULLEY (1) RAMP PLATE (2) O-RING (1) WEIGHT ROLLERS (1) FACE SEALDRIVE PULLEY/CLUTCH/DRIVEN PULLEY Measure the moveable drive face bushing I.D. SERVICE LIMIT: 27.06 mm (1.065 in) Check the drive face boss for wear or damage. Measure the 0.0. at the drive face sliding surface. SERVICE LIMIT: 26.94 mm (1.061 in) ASSEMBLY 3-5 Nem (30-50 kg-cm, 26-43 ino} (1) FACE SEAL COVER, (2) WEIGHT ROLLERS he (oh DRIVE PULLEY COLLAR (6) RAMP PLATE (4) MOVEABLE DRIVE FACE 50-60 Nenv (5.06.0 kg-m, 3643 feb} 8-6DRIVE PULLEY/CLUTCH/DRIVEN PULLEY Lubricate the inside of the rive face with grease, then instal the weigh oes can (1) WEIGHT ROLLERS NOTE Use 25—30 9 of grease and apply evenly to the inside, Specified grease: Lithium based grease + Mitsubishi: HD—3 Nippon Sekiyu: Lipanox Deluxe 3 + Idemitsu: Autolex + BelRay Moly Lube 126 EP#O + Sta-Lube MP Grease #3141 (2) FACE SEAL Apply grease to the O-ring and install it. (1) RAMP PLATE (3) FACE SEAL COVER Install the ramp plate and face seal cover, and tighten the cover attaching bolts ‘TORQUE: 3—5 Nem (30-50 kg-em, 26-43 intb) Note + Moke sure that the O-ring is in position. (2) O-RING (4) BOLTS INSTALLATION (1) DRIVE FACE COLLAR Apply grease to the drive pulley collar and insert it into the moveable drive pulley face Clean off any grease or oll rom the drive pulley faces. Install the moveable drive face onto the crankshaft. 2) CRANES RAFT 8-7DRIVE PULLEY/CLUTCH/DRIVEN PULLEY Lay the drive belt on the driven pulley. Squeeze the drive belt to widen the riven pulley faces then set the drive belt on the drive pulley face collar. Clean the drive pulley face and install the pulley face on the crankshaft ‘Set the washer on the crankshaft and loosely install the drive face aut. (2) DRIVE FACE NUT Hold the drive pulley and tighten the drive face nut. Ti) UNIVERSAL HOLDER, 077250030000 TORQUE: 50-60 Nem (5.06.0 kgm, 36-43 ft-lb) Ww Don ‘get oil or grease on the drive belt or pulley faces. Reinstall the removed parts in the reverse order of removal. CLUTCH/DRIVEN PULLEY REMOVAL Remove the left crankcase cover and drive belt (page 83). Hold the clutch outer and remove the driven pulley nut, Remove the clutch outer. (2) UNIVERSAL HOLDER 977250030000 8-8DRIVE PULLEY/CLUTCH/DRIVEN PULLEY INSPECTION Check the clutch outer for wear oF damage. Measure the clutch outer .D. SERVICE LIMIT: 130.5 mm (5.14 in) Check the clutch shoes for wear or damage Measure the clutch lining thickness. ‘SERVICE LIMIT: 2.0 mm (0.08 in) See page 8-12 for clutch shoe replacement. NOTE + Replace the clutch shoes as 8 set. Remove the driven pulley/eluteh assembly. ee (1) ORIVEN BUTLEVICLUTCH DISASSEMBLY (LOCK NUT WRENCH, 38. mm _ 07916~ 1870002 Hold the driven pulley/clutch assembly with the clutch spring ‘compressor. CAUTION + Donor tighten the tool more than necessary or the drive plate ‘may be damaged. ‘Set the tool in a vise and remove the 28 mm drive plate nut. (2) CLUTCH SPRING COMPRESSOR Loosen the tool and disassemble the driven pulley/clutch as aes sembly.DRIVE PULLEY/CLUTCH/DRIVEN PULLEY Remove the seal collar. ull out the guide roller pins and guide rollers. Remove the moveable driven face from the driven face. INSPECTION Measure the driven face spring length SERVICE LIMIT: 83.2 mm (3.28 in) Check the driven face assembly for wear or damage. Measure the driven face 0.D. ‘SERVICE LIMIT: 33.94 mm (1.336 in) ‘Check the bearings for play Replaced the bearing if it has excessive play (page 8-11). (1) SEAL COLLAR (1) GUIDE ROLLER (2) MOVEABLE DRIVEN FACE (3) PIN (8) DRIVEN PULLEY FACE 8-10DRIVE PULLEY/CLUTCH/DRIVEN PULLEY Check the moveable driven face for wear, seratches or scor ing. ‘Measure the moveable driven face 1.0. SERVICE LIMIT: 24.06 mm (1.362 in) Check the guide groove for stepped we CCheck the oil seal and O-ring for damag + or wear Replace if necessary, DRIVEN PULLEY FACE BEARING REPLACEMENT, Drive the needle bearing out of the driven pulley face. Remove the snap ring and drive the outer bearing out of the driven face (1) BEARING DRIVER Pack all bearing cavities with 8.0~ 8.59 grease. SoAniG DANERE ‘grease + Nippon sekiyu 3, Sta-Lub MP grease: #3141, o¢ Bel-Ray Moly Lube 126 Ep#0. Use a bearing driver to drive the outer b2aring into the driven face with the sealed end facing out. Seat the snap ring in its groove. 8-11DRIVE PULLEY/CLUTCH/DRIVEN PULLEY Press the needle beating into the driven face. (1) RIVER, (2) ATTACHMENT, 32 x 35 mm 07749-0010000 077460010100 PILOT, 20 mm 07460040500 CLUTCH DISASSEMBLY (1) cIRCUPS Remove the circlips and retainer plate. (2) RETAINER PLATE Pull out the clutch weights/shoes and spring from the drive (1) CLUTCH SPRINGS: plate. " (2) CLUTCH WEIGHT/SHOES Remove the damper rubbers from the drive plate. een (Check the disassembled parts for wear or damage, and replace if necessary NOTE Replace the clutch weights/shoes as a set 8-12DRIVE PULLEY/CLUTCH/DRIVEN PULLEY in circu (2) RETAINER PLATE (3) DAMPER RUBBER, (4) DRIVE PLATE (6) CLUTCH SPRING (5) CLUTCH WEIGHT/SHOES Install the damper rubbers on the shart pins on the drive plate. SESE (2) DRIVE PLATE avevor PINs Apply 2 small amount of grease to the clutch weight pivot pins, (3) DAMPER RUBBER. Set the clutch weights/shoes and clutch springs and then in: (1) CLUTCH SPRINGS ther onto the drive plate. 8-13DRIVE PULLEY/CLUTCH/DRIVEN PULLEY (ay cIRCLIPS Install the retainer plate and secure with the circlips. (2) RETAINER PLATE ASSEMBLY (1) DRIVEN FACE (2) MOVEABLE DAIVEN FACE (8) OWL SEAL: (7) GUIDE ROLLER PIN (5) OW'SEAL (4) ORINGS (6) GUIDE ROLLER. Clean the pulley faces. (1) o-RINGS: (2) SEAL COLLAR, Install the oil seals onto the moveable driven face Coat the O-rings with grease and install them onto the moveable driven face Apply grease to the inside of the moveable driven face. Install the moveable driven face onto the driven face. Apply grease to the guide rollers and pins and install them into the hole of the driven face. Install the seal colar 8-14DRIVE PULLEY/CLUTCH/DRIVEN PULLEY Set the driven pulley assembly, driven face spring and clutch assembly onto the clutch compressor. ‘Align the flat surface of the driven face with the flat on the: clutch drive plate Compress the tool and install the 28 mm crive plate nut loose- Wy. Set the too! in a vice and tighten the drve plate nut to the specified torque TORQUE: 5060 Nim (5.06.0 kg-m, 35-43 felb) Remove the driven pulleyiclutch assembly from the tool INSTALLATION Install the driven pulley/clutch assembly ento the drive shat Install the clutch outer and tighten the nut while holding the clutch outer with the universal holder. TORQUE: 35~40 N-m (3.54.0 kgt-m, 25-29 fib} Install the drive belt (page 8-7). Install the left crankcase cover (page 8-2) Install the removed parts in reverse order of the removal (1) LOCK NUT WRENCH, 39 mm 07916— 1870002, (2) CLUTCH SPRING COMPRESSOR (07960--kM110000. (1) UNIVERSAL HOLDER] (077250030000 8-15FINAL REDUCTION 9-09. FINAL REDUCTION SERVICE INFORMATION 9-1 FINAL REDUCTION INSPECTION 92 ‘TROUBLESHOOTING 9-1 FINAL REDUCTION ASSEMBLY 95 FINAL REDUCTION DISASSEMBLY 92 SERVICE INFORMATION SPECIFICATIONS Specified olHonda 4-stroke oil, SAE 10W—40 or equivalent Oil capacity: 0.18 liter 0.19 US at, 0.16 Imp atl at cisassembly 0.15 liter (0.16 US at, 0.13 Imp atl at change TRORQUE VALUE ‘Transmission case cover bolt 1114 Nem (1.11.4 kgm, 8 10 ft) TOOLS Special Bearing remover, 12 mm 07936—1660001 “spindle assy (079361660100) romover weight (077410010201 or 07836-3710200) Bearing remover handle 079363710100 Bearing remover, 17 mm 07936~ 3710300 Shaft protector (07931— 1870000 Seal and case assembly tool 07965-1480010 assembly collar (079651480100) assembly shaft (07965— 1480200), Universal bearing puller 076310010000 Equivatent commercially available in U.S.A. Common ‘Attaachment, 32 x 35 mm 07746-0010100 Attachment, 37 x 40 mm 077460010200 Attachment, 42 x 47 mm 077460010300 Pilot, 12 mm 077460040200 Pilot, 20 mm 077460040500 Driver 077490010000 TROUBLESHOOTING Engine starts but scooter won't move + Damaged transmission + Seized transmission seized or chipped gears ‘bearing + Oil level to0 high + Worn or damaged oil sealFINAL REDUCTION FINAL REDUCTION DISASSEMBLY Remove the driven pulley (Page 8-8. Drain the final reduction oil [Page 2-6) Remove the tear wheel (Page 15-21 Remove the transmission case cover by removing the attach: Ing bolts. Remove the gasket and dowel pins. Remove the thrust washers, Remove the final gear and final shaft Remove the countershaft and washer. FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage. Inspect