Honda CX650C 1983, Shop Manual

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Page 2: ...some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe Please understand that those warnings could not cover all conceivable ways in which service whether or not recommended by Honda might be done or of the possibly hazardous consequences of each conceivable way nor could Honda investigat...

Page 3: ...ormation and troubleshooting for the section The sub sequent pages give de ileel procedures If you don t know what the source of the trouble is refer to section 22 Troubleshoot ing AIl informafion illustra cons direc tions and specifications included in this publication are based on the latest product information available a t the time of approval for printing Monda Motor Co Ltd reserves the right...

Page 4: ...HoNna CX65OC MEMO Date of Issue December 1982 O HOIVDA MOT8W CO LTD ...

Page 5: ...DA or HONDA recommended parts and lubricants or their equivalents Parts that do not meet HONBA s design specificaiions may damage the motorcycle 2 Use the special tools designed for this product 3 Use only metric tools when servicing this motorcycle Metric bolts nuts and screws are not interchangeable with English fasteners The use of incorrect tools and fasteners may damage the motorcycle 4 Insta...

Page 6: ...serial number is stamped on the right side of the steering head The engine serial number is stamped on the lower left side of the engine case The carburetor identification number is on the left side of the carburetor body The color code label is attached to the air cleaner cover When ordering a color coded part always specify its designatedcolor Dare of issue December 1982 O HONBA MOTOR CO LTD ...

Page 7: ...320 mm 12 6 in 155 mm 6 1 in 196 kg 432 Ibs 210 kg 463 Ibs Diamond Telescopic 160 mm 6 3 in Swing arm l20 mm 4 7 in 0 40 kPa 0 0 4 kg cm2 0 6 psi 100190 1957H Tubeless 140190 1570W Tubeless 225 kPa 2 25 kg cm2 32 psi 225 I Pa 2 25 kg cm2 32 psi 225 kPa 2 25 kg cm2 32 psi 280 kPa 2 80 kg cm2 40 psi Single disc brake 516 cm2 80 sq in Internal expanding shoes 201 cm2 31 sq in 12 4 lit 3 28 US gal 2 7...

Page 8: ... 25132 1 036 28129 0 839 31126 3 091 11134 Left foot operated return system 1 N 2 3 45 2 60 1 80 cc 5 4 63 1 or ELECTRICAL Ignition type lgnition timing F mark Full advance Starting system Alternator Battery capacity Spark plug Transistorized 15 BIDC at idle 40 i 1 5 BTDC 3 500 rpm Starting motor 14V 252W 5 000 rpm l 2V 14AM LIGHTS Standard I leadlight HighILow Taillbrake light Turn signals Front ...

Page 9: ... 28 0 42 2 0 2 5 1 5 2 0 Z O 1 4 Engine mount bolts 12mm 1Omm Front engine hanger nut Front axle Front axle pinch bolt Steering stem nut Front fork upper pinch bolt Front fork lower pinch boit Front fork brace bolt Front fork ttrbe cap Front fork socket bolt Handlebar I olderbolt Rear axle nut Final driven ftange bolt Rear shock absorber mount boit nut Rear brake stopper arm bolt Foot peg bolt Pas...

Page 10: ...4 30 2 4 3 0 Rear fender bolt 2 14 30 40 3 0 4 0 Torque specifications listed above are for the most important tightening points If a torque specification is not listed follow the standards given below STANDARD TORQUE VALUES TY 5 mm bolt nut 6 mm bolt nut 8 mm bolt nut 10 mm bolt nut 12 mm bolt nut Torque N m kg m ft lb p 4 5 6 0 0 45 0 6 3 3 4 3 8 1 2 0 8 1 2 6 9 18 25 1 8 2 5 13 18 30 40 3 0 4 0...

Page 11: ...N ALTERNATIVE 7404 0020000 Equivalent tool commercially available in U S A rburetor s h r o n i z a tor Pilot Screw AW 260 MC7 Clutch Center Holder 07907 MC70000 Bearing Remover Set 07936 3710000 ng Remover 07917 3710000 Equivalent tool commercia p p p Date of Issue December 1982 O HQRDA MOTOR CO LTD ...

Page 12: ...10000 Lock Nut Wrench 30x32mm 07716 0020400 Bearing Remover Expander A 07746 0050100 1 Bearing Remover Corret 15mm 07746 0050400 Bearing Remover Corret 17mm 07746 0050500 Equivalent tool commercially available in U S A Flvwheel Puller 1 07743 00200011 1 Flvwheel Puller Attachment 32xJ5mm 07746 0010100 Attachment 42x47mm 07746 0010300 p 07746 0010500 Pilot 15mm p 07746 0040300 p p 07746 0040400 p 7...

Page 13: ...ct a sharp edge or corner Clean the attaching surface thoronghly before applying tape 63 Do not use wires or harnesses with a broken insulator Repair by wrapping then with a protec tive tape or replace them e Route wire harnesses to avoid sharp edges or corners e Also avoid the projected ends of bolts and screws a Keep wire harnesses away from the exhaust pipes and other hot parts ea Be sure gromm...

Page 14: ...GENERAL INFORMATION II IROTTL E J CABLES l Dare of Issue December 1982 O HONDA MOPOR CO LTD ...

Page 15: ...HONDA exasoc GENERAL Il adFoRMAIIoM PULSE GENERATOR WIRE 1 ALTERNATOR l P STARTER MOTOR BATTER CABLE GROUND Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 16: ...SION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent crankcase emissions from entering the atmosphere Blow by gas is returned to the combustion chamber through the breather tube separator and intake pipe CARBURETOR CLEANER FRESH AI s BLOW BY R GAS EMISSION CONTROL INFORMATION LABEL An Emission Controi Information Label is attached to the air cleaner cover a s shown ...

Page 17: ...Dare of Issue December 1982 G 3 HONDA MOTOR CO LTD ...

Page 18: ... J HoNna LUBRICATION P 6x6506 Date of Issue December 1982 O WONDA MOTOR CO LTD ...

Page 19: ...be L 20 0 20 40 60 80 1 0 0 used when the average temperature in your I I 1 riding area is within the indicated range 70 20 10 0 10 20 30 4 0 Oil oumo deliverv 14 0 14 2 litlmin a t 2 500 rprn 1 Final drive gear ease LRecommendedoil 1Hypoid gear oil Above 5 410 F Below 5 410F p SAE SAE90 80 1 Oil bevel Too LOW High Oil Pressure External oil leaks Pressure relief valve stuck closed Worn piston ring...

Page 20: ...s valve in the oil filter bolt Install a new oil filter element and retighten the oil filter bolt NOTE p rGake sure that the 0 ring on the filter bolt 1 OIL FILLER CAPIDlPSTlCK and the oil filter cover are not damaged and OIL FILTER BOLT DRAIN BOLT P O RINGS FILTER COVER OIL FILTER Torque the oil filter bolt TORQUE 20 25 Nem 2 0 2 5 kg m 1 48 ft lb Reinstall the drain plug making sure the sealing ...

Page 21: ... pump Clean the oil strainer and oil pan thoroughly Make sure the 0 ring on the oil strainer outlet pipe is in good condition and install the oil strainer 0 1L TABS GASICET STRAINER Replace the oil pan gasket with a new one Align the grooves of the oil pan with the tabs of the oil strainer and install the oil pan Fill the crankcase with recommended oil page 2 11 GROOVES OIL PAN 4 p w Date of Issue...

Page 22: ... OIL REPLACEMENT Remove the oil filler cap Remove the drain bolt r drain ail oil from the final gear case Reinstall the drain bolt securely Fill the gear case with the recommended oil up to the correct level Olb CAPACITY 960 18 CC 5 4 6 1 RECOMMENDED Olb HYPOID GEAR Qlb SAE 90 Above 5 O 4 1 1 SAE 80 Betaw 5 sblOF Oli LEVEL CONTROL CWBLE kUBDlCATlOM Periodically disconnect the throttle and clutch c...

Page 23: ...TER AND SPEEDOMETER GEAR l 1 SI BE STAND l ENGiNE I 1 BRAKE PEDAL PIVOF l BRAKE CALIPER PIVOT A Sri cone Grease 1 SPECIAL IUBRICANI SHOCK AB RBEF PPER MOUNT BUSHING ta SUSPENSION LINKAGE PIVOTS CAUTION p p p 6 p p t y paste grease contalntng more than 3 5 4 molybedenum such as o l k o t e G n PASSE manufactured by Dow Corning U S A Woeol paste manufactured by Sumico Lubricant Co Ltd Japan Other lu...

Page 24: ... m W p MEMO Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 25: ...See page 2 2 Engine oil filter See page 2 2 Final drive gear oil See page 2 4 SPEC1FICAIIBNS Engine Spark plug Recommended spark plug I Standard For extended high speed 1 riding L p NGK UPR8EA 9 DPRSEA 9 1 Plug gap Ignition timing F rnark Full advance Valve clearnace IN EX Throttle free play Idle speed Vacuirm pressure differer between carhuretors Cylinder compression Clutch free play 0 8 0 9 mm 0...

Page 26: ...225 2 25 32 280 2 80 40 l i I l p p l l p p lrre brand p p p p p 1 Suspension air pressure 0 40 kPa 0 0 4 kg cm2 O 6 psi Special Vacuum gauge Carburetor synchronization wrench Common Valve adjusting wrench l 0 X 12 mm Valve adjuster R 07404 0020000 or M937B 021 XXXXX USA only 07908 4220201 07708 0030200 or 07908 3230000 or commercially available in U S A 07708 0040400 Bare of Issue December 1982 O...

Page 27: ...THORIZED HONDA DEALER UNL ESS THE OWNER WAS PROPER TOOLS AND SERVICE D A T A AND IS MECHANICALLY QUALIFIED c I N THE INTEREST OF SAFETY WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED HONDA DEALER NOTES 1 Service more frequently when riding in dusty areas 2 Service more frequently when riding in rain or at fiill throttle 3 For higher odometer readings repeat at the frequency interval es...

Page 28: ...uel cup making sure the new 0 ringis in place Finger tighten the cup first then torque it to specification TORQUE 3 5 N ETI 0 3 0 5 kg m 2 4 ft lb After installing turn the fuel valve ON and check that there are no fuel leaks THROTTLE OPERATION NOTE The accelerator pump may flood the engine during this inspection Check for smooth throttle grip rotation from fully closed to fully open positions at ...

Page 29: ...andlebar all the way up to fully closed Make sure the choke valve is closed by trying to move the choke lever on the carburetor after removing the Fuel tank There should be no free play Adjust if necessary by removing the carburetors page 4 2 and loosening the choke cable clamp on the carburetor and movingthe choke cable casing so the choke lever is fully closed Tighten the clamp Pull the choke le...

Page 30: ...t AIR CLEANER ELEMENT Clean the air cleaner element by tapping it lightly to loosen dust Blow away remaining dust with com pressed air from the outside of the element Replace the element if it is excessively dirty torn or damaged Install element and cover Install the right side cover Date of Issue December 1982 O HONDA MOIOR CO LTD ...

Page 31: ...k plug caps Clean any dirt from around the spark plug base Remove and discard the spark plugs Measure the new spark plug gaps using a wire type feeler gilage SPARK PLUG GAP 8 8 0 9 mm 6 831 0 035 in Adj ist by benciingthe side electrode carefully With the plug washer attached thread the spark plugs in by hand to prevent crossthreading Tighten the spark plugs another 112 turn with a spark plirg wre...

Page 32: ...e between the clearance adjusting screw and valve stem VALVE CLEARANCE IN 0 16 mm 0 604 in EX 0 12 mm 0 605 in TIMING INSPECTION VALVE ADJUSTING HOLE WRENCH l 0 X 12 mm 07708 0030400 Adj ist by loosening the lock nut and turning the screw until there is a slight drag on the feeler gauge Hold the screw and tighten the lock nitt TOROUE 28 25 N m 2 0 2 5 kg m I 19 ft lb Recheck the valve clearances T...

Page 33: ...t the vacuum gauges Apply vacuum of 12 20 mm Hg 0 5 0 8 in Hg to the fuel valve vacuum tube Start the engine and adjust the idle speed to 1 100 t 100rpm The difference of vacuum between cylinders should be less than 40 mm 1 6 in Hg Loosen the adjusting screw lock nut Balance the vacuum between cylinders to within 40 mm 1 6 in Hg of each other by turning the adjusting screw with tool 07908 422Q100 ...

Page 34: ...VE TANK CAP Check the coolant level of the reserve tank with the engine runing at normal operatingtemperature The level should be between the FULL and LOW level lines If necessary remove the reserve tank cap and fill to the FULL level line if necessary FULL RIIARK LOW MARK RADIATOR CORE Check the air passages for clogging or damage Straighten any bent fins or collapsedcore tubes Remove insects mud...

Page 35: ... OWER WATER HOSE UPPER LEVEL LINE The batfery electrolyte contains sulfuric acid Protect your eyes skin and clothi g In case of conmct fiuslt thoroughly wiffz w f e r md call a doctor if elecpolyte geis i yozsr eyes BRAKE FLUID Check the front brake fluid reservoir level If the level nears the lower level mark fill the reservoir with DOT 3 Brake Fluid to the upper level mark Check the entire syste...

Page 36: ... the pads reaches the edge of the brake disc Refer to page l fi 5 CAUTION Always replace the brake pads in pairs to assure even disc pressure ARROW BRAICE DISC BRAKE SYSTEM BRAKE SYSTEM HOSE Make sure that the brake hose is not deteriorated and check the entire brake system for leaks BRAKE PEDAL HEIGHT Loosen the lock nut Adjust the brake pedal height by turning the stopper bolt Retighten the lock...

Page 37: ...turning the switch adjusting nut adjusting brake pedal play and pedal height e Do not turn the switch body HEADLIGHT AIM Adjust vertically by loosening both headlight case mounting bolts Adjust horizontally by turning the adjusting screw on the headlight rim Turn the adjusting screw clockwise to direct the beam toward the right side of the rider Adjust the headlight beam as specified by local taws...

Page 38: ...m 0 3 in p Do nor burnyourself on rbr exltousr pipe p pp Recheck the clutch operation SIDE STAND Check the rubber pad for deterioration or wear Replace if any wear extends to the wear line as shown Check the side stand spring for damage and loss of tension and the side stand assembly for freedom of movement and for being bent replacing use a rubber pad with the mark Over 260 Ibs ONLY Spring tensio...

Page 39: ...e front fork air pressure when the front forks are cold Place the vehicle on its center stand Remove the valve cap and measure the front fork air pressure FRONT FORK AIR PRESSURE 8 40 kPa 0 0 4 kg cm2 0 6 psi REAR Place the motorcycle on its cente stand Move the rear wheel sideways with force to see if the swing arm bearings are worn Replace if exces sively worn pagel4 16 Check the shock absorber ...

