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    A. Honda CT90 - CT110 78-82 FACTORY SHOP MANUAL PDF

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    A. Honda CT90 - CT110 78-82 FACTORY SHOP MANUAL PDF

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    Zavier Dentith
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    A. Honda CT90- CT110 78-82 FACTORY SHOP MANUAL .pdf

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    A. Honda CT90 - CT110 78-82 FACTORY SHOP MANUAL PDF

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    Zavier Dentith

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    © All Rights Reserved
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    CTso ’77-’79 CT110’80-’82 Thank you for your patronage. This CD was purchased from @home backup. If it was purchased or obtained by any other means, you have illegally obtained this CD and are in violation of it copyrights. Report copyright violations to: @home backup Attn: Manual Backups 2902 Grasmere St. Garland, TX 75040 Unauthorized duplication or distribution is strictly prohibited. Copyright © 2001 @home backup. All Rights Reserved. Designated trademarks and brands are the property of their respective owners. 2 HONDA CT90-110 INTRODUCTION ‘This shop manual contains service information and procedures for 1977 through 1979 CT90's and 1980 through 1982 Honda CT110's. Motorcycles manufactured after December 31, 1977 are equipped with emission controls. These are covered in this shop manual, in Section Vil (‘78% EMISSIONS ADDENDUM, CT110 service information begins on page 141, ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE, AND WITHOUT INCURRING ANY OBLIGATION WHATEVER | NO PART OF THIS PUBLICATION MAY BE REPRO- DUCED WITHOUT WRITTEN PERMISSION. HONDA MOTOR CO., LTD. Service Publications Office Date of Issue: Mar., 1982 (HONDA MOTOR CO., LTD. HONDA CT90-110 1 SPECIFICATIONS. . 3 I SERVICE INFORMATION 1, SERVICE DATA ....... 5 2. TORQUE SPECIFICATIONS 7 3. SPECIAL TOOLS 8 4, LUBRICATION POINTS 8 5. WIRING DIAGRAM . : 10 6. TROUBLE SHOOTING CHART " 7. MAINTENANCE SCHEDULE 20 IIL INSPECTION/ADJUSTMENT . IV ENGINE |. ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVES CYLINDER/PISTON LUBRICATION SYSTEM : 56 CLUTCH/GEAR SHIFT/OIL PUMP te soo 87 5. AUXILIARY TRANSMISSION : - 65 A.C. GENERATOR/CAM CHAIN TENSIONER seeeeeeeen es) ‘TRANSMISSION /CRANKSHAFT/KICK STARTER covet eceteeeeeeee TH CARBURETOR ....... Seen ee eee eee eee een Ze) 36 38 50 Vv FRAME 1, FRONT WHEEL/FRONT SUSPENSION/STEERING 2, REAR WHEEL/REAR SUSPENSION. 3. TAIL LIGHT/FUEL TANK 4, WIRING . £sse VI ELECTRICAL 1. BATTERY CHARGING SYSTEM oor cee covet eeete cere s 99 2. IGNITION SYSTEM 103 3. SWITCHES 106 VII_'78% EMISSIONS ADDENDUM - - + 109 VIIL ‘79 ADDENDUM: 137 IX 80 CT110 ADDENDUM «+++ 2-5 02-50ee sree mT X '81CT110 ADDENDUM XI 82 CT110 ADDENDUM . “an oe 185 Date of Issue: Mar., 1982 HONDA MOTOR CO., LTD. I SPECIFICATIONS Front Suspension, Travel Rear Suspension, Travel Front Tire Size, Type Rear Tire Size, Type Front Brake Rear Brake Fuel Capacity Fuel Reserve Capacity Auxiliary Fuel Tank Capacity Caster Angle Taal Length Front Fork Oil Capacity = Speciation DIMENSION Overall Length e70mm (738%) Overt ah Tom (201 in) Ove Hehe 060mm (a7 in) | Wea! Be 220mm (480m) ara 75mm (308 in Ground esas osm (85m) Dry Weight 90 kg (198.5 Ib.) FRAME Tipe dak bene Telescopic fork, 102 mm (4.0 in} Swing arm, 77 mm (3.0 in) 2.75-17-4PR Knobby, tire air pressure 1.76 kg/cm? (25 psi) 2.75174 PR Knobby, tire air pressure 2.25 kg/em? (32 psi) Internal expanding shoes Internal expanding shoes 6.5 lit (14US. gal. 1.21 Imp. gal.) os tit (0.2US.gal. 0.18 Imp. gal) 233i. (0.6US. gal. 0.84 Imp. gal) 63" 75mm — (Bin) 125-135 cc (4.24.6 02s.) To fill dry fork assembly 180-140 ce (4.4 -4.7 02.) To refill after draining 120- 130.e¢ (4.1 -4.4 02.) ENGINE Type Cylinder Arrangement Bore and Stroke Displacement Compression Ratio Carburetor, Venturi Dia. Valve tr i Capacity Lubrication System Fuel Required Alc Filtration Air cooled 4-stroke OH.C. engine Single cylinder 75. inclined from vertial 50 x 45.6 mm (1.970 x 1.797 in) 89.5cc (5.46 cu in) B2:1 Piston valve type, venturi dia. 16 mm (0.64 in) (Chain driven over head camshaft O9 it, (0.95US.qt. 0.80 Imp. at.) Forced pressure and wet sump | Low-lead oF regular gasoline of 91 research octane (86 pump octane) or higher Oiled polyurethane foam filter Date of Issue: Oct., 1977 © HONDA MOTOR CO., LTD. SPECIFICATIONS i 1 k9 (1978) model toms Specifications Intake Valve = Opens =» eme Closes 20° ABDC. Exhaust Valve: Opens 25° BBDC Closes 8° ATOC Valve Clearance IN/EX. 0.05 mm (0,002 in) Engine Dry Weight 24 kg 629 1b) Air Screw Opening 1 Pilot Screw Opening 1a Idle Speed 1,300 rpm DRIVE TRAIN Clutch Wet multi plate automatic ‘Transmission 4-speed constant mesh Primary Reduction 3.722 Gear Ratio 1 2538 " 1.611 m 1.190 wv 0.958 Auxiliary Transmission High/Low 1.000 / 1.867 Final Reduction Gear Shift Pattern Left foot operated return system 3,000, drive sprocket 15 T, driven sprocket 457 ELECTRICAL Ignition Ignition Advance mark Max. advance Starting System Alternator Battery Capacity Fuse Capacity Spark Plug Condenser Capacity Battery and ignition coil 1,300 rpm 10° Toc 26° - 32° Kick starter AC Generator BV — 55 AH 18 amp. USA, model D8HA (NGK), X24FS-U (ND) Canada mode! 0.27 -0.334F DR8HS (NGK), X24FSR-U (ND) (0.062 kw/6,000 rpm Date of Issue: Oct., 197 © HONDA MOTOR CO.,LTD. Il SERVICE INFORMATION € HONDA crso 1.SERVICE DATA enone Unit mm find tem Seviee Limit 50.10 (19728) Cylinder | Taper 0.05 (0.002) [outofround (0— 0.0004) 0.05 (0.002) Piston 0. D. 49.97-49.99 (1.9673 — 1.9681) | 49.80 (1.9606) Piston pin I. D. 14.002—14.008 (0.5513 — 0.5515) | 14.04 (0.5528) Piston pin O. D, 13,994—14,000 (0.5509 — 0.5512) | 13.960 (0.5496) : Tophsecond 018-035 (0.006 0.014) | 0.60 (0.020) —] uiiston 110d one S20 Oil 0.15-0. (0.006 — 0.016) | 0.50 (0.020) Paton tein ring lear | Toneond 0010-0088 waoot -o00te) 12 Wx047 oi .010-0.045 (0.0004 0.0018) | 0.12 (0.0047) itn rng Wickes 1.17521.190 (60465 ~ 0.0469) | 1.130 (0.0445) 2475-2490 (0.0074 ~ 0.0900) | 248 (0357 ve sumo. Bas6-2408 (02140-02182) | 545 102100) | _ sas5-s.aas (0.2140 ~0.2148) | 5416 (02132) Va ge 3. Savooe.s 02167 -02T61) | eaze WAIT I, 0.010-0.030 (0.0004 — 0.0012) | 0.08 (0.0032) Vave ovale guide clearance 10800050 (0.0072 0.0020) | 0.100020) src uth (1262) 306 (1208) Valve spring __ (1.043) 255 (1.004) Prod Out al Won (a8 462170578 - [nner kg/mm (ibsJin.) | 9.5-10.5/18.4 _(209-23.1/0.724) = Valve face width IN/EX 12-15, (0.048 — 0.060) 1.8 (0.072) Vale sot with inex io ‘aoe is 088) am heiaht IN/EX 24.90-2488 (0.9803 0.9855) (0.9686) eon RL End 17.927-17.938 (0.7058 — 0.7062) (0.7047) | Cent ZE.S17 = 25900 (1.0204 = 10200) | 2590-0167) Camshaft end bearing |. D. R. End 18,000-18,018 (0.7087 — 0.7094) | 18.05 (0.7106) : Lend e.000=26.020 (1.0238 — 10248) | 260510266) [ewer 28-28 (0.12 0.1142) | 24 (004) Clutch pat thicknes 8-207 (0.0780 0.0818) (0.0728) Cth plate worn 02 008) “002 | 27.0 (1.0630) (1.0236) Clutch spring 10-10.4/15 (22~22.9/0.591) —— Crankshaft run out {at ends) - 00.015 (0-0.0008) | 0.10 (0.0040) Ganka onion y aio-035 (0004-0010) | 08 (0022) | 8-001 @.= oaa0e) | 005 aon) Connecting od sand 1D ta.012-14.028 (05617-08823) | 14060105531) Connecting rod big end side clearance 7 0.10-0.35 (0.004—0.019) | 0.8 (0.032) Gamecing od bigendredalsewerce =| 0-a01 (008004) | eas (0.021 Ctuch ve ger. 2400-2402 08440-09487) | 24:15 09808) Clutch center guide 0.0 22.0-22.1 (0.8661 — 0.8701) | 21.85 (0.8602) Clutch era ude wero coro ‘005-0087 ©0002 —00018)| 0.18 (0.0060) Date of Isue: Oct. 1977 © HONDA MOTOR CO., LTD. € HONDA SERVICE DATA cTs0 a . < 7 tem Standard Service Limit Rocker arm shaft 0. D._ 9972-9987 (0.3026 ~ 0.3032) | 992 (0.3906) Rocker arm 1D. "10.000—10.015 (0.3037 — 0.3043) | 10.10 (0.3976) [Primary drive gear 1B | 2a00-24.02 (045 — 0.946) | 24.15 0.951) Crankshaft toclutch center guide clearance (0.005~0.047 (0.0002 - 0.0019) | 0.15 10.060) ‘Tensioner spring free length | SPring A 65 (2.6) 60_ (2.4) | rina treet Spring BS 408 (1992) 4018) {nner t-auter rotor 0.15 (0.008) 0.2 (0.008) Oil pump Cuter rotortobody 1 9.15-0.20 (0.0060 0.0080) | 0.25 (0.010) Roterto-cover 0.02-0.07 (0.0008 ~0.0028) | 0.12 (1.0047) Shift fork 1.0. | 42.00 (1.6535) 42.1 (1.6575) Shift fork ends thickness ~|596-604 (0.2246 -02978) | 5.70 (0.2244) Shiftaru 41.950~61.975 (1.6516 — 1.6526) | 41.80 (1.6457) Shite du 61-62 (0.2402-0.2441) | 6.4 (0.2520) [Shit forkctosif rum clearance 005 (0.0020) (02 (0.008) ‘auniry wanamision Idler guar shaft 0.0. | 12.966—72.984 (05105-05172) | 12.85 (05140) Y ‘o Idler gear I. D. 13,000-13.018 (0.5200 — 0.5207) | 13.10 (0.5157) FRAME tem ‘Standard | Service Limit Front/rear axle shoft bend 0-005 (0-002) | 0.2 (0.008) _| onstarwea bearing ty |*2E LC 8 (-0.002) | 0.1 ‘ont/rear wheel bearing Play | Ragiat 0.003-0.008 {0.0001 — 0.0003) | 0.04 (9.0016) ~Frontiear brake drum IO. 1100 (4.3307) 1110 (4.370) i Face enout [0-05 -002) 10 (0.04) [eee “0-05 (00.02) (0.04) [Front fork spring 208 (i EZ “Rear shock absorber spring 223 (8.78) 207 (8.16) Front fork piston 0.0. ~[ Boies0-2007% (1210-1220) | 9086 (1.216) [Front fork bottom ease. 31,000-31.089 (1.221 = 1.223) | 31.10 (1.225) Brake lining thicknese 40 (0.16) 20 (0.08) Date of Issue: Oct., 1977 © HONDA MOTOR CO.,LTD. cT90 2. TORQUE SPECIFICATIONS ENGINE 7 - Tightening point _oty Thread ia, | Torque kgm (lbs ft) Cylinder head nut 4 8 | 20-25 (145-181) Camshaft sprocket bolt 2 6 [09-12 (65-87) Cam chain guide rller bolt 1 6 | 09-14 (65-101) [Spark advancer bott 1 6 | 08-12 (58-87) | Guuteh feck nut -_ 1 16 | 38-45 (274~325) [A.C. generator rotor bolt 1 a | 26-32 (188-232) "A.C. generator stator bolt 3 6 08-12 (58- 87) Shift drum bolt 7 6 | oe-12 (58-87) FRAME 7 Tightening point ary Thread dia. | Torque kgm (Ibs) Handlebars setting botts + 6 2-12 (58- an | Steering stem nut 4 | 60-70 _(43.4—50.7) Front fork bolt 2 10 | 35-45 (253-326) ‘Steering bottom bridge bolt 2 8 18-25 —(13.0- 18.1) | Swingarm pivot bolt 1 10 0-60 (28.0 43.4) Fear shock absorber upper nut [2 10 535 (18.1~25.3) Rear shock absorber lower nut 2 8 5-35 (18.1 25.3) Front axle nut 1 10 (25.3 36.2) ear axle nut _ 1 10 55.0 (253 96.2) Rear axle sleeve nut 1 16 | 35-45 (253-326) Driven sprocket bolt 4 8 | 18-25 130-18.) Rear brake stop arm BOR : 2 3 [18-25 130-18.1)_ Engine hanger bolt 2 10 | 30-40 (217-29.0) ‘Step bar bolt - 4 8 18-25 (13.0- 18.1) ‘Torque specifications listed above ar below. Standard Torque Specifications important tightening points. Others should be tightened to standard torque Type Torque kg-m (Ibs-ft) Type Torque kg-m (Ibs-ft) Smmboltandnut | 048-060 (33-43) | Smmscrew 035-050 (25~ 36) Gmmboltandnut | 08 —1.2 (68-87) | Smmscrow 07-11 (81-80) mm bolt and nut | 1.8 —25 — (13,0—18.1) | Gmmflange boltand nut | 1.0 ~ 1.4 ( 7.2—10.1) 10mm bolt andrut | 30 —4.0 — (21.7-29.0) | 8mmtiangebolt end nut | 24 —30 (17.4—21.7) 12mmboltandnut | 5.0 —6.0 —(96.2—43.4) | 10 mm flange bolt and nut | 30 —4.0 (21.7 ~ 290) Date of Issue: Oct.,.1977 © HONDA MOTOR CO., LTD. 3.SPECIAL TOOLS HONDA cTso Faraiapee at ji 36mm pin spanner (07902 — 0010000 86 ‘Tappet adjusting wrench 07908 — 0010000 24 ‘Steering stem nut wrench | 07915 — 0300000 86 Tard ana tras a [clutch outer holder (07932 — 0340000 58 Rotor puller — (07933 — 2160000 =) | Valve guide driver 7 07942 — 3290100 42 Valve guide driver - - 07942 — 1180100 42 Valve spring compressor 07957 — 3290001 a Orso a - 07949 — 3000000 85,91 Bearing driver attachment _ 07945 — 0980000 85,91 Bearing driver | (07949 — 6110000 _ 92 Bearing driver attachment 07945 — 3330100 92 a So a ——| prea ee a Oil seal guide — (07974 — 1280000 43 | Se mesa a Spring holder 7 07967 — 1150100 93 Date of Issue: Oct., 1977 © HONDA MOTOR CO.,LTD. BRAKE CAM Ga Date of lise: Oct, 1977 © HONDA MOTOR CO.,LTD. 9 5.WIRING DIAGRAM BE | re SER TUR SoM etn) & 3 3 5 iby i i i . 10 Date of Ise: Oct., 1977 © HONDA MOTOR CO.,LTD. 6. TROUBLE SHOOTING CHART ‘A. ENGINE WILL NOT START (OR HARD STARTING) RESULT Gatoline does not Gasoline reaches 1 reach carburetor carburetor CHECK OR ADJUS- ‘TMENT ! Check if gasoline reaches carburetor bby turning drain pl (NOTE) Use a con: ‘tainer to receive the drained gasoline it | 2| Spark occurs 'No spark occurs Weak spark a ——1 ‘Compression. leak oF no com- pression + Compression normal Remove spark plug | and try spark test Engine fires but does not start eH 5 | Spark plugnot Spark plug wet a wet Cc 2) Lia) POSSIBLE CAUSE Lack of fuel in fuel tank Clogged fuel line between fuel tank and carburetor Clogged fuel cock Clogged fuel tank cap breather hole Faulty spark plug Fouled spark plug Fouled, burnt or pitted contact breaker points Improper breaker point gap Faulty condenser Broken or shorted high tension cord Open or shorted ignition coil Faulty ignition switch Improper ignition timing Engine not cranked (clutch slipping) No valve clearance Valve stuck open ‘Worn cylinder and piston rings Blown cylinder head gasket Flaw in cylinder head Improper valve Choke valve excessively open Carburetor air screw opened e cessively Air leaking through intake manifold Improper igni Flooded carburetor Choke valve closed excessively Throttle valve opened excessively Date of Issue: Oct., 1977 © HONDA MOTOR CO.,LTD. 11 TROUBLESHOOTING CHART B. ENGINE LACKS POWER (AUX. TRANSMISSION OPERATES PROPERLY) RESULT CHECK OR AD- POSSIBLE CAUSE SUSTHENT ° a —— fais ves of j “ground and sin by — Brake craig 7 Faulty whet beating [wetspin rey Drive cain oo tht ee. Over itened ace nt 2 ioe L we ire Pres (2) Faulty tire valve ~ | ration from low to sooo eon with tp: —_ Bing on charee 9) cute sping pa rere Worn eh ace | peclraed || wit ngine seed (8) hrc pat ureven rise) cecccccesssny [8 Worm uth wight ~-£ frvupgedvaty, | E15) Clutch sping weakened 1 (1) Carburetor choked 4 ane (2) Air cleaner clogged iu posses + (8) Clogged fuel fine 5 nec inition | (a) Gonped brat ole in ful ak xp + timing { LW) Clogged mutfier Tanning]. Taope anon ee asa eee (1 taniton unin imroper — eck toot [ ¢ | Tappet clearance | [ Improper tappet (1) Improper valve clearance reveal | ctosrence Fi 1 § (2) Worn valve seat (valve not seating on scree __] | aernee __]. pg ctr com> | Sate Soe seeee pret (th em 1 (1) Valve stuck open | Compression) [,oss of compression} — fe Worn eylinder and piston rings real [os of compre (3) own evlindr hed ett —— (4) Improper valve timing 12 Date of Issue: Oct., 1977 © HONDA MOTOR CO., LTD. TROUBLESHOOTING CHART 10 " 12 13 lug fouled or discolored Engine il level proper Improper level or fouled oil ‘Lubricated pro: | perly ‘head hold-down cap 1 and check for tubri- Remove spark plug! jemove oylind nut (copper washer) cation a Engine does not knock Engine knocks a @) @ cy 2) a 2) @) a) a (2) @) 4) 6) Not serviced frequently enough Not serviced frequently enough Improper heat-ange Level too high Level too low Oil excessively fouled Clogged oil passage Poor delivery of oil pump Excessive carbon in combustion ‘chamber Wrong or bad fuel Cluteh slipping Mixture too lean Worn piston and cylinder Mixture too lean Wrong or bad fuel Excessive carbon in combustion chamber Ignition timing too early Date of Issue: Oct., 1977 © HONDA MOTOR CO., LTD. 13 TROUBLESHOOTING CHART . ROUGH IDLE OR POOR LOW SPEED PERFORMANCE (CARBURETOR IS. CORRECTLY JETTED FOR LOCAL ALTITUDE.) RESULT CHECK OR ADJUST- timing and valve iy a ‘check carburetor air} Adjusted properly ‘Adjusted ~ L incorrectly =|, past carburetor ——— Remove spark plug and try spark test [ — aking Air leaking Co) Weak or inter= itent spark | Good spark occurs L L POSSIBLE CAUSE Engine out of time Improper valve clearance Mixture too lean or too rich Faulty carburetor gasket Carburetor not tightened securely Faulty intake pipe gasket Deteriorated carburetor O-ring Faulty or fouled plug Fouled, roughened or pitted breaker point surface Condenser shorted Faulty ignition coi 14 Date of Issue: Oct., 1977 © HONDA MOTOR CO.,LTD. HONDA crTso TROUBLESHOOTING CHART D. ENGINE LACKS HIGH SPEED PERFORMANCE CHECK OR ADJUST- POSSIBLE CAUSE RESULT ear Cheek ignition} kK =—-{ timing and valve | | tappet clearance = 7 a oa if (1) Engine out of time 1 [Correct Wrong =, (2) Improper valve clearance | Disconnect fuel tube | “at carburetor and No fuel in tank: 2 | Fuelflowing | [No fuel flowing Fuel tube clogged |_ out out 1 Fuel tank cap breather hole I | ful valve and car | clogged buretor jet for clog: | = Clogged jot 3 [Not clogged Glogned Clogged fue iter - - 5 a Clogged fuel valve 5 Replace carburetor | a fa sere main jet i Condition aap (1) Size too small 41 ravated {2) If improved with smaller size et: i 4) Air cleaner clogged bb) Choke plate not opened fully (1) Improper valve timing “F check valve spring | + tension i (1) Faulty valve spring Date of Issue: Qct., 1977 15 © HONDA MOTOR CO., LTD. TROUBLESHOOTING CHART E, SMOKY EXHAUST RESULT CHECK OR ADJUST- MENT Make fong runs at speed - (1) ~— @) 1 | No smoke emitted 3) a) Return throttle 6) 2|INo smoke emitted rpauiety | [White smoke emit. ted immediately af ter returning throttle rio r Make long runs st lowspecs — — a 3[No smoke omit] [witesmoke} | ® h F, DEFECTIVE CLUTCH RESULT CHECK OR ADJUST- MENT ‘Adjust clutch pro- erly i (1) Weak clutch spring POSSIBLE CAUSE Worn eylinder and piston rings Oil level too high Piston rings installed upside down Faulty piston or cylinder Flaws in cylinder head Worn inlet valve guide or valve stern Valve guide O-ring not seated properly Worn exhaust valve stem and valve guide Exhaust valve guide not seated proper- v Worn exhaust valve stem seal POSSIBLE CAUSE (2) Worn or distorted clutch plate (3) Worn or distorted friction dise (4) Worn clutch weight eneinger wntepoal ad ont i Motorcycle tends to creep. (1) Distorted clutch plate or friction dise (2) Uneven clutch spring tension > Date of Issue: Qet., 1977 © HONDA MOTOR CO.,LTD. 16 HONDA cT90 TROUBLESHOOTING CHART G. HARD SHI IETING ‘COMPLAINT == (Clute normal) a 2) Hard shifting 8 a) Gears jumping out of position during operation |} + (6) - 6) ra 2) ra 2) @) ENGINE NOISE COMPLAINT ‘Tappet noise Piston slap Cam chain noise Clutch noise Drive and driven gear noise w 2 POSSIBLE CAUSE Gearshift arm spring broken Shift fork broken Sluggish movement of shift drum and shift fork ‘Transmission gear dog chipped or broken Shift arm pawl coming out of shift drum pin Improper setting stopper plate and stopper Broken shift return spring ‘Shift shaft interferring with case or cover Worn or broken shift fork guide pin Bent or worn shift fork Broken or weakened shift drum stopper spring POSSIBLE CAUSE Excessive valve clearance Worn tappet Worn piston and cylinder Excessive carbon in combustion chamber ‘Worn piston pin and connecting rod small end Worn camshaft bearing Worn camshaft sprocket teeth Excessively elongated cam chain Excessive backlash betwet outer Weakened clutch spring ‘clutch plate and clutch Worn or deteriorated driven gear damper Worn gear teeth Date of