the final gear and final shaft for seizure, wear or dam: (1) FINAL SHAFT age. (2) FINAL GEAR 9-2FINAL REDUCTION Jnspect the transmission case bearings: (3) DRIVE SHAE GeArING b fi2) ow seat ‘ Tum the inner race of each bearing with your finger ‘The bearings should tun smoothly and quietly. Also check that the bearing outer race fits tightly in the crankcase. Remove and discard the bearings if they de not turn smoothly, ‘quietly, or if they fit loosely in the case. Inspect the oll seal for wear or damage: replace if necessary. ee (3) COUNTER SHAFT| (4) FINAL SHAFT BEARING BEARING Inspect the transmission case cover bearings as above, andre. (1) FINAL SHAFT BEARING place thom if necessary (2) DRIVE SHAFT NoTE + Do not remove the drive shaft from the cover. the drive shaft is removed from the caver, the drive shaft bearing must be replaced with a new one, Inspect the drive shaft and gear for wear of damage. (3) DRIVE SHAFT BEARING (6) TRANSMISSION CASE (4) COUNTER SHAFT” COVER NEEDLE BEARING BEARING REPLACEMENT av oawe Samer ' BARING, CAUTION i + Never reinstall « used bearing, once the bearings are removed, they must be replaced with mew ones. Remove the drive shaft bearing from the left crankcase using the following tools: Bearing remover set, 12 mm 07936— 1660001 Spindle assy, 12mm 079361660100 Remover weight 07741 0010201 or 07936-3710201 13) COUNTER SHAFT B (2) FINAL SHAFT NEEDLE BEARING’ BEARING Remove the oll seal and drive the final shaft bearing from the left crankcase Ti ORIVER 977490010900) NOTE + The countershaft needle bearings cannot be replaced “+ Ifthe bearing in the transmission case cover fails, the cover ‘must be replaced; the same is true for the countershaft needle bearing in the left crankcase. Drive @ new drive shaft bearing into the left crankcase (2) ATTACHMENT, 32 x 35 mm! 077460010100 PILOT, 12 mm 07746 —0040200 9-3FINAL REDUCTION Drive @ new final shaft bearing inta the left crankcase. Press the drive shaft out of the transmission case cover using the shaft protector 07931 ~ 1870000, Remove the oil seat from the transmission case cover and dis card it Remove the final shaft bearing from the transmission case cover using a following tools; Bearing remover, 17 mm 07936—3710300 Remover handle (079363710100 Remover weight (077410010201 or 079363710201 Uf the drive shaft bearing has been removed with the drive shaft, remove the bearing from the drive shaft using 9 Bearing Paller and Shaft Protector 07931 ~ 1870000. Drive a new drive shaft bearing into the transmission case (1) RIVER 07749. (1) DRIVE SHAFT 2010000, CES ¢. S P12) ATTACHMENT, 42 x 47 mm (07748 0010300 PILOT, 20 mm_ (07746. -0040500 (1) DRIVE SHAFT (2) DRIVE SHAFT BEARING 13) UNIVERSAL BEARING PULLER 07631 0010000 (Equivalent commercially available in U.S.Al (2) SHAFT PROTECTOR (07931 - 1870000 (a) onIvER, 07749 991 00005 12) ATTACHMENT, 42 x 47 mm 077460010300 PILOT, 20 mn 07746—0040500FINAL REDUCTION STTACHMENT, 37 x 40 mm Drive @ new final shaft bearing into the transmission case (1) DRIVER. 977460010200 cover 077490010000 ‘Set the drive shaft into the transmission case cover and pullit_ (1) ASSEMBLY SHAFT _¥ii Using a seal and case assembly tool, 07965 - 1480010 (as: (07965~ 1480200 fy sembly collar 07965~ 1480100 and assembly shaft 07965. 4 1480200), Apply grease to the lip of a new oil seal and install it. (2) ASSEMBLY COLLAR, 079651480100 FINAL REDUCTION ASSEMBLY Apply grease to the lip of the final shaft oll sea (OI SEAL Install the countershatt, final shaft, final gear and thrust wash- 11) THRUST WASHERS: (2) FINAL SHAFT (3) COUNTER SHAFT (4) FINAL GEAR 9-5FINAL REDUCTION Install the dowel pins and a new gasket. (1) Dowel PINS Install the transmission case cover with seven bolts and tight fen them, TORQUE: 11-14 Nem (1.1~1.4 kg-m, 8—10 fb) Install the moveable driven face/clutch (Page 8-15). Install the drive pulley, drive belt and left crankcase cover {pages 8-3 and 8-4) Ingtall the rear wheel (Page 15-4), Fill the final reduction case with the specified oil (page 2-1), 9-6ALTERNATOR/STARTER CLUTCH (0.81.2 kg-m, 6-9 ftib) (1.82.2 kgm, 13~16 fe) Gs, 10-010. ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION 10-1 FLYWHEEL INSTALLATION 10-6 RIGHT CRANKCASE COVER REMOVAL 10-2 STATORINSTALLATION 10.6 STATOR REMOVAL 10-2 RIGHT CRANKCASE COVER FLYWHEEL REMOVAL 10.2 INSTALLATION oe STARTER CLUTCH 10-3 SERVICE INFORMATION GENERAL @ Refer to section 5 for engine removallinstallation. @ Refer to section 16 for troubleshooting and inspection of the alternator. © Refer to section 16 for service procedures and information about the starter motor. SPECIFICATIONS aa STANDARD wi SERVICE UT | Starter driven gear 1.0, I 20.026 — 20.045 (0.7884—0.7892) 20.1010.791) TORQUE VALUES. Flywheel nut Oil bolt 8mm 10mm Starter clutch socket bolt TOOLS Special Flywheel puller Common, Flywheel holder 50—60 Nem (5.06.0 kg-m, 36-43 feb} 8-12 Nem (0.8—1.2 kg-m, 69 ftlb) 18—22 Nem (1.8-2.2 kg-m, 13—16 feb} 10-14 Nem (1.01.4 kg-m, 7—10 ft-lb} Apply a locking agent. 07933~KG20000 (077250040000 or Band strap wrench {commercially available in U.S.A.) 10-1ALTERNATOR/STARTER CLUTCH RIGHT CRANKCASE COVER REMOVAL Remove the engine (page 5-2) Disconnect the crankcase breather tube from the right crank: Remove the three oil bolts and the oll pipe bolt, and remove the oll pipe. Disconnect the water hose from the right crankcase cover. [LUDFIGHT CRARKCASE COVER Remove the right crankcase cover bolts and cover ae Remove the dowel pins and gasket. STATOR REMOVAL LUD SCREWS ggg (2) STATOR Remove the pulse generator attaching screws and the pulse ‘generator. Remove the three screws and the stator from the right erank- FLYWHEEL REMOVAL Remove the cil orifice from the end of the crankshaft, 10-2ALTERNATOR/STARTER CLUTCH Hold the flywheel with a flywheel holder and remove the ty: wheel nut. Remove the pin. Femove the flywheel with a flywhes! puller. Remove the woodrut key. STARTER CLUTCH REMOVAL Remove the starter idle gear and shaft Remove the sot plate and starter driven gear (i) Pint DP Were! Dy FLWWHEEL HOLDER 07725-0040000 or BAND STRAP WRENCH (Commercially a \) :@ wailable in U.S.A.) y 1) FLYWHEEL PULLER, 07933 KG20000 (STARTER IDI LE GEAR | + © (2) SHAFT >y-—'6) 807 TOM Baus RACE q 5-17 STEEL BALLS (19) 14-17STEERING/FRONT WHEEL/BRAKE/SUSPENSION Lubricate the top cone race with grease. (1) TOP CONE RACE Install and tighten the top cone race. NOTE Check that the steering stem rotates freely and that there is W2) STEEL BALLS no vertical play. ES TORQUE: 2—3 Nem (20-30 kg-em, 17—26 intb) Install the steering stem lock nut and tighten it while holding (1) STEERING STEM WRENCH the top cane race (07918 -GK00000 TORQUE: 10-20 Nem (1.02.0 kg-m, 7—15 feb) (2) STEERING STEM WRENCH 07916—1870101 Install the following — Front wheel (Page 14-8), Handlebar (Page 14-4), Instrument assembly [Page 16-14), 14-18REAR WHEEL/BRAKE/SUSPENSION (0.81.2 kgm, 6-9 ft 80-100 Nem (2430 Nem a" (8.0-10.0 kg-m, 58-72 ftb) (2.43.0 kgm, 1722 feb) 28. 32m (2.8-3.2 kgm, 20-23 feb) 2420 Nem (2.4-3.0 kgm, 17-22 fb) 15-015, REAR WHEEL/BRAKE/SUSPENSION SERVICE INFORMATION 15-1 REARBRAKE 15-5 | ‘TROUBLESHOOTING 15-1 REAR BRAKE PEDAL/BRAKE LOCK EXHAUST MUFFLER 15-2 SYSTEM 15-7 REAR WHEEL 15-2 REAR SHOCK ABSORBER 15.9 SERVICE INFORMATION GENERAL Refer to the Tubeless Tire Repair Manual fo SPECIFICATIONS tre, removal, repair, and remounting pracedures. [ IeMS Rear wheel rim runout Rear brake drum 1.0. Rear brake lining thickness [Rear shock absorber spring Tree length STANDARD wom tn) ‘SERVICE LINAT mm fin —— 20.08 ——— 2010.08, | Hoows ~ iit0aan 2 ee [Resta 83.8 9.20) TORQUE VALUES Rear wheel hub nut Rear axle nut Rear brake arm bolt Rear shock absorber mount bolt Rear shock absorber damper nut Rear brake pedal shaft stay nut TOOLS Special Spring holder attachment Rear shock absorber attachment Common Shock absorber compressor Driver Attachment, 42 x 47 mm Pilot, 15 mm TROUBLESHOOTING Rear wheel wobbling Bent rim Foulty tire ‘Axle not tightened properly Soft suspension + Weak shock absorber spring Brake squeaks + Worn brake linings + Foreign matter on tinings Rough brake drum shoe contacting lining 28-32 Nem (2.83.2 kg-m, 20-23 ft-lb) apply 0.1 80-100 Nem (8.0~10.0 kg-m, 58—72 ft-lb} 8—12.Nem (0.8— 1.2 kg-m, 6-9 feb), 24~30 Nem (2.4—3.0 ko-m, 17 ~22 ftb} 15-25 Nem (1.5 ~2.5 kg-m, 11—18 feb} 8-12 Nem (0.8-1.2 kg-m, 6-9 ft-lb) 07967~ 1180100 (07967—GA70001 or 07967—GA70101 07959-3290001 (077460010000 077460010300 077460040300 Poor brake performance Brake