Page 40: ...acity Check the front and rear wheels for trueness page 13 12 14 4 Measure the tread depth at the center of the tires Replace the tires if the tread depth reaches the followins limits Minimum tread depth Front 1 5 mm l6in Rear 2 0 mm 3 32in STEERING HEAD BEARINGS NOTE Check that the control cables do not interfere with handlebar rotation Raise the front wheel off the ground and check that the hand...

Page 41: ...MEMO Dare of Issue December 1982 HONDA MOTOR GO LTD ...

Page 42: ...FUEL SYSTEM Date of Issue December 198 6 3 HBNDA MOTOR CO LTD ...

Page 43: ...m 0 28 0 42 kg m 2 3 ft lb Special Carburetor pilot screw wrench 07908 4220201 Fuel valve lock nut Hand vacuum pump A973X 041 XXXXX 20 25 N m 2 0 2 5 kg m 14 18 ft lb U S A only or ST AH 260 MC7 Common Float level gauge 07401 001 0000 Engine Cranks But Won t Start Lean Mixture No fuel in tank e Carburetor fuel jets clogged e No fuel getting to cylinders B Vacuum piston stuck closed 7 00 much fuel ...

Page 44: ... remove the carburetor assembly from the left side CARBURETOR INTAKE PIPE THROTTLE CABLES Loosen the choke cable holder screw and disconnect the choke cable Loosen the cable lock nuts and disconnect the throttle cables Remove the carburetors CHOKE C A B L HOLDER CARBURETOR SEPARATION Disconnect the choke connecting springs CHOKE CONNECTING SPRINGS Date of Issue December 1982 C 3 HONDA MOTOR CO LTD...

Page 45: ...nt bolt lock washer tabs down Remove the throttle joint bolt and lock washer Remove the rear stay plate Remove the front stay plate I OCK WASHIER THROITLE JOINT BOLT FRONT SPAY PLATE Date of Issue December 1982 6 3HONDA MOTOR CC L I D ...

Page 46: ...all them on the fuel joint pipes Joint the right and left carburetors together FUEL JOINT PiPES LOCK WASHER TABS Install the front and rear stay plates and tighten the screws TORQUE 2 8 4 2 N m 0 28 0 42 kg m 2 2 3 ft lb Install the throttle joint lock washer and bolt Tighten the joint bolt and bend the lock washer tabs up against the bolt head JOINT BOLT Bate of Issue December 1882 O FIBNESA MOTO...

Page 47: ...ONNECTING SPRINGS DISASSEMBLY INSPECTION Remove the vacuum cylinder from the carburetor and remove the vacuum piston VACUUM CYLINDER FULL OPEN STOP Remove the full open stop Remove the needle set screw and the jet needle NEEDLE SET SCREW Date of Issue December 1982 O HONBA MOTOR CO LTD ...

Page 48: ...r other damage SET SCREW AIR JET COVER Remove the seal ring and air jet cover SEAL RING SECONDARY AIR JET SLOW AIR JETS Blow open the primary main air jet secondary air jet and slow air jets with compressed air NOTE e Never clean carburetor jets with wire or drills They will enlarge the openings re sulting in excessive fuel consumption D Do not try to remove the air jets PRIMARY MAIN AIR JET Date ...

Page 49: ...re setand should not be removed unless the carburetor is overhauled Remove the float chamber body Remove the float arm pin float and float valve FLOAT ARM PIN Inspect the float valve and seat for deposits grooves or other damage Replace the valve and seat as a set if either one requires replacement F OAT VALVE Bate of Issue December 1982 O HONBA MOTOR CO LTD ...

Page 50: ...rew CAUTION Damage to the pilot screw seat will occur i f the pilot screw is tightened against the L Remove the pilot screw Inspect the pilot screw and replace it if it is worn or damaged page 4 13 Remove the prinary nozzle and slow jet l i l t the carburetor to remove the needle jet Clean the passages and jets with compressed air PRIMARY NEEDLE JET SECONDARY MAIN JET f 4OLDER MAIN JET PRIMARY NOZ...

Page 51: ...ve cover and spring Remove the diaphragm and O ring Inspect the air holes and diaphragm for cracks or brittleness ACCELERATOR PUMP DISASSEMBLY Remove the accelerator pump cover and spring COVER DIAPHRAGM SPRING 0 RING COVER DIAPHRAGM COVER Bare of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 52: ... accelerator pump air cut off valve and vacuum cylinder reverse the disassembly pro cedure NOTE DIAPI IRAGM SPRING When installing the air cut off valve 0 ring make sure the flat surface is toward the body O RING COVER SLOW NEEDLE JET SET NEEDLE JET HOLDER Install the jets into the carburetor body NOZZLE MAIN JET PLUG MAIN JET 4 10 Bate of Issue December 1982 C 3 I IONDA MOTOR CO LTD ...

Page 53: ...ting the float valve and the carburetor in clined 1 45O from vertical FLOAT LEVEL 15 5c 1 m m 0 61 0 04in Replace the float if the float level is not within the specification FAST IDLE ADJUSTMENT p P l FAST IDLE 1 500 2 500 rpm If adjustment of the fast idle is necessary remove the carburetors page 4 21 and close the throttle valves by turning the throttle stop screw out Adjust fast idle by openin...

Page 54: ...1 3 3 mm 8 12 0 13 in Adjust by bendingthe choke link arm CARBURETOR INSTALLATION Install the carburetors in the reverse order of removal Tighten the intake manifold bolts and carburetor bands cecurely NOTE Check the throttle and choke valve operation 1 1 before installation After installation perform the following adjust ments e Throttle grip free play Page 33 41 e Carburetor synchronization Page...

Page 55: ...is sufficient 3 Attach a tachometer 4 Adjust the idle speed with the throttle stop screw IDLE SPEED 1 100 t 100 rpm 5 Turn the pilot screw in or out to obtain the highest engine speed 6 Readjust the idle speed with the throttle stop screw 7 Turn the pilot screw in gradually until engine speed drops l00 rpm NOTE p p I IA IIPGR CAP If the pilot screw seats before engine speed drops 100 rpm go to ste...

Page 56: ...ttach the Vehicle Emission Control Informa tion Update Label as shown Refer to service Bulletin St l32 for information on obtaining the label NOTE Do not attach the label to any part that can be easily removed from the vehicle Operation at m altimde lower than 5 000 ft 1 500 m with the carbuwtors adjusted for laigh altitudes may ccrlrse the engine to idle rotdghly and stall Men the vehicle is to b...

Page 57: ...Fuel should flow out from the fuel outlet tube when 12 20 mm Hg 0 5 0 8 in Hg of vacuum is applied IF the flow of fuel is restricted turn the fuel valve to RES and check if fuel flows out then If fuel flows out of the fuel outlet the fuel valve diaphragm is damaged or the fuel or vacuum circuit is clogged When the flow of fuel is still restricted with the fuel valve at RES it indicates that either...

Page 58: ...reen Blow dust and sediment off the screen using compressed air Check the O ring for deterioration or damage and replace it with a new one if necessary Remove the diaphragm cover by removing the four attaching screws Inspect the diaphragm for deterioration or damage Clean the fuel valve using compressed air NOTE DIAPHRAGM COVER DIAPHRAGMS Blow open all passages with the valve in ON and RES positio...

Page 59: ...f the fuel valve Also make sure that fuel is not leaking s Hold the fuel valve while turning the fuel I valve lock nut STRAINER SCREEN 0 RING n LOCK NUT GOV FUEL VALVE L 2 FUEL VALVE FUEL TUBE F U E L TANK INSTALLATION Connect the fuel tube vacuum tube and tube to the fuel valve air vent AIR VENT TUBE VACUUM TUBE REAR TANK MOUNT BOLT Install the fuel tank and tighten the fuel tank mount bolts Inst...

Page 60: ... case BOLTS Remove the battery box and coupler bracket BATTERY BOX COUPLER BRACKET Loosen the air cleaner connecting tube bands CONNECTING TUBE BAND CASE MOUNTING BOLT BREATHER TUBE Remove the air cleaner case mounting Disconnect the crankcase breather breather separator Remove the air cleaner case with separator from the rear bolt tube at the the breather BREATHER SEPARA TOR Date of Issue Decembe...

Page 61: ...aner case by turning it counter clockwise 90degrees AIR CLEANER CASE INSTALLATION Install the air cleaner case in the reverse order of removal sealing agent to the intake tube p 2 CRANKCASE BREATE IER 7 UF3E BR EAIMER DRAIN TUBE Dare of Issue December 1982 O HONDA MOTOR CO l TD ...

Page 62: ...17 22 ft lb 13 20ft lbi Date of Issue December 198 O WONDA MOTOR CO LTD ...

Page 63: ... Engine weight Engine oil capacity Engine oil recommendation Coolant capacity Radiator and engine TORQUE VALUES Front engine hanger nut Front engine mount bolt 10 mm 12 mm Rear engine mount bolt 10 mm 12 mm Left foot peg bolt Passenger foot peg bolt Exhaust chamber bolt Muffler band bolt 74 5 kg 164 lbs 3 6 lit 3 8 US qt 3 2 Imp qt See page 2 1 1 7 lit 1 8 US qr 2 5 Imp qt 30 40 N m 3 0 4 0 kg m 2...

Page 64: ...l page 2 31 and coolant page 9 31 Remove the carburetor intake pipes FAN MOTOR WIRE COUPLER Disco1 motor inect the spark plug caps and the cooling fan wire coupler SPARK PLUG GAP OIL PRESSURE SWITCH WIRE Disconnect the switch wires temperature sensor and oil pressure TEMPERATURE SENSOR WIRE Dare of Issue Beeember 1982 O HONDA MOT8W CO LTD ...

Page 65: ... Disconnect the neutral switch wire ALTERNATOR WIRE COUPLER PULSE GENERATOR WIRE COUPLER F R O N T F R A M E COVER Remove the two screws attaching the front frame cover and the cover SCREW TACHOMETER Disconnect the tachometer cable at the tachometer TACHOMETER CABLE Date of Issue December 198 C 3 HQNDA MOTOR GO LTD ...

Page 66: ... BREATHER TUBE Disconnect the crankcase breather tube EXI IAUST PIPE JOINT NUTS Remove the exhaust pipe joint nuts L oosen the exhaust pipe clamp bolts the exhaust pipes and remove EXHAUST PIPE GL AWIP BOLT EXHAUST PIPE Date of Issue December 1982 O HONDA MOTOR GO LTD ...

Page 67: ...emove the right and left foot pegs and brake pedal Remove the exhaust chamber mounting bolts and the chamber ENGINE REMOVAbliiNSTALbATION MUFFLER MOUNTING BOLT EXHAUST M U F L E R CLAMP BOLT FOOT PEG BRAKE PEDAL EXHAUST CHAMBER CHAMBER MOlJNTlNG BOLTS Bate of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 68: ...ATTERY GROUND CABLE Bisconr cables the starter motor and battery ground STARTER MOTOR CABLE ENGINE REAR MOUNTING BOLTS Place a jack under Remove the engine the real engine to support its mounting bolts weigl it Date of Issue December 1982 6 3 HONDA MOTOR CO LTD ...

Page 69: ...nt assemb ly by moving the engine backward Make sure that the final drive splines are exposed 5 6 mm from the end of the universal joint NOTE s Align the mounting surfaces carefully to prevent damage to mounting bolt threads wire harnesses and cables e Route the wires and cables properly Page 1 10 l l FRONT MOUNTING BOLTS UNIVERSAL JOINT 45 70 N m 60 80 N m 4 5 7 0 kcl m 33 51 ft lb 6 0 8 0 kg m 4...

Page 70: ...Date of Issuer December 19622 O HONBA MOTOR CO LTD ...

Page 71: ...ORMATBON GENERAL All cylinder head maintenance and inspection can be accomplished with the engine installed Before removing the cylinder heads it is necessary to drain coolant from the cylinder water jackets by removing the drain bolts The engine must be cool before removing the cylinder head SPECIFICATIONS Unit mm in p Cylinder compression cold Rocker arms and Shafts Valve spring PreloadILength D...

Page 72: ... lb 20 25 Nem 2 0 2 5 kg m I4 18 ft lb TROUBLESHOOTING Engine top end problems are usually performance related which can be diagnosed by a compression test or are noises which can usually be traced to the top end with a sounding rod or stethoscope Low Compressionor Uneven Compression m Valves lncorrect valve clearance Burned or bent valves Broken valve spring lncorrect valve timing Sticking valve ...

Page 73: ... the radiator page 9 61 Remove the front frame cover and front engine hanger Remove the exhaust pipe Remove the carburetor intake pipe bolts Remove the water pipe joints and water pipes FRAME COVER FRONT ENGINE HANGER IN7 AKE PIPE BOLTS EXI IAUST PlPE WATER PlPE WATER PlPE JOINT Dare of Issue December 1982 O HONDA MOTOR CO LTD 6 3 ...

Page 74: ... 94 Remove the crankshaft hole cap and timing inspec tion cap Bring the piston to T D C of the compression stroke by turning the crankshaft NOTE o Align the index mark with the TR mark for the right cylinder D Align the index mark with the TL mark for the left cylinder Loosen the cylinder head bolts in a crisscross pattern in two or more steps Remove the rocker arm holder assembly ROCKER ARM HOLDE...

Page 75: ...se dowel pins Remove the oil control orifice and 0 ring Remove the cylinder head gasket ROCKER ARM HOLDER DISASSEMBLY Withdraw the rocker arm shafts and remove the wave washers and rocker arms OIL CONTROL ORIFICE AND 0 RING GASKET ROCKER ARM ROCKER ARM ROCKER ARM Bate of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 76: ...TION Inspecteach rocker arm for scoring damage or clogged oil holes Measure the I D of each rocker arm SERVICE LIMIT 15 04 mm 0 592 in If a rocker arm shows wear or damage to the adjusting screw or push rod contact faces inspect the push rods and stern contact faces for scoring scratches or evidence of insufficient lubrication Inspect the push rods for wear damage and true ness 6 6 Date of Issue D...

Page 77: ...om the head surfaces a Do not damage the gasket surfaces e Avoid dropping gasket material into the jackets or oil passages F Gaskets will come off easier if they are soaked with solvent CY LINDEW HEAD INSPECTION Check the spark plug hole and valve areas carefully for cracks Check the cylinder head for warpage with a straight edge and feeler gauge in an X pattern SERVICE LIMIT 0 10 mm 8 840 in VALV...

Page 78: ...pect for trueness burring scoring or abnormal stem end wear Check the valve movement in the guide Measure and record each valve stem O B SERVICE LIMITS IN 6 54 mm 0 258 in EX 6 54 mm 8 258 in I STEM TB GUIDE CLEARANCE INSPECTION Ream the guides to remove any carbon build up before checking the clearance operation r It is important that the reamer always be rotated in the same direction when it is ...