Issue: Oct 1977 © HONDA MOTOR CO., LTD. 17 TROUBLESHOOTING CHART I, MOTORCYCLE PULLED TO ONE SIDE COMPLAINT (Front and rear tire pressures are normal) Hard steering in both directions Wheel wobbling Motorcycle tends to be pulled only to one side Ht J. FAULTY FRONT AND REAR SHOCK ABSORBERS COMPLAINT = (Front and rear tires properly inflated) Soft ride Hard ride = pene Noise in suspension a @) a @) @) a 6 a @) @), a) a 2) 3) a a (2) 8) o (2 @ POSSIBLE CAUSE ‘Steering head top thread nut excessively tightened Broken steering steel balls Bent steering stem Excessive play in wheel bearing Distorted wheel rim Loose spokes Twisted frame Drive chain adjuster not adjusted equally Unbalanced front and rear shock absorbers Front and rear wheels out of line Bent front fork Bent rear fork POSSIBLE CAUSE Weakened spring Excessive load Lack of ol in front fork. Oil teak Faulty front fork Faulty rear shock absorber Excessive oil in front fork Lack of olin front fork Faulty shock absorber stopper rubber Lack of olin shock absorber 18 Date of Issue: Oct., 1977 (© HONDA MOTOR CO., LTD. HONDA cTso TROUBLE SHOOTING CHART K, FAULTY BRAKE COMPLAINT POSSIBLE CAUSE ~ (Brakes are properly adjusted) (1), Worn brake lining [+ (2) Worn brake shoe cam }- (3) Worn brake cam L (a) Worn brake drum |-—{ Adjuster no longer effective (1) Worn brake shoe - (2) Foreign particles on brake lining ed L- (3) Roughened brake drum shoe contacting face (4) Worn brake panel bushing [ ines tae | Ff Ns orwawr ake L. PREMATURE ELONGATION OF DRIVE CHAIN ‘COMPLAINT POSSIBLE CAUSE — (1) Improper adjustment (2) Lack of lubricant (3) Worn sprocket Promature elongation of drive chain Date of fue: Oct, 1977 HONDA MOTOR CO.,LTD. 19 7.MAINTENANCE SCHEDULE 1977 (K8) model ‘This maintenance schedule is based upon average riding conditions. Machines subjected to severe use, or ridden in unusually dusty areas, require more frequent servicing, inTiaL | REGULAR SERVICE PERIOD SERVICE | Perform at every indicated month or mileage PERIOD interval, whichever occurs frst Month 1 3 6 2 Mile 1.500 | 8000 | 6,000 L _ Km 2500 | 5,000 | 10,000 | ENGINE OIL R R - | | CENTRIFUGAL OIL FILTER - c OIL FILTER SCREEN L a SPARK PLUG 1 ‘CONTACT BREAKER POINT IGNITION TIMING. VALVE CLEARANCE [CAM CHAIN TENSION [Tt POLYURETHANE FOAM AIR FILTER | (service more frequently c ELEMENT. if operated in dusty areas, [CARBURETOR 1 [THROTTLE OPERATION FUEL FILTER SCREEN FUELLINES ‘CLUTCH [1 DRIVE CHAIN wiac | fee BRAKE SHOES T BRAKE CONTROL LINKAGE o _WHEEL RIMS _ 1 TIRES 1 FRONTFORK OIL ora | FRONT Al REAR FORK BUSHING jt STEERING HEAD BEARINGS | SIDE STAND BATTERY 1 t LIGHTING EQUIPMENT T 1 NUTS, BOLTS ( TIGHTEN ) 1 1 {| - -lol-|-|- |~ Inspection, clean, adjust or replace if necessary. “RReplace C-Clen—_L—Lubricate "Initial service period 200 miles. *** Initial service period 1,500 miles. 20 Date of Ise. Oct, 197 © HONDA MOTOR CO., LTD. MAINTENANCE SCHEDULE WHICHEVER + ODOMETER READING [NOTE (2)] ‘comes [<> | FIRST / / / / 1 800 mi. /2400 {4800 mi. /1200 mi. EVERY (1000km) _//(4000km)_/ (8000km)_/(12000km) REPLACE EVERY ENGINE OIL, YEAR Rg 1200. (200k ENGINE OIL FILTER ROTOR | | i ENGINE OIL FILTER SCREEN [AIR CLEANER T nore) | + FUEL LINES | [SPARK PLUG. + VALVE CLEARANCE 1 * CONTACT BREAKER POINTS 1 = IGNITION TIMING 1 [CAM CHAIN TENSION A 1 ' ITEM “THROTTLE OPERATION = CARBURETOR IDLE SPEED = CARBURETOR CHOKE L U i "INSPECT EVERY {600mi. (1000 km) t Sarecrant [roreor | BATTERY ELECTROLYTE | MONTH BRAKE SHOE WEAR - “BRAKE FREE PLAY — i BRAKE LIGHT SWITCH i |S HEADLIGHT AIM 1 [SIDE STAND ~ cures i = SUSPENSION i 7 SPARK ARAESTOR — = NUTS, BOLTS, FASTENERS i WHEELS/SPOKES i =+ STEERING HEAD BEARING i 1. 1 1 IL C t C c T t |: INSPECTION, CLEAN, ADJUST, OR REPLACE IF NECESSARY. c: CLEAN R: REPLACE A: ADJUST ++IN| THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED HONDA DEALER. + SHOULD BE SERVICE BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED. NOTES (1) More frequent service may be required when riding in dusty areas. (2) For higher odometer readings, repeat at the frequency interval established here. (3) Initial service period 200 mites. Date of Issue. Oet., 1977 © HONDA MOTOR CO., LTD. a Il INSPECTION/ADJUSTMENT © CONTACT BREAKER POINT GAP INSPECTION + Remove the point and generator covers. ADJUSTMENT NOTE __ _ Contact breaker point gap must be adjusted before the ignition timing adjustment is performed. POINT GAP. 0.30.4 mm (0.012.0.16 in.) LOCKING SCREW HONDA cTs0 (1) Rotate the A.C. generator counterlockwise to find the position where the point gap is at ma: (2) Check the point gap with wire gauge. POINT GAP, 0.3.0.4 mm ( *+ When adjustment is necessary, observe the following (1) Rotate the A. C. generator rotor counterclock- ‘wise to find the position where the point gap is at maximum, (2) Loosen the contact breaker plate locking screws and move the contact breaker plate to achieve correct sap. (3) When properly adjusted, retighten the locking NOTE pee Tot allow the plate to move when tightening the | locking screws. (4) Rotate the A.C. generator rotor soveral times recheck the breaker point gap. If the gap is incor- rect, repeat the steps (1) thru (4) above. 22 Date of Issue: Qet., 197 © HONDA MOTOR CO., LTD. HONDA cTs0 © IGNITION TIMING Do not perform this operation until point gap has been adjusted. Static test (with a use of test lamp) CAUTION Use caution when adjusting the timing not to touch ‘the points with a screwal LOCKING scREW Dynamic test (with a use of stroboscopic light) Wake the connections as described in the booklet fur- 1d with the service tester. INSPECTION/ ADJUSTMENT (1), Remove the point and generator covers. (2) Turn on the ignition switch. (3) Rotate the A.C. generator rotor slowly in the counterclockwise direction. (4) Align the “F"" mark on the rotor with the index: ‘mark on the stator on compression stroke, (6) The contact breaker points should just start to open when both marks align (the timing light should ‘come on). If the timing of the breaker point open: ing is incorrect, adjustment is made by loosening the base plate locking screws and carefully rotating the base plate until the light comes on. TO ADVANCE TIMING... .Rotate the base plate clockwise, TO RETARD TIMING. . . ..Rotate the base plate _____ counterclockwise. (6) Retighten the base plate locking screws securely, ex: ercising care not to allow the base plate to move. (7) Rotate the A.C. generator rotor several times and recheck the timing. If the moment of point opening is incorrect, repeat the steps (3) thru (7) above. ldling: 1300 «pm "MARK ALIGNED WITH INDEX MARK 2600 rpm “ADVANCE” MARKS ALIGNED WITH INDEX MARK ‘ADVANCE MARKS and INDEX MARK Date of Issue: Oct., 1977 (© HONDA MOTOR CO., LTD. 23 INSPECTION/ ADJUSTMENT © SPARK PLUG ee car { _ [807m —] Tz 024-0028 in) | 4 Check: threats + guskert — cheek + erack {To install, first thighten finger tight, then tighten with @ | spark plug wrench to compress the washer. * VALVE CLEARANCE et should be performed while the engine is cold, (1), Remove the tappet hole caps and generator cover VALVE CLEARANCE (IN, EX) (0.05 £0.02 mm (0.002 0.0008 in.) ‘ADJUSTING Locknut 7" mark and, (2) Rotate the A.C. generator rotor in the counterclock wise direction and align the “T” mark on the rotor with the index mark on the stator. Perform this operation with the cylinder at T.D.C. (top-dead-center) of the compression stroke, In this position, the intake and exhaust valves should be fully closed. = dire HONDA cTso To clean uso a plug cleaner 2p or steal wit deposit damage PLUG CLEANER. (3) Check the clearance of both valves by inserting a feeler gauge between the tappet adjusting screw and the valve stem, (4) Adjustment is made by loosening the tappet screw lock nut and turning the adjusting screw until there is slight drag on the feoler gauge. ‘TAPPET ADJUSTING WRENCH ‘NO. 07908-00100 if x mark Indes Hold the adjusting screw while the lock nut is being tightened, (6) Rotate the A.C. generator rotor several times and re: ‘check the clearance with the feeler gauge. 24 Date of Isue: Oct., 1977 © HONDA MOTOR CO., LTD. HONDA cT90 © IDLE SPEED AND MIXTURE Perform this operation while the engine is hot. | HROTTLE STOP SCREW © THROTTLE CABLE (1), Minor adjustment is made with the upper adjuster. THROTTLE GRIP FREE PLAY —[ 2-6mm (0.08-0.24 in) | upPER — ADJUSTER INCREASE PLAY INSPECTION/ ADJUSTMENT (1) With engine running at operating temperature, turn the throttle stop screw counterclockwise to obtain the lowest stable idle speed possible, ‘Turn the air serew (pilot screw on 1978 (K9 model) in either direction to find the setting that produces the highest idle speed obtainable without readjust ing the throttle stop screw. NOTE: If air/pilot screw adjustment causes idle speed to increase beyond 1300 rpm, turn the throt tle stop screw farther counterclockwise to lower the idle speed and repeat step 2. (2) (3) After air/pilot screw adjustment has been completed, adjust the throttle stop screw to achieve the speci fied idle speed of 1300 rpm. Open and close the throttle @ few times to verify proper throttle re sponse, prompt return to idle, and stable idle speed. [IDLE SPEED | 1300 rpm ll lee STANDARD AIR SCREW OPENING | 1977(k8) model = one | Tatura STANDARD PILOT SCREW OPENING | 1976/49) model (2) Major adjustment is made with the lower adjuster. + If adjustment is to be made with the lower adjuster, loosen the upper adjuster. + Make sure the rubber cap is tightened securely. | RUBBER CAP INCEASE PLAY LOWER