Honda NU50, Shop Manual

Page 1: ...rrf H O DA 7 SHOP MANUAL NU50 NU50M ...

Page 2: ...ons against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render il unsafe Please understand that these warnings cannot cover all conceivable ways in which service whether or not recommended by Honda might be done or of the possible hazardous consequences of eilch conceivable way nor could Honda investigate all such ways Anyone us...

Page 3: ...e TECHNICAL FEATURES in section 14 If you don t know the source of the trouble go to section 15 TROUBLESHOOTING ALL INFORMATION ILLUSTRATIONS DIRECTIONS ANO SPECIFICATIONS IN CLUOEO IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT IN FORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING HONDA MOTOR CO LTD RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITH OUT NOTICE ANO WITHOUT INCURRING AN...

Page 4: ...h call bt highly xplosil l Du I O smoke or of ow j1ames or xparks I ar the bauery especiaffy while chargillg il 1 Use genuine HONDA or HONDA recommended parts and lubricants or their equillalent Parts that do not meet HONDA s design speCIfications may damage Ihe motorcycle 2 Usc lht special tools designed for this product 3 Use only metric 100ls when serllicing this motorcycle Metric boilS nuls an...

Page 5: ...n the steering head left side The engirre serial number is stamped on the right side of the crank ase 1 2 4 The VIN vehicle identification numbed is on the Safety Cf rtification label on the steering head right side IDENTIFICATION NUMBER The carburetor identification number is on thl carburetor body Date of Issue Nov 1981 HONDA MOTOR CO LTO ...

Page 6: ...x 39 3 mm 1 57 x 1 55 inl 49 cmJ 2 99 eu In 7 3 90 Cl 3 0 U S oz 2 5 Imp ozl 1 0 lit 11 1 U S qt 0 9 Imp qr l Forced and wet sump Reed valve conlrollcd Reed valve controlled 67S ISSDC 67 5 ABDCI 47 S BBDCI 47 5 ABDCl 16 0 kg 35 3Ib 16 9kg 37 3Ibl 1 800 rpm 0 Close 0 Close Scavenge Open Clo e Engine dry weight Idle speed Ty F suspension travel R suspension lravel Vehicle capacity load F tire size p...

Page 7: ...larting motol and kick Sfarter A C Generator 12V 65Wf5 000 rpm NGK I NO STANDARD BPR 5H W16FPR For extended high BPR 6HS W20FPR speed operation For cold climate BPR4HS W14FPR L I below 5 C 41 F 0 6 0 7 mm 10 024 0 028 in 15 BTDC 12V 2 5AH 12V 4AH 7A LIGHTS Headlight Low High Tail Stoplight Speedometer light High btl lrn indicator Turn signal From Rear Turn signal indicator Oil indicator light l5 2...

Page 8: ... A TOOLS SPECIAL COMMON I I AlternillC l l F10 Tool No Tool No Remarks Ref Page Tool I 07401 0010000 46 Spanner A 07701 002000 Spoke nipple tightenir lg Lock nut wrCr lch 07716 0020400 Stem nut ti hWl1in 11 8 socket 30x 32 mm Commercially available EXteMion bar handle 07716 0020500 Stem nut tightening 11 8 Commercially available Universal holder 07725 0030000 Clutch Outer holding 8 17 8 23 Attachm...

Page 9: ...50 4 0 5 0 29 36 Real axle nut 1 14 80 100 8 0 10 0 58 721 Engme hanger bolt Upper 1 10 59 65 5 9 6 5 43 47 Lower 1 10 35 45 3 5 4 5 25 33 I R al shock absorber 2 10 30 40 13 0 4 0 22 29 Footpegs 4 8 20 30 2 0 3 0 14 221 1 _ KICkSlil m L_ _L L 8 _ 8 6 9 1 Torque specifications listed above arc for mporrant fasteners Others should be tightened to the HJndard IOHllll values l ll low STANDARD TO ROUE...

Page 10: ...NDA NUSO NUSOM CABLE WIRE HARNESS ROUTING GENERAL INFORMATION FRONT BRAKE CABLE MAIN WIRE ffi 4 H_ARNESS Date of Issue Nov 1981 HONDA MOTOR CO LTO REAR BRAKE CABLE 9 REAR BRAKE CABLE FRONT BRAKE CABLE 1 7 ...

Page 11: ...E CABLE THROTTLE CABLE J jt I t FUEL IINE OIL OIL OUTLET LINE INLET LINE BYSTARTER CHAMBER AIR CLEANER OIL OUTLET LINE FUEL LINE LlP trUMP CO ECABLE ALTERNATOR WIRES sAnER BREATHER TUBE AIR VENT TUBE CARBURETOR DRAIN TUBE 1 8 10 Date of Issue Nov 1981 HONDA MOTOR CO LTD ...

Page 12: ... HONDA NU50 o NU50M OIL PUMP CONTROL CABLE GENERAL INFORMATION THROTTLE CABLE Dale of Issue Nov 1981 HONDA MOTOR CO LTD 11 1 9 ...

Page 13: ...GENERAL INFORMATION NU50MI 2aONDA NU50 NU50M NU50 NU50M C O I UNIT NU50 BATTERY BATTERY FUSE BOX 1 10 12 Date of Issue Noy 1981 HONDA MOTOR CO LTD ...

Page 14: ...ION SYSTEM PISTONI f CRANKSH A F T FINAL GEAR SHAFT 2 0 Cj HONDA NUSO NUSOM OIL OUTLET LINE ii OIL INLET LINE CARBURETOR J Fuel 2 slloke Injector oil ill Mixed fuel and 011 Gealo l Date of Issue NOli 1981 HONDA MOTOR CO LTO ...

Page 15: ...mp Bleed air from the oil pump if here is air in the oil inlet line from lhe oil tank to the oil pump or il the oil line is discon nected Page 2 7 Bleed air from Inc oil outlet lir e from the oil pump to the carburetor if the line is disconnecTed Page 2 7l SPECIFICATIONS Engine Oil Oil recommendation Oil lank capacity Oil pump delivery Hondij 2 troke Injector Oil or its equivalent _ 1 0 liler 1 1 ...

Page 16: ... adjusted properly insufficient oiling 2 Low qUlllity oil Seized piston 1 No oil in lank or clogged oil line 2 Pump no properly adjusted insufficient oiling 3 Air in oil lines 4 Faulty oil pump 5 Clogged oil strainer Oil not flowing out of tank 1 Clogged oil tank cap breather hole 2 Clogged oil strainer 2 2 16 HONDA NU50 NU50M Date of Issue Nov_ 1981 HONDA MOTOR CO lTD ...

Page 17: ... drain plug and drilin thc oil Make SUfe Ihal the realing washer on the drain plug is in good condition ilnd reinstall the drain plug TORQUE 10 14 N m 11 0 1 4 kg m 7 10 ft lb Refill the case up to the proper level OIL CAPACITY 90 cc 3 0 US oz 2 5 Imp oz SPECIFIED Oil 90 gear oil l1einSlal1 the oil check bolt Start Ihe engine and check for leaks alter driving LUBRICATION OIL LEVEL CHECK HOLE DRAIN...

Page 18: ...d clean the interior of the oil tank thoroughly Check the oil indicator switch page 13 161 HONDA NU50 NU50M Oil INDICATOR SWITCH WIRE INSTALLATION Installation is the reverse of removal Refill the tank up to the upper level Check for leaks 2 4 OIL STRAINER OIL LINE 18 QlllNDICATOR SWITCH OILTAN Dale of Issue Nov 19B1 HONDA MOTOR CO lTD ...

Page 19: ...ne screen OIL STRAINER CLEANING Clean thc oil strainer screen with compressed air In51allation 01 the all strainer is the reverse order or removal Fill the oil lank with thl recommended oil up to the proper level and bleed air from the oil pump and oil lUbe Page 2 7 NOTE I nnect the oil tube securely 1 I Ck for leaks _ 1 OIL PUMP Removal Remove the engine Page 5 21 NOTE Before removing Ihe oil pum...

Page 20: ...p gear CAUTION om o not disassemble the IIP _ _ __ __ _ Installation Install the oil pump onto the crankcase CAUTION I ubrical rhe pump l UIIJ O I I l tJl clean reosc before installatioll Make Sllre Ihar Ilw oil pump is inscrled the crankcase propcr _ _ ___ TIghten Ihc oil pump attaching bolt securely Reconnect the oil outlet line as shown o HONDA NU50 NU50M OIL OUTLET LINE OIL PUMP SPIGOT FIT OlL...

Page 21: ...ommended oiL Place a shop towel around the oil pump and discon nect the all inlet line from the oil pump Fill the oil pump with oil by squirtin clean oil through the port about 3 eel Fill the oil line with oil and connBct it to the oil pump POrt Aher In l flation make sure there is no air in the oil mlet lint RECOMMENDED OIL INLET PORT OIL PUMP 01 L OUTLET LINE 1 Disconnect the oil oUllet Ime al t...

Page 22: ...N SEKIYU L1PANQX DELUX 3 0 159 lDEMIT U CORONEX 3 or equiv llenl 0 35 0 53 oz l Starter idle gear General purpose grease FRAME NOTE u _ WHEEL BEARING DUST SEAL BRAKE CAMSHAFT Use general purpose JfcaSlJ for parts not listed Apply clean engine oil or grease to cables not specified OILFELT SPEEDOMETER GEARIDUST SEAl WHEEL BEARINGIDI TANCE COLLAR MAIN STA 0 PIVOT FINAL REDUCTION 90 GEAR 01 L 90 ce 3 ...

Page 23: ... 2 5 See page 6 2 See page 6 5 SPECIFICATIONS ENGINE SPARK PLUG r NGK ND STANDARD BPR 5H W16FPR For extended high BPR 6HS W20FPR speed operatio I For col clima c BPR 4H W14FPR L below 5 C 41 F SPARK PLUG GAP COMPRESSION IGNITION TIMING THROTTLE FREE PLAY lDLE SPEED AlA SCREW OPENING 0 6 0 7 mrn 0 024 0 028 m 130 kPa 13 0 kg em 185 psi 15 i 3 0 2 000 rpm BTDC CONSTANT 2 G mrn 118 1 4 in 1 800 rpm 2...