Page 79: ...E GUIDE REPLACEMENT If the stem to guide clearance still exceeds the service limits with new guides replace the valves and guides NOTE VALVE GUIDE DRIVER 6 6mm 07942 65701 00 or 07742 001 0200 1 Be careful not to damage the cylinder head 1 1 when replacing valve guides J Support the cylinder head and drive out the guide from the valve part VALVE GUIDE DRIVER 6 6 mm 137942 6570100 or 07742 0010200 ...

Page 80: ...ht coating of Prussian Blue to each valve seat Lap each valve and seat using a rubber hose or other hand lappingtool Remove and inspect each valve CAUTION The valve cannot be ground If the valve face is burned or badly worn or if it contacts the seat unevenly replace the valve Inspect the width of each valve seat STANDARD 9 1 1 3 mm 0 04 0 05 in SERVICE LIMIT 2 0 mm 0 08 in If the seat is too wide...

Page 81: ...able in U S A p VALVE SEAT REFACING Use a 45 degree cutter to remove any roughness or irregularities from the seat NOTE p p Fieface the seat with a 45 degree c the valve guide is replaced 2 Use a 32 degree cutter to remove the top 114 of the existing valve seat material Use a 60 degree cutter to remove the bottom 114 of the old seat Remove the cutter and inspect the area you have just removed Date...

Page 82: ... and onto the seat to make a clear pattern NOTE The location of the valve seat in relation to the valve face is very important for good sealing A if the contact are is too high on the valve the seat must be lowered usinga 32 degree flatcutter If the contact area is too low on the valve the seat must be raised using a 60 degree inner cutter a 1 1 2 3 mm 0 04 0 05 in CONTACT 100 HIGH CONTACT TOO LOW...

Page 83: ...s CYLINDER HEAD ASSEMBLY Install the valve stem seals and spring seats Lubricate the valve stems with oil and insert the valves into the guides install the valve springs and retainers SPRING SEAT wound coils facing the head Replace the stem seals with new ones whenever disassembled STEM SEAVALVE SPRINGS RETAINER COTTERS VALVE SPRING COMPRESSOR 07757 0010000 Install the valve cotters CAUTION To pre...

Page 84: ...EMBLY ROCKER ARM SHAFT ROCKER ARM EX Apply oil to the rocker arm shafts Assemble the rocker arms shafts and wave washers Make sure the rocker arm cut outs align with the assembly bolt holes CYLINDER HEAD ROCKER ARM INSTALLATION Clean the cylinder surfaces of any gasket material NOTE Do not darnage the gasket surfaces Bate of Issue December 1982 HoN DA MOTOR CO LTD ...

Page 85: ...sh rods are down and the timing marks align the piston is on compression for the right cylinder Align the index mark with the TL mark for the left cylinder DOWEL PINS PUSH RODS Install the cylinder head install the cylinder head dowel pins Apply Multipurpose NLGl No 2 MoS2 additive Grease to the ends of each push rod Install the push rods into the rocker arm retainers DOWEL IRIS PUSH RODS lnstall ...

Page 86: ...ll the cylinder head cover spark plug caps lnstall the water pipes and pipe 0 rings and connect the joints with new FRONT ENGINE HANGER lnstall the carburetor intake and exhaust pipes lnstall the front engine hanger TORQUE I0 m m b i t 45 70 M m 4 5 9 0kg m 33 51 ft lb 12 m m bolt 68 80 I dem 6 0 8 0kg m 43 58 ft lb Install the radiator Page 9 91 Fill the cooling system with the recommended coolan...

Page 87: ...Bate of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 88: ...CLUTCH101k PUMP 20 25 N m 2 0 2 5 kg m 14 17 ft lb Bate of Issue December 1982 O HONDA MOTOR CO LIB ...

Page 89: ...L TORQUE VALUES Clutch lock nut 80 100 N m 8 0 10 0 kg m 58 72 fr lb Engine hanger bolt 10 mm 45 70 N m 4 5 7 0 kg m 33 51 ft lb 12 mm 60 80 N m 6 0 8 0 kg m 43 58 ft lb TOOLS Special Clutch center holder 07923 4150000 or equivalent commercially available in U S A Common Lock nut socket wrench 26 X 30 mm 07716 0020203 or 07716 0020202 Extension 07716 0020500 or equivalent commercially available in...

Page 90: ...r on the cover to help remove it CLUTCH CABLE CLUTCH COVER LIFTER PIECE CIRCLIP CLUTCH LIFTER REMOVAL Remove the lifter piece circlip spring clutch lever and O ring SPRING LEVER CLUTCH LIFTER PLATE REMOVAL Remove the bolts springs and lifter plate Loosen the bolts in an crisscross pattern in LIFTER PLATE Date of Issue December 1982 O HBNBA MOTmC R CO LTD ...

Page 91: ...ck nut and lock washer Remove the pressure plate discs A and B plates A and B and the clutch center as a unit Remove the outer guide and clutch outer Remove the thrust washer p m CLUTCWlOIL PUMP p T LOCK NUT SOCKET WRENCH 26 X 30 mm 07716 002023 or 07716 0020202 EXTENSION CLUTCH CENTER HOLDER 07923 4150000 or EQUIVALENI CLUTCH CENTER CLUTCH OUTER THRUST WASHER Bate of Issue December 1982 O HONBA M...

Page 92: ...asure the disc thickness SERVICE LIMITS Disc A 2 30 mm 0 894 in Disc B 3 10m m 6 122 inf CLUTCH PLATE Check for plate warpage on a surface plate feeler gauge SERVICE LIMIT 0 20 mm 0 008 in using a e CLUTCH PLATE B Check the wave spring for damage Date of Issue December 1982 6 3 I4ONDA MOTOR CO LTD ...

Page 93: ...outer guide SERVICE LIMIT 31 90 mm 1 256 in Check the clutch outer needle bearing for damage or excessive play Replace the needle bearing with a t necessary one i p p p CLUTCH SPRING INSPECTION Measure the spring free length 1 SERVICE LlMIT 37 9 mm 1 49 in Replace all the springs if even one is shorter than the service limit 1 lI I I 1 l Date of Issue December 1982 O HONDA MOTOR Co LTD ...

Page 94: ...nstall the clutch outer and outer guide OUTER GUIDE r Install the pressure plate on the clutch outer p Install the clutch plates and discs in the clutch outer as shown here and on page 7 7 NOTE The disc on the pressure plate is identified by p CLUTCH DISC B Date of Issue December 1882 O HOrUD 4 MOTOR CO LTD ...

Page 95: ...UIDE PRESSURE PLATE NOTE The tabs on clutch disc B to be placed on the 1 pressure plate side is srnaller than clutch disc the clutch center l CLUTCH CENTER Install the clutch rotating the clutch center center aligning the splines by Bate of Issue December 1982 O HBNDA MOTOR CO LTD ...

Page 96: ... holder 3 LOCKWASHER Install the lock washer and lock nut lnstall the lock washer with the mark OUT SIDE facing out e Install the lock nut with the flat end facing 1 out LOCK N U T LOCK NUT WRENCH 26 x 30 mm 07716 Ob20203 EXTENSION Attach the Clutch Center Holder to the pressure plate boss to prevent it from turning Tighten the lock nut fORQUE 80 100 N m 8 0 10 0 kg m 58 72 fl lbl CLUTCH CENTER HO...

Page 97: ... lrlstall the clutch Icver sprinq ar d crrclrp Iiotate the clutch lever to align the hole in the lever with the t lolc in the clutch cover and insert ttie liftcl piece OIL SEAL SPRING LEVER CLUTCH CABLE GASKET Install the clutch cover gasket Install the clutch cover Connect the clutch cable and adjust the 3 14 clutch Page CLUTCH COVER Bate of Issue December 1982 C 3 HONBA MOTOR CO LTD ...

Page 98: ...igh r ront engine hanger Drain the oil from the engine RIGHT FRONT ENGINE HANGER 018 PRESSURE SWITCH WIRE Disconnect the oil pressure switch wire Remove the engine front cover attaching bolts and front cover ENGINE R O N I COVER GASKET COLLARS AND 0 RINGS Remove the jowel pins collars Q rings and gasket DOWEL PINS Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 99: ...ve chain Remove the three oil pump mounting bolts and oil pump PRESSURE RELIEF VALVE Remove the oil pressure relief valve and oil inlet pipe Remove the pump cover thrust washer pump shaft and drive pin Remove the inner and outer rotors PIN THRUS WASHER PUMP COVER Date of Issue December 1982 C 3 HONDA MOTOR CO LTD ...

Page 100: ...e pump tip clearance SERVICE LIMIT 0 10 mm 0 004 in Measure the pump body clearance SERVICE LIMIT 0 3 mm 0 014 in Measure the pump end clearance with a straight edge and feeler gauge SERVICE LIMIT 0 30 mm 9 004in Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 101: ... as a unit if the spring or plunger is damaged SPRING SEAT SPRING PIN OUTER ROTOR INNER ROTOR THRUST WASHER OIL PUMP ASSEMBLY Insert the outer and inner rotors into the pump body Slide the drive pin into the pump shaft and install the shaft Install the thrust washer and dowel pin Install the pump cover Install the oil inlet pipe Install the oil pressure relief valve Date of Issue December 1982 O H...

Page 102: ...en sprockets and install the driven sprocket onto the oil pump DOWEL PIN Tighten the pump sprocket bolt and relief valve Adjust the chain free play by moving the pump right or left FREE PLAY 2 8 3 5 mm 0 88 8 14 in Tighten the three pump bolts TORQUE 8 32 2 m 8 8 1 2 kg m 6 9 ft lb Wecheck the oil pump drive chain free play Date of Issue Deeernber 198 O I IONDAMOTOR CO LTD ...

Page 103: ...T FRONT ENGINE HANGER Install the right engine hanger and tighten the bolts TORQUE mm bolt 68 88 N m 6 0 8 8kg m 43 58 ft lb 18mm bolt 46 70 N m 4 5 9 8 kg m 33 51 ft lb Install the front Frame cover Connect the clutch cable and adjust the clutch free play Page 3 14 Install the radiator and fill to the proper level with coolant Page 9 9 Add the specified amount of engine oil Section 2 Date of Issu...

Page 104: ...ALTERNATOR FLYWB BEE L REAR COVER 28 25 N m 1 8 2 5 kg m 13 18 ft lb Date of Issue December 1982 C 3 HONDA MOTOR CO LTD ...

Page 105: ... the alternator and stator wires and wire harnesses when removing or installing parts For alternator inspection see section 17 BatteryICharging System SPEC1FIGATIONS Unit mm in TORQUE VALUES p Alternator rotor bolt Starter clutch torx bolt SERVICE LIMIT 0 20 0 008 TOObS Special Gear holder forx driver bit 140 Common Extension Flywheel puller Driver Attachment 42 X 47 mm Pilot 22 mm 90 105 N m 9 0 ...

Page 106: ...e the radiator Section 9 WATER PIPE HOLDERS WATER PUMP REMOVAL Remove the water pipe holders and the water pipe WATER PIPE WATER PUMP COVER Remove the water pump cover and dowel pins Remove the cap nut copper washer and impeller Remove the impeller collar CAP NUT IMPELLER COLLAR Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 107: ...VER SCREW PULSE GENERATOR Remove the screws Remove the crankshaft pulse 6 mm generator by bolt and spark removing advancer the two from the 6 mm BOLT SCREW ADVANCER STARTER MOTOR REAR COVER REMOVAL Remove the starter motor and gearshift pedal GEAR SWIFT PEDAL Date of Issue December 1982 O I IONDA MOTOR CO LTD ...

Page 108: ...ER Ren eve the engine rear cover Remove the collars 0 rings dowel pins and gasket Remove the final shaft boot ENGINE REAR COVER COLLAR AND 0 RINGS GASKET DOWEL PINS FINALSt AFT BOOT Date of Issue December l982 O HONDA MOTOR CO L TD ...

Page 109: ... rear cover water pump mechanical seal Page 9 1 1 final shaft and shift spindle oil seals neutral wire clamp and disconnect it from the neutral switch neutral switch and sealing washer WIRE CLAMP NEUTRAL OIL SEAL SWITCH BOLTS STATOR Remove the alternator stator and the final shaft bearing p Refer to page 20 3 for neutral switch inspection IRIAL SHAFT BEARING Bate of Issue December l982 O HONDA MOT...

Page 110: ... engine cover Page 7 10 Atwch the Gear Holder to the primary drive GEAR HOLDER 07924 MC70002 01 07924 MC70000 or 07924 42 50000 gear FLYWHEEL BOLT Remove the flywheel bolt Remove the Flywheel usingthe Flywheel puller Date of Iss le December 1982 O HONDA MOTOR CO LTD ...

Page 111: ...eeth for damage Measure the redclction gear D Measure the reduction gear shaft O B then calcu late the gear to shaft clearance SER ICE LIMIT 0 20 mm 0 008 in STARTER DRIVE GEAR INSPECTION Check the drive gear for damage excessive wear indenta cons or other Faults STARTER DRIVEN GEAR REDUCTION REDUCTION SHAFT GEAR Dare of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 112: ... rollet and cplac e11IF t IS worn or damaged Inspect the clutch outet fol da nagetl or won iolle sulfaces I xalninc the sprln s and plu lgolsf o d sto tion or excessive wear INSPECT FOR WEAR STARTER CLUTCH OUTER INSTALLATION Slide the clutch outer into the flywheel aligning the holes with the dowel pins in the flywheel Coat the threads and undersides of the Torx bolts with a locking agent prior to...

Page 113: ... washers and reduction gear Use two thrust washers one on each side of the reduction aear Install the needle roller bearingin the drive gear Install the drive gear onto the crankshaft REDUCTION GEAR DRIVE GEAR FLYWHEEL INSTALLATIOM Install the flywheel onto he crankshaft NOTE d Align the key in the crankshaft with the keyway in the flywheel s Rotate the flywheel counter clockwise to aid installati...

Page 114: ...d cover ENGINE REAR COVER INSTALLATION Assemble the rear cover in the reverse order of disassembly fully Refer to page 9 1 1 for water pump mechanical seal installation ATTACHMENT 42 X 47 mm 0 7746 0010300 AND PILOT 22 mm 07746 0041000 lnstall the final shaft lnstall the final shaft removed install the dowel pins stop ring boot and stator if 0 ring collars and gasket DOWEL PINS Date of Issue Decem...

Page 115: ... 18 25 N m 1 8 2 5 kg m 12 18 Cr lb 6 mm bolts 8 12 Mem 8 8 4 2 kg m 6 9 ft lb STARTER MOTOR Install the starter motor Align the punch marks the gearshift spindle and on the gearshift install the pedal pedal and SPARK lnstall tI advancer advancer ADVANCER 1e pulse generator by aligning i t s toot1 base plate rotor onto i with the cu the t out spark in the ROTOR TOOTH Date of Issue December 1982 O ...