not adjusted properly Contaminated brake linings Worn brake linings Worn brake shoes at cam contacting area Worn brake cam Worn brake drum Improper engagement between brake arm and cam- shaft serrations 15-1REAR WHEEL/BRAKE/SUSPENSION EXHAUST MUFFLER REMOVAL Remove the right rear cover {page 13-2), Remove the three exhaust muffler mounting belts, two ex: haust muffler joint nuts and exhaust muffler. INSTALLATION Loosely install the exhaust muffler in the reverse order of re- ‘moval, then tighten the two joint nuts and three mounting bolts. REAR WHEEL Remove the right and left rear covers (page 13-2), Remove the exhaust muffler Remove the thee bolts and rear fender, (2) RIGHT SHOCK Remove the right rear shock absorber mount bolts and right pene rear shock absorber, Remove the rear axle nut. (IV AXLE NUT | 15-2REAR WHEEL/BRAKE/SUSPENSION Remove collar B, swing arm, collar A and the rear wheel INSPECTION WHEEL RIM Place the rear wheel in a truing stand Spin the wheel by hand and measure the rim runout using a dial gauge SERVICE LIMIT: AXIAL: 2.0 mm (0.08 in} RADIAL: 2.0 mm (0.08 in) BEARING Turn the inner race of each bearing with your finger. The bear ings should turn smoothly and quietly. Also check that the: outer race fits tightly in the crankshatt Remove and discard the bearings if the races do not tun smoothly, quietly, or if they fit loosely in the swingarm NOTE Replace the bearings in pairs. REAR WHEEL BEARING REPLACEMENT. Remove the oil seal from the swing atm. Drive the rear whee! bearings aut of the swing arm. Romove the outer oil seal (1 sync Anil si STB * (2) COLLAR BE (HOWL SEAL (2) BEARING 15-3REAR WHEEL/BRAKE/SUSPENSION Drive a new oll seal into the swing arm. “ (2) ATTACHMENT 42 x 47 mm (07748 -0010300, PILOT, 15 mm. (07746--0040300 Drive @ new bearings into the swing arm. NOTE + Do not allow the bearings to tilt while driving them in. CAUTION (1) onIVvER TION _ = — 077490010000 + Never reinstall the old bearing, Once the bearing is removed, it ‘must be replaced with a new ane. Drive @ new cil sel into the swing arm. REAR WHEEL DISASSEMBLY Remove the three nuts and remove the spoke plate from the wheel rim, Coat the threads of the flange nuts and bolts with oil, and in stall the spoke plate on the wheel rim. Tighten the flange nuts. TORQUE: 28—32 Nom (2.8-3.2 kg-m, 20~23 fib) NOTE + Align the eutout in the spoke plate with the air valve of the whee! INSTALLATION 28-32 Nem (2.8~3.2 kgm, 20-23 tt). Apply oil 15-4Install the rear wheel Install collar A, swing arm and collar 8. Install and tighten the rear axle nut. TORQUE: 80~ 100 N-m (8.0~ 10.0 kg-m, 58—72 ft-b) Install the exhaust pipe (page 15:2) Install the right and left rear cover (page 13-2), REAR BRAKE Remove the rear wheel (page 15-2) INSPECTION Measure the brake drum 1.0. SERVICE LIMIT: 111.0 mm (4.37 in) ‘Measure the rear brake lining thickness. SERVICE LIMIT: 2.0 mm (0.08 in) + Contaminated brake linings reduce stopping power. Keep grease off the linings, + Brake dust contains asbestos which can be harmful to your health. Do not use compressed air to clean brake parts. Use vacuum with a seated dust collector. Wear a protective face ‘mask and wash your hands when finished. cour » REAR WHEEL/BRAKE/SUSPENSION (2) swing ARM A) \eREAR WHEEL/BRAKE/SUSPENSION DISASSEMBLY Disconnect the brake cable from the brake arm by removing the adjusting nut and set plate bolt. Remove the brake shoes. ASSEMBLY (1) BRAKE CAM (3) BRAKE SHOES Apply grease to the brake cam and anchor pin. Install the brake cam. (4) BRAKE ARM 43) BOLT 12.Nem 1.2 kgm, 6-9 feb) = ANCHOR PIN 15-6REAR WHEEL/BRAKE/SUSPENSION Install the wear indicator plate, aligning the wide tooth of the 4 T WEAR INDICATOR. late with the wide groove on the brake cam. plate with the wide gr the braki apes Install the brake arm onto the brake cam, aligning the punch mark on the cam with the scribed line on the arm, Tighten the brake arm bolt. TORQUE: 8-12 Nem (0.8—1.2 kgm, 6—9 ft-lb) Install the brake arm return spring Install the brake shoes, Connect the brake cable to the brake arm Insert the brake cable into the groove in the left crankcase and install the plate a8 shown, Install the rear wheel [Page 15-5) Adjust tho rear brake free play (Page 3-10) (4) BOLT (3) BRAKE CABLE REAR BRAKE PEDAL/BRAKE LOCK a ~~ PBLis) BRAKE LOCK PLATE SYSTEM (1) CABLE | NUT BRAKE LOCK CABLE REMOVAL Remove the floor board (page 13-5) Loosen the brake lock cable lock nut and disconnect the brake lock cable trom the brake lock plate and spring. Remove the brake lock cable from the leg shield by loosening the cable nut (2) BRAKE CABLEREAR WHEEL/BRAKE/SUSPENSION. BRAKE CABLE/PEDAL REMOVAL Disconnect the brake cable from the brake lock, Remove the brake pedal by removing the attaching nuts. INSTALLATION Installation is the reverse order of removal NOTE + Apply grease to the sliding surfaces and the pivot, Adjust the rear brake and brake lock (page 3-12). (1) BRAKE LOCK Uz CABLE suum Goeiee £9 ge, co oraxe tock *s Ln. 6-9 fib) 15-8REAR WHEEL/BRAKE/SUSPENSION REAR SHOCK ABSORBER REMOVAL Remove the right and left rear cover (page 13-21 Remove the left rear shock absorber mount bolts and remove the left shock absorber. Remove the exhaust muller (page 15:2) and remove the right tear shock absorber mount bolts. Remove the right rear shock absorber DISASSEMBLY [11 SHOCK ABSORBER COMPRESSOR 079593290001 Install the spring compressor as shown and compress the: spring. if (2) REAR SHOCK ABSORBER ATTACHMENT 07967—GA70001 or 07967 -GA70101 Ke (8) SPRING HOLDER ATTACHMENT Sraet ieabiee ahs INSPECTION Measure the spring free length SERVICE LIMIT: 233.8 mm (9.20 in) Inspect the damper for damage and replace if necessary 15-9REAR WHEEL/BRAKE/SUSPENSION ASSEMBLY (2) SPRING SEAT (3) DAMPER. 24-30 Nm (1) SPRING (2.43.0 kgm, 17-22 feb} 15-25 Nem (1.52.5 kgm, 11-18 feb} Install the shock absorber spring with the closely wound coils (1) SHOCK ABSORBER COMPRESSOR toward the top. (07959-32900 Compress the shock absorber with the compressor and attach- ment as shown. (2) REAR SHOCK ABSORBER ATTACHMENT 07967--GA70001 or 07867—GA70101 (3) SPRING HOLDER ATTACHMENT (07967- 1180100 Extend the damper tod fully and apply a locking agent to the (1) Lock NUT threaded portion of the damper rod. Install the lower joint and tighten the lock nut TORQUE: 15—25 Nem (1.5~2.5 kgm, 11-18 feb) be 15-10REAR WHEEL/BRAKE/SUSPENSION INSTALLATION Install the rear shock absorber in the reverse order of removal and tighten the upper and lower mount bolts. TORQUE: 2430 Nem (2.43.0 kgm, 1722 feb) 15-11ELECTRICAL EQUIPMENT (2) STARTER (>) RELAY \ (1) BATTERY (10) SPARK PLUG (9) ALTERNATOR (8) PULSE GENERATOR, (6) REGULATOR! RECTIFIER (71 cI UNIT 16-016. ELECTRICAL EQUIPMENT | SERVICE INFORMATION 16-1 LIGHTS/BLUBS 16-15 | TROUBLESHOOTING 16-2. SWITCHES/HORN 16-17 | BATTERY 16-4 FUELUNIT/GAUGE 16-19 CHARGING SYSTEM 16-5 THERMOSTATIC SWITCH 16-20 IGNITION SYSTEM 16-7 TEMPERATURE GAUGE 16-21 STARTING SYSTEM 16-10 RETRACTABLE HEADLIGHT (CH150D) 16-22 INSTRUMENTS, 16-13 l - SERVICE INFORMATION GENERAL © Battery fluid level should be checked regulary. Fill with distilled water when necessary, © Quick charge a battery, only in an emergency. Slow-charging is preferred © Remove the battery from the scooter for charging, If the battery must be charged on the scooter, disconnect the battery cables. _ + Donor smoke, and keep flames avay from a charging battery. The gas produced by a battery will explode if flames or sparks are rough near. '® Ignition timing cannot be adjusted. I the timing is incorrect, inspect the CDI unit and pulse generator and replace any faulty parts. © Some wires have different colored bands around them near the connector. These are connected to other wires which cor respond with the band color ‘© All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnecting © The following color codes used are indicated throughout this section and on the wiring diagram, Bu = Blue & = Green Lg = Light Green R = Red BI = Black Gr = Gray © = Orange W = White Br = Brown Ub = Light Blue P= Pink ¥ = Yellow © To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually e made without removing the part from the scooter. Simply disconnect the wires and connect a continuity taster or volt: ‘ohmmeter to the terminals or connections, © A continuity tester is useful when checking to find out whether or not there is an electrical connection between two points. An ohmmeter is needed to measure the resistance of a circuit, such as when there is @ specific coll resistance