Page 24: ...ally dusty iIrlHIS require more frequent ervicing I INSPECT AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST L LUBRICATE HONDA NU50 NU50M These iterns an simple 10 perform and may be serviced by the owner other maintenance items should b serviced by all autho iled Honda dealer 3 2 24 Date of Issue Nov 1981 HONDA MOTOR CO LTD ...

Page 25: ...rkJi T m Iltt eqllipml lIf wllile draining fud Remove Ih fuel strillner bolt and pull oUt lha fuel sualner and O rlng Wa h the fuel straIner in clean non flammable or high flash pomt solvent Reinstall the fuel str iner and new a ring InIO the luel valve Hand tighuafl the luel stramer bolt mak1ll9 sure the new 0 flng is in pla Then torque to specifica l Ifl TORQUE 0 3 0 5 kg m 2 4 h lb FUEL STRAINE...

Page 26: ...l lhl element and retainer Il1stall the iii r cleaner cover WASH IN SOLVENT SQUEEZE OUT SOLVENT THOROUGHLY GEAR OIL SQUEEZE OUT EXCESS OIL BYSTARTER ElEMEN Remolll the bystarler chamber from the holder Remove the chamber cap from the chamber body and remove the element and plate Wa h the element In non flammable or high flash point olvel1t q leeze out and allow to dry Soak the Iemenl in clean moto...

Page 27: ... 4H5 W14FPR L 2 mm SPA DIsconnect the Spii k plug C plug Visually Irupec the spark p The center electrode shoul tnl side eleclfode should h Discard the spark plug if Ihe the insulator cracked or c deposns can be removed b plug can lie reused Inspec gau JC and adjust by bending For cold hma e Ibelow S C 4 F SPECIFIED SPARK PLUGS IST NOAAO C For CloClendcd hlSh BP speed operation Check the washer to...

Page 28: ...fJr Clell lubricaTioll Troubleshooting Excessive white smoke or hard statting Pump control lever excessively open Siezed piston Pump control I ver nOI properly adjusted HOND A NU50 NU50M IDLE SPEED ADJUSTMENT Attach an engine tachometer Turn the lhrottle stop screw to obtain the specified idle speed of 1 800 rpm When the engine misses or runs erratic proceed as follows 1 Screw in the air screw unt...

Page 29: ...ing with a timing ligtll Tlmmg is correct if Ihe index mark aligns with the F mark Within 3 at 2 000 rpm IGNITION TIMING 15 3 BTDC 2 000 Ipm INDEX MARK MAINTENANCE COMPRESSION TEST Warm up the engine SlOP the IIng ne and remove the spark plug Insen a compression gauge Open the thronle grip fully and operate the kick starter several limeS COMPRESSION 11 0 15 0 kg cm 2 156 213 psiI Low compressiol c...

Page 30: ...ll forms Of sediments accumulate on the bonom BRAKES BRAKE ADJUSTMENT Measure the fronl and rear brake lever free plays at the end of the levers FREE PLAY FRONT and REAR 10 15 mm 3 8 5 8 in If adjustment is necessary turn the urake adjustm9 nut RELOCATION OF FRONT BRAKE ARM ON BRAKE CAMSHAFT U the front b ake lever ree play is eXCp Slve so that the above procedure IS no longer effective relocate t...

Page 31: ...sembly for sig05 of damagiL Replace any components which CilnnOl be repaired Tighten all nuls ilnd bolts 10 the specified torque values Page 1 41 REAR Place the motorcycle on the center stand Hold the leaf carrier by one hand and move the hd crankcase sideways with force to see if the 5wingarm bushings ilfe worn Replace If excessively worn Check the entire suspension aSlOcmbly Be sure it is secure...

Page 32: ...d horizontal beam with the adjusting screws NOTE Adjust the headHgl ll beam as specified bv local laws and regulations 111 impro JI rly adjll w t helltllight mllY hlind oll comillg dril trs Qr if mllY faif to lighr Ihe rood for II sofe distallct WHEELS TIRES Check Ihe lire pressures NOTE Tire pressure should be checked when the tires are COLD TIRE PRESSURES Front 125 kPa 11 25 kg cm1 18 psi Rear 1...

Page 33: ...USOM NUTS BOLTS FASTENERS Check th t all ch issis nuts ill d bolts 1ft tightened to correct torque alues Page 1 4 Check all coltl r pins and safety clips Date of Issue Nov 1981 HONDA MOTOR CO LTO 33 MAINTENANCE 3 11 ...

Page 34: ...FUEL SYSTEM Ciif HONDA NU50 NU50M U a i Q 4 0 34 Date of Issue Noy 1981 e HONDA MOTOR CO LTO ...

Page 35: ..._ r__ 2 m m I Identifrcation number r PA13E I Float lev 1 12 2 1 0 mm 0 48 0 04 in Ail screw opening 2 turns Qut lelle spl1ed 1 800 150 rpm I Throllie grip free play 2 6 mm 1118 1 4 in TOOL Floin level Gauge 0740 I OO 10000 TROUBLESHOOTING Engine cranks but won start 1 No fuel in lank 2 Clogged fu 1 lube 3 Clog Jcd fllcl stri rW 1 Too much fuel getting to cylinfJer 5 CI09 cd ail cleaner 6 F lulty ...

Page 36: ... Ihe throttle valve spring carbu to cap and thronle valve HONDA NUSO NUSOM CARBURETOR CAP THROTTLE VALVE SPRING THROTTLE CABLE THROTTl VALVE Pry off the needle teta er and remove the jet needle JET NEEOLE THROTILE VALVE INSPECTION Check the jel needle and throttle valve for wear or damage NEEDLERETAINER CLlP SECOND NOTCH I TOI JET NEEDLE ru On J 4 2 36 Date of Issue NOli 1981 HONDA MOTOR CO lTD ...

Page 37: ...TOR ATIACHING NUTS Remove the holts attaching Ihe rear fender Relnove the ail cleaner bracket atlaching boilS and the air cleaner with bracket Remove he carburelOr and disconnect Ihe dram tube rom 11 AIR CLEANER L 7 BOLTS MOUNTING BRACKET FLOAT FLOAT VALVE JETS OISASSEMBLY Place a drain pan under the carburelOr and loosen the carburetor dlain screw to allow tuel 10 drain in the drain pan Remove th...

Page 38: ... Check the valve seat for wear or damage Check Ihe float for deformation or fuel inside the float Remove the air screw record the number of rotations until it seats lighllv so it can be returned to the orlgimll position UTION J 1101 force the screw agaillst its seQr 10 p el 11 damage VALVE SEAT AlA 5 REW 4 4 38 Date of Issue NOli 1981 HONDA MOTOR CO LTD ...

Page 39: ...float and float pin Tighten the floal screw securely FLOAT LEVEL INSPECTION Measure the ftoat level at the main jet parallel with the float oin FLOAT lEVEL 12 2 t 1 0 mm O 48 t 0 04 inl Replace Ihe float II It IS Qut of the specified level lange Check the operation of the float and install the float chamber Dale of Issue Nov 1981 e HONDA MOTOR CO LTD FLOAT THROTTLE STOP SCREW 39 FLOAT SCREloV AIR ...

Page 40: ...ender to the air cleaner mounting bracker HONDA NUSO NUSOM FENDER ATTACHING BOLT BolIS MOUNTING BRACKET Connect the tubes and line to the carburetor BYSTAATER TUBE AI R VENT TUBE BYSTAfHER TUBE OIL OUTLET TUBE THROTTLE VALVE INSTALLAnON Install the jet needle on the throttle valve and secure with the needle clip NEEDLE CLIP RETAINER LEAN JET NEEDLE 1 1st TCH 1U STO 2nd NOTCH THROTTLE VALVE i RICH ...

Page 41: ...etor body NOTE Align the groove in the valve with the throule SlOp screw on the carburetor body Tighten the carburetor cap Perform the following adjustments and operation Throttle cable free play adjustment Page 3 51 Oil pump control cable adjustment lPage 3 61 011 pump and line bleeding Page 2 71 Idle soeed Jdiustment Page 3 61 Date of Issue No 1981 CD HONDA MOTOA CO lTD THROTTLE CABLE CARBUA TOR...

Page 42: ...for cracks damage or clearance between Ihe seal and reed Replace the valve if necessary CAUTION Do lOt disassemble or bend the reed stopper To do so can cause loss of power and t ngine damage If the sropper reed or valve sear i f faulty replace them as a unit REED VALVE INSTALLATION The installation sequence is essentially the reverse of removal Connect the bystarter lube to the intake pipe After ...

Page 43: ...l line Kci p 011 0 from flames Of sparks Wipe lip spilled gasoline at once Turn lhe fuel valve ON and drain the gasoline into a safe container labeled for g8soline Droi the gasoline illfO a safe cOfltaint f labeled for gowlint Remove the lock nut and remove the fuel valve Date oi Issue Nov 1981 HONDA MOTOR CO LTD 43 LOCK NUT FUEL SYSTEM MOUNTING NUT 131 4 9 ...

Page 44: ...VAL S 1 I l lIIIilfj ep gasoline away from flames or sparks llIipc Ufl spilled gasolint at O lce rf raill lhe gUSolilH nlO a mie coma lIef J befe l for Sliw inc Remove the fuel valve page d lOL Remove the fuel tank mounting nuts and plain washers Raise the seat seat bridge and shroud Remove the fuel lank FUEL TANK INSTALLATION The installation is the reverse of lemQlfa 4 10 BGCI 15 4 1 HONDA NU50 ...

Page 45: ...ENGINE REMOVAL INSTALLATION 5 0 46 HONDA NUSO NUSOM Date of Issue Nov 198 HONDA MOTOR CO lTD ...