Page 116: ...r Install the pulse generator assembly aligning the right pulse generator steel core with the rotor tooth Tighten the screws securely STEEL CORE ROTOR TOOTH INDEX FS MARK Rotate the crankshaft clockwise and align the FS mark on the left side with the index mark on the rear engine cover Check that the rotor tooth is aligned with the left pulse generator steel core Check the air gap between the roto...

Page 117: ... surface su ace indicated and install install the pulse generator cover PULSE GENERATOR COVER IMPELLER COLLAR WATER PUMP INSTALLATION Install the impeller collar on the camshaft NOTE For water pump mechanical seal replacement refer to page 9 1 1 Bate of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 118: ... and seat washer if the mechanical seal is replaced SEAL WASHER IMPELLER COPPER WASC ER lnstali the impeller copper washer and cap nut on the camshaft Tighten the cap nut TORQUE 8 42 Nern 0 8 1 2 kg m 6 9 ft lbj Rotate the crankshaft to make sure that the pump turns freely without binding CAP NUT DOWEL PINS RUBBER PAGI ING Check the pump cover rubber packingfor deteriora tion or damage and replace...

Page 119: ...s 8 12 N m 0 8 4 2 kg m 6 9 ft lb Apply soapy water to new water pipe 0 ring and insert the water pipe into the pump cover NOTE Make sure that the 0 ringis not twisted 1 WATER PIPE O I N G WATER PIPE HOLDERS install the water pipe holders Tighten the upper bolts first then tighten the lower bolts Date of Issue December 1982 O HONBA MOTOR CO LTD ...

Page 120: ...6 8 0 L l N G SYSTEM 940 Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 121: ...5 kg cm2 10 8 15 2 psi p p p p 55 Distilled water i 45 ethylene glycoi 3 2 26OF 50 Distilled water 50 ethylene glycol 37 6 35 water 55 ethylene glycol 44 5 6 48 F l 7 liters l 8 US qt Reserve tank 0 38 liters 0 40 US qt 1 p Unpressurized 107 7 6 226 1 Boiling point with 50 50 mixture Cap on pressurized 125 6 258 TOOLS Special Meciianrcal seal driver a irachn ent 07345 41 50400 or GN AI I 065 415 U...

Page 122: ... six seconds NOTE Before installing the cap on the tester rnois p p p RADIATOR CAP RELIEF PRESSURE 90 i 15 kPa 0 9 0 15 kg cm2 12 8 i 2 1 psi RADIATOR LEAKAGE TEST Pressurize the radiator engine and hoses and check for leaks press e can damage theradiator Do not exceed 10 5 kPa 1 05 kglcrnL 14 9 psi 1 Repair or replace components if the system will not hold specified pressurefor a t least six seco...

Page 123: ...in bolts CAUTION RADIATOR CAP Do not overtighten the radiator drain plug 1 RADIATOR DRAIN PLUG CYLINDER DRAIN PLUG RESERVE TANK Fill the system with a 50 50 mixture of distilled water and ethylene glycol Bleed air from the radiator Start the engine and run until there are no air bubbles in the coolant and the level stabilizes D Stop the engine and add coolant up to the proper level if necessary e ...

Page 124: ... HOSE Disconnect the by pass hose Remove the water pipe joints and water pipes Remove the thermostatbracket bolts Pull the thermostat housingoff the radiator hose WATER PIPE BRACKET JOrNT B 0LT Separate the thermostat bracket from the therrno stat housing Remove the thermostat cover and take out the thermostat Remove the water temperature sensor TEMPERAT URE SENSOR GOV E R Date of Isscie Deeernbeu...

Page 125: ...er touch the pan or false readings will result Technical Data Valve lift 8 mm 0 31in minimum NOTE B Replace the thermostat if the valve stays open a t room temperature or if it responds a t temperatures other than those specified Valve lift must be checked by applying heat for five minutes THERMOMETER 1 THERMOSTAT E INSTALLATION Insert the thermostat into the thermostat housing Install a new 0 rin...

Page 126: ...IPE WATER PIPE JOINT Connect the temperature sensor wire to the sensor Fill the system with the recommended coolant page 9 31 Install the fuel tank and seat TEMPERATURE SENSOR RADIATOR COOLING FAN REMOVAL Remove the seat and fuel tank Remove the radiator covers Brain the coolant from the radiator Disconnect the fan motor and thermostatic switch wire coupler Disconnect the adiator overflow tti be L...

Page 127: ...e radiator mounting off the upper and lower nuts and pull the radiator hoses FAN SI I ROUD WIRE CLAMPS DISASSEMBbY Bend down the thermostatic switch and fan motor wire clamps and remove the wires Remove the four fan shroud mounting bolts and Fan shroud from the radiator Date of Issue December 198 2 O HQNDA MOTOR CO LTD ...

Page 128: ...pect the radiator soldered joints and seams for leaks Blow dirt out from between core fins with com pressed air If insects etc are clogging the radiator wash them off with low pressure water Carefully straighten any bent fins FAN MOTOR SHROUD FAN MOTOR TOP MARK ASSEMBLY Place the fan motor on the shroud with its TOP mark facing up and tighten the three screws Date of Issue December 1982 O WONDA MO...

Page 129: ...n shroud to the radiator with the four bolts Connect the wire to the fan motor coupler and the thermostatic switch COOLING FAN NU4 FAN SI IROUD FAN MOTOR COUPLER CLAMPS Secure the wires with the clamps on the shroud THERR OSTAPIC SWITCH MOUNT NUT INSTALLATION Install the radiator onto the frame and tighten the mounting nuts Date of issue December 1982 O MONDA MOTOR CO LTD ...

Page 130: ...ighten the hose bands Connect the overflow tube to the ses t c filler 3 the radiator neck Connect the thermostatic switch and fan motor wire coupler to the wire harness Install the radiator covers Fill the cooling system page 9 31 Date of Issue December 1982 O HONDA MOTOR GO LTD ...

Page 131: ... 9 1 2 for installation instruc tions using the tool available only in the U S A Drive the mechanical seal into position in the rear cover with the mechanical seal driver attachment and bearing driver handle Be careful not to damage the water pump housing p p Assemble the driver as follows Install the seal driver attachment onto the driver handle Place the mechanical seal into the attachment B Dri...

Page 132: ...f the metal casing of the seal NOTE Some mechanical seals may be precoatedwith sealant from the factory Position the seal and tool in the rear cover Install the guide plate and nut onto the bolt from the back side of the cover Torque the nut to 42 6 44 8 4 m 380 400 lb in 31 6 33 3 Ib ft Remove the tool and inspect the installation MECHANICAL INSIALL ER SEAL CUP ENGINE MECHANICAL SEAL INSTALLER GN...

Page 133: ... MEMO Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 134: ...Date cif Issue December 1982 O HONDA MOTOR CO LTD ...

Page 135: ... 027 0 5518 0 5522 1 14 046 10 5530 IShaft 8 D 13 982 14 000 0 5505 0 561 2 1 13 966 0 5500 IN EX Front Rear Camshaft holder I D 1 22 000 22 021 0 8661 0 8670 1 22 050 0 8681 1 26 000 26 021 1 0236 1 0244 1 26 170 1 0303 Camshaft bearing DD 1 p p 37 988 1 4956 38 143 1 5017 21 959 21 980 0 8645 0 8654 25 959 26 980 1 0220 1 0622 TORQUE VALUES 37 87 1 491 38 02 1 497 21 910 0 8526 25 99 0 1 0201 Ca...

Page 136: ... the push rod by inserting the retaining pin through the push rod to the tensioner base Remove the cam chain tensioner set bolt and tensioner CAUTION p p set bolt has a special thread pitch use any other bolt in its place SET PLATE SET BOLT CAM CHAIN TENSIONER Remove the chain tensioner slipper Remove the cam chain guide CAM CHAIN U I B E CHAIN TENSIONER SLIPPER PUSH ROD BOWEL BOLTS Remove cket an...

Page 137: ...N Measure the O D of each camshaft bearing johrnal SERVICE LIMITS FRONT 21 910 mm 0 8526 in REAR 25 910 mm 1 0261 in Calculate the journal and bearingclearance SERVICE LIMIT 0 260 mm 6 0 1102in Inspect the worm gear for wear or damage Date of Issue December 1982 O MONDA MOTOR CO LTD GEAR HOLDER 07924 MC70002 or 04924 MC70000 or 07924 41 50000 LOCK NUT SOCKET WRENCH 17 X 27 mm 07907 MC70000 or 0790...

Page 138: ...be SERVICE LIMIT IN 37 137mm 1 491 in1 EX 38 82 mm 1 497 in Measure the CAMSHAFT HOLDER INSPECTION Measurethe camshaft holder D as shown SERVICE LIMIT 22 058 mm 0 8681 in CAMSHAFT BEARING INSPECTION Measurethe bearing I D SERVICE LIMIT 26 178 mm 1 0303 in Bate of Issue December 198 oHQNDA 60 LTD ...

Page 139: ...nto the rocker arm shaft and remove the rocker arm shaft Remove the rocker arm and wave washer ROCKER ARM INSPECTIBN Inspect the rocker arms for wear or damage to the camshaft contact surfaces or clogged oil holes Measure the I D of each rocker arms SERVICE LIMIT 14 046mm 0 5530 in Dare of Issue December 1982 C 3 HONDA MOTOR CO LTD ...

Page 140: ...STALLATION Install the rocker arms with the offset toward the inside and facing each other a s shown SPRINGS Install the rocker arms and thrust springs in the cylinder block and then insert the rocker arm shafts engine oil before installation threaded end facing the rear cam sprocket side Install the thrust springs on the inside of the rocker arms ROCKER ARM SHAFT R O C K E A R M S Date of Issue D...

Page 141: ...ALLATION Lubricate the camshaft journals with Multipurpose NLGl No 2 MoS2 additive Grease Install the camshaft thrust washer and insert the camshaft Prom the front Install the camshafi holder gasket 0 ring and collar Date of Issue December 1982 O I ZONDAMOTOR CO L TD m GAMSHAFTlCAM CHAIN LOCK BOLT CAMSHAFT JOURNALS ...

Page 142: ...e lock washer with the mark OUT SIDE facing out CUT OUT GEAR HOLDER LOCI NUT SOCKET WRENCH 17 X 27 mm 07924 4150000 or Install the cam sprocket and finger tighten the bolts Hold the cam sprocket with the Gear Holder Then tighten the lock nut TORQUE 88 106 N m 8 0 10 0kg m 58 92 ft lb 07907 41 50000 or 07907 MC70000 or 07924 MC70000 or COMMERCIALLY AVAILABLE IN iJ S A 07924 ME90000 Remove the cam s...

Page 143: ... timing is correct when c The cam sprocket bolts are in line with the aligning marks on the engine case s Check that the flywheel woodruff key aligns with the index mark on the crankshaft cap NOTE When inspecting the valve timing push the cam chain from the right side so the tensioner the chain is pulled taut p ALIGNING MARKS WOODRUFF KEY CENTER BETWEEN 2ND AND 3RD TOOTH FROM WOODRUFF KEY Date of ...

Page 144: ...orque the cam sprocket bolts TORQUE 16 20 N m 1 6 2 0 kg m 12 14 ft lb COMMERCIALLY AVAILABLE IN U S A CAM CHAIN AUTOMATIC CAM INSTALLWT161V Install the cam chain CHAIN TENSIONER tensioner slipper and guide CAM GWAlN GUIDE Install the tensioner into I Iace on the engine case TENSIONER BODY SLIPPER PllU Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 145: ...ically give tension to the cam chain Make sure the push rod moves smoothly by pressingthe steel ball in CAM CHAIN SET PLATE lnstall the cam chain set plate and tighten the bolts ENGINE OIL Pour about 10 cc of engine oil into the oil pockets of the cylinder block Install the flywheel Page 8 9 and the cylinder head Page6 14 Adjust the valve clearance Page 3 8 lnstall the engine See section 5 Add the...

Page 146: ...TRANSMISSION Date of Issue December 1982 O HONDA MOTOR CO L I D ...

Page 147: ... gears To service the transmission it is nesessary to remove the engine from the frame SPECIFICATIONS Unit mm in 1 30 95 1 219 1 0 1 2199 1 2209 Transmission C 2 gear bushing 27 500 27 521 1 0827 1 0835 27 54 1 a841 p 29 020 29 041 1 l425 1 1433 29 10 l 146 C 3 gear Bushinq O D i i l409 2 1417 28 95 1 140 A l J a t C1 19 987 20 000 0 7869 0 7874 19 96 0 786 Countershaft 0 D at C2 1 27 459 27 480 1...

Page 148: ... mm 07746 0010300 Driver 07749 001 0000 Attachment 52 X 55 mm 07746 0010400 Pilot 25 mm 07746 0040600 Attachment 62 X 68 mm 07746 0010500 Pilot 20 mm 07746 0040500 Attachment 32 x 35 mm 07746 0010200 TROUBLESHOOTING Hard to Shift e Improper clutch adjustment too much free play BD Shift forks bent e Shift shaft bent a Shift Cork claw bent s Shift drum cam grooves damaged e Shift guide pin damaged T...

Page 149: ...ve the neutral switch plate drum cam plate gearshift drum pin and collar NOTE 1 Do not disassemble the shift drum plates and 1 pin except when replacement is necessary L J Check all removed parts for wear or damage NEUTRAL 6 mm BOLT ARM SWITCH PLATE FIiAL SHAFT DISASSEMBLY Compress the spring with a press and Crank Cap Driver and remove the spring cotters CRANI CAP DRIVER 07945 4150100 Remove the ...

Page 150: ...r or damage FINAL SHAFT ASSEMBLY Slide the lifter spring and retainer over the shaft Compress the spring in the Crank Cap Driver and install the spring cotters NOTE I RETAINER cOTTE S I Make sure that the cotters are properly seated 1 L_ DAMPER SPRING RETAINER SPRING COTTERS Bare of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 151: ... remove the clutch a s an assembly Section 7 Remove the oil separator Remove the transmission holder bolts Remove the final drive spline collar OIL SEPARATOR TRANSMISSION HOLDER DOLTS FINAL DRIVE SPLINE COLLAR Date of Issue December 1982 C 3 HONDA MOTOR CO LTD ...

Page 152: ...se by rotating the shift drum COUNTERSHAFT Drive the ends of the counterstlaft and shift drum carefully and evenly with a soft hammer until the transmission holder is clear of the engine case Wemo case the transmission assembly from the engine Date of Issue December 1982 O HONDA BAOTOR 60 LTD ...

Page 153: ...hift drum SHIFT FORK M2 GEAR C2 GEAR Remove the thrust washers 2nd and 5th gears from the countershaft and mainshaft M5 GEAR C5 GEAR COUNTER SHAFT Remove the countershaft I s t 3rd and 4th gears and washers by removingthe countershaft Bare of issue December 1982 O HONBA MO rOR CO LTD ...