in volved, or when checking for high resistance caused by corroded connections, SPECIFICATIONS, 18.0 A max. at 10,000 rpm (14V} Transistorized non adjustable eegulator Voltage regulator TEM SPECIFICATIONS Battery Capacity 12V 9H Z [Specific gravity [_1-270-1.290 at 20°C (68°F) Charging current 0.9 A max Alternator ‘Charging mpm 1.300 «pm max (14V) oo - 14.8 A min, at 5,000 rpm (14V) Capacity ‘Spark plug ‘Standard DPA7EA-9 (NGK!, X22EPR-US (ND) Optional _ DPROEA-9 (NGKI, X20EPR US (ND) Spark plug aap a 0.80.9 mm 10.03--0.04 in) _ lgpition coil resistance Primary ~ | 0.16 0.208 = ‘Secondary | 36-46 ka _ lnition timing [__10° BTDC at 1,500 rpm Starter motor brush length : 6.5 mm (0.26 in) 16-1ELECTRICAL EQUIPMENT TORQUE VALUES Headlight motor attaching nut (CH150D); 10-12 Nem (1.01.2 kg-m, 7-9 feb} Link atm pinch bolt {CH1500) 10—12 Nem (1.0—1.2 kgrm, 7—9 fb) Headlight motor set nut (CH1500): 8-12 Nem (0.81.2 kg-m, 6-8 ftb} TROUBLESHOOTING CHARGING SYSTEM No power + Dead battery — Low water level. Battery sulfation, ~ Internally shorted battery. — Charging system failure. + Disconnected battery cable + Fuse burned out + Faulty ignition switch Low power + Weak battery + Loose battery connection + Charging system failure IGNITION SYSTEM No spark at plug + Faulty spark plug + Poorly connected, broken or shorted wire Between pulse generator and CDI unit. — Between COI unit and ignition col Between CO! unit and ignition switch. — Between ignition coil and spark plug + Faulty ignition switch + Faulty ignition coil + Faulty COI unit + Faulty pulse generator STARTING SYSTEM Starter won't turn Fuse burned out Weak battery Faulty ignition switch Faulty starter switch Faulty front or rear brake light switch Faulty starter relay Poorly connected, broken or shorted wire Faulty starter motor Intermittent power + Loose battery cable + Loose charging system connection + Loose connection or short circuit in lighting system + Loose ignition system connection Charging system fai + Loose, broken or shorted wire or connection + Faulty regulator/rectifier + Faulty alternator Engine starts but tus poorly + Ignition primary circuit = Faulty ignition coil — Loose or bare wire or connector. Poorly contacted ignition switch. + Ignition secondary circuit = Faulty ignition coil — Faulty spark plug, — Faulty spark plug wire = Poorly insulated plug cap. + Improper ignition timing Faulty pulse generator. — Stator not installed property. Faulty CDI unit, Lack of pows + Weak battery + Loose or bare wire or connection + Foreign matter stuck in starter or starter gear Engine does not start, but starter rotates + Faulty starter pinion + Low battery 16-2DIGITAL SPEEDOMETER Meter does not indicate properly Dead battery Fuse burned out Faulty ignition switch Poorly connected, open or shorted wite Faulty meter unit| Faulty speedometer gear Broken or disconnected speedometer cable Faulty speed sensor (reed switch) RETRACTABLE HEADLIGHT Headlight does not open or close + Dead battery + Fuse burned out Binded linkage Open circuit Faulty motor jadlight does not come on Battery discharged Fuse burned out Burnt bulb Inoperative linkage + Open lighting circuit + Faulty limit switch + Fauity lighting relay + Faulty timer unit oe ELECTRICAL EQUIPMENT 16-3ELECTRICAL EQUIPMENT BATTERY REMOVAL/INSTALLATION Raise the seat. Remove the battery cover, Disconnect the negative cable first, then disconnect the posi tive cable. Remove the battery. The installation sequence is essentially the reverse order of re moval NOTE + Connect the battery breather tube to the battery breather pipe securely CAUTION + Check routing of the breather tube as shown on the battery cau- tion label. SPECIFIC GRAVITY TEST Test each cell by drawing electrolyte into a hydrometer SPECIFIC GRAVITY (20°C, 68°F) 1.270- 1.290 1.230 or below The battery must be charged if the specific gravity falls below 1.230 Fully charged ‘Undercharged NOTE +The specific gravity varies with the temperature as shown. (Specific gravity changes by 0.007 for every 10°C, 50°F} + Replace the battery if sulfation has formed, or if the space below the cell plates is filed with sediment. I + The battery contains sulfurie acid + Avoid contact with skin, eves, or clothing. Antidote: Flush th water and get prompt medical attention 16-4 CAUTION INSERT THE BATTERY BREATHER TUBE Ste araniee (1) SPECIFIC GRAVITY—= CLES eee ew sc 80" SI" 6a 7 ae" Oe aa l Helectaéivie rebenarUae ec»BATTERY CHARGING Remove the battery Remove the cell caps trom the battery. Connect the charger positive (+) cable to the battery positive (4) terminal Connect the charger negative (| cable to the battery negative. (terminal Charging current: 0.9 amperes maximum, + Keep flames and sparks away from a charging battery to pre- vent igniting the hydrogen gas produced by the battery. + Turn power ON/OFF at the charger, not atthe battery termi- ‘nals to prevent sparks near the battery cells. + Discontinue charging if the electrolyte temperature exceeds Asc ai7"h). CAUTION + Quick charging should only be done in an emergency; slow charging is preferred Charging time: 3-18 hours Charge the battery st 0.9A until specific gravity is 1.270 — 1.280 (20°C, 68°F) CHARGING SYSTEM CHARGING CIRCUIT ELECTRICAL EQUIPMENT iy |,OB; as 25 = “2 O S cE | = RBG) SPECIFIC GRAVITY VS CHARGING TE 3 sawp | § a 2 sao) Ke 10005 Se oe cuanal tie fm (4) FUSE (1) ALTERNATOR 5) \GNITION SWITCH (31 VouTace SENSOR 3 (2) REGULATOR/RECTIFIER 16-5ELECTRICAL EQUIPMENT CURRENT TEST NOTE + Be sure the battery is in good condition before performing this test Warm up the engine: Raise the seat and remove the battery cover. Remove the fuse holder cover and disconnect the red wire lead from the fuse holder terminal Connect an ammeter between the red wire lead and fuse holder terminal as shown, Connect the voltmeter across the battery terminals. Start the engine, gradually increase engine speed and read the ‘ammeter and voltmeter. The ampere and voltage should be OA and 14 15V, Uf the readings do not mest the specifications, check the wires {or loose connection and rapair if necessary. If the wires are in {900d condition, replace the regulatorirectifier with a new one and retest. If the readings stil do not meet the specifications, perform the alternator output test ALTERNATOR OUTPUT TEST Remove the right and left rear covers and the frame center cover (page 13-2) Disconnect the regulator/rectfier coupler. Remove the black wire from the coupler and reconnect the coupler. Connect the ammeter and voltmeter the same as for the cur Start the engine and gradually increase the engine speed. Engine speed | 5,000 rpm. 10,000 rpm. | ALTERNATOR INSPECTION NOTE ‘This test can be made without removing the stator from the engine Remove the frame center cover (Section 13) Disconnect the stator coupler Check the continuity between the yellow wieos and ground There should be continuity between the yellow wires, and no continuity between each yellow wire and ground. Refer to section 10 for stator removal [77 STATOR COUPLER 16-6REGULATOR/RECTIFIER INSPECTION Remove the frame center cover (page 13-2) Disconnect the regulatoritectifier wire coupler Check the continuity between the wire terminals. NOTE + The test results shown are for @ positive ground ohmmeter land the opposite results will be obtained when a negative ground ohmmeter is used Normal direction: Continuity ELECTRICAL EQUIPMENT (1) REGULATORRECTIFIER [_ @ PROBE © PROBE 1 Yet i Red ~~ Yellow (1) NORMAL (2) RED DIRECTION | : ts £4h Spnowe SO PROBE z i | = Yelow | ge D a Fed g | ' \e)nevense \ Sireerion 16) oREEN IGNITION SYSTEM CIRCUIT (@) col unit avteuimion swine 6 uw / /eNGNESTor swrrch |S] s sw (a) SPARK il Pug BI: BLACK (5) PULSE | (7) IGNITION R RED Generator = L7H IGNIT ere I Ws yellow (ey excITER con 8 Sees Bu BLUE 16-7ELECTRICAL EQUIPMENT IGNITION COIL INSPECTION Remove the left rear cover (page 13-2) Disconnect the ignition coil wires and the spark plug cap. ‘Measure the resistance between the ignition coil primary wire terminals, RESISTANCE: 0.160.200 Remove the spark plug cap trom the spark plug wire and mea: sure the resistance between the spark plug wite and the pr mary coll terminal (B1Y} RESISTANCE: 3.64.6 ko Measure the spark plug cap resistance RESISTANCE: 3.75—6.25 ko REPLACEMENT Remove the ignition coil mounting bolt and replace the coll if necessary. EXCITER COIL INSPECTION NOTE + This test can be performed with the stator installed in the engine. Remove the frame center cover (Section 13) Disconnect the stator