Page 46: ...for servicing Crankshaft Oil pump SPECIFICATION Engine weight TORGUE VALUES Engme hanger boilS Upper lower At shock absorber Aear axle nut Date of Issue Nov 1981 0HQNDA MOTOR CO LTD NU50 15 9 kg 351bJ NU50M 16 8 kg 137lbJ 59 65 N m 15 9 6 5 kg m 43 47 ft lbl 35 45 N m 13 5 4 5 kg m 25 33 fHb 30 40 N m 3 0 4 0 kg m 22 29 fHbl BO l00 N m B 0 l0 0 kg m 58 72 ft lbl 47 II 5 1 ...

Page 47: ... Turn the fuel valve OFF and drain the fuel from the carburetor Disconnect th fuel liM H the carburewr fA dili ii i I Keep ga sofi e away from flames Of pa ks Wipe lip Jilled gasolille 1 ol ce DiSCOI IH Ct the oil inlet tube at the oil pump MOUNTING BOLT HONDA NU50 NU50M REAR BRAKE CAGLE SETTING PLATE REAR BRAKE CABLE ADJUSTER OIL PUMP CONTROL CABLE 1 J m 1 Disconnec t the starlet wir coupler and ...

Page 48: ... bolts to the specified torque values TORQUE VALUES Upper bolt 59 65 N m 5 9 6 5 kg m 43 47 ft lbJ lowu bolt 35 45 N m 3 5 4 5 kg m 25 33 ft lbl Shock absorber nut 30 40 N m 3 0 4 0 kg m 22 29 ft lbJ Perform the fullowing inspections and adjustments after inU3llation Wire iIlti cable routing Page 1 6 1 8 Carburetor adjuSiment Page 3 51 Rear brake adjustment Page 3 7 o I pump bleedmg pllming P lge ...

Page 49: ...CYLINDER HEAD CYLINDER PISTON 8 12 N m 0 8 1 2 kg m 6 9 h lb 6 0 50 HONDA NU50 NU50M Dale of Issue Nov 1981 to HONDA MOTOR CO LTO ...

Page 50: ...55241 40 000 40 015 39 950 39 960 0 040 0 055 10 002 1 O OOB 9 994 10 000 0 002 0 012 0 15 0 35 14 005 14 017 ITEM Cylinder head warpage Cylinder bore p 0 0 4 mm from bottom of IHon piston skirtl Cylinder Ie piston clearance Piston pin hole 1 0 Piston Dm 0 0 PistorHo p1ston pin cle lrancc Piston ring end gap tOP second Connecting rod small end 1 0 TORQUE Cylinder h ad bolt TROUBLESHOOTING CompreSS...

Page 51: ...ox HONDA NU50 NU50M CHOKE CONTROL BOX SPARK PLUG CAP CYLINDER HEAD Remove the four cvlinder head bolts and the cvlin del head CYLINDE R HEAD INSPECTION Check the cylinder head for warpage with a straight edge and II feeler gauge in the directions shown SERVICE LIMIT 0 10 mm 0 004 in BOLTS 6 2 52 Date of Issue Nov 1981 HONDA MOTOR CO l TO ...

Page 52: ...e combustion chambf T Oil alld guskn surfaces Remon corbo deposits from tile piSlOIi head CYLINDERj PISTON CYLINDER REMOVAL Remove the exhaust muffler by removing the attaching bolts and nuts Remove the cylinder CAUTION Do 1I0f pry bt II C 11 hI cylinder olld crallkcase or strike fhe illS CYLINDER HEAD CYLINDER PISTDN CYLINDER Date 01 Issue Nov 1981 V HONDA MOTOR CO l TO_ 53 6 3 ...

Page 53: ...fo th aallkCl1se HONDA NU50 NU50M PISTON PISTON PIN PISTON PIN CLIP PISTON RING EXPANDER REMOVAL Remove the piston rings NOTE Spread each piston ring and remove by lifting it up at a point just opposite the gap Remove the expander CYLINDER PISTON INSPECTION Check Ii ll cylinder and piston for wear or damage Clean carbon deposits from the exhaust port area 6 4 TOP RING SECOND RIN EXPANDER r J 11 JI...

Page 54: ...the cylin ell is O b r placeu Willi J IIt W olle use J I Cylifldt f IUlI iIlK the sallie lurk as the uld Ollt I Mi asure the piston 0 0 at a point 4 mm from the bottom of the skirt and 90 0 to the piston pin hole SERVICE LIMIT 39 900 mm 1 5709 in Calcul ltc the piston te cylinder clearance SERVICE LIMIT 0 100 mm 0 0039 in Measure Ihe piston pin hole I D SERVICE LIMIT 10 030 mm 0 3949 in Measure th...

Page 55: ...ng the piston and measure the end gap CONNECTING ROD INSPECTION Install the bearing and piston pin ir the connecting rod small end and check for excessive play Measure the connecting rod small end 1 0 SERVICE LIMIT 14 030 mm 0 5524 in i i I I PLAY HONDA NU50 NU50M PIN PISTON RING I I if 1 0 PISTON CYLINDER INSTALLATION Clean the gasket surfaces of the cylinder and crank case 6 6 56 Date of Issue N...

Page 56: ... OfJd rillg Check Ihe fit of each ring In liS groove by pre5 ing the ring inlO Ihe groove 10 make sure lhal iI is ffum lNlth Ihe p ston al several points Mound the ring A flOR that WIll not comp ess means that the rmg groove is dirty and it should be Cleaned Do I Ol replace m ril g irJlOlil rep acing lht mill Be sure the ring end gaps 3fC aligned with the piston ring pmS in the ring grooves CYLIND...

Page 57: ...nkcase Place the cylinder gasket all the nankcase Lubl ici11e the piston a j cylinder with 2 stroke oil and install the cylinder over the piston while com pressing the piston rings CYLINDER HEAD INSTALLATION Install the cylillder head on the cylinder using a new cylinder head gasket Install ilnd lighten the lour cylinder head bolts TORQUE 8 12 N m 0 8 1 2 kg rn 6 9 ft lb Install the spark plug and...

Page 58: ...der head Iutillg mrla C Ihorouithly CYLINDER HEAD CYLINDER PISTON CHOKE CONTROL BOX SPARK PLUG CAP Install the muffler Perform the following Inspections Compression test page 3 7 Check fOf abnormal engine noise Check for cylinder air leaks EXHAUST MUFFLER Dale of Issue Nov 1981 HONDA MOTOR CO LTD 59 6 9 ...

Page 59: ...ALTERNATOR 7 0 I 35 40 N m 3 5 4 0 kg 25 29 ft lb 60 HONDA NU50 NU50M Date of Issue NOli 1981 HONDA MOTOA CO LTD ...

Page 60: ...ulse generator from The tator base See Chapter 13 for alternator inspection Remove the NU50M Slilrler whenevl r the flvwheel is removed TORQUE 7 ALTERNATOR 7 1 7 2 7 4 HI Flywheel nUl TOOLS Special Flywheel Holder Flywheel Puller 35 40 N m 3 5 4 0 kg m 25 29 ft jb 07924 1870000 or Band Sirap wrench lcommercially available in U S A 07933 1550002 Dale of Issue Nov 1981 HONDA MOTOR CO LTD 61 7 1 ...

Page 61: ...50M starter motor NU50M STARTER COUPLER HONDA NU50 NU50M ALTERNATOR Remove the bolts attaching the generator cover and remove the cover Perform the following procedure lor the NU50M alternato removal after remoying the alternator cover 1 Remove the rear fender 2 Unc1amp the wire from the staner motor body 3 Remove lhe staner motor by pulling il up toward the lelt crankcase STARTER MOTOR 7 2 62 Dar...

Page 62: ...from being lost FLYWHEEL HOLDER 07924 1870000 OR BAND STRAP WRENCH COMMERCIALLY AVAILABLE IN U S A NUT WOODRUFF KEY Remove the gasket Remove the stator by removing the twO attaching bolts NOTE 00 not remove the pulse generator from the stator base Avoid damaging the stator coils Inspect the alternator Page 13 6 13 8 BO TS Date of Issue Nov 19B1 H0 I1A MOTOR CO LTD 63 7 3 ...

Page 63: ... crankshaft Install the flywheel holder TorQue the flywheel 10 mm flange nut TORQUE 36 40 N m 3 5 4 0 kg m 25 29 ft lbl FLYWH EL HOLDER 07924 1870000 OR BAND STRAP WRENCH CQMMEACIAllY AVAILABLE IN U S A CLAMP Perform the following procedure for the NU50M alternator installation 1 Inslall the starter motor 2 Clamp the alternator wire and starter motor wire on the starter motor body 3 Install the re...

Page 64: ... the wires on the intake pipe Connect the alternator connectors and the NU50M starter motor coupler Clamp the wires on the inside of the frame AL TERNATOR COVER STARTER MOTOR COUPLER ALTERNATOR CLAMPS ALTERNATOR COUPLER Check the ignition timing page 3 7 INDEX MARK Date of Issue Nov 1981 HONDA MOTOR CO LTD 65 7 5 ...

Page 65: ...DRIVE AND DRIVEN PULLEY KICK STARTER CLUTCH HONDA NUSO NUSOM 35 45 N m 13 5 4 5 kg m 25 33 ft lb 8 0 66 Date of Issue NOli 1981 HONDA MOTOR CO LTD ...

Page 66: ...ick spindle iJ D 10 013 10 035 10 3942 Q 3951 10 100 0 3976 bushing 0 0 13 973 14 000 0 5501 0 5512 13 900 0 5472 Idle shaft 1 0 14 016 14 051 0 55t8 Q55321 I 14 100 0 5551 bushing 0 0 17 965 18 000 lO 7069 0 70871 I 17 900 IO 7047 Idle shaft Left cover 13 957 13 984 0 5495 Q 5506 13 900 0 5472 O D i left crankcase L 57 13 984 0 5475 0 55061 13 900 10 5472 SPECIFICATIONS l__ _ T E M j l 0 STANDARD...