ADJUSTER, DECREASE PLAY 7 Replace the throttle cable if both adjustments are no loge ear " | Date of Issue: Oct., 1977 (© HONDA MOTOR CO., LTD. 25 2\ HONDA INSPECTION/ ADJUSTMENT creo CAM CHAIN TENSIONER Perform this adjustment while the engine isi ing. | > (0 poroninaay 1 tum,_At is, techn shouldbe automatically Adjusted by force of the tensioner springs. (2) If the chain is still noisy, remove the tensioner plug and screw in the adjusting bolt 8 gradually until the ccam chain is no longer noisy. After completing adjustment tighten the adjusting bolt A, lock nut and plug. ZF vocknut —— ADJUSTING BOLT A ADJUSTING BOLT B TENSIONER PLUG 2.0.3.5 kgm (14.5.2 lbs ft) * AIR CLEANER CLEANING Gasoline or low flash point solvents are highly flam- [mee and must not be used to clean the air cleaner element. covER BAND (1) Remove the wing nut and loosen the band, an ann ‘ w the wing nut and loosen the band, and remove the cover and band. (2) Remove the stud and mounting plate. (3) Pull out the air cleaner element, ta wast neuzansowvenr —®! WalngouT (6) SOAK INGEAR OIL 7) SaUEEZE OUT AND sae 0-90 EXCESSIVE OIL 8 Date of isve:0et,1977 Stiosba woTOK CO, Lr HONDA cTs0 INSPECTION/ ADJUSTMENT © OIL FILTER CLEANING (1) Drain engine ol (2) Remove the kick pedal and right crankcase (3) Remove the clutch outer cover and clean the filter chamber with lintfree cloth. (4) Toclean the cil filter screen, pull the screen ‘out, and wash in clean solvent. OIL FILTER SCREEN © FUEL FILTER CLEANING (1) Turn the fuel valve to the “OFF” position. (2) Drain fuel from the carburetor by removing the drain screw. [After assembly, turn the FUEL valve to “ON” and | check for leaks. _| — FILTER SCREEN ‘Wash in clean solvent or blow off rt with compressed ar. Date of sue: Oct, 1977 © HONDA MOTOR CO.,LTD. 21 INSPECTION/ ADJUSTMENT HONDA cTs0 © ENGINE OIL Oil Level (1) Operate engine for approximately a few minutes, (2) Stop the engine, place the motorcycle on the center stand, (3) Check the oil level with the filler eap dipstick (4) To check the oil level, insort the dipstick, but do ‘not screw in. il level must be between the upper and lower level marks (6) If the level is low, fill with recommended grade oil to the upper level mark on the gauge. Drain the oil and pour fresh oil if the oil is contaminated, UPPER LEVEL MARK. LOWER LEVEL MARK. tinans onaIN pLus oi caraciry_ 20:35 kgm 0. it, (0.95 US a (14-250 te-4| | immed + cLuTcH oo 7 \ ‘ADJUSTING SCREW il Change (1) Remove the drain plug to drain oi from the engine. (2) Operate the kick starter pedal several times to drain all residual oil remaining in the crankcase. (3) Reinstall the drain plug and refill with fresh oil to the upper level mark. (4) Recheck the oil level. OIL SPECIFICATION Use Honda 4-stroke oil or equivalent, API service classification — SE Al tomp. — SAE 10 — 40 ‘Above 15°C (59°F) SAE 30 0°C (32°F)-15°C (59°F) SAE 200rSAE 20W Below 0°C (32°F) SAE 10W OIL LEVEL SHOULD. BE BETWEEN THESE (1) The clutch is adjusted with the engine off. Remove the cover protector and loosen the adjuster lock nut. (2) Turn the clutch adjusting screw clockwise about one turn; do not turn excessively. (3) Next, slowly turn the screw counterclockwise and stop when the screw meots resistance. (4) From this point, turn the adjusting serew clockwise 1/8 to 1/4 turn, and tighten the lock nut. + Don’t turn out the adjusting screw more than ne: essary. + Hold the adjusting screw while tightening the lock nut. (5) Check the operation of the clutch. NOTE _ ‘After the adjustment has been made, check to see that the ongine starts easily and that the clutch is not slipping and is properly dssngag- ina * Make sure that the engine will not stall or lunge when the ears are shifted 28 Date of Issue: Oct., 1977 (© HONDA MOTOR CO., LTD. HONDA cTso INSPECTION/ ADJUSTMENT © CYLINDER COMPRESSION [netoutbewaredop] [4 Tm aw ete wero ety | @) Tumse woe hota] ‘open position = Low compression is due to the following causes: + Leaking valve + Faulty piston rings, piston and cylinder + Blown cylinder head gasket + Insufficient valve clearance. Unusually high compression is due to excessive car: bon deposits on the combustion chamber or on the piston head. © Engine must be disassembled for complete inspec tion or repair in these cases. “To avoid leaks, screw gauge adapter into spark plug hole | securely. (3) Kich several times Kick with rapid, full strokes until gauge needle reaches the highest reading Date of sue: Oct. 1977 © HONDA MOTOR CO.,LTD. 29 INSPECTION/ ADJUSTMENT © FRONT BRAKE FREE PLAY mm (0.81.2 in) (1) Perform major free play adjustments at the front ‘wheel. Loosen the lock nut and turn the adjusting rut to increase or decrease brake lever free play. (2) Perform minor free play adjustments at the handle: bar. Loosen the lock nut and turn the adjuster to increase or decrease brake lever free play. ~ LOCK NUT UPPER ADJUSTER Lock NUT WEAR INDICATOR If the” "mark on the indicator aligns with the “4” ‘mark on the brake panel at full application of the brake, replace the brake shoes. 30 Date of Issue: Oct., 1977 © HONDA MOTOR CO., LTD. INSPECTION/ ADJUSTMENT Adjust rear brake pedal free play by turning the adjust- ing nut which is located at the rear wheel. WEAR INDICATOR ADJUSTING NUT If the“ E ""mark on the indicator aligns with the ” a ”" INCREASE PLAY mark on the brake panel at full application of brake, re- place the brake shoes. © REAR BRAKE STOPLIGHT SWITCH =! RETARD ADVANCE Turn the adjusting nut as required. ‘The stoplight should come on when the brake pedal is, depressed to the point where the rear brake just starts to take hold Date of sue: Oct, 1977 HONDA MOTOR CO. LTD. 31 INSPECTION/ ADJUSTMENT © DRIVE CHAIN + INSPECTION DRIVE CHAIN SLACK [20 mm (0.8 in) + ADJUSTMENT 2) and lubricate (1) Place the motorcycle on its center stand. sprocket and driven sprocket, If chain slack is found to exceed the limit, adjust as follows \ Steve nut (2) Turn both adjusting nuts an equal number of turns ~ until the drive chain tension is obtained x (8) Tighten the sew mut exle nut and ath adustng a, outs. sueeve nut ~~ (4) Install the cotter pin and spread the ends. 3545 kom) (25332. | L DECREASE “AXLE NUT SLACK 35-50 kom (25,3-36.2 tbs-tt) oN ™ | INCREASE SLACK COTTER PIN ADJUSTING NUT 32 Date of Issue: Oct., 1977 © HONDA MOTOR CO., LTD. ‘Check drive chain tension midway between the drive INSPECTION/ ADJUSTMENT (1), Remove the right side cover (2) Remove the battery band bolt and pull the battery out. (3) Check electrolyte level, The level should be between the upper and lower level marks. (4) If itis not, add distilled water to the upper level. NOTE _ ~ Replace the battery if sulfation is evident. Replace the battery if there is excessive sediment on | the bottom ofthe call ~The battery contains sulfuric acid and should be handled with care. + Do not overfill beyond the UPPER level. * Avoid contact with skin, eyes or clothing. Flush with water and get prompt medical attention when in con: RIGHT SIDE tact with skin or eyes. BATTERY BAND pen x Sp ELECTROLYTE LEVEL ~g | THE LEVEL SHOULD BE BETWEEN ‘THESE TWO MARKS. ELECTROLYTE SPECIFIC GRAVITY 12601280 (20°C (68°F | = 1.280 or below: Undercharged - Ss 1.220 or below: Recharge the battery HYDROMETER. | e | —_ specific gravity, see page 102 | ELECTROLYTE \ Date of lsue: Oct, 1977 © HONDA MOTOR CO.,LTD, 33 HONDA cT90 INSPECTION/ ADJUSTMENT © FRONT FORK OIL CHANGE (1) Remove the front fork drain plugs and fork filler plugs. (2) Drain the oil by pumping the fork up and down, (3) Replace the drain plugs after draining. DRAIN PLUG * Drain and refill both fork logs at the same time. FILLER PLUG 3.5-4.5 kgm (25,3326 Ibet) ate FTo fill dry fork assemBty] NX 130-140 cc (4.4.4.7 02.) NS “To refill after draining ; 120-190 ce (41-44 02.) (4) Pour ATF (automatic transmission fluid) into each fork leg (5) Securely tighten the filler plugs, 34 Date of Issue: Oct., 1977 © HONDA MOTOR CO.,LTD. HONDA crs0 INSPECTION/ ADJUSTMENT. * SIDE STAND. Check the side stand for proper return operation. (1) With the side stand lowered, raise the stand off the ground using the center stand. (2) Attach a spring scale to the lower end of the stand and measure the force required to raise the stand, (3) The stand condition is correct if the measurement falls within 2-3kg (4.4-6.6 Ibs). If excessive force is required to raise the stand, this may be due to neglected lubrication over tight: ened pivot bolt, worn side stand bar or bracket or otherwise excessive tension, Check for : incorrect installation deformation damage return operation — Check for : damage Check for : wear deterioration Check the rubber block for deteriors tion or wear. When the rubber block ‘wear is s0 excessive that it is worn down to the wear line, replace it with WEAR LIMIT LINE No GooD Date of Issue: Oct. 1977 35 (© HONDA MOTOR CO.,LTD. V ENGINE 2.ENGINE REMOVAL/INSTALLATION HONDA cTs0 + Shift the transmission into neutral position. + Set the motoreyele on the center stand, + Turn the ignition switch to the OFF position. (5) AIR CLEANER (8) DRIVE CHAIN \ (4) CARBURETOR (3) STEP BAR » ~ Drain fuel by removing the dain (ee 7 ree - + Gasoline is inflammable 25Kgm | —_ L(13.0- 18.1 ste | ekGesciiee ieee 0-18.1 Ibs-tt | 96 Date of Issue: Oct., 1977 © HONDA MOTOR CO.,LTD. ENGINE REMOVAL/INSTALLATION (12) ENGINE HANGER BOLTS 3.0-4.0 kgm ] (21.7-290 ibs) (10) SPARK PLUG LEAD Perform the following with care while/after installing the engine, Rear brake adjustment .. .