wire connector. Measure the resistance between the black/red wire terminal and ground: RESISTANCE: 50-3500 NOTE + Measure resistance in the x 10 range. Refer to section 10 for stator removal CDI UNIT INSPECTION Remove the frame center cover. Disconnect the coupler and remove the CDI unit 16-8ELECTRICAL EQUIPMENT Measure the resistance between the terminals. Replace the CDI unit if the readings are not within the speci: cations in the table below. NOTE + For accurate testing, tis necessary to use a specified test le, Use of an improper tester ot measurements in an im: proper range may give false readings + Use Sanwa Electric Tester 073080020000 or Kowa Electric Tester TH-SH, or Digital multimeter, KS—AHM— 32-003 (U.S.A. only) + In the table, “Needle swings then returns" indicates that there is @ charging current applied to a condenser. The ‘needle will then remain at “s"" unless the condenser is dis: charged. Use the x ki? range for the Sanwa Tester. Use the x 1008 range for the Kowa Tester PULSE GENERATOR INSPECTION Remove the frame center cover (Section 13). Disconnect the pulse generator coupler and measure the resis: tance between the groen/white and biue/yellow wire termi nals, RESISTANCE: 50-170 9 For pulse generator replacement, refer to page 10-2. sw (4) ExT (2)1GN (3) 6c wet 11) PULSE GENERATOR COUPLER 16-9ELECTRICAL EQUIPMENT STARTING SYSTEM STARTING CIRCUIT (21 IGNITION cn eartery SWITCH s ne 5 FUSE TOA vig ia man ruse L— 8 70) (5) REAR BRAKE Ugh switce (6) STARTER va] Gir MoroR as) (7) STARTER SWITCH f: RED BL BLACK We WHITE Y: YELLOW G: GREEN (1) STARTER RELAY STARTER RELAY INSPECTION Raise the seat and remove the battery cover. Depress the rear brake pedal and pull the brake lock knob to the “LOCK” position The relay coll is normal if you hear a click when starter button is depressed with the ignition switch ON. Disconnect the battery positive cable and the starter motor ‘cable from the starter relay. Disconnect the starter relay coll wire connectors. Conneet an ohmmeter between the large starter relay termi: nals, Connect the yellowired wite to the battery positive terminal land the green wire to the battery negative terminal using jumper wires (3) YELLOW/RED WIRE ‘Check for continuity between the starter relay large terminals. (2) GREEN WIRE Replace the starter relay with a new one if there is no continu CONNECTOR vy. 16-10ELECTRICAL EQUIPMENT STARTER MOTOR REMOVAL Remove the engine from the frame (Section 5), ~~ 7) STARTER MOTOR MOUNTING BOLT, STARTER MOTOR DISASSEMBLY Remove the two starter motor case screws and remove the ‘motor housing, Pull out the commutator from the front cover. NOTE (Screws STARTER MOTOR INSPECTION i Measure the length of the brushes. ‘SERVICE LIMIT: 6.5 mm (0.26 in) Check to soe that there is no continuity between the starter ‘motor wiee terminal and the motor front cover Confirm that ther Is for no continuity between the brushes, If there is continuity, check for a shorted circuit and repair or replace the front coverELECTRICAL EQUIPMENT Check the commutator bats for discoloration and other visual (1) COMMUTATOR faults. Bars discolored in pairs indicate shorted cols. Check for continuity between pairs of commutator bars. There should be continuity Also, make a continuity check between individual commutator bars and the armature shat, There should be no continuity, STARTER MOTOR ASSEMBLY (1) FRONT COVER (2) O-RING. (3) COMMUTATOR (4) MOTOR HOUSING (5) CASE SCREWS 16-12Insert the commutator into the front cover. (1) FRONT CovER Install the starter motor housing, aligning the tab on the hous- ing with the groove on the front case. Install and tighten the starter motor case screws. STARTER MOTOR INSTALLATION Install the starter motor in the reverse order of removal. NoTE + Before installing the starter motor, check its operation by connecting the starter motor wires to the starter relay. INSTRUMENTS REMOVAL Remove the handlebar lower cover by removing the three rower Cover ELECTRICAL EQUIPMENT (3) MoTOR HOUSING (2) COMMUTATORELECTRICAL EQUIPMENT Remove the llt and right front tun signal covers by removing (1) TURN SIGNAL COVER the ecrews, Disconnect the turn signal couplers. Remove the two handlebar upper cover screws and remove the upper cover with the headlight and instrument visor. Remove the bolt caps over the rear view mirror bolts. Femove the left and right rear view mirrors by removing the: ‘mounting bolts. Remove the rear view mirror set plates and rubber seats. (2) SET PLATE fi Ma#4{3) BOLTS Disconnect the instrument wire couplers, connectors and the (nBguts speedometer cable. Remove the two bolts and instruments, ENG BS (2) SPEEDOMETER CABLE vi 16-14ELECTRICAL EQUIPMENT DISASSEMBLY Remove the terminal nuts and screws and disassemble the in struments. ASSEMBLY/INSTALLATION ‘Assemble and install the instruments in the reverse order of disassembly and removal cnis0: cH 500: LIGHTS/BULBS MUL) He ADLIGHT Wine couPLER HEADLIGHT BULB REPLACEMENT See page 16-22 for CH150D bulb replacement, Remove the handlebar upper cover (page 16-13) Disconnect the headlight wire coupler and remove the rubber boot : (Z| RUBBER BOOT, 16-15ELECTRICAL EQUIPMENT Remove the bulb spring retainer and bulb from the headlight. (.8ut8 Replace the headlight bulb with a new one if necessary. Wear ‘loves when handling the bulb. CAUTION + Do mot put finger prints on the headlight bulb, they may create hhot spots on the bulb. + If you touch rhe bulb with your bare hands, clean it witha cloth ‘moistened with alcohol to prevent its early failure. Install the headight in the reverse order of removal. Check the headlight for proper operation after installing by turning the ignition switeh to the ON and OFF positions HEADLIGHT REMOVAL Remove the handlebar upper cover (page 16-13) Disconnect the headlight coupler (page 16-15) Remove the three screws and the headlight Install the headlight in the reverse order of removal. FRONT TURN SIGNAL LIGHT Remove the two screws and the turn signal light cover, Remove the bulb socket and replace the bulb, am (1) SCREWS: (2) SOCKET REAR TURN SIGNAL LIGHT Oa Remove the tear cover (page 13-2). Remove the turn signal bulb socket and replace the bulb, 16-16ELECTRICAL EQUIPMENT TAILLIGHT BULB REPLACEMENT Raise the seat and remove the bulb protector. Remove the talight bulb socket and replace the bulb, SWITCHES/HORN IGNITION swiTcH. INSPECTION Open the front cover tpage 13-2) Disconnect the ignition switch coupler. Continuity should exist between color coded wires indicated by interconnected circles an the chart below, REPLACEMENT Disconnect the ignition switch wire coupler and remove the two switch mounting belts and the ignition switch, Install a new switch and tighten the two boltsELECTRICAL EQUIPMENT REAR BRAKE SWITCH Remove the frame center cover (page 13-2) Disconnect the rear brake switch wire connectors from the harness, Check for continuity with the rear brake applied. There should be continuity between WIG and GY, and WIG and Y/R term ral HANDLEBAR SWITCHES Remove the handlebar upper cover (page 16-13) Disconnect the handlebar switch couplers. Continuity should exist between color coded wires indicated by interconnected circles on each chart. ENGINE STOP SWITCH Terminal 1G E OFF of RUN color aiw + STARTER SWITCH Terminal HU m2 | st | st2 ° oe | [ meal o—}—o [cotor euW | BW | YR on + DIMMER SWITCH HL Hi lo Hi ° o wr ot eto Lo o | Color uw | Be Ww + TURN SIGNAL SWITCH R iN) t Color | Gr | tb | 0 | & | tow | ow FRONT BRAKE SWITCH ‘The switch is normal i there is continuity between the black and greeniyellow wires when the front brake lever is applied, Replace the switch if it is faulty. (3) ENGINE STOP SWITCH (1) TURN SIGNAL SWITCH (3) HORN SwiTcH (2) STARTER SWITCH (2) DIMMER SWITCH 16-18ELECTRICAL EQUIPMENT HoRN Open the front cover. ‘The hovn is normal fit sounds when a 12 V battery is connect fed acioss the horn wire terminals. Replace the horn if neces: FUEL UNIT/GAUGE FUEL UNIT Remove the left rear cover (page 13-2! and disconnect the fuel Remove the fuel unit from the fuel tank being careful not to damage or bend the fuel unit float arm. {page 4-14), "85: Measure the resistance between the fuel unit wire terminals with the float at the UPPER (FULL) and LOWER {EMPTY} posi RESISTANCE FLOAT POSITION RESISTANCE UPPER (FULL) 4-100 LOWER |EMPTY) 90-100 8 —_l AFTER ‘85: Measure the resistance between the Yellow/White and Blue! White terminals, RESISTANCE: 450-750 0 Measure the resistance between the Yellow/White and Green, {and Blue! White