Page 67: ...motorcycle starts suddenly 1 Brak n clutch weight spring 2 Damaged clutch lining Poor perlOimance at high speed or lack of power 1 Worn drive belt 2 Weak torque spnng 3 Worn welghl roller 4 Faulty driven face 5 Worn or seized driven pulley bearing Clutch noise or smell 1 Oil or gT laSe on drive bell or pulley 2 Worn drive belt 3 Weak torque spring 4 Worn or seized driven pulley bearing HONDA NUSO ...

Page 68: ...the bOlt attaching the left case cover Remo e the leit case cover while holding the kick Harter spindle KICK SPINDLE BEARING INSPECTION Check the kick spindle bearing play by rotating the bearing by hand Replace the bearing with II new one if it is noisy or has excessive play LE FT CASE COVE R KICK SPINDLE BEARING Date of Issue Nov 1981 HONDA MOTOR CO lTD 69 8 3 ...

Page 69: ...Expand the movable driven lace enough to remove the drive belt Ihen remove the drive belt CAUTION Do not bend the drive bell or it will be dam aged DRIVE BElT r itI HONDA NUSO NUSOM DRIVER HANDLE ATTACHMENT 32 Ie 35 mm PILOT 15mm MOVABLE DRIVEN FACE DRIVE BELT INSPECTION Check thc drive belt for cracks separation or abnor mal or excessive wear Measure the drive belt s width SERViCE LIMIT 13 0 mm D...

Page 70: ... sh lh KICK STARTER SPINDLE MOVABLE DRIVE FACE ASSEMBL Y IDLE SHAFT Hold Ihe crankshaft with a starter driven gear holder Remo e the nUl and the movable drive face assembly MOVABLE DRIVE FACE DISASSEMBLY Remove the three bolts attaching the movable drive face seal and remove the seal DRIVEN GEAR HOLDER 07924 H170000 OR BAND STRAP WRENCH COMMERCIALLY AVAILABLE IN U s A Date of Issue Nov 981 HONDA M...

Page 71: ... HONDA NU50 NU50M RAMP PLATE Remove the weight rollers WEIGHT ROLLER MOVABLE DRIVE FACE INSPECTION Check each roHer for wear or damage Measure each roller 0 0 SERVICE LIMIT 15 40 mOl O 606 inl TAKE MEASUREMENTS ATWQAN AREA 8 6 n Date of Issue Nov 1981 HONDA MOTOR CO LTD ...

Page 72: ...mm 10 9827 in DRIVE PULLEY KICK STARTER CLUTCH DRIVEN PULLEY MOVABLE DRIVE FACE ASSEMBLY lubricate the inside of the drive face with grease then install the weight rollers NOTE ApplV 10 15g 0 35 0 53 oz of grease 10 the inside of the drive face evenly SPECIFIED GREASE LITHIUM BASED GREASE MITSUBISHI HD 3 NIPPON SEKIYU UPANQX DELUXE 3 IDEMITSU CQRONEX 3 or equivalent Date of Issue NOli 1981 HONDA M...

Page 73: ...Install the drive lace boss in the movable drive face Install the assembly on the crankshaft CAUTION Clean the hole in 11 mOllable drh e face dril e aCt boss Urld clean tire crallks lllff CRANKSHAFT DRIVEN GEAR HOLDER 07924 1970000 OR BAND STRAP WRENCH COMME RCIALLY AVAILABLE IN U SA Install the drive face and tighten with the 10 mm nut by holding the crankshall with a holder TORGUE 35 40N m 3 5 4...

Page 74: ...mi install the dowel pins Install Ihe idle shaft bushing IIHO the left crankcase cover Install the left crankcase cover NOTE Do not tighten the cover bolts at this time Install the kick pedal by aligning its punch mark with the punch mark of the spindle Tighlt1n the pedal pinch boll Tighten the crankcase cover bolts while pushing I11 j holding the kick starter pedal down 15 or more Dille of Issue ...

Page 75: ...DRIVE PULLEY KICK STARTER CLUTCH DRIVEN PULLEY KICK STARTER I HONDA NU50 NU50M 8 10 76 Dilte of Issue Nov 1981 HONDA MOTOR CO lTD ...

Page 76: ...hah Remove the stopper piaIe Remove the movable drive face assembly Page 8 5 Remove the kick starler driven gear using a com mercial gear puller with puller attachment CAUTION Hold rhe dril l JI gmr wilh fil gers 10 pn l ellf i from falling aI I during rhis operarion DRIVE BELT KICK STARTER SPINDLE STOPPER PLATE DRIVEN GEAR RETURN SPRING END IDLE SHAFT Date of Issue Nov 1981 HONDA MOTOR CO LTD SHA...

Page 77: ...TION SPRING DRIVEN GEAR KICK STARTER SPINDLE Disassemble the kick starter idle shaft KICK STARTER INSPECTION Inspect the kick starter spindle for wear or damage Measure the spindle 0 0 SERVICE LIMIT A Bushing 9 900 mm 0 3898 in B ShaftJ 13 900 mm 0 5472 inl BU S HING KICK STARTER SPRING STOPPER CO PLATE tJ ct 7 KICK STARTER CO IDLE SHAFT 8 12 78 Date of Issue Nov 1981 HONDA MOTOR CO LTD ...

Page 78: ...ushing LD SERVICE LIMIT 10 100mm 0 3976 in Measure the bushing 0 0 SERVICE LIMIT 13 900 mm 0 5472 in Meilsure the kick Slarter cam 1 0 SERVICE LIMIT 14 050 mm 0 5531 in 0 0 Inspect the kick starter idle shaft for wear or damage Measure the idle shah 0 0 SERVICE LIMIT 13 900 mm 0 5472 in Dilte of Issue No 1981 HONDA MOTOR CO lTD 79 8 13 ...

Page 79: ...d of the spring in the hole of the kick starter idle shaft Install the spring collar with the groove in the collar aligned with the spring Install the thrust washer on the idle shaft Kick starter spindle Apply grease to the kick starter drjve gear and kick starter worm gears Install the kick starter cam into the drive gear by aEgning the punch marks Apply grease to the inside of thc starter gear f...

Page 80: ...stoppel plate ARROW BUSHINGS DRIVE GEAR IDLE GEAR Install the kick starter drive gear and can aligning the friction spring with the groove in the lelt crankcase Point the arrow milrk 011 the dnye gear toward the craflKshaft placing the cam on the drive gear by turning it clockwise Install the idle shalt alig ing its punch mark with the kick stilrter carn punch mark CAM THRUST WASHER PUNCH MARKS SP...

Page 81: ...DRIVE PULLEY KICK STARTER CLUTCH DRIVEN PULLEY CLUTCH DRIVEN PULLEY HONDA NU50 NU50M I 30 38 N m 3 0 3 8 kg m 22 27 ft lb 8 16 82 Dale of Issue NOli 1981 HONDAMOTOR CO LTO ...

Page 82: ...UTCH DRIVEN PULLEY Remove the 10 mm nut holding the clutch outer Remove the clutch outer UNIVERSAL HOLDER Withdraw the movable dnven face from the drive shaft with the drive belt while elCpanding the movable driven face MOVABLE DRIVEN FACE Dale of Issue Nov 1981 HONDA MOTOR CO LTO 83 8 17 ...

Page 83: ... FACE DISASSEMBLY Remove the 28 mm nut using the special tools CAUTION o not owmigJlttm he chach spring com prenor CLUTCH SPRING COMPRESSOR 07960 187OCK 8 18 SPRING WASHER LOCK NUT WRENCH 39 mml 07916 1870001 CIRCLlP WEIGHT 84 28mm NUT Date of Issue Nov 1981 HONDA MOTOR CO LTD ...

Page 84: ...ar Withdraw the guide roller pin and guide roller DRIVE PULLEY KICK STARTER CLUTCH DRIVEN PULLEY SEAL COLLAR GUIDE ROLLER PIN GUIDE ROllER l DRIVEN FACE A Y Dale of Issue Nov 1981 HONDA MOTOR CD LTD O MOVABLE DRIVEN FACE 85 SEAL COLLAR 8 19 ...

Page 85: ...uter lor wear or damage Measure lhe clutch outer 1 0 SERVICE LlMIT 107 5 mm 4 23 in Inspect the clutch shoes for wear or damage Measure the thickness of each shoe SERVICE LIMIT 2 0 mm 0 079 in Measure the dri en face spnng free length SERVICE LIMIT 88 0 mm 3 46 inl 8 20 86 Date of Issue Nov 1981 HONDA MOTOR CO LTO ...

Page 86: ...VICE LIMIT 33 930 mm U 3358 in Inspect the movable driven face for wear or damage Measure the movable driven face LD SERVICE LIMIT 34 060 mm 1 3409 in Check the oil seals for wear damage or other faults Check the movable drive face Q rings t1nd replace if worn or damaged Dale of Issue Nov_ 1981 HONDA MOTOR CO lTD 87 OIL SEAL MOVABLE DRIVE FACE 8 21 ...

Page 87: ...Slide the seal collar onto the movable driven face HONDA NU50 NU50M GUIDE ROLLER a RINGS _ _ OIL SEAL SEAL COLLAR CLUTCH SPRING COMPRESSOR 07960 1870000 DRIVEN PULLEY ASSEMBLY Position the driven face assembly spring and drive plate assembly on the clutch spring compressor Compress the spring by turning the handle while aligning the flat faces of the driven face and drille plate 8 22 88 Date of Is...

Page 88: ...1870001 CLUTCH DRIVEN PULLEY INSTALLATION Place the drive belt on the driven face JnnaH the driven face on the drive shaft while spread ing the movable driven face MOVABLE DRIVEN FACE CLUTCH OUTEA Install the dutch outer and tighten the nut TORQUE 35 40 N m 3 5 4 0 kg m 25 29 It lb Install the left case cover Page 8 9 Install the kick starter pedal UNIVERSAL HOLDER Date of Issue Nov 1981 HONDA MOT...