- ~ page 31 Stop light Switch adjustment .. page 31 Drive chain adjustment page 32 Installation direetion of carburetor top... . page 78 Installation direction of drive chain... . page 90 | Le Connection of fuel tubes... . page 96 Date of Issue: Oct., 1977 37 © HONDA MOTOR CO., LTD. 2.CYLINDER HEAD/VALVES Remove the intake pipe, exhaust muffler and ‘generator cover. TAPPET HOLE CAP (7) CYLINDER HEAD COVER \ ‘Apply areate to the threads before \ SPARK PLUG installing | \ — \ _ VALVE @0 _-~ Disassembly and assembly, Page 41 CYLINDER HEAD Disassombly and assembly, Page 40 CAMSHAFT SPROCKET COPPER WASHER // / CAP NUT / Bkom ROCKER ARM Removal Page 40 GASKET + During assembly, apply clean oil to hi * Locate the cutout on the cam chain side it on the cylinder head. GASKET ee Sinseitieed) (6) point ease ~ (4) DoweL Pin Disassembly and assombly, | Page as y | (6) CAMSHAFT Disassembly and assembly, Page 39 (8) SPARK aDvaNceR ~ | 091-2%em Disassembly and assembly, Page 43 {_(6.58,7 tbs-fe) (2) CONTACT BREAKER / NOTE _ , Disassombly and assembly, Page 43 © Routing of contact breaker cable ] (68-87 be] (1) POINT CoveR —— ‘After assembly, perform the following operations: Breaker point gap adjustment . . s+ Page 22 {gnition timing adjustment... 22... Page 23 Valve tappet clearance adjustment ........ . Page 24 Cam chain tentioner adjustment ....... +. Page 26 Cylinder compression test cevee ess Page 28 38 Date of fue: Oct, 1977 © HONDA MOTOR CO., LTD. HONDA cT90 CYLINDER HEAD/VALVES a, DISASSEMSLY/ASSEMBLY ‘© CAMSHAFT DISASSEMBLY (1) Rotate the A.C. generator rotor counterclockwise ‘and align the “"T" mark on the rotor with the index. mark on the stator at compression stroke. (2) Remove the two 6 mm bolts from the eamshaft. (3) Pull out the camshaft NOTE The while the camshaft removed. Failure to do so will result in difficulty in removing the shaft de to in- | creased tention onthe eam chain © CAMSHAFT ASSEMBLY (VALVE TIMING AD- SJUSTMENT) (1) Rotate the A.C. generator rotor and align the “T” mark on the rotor with the index mark (at T.O.C.) (2) Place the cam chain on the camshaft sprocket (3) Install the cylinder head. NOTE Make sure that the “O" mark on the sprocket is aligned | with the cutout in the cylinder head. | (4) Install the cylinder head cover and tighten to the specified torque. (6) Install the camshaft and the two 6 mm bolts with the dowel hole in the shaft facing toward the “ ‘mark. 7" and INDEX MARK Date of sue: Oct. 197 © HONDA MOTOR CO., 17D. 39 CYLINDER HEAD /VALVES ¢ ROCKER ARM DISASSEMBLY/ASSEMBLY VALVE Disassembly and assembly, Page 41 (4) ROCKER ARM (3) TAPPET HOLE CAP Coat the threads with grease before installation. | GASKET 40 Date of sue: Oct, 1977 HONDA MOTOR CO. LTD, HONDA cTso © VALVE DISASSEMBLY/ASSEMBLY ‘After installing, make sure that the cotters are seated CYLINDER HEAD/VALVES VALVE SPRING COMPRESSOR No. 07957-3290001 CAUTION [Be nt conpran te arog exo] VALVE COTTER Property. INNER VALVE SPRING OUTER VALVE SPRING. Do not mix th intake and ex: aust valve springs. OUTER SPRING SEAT VALVE GUIDE ~ O-RING e/ — INNER SPRING SEAT STEM SEAL CAP STEM SEAL, } (Ex. only) Ss SPRING SEAT VaLve GUIDE Replacement and repair, Page 42 O-RING Date of Issue: Oet., 1977 (© HONDA MOTOR CO., LTD. CYLINDER HEAD/VALVES © VALVE GUIDE REPLACEMENT/REPAIR It is recommended to replace the alve guides are renewed. Too. VALVE GUIDE DRIVER No. 07942-3290100 VALVE GUIDE DRIVER 7< INTAKE: No. 07942—1180100 ~ EXHAUST: No. 07942~3290100 [es ‘2 new val ‘uide has been driven to the proper depth, check ‘not damaged, = REAMING VALVE GUIDE [After installing & new guide, ream the guide to size sing the Valve Guide Reamer VALVE GUIDE 1. [IN/EX 5.475-5.485 mm (02167-02161 VALVE GUIDE REAMER No. 07984-0980000 * Always rotate the reamer in the clockwise direction when reaming the guide. + To keep the reamed surface from being scratched, ‘rotate the reamer clockwise as itis pulled out. + Remove all traces of metal particles fram the guide with solvent. 42 Date of Issue: Oct. 1977 © HONDA MOTOR CO., LTD. CYLINDER _HEAD/VALVES © CONTACT BREAKER POINT BASE ASSEMBLY Place the oil seal guide over the cam- shaft ond. Spread a thin fil of oil on ‘the guide to ease seal installation. Carefully install the contact point hou: sing and oil seal. Remove the oil seal guide and check that the oil seal is pro- perly seated. Insert the advancer loca- OIL SEAL GUIDE ting pin. (07974-12800 er CauTION] ) PIN To prevent oil seal damage, the vancer locating pin must be removed before installing or removing the con: —_ ALIGN THE PIN WITH THE GROOVE. ALIGN THIS MARK WITH THE INDEX MARK ON ‘THE POINT BASE POINTS NOTE Inspection, Page 105 ‘After assembly, perform the following operations: * Breaker point gap adjustment... . Page 22 0.3.0.4 mm (0.012:0.016 in) + Ignition timing adjustment... ..... ++ Page 23 [Boot ogo nwa CONTACT BREAKER CABLE @ Ne ems Date of lisue: Oct, 1977 @ HONDA MOTOR CO., LTD 43 HONDA CYLINDER HEAD/VALVES crso b. INSPECTION [Tae nase at seal pin c Standard Service Limit [we [ert | wean © VALVE GUIDE 1.0. TOP iddle and bottom and in two directions at right angles to each other. _ Standard | __ Service Limit 5.475-5.485 mm | 6.525 mm (Replace) INEX | (0.2157-0.2161 in.) | (0.2175 in.) [ Measure the valve stem at three points along its sliding | surface and in two directions at right angles to each other. _| CC Standard Sones Limit wy | BAB 8 468 mm | SABE mm Replace foziasoz162in) | (02139im) ex | 8435-5445 mm | 5416 mm ple (0.2140-0.2144 in.) | (0.2132 in.) 44 Date of sue: Oct, 1977 © HONDA MOTOR CO., LTD. HONDA cTs0 CYLINDER _HEAD/VALVES + VALVE FACE WIDTH + ROCKER ARMILD. we rocker afm I.D. in two direction at right iles to each other. [Standard Service Limit 10.000-10.015 mm | 10.10 mm (Replace) (0.3937-0.3943 in.) | (0.3976 in.) IN/EX (Check for wear or damage. Date of sue: Oct, 1977 45 jONDA MOTOR CO.,LTD. CYLINDER _HEAD/VALVES © CAM HEIGHT "Standard Service Limit 24,90-26.98 mm | 24.6 mm (Replace) (0.9803.0.9835 in.) | (0.9685 in.) IN/EX © CAMSHAFT 0.0. Tossa te coma in wo aetone at Hah anes to] | tach ether oon ene). | L Standard Service Limit 281725330mm | 2580 mm cane (1.0206-1,0208 in.) (1.0197 in.) 1792717888 mm | 1780 mom Repo) iD (0.7058-0.7062 in.) (0.7047 in.) “Measure the end hole in two directions at right angles to. | eachother (both ends), _ ares el 5 36:060-26.020 mim | 26.05 mm (Replace) Leno | ra36-1.0244im) | (10286in) | 18,000-18.018 mm | 18.05 mm (Replace) REND (0.7087-0,7084 in.) _| (0.7106 in.) 48 Date of lsue: Oct 1977 © HONDA MOTOR CO.,LTD. HONDA creo CYLINDER _HEAD/VALVES © VALVE SPRING FREE LENGTH VALVE SPRING FREE LENGTH Standord Service Umit] 31.8mm | 30.6 mm (Replace) | Cue (1.262 in.) (1.205 in.) Tlywen seme | 285mm | 2515 mm (Replace) | INNER SPRING | (1.043 in) (100810) | "Measure the rocker arm shaft at its aiding surface in two directions at right angles to each other. Service Limi 9.92 mm (Replace) | (0.3906 in.) | INSPECTION: ‘Smooth rotation —— Damage or roughness breakage or lubrication Date of Issue: Oct., 1977 47 (© HONDA MOTOR CO.,LTD. CYLINDER HEAD/VALVES © VALVE SEAT REFACING VALVE SEAT GRINDER MOVE UP AND DOWN LIGHTLY © VALVE SEAT REFACING ROUGHNESS OR PITTING J 48" H VALVE SEAT Z\ HONDA cTso * Check the contact between the valve face and the seat. Coat the valve face lightly with Prussion blue, but the valve into the seat and turn it with light pres sure about one full turn. + If the Prussian blue dovs not transfer evenly to the seat, or if the contact is excessive, the valve must be replaced, and the seat ground with a valve seat grin er. NOTE [Grinding stones must be dressed before each usage to ‘ensure that they will refinish valve seats accurately. Follow all instructions supplied with the grinder. (1) Dress the grinding stones to assure even, uniform grinding of the valve seat. (2) As a first step in the operation, remove all the roughness or pitting from the seat using the 45° ‘grinding stone. NOTE ___ | Grinding should be performed until all pits in the seat are removed. | Grinding Angle 29 mm (1.142 in) 45° 26 mm (1.024 in) | GRINDING STONE | 7 | VALVE SEAT (3) Narrow the seat with the dressed 37.5° stone. Grinding 29 mm (1.142 in) 26 mm (1.024 in) | g 48 Date of Issue: Oct, 1977 (© HONDA MOTOR CO.,LTD. HONDA cTs0 SIDE DRESS CYLINDER HEAD/VALVES (4) Narrow the seat at the bottom with the 63.5° grind- as" SEAT DRESS ROTATE WITH LIGHT DOWNWARD RESSURE ts ing stone Grinding Stone | tng Ane IN | __ 32mm (1.260 in) 635° EX | _26mm (1.024 in) _| idth and location on was used in Step (8) Bring he seat tothe comect ‘the valve face with the 45° stone. a "STANDARD VALVE SEAT WIDTH [10mm (008m) | (6) Apply a small amount of fine grinding compound to the valve seat and lap the two surfaces lightly toge- ther by rotating the handle of a suction cup. [CAUTION Ee not allow the lapping compound to enter the | valve guide “| (7) After lapping, apply a thin coating of Prussian blue to the seat, set the valve into the seat and rotate the valve one full turn, The contact is satisfactory if the blue is transfered to the center of the valve evenly. Date of Issue: Oct., 197 (@ HONDA MOTOR CO.,LTD. 49 3.CYLINDER/PISTON (2) CYLINDER DOWEL PIN / ~~ Assembly, Page 52 10x 14 mm PISTON Disassembly and assombly, Page 51 (1) CHAIN GUIDE ROLLER \ 0.9-1.4 kgm | Bowe Yo eee 4 neER See 10x 20mm PISTON PIN CLIP [ Replace whenever | disassembled. cower ow / Teitnm ( GASKET [ Use care when installing to avoid damaging the gasket. — RUBBER SEAL Perform the following operations after assembling: Cam chain tensioner adjustment... Page 26 Cylinder compression test... sess Page 29 50 Date of sue: Oct, 1977 © HONDA MOTOR CO.,LTD HONDA cTso CYLINDER/PISTON a. DISASSEMBLY/ASSEMBLY © PISTON CAUTION] [avoid damasing the Pston whe LOCATE THE "IN" MARK ON THE cuTouT INTAKE VALVE SIDE [ sta ie lp so thatthe ai] | so and cutout nthe pton ae | not aligned. WAYS Be careful to prevent the clip from falling into the erank- Position piston rings s0 end gaps | © PISTON RING are 120° apart and no gap is in [caution line with the ends of the piston ipavcu GammaeaomTis pin, ‘Avoid damaging the piston when installing and ee removing rings. REMOVE RINGS IN THE ARROW DIRECTION. 