and Green terminals with the float at UPPER, IFUL) and LOWER EMPTY} positions. (1) UPPER (FULL Bower on rr ~_Floar PosmTONS| —goncq Town TERMINALS al (FULL) (EMPTY) Yellow/White and Green | 28420 "aza7ose | 2a-aa Blue/White and Green 16-19ELECTRICAL EQUIPMENT FUEL GAUGE Connect the {uel unit wire connectors to the wire harness and turn the ignition switch ON, ted a nore ae ew Belo perorming the otowing tet, oprae the Wn a Perr encce nals to cetermine that the ater eu 6 nora eee Check the fuel gauge needle for correct indication by moving A hese the float up and down. L at ———___— Se Fomtroaion | weaeresrion | Psrtoven ew UPPER {FULL} (FULL) OO [Ltowen emery) | ev iewrryi | ay merosranic (2) suMPeR Wine THERMOSTATIC SWITCH ‘The cooling fan motor is actuated by the thermostatic switch located in the radiator I the fan motor does not start, disconnect the black and green leads from the thermostatic switch and short them together with a jumper wire as shown. Turn the ignition switch on The cooling fan motor should start running. IH it does not start, check for battery voltage from the black lead (positive) to black/blue (negative) of the fan motor cou: ple IF there is no voltage, check for a blown or faulty fuse, loose terminals of connectors, or an open circuit. If it starts, inspect the fan thermostatic switch as follows: Suspend the switch in @ pan of coolant (50—50 mixture) and check the temperatures at which the switch opens and closes. ‘Make sure that there is no switch comtinuity with room tem: perature and gradually raise the coolant temperature. The ‘switch should have continuity Iclose) at 98 102°C (208. 2i5°F) NOTE + Keep temperature constant for 3 minutes before testing continuity, A sudden change of temperature will cause in correct readings between the thermometer and the switch, Do not let the thermometer of switch touch the pan ast will give a false reading Soak the switch in coolant up to its threads. THERMOSENSOR Remove the thermosensor. 16-20Suspend the sensor in oil over a burner and measure the resis tance through the sensor as the oil heats up. we] 20S | 80°C | 10076 [TRO] Temperature | «tazsry | ar7eer) | «r2er) | (248eF) 20 16a Resistance | 1540 + Wear gloves and eye protection. 270 NOTE + Oil must be used as the heated liquid to check the function above 100°C (212°F), You'll get false readings if either the thermometer of thermosensor touches the pan, TEMPERATURE GAUGE Disconnect the wire from the thermosensor and ground it to the engine, ‘Turn the ignition switch ON, ‘The temperature gauge needle should move all the way to the H (How). CAUTION ‘Do not leave the thermosensor wire grounded for longer than 5 seconds or the temperature gauge will be damaged. ELECTRICAL EQUIPMENT (1) THERMOMETER (1) THERMOSENSOR CONNECTOR e (2) JUMPER WIRE 16-21ELECTRICAL EQUIPMENT RETRACTABLE HEADLIGHT (CH150D) un eWienGENTEY KNOB. MANUAL HEADLIGHT OPENING PROCEDURE Es Remove the two screws and raise and support the front cover. Disconnect the emergency connector. Turn the emergeney knob counterclockwise until the headlight link arm touches the stopper. Unhook the end of the headlight stay and hook it into the hole in the headlight link aem, BULB REPLACEMENT ‘Turn the ignition switch OFF. Remove the two screws and raise and support the front cover. Raise the headlight in the manual headlight opening procedure. Remove the headlight coupler and rubber cover. Ae ie las MBL 2) HEADLIGHT COUPLER Gy sute Remove the bulb retainer clip and replace the bulb with 3 new ‘CAUTION + Do not get finger prints on the headlight bulb, they may cause hot spots which will shorten the bulb life. + Remove any finger prints using alcohol and a clean ra. (1) HEADLIGHT COVER LID HEADLIGHT REMOVAL ‘Turn the ignition switch OFF. Remove the two screws and raise and support the front cover. Raise the headlight in the manual headlight opening procedure. Disconnect the heaclight coupler. eo (2) ADJUSTING id SCREWS, Remove the headlight from the bracket by sliding the adjusting screws toward the arrow while pushing the headlight forward. z yo 16-22ELECTRICAL EQUIPMENT HEADLIGHT MOTOR REMOVAL, NOTE + If there is a problem with the headlight mechanism, open the front cover, check the headlight linkage and correct it before using the following procedures, ‘Turn the ignition switch OFF and raise the headlight in the ‘manual headlight opening procedure (page 16-22) Remove the front cover (page 13-3). e 2) COUPI Disconnect the headlight and limit switch wire connectors and wana (21 COUPLER coupler and remove the wire clamp. Remove the headlight pivot bolts and link joint bolt, and (Liu Som BOLT remove the headlight with the rim attached. ~ SSE (2) PIVOT BOLTINUT Remove the headlight link arm pinch bolt and headlight link {arm from the motor shaft Loosen the headlight motor set nut and motor attaching nut. Disconnect the headlight motor wire coupler Remove the headlight base nuts and the headlight base. Remove the headlight motor set nut and attaching nut. Remove the headlight motor from the baseELECTRICAL EQUIPMENT HEADLIGHT MOTOR FINAL GEAR REPLACEMENT Remove the four screws attaching the cover and open the Lift the rack and pinion together with their holder off the final drive gear and swing the assembly around to the side as shown, Remove the final gear. Check that the four sliding rushes under the final gear are at the same height. If the brushes are not the same height, a motor malfunction could occur. Adjust as required. NOTE If the final gear needs to be turned, pull out the drive motor. (1) CLAMP (3) Screws. (1) FINAL GEAR (2) DRIVE MOTOR, 5) BRUSHES. Install @ new final gear on the motor. Make sure that the punch ‘mark on the pinion gear aligns with the fourth gear of the rack fas shown, Install the motor cover and tighten the cover scraws, After replacement, check for normal operation by connecting, the motor coupler. HEADLIGHT MOTOR INSTALLATION Loosely install the headlight motor to the headlight base using the attaching nut and set nut (4) PUNCH MARK (6S. cK (2) FINAL GEAR (1) PINION (1) ATTACHING NUT '3) HOLDER, (2) HEADLIGHT BASE (3) SET NUT 16-24ELECTRICAL EQUIPMENT Install the headlight base with four nuts; route and connect the Tighten the headlight motor attaching nut, TORQUE: 1012 Nm (1.0—1.2 kg-m, 7—9 feb) Make sure that the headlight motor isin the completely closed Position, install the link arm to the motor shaft aligning the punch marks on the link arm and motor shaft Loosely install the link arm pinch bolt Slowly turn the emergency knob counterclockwise and check that the clearance between the link arm and limit switch ‘mounting bolt end is 2.0 mm {0.08 in}, then tighten the link ‘arm pinch bolt (2) unre TORQUE: 10—12 Nem (1.01.2 kg-m, 7-9 feb) ‘Turn the emergency knob counterclockwise until the headlight Tink arm is fully raised. Move the headlight motor until the link arm touches the stop. par, then move the motor in the same direction until the retain fer moves one graduation and tighten the lock nut TORQUE: 8—12 Nem (0.8-1.2 kg-m, 6-9 ftlb) (2) SET NUT. 1a)LINK ARM 16-25ELECTRICAL EQUIPMENT Apply molybdenum disulfide grease to the headlight pivot Collars and install the pivot bolts. Apply molybdenum disulfide grease to the headlight link joint collar and install the headlight link to the headlight rim, Connect the headlight and limit switch coupler, and clamp the Turn the ignition switch ON and place a straight edge along the center of the motor shaft and the canter of the link joint bol. ‘Measure from the top of the edge to the center of the link joint pivot as shown. The distance should be O— 1.5 mm (0—0.06 in) Adjust if necessary, removing the link joint bol, loosening the lock out and turning the link joint. Reinstall the linkage to the headlight. Loosen the stopper bolt lock nut and adjust the stopper bolt Until the bolt head touches the headlight rim, then turn the: stopper bolt clockwise 1/2 turn and tighten the lock nut. Reinstall the front cover and headlight cover lid Turn the ignition switch OFF and check that the headlight lid is flush with the front cover. not, open the front caver, loosen the lock nut and adjust the headlight position by turning the stopper bolt ‘Tighten the lock nut after adjustment Turn the ignition switch ON and OFF to check the headlight for proper operation. INSPECTION Limit switch Disconnect the wite connectors from the limit switch and check for continuity between the terminals. ‘There should be continuity when the limit switeh is depressed ‘and no continuity when the switch is released. (2) WASHER (3) COLLAR (LINK JOINT yf BOLT (a) COLLAR hy ieee (1) MOTOR SHAFT (2) LINK JOINT (4) Lock Nur NUT (6) PIVOT BOLT (5) LOCK (6) STOPPER | (y) PIVOT NUT. 13) LINK JOINT BOLT 16-26Headlight relay Check for continuity between the terminals A and 8; there should be no continuity. Connect # 12 V battery between the terminals C and D; there Should be continuity between the terminals A and B. ELECTRICAL EQUIPMENT Timer unit Measure the resistance between the terminals Unit: ka © PROBE j loc A © PROBE 8 1-50 c = A [10-100 710-100 Use the x ki range fer the Sanwa tester. Use the x 100 range for the Kowa tester Headlight motor Disconnect the headlight motor coupler and measure the resis tance between the terminals. With the headlight closed: (1) HeADLIGH® MOTOR COUPLER | ‘© PROBE | | eee a Serose \ |e cw = Tr = R 2 2 =I G 1 = a A i Uso the xk0 range for the Sanwa tester. Use the «100 0 vange for the Kowa tester. 