Page 89: ...FINAL REDUCTION _ H gO NDA NU50 NU50M 9 0 90 Date of Issue HONDA M Nov 1981 OTOR CO l TO ...

Page 90: ...OOLS SPtJcial Bearing remover set 12 rnm Bearin l or remover 12 mOl Common AltachmCflt 32 x 35 mOl Attachment 37 40 mOl Pilol 12 mOl Pilot 15 mOl Pilot 17 mOl Driver TROUBLESHOOTING 90 gear oil 90cc 3 0 US OZ 2 5 Imp oz 1 07936 660000 07936 1660100 07746 0010100 07746 0010200 07746 0040200 01746 0040300 07746 0040400 07749 0010000 Engine starts but motorcycle wan move 1 Damaged transmiSS100 2 Seiz...

Page 91: ... case Page 2 3 P emove Ihe fCilf fender stilY bolt Remove the boilS attaching the transmission cover and remove the cover TRANSMISSION COVER HONDA NUSO NUSOM Remove the fcaf wheel Page 12 2 Remove the final gear and coul1tershaft Remove the driveshaft from the transmission cover FINAL GEAR TRANS7 ON COVER 9 2 92 Dale of Issue Nov 1981 HONDA MOTOA CO LTD ...

Page 92: ... Oll ck the left case bearings play by rotating the bearing by hand Replace the bearings ith iI new one if t is noisy or has excessive play Oleck Ihe oil seal for weal or damage and replace with a new one if necesS3ry TOOLS Attachment 32 x 35 mm Anilchment 37 x 40 mm Pilot 12 mm Pilot 17 mm Driver o OIL SEAL DRIVE SHAFT LEFT CASE BEARING BEARING REMOVER SET 12MM 07936 1660000 OR INOT AVAILABLE IN ...

Page 93: ...U50 NU50M Clleck the countershaft and gear for wear or dam lge Check the final gear for wear damage or signs of seizure COUNTEASHAFT GEAR FINAL GEAR FINAL REOUCTION INSTALLAnON Clean the cover mating surface of the final reduction case of any gasket material 9 4 M Dilte of Issue Nov 1981 HONDA MOTOR CO LTO ...

Page 94: ...he washer and coumershaft InstaU the countershaft lind final gear Ins taU the breather tUbe Install the dowel pins and a new gasket FINAL REDUCTION FINAL GEAR BREATHER TUBE WASHER TRANSMISSION COVER ASSEMBLY Slide the drive shaft through the bearing from the inside DRIVE HAFT Dale of Issue Nov 1981 o HONDA MOTOR CO LTO 95 9 5 ...

Page 95: ...n face and the clutch outer Page 8 231 Install the left crankcase cover Page 8 9 Pour the pecilied amount of oil through the filter opening SPECIFIED 01 L fr 90 gear oil QUANTITY 90ce 13 0 U S oz 2 5 Imp od Check for leaks alter test riding the motorcycle r ii HONDA NUSO NUSOM TRANSMISSION COVER CLUTCH OUTER LEFT CRANKCASE COVEA Oil lEVEL CHECK HOLE 9 6 96 Dare of Issue Nov 1981 HONDA MOTOR CO l T...

Page 96: ...CRANKCASE CRANKSHAFT HONDA NU50 NU50M 10 0 98 Dale of Issue NOli 1981 e HONDA MOTOR CO l TO ...

Page 97: ... be replaced Rear wheel Final reduction SPECIFICATIONS Page 12 2 Page 9 2 __ _n__ ITEM STANDAf __ m in SERVICE LIMIT mOl inl CONNECTING ROD BIG END SIDE 0 60 0 024 CLEARANCE CONNECTING ROD BIG END RADIAL CLEARANCE 0 05 0 002 CRANKSHAFT RUNQUT A 0 15 0 0061 B 0 10 O OO4J I TOOLS ped 1l Crankcase Puller seal And Case Assembling Tool Bearing Remover Common Attachment 42 x 47 mm Pilot 20 mm Driver Bea...

Page 98: ...ing bracket RenlOve the center stand bracket Page 5 2 Page 2 5 Page 4 91 Page 12 21 HONDA NUSO NUSOM Remove the cylinder head cylinder and piston Page 6 2 31 Remove the alternatOl Page 7 2 Remove the kick Haner driyen gear Page 8 11 171 Remove the final reduction usembly page 9 2 Remove the crankcase attaching bolts 10 2 100 Date of Issue Noy 1981 HONDA MOTOR CO LTD ...

Page 99: ...rankcase halves Separate the c CRANKSHAFT REMOVAL mnk I on the left the special toO Attach I h crankcase shown kshah from the e Remove the cran R 07935 1870000 CASE PULlE T INSPECTION C RANKSHAF de de n rod big end 1 h connecting Mea ure t e with iI feeler gauge 0 024 m 060mm SERVICE LIMIT Nov 1981 Date of Issue TOR CO lTD HONDAMO 0 10 3 ...

Page 100: ...ual runout is y of the total indicator reading SERVICE LIMITS A O 15mmlO 006in B 0 10 mm 10 004 in A 60mmr 60mm B TOOLS Bearing Installation Spin the crankshah bearing by hand and check for play The bearing mUsl be replaced if it is noisy or has excllssivc play Common Attachment 42 117 mrn Pilot 20 mm Driver 07746 0010300 07746 0040500 07749 0010000 PLAY tPLAY l I 11 111 C l fj f I f U u 2J RADIAL...

Page 101: ...o all moving and sliding sul1aces Install the crankshaft Into the left crankcase NOTE lubricate hi crankshah main and journal bearings with Honda 2 stroke injector oil or eQuivalent InSlall a new gasket and the dowel pin 10 he crank case m311ng surface and i1sremble Ihe crankcase halves Assemble the removed parts in Ihe reverse order of remol al Page 10 H SEAL AND CASE ASSEMBLING TOOL 07965 148001...

Page 102: ...FRONT WHEEL FRONT BRAKE FRONT FORK HOND A NU50 NU50M 40 50N m 4 0 5 0 K9 m 29 36 flAbl 11 0 104 1J 5_85N m 7 5 8 5 kg m 54 61 ft jbl 30 40 N m 3 0 4 0 kg m 22 29 ft lbl Date of Issue Nov 1981 HONDA MOTOR CO LTD ...

Page 103: ... mm 0 08 in Aim runout I Axial 2 0 mm 0 08 in Brake drum 1 0 95 0 mm 3 74 in 95 5 mm 3 76 in Brake lining thickness 0 mm 0 04 in Fork spring frea length 129 6 mm 5 10 in 126 2 mm 4 97 in Fork tube unCul 0 20 mm 0 008 in Fork grease 5 lIO lBoz for each TOROUE VALUES II Steering stem nut Steering handle top bridge front bolt Steering handle top bndge bolt Front axle lUI TOOLS Special BaU race remove...

Page 104: ...Improper brake performance 1 Incorrect adjustment of fever 2 Brake shoe worn 3 Brake shoes oily greasy or dirty 4 STake cam waUl 5 Brake drum WOfn 6 Brake arm serrauons Improperly engaged 7 Cam contacting area of shoes worn Front Wheel Wobbling 1 Bent rim 2 Axle nOI lightened properly 3 Bent spokes 4 Excessive wheel bearing play 5 FaUlty or unevenly worn lire Soft Suspension 1 Weak fork springs Fr...

Page 105: ...ed ometer by removing the cable nut Remove the speedome tel lamp sockets and remove the speedometer CAUTION f o nor St t the speedomeTer upside down bl CIIIISt illfc TIIaf llibricaflllllay get on Ihe ellS SPEEDOMETER COVER SPRING SPRING CABLE I NUT GROOVE LAMP SOCKET BOSS INSTALLATION Install the speedometer lamp socket into the speed ometer Connect Ihe sJ t1cdomcmr cable to the speedometer Hook t...

Page 106: ...e right end of thc band is onto the groove of speedometer GROOVE BAND END HEADLIGHT REPLACEMENT AemoV1 the keadlight by removing the attaching bolt washers and collars Dis conneci the headlight connectollo Remove the fiXing screws and collars Remove the headlight beam adjusting screw end replaC1 the he light with a new one BOLT WASHERS ADJUSTING SCREW 11 4 lOB Date of Issue Noy 1981 HONDA MOTOR CO...

Page 107: ...p case and ignition switch Page 11 6 Disconnect the wire connectors Remove the headlight vertical adjusters and remove the headlight case Installation of the headlight case is essentially the reverse order of removal Connect the wires color to color NOTE Check that all wires and cables are rouled properly See page 1 8 IGNITION SWITCH INDICATOR LAMP CASE Adjust the headlight aim Page 3 10 Date of I...

Page 108: ... the lock lab dicks Connect the coupler and install the headlight INDICATOR LAMP REPLACEMENT Aemo tle the screws attaching the Indicator lamp case Remo e the headlIght Page 11 4 Disconnect the indicator lamp connectors COUPLER SCREWS BULB Remove the sockets and replace the indicator bulbs lnst all the indicator lamp case and tighten the screws Connect the indicator lamp wires color to color Instal...

Page 109: ...sing Remove the switch housing Remove the two screws attaching the throttle grip housing and housing NOTE Loosen the rear screw first to ease removal Remove the front carrier by removing lhe cap nut and bolts Remoye the front cover by removing the reflectors Remove the front carrier set bolt Date of Issue Nov 1981 HONDA MOTOR CO LTD SPEEDOMETER SCREWS FRONT COVER 111 HEADLIGHT CASE THROTIlE GRIP H...

Page 110: ...all the steering stem nut and washer Tighten the stem nut to the specified torQue TORQUE 75 85 N m 7 5 8 5 kg m 54 61 ft lb Install and tighten the front carrier set bolt TORQUE 20 30 N m 2 0 3 0 kg m 14 22 ft lbl Clamp the cables and wires to each handlebar clamp Install the front coyer and reflectors NOTE Check that aU wires and cables are routed properly Page 1 6 Install the Iront carrier STEER...