Page 154: ...ARING REMOVER WEIGHT Inspecteach holder bearing for wear or damage They should rotate smoothly and be free of play Remove the bearing from the transmission holder 07936 371 0600 MAINSHAFT Remove the countershaft bearing from the engine case Remove the mainshaft bearing and oil guide plate from the engine case with the special tools NOTE Bearings should be replaced with new ones if they are removed...

Page 155: ...0 mm 01949 in G2 GEAR 31 10 mm 1 224 in C3 and C4 GEARS 29 10 mm 1 146 in Measure the countershaft gear bushing I B and O B SERVICE LIMITS 8 D 23 9 mm 0 943 in D 20 06 mm 0 790 in 0 B 30 06 mm 1 219 in D 27 54 mm 1 084 in COUNTERSHAFT Measure and record the O D of the countershaft a t the locationsshown SERVICE LIMITS A 611 19 96 mm 0 786 in B 621 27 44 mm 1 080 in Calculate the clearance btween t...

Page 156: ... LIMIT 5 58 mm 0 247in SHIFT FORK SHAFT SI IIFI DRUM Measure and record the shift drum O B and transmission holder I D Calculate the clearance between the shift drum and the transmission holder SER ICE LIMIT 0 15 mm 0 086 in TRANSMISSION HOLDER TRANSMISSION ASSEMBLY install the oil guide plate in the mainshaft bearing hole OIL GUIDE PLATE Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 157: ...the transmission holder Insert the needle bearing into outer race Drive the mainshaft bearing into the transmission holder if it was removed NOTE p the transmission holder above the workbench to prevent damaging it 1 TOOLS Mainshaft Bearing a Attachment 62 x 68 mm 09746 0040500 Pilot 25 m m 07746 8040600 ad Driver 07749 001 0000 Countershaft Bearing e Attachment 32 x 36 mm 07746 0048100 e Pilot 20...

Page 158: ...ble the mainshaft and countershaft as shown in the illustration below NOTE JRD MA1NSHAFT M3 GEAR install the rnainshaft 3rd and 4th gears onto the rnainshaft Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 159: ...NTERSHAFIJ3RD GEAR ASSEMBLY lnstall the countershaft with 3rd gear through 4th and 1st gears and into the needle bearing M2 GEAR THRUST WASHERS C2 GEAR Slide 5th and 2nd gears onto the countershaft and mainshaft Place the thrust washers on the M2 and C2 gears Check the engagement of the gears on the counter shaft and mainshaft Date of issue December 1982 O HONDA MOTOR GO LTD ...

Page 160: ... case Place the transmission in neutral and insert the transmission assembly into the engine case NOTE Align the projection on the shift drum with the cut out in the engine case BOWEL PINS TRANSMISSION HOLDER Press the transmission holder into place while rotating the mainshaft and torque the holder bolts TORQUE 6 X 20 m m bolt 15 20 M m 1 5 2 0 kg m 11 744f lb Date of Issue December 1982 O WONDA ...

Page 161: ... G 1 4 kg m 7 1 ft lb After tightening the bolts make sure that the shafts rotate freely OIL SEPARATOR 6 x 3 2 m m BOLTS FINAL DRIVE SPLINE COLLAR Install the final drive spline collar over the counter shaft Install the clutch assembly Section 7 Install the engine front cover Section 7 Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 162: ...TE PIN Install Align install Install plate the dowel pi11into the hole of the shift drum the cam plate hole with the dowel pin and the cam plate the four cam plate pins collar and center HOLE COLLAR CENTER PLATE Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 163: ...PPER ARM SPRING STOPPER ARM Install the stopper arm spring collar tighten with the plain washer and bolt and arm and Install the gearshift arm and shift spindle install the rear cover Section 9 NOTE p After installing the rear cover install the gearshift pedal and check its operation r 1 GEARSHIFT SPINDLE GEARSHIFT ARM Date of issue December 1982 O WONDA MO 1 ORCO LTD ...

Page 164: ...58 69 ft lb Dale of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 165: ... the transmission a pp y molybdenum dis ilfide grease to the journals crankpins and bearings during assembly Unit mm in p p STANDARD p 0 020 0 060 0 0008 0 0024 Crank pin oil clearance 0 028 0 052 0 0011 0 0020 Connecting rod side clearance 0 150 0 350 0 0059 0 014 Cylinder 82 500 82 51 5 3 2480 3 2486 Warpage 1 1 0 10 0 004 1 Piston ring Ring to groove pp 0 025 0 050 0 0006 0 0020 1 p p 0 10 0 00...

Page 166: ...n main bearing Worn rod bearing Piston and Connecting Rod Worn piston or cylinder Worn piston pin or pin hole Worn rod small end Low Compressionor Uneven Compression e Worn cylinder or piston ring Excessive Smoke Worn cylinder piston or piston rings e Improperly installed piston rings e Damaged piston or cylinder Overheating s Excessive carbon build up on piston head e Blocked or restricted flow o...

Page 167: ...ter Remove the bearing cap and mark the bearing caps and rods to indicate cylinder position Remove the left side cap from the transmission Work through the hole on the oil pump side to remove the right side cap BEARING CAP NUTS Turn the crankshaft so that the Place the Piston Remover over push the piston and rod assembly piston is at T D C the rod bolts and out PISTON GEMOVER07941 MC70000 or COMME...

Page 168: ... 804 in Remove the piston rings NOTE Mark the rings so they can be reinstalled on the piston they were removed from Clean and inspect the piston crown Inspect the piston for damage and cracks check the ring grooves for excessive wear Insert each piston ring into the cylinder and measure the ring end gap SERVICE LIMIT TOPISECOND 0 60 mm 0 024 in OIL SIDE RAIL 1 10 mm 0 043 in Date of Issue December...

Page 169: ...ond the limit replace ment is necessary CYLINDER INSPECTION Measure the cylinder I D SERVICE LIMIT 82 60 3 252 in Calculate the piston to cylinder clearance SERVICE LIMIT 0 10 mm 0 004in Oversize pistons are available in the following sizes 0 25 and 0 50 mm Measure the piston pin bore of each piston SERVICE LIMIT 21 040 mm 0 8283 in Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 170: ...the rod SERVICE LIMIT 21 068 m m 0 8294 in CRANKSHAFT REMOVAL Hold the primary driver gear with a Gear Holder Remove the 12 mm bolt and the oil pump sprocket disc spring side plate sub gear and primary gear GEAR HOLDER 07924 M670002 or 07924 MC90001 or 07924 MC70000 or 07924 41 50000 NOTE Mark the sub gear and side plate so that they will face the correct direction during re assembly Dare of Issue...

Page 171: ... Crank Cap Puller or use a press to remove the crankshaft Be carefil not to damage the bearing when removing the crankshaft Place the engine case in a hydraulic press on supports so that it is at least 2 inches above the adjustable cross beam Press the crankshaft out while holding the crankshaft cap ROD SIDE CLEARANCE INSPECTION Install each connecting rod and bearing cap in its original position ...

Page 172: ... oil hole Install each connecting rod and bearing cap in their original positions and torque to specifications even ly in 2 3 steps F i t a t e the crankshaft rnspection TORQUE 41 45 Nmrrp a 4 5 kg m 36 33 F lb Remove the caps and measure the compressed plastigauge The widest thickness determines the oil clearance SERVICE LIMIT 0 085 mm 0 0033in Date of Iss ie December 1982 O HONDA MOTOR CO LTD ...

Page 173: ...d codes to determine the replacement bearingcolor CODE NO CRANK PIN BEARING SELECTION 1igiiy COLOR IDENTIFICATION I CRANK PIN BEARING SIZES 1 1 499 1 S03 mm 1 GREEN 1 495 1 499 mm 1 PINK 1 1 487 1 491 mm 1 46 000 46 008 mm 1 8110 1 8113 in After fitting new bearing inserts they should be recheckedwith plastigauge Dare of Issue December 1982 C 2 WONDA MOTOR CO LTD YELLOW GREEN ...

Page 174: ... the engine case and crankshaft h a r i n g I D s Calculate the journal to bearing clearance SERVICE LIMIT 0 085 mm 0 6033 in Measure the crankshaft cap bearing I D and calcu late the journal t o bearing clearance SERVICE LIMIT 8 885 mm 8 0033 in CRANKSHAFT CAP Date of Issue December 1982 O HONDA MQTOR CO LTD ...

Page 175: ...t of the crankshaft cap bearing support with a hydraulic press and bearing removal tool Use the tool end with the R mark To prevent crankshaft cap damage always use a hydraulic press and bearing removal tool to rerrzovebearirzxs MAIN BEARING DIS ASSEMBLV TOOL 07973 MC70000 R MARK MAIN BEARING BISIASSEMBLY TO PRESS OUT MAiN TOOL 07973 MC70000 IOIJNAI BEARINGS PO F WESS IN MAIN 1 0 PRESS CRANK CAP B...

Page 176: ...AL O D CODES me as I D Jre and record the engine case bearing support Measure the crankshaft cap bearing support D Cross reference the bearing support I D and crank journal codes to determine the replacement bearing color Bate of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 177: ...roove and press the bearings into place Use the end of the tool with the P mark and the attachment NOTE Draw two lines on the outside of the bearings to match the tab to aid in bearing alignment CAUTION Be careful not to damage tlze bearing when press fitting them Lubricate the outer surface of the bearing with engine oil or molybdenum disulfide grease Align the tab of the bearing insert with the ...

Page 178: ...ne case MULTIPURPOSE NLGl 8 1 1 GROOVE No 2 MoS2ADDITIVE Wrap the splines of the crankshaft and timing gear area with vinyl tape to prevent damage to the main journal bearings Install the crankshaft NOTE Make sure that the thrust washer is not displaced l TAPE THRUST WASHER Remove the vinyl tape from the splines Install the thrust washer on the engine case bearing with the oil grooves facing the f...

Page 179: ...l the 0 ringand collar Install the crankshaft holder cap Install the guide bolts in the crankshaft holder cap as shown NOTE Screw in the guide bolts evenly so rat the cap is not tilted Press the crankshaft holder cap into place with the Crank Cap Driver Ol k PUMP DRIVE SPROCKET PRlMARY GEAR MULTIPURPOSE NLGI NO 2 MoS ADDITIVE 0 RING AND COLLAR P GUIDE BOLTS INCLUDED WITH 07945 41 50100 CRAhlK GAP ...

Page 180: ...70002 or 07924 MC70001 or 07924 MC70000 or 07924 41 50000 Install the Drive Gear Holder to prevent the drive gear from turning Torque the primary drive gear bolt TOROUE 80 95 N m 8 0 9 5 kg m 58 69 ft lb Turn the crankshaft to make sure it moves freely PRIMARY DRIVE GEAR Date of Issue December 1982 G 3 HONDA MOTOR CO LTD ...

Page 181: ...mall end with molybdenum disulfide grease Assemble the pistons and connecting rods with the piston pins and new piston pin clips NOTE TOP RING l S I E RAIL IN MARKS R MARK cs Do not interchange the pistons piston pins and connecting rods e Make sure that the piston pin clips are properly seated BI Install the piston with the L mark on the left and the piston with the R mark on the right Bate of Is...

Page 182: ... r The rod assemblies should be installed with the piston IN markings to the rear ts Install the piston with the W mark on the right cylinder and piston with the L mark on the left cylinder fi FRONT OIL HOLE I OIL HOLE PISTON RING COMPRESSOR OR EQUIVALENT Lubricate the piston and piston ring with engine oil Bringthe crankshaf to TBC Compress the piston rings and insert the piston into the cylinder...

Page 183: ...ations M p J CONNECTING ROD BEARING CAP CYLINDER COMPRESSION Warm up the engine to operating temperature Stop the engine Disconnect the spark plug caps and remove the spark plugs Turn the engine stop switch OFF Insert a compression gauge into the spark plug hole Open the throttle valves fully and crank the engine with the starter motor until the gauge needle stops rising within 4 7 seconds COMPRES...

Page 184: ...RONT WHEELJSUSPEMSION 25 35 N m 12 5 3 5 kg m 90 1 26 Nem 18 25 Nem 1 8 2 5 kg m 13 18 ft lb 30 45 N m 3 0 4 5 kg m 3 5 4 0 kg m 22 33 ft lh 22 29 ft lb Date of Issue December 1982 G3 HONDA MOTOR CO LTD ...

Page 185: ...k tube cap Front fork socket bolt TOOLS Special Snap ring pliers Hex wrench 6 mm Fork seal driver Ball race remover Steeringstem driver 25 35 N m 2 5 3 5 kg m 18 25 ft lb 9 13 N rn 0 9 1 3 kg m 7 9 ft lb 45 55 N m 4 5 5 5 kg m 33 40 ft lb 55 65 P4 m 5 5 6 5 kg m 40 47 ft lb 90 120 N m 9 0 12 0 kg m 65 87 ft lb 18 25 N m 1 8 2 5 kg m 13 18 ft ib 30 45 N m 3 0 4 5 kg m 22 33 ft lb 18 28 N m 1 8 2 8 ...

Page 186: ...teering stem nut or bearings Loose lock nut on swing arm pivot bolt Unbalancedtire and wheel o Bent wheel s Excessive lateral runout in wheel Bent forks e Bent swing arm Bent or cracked frame o Loose engine mounts Soft Suspension o Weak fork spring e Insufficient fluid in front forks e Insufficient fork air pressure Hard Suspension o Incorrect fluid weight in front forks BP Clogged fork hydraulic ...

Page 187: ...ts and remove the case DISASSEMIBLVIASSEMBL Remove the retaining screws and horizontal adjust ing screw from the rim Remove the two headlight unit retaining screws and headlight unit Assembly is the reverse of disassembly ADJUSPJNG SCREW CASE INSTALLATION Align the punch marks on the headlight c bracket ase and PUNCH MARKS Dare of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 188: ...clamp a s shown Connect the red small 9P and black small GP couplers Connect the white small 6P coupler secure it with the upper clamp and position its harness to the interior of the headlight case p WHITE 6P COUPLER CLAMP 1 Date of Issue December l982 C 3 l IONDA MOTOR CO LTD ...

Page 189: ...y Page 3 13 I iEADL1GI I T COUPLER l CLAMP CLAMP HEADLIGHT BRACKET BRACKET REMOVAL INSTALLATION Remove the instruments page 13 5 Remove the headlight bracket mount bolts and bracketltt rn signal assemblies Install the headlight bracket INSTRUMENTS REMOVAL Remove the headlight case Disconnect the instrument wire connectors and coupler Remove the speedometer and tachometer cables from the instrilmen...

Page 190: ...der of disassembly MOUNTING BRACKET L NUTS LOWER COVER HANDLEBAR REMOVAL Disconnect the front brake light switch wires and remove the master cylinder Do not loosen the brake hose unless neces F l MASTER CYLINDER p r After removing the master cylinder keep it level Bo not tilt the mster cylirzhr or rum ifupside down s Do not hang the nzaster cylinder by the brake hose BRAKE 16tl r SWITCH WIRES SCRE...