2nd RING OIL RING — Install the rings with the markings up. Date of Issue. Oct., 1977 51 © HONDA MOTOR CO.,LTD. CYLINDER/PISTON © CYLINDER INSTALLATION Apply @ thin coat of oil on the cylinder wall and piston rings before installing the cylinder. As the eylinder is in- stalled, compress the piston rings with your fingers to lease entry of the piston into the cylinder, CAUTION ‘Avoid damaging the pisto ton in the eylinder. ! CYLINDER. CAM CHAIN After the piston has entered the cylinder, route the| ‘chain forward through the hole in the cylinder. © GUIDE ROLLER ASSEMBLY GUIDE ROLLER PIN 0.9-1.4 kg-m (6.5-10.1 Ibs-Ft) GUIDE ROLLER 52 Date of Issue: Oct., 1977 © HONDA MOTOR CO.,LTD, HONDA cTso CYLINDER/PISTON b INSPECTION © CYLINDER TOP MIDDLE BOTTOM © PISTON 0.0. [ Measure 1.D. of the cylinder in at dle and bottom of piston travel, and in two directions at right| angles to each other. __ Standard Service Limit {50,00-50.01 mm | 50.10 (Repair or 1D. replace) __|_(1.9685-1.9689 in.) | (1.9724 in) 0.01 mm | 0.05 mm (Repair TAPER cr replace) (0.0004 in.) (0.002 in.) ‘0.01 mm (0.05 mm (Repair OUT-OF-ROUND | (or replace) (0.0004 in.) (0.002 in.) If the above limits are exceeded, the cylinder must be rebored and oversize piston and piston rings fitted. STANDARD OVERSIZES: 0.25 mm, 0.60 mm, 0.75 mm, 1.00 mm (0.01 in, 0.02 in 0.03 in 0.04 in) Measurements should be taken at a point 10 mm (0.4 in) from the lower end, ‘Standard ~ | Service Limit 49.97.49.99 mm ‘49,80 mm (Replace) (1.9673-1.9681 in.) (1.9606 in.) Date of Issue. Oct., 1977 © HONDA MOTOR CO., LTD. 53 HONDA CYLINDER/PISTON ‘* PISTON-TO-PISTON RING CLEARANCE PISTON RING Standard Service Limit 0.010-0.045 mm. 0.12 mm (Replace) (0.0004-0.0018 in.) (0.0047 in.) «© PISTON PIN BORE LD. “Standard Service Limit 14,002:14.008 14.04 mm (Replacs) (0.55130.5516 in.) (0.5528 in.) © PISTON RING END GAP ‘Measure the ring end gap with the ring inserted in the cylinder to a point 10 mm (0.4 in.) from bottom. Standard ‘Service Limit on, (0.16.35 mm. _|0.50 mm (Replace) | TOP/SECOND) (o'996 001 ) | (0.02in.) [0.150.40mm — 0.50 (Replace) ] | | (0.006.0.016 in) | (0.02 in) 54 Date of Issue: Oct., 197 © HONDA MOTOR CO., LTD. HONDA cTs0 CYLINDER/PISTON PISTON RING THICKNESS ike measurements at several points. | Standard | Service Unt] | TOP and 1.175-1.190 mm_—_| 1.13 mm (Replace) SECOND (0.0463-0.0469 in,)/ (0.0445 in.) o1 2.476-2.490 mm | 2.43 mm (Replace) [OW RING | (o:9874.0.0080 in.) (0.0967 in) © PISTON PINO.D. Standard Serve nt 13:994-14.000 mm 78.960 mm (Replace) (0.5800-05513 in) (0.5496 in) Date of Issue: Oct., 197 © HONDA MOTOR CO., LTD. HONDA 4.LUBRICATION SYSTEM cTs0 © LUBRICATION CIRCUIT DIAGRAM TO RETURN MAINSHAFT COUNTERSHAFT J] AORTA sion cena FPGAL, L[opannsar | To RETURN / 17 OIL FILTER (CRANKSHAFT TO RETURN ROCKER ARM (In) 56 Date oflssue: Oct, 1977 (© HONDA MOTOR CO., LTD. — ‘lL PUMP CRANK CASE 5.CLUTCH/GEAR SHIFT/OIL PUMP + Drain engine oil, + Remove the step bar and shift pedal. DRUM STOPPER Disassembly and assembly, Page 60 DRUM STOPPER PLATE Disassembly and assembly, page 60. (4) DRIVEN GEAR ef (5) GEARSHIFT SPINDLE Disassembly and sstembly, Page 60 (3) CLUTCH Disassembly and ssembly, page 59 / jicieaey whenever disassembled. lL PUMP Disassembly and assembly, page 61 9 > Sy cuuren Lever —_& Assembly, page 61 CLUTCH BALL RETAINER CLUTCH LIFTER * CLUTCH ADJUSTING BOLT ~ PROTECTOR (1) RIGHT CRANKCASE COVER ‘After installation, check and adjust the clutch, Page 28, Date of Isue. Oet., 1977 © HONDA MOTOR CO.,LTD. 57 CLUTCH/GEAR_SHIFT/OIL_ PUMP. a. DISASSEMBLY /ASSEMBLY © CLUTCH REMOVAL AND INSTALLATION + Drain the engine oil + Remove the clutch outer cover. Sa cuvToH assy cLuren ouren HoLoER No, 07923-0340000 CAUTION] Do nat harmon Gi Sate To GG ONO] 16 mm LOCK NUT WRENCH }0 not hammer the clutch Into or out of position, as si anol this will result in a damaged clutch or other defect. No.07916-374 © LOCK WASHER INSTALLATION [CAUTION ‘After tightening the lock nut, band a tab of the lock er to prevent loosening v8 turn in the lock nut to align the tab with the n the head of the lock nut. LOCK WASHER 16mm LOCK NUT [3645kom [erases 58 Date of Issue: Oct, 1977 © HONDA MOTOR CO., LTD. CLUTCH/GEAR SHIFT/OIL_ PUMP CLUTCH DISASSEMBLY/ASSEMBLY + CLUTCH WEIGHT INSTALLATION + DAMPER SPRING DISASSEMBLY/ASSEMBLY CLUTCH WEIGHT STOPPER RING: /ORIVEPLATE, |} CLUTCH OUTER eaeD moaooD CLUTCH WEIGHT oniverLsre \ ‘5mm SCREW ~~ DAMPER SPRING [ Tighten these screws in a criss-cross pattern and in two | | or more steps. a CLUTCH SPRING © CLUTCH PLATED "> CLUTCH PLATE.C j \ CLUTCH PLATES 2 \ CLUTCH SPRING || [insert these springs between the clutch plates A and D. CLUTCH SPRING (SUB SPRING) ings between the clutch plates A and C. CLUTCH CENTER Insert the GUIDE Date of Issue: Oct. 197 © HONDA MOTOR CO., LTD. 59 CLUTCH/GEAR SHIFT/OIL-PUMP ‘© SHIFT SPINDLE DISASSEMBLY/ASSEMBLY The shift spindle hole in the left crankcase cover is pro- vvided with an oil seal and care must be used in installing the spindle to avoid damage to it by rotating it by hand. GEAR SHIFT ARM _>> SHIFT RETURN SPRING SHIFT SPINDLE CLUTCH LEVER SHIFT RETURN . SPRING PIN. \@ Tnsert the end ofthe spring into ie) \ | itt retain pr ‘After installing the lever, check f or operation. ‘¢ DRUM STOPPER PLATE INSTALLATION © DRUM STOPPER INSTALLATION Before tightening the pivot bolt, | ‘make sure that the stopper is posi tioned properly. DRUM STOPPER PLATE HOLE | PIN SHIFT ORUM Hold the plate against the drum firmly until the pin on] _ PIVOT BOLT || \ the drum has entered the pin hole. 08-1.2 kgm SPRING - 6.88.7 Ib ft After the bolt has been tightened, check the stopper for operation, 60 Date of Issue: Oct., 1977 @ HONDA MOTOR CO., LTD. SHIFT/OIL_ PUMP. Install the clutch lever towards the center of the clutch as shown, + OIL PUMP DISASSEMBLY/ASSEMBLY OUTER ROTOR Teo EF cover (WR ROTOR SHAFT insert the shaft into hole in the inner rotor, aligning the shaft heed with that of th CAM CHAIN GUIDE SPROCKET SHAFT Check that the end of the rotor shaft engages the groove in the end of the sprocket shaft. Date of fue: Oct. 1977 CHONDA MOTOR CO.,LTD, 61 HONDA cTso CLUTCH/GEAR SHIFT/OIL PUMP. b. INSPECTION ‘© OIL PUMP ROTOR TIP CLEARANCE © OIL PUMP OUTER ROTOR-TO-BODY CLEARANCE Standard Service Limit 0.15020 mm 0.25 mm (Replace) _10.006.0.008in) | (0.010) | Check the rotors for wear, nicks or seratches, and for | freedom of any foreign matter. © FRICTION DISC THICKNESS ~ Standard _y 282.9 mm 2.4 mm (Replace) | (0.1102.0.1142in.) 0945 in.) Check the friction discs, replacing those which are found to be worn or damaged. 62 Date of Issue: Oct., 197 (© HONDA MOTOR CO., LTD. CLUTCH/GEAR_SHIFT/OIL_ PUMP © CLUTCH PLATE THICKNESS ‘© CLUTCH PLATE WARPAGE ‘¢ CLUTCH SPRING FREE LENGTH Standard Service Limit 1.93.2.07 mm 1.85 mm (Replace) (0.0760.0,0818 in.) (0.0729 in.) ‘Take measurements at several points. ments at severat points, _ J ndard Service Limit 0.2mm (0.5 mm (Replace) (0.008 in.) (0.020 in.) The plate must be within specifications along its enti circumference. __ FREE LENGTH ‘Standard Service Limit 27 mm 26 mm (Replace) (1.0830 in.) (1.0236 in.) Date of Issue: Oct., 1977 © HONDA MOTOR CO., LTD. 63 CLUTCH/GEAR_SHIFT/OIL-PUMP. ‘© CLUTCH DRIVE GEAR 1.0. 24.00-24.02 L_(0.0449.0.9457 in.) (0.9508 in.) Check the driven gear if the drive gear is worn or d aged, __ DAMAGE OR WEAR © CLUTCH CENTER GUIDE Standard ‘Service Limit 122.0-22.1 mm | 21.85 mm (Re on. ____|(0.8861-0.870 n)_| (0.8602 in) GUIDE-TO-CRANKSHAFT(0.006-0.047 mm | 0.18 mm (Repla. CLEARANCE (0.00020,0019 in) | (0.060 in} | 64 Date of Issue: Oct., 1977 © HONDA MOTOR CO., LTD. 6.AUXILIARY TRANSMISSION SHIFT FORKSHAFT KNOCK PIN _- IDLER GEAR SHAFT SHIFT FORK Disassembly and assembly, Page 66 IDLER GEAR Disassembly and assembly, Page 66 CHANGE LEVER, Z LOW GEAR Disassembly and assembly, Page 66 Shift lever installation x cup Dae of sue: Oct, 1977 2 'HONDA MOTOR CO LTD. 65 AUXILIARY TRANSMISSION a. DISSASEMBLY/ASSEMBLY _- LEFT CRANKCASE COVER / KNOCK PIN ‘Align the pin with the slit in the left erankease cover. IDLER SHAFT , IDLER GEAR Place the shift lever on the H side to faci } HIGH SPEED GEAR SHIFT LEVER | Align the boss with the groove in the | shite rm | falls into the detent in the shaft by sliding the shaft back and forth several times. a installing the shift fork, check that the steel =| SHIFT FORK SHAFT : Note the installation direction. ] EAIETEORET install the shaft so that the long end “A is in the left crankcase cover. 