Page 111: ... freerv PUNCH MARK PUNCH MARK InstaU the lighting switch housing on the handlebar with the punch mark on the handlebar aligned With the split in the switch housing Tighten the forward screw first then tighten the fear screw 10 the same torQue TURN SIGNALS Install the headlight case Page 11 5 Install the turn signals and route the wires into the headlight Page 1 8 lnslall the speedometer Page 11 3 ...

Page 112: ...E SPEEDOMETER CABLE AX LE INSPECTION Set lhe axle in V blocks and measure the runou The actual runout is 1 2 of the TIR ITotallndicator Reading SERVICE LIMIT 0 20 mm to 008 in PLAY 1 f T T i PLAY I Tn 1 l IT Check the wheel bearing play by placing the wheel in a ruing stand ilnd spinning the wheel by hand Replace the bearings if they ilre noisy or have exces siye play WHEEL BEARING INSPECTION AXIA...

Page 113: ...g a dill indicator SERViCE LIMITS Radial 2 0 mm 10 08 in Axial 2 0 mm 10 08 in FRONT WfiEEL DISASSEMBLY Remo e the axle collar dust seal meel bearings and distance collar from the wheel hub FRONT BRAKE DRUM INSPECTION Remove the brake panel from lhe fronl wheel and measure the brake drum 1 0 SERVICE LIMIT 95 5 mm 3 76 in AXLE COLLAR Dut fb SEAL Dale of Iswe Nov 1981 HONDA MOTOR CO lTD 115 11 11 ...

Page 114: ...facing out Contaminatell b tJk linings rt dll stopping POI t f Krep gre w off lhe linings ami broke drum Apply grease to the inSide of the dust seal Install the dust seal and axle collar FRONT WHEEL INSTALLATION Install the brake panel into the wheel hub aligning the speedometer gear tabs with the grOOlles in the hub DRIVER I ATIACHMENT 28 x 30 mm PILOT 10 mm 07946 1870100 OR 07946 3570000 DUST SE...

Page 115: ... axle nut to the specified torque TORQUE 40 50 N m 14 0 5 0 kg m 29 36 It fb ConneCt the speedOmeter and brake cables Adjust the front brake lever free play page 3 81 AXLE NUT FRONT BRAKE CABLE LEFT FORK LEG SPEEDOMETER CABLE FRONT BRAKE BRAKE LINING INSPECTION Measure the brake lining thickness SERVICE LIMIT 1 0 mm Q inl CQ llumimlled brake fillillgs redu e stoppillg flQ Keel grease off he lining...

Page 116: ... RETURN SPRINGS BRAKE CAM BRAKE CAM ASSEMBLY Apply silicon grease to the anchor contacting area of each shoe and the brake shoe contacting area of the brake cam Install the brake cam A I oid lell Krrose 01 the il1side of he broke dmm Teoll till inside of the broke panel thorough 11 14 118 Date of Issue Nov 1981 HONDAMOTOA CO l TO ...

Page 117: ...ilrm with the punch mark on the cam lnnall arxJ tighten the brake arm bolt PUNCH MARKS BRAKE CAM Apply grease to the IIlside of Ihe dust seal ilnd to the speedometer gear Install the speedometer geilr and dust seal Hook the hrake shoe springs to the brake shoes as shown lind installihe brake shoes BRAKE ARM RETURN SPRING FELT RING SPEEDOMETER GEAR FRONT FORK FRONT FORK REMOVAL Remove the front whe...

Page 118: ...emove the 35 mm internal circlip Remove the fork tube FORK TUBE FRONT FORK DISASSEMBLY INSPECTION Check the lork tube lor rU lout Check each part for abnormal wear or damage NOTE Replace the front fork tvbe if it is bent DUST COVER RUBBER BUSH LEFT FORK 11 16 120 Date of Issue Nov 1981 HONDA MOTOR CO LTD ...

Page 119: ...BRAKE FRONT FORK FRONT FORK ASSEMBLY INSTALLATION NOTE Before assembly apply grease to the sliding surfaces of each fork lUbe Sg 0 18 oz Assembly of the front fork is the reverse order of disassembly Install the fork into the steering stem Install the front fender and tighten the bolts Date of Issue Nov 1981 HONDA MOTOR CO LTO 121 11 17 ...

Page 120: ...g bolts HORN COUPLERS STEERING STEM TOP CONE RACE Remove the steering head top cone race Remove the steering stem being careful not to allow the steel balls to fall OUt BALL RACE DISASSEMBLY ASSEMBLY TO REMOVE TO INSTALL Use the special tool BALL RACE DRIVER to remove the ball races BALL RACE DRIVER 07945 GA70000 y To install the ball races use the special 1001 Ball 4 race driver CAUTION 1 Do no a...

Page 121: ...L RACE STEEL BALLS 26 BOTTOM CONE rtIJ RACE TOP CONE RACE NOTE Check Ihat Ihe steeling stem rotates freely without vertical play Install the tOp bridge Inslllllthe washers and bolts Tighten lhe bolts to the specified torque TORQUE 30 40 N m 3 0 4 0 kg m 22 29 ft Ibl Install the horn Route the wires and connect the wire couplers and connectors page 1 6 Install the h mdlebars Page 1l S and front for...

Page 122: ...REAR WHEEL REAR BRAKE REAR SUSPENSION 30 40 N m 3 0 4 0 kg m 22 29 f lb 12 0 124 HONDA NUSO NUSOM 0 I 80 100 N m f8 0 10 0 kg m 58 72 ft lll Date of Issue Nov 19B1 OHONDA MOTOR CO l TO ...

Page 123: ... Rear Shock Absorber Compressor Attachment TROUBLESHOOTING STANDARD mm lin 95 0 13 741 4 0 0 161 163 6 6 44 80 100 N m 8 0 10 0 kg m 58 72 ft lbl 30 40 N m 3 0 4 0 kg m 22 29 t fb 07959 3290001 or 07959 3290000 07967 GA70000 SERVICE LIMIT mm 2 0 0 08 95 5 3 76 2 0 0 08 160 3 6 31 Rear whl 1 wobbling I Bent rim 2 Faulty tire 3 Axle n01 tight ned properly Soh suspension I Weak shock absorber spring ...

Page 124: ... ear fender illllachmg bolts and remove the rear fender r fi HONDA NU50 NU50M REAR FENDER ATTACHING BOLTS MUFFLER NUTS Remove the rear xle nul Remove the rear wheel REAR AXLE REAR WHEEL RIM RUNOUT INSPECTION Check the nm fOI nmout usmg a dial indicator as shown SERVICE LIMITS Radiil 2 0 mm 0 08 in AliI al 2 0 mm 0 08 inl 12 2 126 Dale 01 Issue Nov 1981 Q HONDA MOTOR CD l TO ...

Page 125: ...MIT 95 5 mm 3 76 in REAR WHEEL INSTALLATION Install the feilr wheel and torque the axle nut TORQUE 80 100 Nom 8 0 10 0 kgom 58 72 fHbl Install the reilr fender Install the muffler REAR WHEEL REAR BRAKE REAR SUSPENSION REAR AXLE NUT MUFfLER O ie of Issue Nov 1981 et HONDA MOTOR CO LTD 127 12 3 ...

Page 126: ...rear wheel Page 12 2 REAR BRAKE LINING THICKNESS INSPECTION Measure the brake lining thickness SERVICE LIMIT 2 0 mm O OB inl REAR BRAKE DISASSEMBLY WEAR INDICATOR PLATE BRAKE CAM fi L SPRINGS I HONDA NU50 NU50M 12 4 128 Date of Issue Nov 1981 HONDA MOTOR CO LTD ...

Page 127: ...late aligning the wide groove on the cam with the wide tooth on the plate NOTE Install the plate with the arrow mark facing the brake shoes Install the brake arm aligning the mark on the brake arm with the punch mark on the brake cam REAR WHEEL REAR BRAKE REAR SUSPENSION BRAKE CAM PUNCH MARKS BRAKE ARM Install the spring guide and brake arm spring Dilli of Issue Nov 1981 HONDA MOTOR CO LTD 129 SPR...

Page 128: ...ft lbl REAR BRAKE CABLE BRAKE CABLE HOLDER Instalt the brake arm cover and the brake joint on the brake arm and install the brake adjuster Install the brake shoes and springs Install the eaf wheel Page 12 3 and adjust lhe rear brake Page 3 8 SHOCK ABSORBER REMOVAL Remove the rear shock absorber upper and lower nuts and washers BRAKE ADJUSTER JOINT ARM COVER SHOE SPRINGS L T i BRAKE SHOES UPPER NUT...

Page 129: ...line Disconnect the wire harness connectors Remove the lellr carrier with fuel tank bV removing the mounting bollS Ko ep gasOlifW Uk Gy frolll 1umt s ur spark hYpt liP spilled gasiJlil t QI OIlCt J OISASSEMBLy ATTACHMENT07967 GA70000 Compress the shock and remove the upper joint COMPRESSOR 07959 3290001 UPPER JOINT REAR DAMPER UPPER JOINT LOCKNUT STOP RUBBE R DatI of Issue NOli 1981 HONOftMOTOR CO...

Page 130: ...tightly wound coils facing up Apply locking agent to the lock nut threads and torque the lock nul TOROUE 15 20 N m 1 5 2 0 kg m 11 14 h lb COMPRESSOR 07959 3290001 LOCK NUT CONNECTORS REAR CARRIER FUEL LINE Install the feaT shock absorber Install the rear carrier with the fuel tank Connect the fuel line and the wire harness connectors INSTALLATION 12 8 132 Date of Issue Nov 19BI HONDA MOTOR CO LTD...