16-2717. WIRING DIAGRAM =| 00302—KN7—6710WIRING DIAGRAM “85 CH150D: 17-20030Z--KN7— 8300 WIRING DIAGRAM 17-3AFTER’BS CH150D:WIRING DIAGRAM AFTER’85 CH150 CANADA 17-40030Z—KN7 —7500 rere] tees18. TROUBLESHOOTING ENGINE DOES NOT START OR HANDLING 18-5 luce 18-1 POOR SUSPENSION PERFORMANCE 18-5 eee ae rowes 182 poOR BRAKE PERFORMANCE 185 SSORROWNCEATION conver we POOR PERFORMANCE ATHIGH SPEED 18-3 STARTERMOTOR a acme noe 19.4 DIGITALSPEEDOMETERICH150D) 18-8 CLUTCH, DRIVE AND DRIVEN PULLEYS 19-4 RETRACTABLEHEADLIGHTICH150D) 18-8 ENGINE DOES NOT START OR IS HARD TO START Symptom Probable cause 1. Check for fuel flow at the No FUEL TO— (1) No fuel in tank carburetor by loosening drain screw CARBURETOR (2) Clogged fuel tube to carburetor, vacuum tube to intake pipe FUEL TO CARBURETOR (3) Clogged fuel valve (4) Clogged float valve (5) Clogged fuel tank cap breather hole (6) Clogged tue! titer (7) Clogged fuel strainer 2. Try spark test WEAK OR NO SPARK. 211) Fautty spark plog (2) Fouled sparkplug SPARK JUMPS (3) Fauity CDI un | (8) Faulty pulse gonerator (5) Broken or shorted spark plug | {6) Broken or shorted ignition coil | (7) Faulty ignition switch 2. Test cylinder compression LOW COMPRESSION #1) Vaive clearance too small (2) Improper vale and seat contect NORMAL COMPRESSION (3) Wor evlinder and piston sings (4) Valve stuck open (5) Seized valve (8) Improper valve timing Ha 17) Leaking cylinder head gasket 4, Star by following normal ENGINE FIRES aUT———___+1) Fautty auto bystarter starting procedure SOON STOPS (2) intake pipe leaking (3) Improper ignition timing ENGINE DOES NOT FIRE (4) Incowrectly adjusted plot screw 5. Remove the spark plug Wer PLUG ——_e11) Flooded carburetor (2) Faulty auto bystartor ory (2) Throttle valve open excessively (4) Diy air cleaner 18-1‘TROUBLESHOOTING ENGINE LACKS POWER 1. Accelerate lightly ENGINE SPEED INCREASES 2. Check ignition timing connect 3. Check valve clearance connecry 4, Test cylinder compression NORMAL Check carburetor for clogging NOT CLogGeD 6, Remove spark plug NOT FOULED OF DISCOLORED 7. Check oil level and condition CORRECT AND NOT CONTAMINATED 8. Remove cylinder head oil pipe bolt and inspect VALVE TRAIN LUBRICATED PROPERLY 9. Check for engine overheating NOT OVERHEATING 10, Accelerate or run at high speed ENGINE DOES NOT KNOCK ‘Symptom Probable cause ENGINE SPEED DOES NOT————*1) INCREASE SUFFICIENTLY 2) 3) ay 6) 6) INcoRRECT ——»1) (2) INCORRECF +1) 2) 100 Low +1) (2) re a 6) Clogged air cleaner Restricted fuel flow Clogged fuel tank breather hole Clogged muffler Faulty auto-bystarter ‘Split carburetor vacuum piston di: aphragm Faulty CDI unit Faulty pulse generator Improper valve clearance adjust- Worn valve seat Improper valve and seat contact Worn cylinder and piston rings Leaking cylinder head gasket Flaws in cylinder head Improper valve timing cLogceo + Carburetor not serviced frequently enough FOULED OR DISCOLOREDR-———(1) 2 INCORRECT OR CONTAMINATED —e(1) Qi Bi VALVE TRAIN NOT———11) LUBRICATED PROPERLY 2) OVERHEATING (1) (2) Gh aw (5) (6) 7 ENGINE KNOCKS ————»1) 2) 3) a 6) Plug not serviced frequently enough Use of plug with improper heat range Oil evel 100 high Oil level to0 low Oil not changed Clogged oil pipe Faulty oil pump Insufficient coolant Thermostat stuck closed Worn eylinder and piston rings Lean mixture Fuel contaminated Excessive carbon build-up in com bustion chamber Ignition timing to0 advanced Excessive carbon build up in com bustion chamber Use of poor quality fuel Clutch slipping Lean mixture Ignition timing too advanced 18-2TROUBLESHOOTING POOR PERFORMANCE AT LOW AND IDLE SPEEDS 1. Check ignition timing CORRECT 2. Check catburetor pilot screw adjustment CORRECT 3. Check foF leaking intake pipe NOT LEAKING 4, Perform Spark test GOOD SPARK ‘Symptom Probable cause INCORRECT #1) Faulty CDI unit (2) Faulty pulse generator INCORRECT (1), Fuel air mixture too rich (Turn serow in) (2) Fuel air mixture too lean (Turn serew out) LEAKING +11) Deteriorated O-ring (2) Loose carburetor (3) Damaged insulator rubber (4) Air leaking past intake pipe vacuum joint WEAK OR INTERMITTENT SPARK——(1) Faulty, carbon or wet fouled spark plug (2) Faulty CDI unit (3) Faulty pulse generator (4) Faulty ignition coit (5) Broken oF shorted spark plug wire (6) Faulty ignition switch POOR PERFORMANCE AT HIGH SPEED 1. Check ignition timing ‘CORRECT 2. Check valve clearance conrecr 3, Disconnett fuel tube at ‘automatic fuel valve FUEL FLOWS FREELY 4, Remove Carburetor and check for clogged jet NOT cLogceD 5. Check valve timing correct 6. Check valve spring tension NOT WEAKENED ‘Symptom Probable cause INCORRECT» 1) Fauity CDI unit (2) Faulty pulse generator INCORRECT» (1) improper valve clearance adjust- (2) Worn valve seat FUEL FLOW RESTRICTED (1) No fuel in fuel tank (2) Clogged fuel tube or filter (3) Clogged fuel tank cap breather hole (4) Faulty fuel valve cLoeceo———_—_ciean INCORRECT—»cam sprocket aligning marks not aligned WEAK + Faulty spring 18-3TROUBLESHOOTING ENGINE NOISE ‘Symptom 1. Valve noise th 2) 2. ist 9918 (2) 3. Cam chain noise erty (2 3) 4, Crankshaft n99¢@ $a i@ii@ i$ i $+) (2) 8. G86 9058 —$ $$$ ii ii) (2) CLUTCH, DRIVE AND DRIVEN PULLEYS ‘Symptom 1 Engine starts, but scooter does not move —————*(1) (2) 3) (a) 8) 6) a Scooter creeps or engine starts but soon stops —————_—»(1) 2) 3) Engine lacks power at start of 8 grade») (2) a a) S) Engine lacks power at high spees 1) @ 3) ‘There is abnormal noise or smell while running ————————»1) (2 3) a Probable cause Valve clearance too large worn rocker arm andior camshaft Worn piston and cylinder Worn piston pin and connecting rod small end Damaged cam chain tensioner Worn cam sprocket teeth Worn or damaged cam chain Worn main journal bearing Worn crank pin bearing Worn or damaged final reduction gears ‘Worn final reduction gear shaft splines Probable cause Worn oF slipping drive bett Broken ramp plate Broken drive face spring Separated clutch lining Damaged driven pulley shaft splines Damaged transmission Seized transmission Broken shoe spring Clutch outer and clutch weight stuck Seized pivot Worn or stipping drive belt Worn weight rollers Seized drive pulley bearings ‘Weak driven face spring Worn or seized driven pulley bearings Worn oF slipping drive belt Worn weight rollers, Worn driven pulley bearings Oil or grease fouled drive belt Worn drive belt Weak driven face spring Worn or seized driven pulley bearings 18-4TROUBLESHOOTING HANDLING ‘Symptom Probable cause Check tive pressure INCORRECT + agjust tie pressure correct 41. Steering he | wy Ant) Top cone race t00 tight (2) Damaged stearing steel balls 2. Either wheel is wobbling (1) Excessive whee! bearing play (2) Bent vim (3) Loose axle nut 3. Scooter pulls to one side (1), Misaligned front and rear wheels (2) Bent front fork POOR SUSPENSION PERFORMANCE Symptom Probable cause Check tire pressure INCORRECT + agiust tire pressure CORRECT 1. Suspension is t00 soft $a $$_$________________2.11) weak shock spring (2) Excessive load (3) Shock damper oil leaking 2. Suspension is too hard Bent fork tube or shock rod 3. Suspension is noisy (1) Fork slider and tube binding (2) Fork sider and spring binding (3) Damaged shock stopper rubber (4) Loose steering stem nut POOR BRAKE PERFORMANCE ‘Symptom Probable cause Check brake free play INCORRECT + Agjust brake conRect 1. Wear indicator arrow aligns with index mark on brake panel—————— (1) Worn brake linings (2) Worn brake cam (3) Worn brake cam contacting area con brake shoes (4) Worn brake drum 2. Brake squeaks nt) ron brake tings (2) Foreign