66 Date of lsue: Oct, 197 CHONDA MOTOR CO.,LTD. AUXILIARY TRANSMISSION b. INSPECTION © IDLER GEAR 1.D. (0.5108.0.5112 in) [ Standard | Service Limit 73.000-18.018 min 13:10 mm osteosizsin) | (stsvim | Standard Service Lint 12,966-12.984 mm 12.85 mm (0.5140 in) © GEARS. DAMAGE oO CHECK FOR WEAR OR DAMAGE Date of Issue: Oct., 1977 © HONDA MOTOR CO.,LTD. 67 HONDA 7.A.C.GENERATOR/CAM CHAIN cTso TENSIONER + Before disassembly, drain the oil from the engine. + Remove the auxiliary transmission. + Perform Steps (4) thru (6) after the cylinder has been removed. (4) CAM CHAIN NEUTRAL SWITCH Routing of switch wires, Page 69 (6) CAM CHAIN TENSIONER Disassembly /assembly, Page 70 Do not forget to install at assembly. fe AG. GENERATOR ROTOR Inspection, Page 100 [cauTion} * Remove the stator after dismounting the engine to avoid damaging the wire harness + Avoid damaging the coils. 081.2 kgm | (5.8-8,7 Ibs-ft) (6) CAM CHAIN GUIDE SPROCKET, Disassembly /assembly, Page 69 TENSIONER SPRING A —— TENSIONER SPRING 8 ADJUSTING SCREW — 2 seat gout 2035 kom | (14.5-25.316 Ibs-ft) 263.2 kom NS (18.8-23.2 Ibs-ft) (3) AC. GENERATOR ROTOR Disassembly/assembly, Page 69 Perform the following inspection and adjustment after assembling the tensioner: Cam chain tension Page 26 Dale of e024, 1977 88 S tioxba hiorok CO, 1. HONDA cTso A.C.GENERATOR/CAM CHAIN TENSIONER . DISASSEMBLY/ASSEMBLY ‘© A.C. GENERATOR ROTOR REMOVAL, ROTOR PULLER No. 079332160000 —| ‘SPRING Route the end of the wire through the hole in the switch while compressing the spring. ~ Align the cutout inthe end withthe pump rotor shaft | while rotating the sprocket by hand. | + Apply clean engine ol to the shaft during assembly. Date of Issue: Oct., 1977 69 © HONDA MOTOR CO.,LTD. A.C.GENERATOR/CAM CHAIN TENSIONER © CAM CHAIN TENSIONER DISASSEMBLY/ ASSEMBLY (1) Remove the cylinder head, (2) Remove the cam O-RING (3) aoyuStING BOLT-A PLATE-A % (4) TENSIONER PUSH ROD ——— PLATES [ Place the cutout toward adjusting bolt A, 70 Date of Issue: Oct., 1977 ‘© HONDA MOTOR CO.,LTD. hae 8. TRANSMISSION/CRANKSHAFT/ KICK _SARTER (3) DRIVE SPROCKET (4) GEARSHIFT FORK Disassembly /assembly, Page 73 (2) KICK STARTER SPINDLE Disassembly assembly, Page 74 (5) TRANSMISSION 7 Disassembly assembly, Page 73 (6) CRANKSHAFT ASSY _— CAUTION ‘Make sure that the gasket isin place before assembling. . (1) RIGHT CRANKCASE Parts (4) and (5) can be removed as an assembled unit. Date of fe: Oct, 1977 1 © HONDA MOTOR CO., LTD. HONDA cTs0 TRANSMISSION/CRANKSHAFT/KICK STARTER a. DISASSEMBLY/ASSEMBLY (© TRANSMISSION ASSEMBLY + With the gearshift drum in place, engage the counter- ‘gear assembly with the main drive gear assembly. ‘Then, while holding the assemblies together, slip the {nds of the shafts into holes in the left erankcate. MAIN SHAFT / COUNTERSHAFT GEARSHIFT DRUM NEUTRAL SWITCH Position the rotor toward the switch so that the switch ‘can be installed easily. GEARSHIFT DRUM SETTING BOLT ee After the transmission has been assembled, rotate the main shaft to check that the gears rotate freely. Install the washer with the sharp edge facing to the outside of the case. 72 Date of Isue: Oct, 197 (© HONDA MOTOR CO., LTD. HONDA cTso TRANSMISSION/CRANKSHAFT/KICK STARTER TRANSMISSION GEARS COUNTERSHAFT \ » BA MAIN SHAFT ‘© GEARSHIFT DRUM ASSEMBLY _ RIGHT SHIFT FORK (COUNTERSHAFT SIDE) [Mark the shift forks so that they can be pli re removed. LEFT SHIFT FORK (MAIN SHAFT SIDE) SHIFT DRUM NEUTRAL SWITCH ROTOR Date of lsu: Oct, 1977 GHONDA MOTOR CO., LTD. 18 HONDA cTs0 TRANSMISSION/CRANKSHAFT/KICK STARTER © KICK STARTER + Assemble the ratchet spring (1), stopper (2) and re: turn spring (3) in the order named. (2) STOPPER “Align the stopper with the boss of the right crankcase. RIGHT CRANKCASE (3) RETURN SPRING (1) RATCHET SPRING = this end of the retumn | ine up the spring with t spring into hole in the cutout ‘groove in the in the __| © TIMING GEAR DISASSEMBLY Scribe an aligning mark over the crankshaft from the ‘Scribe an aligning mark over a new sprocket at the center ‘center between two teeth. Then, remove the sprock: of two teeth. Install the sprocket on the erankshaft with et. the marking on the sprocket aligned with the marking (on the crankshaft. * ASSEMBLY —_ CENTER OF ANY ADJACENT TEETH NEVER SCRIBE ACROSS OIL SEAL CONTACTING SURFACES. 14 Date of Issue. Oct., 1977 © HONDA MOTOR CO., LTD. HONDA cT90 b. INSPECTION TRANSMISSION GEARS ‘© GEARSHIFT DRUM/GUIDE PIN INSPECTION ‘Wear or damage © GEARSHIFT FORK L.D. Wear oF Damage Wear or Damage TRANSMISSION/CRANKSHAFT/KICK STARTER ‘Standard Service Limit OD. | 41:95047.975 mm | 41.80 mm (Replace) i (1.8516-1.6526 in.) | (1.6457in.) Groove | 6.1.6.2 mm 16.4 mm (Replace) Lwiath | (0.24020.2441 in.) | (0.2520 in.) ‘Check the bore diameter in two positions at right angle toch other. Standard | __Service Limit 42.00 mm %2.10 mm (Replace |_1.6538in.) (1.6578 in) “Seanderd Serve Limit 596.608 mm] 5:70 mm (Replace (0.2046023700) | (02244 in) Date of Issue: Oct, 1977 © HONDA MOTOR CO., LTD. TSANSMISSION/CRANKSHAFT/KICK STARTER ‘© CONNECTING ROD SMALL END 1.0. ‘Standard Service Limit (0.100.35 mm (0.8 mm (Replace) (0.004.0.019 in.) (0.032 in.) Measure the radial clearance in two directions, i} ETS Siandard Senvice Umit 0.0.01 mm 10.05 mm (Replace) (00.0004 in) (0.002) 76 Date of Isue: Oct, 1977 © HONDA MOTOR CO., LTD. HONDA cTso TRANSMISSION/CRANKSHAFT/KICK STARTER © CRANKSHAFT BEARING PLAY Standard Service Limit wat play | 0:10-0.36 mm | 0.80 mm (Replace) Axiatpley | (0.0040.019in.) | (0.032 in.) cial 0.01 mm (0.05 mm (Replace) Radial Ply | (¢9.0008 in.) | (0.002 in.) © CRANKSHAFT RUNOUT = Standard Service Limit 00.015 mm 0.1 mm (Replace) - (0-9.0006 in.) (0.004 in.) at points shown. (1.4 in) Date of lve: Oct. 1977 © HONDA MOTOR CO., LTD. 11 9. CARBURETOR 1977 (K8) model * Dre * Do not bring an open flame near gasoline. Wipe off spilled gasoline at once. RUBBER CAP Check the cap for any evidence of cracks or deteriora: tion Fy =“ pe, HIGH ALTITUDE SELECTOR KNOB AIR SCREW NOTE * Clean all removed parts in solvent and Blow dry with ‘compressed air. + After the carburetor has been assembled, turn on the {uel valve and check for leaks. Perform the following operations after assembling the carburetor: ‘Throttle grip free play Page 25 Idle speed adjustment. Page 25 fuel from the carburetor By loosening the drain 8 , elem Oe Cran eeen \ 7 HONDA cTs0 Ba € THROTTLE CABLE Disassembly and assembly, Page 80 Install the valve with the groove facing toward the stop screw. FUEL FILTER, The filter screen must be cleaned whenever disassembled Q Q ore ae earl as esse the tubes from the carburetor or dismantling the fuel ve. * Check each tube for cracks or deterioration. + To reconnect the tubes, refer to page 96 78 Date of Issue: Oct., 1977 © HONDA MOTOR CO., LTD. HONDA eTe0 CARBURETOR 1978(K9) model RUBBER CAP (Check for cracks and deterioration. THROTTLE CABLE Disassembly and assembly, Page 80 Install the valve with the groove | {acing toward the stop serew. stor screw PILOT SCREW Oo INTAKE PIPE DRAIN SCREW _ FUEL FILTER fe =a Clean all removed parts in solvent and blow dry with compressed air. After the carburetor has been assembled, turn on the fuel valve and check for Ie Perform the following operations after assembling the carburetor: Throttle grip free play Idle speed adjustment. Page 25 + Page 25 Date of Issue: Oct. 1977 79 © HONDA MOTOR CO., LTD. CARBURETOR a. DISASSEMBLY /ASSEMBLY © THROTTLE VALVE + Disconnect the end of the throttle cable from the ‘groove in the throttle valve. ‘THROTTLE CABLE JET NEEDLE RETAINER ‘Set the jet needle retainer in the bot- tom properly at assembly, ‘CARBURETOR T ‘OR TOP OUTER END ADJUSTER, Qa" NEEDLE RETAINER NEEDLE CLIP NEEDLE JET [The needle and needle jet must be installed as a matched set. Do not re- THROTTLE VALVE + At assembly, turn in the adjuster all the way as far as it will go. + Make sure that the outer end of the throttle cable is inserted in the hole in the cable adjuster properly. 80 Date of Issue: Oct., 1977 © HONDA MOTOR CO.,LTD. © CARBURETOR FLOAT AND JETS (1977 K8 model) CARBURETOR © CARBURETOR FLOAT AND JETS (1978 K9 model) SLOW JET MAIN JET (Gesoli is inflammable. CAUTION + Use extreme caution in assembling and disassembling the carburetor to avoid damaging the carburetor jets. + Clean all removed parts in solvent and blow with compressed air a @) @ a ) ) ) ‘Turn the fuel valve to OFF. Drain fuel from the carburetor by loosening the drain screw. Remove the throttle valve and air cleaner band. Re- move the carburetor. Remove the float chamber for access to the float, and jets. Date of Isue: Oct. 1977 © HONDA MOTOR CO.,LTD. 81 CARBURETOR b, INSPECTION © FLOAT HEIGHT FLOAT FLOAT HEIGHT (1) Hold the carburetor with its main bore in a vertical position, so the float arm tang wi without compressing the spring loaded pin in the end of the valve. (2) Position the gauge on the carburetor with the end of the float height indicator against the float. If the gauge has been set to the specified float height, and the carburetor float level is properly adjusted, the end of the indicator will just touch the float, without causing the float to move. (3) If float height is found to be incorrect, carefully bend the float arm tang toward or away from the float valve Until the specified float height is obtained, just close the float valve, © FLOAT VALVE © CARBURETOR SETTING TABLE 1977 (KB) model 1978 (K8) mode! Identification mark ‘556A BTA ‘Main jet No. Fez #65 ‘Slow jet No. #36 #38. LEAN MIXTURE I Jet needle setting |__3rd groove STANDARD 2nd groove RICH MIXTURE ‘Ar serew opening Turn 1% Float height 20 mm (0.8in.) 10.7 mm (0.43 in) ladle speed 1,300 rpm = 82 Date of Issue: Oct., 197 © HONDA MOTOR CO., LTD. V FRAME seroD —-FRONTWHEEL/FRONT SUSPENSION/ STEERING HANDLEBAR Disassembly and assembly, Page 84 HANDLEBAR CLAMP LEVER ‘SPEEDOMETER