Page 131: ...nuts to the specified torque TORQUE 30 40 N m 13 0 4 0 kg m 22 29 ft Ib Check the operation of the ock absorber by preUlog down on the end of the frame several tImes REAR WHEEL REAR BRAKE PEAR SUSPENSION Date of Issue Nov 1981 HONOAMOTOR co LTD 33 12 9 ...

Page 132: ... The gas produced by a ballery IS very flammable and can explode lynit on timing nmflOI be adiusted since the C O I ullit is non adiustable lithe timmy incorrect inspect the C D unit and alte mawr and replace ilny faulty parts SPECIFICATIONS Charging System B 1ttery SPECIFICATION T Mu P r 2 5 50 t 2 V 4 A H 7N U 5 O M Specific grav ty 1 270 1 290 at 20 C 68 FI I I AlternatO Chalf ing rate CharSI r...

Page 133: ...tOP switch 6 Faulty larter relay 7 Poorly connected broken or shorted wire 8 Faulty starter motor HONDA NU50 NU50M Intermittent power 1 loose battery cable 2 loose charging system connection 3 Loose connection or short circuit in lighting system Charging system f ulure 1 loose broken or shorted wire or connection 2 Faulty silicon rectifier 3 FaUltY alternator Engine staru but runs poorly 1 Ignitio...

Page 134: ...RE o 10 20 30 40 C 32506886 ELECTROLYTE TEMP VS SPECIFIC GRAVITY 1 297 1 300 u 1 240 1 280 1 260 The battery must be charged if the specific gravity falls below 1 230 The specific gravity varies with the tempera ture as shown Specific gravity changes by 0 007 for every lQ C Replace Ihe battery 11 sulfalion has formed or if the space below the cell plates is filled with sediment The JlltIl ry cOlll...

Page 135: ...porks I or rhl baftt r ulls f iscolltinlll charging If Ille dec o 1 t1 tem Qtllreexcl eds 45 C II F CAUTION Quick chargillg should vllly be done in Oil emcrgi l1cy slow charging i prcjerred Charging timo 3 15 hours Charging Charge the battery until specific gravity i5 1 270 1 290 20 C 69 Fl 1 300 1 290 1 270 1 260 1 220 u 1 180 u 140 V 1 100 060 0 SPECIFIC GRAVITY VS CHARGING TIME 2 6 8 0 12 1 1 1...

Page 136: ...G SYSTEM RECTIFIER BATTERY ALTER ATOR CHARGING CIRCUIT ALTERNATOA SILICON RECTIFIER BAITERY COMBINATION SWITCH k HEADLIGHT TAILLIGHT SPEEDOMETER LIGHT YELLOW FUSE __ W H IT E tf 4__ RE D _ o l RED Date of Issue Nov 1981 HONDA MOTOR CO LTO 139 13 5 ...

Page 137: ...VI NOTE ALTERNATOR INSPECTION Alternator removal installation Page 7 2 O 3 1 5S O 5 1 Sn Yellow Engine ground White Engine ground It is not necessary to remove the stator to make this test NOTE Disconnect the stator connectors Check the resistances between Ihe connectors with an ohmmeter in the RX1H Hinge Replace the stator coil and flywheel as a set SILICON RECTIFIER INSPECTION Check lor continui...

Page 138: ... e O 1 UNIT ALTERNATOR SPARK IGNITION PLUG COIL IGNITION CIRCUIT ON BlACKM HITE ALTERNATOR 0 0 C O 1 UNIT BLACKI DIODE IGCONOENSERI RED IGNITION COIL seR BLUEIYE LLOW PUlSER COIL EXCITER COil GREEN GREEN Daftl of 1 5ue Nov 1981 HONDA MOTOR CO LTD 141 13 7 ...

Page 139: ...IU Measure the resistances of the primary and secondary coils RESISTANCES Primary coil O 2 O 3n o L Secondary coil 3 4 4 Zn NOTE i if the ignition coil will function properly after 3 minutes of operation perform the performance test described on Ihe next I i page Performance tesl Perform the 3 point spark test with a service tester PRIMA Y ELECTRODE SPARK I MORE THAN 6 mm 1 4 in I I SECONDARY ELEC...

Page 140: ...or conneClon and measure the resistances between the connectors with i1n ohmmeter selon the RX In scale It is not necessary to remove the stator to make this test CAUTlON_ rRep ace tile stutor and flywheel as a Ie if i he Qnc leeds repfacemem C O I UNIT Raise Ihe seat Remove the se lt bridge and shroud SEAT BRIDGE C D 1 UNIT Remove the C D I unit Disconnect Ihe coupler Date of Issue Nov 1981 HONDA...

Page 141: ...per range may give false readings Use a SANWA ELECTRIC TESTER Type SP l0D PIN 07308 0 20000 or KOWA TH 5H TESTER In the table Needle swings then returns indicates that there is a charging corrent applied to a condenser The lester needle wililhen remllin at 00 unless the condenser IS discharged NOTE I Take readings in Rxkn range IGN PC E 5 E r I SW EXT PC E IGN PROBE i SW i f 00 00 00 1 1 Needle sw...

Page 142: ... lew batteries perform lhc lero adjustment in the measur ing range for accurate readings Measure the resistances between the terminals Replace the regulator rectifier with a new one if the readings do not fall within the limits shown in the table NOTE I I PR OBE PINK BLACK RED WHITE PROBE PINK 1 5 BLACK 1 5 00 00 RED 00 00 00 WHITE 00 0 5 10 RESISTOR NU50M only Check the resistance between the res...

Page 143: ...TER RELAY INSPECTION ConnecT iI 12V battery across the Green Ycllow l and Yellow Red terminals Check for continuity between the Red and Red White terminals with an ohmmeter The relay is normal if there is continuity GAEENIYELLOW STARTER MOTOR REMOVAL TlU xhallsr IlIl1fj1er call be I CIT 11m He carefltl I ot fU bllm yourselfd ring operatio Remove the alternator covel Remove the starter motor Page 7...

Page 144: ...LIMIT 4 0 mm 0 16 in COMMUTATOR INSPECTION Check he commutator for discoloration and other visual faults Blackened adjacent segments are an indication of a shorted circuit CAUTION Do 11m use sal dpaper ro cleal lle commutator Check for continuity between segments and com mur nor and shah The commutator is normal if there is continuity bel veen the segments There should be no continuity between the...

Page 145: ...BRUSH HOLDER PLATE Insert the commutator into the starter body Lubricate the starter pinion with clean grease InSlnll the pinion and starter cover Attach the starter wires and install the terminal cover tr STARTER MOTOR INSTALLATION NOTE Before installing the starter test for operation by connecting the starter coupler to the wire harness Instal the starter motor Page 7 4 Secure the wires with the...

Page 146: ...hould exin between color coded wires indicated by interconnected circles on each chan TURN SIGNAL SWITCH GREY LIGHT ORANGE BLUE R 0 0 N L 0 C HEADLIGHT DIMME R SWITCH IBROWN BLUE WHITE Hi IN Lo HORN SWITCH LIGHT GREEN GREEN OUT PUSH 0 to HORN Connect the horn to fully charged 12V battery and be sure the horn sounds properly Dale of Issue No 1981 HONDA MOTOR CO LTD 149 13 15 ...

Page 147: ... SWITCH BLACK IGREENI YELLOW ENGINE STOP SWITCH BLACK GREEN WHITE OFF 0 O RUN OFF 0 0 STARTER SWITCH INU50M only HONDA NU50 NU50M FRONT STOP LIGHT SWITCH WIRES ENGINE STOP SWITCH STARTER SWITCH 13 16 50 Date of Issue Nov 1981 HONDA MOTOR CO LTD ...

Page 148: ...onnect the coupler and turn the ignition switch ON With the float fully raised measure the resistance between the terminals Green Red 1 to Black I I I 340n approx Operate the turn signals to see that the battery circuit is nO mal then perform the following inspectIon RaIse and lower the float to make sure that the oil leve indicator lamp blinks Should the lamp fail to go on and go out as the float...

Page 149: ...tive Discharge Ignition C D I UNIT ALTERNATOR SPARK PLUG 14 1 14 3 14 5 14 8 ADVANTAGES 1 The C D I gives a strong spark at high rpm and resists spark plug fouling at low rpm 2 The C D I does not require adjustment it has no wearing parts 3 The NU50M ignition system works on A C voltage Date of Issue Nov 1981 CO HONDA MOTOR CO LTD 153 14 1 ...

Page 150: ...lows current to pass in one direction only Alternating current induced in the pulse coil is used to open and close the C D I unit electronic switch SeAl through the gage circuit the SeA and gate circuit are more complex than shown The magneto charges the condenser with the SeR open The condenser is grounded through the SeR when the SeA closes The condenser then discharges through the ignition coil...

Page 151: ...he carburetor choke circuit and directly to the control 00 CONTROL BOX The camra box has three control lines connected to it 111 an air line from the bystarter 121 a fuel line from the carburetor choke circuit and 3 a fuel line to the intake pipe The flow of air and fuel through these lines is controHed by 8 bimetal strip Jnd valve inside the control box iF Dilte of Issue Nov 1981 0 HONDA MOTOR CO...

Page 152: ...ds and mo es the control valve as it is heated by the engine The valve moves 0 5 mm for each one degree centigrade 1 8 Fl change ir engine temperature As the valve moves it opens the air pilssage directly from the bystar er This air mixes with the carburetor choke circuit mixture and leans it out to keep the engine running smoothly ABOVE 46 C 115 F When the engine temperature is above 46 C 1115 FJ...

Page 153: ... FACE BALL BEARING DRIVE FACE NEEDLE BEARING DRIVEN FACE SPRING CLUTCH WEIGHT DRIVE SHAFT CLUTCH OUTER DRIVE PULLEY DRIVEN PULLEY DRIVE PULLEY DRIVEN PULLEY 1 7 Q 8 8j When the engine is running at low speed the unit can increase or multiply lOrqUl so that more torque is delivered than at high engine peed through 3 greater drive ratio REDUCTION RATIO 2 1 As the speed of the engine increases or loa...