matter on brake linings (3) Rough shoe contacting face of brake drum 3. Brake performance is poor —————_____________+1) Faulty or elongated brake cables (2) Brake shoes improperly contact, brake drum (3) Mud or water in brake drum (4) Brake linings fouled with grease or oil 18-5TROUBLESHOOTING FUEL GAUGE POINTER DOES NOT REGISTER CORRECTLY (IGNITION SWITCH ON) ‘Symptom Probable cause 1. Check battery circuit by operating SIGNALS DIM, REMAIN ON——*(1)_ Blown fuse turn signal OR DON'T OPERATE (2) Weak or dead battery (3). Faulty ignition switch SIGNALS OPERATE PROPERLY (4) Loose or disconnected (5) Open circuit 2, Remove fuel unit from tank and POINTER MOVES + Faulty float check operation of pointer by moving float Float up: Pointer at FULL Float down: Pointer at EMPTY POINTER DOES NOT MOVE 3. Check operation of pointer by POINTER MOVES Open or shorted fuel unit ‘opening and shorting fuel unit terminal on harness side POINTERDOES NOT MOVE 4. Check for lobse, disconnected or INCORRECT (1) Disconnected connector incorrect connections (2) Incorrectly connected connector coRRECT + open or shorted circuit in meter POINTER FLUCTUATES OR SWINGS {IGNITION SWITCH ON) ‘Symptom, Probable cause 1. Check battery circuit by SIGNALS DIM, REMAIN ON—*(1), Blown fuse operating turn signals OF DON'T OPERATE (2) Weak or dead battery (3) Open or shorted ignition switch SIGNALS OPERATE PROPERLY {4) Loose or disconnected ‘connections, (8) Open circuit 2. Remove fuel unit from tank and POINTER DOES NOT MOVE IN————®Poor contact in Fuel unit check operation of pointer ACCORDANCE WITH FLOAT by moving float POINTER MOVES IN ACCORDANCE WITH FLOAT 3. Check each tonnector INCORRECT + Loose or disconnected con @] + open or shorted circuit in meter 18-6STARTER MOTOR ‘TROUBLESHOOTING STARTER MOTOR WILL NOT TURN 1. Check operation of brake light switch by applying brake COMES ON 2. Check battery circuit by operating turn signals SIGNALS OPERATE PROPERLY 3, Check operation of star by depressing starter button ley RELAY OPERATES PROPERLY 4. Connect starter motor directly to battery STARTER TURNS ‘Symptom Probable cause DOES NOT COME ON-——»(1) Blown fuse (2) Weak or dead battery (3) Faulty brake light switch (4) Disconnected terminals (5) Open or shorted ignition. switch SIGNALS DIM, REMAIN ON Dead battery OR DON'T OPERATE RELAY DOES NOT OPERATE————(1) Poor starter switch contacts (2) Open or shorted starter relay (3) Loose terminals STARTER MOTOR DOES NOT———*(1) Worn brushes TURN (2) Open or shorted wires of rotor (3) Open starter motor cable (4) Loose terminals Open wire harness STARTER MOTOR TURNS SLOWLY 1. Check battery circuit by operating turn signals SIGNALS OPERATE’ PROPERLY 2. Connect starter motor cable directly to battery STARTER MOTOR TURNS SLOWLY 3, Rotate crankshaft ‘Symptom Probable cause SIGNALS DIM, REMAIN ON Weak or dead battery ‘OR DON'T OPERATE STARTER TURNS NORMALLY———(1), Loose connector or terminal (2) Poor contact in starter relay (3) Faulty starter clutch HARD TO TURN + Seized engine ‘TURNS EASILY $$________________s rauity starter motor STARTER MOTOR WON'T STOP TURNING 1. Tum ignition switch OFF NOT STOPPED STOPPED + Fauity starter one-way clutch Starter relay shorted or stuck closed 18-719. TECHNICAL FEATURES RETRACTABLE HEADLIGHT (CH150D) CONSTRUCTION AND OPERATION ‘An electric motor is used to open and close the headlight lid using a link mechanism, RETRACTED POSITION OPEN ang ON POSITION HEADLIGHT NORMAL CLOSED RELAY up OPEN rv — Fl INDICATOR a eae oa HEADLIGHT] + BrAM 1 RELAY. INDICATOR Fuse isa 'GNITION SWITCH } MAIN FUSE R 158 Heap | = 89> eww sven +8: w: ucHTL*~G— lo Dimer starter | SWITCH SWITCH - Timer{ : Ltn" | Ege unr swiren = earrery HEADLIGHT MOTOR 19-1TECHNICAL FEATURES OPERATION RETRACTED POSITION TO LIGHTING POSITION ‘When the ignition switch is turned ON, current flows from the battery to the (A) point of the auto park switch in the headlight ‘This current energizes the motor rolay and turns ON motor switches “A” snd “8 ‘The battery current flows from th switches are turned 180° motor switch “A” to “B" through the motor to operate it. At the same time the auto park {As the motor turns and the headlight is raised by the linkage, the auto park switchs are positioned as shown in Figure 2. When the headlight mechanism reaches the end of it travel, the limit switch closes, energizes a normally closed relay and turns the headlight lid indicator off When the auto park s the motor switches " ches are positioned shown in Figure 2, points (@) and) ‘and “B", stopping the motor re opened and the motor relay turns OFF LIGHTING POSITION TO RETRACTED POSITION When the ignition switch turned OFF, the headlight goes off and the battery current flows to the point ) of the auto park switch through the ignition switch and @ 5 A fuse. This current energizes the motor relay to close motor switches “A and “B. Since there is continuity between the ©) and © points of the auto perk switch as shown in Figure 2, the motor turns and the auto park switches also rotate 180° When the headlight is retracted completely by the motor, the auto park switches are positioned as shown in Figure 1 and there is no continuity between them, and the motor stops. RETRACTED POSITION OPEN AND ON POSITION foie crossnen fm i (rosea) [arte gon mie mal SS orarag rere, Figure 1 Figure 2 19-220. INDEX Air Cleaner Cur Ot Valve Alternator/Starter Clutch Auto Bystarter Automatic Fuel Valve Battery Brake Light Switch/Starter Limiter Switch Lock Lever Shoe Wear System Cable & Harness Routing Camshatt Installation Removal Carburetor Installation Removal Carburetor-le Speed Charging System Clutch Shoe Wear ClutchiDriven Pulley Coolant Replacement Cooling System Hoses & Connections Crankease/Crankshaft ‘Assembly Breather ‘Separation Crankshaft inspection Cylinder Head Valves Cylinder/Piston Compression Head Assembly Cylinder Head Cover Assembly Disassembly Installation Removal Cylinder Head Disassembly Installation Removal Cylinder Instaliation Removal Drive Pulley/ClutchiDriven Pulley Belt Belt Air Cleaner Pulley Electrical Equipment Emission Control Information Label System Engine Removaliinstallation Instaliation Engine Oit Filter Sereen Cleaning Engine Removal Evaporative Emission Control System Exhaust Mutter Final Reduction Assembly Disassembly Inspection Float/Float Valveidets: Floorboats Flywheel Installation Removat 35, 35, 416 43 101 43 413 16.4 312 B41 3:10 3:10 17 eta 64 au 45 a7 165 3412 122 124 37 na 15 4n7 112 1a 61 cal 39 612 615 64 615 67 613 66 76 72 at 39 83 161 a4 112 5B 56 22 52 38 15:2 ot 95 92 48 135 106 102 Frame Covers Center Cover Front Brake Cover Fork/Steering Suspension Wheel Fuel Line System Tank UnitiGauge General Information Safety Handlebar Headlight Aim Gigh Altitude Adjustment Ignition System Ignition Timing Instuments Lott Crankcase Cover Left/Right Rear Cover Leg Shiels LightsiBlubs Lubrication Points Maintenance Schedules ‘Model Identification Nut, Bolt, Fastener | Pump Assembly Disassembly Inspection Installation Removal Pilot Screw Adjustment Piston Installation Removal. Purge Control Valve Inspection [California Modell Radiator Coolant Core Grille : oar Wheol/Brake/Suspension Rear Brake: Pedal/Brake Lock System ear Shock Absorber ‘Wheel Retractable Headlight (CH150D) Right Crankcase Cover Installation Removal Service information Alternator/Starter Clutch Cooling System Crankease/Crankshatt Cylinder Head: Valves CylinderiPistan Drive PulleyiClutchiDriven Pulley Electrical Equipment Engine Removaliinstallation Final Reduction 134 13.2 14.9 133 14.15, lane 14.6 ata 16:19 vt 143 a2 4.12 167 38 1613, 83 13.2 135 16.15 418 13.4 151 155 15:7 15:9 15.2 16.22 106 10.2 10-1 124 Wt et a ca 161 51 ot 20-1INDEX Frame Covers Fuel System Lubrication Maintenance ear Wheel/Brake/Susnension Steering/Front Wheel/Brake/Suspension Service Rules Side Rail Stand Spark Plug Specifications Starter Clutch Starting System Stator Installation Removal ‘SteotingiFront Wheel/Brake/Suspension Head Searing Suspension Switehes/Horn System Testing Technical Features Tomporature Gauge Thermosensor Theemostat Thermostatic Switch Throttle Operation Tools Torque Values Transmission Oil Troubleshooting Cooling System Crankcase/Crankshaft Cylinder HeadiValves Cylinder Piston Drive Pulley/ClutehiDriven Pulley Electrical Equipment Final Reduction Fuel § Lubrication Rear WheeliBrake/Suspension Stoering/Front Wheel/Brake/Suspension Vacuum Chamber Valve Clearance Guide Replacement Seat Inspection and Refacing Water Pump Wheel Wiring Diagram 20-2