Page 191: ...r switch assembly Disconnect the clutch switch wires Remove the clutch lever bracket holder and bracket Disconnect the choke cable from the choke lever CLCJTCH LEVER BRACKET BRACKET HOLDER CHOKE LEVER Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 192: ...h mark with the upper face of the lower holder Install the upper holder tighten the forward bolts first then tighten the rear bolts TORQUE 25 35 N m 2 5 3 5 kg m 18 25 ft ils Install the bolt caps Apply grease to the throttle grip slidingsur face and slide the throttle grip over the handlebar Attach the weights to the end of the handlebar Bate of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 193: ... not pinched between the switch assembly and the hand Install the front brake master cylinder with the UP mark on the holder facing up Align the end of the holder with the handlebar punch mark Tighten the upper bolt first then the lower bolt Connect the brake light switch wires Connect the choke cabie to the choke lever PiNS UP MARK PUNCH GARK CHOKE LEVER Date of Issue December 1982 O HONDA MOTOR ...

Page 194: ...the end of the holder with the purtch mark on the handlebar lighten the upper bolt first then the lower bolt Connect the clutch switch wires PUNCH MARK WIRE BANDS Route the wires and cables properly page 1 9 and install the wire bands 0 Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 195: ... PINCI I BOLT Loosen the axle pinch bolt Loosen and remove the front axle Remove the front wheel NOTE Do not operate the front brake lever after removing the wheel To do so will make it difficulty to refit the brake disc between the brake pads INSPECTION AXLE Set the axle in V blocks and measure the runout The actual runour is 1 2 of the total indicator reading SERVICE LIMIT 0 2mm 0 0 1inj Date of...

Page 196: ... in a truing stand Spin the wheel slowly and read the runout using a dial indicator SERVICE LIMITS RADIAL RUNOUT 2 0mm 0 08 in AXIAL RUMOUT 2 6 m m 0 08 in The wheel cannot be repaired and must be replaced with a new one if the service limits 1 are exceeded p p p l DISASSEMBLY Remove the brake disc mounting bolts and disc Remove the seal and speedometer gear retainer PLAY SPEEDOMETER GEAR RETAINER...

Page 197: ...tance collar from the hub Do not get grease on the brake disc or will be redliced NOTE The cast wheel has no rim band 1 BI The front wheel uses a tubeless tire For 1 tubeless tire repair refer to the Honda l Tubeless Tire Manual WHEEL BEARING REMOVER COLLET 15 mm 07746 0050400 08 EQUIVALENS Dare of Issue December 1982 oHONDA MOTOR CO LTD 7i 3 8 63 ...

Page 198: ...side is facing out lnstall the brake disc onto the wheel hub TOROUE 3 5 4 0 jW l n 3 54 0 kg m 22 29 F lb Clean the brake disc with a high quality degreasing agent Install the speedometer gear retainer into the wheel hub aligningthe tangs with the slots Install the left seal PILOT 15 mm 07746 0040300 nlsc LEFT SEAL Disassemble the speedometer gear box and lubricate the gears and sliding surfaces S...

Page 199: ...ll the right seal and side collar INSTALLATION Fit the calipers over the disc taking care nor to damage the brake pads Align the speedometer gear box with the boss on the left fork leg as shown TANGS SIDE COLLAR RIGHT SEAL SPEEDOMETER SEAR BOX Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 200: ...ied torque Tighten the axle pinch bolt to the specified torque TORQUE 18 25 Nsm 1 8 2 5 kg t n 13 W 8f lb FRONT AXLE Install the speedometer cable into the speedometer g a r box and tighten the set screw SPEEDOMETER CABLE Date of Issue Deeernher 192 G 3 HONDA MOTOR CO LTD ...

Page 201: ...ase front fork air pressure FORK TUBE CAP CAUTION p B If air pressure is not released before dis assembling the fork tube cap may become a projectile s The cap is also under spring pressure Use care when removing wear eye and jirce pro iection Hold the fork tube in a vise with soft jaws or a shop towel and remove the fork tube cap p p p careful not to damage the fiork tube s sliding surface 1 Date...

Page 202: ... EQUIVALENT Hold the fork slider in a vise with soft jam or a shop towel Remove the socket bolt with a hex wrench NOTE Temporarily install the spring and fork bolt if The piston and reboundspring can be removed from the right fork BUST SEAL PLASTIC WASHER Remove washer the dust seal seal and plastic SPONGE SEAL 13 18 Date of Issue December 1982 O HQNDA MOTOR CO LTD ...

Page 203: ...he sllclei 1 Ile sl detbusli nq w l l he forced out by the fork tul e busli g I elnovc the o l locl Ijlece from ns tie the slidrr L i lid aw a cI 2 h 7 4 FORK SLIDER 0 1 1 SEAL BACK UP RING SLIDER BUSING Remove the oil seat back up ring and slider bushing from the fork tube NOTE Do not remove the fork tube bushing unless it is necessary to replace it with a new one See bushing inspection page 13 2...

Page 204: ...FORK SLIDEW PI TBN Check the fork tube fork slider and piston for score marks scratches or excessive or abnormal wear Replace any components which are worn or damaged Check the fork piston ring for wear or damage Check the rebound spring for fatigure or damage e FORK TUBE Set the fork tube in V blocks and read the runout SERVICE LIMIT 0 20 mm 0 008 in Bate of Issue December 1982 O HONDA MOTOR CO L...

Page 205: ...cessive scoring or scratching or if the teflon is worn so that the copper surface appears on more than 314 of the ASSENIBL Y FORK BRACE Before assembly wash all parts with a high flash point or non flammable solvent and wipe them off completely PISTON PISTON AIR VALVE CAP BOLT FORK TUBE SPAGER SPRING SEAT Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 206: ...6 mm hex wrench NOTE Temporarily install the fork spring and fork cap bolt to tighten the socket bolt TORQUE 15 25 Nem 1 5 2 5 kgm 11 78 ft lb FORK SEAL DRIVER 07947 4630100 Place the slider bushing over the fork tube and rest it on the slider Put the back up ring and an old bushing or equivalent tool on top Drive the bushinginto place with the seal driver and remove the old bushingor equivalent t...

Page 207: ...SPoNG SEAL PLASTIC WASHER SNAP RING OIL SEAL BACK UP W lNG Pour the specified amount of ATF into the fork tube CAPACITY 480cc 16 2 OZS FORK SPRING FORK TUBE CAP Install the fork spring spring seat and spacer into the fork tube direction the narrow coils should face toward the bottom Install and torque the fork tube cap Date of Issue December 1982 oHONDA MOTOR CO LTD 13 123 ...

Page 208: ... removal front fender brake caliper front wheel Tighten the front fork brace to the specifiedtorque TORQUE 18 28 M m 1 8 2 8 kg m 13 28 Bt lb lnstali the bolt caps Fill the fork tubes with air to 8 40 kPa 8 0 4 kg cm2 0 6 psi CAUTION a hand operated air pump to fill thefork tubes Do not use compressed air r Maximum pressure is 300 kPa 3kg cm2 43 psi Do not exceed this or fork tube component damage...

Page 209: ...ge 13 5 ignition switch page 20 5 handlebar page 13 61 front wheel page 13 11 front emblem horns with bracket FRONT EMBLEM HORNS LOCK NUT WRENCH HORN BRACKET 30 X 32 mm EXTENSION BAR COMMERCIALLY OR EOlJIVAbENT A V A l LARLE steeringstem nut front forks page 13 17 fork top brodge FORK TOP BRIDGE Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 210: ...ls to fall BEARING INSPECTION Check the upper and lower bearing race surfaces and steel balls for wear or damage and replace if necessary BEARING A JUSTMENTNUT BBTTOM CONE RACE REPLACEMEPt1 T Inspect the boMom cone race for wear or damage and replace if necessary Remove the bottom cone race with a hammer and a drift BOTTOM CONE RACE Date of Issue December W982 O HONDA MOTOR CO LTD ...

Page 211: ...ol NOTE If the motorcycle has been involved in an accident examine the area around the steering head for cracks STEERING STEM DRIVE 07946 NIB00000 OW 07946 371 0100 AND 07964 ME100200 BALL RACE REMQVER BRlVER 07946 371 0400 U BALL RACE remove the upper ball race with the special tool 1 BALL RACE REMOVER DRlVER 07946 371 0400 DRIVE OUT TOP BALL RAC PILOT IN BoT7 OM BALL RAGE p p Date of Issue Decem...

Page 212: ...tom ball race and install 19 ball bearing Insert the steering stem into the steering head pipe and install the top cone race no hall race installation Bottom hall race installation 1 c _ _ BALL RACE REMOVERIDRIVER PILOT IN 07946 371 0400 TOP BALL RACE DRIVE IN BOTTOM RACE BOTTOM BORE U BALL BEARINGS TOP GONE RACE STEERING STEM PIN SPANNER STEERING STEM SOCKET Install the bearing adjustment nut and...

Page 213: ...idge and stem nut Temprarily install the front forks and tighten the stem nut TORQUE 90 120 M m 9 0 12 0 kg m 65 87 81 lb Install the removed parts in the reverse order of removal EXTENSION BAR COMMERCIALLY AVAILABLE Dale of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 214: ...HONDA REAR WHEEL SUSPENSIOMIBRAKE CX65OC Date of Issue Becernbet 1982 0i iONDA MOTOR CO LTD ...

Page 215: ... 1 Rear wheel rim runout p p p p p Shock absorber spring free lenqth 241 9 mm 9 52 in Brake drum I D 1 160 0 160 3 mm 6 30 6 31 in 1 161 mm 6 34 in TORQUE VALUES Reqr axle nut Brake torque link bolt Axle pinch bolt Brake arm Shock absorber mount bolt Final driven flange Swing arm left pivot bolt Swing arm right pivot bolt Swing arm pivot lock nut TOOLS Special Swing arm pivot lock nut wrench Hex h...

Page 216: ... TROUBLESHOOTING Oscillation a bent rim m Loose wheel bearings B Faulty tire e Loose axle e l i r e pressure incorrect e Swing arm bearings worn o Worn tires Soft Suspension e Weak spring s Hard Suspension Bent shock absorber Suspension Noise s Shock case binding e Loose fasteners 077460050500 or equivalent commercially available in U SA 07746 00501 00 Date 04 Issue December 1982 O HONDA MOTOR CO ...

Page 217: ...NUT REAR AXLE AX1 E PINCH BOLT Remove the brake torque link bolt and disconnect the torque link Remove the brake adjusting nut and the brake rod Loosen the axle pinch bolt and remove the rear axle Move the wheel to the left to separate it from the final drive gear case and remove the rear wheel Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 218: ...k the wheel bearing play by rotating the wheel by hand Replace the bearings with new ones if they are noisy or have excessive play WHEEL RIM WklN0bl T Check the rim for runout by placing the wheel in a truing stand Spin the wheel slowly and read the runout using a dial indicator SERVICE LIMITS RADIAL RUNOUT 2 0 mm 0 08 in AXIAL RUNOUT 2 0 m m 0 08 in The wheel cannot be serviced and must be replac...

Page 219: ...N FLANGE DISASSEMBLY Remove the final driven flange mount the driven flange out of the hub bolts and lift WHEEL BEARING REMOVER COLLET 17 mm n7746 0050500 OR EQUIVACENT Remove the wheel bearings and distance the special tool collar with 07746 0050100 OR EQUIVALENT Date of Issue December 1982 O HONDA MOPOR CO LTD l 4 5 ...

Page 220: ...ty The wheel uses a tubeless tire For tubeless tire repairs refer to the Tubeless Tire Manual Pack all bearingcavities with grease Press the distance collar into place from the left side Drive the right ball bearing in first then the left ball bearing CAUTION Drive the bearings in squarely BI I zst zll the bearings with the sealed encl facing out mnki zgsure they are firlly seated A DRIVER 07749 0...

Page 221: ...MoS2 additive to the final driven flange and ring gear engagement splines Loosen the final gear case attaching nuts to ease axle installation and to assure proper driven flange alignment Engage the rear wheel with the final drive case making sure the splines are correctly aligned SWING ARM SIDE COLLAR Insert the rear axle through the swing arm collar brake panel l u b and final drive gear side REA...

Page 222: ...rake arm pin and install the brake adjusting nut Tighten the brake torque link bolt TORQUE 15 25 RI m 1 5 2 5 kg m 11 18 It lb AXLE NUT REAR AXLE AXLE PINCH BOLT Inflate the rear tire page 3 36 Adjust the rear brake page 3 13 TORQUE LINK BOLT BRAKE AD USTINGNUT REAR BRAKE PANEL LINING THICKNESS INSPECTION Measure the rear brake lining thickness SERVICE LIMIT 2 0 m m 0 08 in Replace the brake shoes...

Page 223: ...e anchor pins and brake cam Install the brake cam p lining reduce stopyitlg yo W Keep grease ojf the brake linings Wipe arty excess grease off the cam Install the following brake shoes cotter pins WEAR INDICATOR Install the felt seal and wear indicator tooth with the brake cam punch mark aligning i t s FELT SEAL ALIGN Date of Issue Becernber 1982 O HONDA MOTOR Co LTD ...

Page 224: ...ARKS REAR BRAKE PEDAL Remove the right and left mufflers page 5 16 Remove the rear brake adjustingnut BRAKE ADJUSTING NUT BRAKE LIGHT SWITCH SPRING COTTER PIN Disconnect the brake light switch spring from brake pedal shaft arm Remove the cotter pin clevis pin and brake rod the BRAKE ROD CLEVIS PIN BRAKE PEDAL SI IAFT ARM Date of Issue December 1982 O HONDA RPIO TOR CO LTD ...

Page 225: ...it Align the punch mark on the brake pedal with the punch mark on the pedal shaft and install the brake pedal lighten the brake pedal pinch bolt TORQUE 10 15N rn 1 0 1 5 kg m 9 1 1f l lb Attach the brake pedal return and brake light switch springs Attach the brake rod to the brake pedal shaft arm Install the brake adjusting nut Adjust the rear brake page 3 13 Install the mufflers B R A E PEDAL SI ...

Page 226: ...ight shock absorber Remove the left shock absorber upper mount and remove the shock absorber from the upper mount stud bolt Raise the rear wheel and remove the left shock absorber lower mount and left shock absorber SI IOCK COMPRESSOR 07959 3290001 DISASSEMBLY Set the shock in the compressor as shorn and compress the spring 30 mm by turning the compres sor handle CAUTION shock spring and the clevi...

Page 227: ...ng the loci nut in the direction shown and removing the compressor LOCK NUT SPRING FREE LENGTH Measure the rear shock absorber spring free length SERVICE LIMIT 234 6 mm 9 2 in ASSEMBLY Place the spring adjuster the spring lower seat spring upper seat and stopper rubber on the damper Date of Issue December 1982 C 3 HONDA MOTOR CO LTD ...