Page 154: ... pushes in the weight rollen against the drive face is iIltilched to the boss of the drive face with a nul DRIVE FACE RAMP PLATE WEIGHT ROLLER AS SPEED INCREASES A the speed of engine increases centrifugal force on the weight rollers is also increased This pushes the movable drive lace tflwilrd The unit Ih ln acts with iI reduced drive ratio by allowing the drive belt 10 run on a pulley of greater...

Page 155: ...riven face spring is always exerted on the movable face to push it againstlhe driven face Therefore vhen engine s d is increased the driven pulley turns and the clulen connects 1ilutomatically The effective diameter of the drive pullev is increased The movable face is forced outward by means of the belt until an equilibrium is rnched bet ee the torque tension of the belt and force of the spring Wh...

Page 156: ... switch is turned On the indicator lamp will light and remain on lor several seconds signifying that the tamp IS nOt blown Con truction The sensor consists of an indicator lamp on the face of the fuel gauge dial The oil level sensor makes use of a float and a leed alve housed in a post The switch is normally open The float arm has a magnet thai slides over the post up and down as the float moves a...

Page 157: ... chafyed The curren energizes the exciter coil to close Ihe reed switch The mdicator lamp will then go on Meanwhile the condenser becomes fully charged within sel eral seconds after Ihe ignition switch has been turned on Since under such a condition curren is no longer drawn bv the condenser the exiter COIl is de energized As iii result Ihe leed SWitch is rurned off and the indicator tamp goes out...

Page 158: ... cap breather hole 2 Remove spark piug and WEAK OR NO SPARK III Fa llty plug wst spark 12 Fouled plug 3 Broken or shorted high tension wire GOOD SPARK 14 Open or shorted ignition coil 1 15 Faulty ignition switch 16 Foully C D 1 unit 171 Faulty alternator 3 Test cylindiH compression LOW COMPRESSION III Stuck pinon rings 12 FaUlty reed valve NORMAL COMPRESSION 131 Worn cylinder and piston rings I 4 ...

Page 159: ...toO lean ENGINE KNOCKS ENGINE OVERHEATS J Worn piston or cylinder 21 Mixture lOa lean 3 Incorrect or poor qualitv fuel 41 Excessive carbon in combustion chamber 5 Ignition timing tOO early Probable Cau e INCORRECT TIMING 1 Incorrect timing Haulty C D 1 unit or alternator ENGINE DOES NOT KNOCK 7 Rapidly accelerate or run It high SPl ltUS 1 Check ignition timif g ENGINE DOES NOT OVERHEAT J PlUG NOT ...

Page 160: ...TRICTED FUEl FLOW 1 Empty fuel tank 2 Clogged fuel tube or fuel filter 3 Clogged fuel tank cap breather holl l 4 Clogged fuel valve CLOGGEO 1 Cloggedjel Probable Cause From and rcar tirl pressures correct 1 Steering stem nut too tight 2 Damaged steering stem bearings STEERS TO ONE SIDE OR DOES NOT TRACK STRAIGHT Check d p u 1 HARD STEERING I 2 FRONTfR REAR WHEEL WOBBLING III Worn or loose wheel be...

Page 161: ...rter switch 2 Broken or shorted starter relay 3 loose connector or terminal 1 Worn brushes 2 Broken o shorted rotor wind ings 3 Broken starter moror Wire 4 Loose terminal MOTOR ROTATES SLUGGISHLY OR FAI LS TO CRANK ENGINE Check battery circuit by operating turn signals SIGNALS DIM REMAINED _ ON OR NOT OPERATED AT ALL Probable Cause 1 Deildbattery SIGNALS OPERATED PROPEALY I 2 Connec1 starter motor...

Page 162: ...nnected terminal CORRin 4 Remove oil level sensor and check operation Float up Lamp off Flat down lamp on CORRECT INCORRECT INCORRECT ll Loose or disconnected terminal l2 Broken wire harness 3 Incorrect COnnection _ 1 Stuck float 2 Broken or shorted balancing Coils INDICATOR LAMP REMAINS ON WITH SUFFICIENT OILIN OIL TANK IGNITION SWITCH ONI 1 Check for loose disconnected or improperly connected te...

Page 163: ...WIRING DIAGRAM 16 I Jl E J l y Sl AA I L IX r r I I L L R nfffiUf r cnT iiS G ltll li 0 10lGl 1 COllHi l IIUJl IUFl I SlG tIL IM o n l tp nu U auK LlOO lOo EEII _ It 0030Z GCl 6700 16 1 ...

Page 164: ...j rL l I ttF 0 1 gf o I _ill PL J J nE g f MSl nxl 1 lJV im 1ilG l GUM IOCA1 lR lm liij O PllESSUI E L1GlT lM t ll l s ll lJm P llJij _ ENGII STt SWlrCil I TtJlH SGW L S1l ITOl OlMMEIl 110 HORN SlillTCH I e e i I 10 f0 e BAli aATZ 10 0 T 10 Dale of Issue Nov 1981 HONDA MOTOR CO l TO 169 ...

Page 165: ...WIRING DIAGRAM NU50M SWlto COla n BATl aut G 00 In fa CF 16 2 L F IN i rO L IV ...

Page 166: ...072974 07916 1870001 lock Nut Wrench Remove and install the dnven pulley nul APPLICABILITY DESCRIPTION GENERATOR HIC TOOL NUMBER 1072982 107933 1550002 I Flywl1eel Pulfer I Flywheel removal TRANSMISSION CRANKSHAFT HfC TOOL NUMBER DESCRIPTION APPLICABILITY 0753509 07746 0010100 AtTachment 32 x 35 mm To Install transmISSIOn cover beanng 6202 anc I left crankcase bearmg 6201 0753491 07746 0010200 Ana...

Page 167: ...00 I Driver WHEEL BRAKE Hie TOOL NUMBER DESCRIPTION CONVENIENCE TOOLS The following tools arc supplied by American Honda but nrc not required tools for this model Hie TOOL NUMBER DESCRIPTION APPLICABILITY 1099456 07967 GA70000 Rear Shock Absorber Rear shock absorber dis assembly_ Compressor Altachment 0688168 07959 3290001 Rear Shock Absorber Rear shock absorber dis assembly Compressor SPECIAL INF...

Page 168: ... NOT THREADED I I 7 mm NOT THREADED 6mm THREADED o o mm THREADED o 7mm NOT THREADeD O mm THREADeD Drill an 8 mrn Stu 0 hole her 00 not th sad j 9 ACIL_ __ L THREADED 32 5mm r I I I I I I I I l 8 Smm An 8 x 58 mm bolt is used in the new hole with an 8 mnl nut to disassemble either the NU50 or the NX50 crankcases i AmcriC ln Honda Motor Co loc 1982 AU Rights Reserved 3 OF 3 ...

Page 169: ... b l1h ry Imy the sp lccr is siher o lln d tnd about 4 mill lhick by 65 mm long If the sl lca has already 11 im l illcu no further work is rC4uircd If the spaca baSil been installed perform the stl PS described bclo INSTALLATION J Remow the battery cover 2 Disconnect the battcry ca bles negative cablc first then positive cable 3 Rt movc the bauery 4 Remove and discard the bxl6 mm ballery tray moun...

Page 170: ...d motorcycles that He still in sIock mUSl be updated before release to customers PARTS INFORMATION Baltery Tray Sp lcer Bolt 6 20 mm 2 req d Hie 1 11935 HI C 074656 PIN 3l512 GCI OOO PI N 93494 06020 00 WARRANTY INFORMATION For ing c mOlOrcycfc claims usc Warranty Claim form V02 for multiple cl lims use 04 Use defect code 449 wilh a time of 0 2 hours per motorcycle AMERICAN HONOA MOTOR CO INC SERV...

Page 171: ...hl rcplacl ll1Clll of the lIluffler pacer and various fl laled ra tencrs Honda Motor Co LTD has determined thai a de fcc which relates to 1110lor whick art ty exist in Ihe air cleaner brackel on eCI l in Honda lllotor cks rh air cleaner br tckcl which l1 Cl r c as Ihe tront j1JOllll1 It l lhl rcar co kr m I i rack dlle to l nginc vibration If cr lcking 1l ur tlh fender ill makl a retlliing noi l b...

Page 172: ...TORCYCLES IN DEALER INVENTORY I 1 l i1 10 mill ll h l 10 relllfne Ihe air clt aner IIltlullIin l 1h llwll rt lllO e Ille air clCalll r BRACKET REPLACEMENT PROCEDURE A ll l led nWHHl Yl ks Ihal are 1111 in wc Ih lher nc nl uscd mu l have Ihl old l Ie brllcl cl or all crrlch d 11 1 11 ror lckcl and n l ued fa lcner rcpl li cd before rt lca c OeU llllllt I Do nnt rcka c an Ilwlorcy e 4uippcd ilh Ihc ...

Page 173: ...Y 1983 PARTS INFORMATION uhrnil 1 I lliar paJt llJ kr I the tjll l 111 tl pi it hrach I rCtjuirl d Ih J kl I VI 1 Unling Kit illl lud c Ihe fnlinw If g p lI l hl H kt sliffent tifknt h l1 O 111111 jor r ill knd l lifklll J hill mill ilH ranl e hC Ilwr tkr sp t1 r l11 J III III f1cl P l r bollS 60 I1Hll II 14 14742 1 I 72 1 iCI 1 OO S it Ckalll r Bracket l c i1ry II C 125KY2 P 17211 1 010 52 1ll WA...

Page 174: ...d el lIloullllng ll unl ALL PARTS ARE NEW UNLESS OTHERWISE NOTED J N 6 s 771 L t t W 6 JLTC 1 u C o c o l K r lhl rl IlH1 I rail in l l l rJOInn l1h Ian tl lld lrralll rrllcl dllll AMERICAN HONDA MOTOR CO INC 5f RVICE OEPAfHMENT 4 OF 4 ...