Page 228: ... the lock nut is seated against the 1 I rod s bottom thread I CLEVIS PIN Align the spring with the upper joint while releasing the compressor INSTALLATION Install the left shock absorber onto the swingarm and tighten the lower mount bolt TORQUE 30 40 Mern 3 0 4 8kg m 22 29 e lb Install the left shock absorber onto the frame and tighten the upper mount TORQUE 30 40 M m 3 8 4 0 kg m 22 29 Fp lb Inst...

Page 229: ... Remove the left pivot bolt using the 20 mm Hex Head Wrench Remove the right pivot b o l t a n d remove the swing arm Remove the brake torque link from the swing arm Date of Issue December l982 O HONDA MOTOR CO LTD REAR WHEELISUSPENSIONIBRAKE W SWING ARM PIVOT LOCK NUT WRENCH 07908 ME90000 PIVOT CAP LOCK NUT HEX HEAD WRENCH n7s17 7lnr lon OR EQUIVALENT RIGI IT PIVOT BOLT EQUIVALENT COMMERCIALLY AV...

Page 230: ...a 29 mm 8 D washer or equivalent and attachment onto the shaft Install the slide hammer and handle and remove the race Repeat for the other side Install new grease retainer plates and drive new bearingouter races into the swing arm pivot DUST SEAL PIVOT BEARING INNER RACE REMOVER WEIGHT BEAW1NG REMOVER 07936 3710200 or 07936 41 50000 4 07741 001 0201 Not available rn U S A or 07936 371 0500 DRIVER...

Page 231: ...em 1 5 2 5 kg m 11 18 ft lb Pack all bearingcavities with grease Apply grease to the pivot bolt tips and dust seal lips HEX HEAD WRENCH 14 mm OR RIGHT PIVOT BOLT EQUIVALENT Install the swing arm and pivot bolts Tighten the right pivot bolt E the specified torque TORQUE 90 120 Wrn 9 6 1 2 0 kg m 65 87 lir lb Dare of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 232: ...eft pivot bolt to the specified torque SWING ARM l_OCK NUT WRENCH 07908 ME90000 lighten the lock nut while holding the left bolt TOROUE WRENCH SCALE READING 93 115 Nmm 9 3 1 1 5 kg m 64 85 ft lb ACTUAL TORQUE APPLIED 100 130 1V m 10 0 13 0kgm 72 94 Install the final gear case page 1 33 Install the rear wheel page 14 7 install the shock absorbers page 14 14 pivot ft lbI HEX I 4EAD WRENCH 10 mm OR E...

Page 233: ...MEMO Date of Issue December 1982 O HOIVDA MOTOR Co LTD ...

Page 234: ...HYDRAULIC BRAKE 25 30 N m 3 0 4 5 kg m 22 33 ft lb 14 1 8 ft lb Bate of Issue December 1982 O WONDA MOTOR CO LTD ...

Page 235: ... check brake operation before riding the motorcycle SPECIFICAlloNS Unit mm in p STANDARD p SERVICE LIMIT Front disc thickness 4 9 5 1 0 19 0 20 p p p p 4 0 0 16 Front disc runout i 0 3 0 012 Front master cylinder I D p p p Front master piston 8 D p p p p Front caliper piston O D Front caliper cylinder I D 32 030 32 080 l 2630 1 2630 32 09 1 263 TORQUE VALUES Brake hose bolt Front brake caliper bra...

Page 236: ...ged hydraulic system Pads glazed or worn excessively Brakes Drag e Hydraulic system sticking sr Sticking piston s Incorrect rear brake pedal adjustment Brakes Grab or Pull to One Side Pads contaminated i s c or wheel misaligned Brake ChaRer or Squeal a Pads contaminated Excessive disc runout Caliper installed incorrectly Disc or wheel misaligned Date of Issue December 1382 O HONDA MOTOR CO LTD ...

Page 237: ...hen fluid stops flowing out of the bleed valve contaminate k stopping power Discard contaminated xlds and clmn a contantinate c dise svith a high quality brake greasing agent 20mm 314 in SPAGER BRAKE FLUID FILLING NOTE p Do not mix different types of not compatible Close the bleed valve fili the reservoir and install the diaphragm To prevent piston overtravel and blake fluid see page keep a 20 mm ...

Page 238: ...ake Bleeder No 6860 or equivalent to the bleed valve Pump the brake bleeder and loosen the bleed valve Add fluid when the fluid level in the master cylinder reservoir is low Repeatthe above procedures until air bubbles do not appear in the plastic hose NOTE If air is entering the bleeder from around the bleed valve threads Seal threads with teflon tape If a brake bleeder is not available perform t...

Page 239: ...gf quality brake cle easiug agent BRAKE PAD DISC PAD REPLACEMENT NOTE Always replace the brake pads in pairs to assure even disc pressure Remove the caliper bolt Pivot the caliper up out of the way and remove the caliper from the bracket CALIPER BOLT PAD PIN RETAINER PAD PINS Remove the pad pin retainer and pull the pad pins out of the caliper Remove the brake ads Dare of Issue December 1982 O I I...

Page 240: ... the new pads in the caliper install the pad pins one pad pin first then install the other pin by pushingthe pads against the caliper to depress the pad spring RETAINER Place the pad pin retainer over the pad pins Push the retainer down to secure the pins Install the pad pin retainer bolt Date of Issue December 1982 6 3HONDA RiiQ T0R CO LTD ...

Page 241: ...SILICONE GREASE OR BRAKE FLUID PIVOT I4OLE Apply silicone grease or brake fluid to the caliper pivot bolt and insert the pivot bolt into the pivot bolt hole PIVOT BOLT Pivot the caliper down so the brake disc is posi tioned between the pads making sure not to damage the pads Install the caliper bolt and tighten it TORQUE 20 251V m 2 Q 2 5 kg m 14 18 Is ib CAblPER BOLT Dare of Issue December 1982 O...

Page 242: ...Drain brake fluid from the hydraulic system Disconnect the brake light switch wires Remove the brake lever and rear view mirror from the master cylinder Disconnectthe brake hose Avoid spilling brake fluid on painted surfaces Place a rag over the fuel tank whenever the brake svstem is serviced When removing the oil hose bit cover the end of the hose to prevent contamination Secure the hose to preve...

Page 243: ...e the primary cup and spring Remove the brake light switch from the master cylinder body if necessary Clean the inside of the master cylinder and reservoir with brake fluid INSPECTIBN Measure the master cylinder I D SERVICE LIMIT 14 065 mm 0 553in Check the master cylinder for scores scratches or nicks Dare of Issue December 1982 O HONDA MOTOR CO LTD SECONDARY m CUP A CUP ...

Page 244: ...do nor allow the lips to turn inside out Be certain the circlip is seated firmly in the groove p BRAKE FLUID g c 4 FRONT BRAKE n SWITCFI Install the piston clip and boot PUNCH MARK Race the master cylinder on the handlebar and install the holder with the two mounting bolts Align the end of the holder with the punch mark on the handlebar Tighten the top bolt first Install the oil hose with the bolt...

Page 245: ... pads and pad spring caliper pivot collar and boots pistons from the caliper PAD SPRING If necessary apply compressed air to the caliper fluid inlet to get the piston out Place a shop rag under the caliper to cushion the piston when it is expelled Use the air in short spurts I Do not bring the nozzle too close to the inlet I Examine the pistons and cylinders for scoring scratches or other damage a...

Page 246: ...faces wherz renzovingthe senls PISTON INSPECTION Check the pistons for scoring scratches or other faults Measure the piston diameter with a micro meter SERVlCE LIMIT 31 94 mm 1 258 in CYLINDER INSPECTION Check the caliper cylinder bore for scoring scratches or other faults Measure the caliper cylinder bore SERVICE LIMIT 32 09 mm 4 263in1 Date of Issue December 1981 O HONDA MOTOR CO LTD ...

Page 247: ...es proper1 y lnstall the pad spring and pads lnstall the caliper pivot bolt if it was removed TORQUE 25 36 IV wt 2 5 3 0kg m 48 22h lb PAD S P I N C 01 16 SEALS PISTONS PIVOT BOOT PAD SPRING INSTAl_LATION Install the pivot boot and pad spring as shown Apply silicone grease or brake fluid to the caliper pivot bolt lnstali the caliper assembly over the brake disc so that the disc is positioned ktwee...

Page 248: ...Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 249: ...7 P ITEM STANDARD SERVICE LIMIT I Final gear oil 1 160 180 cc 5 4 6 1 02s p Recommended oil Hypoid gear oil API GL 5 Above 5 1 4 l F SAE 90 Below 5 41 FSAE 80 Gear backlash 1 0 08 0 1 8 mm 0 003 0 007 in 0 30 mm 0 012 in 1 Gear assembly preload p p L 0 2 0 4 N m 2 4 kg cm 1 2 2 4 in lb 1 1 TORQUE VALUES Pinion bearing retainer Pinion nut Gear case cover bolt 10 mm 8 mm Final gear case attaching nu...

Page 250: ... ME80000 07939 ME80000 07931 4630300 or 07947 371 0101 and 07746 00 10200 07746 0030100 07746 0030200 f or Driver 07945 3710200 TROUBLESHOOTING Excessive Noise Worn or scored ring gear shaft and driven flange Scored driven flange and wheel hub Worn or scored drive pinion and splines ab Worn pinion and ring gears Excessive backlash between pinion and ring gear Oil level too low Oil Leak Clogged bre...

Page 251: ...se and secure the case in a vise with soft jaws or shop rags by clamping the axle Place the shock mount between the jaws for stability Separate the drive shaft from the gear case by gently revolving the shaft in a circular motion while tugging slightly DISASSEMBLY Remove the spring oil seal and stop ring from the drive shaft FINAL GEAR CASE ATTACHING NUTS DRIVE SHAFT L OIL SEAL NOTE Replace the oi...

Page 252: ...stall a new stop ring Install the spring UNIVERSAL JOINT REMOVAb lNSTAhLATION Remove the swing arm page 14 15 l STOP RING DRIVE SHAFT OIL SEAL S T O RING Remove the universal joint from the final shaft UNIVERSAL JOINT Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 253: ...move the distance collar Remove the dust guard plate bolts and the 6 guard plate by turning it clockwise DUST GUARD PLATE Remove the eight case cover bolts and cover If the ring gear stays in the cover do the following Place the cover in a press with the ring gear down Make sure the cover is secrely supported Press the ring gear out of the cover with driver 07749 0010000 and attachment 32 X 35 mm ...

Page 254: ...NT 32 X 35 mm 09746 0010100 PI LOT 30 mm 07746 0040700 RING GEAR BEARING REMOVAL COMMERCIALLY Remove the ring gear bearing and gear adjusting spacer BEARING PU LbER ATTACHMENT RING GEAR BEARING 07947 6340201 Olb SEAL CASE COVER OIL SEAL REPLACEMENT Remove the oil seal from the case cover and press in a new oil seal Date of Issue December 1982 O HONDA MOTOR Co LTD ...

Page 255: ...nt holder onto the pinion joint and remove the pinion shafi nut Remove the col and pinion joint B 0LT LOCK TAB Remove the retainer lock tab RETAINER WRENCH 07910 ME80000 Remove wrench the pinion retainer with the pinion retainer Bare of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 256: ...tool Remove the pinion adjustment spacer COMMERCIALLY AVAILABLE BEARING PULLER PINION BEARING OIL SEAL DRIVER 07749 001 0000 PINION RETAINER 011 SEAL REPLACEMENT Remove the O ring and oil seal from retainer Coat a new O ring with oil and install retainer Drive a new oil seal into the retainer To install a new oil seal use driver 07945 3330300 the pinion it onto the attachment Date of Issue Decembe...

Page 257: ...TION Always wear gloves when handling the gear case after it has been heated NOTE Use bearinsremover 35 mm 07936 3710400 to remove the ring gear case hearing OIL SEAL DRIVER 07749 001 0000 Remove Drive a tools the ring gear shaft oil seal new oil seal into the case using the special DRIVER 07945 3330300 07749 001 0000 Drive new pinion and ring gear bearings case into the ATTACHMEN 32 x 35 m m ATTA...

Page 258: ...ACER PINION GEAR ASSEMBLY Install the original pinion gear spacer When the gear set pinion baring andlor gear case has been replaced use a 2 0 mm thick spacer DRIVER DRIVER 07746 00301 00 OR 07945 371 0200 Press the bearingonto the pinion gear shaft wi h the special tools shown ATTACHMENT 25 mm I D 07746 0030200 Date of Issue December 1982 O WONDA MOT8W CO LTD ...

Page 259: ...e TORQUE 100 320 M m 1 0 12 0 kg m 72 87 fi lb PINION RE TAINER WRENCH 09910 ME80000 RING GEAR BEARING RING GEAR SPACER RING GEAR ASSEMBLY Install the original spacer onto the ring gear NOTE If the gear set pinion bearing ring gear bearing andlor gear case is replaced install a 2 0 mm thick spacer p u Place the ring gear bearing over the ring gear shaft Place a new ring gear bearing on the ring ge...

Page 260: ...60 mm 0 012 0 024 in and the GEAR CASE COVER STOP PIN Remove the ring gear IF the clearance exceeds the service limit heat the gear case cover to approxi mately BO C 176 and remove the stop pin by tappingthe cover Always wear gZove 1vIzen haizrlli zgthe gear case cover after it has been heated i Install a stop pin shim to obtain the correct clearance SHIM THICKNESS A 0 70 mm 0 004 in B B 1Smm 0 00...

Page 261: ... pattern check Place the wave washer and ring gear into the gear case Apply gear oil to the lip of the oil seal on the gear case cover and install the gear case cover 10 mm BOLTS 8 mm B 0LTS Tighten all the cover bolts in 2 3 steps until the cover evenly touches the gear case then tighten the 8 mm bolts to the specified torque in a crisscross pattern in two or more steps TORQUE 23 28R1 m 2 3 2 8 k...

Page 262: ...E If the patterns are not correct remove and replace the pinion spacer Replace the pinion spacer with a thicker one if the contacts are too high toward the face TOO HIGH DRIVE SIDE COAST SIDE Replace the pinion spacer with a thinner one if the contacts are too low to the flank side The patterns will shift about 1 5 2 0 mm 0 06 0 08 in when the thickness of the spacer is changed by 0 10 mm 0 004 in...

Page 263: ...Compare the difference of the three measurements DIFFERENCE OF MEASUREMENT SERVICE Llk lll 0 10 mm 0 004 in If the difference in measurements exceeds the limit it indicates that the bearingis not installed squarely Inspect the bearings and reinstall if necessary If backlash is too small replace the ring gear spacer with a thinner one Backlash is changed by about 0 06 0 07 mm 0 002 0 003 in when th...

Page 264: ... and install the pinion joint Install the pinion joint holder tool and tighten the pinion nut TORQUE 68 120N m 26 8 12 0 kg m 92 89 fi lb Remove the pinion joint holder tool LOCK TABS PINION JOINT HOLDER Make sure that the gear assembly rotates smoothly without binding by turning the pinion joint GEAR ASSEMBLY PRELQAD 0 2 0 4 Fd m 2 4 kg cm 1 2 2 4 in lb Date of Issue December f 982 O HONDA MOTOR ...

Page 265: ...ing on the drive shaft lightly CP Be careful not to damage the drive shaft oil seal Lubricate the splines of the drive shaft with multipurpose NLGI No 2 MoS2 additive Grease Insert the drive shaft assembly into the swing arm and align its splines with the universal joint Attach the gear case onto the swing arm loosely NOTE ITo ease axle installation do not tighten the gear case nuts until after th...

Page 266: ...ch bolt TORQUE 20 38 N m 2 0 3 0 kg m 14 22 ft lbf Install the left shock absorber page 14 14 FINAL G EAR CASE ATTACHING NUTS Make sure that the case drain bolt is tightened Remove the oil filler cap and pour the specified amount of recommendedoil up to the filler neck RECOMMENDED OIL HYPOID GEAR 011 Over sac SAE 90 Below O C SAE 80 OIL CAPACITY 160 180 cc 5 4 6 1 O Z FILLER DRAIN BOLT WEAR CAP AX...

Page 267: ...Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 268: ...BATTERY CHARG W SYSTEM BATTERY CHARGING DIAGRAM 6 I ALTERNATOR Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 269: ... _ _ _ l C I Charging rate 1 4 amperes maximum p p p P p Aiternator M gh beam 18 amperes minimum 5 000 rpm 14 volts l Voltage regulator Transistorized non adjustable ___ p p _ _ 1 L No Power Key Turnd On Dead battery bow fluid level Low specific gravity Charging system failure e Disconnectedbattery cable Main fuse burned out Faulty ignition switch Low Power Key Turn On Weak battery Low fluid level...

Page 270: ...y charged 1 Below 1 260 1 Undercharged NOTE e The battery must be recharged if the specific gravity is below 1 230 e The specific gravity varies with the tem perature a s shown in the table e Replace the battery if sulfation is evident Lor if the space below the cell plates is filled with sediment p Irolyte corrtains sulfirric acid A void contact with skin eyes or clothing ntidote d luslr with wat...

Page 271: ...rgingif the eleclrolyte lem peraare exceeds 45 G 113 Quick charging shozdd only be done in an emergency slowcharging is preferred J After installing the battery coat the terminals with clean grease before reconnecting the battery cables Route the breather tube as shown on the battery caution label CHARGING SYSTEM CHARGING OUTPUT TEST Warm up the engine before taking readings Disconnect the main fu...

Page 272: ...ty to ground See Stator Removal Page 8 5 VOLTAGE REGULATOR RECTIFIER TEST Check the resistances between the leads with an ohmmeter NOTE The test results shown are for a positive ground ohmmeter and the opposite results will be obtained when a negative ground ohmmeter is used NORMAL DIRECTION CQNTINUITY REDIWHIPE REDIWUITE YELLOW REVERSE DIRECTION NO CONTINUITY probe probe GREEN YELLOW I GREEN I Da...

Page 273: ...ANCE TEST Pest with a voltmeter Connect a voltmeter across the battery Check regulator performance with the engine running The regulator must divert current to ground when battery voltage reaches 14 0 15 0V BLACK Dare of Issue December 1982 C 3 I4BNDA MOTOR CO LTD ...

Page 274: ...BGNIT16N SYSTEM PULSE GENERATOR IGNITION SYSTEM DIAGRAM IGNITION CO1L ENGINE IGNITION Dale of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 275: ...m 0 018 0 026 in TOO1s Special Timing inspection plug Common Circuit tester Engine Cranks But Will Not Start Engine stop switch OFF D No spark at plugs e Faulty spark unit b Faulty pulse generator No Spark at Plug rr Engine stop switch OFF e Poorly connected broken or shorted wires Between ignition switch and engine stop switch Between spark unit and engine stop switch Between spark unit and ignit...

Page 276: ... blacklwhite coupler terminal and the high tension terminal NOTE e Use a Kowa Tester Tti 5H or Sanwa Tester 07308 0020000 l e Use new test batteries for this test 1 Connect the negative probe of the tester to the coupler terminal and positive probe to the high tension terminal and measure the resistance RESISTANCE SAIVWA TESTER 200 350 k 2 KOWA TESTER 50 200 k 2 Change the tester polarities and me...

Page 277: ...proximately 3 mA Needle should swing Change the tester polarities Replace the ignition coil if there is continuity REMOVAL Disconnect the ignition switch couplers Remove the coil by removing the attaching bolts INSPECIIBN Remove the swing arm Page 14 15 air cleaner case Page 4 18 and rear inner fender Remove the pulse generator cover IGNITION SYSTEM t IGNITION COIL BO LTS PULSE GENERATOR COVER Dat...

Page 278: ...e with white tube and blue leads Left cylinder COIL RESISTANCE 530i 50 ohms 20 6 SPARK UNIT INSfaECS lBN Disconnect the pulse generator coupler Attach the negative lead to any convenient ground Turn the ignition switch on terminal R of the spark unit 6 pole coupler Attach the negative lead t o any convenient ground Turn the ignition switch on Ground each corresponding terminal L blue wire terminal...

Page 279: ...order of SPARH ADVANCER Remove the pulse generator Page 8 3 Check the mechanical advancer cam for sticking Lubricate the sliding surfaces and check the spring for loss of tension and advancer pin for excessive wear NUTS SPARK UNITS SPARK ADVANCER p advancer when assembling p PULSE GENERATOR Install the spark advancer Install the pulse generator and adjust the ignition timing Page 83 12 Date of Iss...

Page 280: ...g hole cap and install the timing inspection plug 07999 41 50000 Connect a timing light to the right cylinder Connect a tachometer Start the engine and check the ignition timing At 1 100 F l00 rpm The index mark should be aligned with the FI mark At 1 500F 100 rpm Timing advance should start At 3 500 F 150 rpm Timing advance should stop The index mark should be between the full advance marks Check...

Page 281: ...HONDA CX65OC MEMO Date of Issue December 1982 O IiONDA MOTOR CO LTD ...

Page 282: ...STARTER SYSTEM STAI FU RTER MOTOR c RED STARTER COIL i FIELD MAGNET Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 283: ...e Faulty ignition switch Faulty starter switch e Faulty neutral switch a Faulty starter relay switch Loose or diconnected wire or cable er Clutch switch diode open a Faulty clutch switch Starter Motor Turns Engine Slowly cs Low battery B Excessiev resistance in circuit s Binding in starter motor Starter Metor Turns But Engine Does Not Turn Faulty starter clutch o Faulty starter motor gears m Fault...

Page 284: ...ect the brushes and measure the brush length Measure brush spring tension with a spring scale SERVICE LIMITS Brush length 5 5 mm 0 22 in Brush spring censican 480 g I4 l l 0 2 BRUSH SPRINGS COMMUTATOR GOMMUNTATOR INSPECTION Remove the starter motor case NOTE Record the location and number of thrust washers Inspect the commutator bars for discoloration Bars discolored in pairs indicate grounded arm...

Page 285: ...EEN CABLE TERMINAL AND MOTOR CASE NORMAL FIELD GO1L INSPECTION Check for continuity from the cable terminal to the motor case and from the cable terminal to the brush wire Replace the starter motor if the field coil does not have continuity or if it is shorted to the motor case CONTINUITY BETWEEN CABLE TERMINAL AND BRUSH WIRE INSULATED NORMAL NOTCH PIN CASE ASSEMBLY I NSTALLATION Assemble the star...

Page 286: ...order of removal REAR BRACKET STARTER RELAY SWITCH INSPECTION Depress the starter switch button with the ignition ON The coil is normal if the starter relay switch clicks STARTER RELAY SWITCH Connect an ohmmeter to the starter relay switch terminals Connect a 12 V battery to the switch cable terminals The switch is normal if there is con tinuity ...

Page 287: ...ve the fuel tank Remove the clutch switch diode harness CLUTCH SWITCI I DIODE from the wire NORMAL DIRECTION CONTINUITY REVERSE DIRECTION NO CONTINUITY INSPECTION Check for continuity with an ohmmeter Date of Issue December 1982 O HBNDA MOTOR CO LTD ...

Page 288: ...Date of Issue December 1982 O HONBA MOTOR CO LTD ...

Page 289: ...hout this section and on the wiring diagram Bu Blue G Green LG bight Green R Red B1 Black Gr Grey 0 Orange W White Br Brown LB Light Blue P Pink Y Yellow To isolate an electrical failure check the continuity of the electrical path through the part A continuity check can usually be made without removing the part from the motorcycle Simply disconnect the wires and connect a continuity tester or volt...

Page 290: ...w the switch in the crankcase and leave two threads from the bottom Then tighten it to the OIL P R E S S U ESWITCI I specified toraue Do not over tiahten it prevent damage to the engine cover CON 30 F 0 3 REAR BRAKE LIGHT SWITCH 4 psi d BRAKE LIGIJiT SWITCH Check the rear brake light switch for continuity with the rear brake applied FRONT BRAKE LIGHT SWITCH Check the front brake light switch for c...

Page 291: ...of the clutch lever safety switch with the clutch released and applied Replace if necessary HANDLEBAR SWITCHES GROUND NEUTRAL SWITCH WIRE CLUTCH SWITCH CLUTCH APPLIED CONTINUITY HEADLIGHT CLUTCH RELEASED NB CONTINUITY HI L0 S b J l 1 T C I I The handlebar cluster switches lights turn signals horn etc must be replaceda s assemblies Remove the headlight Continuity tests for the components of the han...

Page 292: ...F Br W to LBIW and 8 W RIGHT GPto LB WrIW to O W HORN BUTTON LG to WIG with button depressed Mo continuity with button relaesed Color code Tlrrrr Signal Switch Horn Button I Color codfl LG i WIG 1 ENGINE STOP SWITCH STARTER BUTTON B to R with button pushed in BIIR to BuIW with button out Starter Button Dare of Issue December 198 O HONDA MOTOR CO LTD ...

Page 293: ...WITCH POSITION Engine Stop Switch p RUN IGNITION SWITCH LOCK No continuity OFF No continuity ON R to B Br W to Br continuity PARK Br R continuity IGNITION SWITCH REMOVALIINSTALLAPION Remove the instruments page 13 5 and headlight bracket page 13 5 Remove the two ignition switch mounting bolts and ignition switch Install the ignition switch in the reverse order of removal Date of Issue December 198...

Page 294: ...positior it in the I ON and OFF positions niddle Push the lugs from the c base and remove the contact CONTACT BASE LUGS Assemble the ignition switch in the reverse order of disassembly Date of Issue December 1982 O HONBA MOTOR CO LTD ...

Page 295: ...otor should start running If it starts replace the fan thermostatic switch and retest If it does not start check for battery voltage from the black lead positive to the green lead negative of the fan motor coupler If there is no voltage check for a blown or faulty fuse loose terminals or connectors or an open circuit JUMPER WIRE TEMPERATURE GAUGE Remove the fuel tank page 4 1 5 Disconnect the wire...

Page 296: ...m in the bulb or wiring replace the brake and tail light sensor with a new one if the warning light does not go out after a few seconds check the brakeftail light bulb filament and replace if necessary If the brakeltail light bulb is OK check the wiring for an open or short circuit If there is no problem in the wiring replace the brake and tail light sensor with a new one BRAKE AND TAIL LIGHT WARN...

Page 297: ...dicator panel attaching screw and raise the indicator panel Replace the bulb After installing a new bulb check for continuity If the bulb does not light inspect the wiring for an open or short circuit or for loose connections Dare of Issue December 1982 O HONDA MOTOR CO LTD SCREWS INDICATOR PANEL SCREW ...

Page 298: ...a new bulb check for continuity If the bulb does not ligh inspect the wiring for an open or short circuit or check for loose con nections TURN SIGNAL BULB Remove the turn signal lens to remove the bulb CAUTION M overtighten the lens mounting screws to prevent cracking the lens 1 Date of Issue December 1982 O HONDA MOTOR CO LTD ...

Page 299: ...NSE PLATE Remove the two tail light mounting nuts and tail light TAIL LIGHT TAIL LIGHT LENS Remove the two tail light lens attaching cap nuts and replace the bulb Date of Issue December 1982 O HONBA MOTOR CO LTD ...

Page 300: ... MEMO Dare of Issue December 1982 O HOIIDA MOTOR CO LTD ...

Page 301: ...ShliCii DIVUER SnliCli HOW S l l i C i l TURN SIWAL S mTCH 81 h A C Br MOW9 Y YELLOW 0 ORANCE R RLUE ih LIGHT BLUE G GREEN ir LlWli GREEti R RED P PINK W MITE Cr GnW Date of issue December 1982 G3 HBNDA MOTOR CO LTD ...

Page 302: ...fuel valve diaphragm 6 Clogged fuel valve vacuum and air vent tube Faulty spark plugs Fouled spark plugs Faulty spark unit Broken or shorted high tension wires Broken or shorted ignition coil Faulty ignition switch Faulty pulse generator Low battery charge LOW COMPRESSION 1 lrnproper valve clearance 2 Valve stuck open 3 Worn cylinder and piston rings 4 Damaged cylinder head gasket 5 Seized valve 6...

Page 303: ...1 Faulty spark unit 2 Faulty pulse generator CORRECT 3 Faulty ignition advancer I 6 Check valve clearance INCORRECT b 1 Improper valve adjustment 2 Worn valve seat CORRECT 4 7 Test cylinder compression TOO LOW bp l Valve stuck open 2 Worn or damaged cylinder NORMAL and piston rings 3 Leaking head gasket 4 Improper valve timing 8 Check carburetor for clogging CLOGGED B 1 Carburetor not serviced NOT...

Page 304: ... CAUSES 1 Check ignition timing and valve INCORRECT P 1 lmproper valve clearance clearance 2 Improper ignition timing Faulty spark unit or L CORYECT spark advancer 2 Check carburetor pilot screw INCORRECT See Fuel System Section adjustment t 3 Check for leaking intake pipt LEAKING 1 Deteriorated insulator 0 ring 2 Loose carburetor NO LEAK 3 Damaged fuel valve vacuum l tube t 4 Perform spark test G...

Page 305: ...e carburetor and check CLOGGED a l Clean the jet for a clogged jet NO CLOGS 4 4 Check valve timing IMGORRECT h 1 Cam sprocket not installed properly CORFECT ai 5 Check valve spring tensipn WEAK h l Faulty spring NOT WEAKENED POOR HANDLING Check tire pressure 1 If steering is heavy 2 If either wheel is wobbing POSSIBLE CAUSES 1 Steering top thread nut too tight 2 Damaged steering head bearings h 1 ...