REMOVAL, fasion (25:3-32.6 tbs-ft) aan kom Gp, 1 0 (2 (13:0-18.1 tbs-fe) OS (3) FRONT FORK Disassembly and assembly, Page 87 COTTER PIN INSTALLATION (1) FRONT WHEEL 3550kem Disassembly and assembly, Page 85 | (26.3-96.2Ibs-ft) ‘After assembly, perform the following operations: ‘Throttle grip free play adjustmen Brake lever free play adjustment Date of sve: Oct, 1977 © HONDA MOTOR CO., LTD. 83 FRONT WHEEL/FRONT SUSPENSION/STEERING ¢€ HONDA cTso a. DISASSEMBLY/ASSEMBLY © HANDLEBAR Tighten the forward screw first, then tighten the rear BRAKE LEVER PIVOT BOLT Do not tighten the bolt sufficiently to bind the brake lever. Make sure that the lever operates frooly, then tighten the lock nut. BRAKE LEVER — Lock nut HANDLEBAR UPPER HOLDER, INSTALLATION _— THROTTLE CABLE Insert the end of * [Align the dowel hole | in the handlebar with the dowel on the switch, the groove in the grip. ENGINE STOP SWITCH 0.8-1.2 kgm (6.8.8.7 Ibs-ft) HANDLEBAR LOWER HOLDER * Install the clamp with the punch mark forward. PUNCH MARK. + Tighten the forward bolts first, HANDLEBAR INSTALLATION wottle cable in the holes in the throttle grip. Then make sure the cable is centered in Ge) TURN SIGNAL INSTALLATION PUNCH MARK Install the handlebar with the punch marks aligned with the top of the lower holders. PUNCH MARK ‘Align the punch mark on the mount with the split in the signal 84 Date of Issue: Oct., 1977 © HONDA MOTOR CO.,LTD. HONDA cTs0 FRONT WHEEL/FRONT SUSPENSION/STEERING © FRONT WHEEL FRor BRAKE SHOE INSTALLATION NOTE Install tire with arrow pointing i BRAKE SHOE ection of rotation. TIRE PRESSURE 1 7 | (25 psi) Baal BRAKE SHOE SPRII ee CA ‘SPEEDOMETER GEAR og, 0 @ A Spot WEAR INDICATOR ~ | ‘Be careful to keep oil or grease off the brake linings or brake drum. BRAKE ARM © DRIVING WHEEL BEARING + BRAKE ARM INSTALLATION BEARING DRIVER No, 07949-3000900 |) BEARING DRIVER ATTACHMENT ‘No. 07948-0980000 Date of fsue: Oct, 197 © HONDA MOTOR CO., LTD. 85 € HONDA FRONT WHEEL/FRONT SUSPENSION/STEERING cTs0 © STEERING STEM STEERING STEM NUT REMOVAL STEERING HEAD TOP THREAD NUT ‘STEERING STEM NUT WRENCH 36 mm PIN SPANNER No. 07915-0300000 ‘No. 07902-0010000 =S ‘STEERING STEM NUT 6.0-7.0 kgm (43.4 — 50.7 Ibs) FORK TOP BRIDGE Screw in the top thread nut until resistance is felt, then, back it off about "/e turn to ensure smooth rotation without play in all direc- tions. ‘TOP THREAD NUT BALL RACE DRIVER STEEL BALLS (21 pes) eaten ‘TOP BALL RACE ‘BOTTOM BALL RACE <= ‘STEEL BALLS (21 pes) STEERING STEM & FRONT FORK INSTALLATION Pal upon each front fork into po Sitio in the top and bottom fork 77 idge using log. 1m (pitch ff iba anhow 86 Date of sue. Oct, 197 © HONDA MOTOR CO., LTD. HONDA cTs0 FRONT WHEEL/FRONT SUSPENSION/STEERING ¢ FRONT FORK Before disassembly, drain oil from the fork and re- move the 37 mm snap ring. 37 mm SNAP RING INSTALLATION + Install the ring with the sharp edge end facing up. FORK SEAL DRIVER No. 07947-1180001 ~~ OIL SEAL CAUTION. 37 mm SNAP RING / 7 TG Install the spring pich end up. the narrow ® FORK PIPE e/ BOTTOM CASE During assembly, be careful to prevent dust and dirt from entering. /~ damaging the Use care in assembling to avoid seal, Fo fil dry fork assembly 130-140 oc (4.44.7 02.) To refill after draining ATF (Automatic Transmission Fluid) NOTE * After assembly, check for operation and signs of leaks. * Wipe clean excess fluid from each fork. +_After assembling, check for oil leaks Date of Issue: Oct., 197 © HONDA MOTOR CO., LTD. 87 FRONT WHEEL/FRONT SUSPENSION/STEERING b. Inspection © FRONT AXLE BEND HONDA cTso0 © BRAKE LINING THICKNESS ‘Standard Service Limit Stendard Service Limit 00.05 mm 4.0mm 2.0 mm (Replace) (0-0.002 in.) L(0.16 in.) (0.08) Act bend is 1/2 of total in “Take least measurement. ‘© FRONT WHEEL RUNOUTS © BRAKE DRUM ID. ‘Standard Standard Service Limit 00.5 mm Axialrunout | ooo2im) 005mm Radial runout | {oo09'n,) 1.0 mm (Replace) (0.04 in.) 110.0 mm (4.3307 in.) 111.0 mm (Replace) (4.3701 in.) NOTE (Check the spokes for looseness, Date of Issue: Oct., 1977 © HONDA MOTOR CO., LTD. HONDA cTso0 FRONT WHEEL/FRONT SUSPENSION/STEERING © FRONT WHEEL BEARING PLAY ‘¢ FRONT SUSPENSION SPRING FREE LENGTH YM Se ara) RADIAL PLAY L ___ Standard Service Limit 203 mm 185 mm (Replace) [ ‘Standard NOTE (0-0.05 mm (0.1 mm (Replace) ‘The front sus sion springs should be installed as a L Radial play| (0,0001-0.0003 in.) | (0.0016 in.) + FRONT FORK PIPE INSPECTION —? + FRONT FORK BOTTOM CASE |.D. Bend or scratches + FRONT FORK PISTON 0.0. [Sandan “Serviee Limit ‘Standard Service Limit 30.950-30.975 mm 30.85 mm (Replace) 31.000-31.039 mm ‘31.10(Repiace) (1.219-4.220 in) (1.218 ind) 4 (1.221-1.223 in.) (1.228 in) Date of Issue: Oct., 1977 © HONDA MOTOR CO.,LTD. 89 2.REAR WHEEL/PEAR SUSPENSION DRIVE CHAIN INSTALLATION RETAINING CLIP [355.0 kgm (25.3 ~ 36.2 Ibe-f) ROTATING DIRECTION 3545kom | | (25.3 32.6 lost DRIVEN SPROCKET 7 REAR WHEEL Disassembly and assembly, Page 92 Y Disassembly and assembly, Page 91 25-35 kom [08.1 25,3 tose REAR SHOCK ABSORBER Disassembly and assembly, Page 93 1B25kem | (13.0-18.1 lost) COTTER PIN INSTALLATION — 40-6.0kem (29.0 ~ 43.4 Ibsft) REAR BRAKE PEDAL PIVOT PIPE 1.8.2.5 kgm (13.0-18.1 Ibs-ft) After assembling, perform the following operations: Brake pedal play adjustment . ........... + Page 31 Rear brake stoplight switch adjustment Page 31 Drive chain slack adjustment ...... Page 32 90 Date of Issue: Oct., 197 (© HONDA MOTOR CO.,LTD. HONDA cTs0 REAR WHEEL/REAR SUSPENSION a, DISASSEMBLY/ASSEMBLY © REAR WHEEL + BRAKE SHOE ASSEMBLY BRAKE SHOE BEARING erate faneresat ee V/ DusT SEAL (iO _-WEAR INDICATOR Z BRAKE SHOE a be — 7 ays. @ COLLAR ‘Do not allow oll or grease to come ae rake drum 3d Linings. —— apJusTER NOTE e BRAKEARM gf “The wheel can be removed by removing the axle shaft | ‘only (with the sleeve nut left intact) without removing the drive ch - + DRIVING WHEEL BEARING BEARING DRIVER No. 07949-3000000 + BRAKE ARM INSTALLATION Align tug with cutout here. ‘BEARING DRIVER ATTACHMENT ‘No. 07945-0880000 ‘Align punch marks. Date of Issue. Oct., 1977 © HONDA MOTOR CO., LTD. 91 HONDA REAR WHEEL/REAR SUSPENSION cTs0 © DRIVEN FLANGE FINAL DRIVEN SPROCKET ADJUSTER, @ BEARING DRIVEN FLANGE + DRIVING WHEEL BEARING BEARING DRIVER No. 07949-6110000 BEARING DRIVER — ATTACHMENT No. 07948-3301000 + TOOTHED WASHER INSTALLATION = NOTE NOTE Drive the bearing squarely, being careful not to allow it ‘Bend two tabs against the corresponding sides of head of to tit. each bolt. 92 Date of Issue: Oct., 1977 © HONDA MOTOR CO.,LTD. HONDA cTso0 + REAR SHOCK ABSORBER REAR WHEEL/REAR SUSPENSION REAR SHOCK ABSORBER SPRING REMOVAL @e@ © REAR SHOCK ABSORBER DISASSEMBLING Too. @- No, 07959-3290000 Before installing the nut, apply seal- O ant to the threads. ‘STOP RUBBER SPRING GUIDE REAR SHOCK ABSORBER SPRING Install the spring with the narrow pitch end up. SPRING HOLDER, ATTACHMENT No. 07967-1150100 Qu—vee ‘After installation, check the operation of the rear shock absorbers. REAR SHOCK ABSORBER ADJUSTMENT tnimivy NOTE + The adjusters should be set in po- sition “III” under average riding condition. : + Set both adjusters at the same posi- 36 mm PIN SPANNER tior Date of Issue: Oct., 197 93 © HONDA MOTOR CO.,LTD. REAR WHEEL/REAR SUSPENSION b INSPECTION © REAR AXLE BEND © BRAKE DRUM 1.D. Standard ‘Service limit 710.0 mm 110.0 mm ‘Standard Service Limit (6.3307 in.) (4.370 in.) 00.05 mm (0.2 mm (Replace) |_(0-0.002 in) 8 in.) ——— clipper gauge and in two directions at right angles to ‘Actual bend is % of total indicator reading. each other. © REAR WHEEL RUNOUT © BRAKE LINIG THICKNESS [—_Standare Service Limit Standard Service Limit 40mm 2.0 mm (Replace) ‘Axial runout. | 0-0.5mm 1.0 mm (Replaced (0.16 ind) (0.08 in.) (0.02in) __|__(0.04 in) i (0.0.5 mm .0 mm (Replace) Radiat runout | (oozin) | _(0.04in.) 94 Date of Issue: Oct. 1977 © HONDA MOTOR CO.,LTD. REAR WHEEL/REAR SUSPENSION ‘© REAR WHEEL BEARING PLAY ‘¢ REAR SHOCK ABSORBER SPRING FREE LENGTH AXIAL GES RADIAL a [Standard Serves 1 C Standard Service Limit] Taxa pay | 005mm ‘0:1 mm (Replace) 223 mm 207 mm (Replace) | | Axil Play | (0.0,002 in.) (0.004 in.) (8.78 in.) (8.16 in.) vas png| 0-003-0.018 mm | 0.04 mm (Replace) | Resiat ley | (¢,0001-0.0007in.)| (0.0016 in.) © REAR SHOCK ABSORBER CHECK ‘© FINAL DRIVEN SPROCKET CHECK —Bend or damage coop a N\ Oil leaks check operation ofthe damper by x moving he damper Saf Up end down, Resistance should be felt No GooD only when the shaft is moved up. Date of Issue: Oct., 1977 95 © HONDA MOTOR CO.,LTD. 8. TAILLIGHT/FUEL TANK + TAILLIGHT + FUEL TANK ‘3mm SCREWS —__ NOTE ing open flames near gasol OR = BLACK STRIPES oon ON SURFACE No STRIPES. NOTE | + Thoroughly clean the interior ofthe fuel tank, *+ Check the fuel tubes for evidence of cracks or dete- 7 Fioration. | | NOTE fuel tank Do not over tighten the screws, as over tightening may damage the lens. BLACK STRIPES ON SURFACE Sa , AUXILIARY FUEL TANK, ‘Connect the tube with stripes to the 96 Date of Issue. Oct., 1977 © HONDA MOTOR CO., LTD. 4, WIRING € HONDA cTso © CABLE ROUTING SJ 97 HONDA cT90 WIRING ‘© WIRE HARNESS ROUTING FRONT BRAKE STOPLIGHT SWITCH ENGINE STOP SWITCH NOTE ‘Make sure that the battery cable is not pinched between the battery cover and frame. RIGHT SIDE COVER of ie) f \ partery sreatner Tuse (| | | | Moh REAR HARNESS Clamp the harness to the back of the rear fender. IGNITION coIL XK SILICON DIODE RECTIFIER 98 Date of lsue: Oct. 1977 CHONDA MOTOR CO.,LTD. VI ELECTRICAL 1.BATTERY CHARGING SYSTEM IGNITION SWITCH © DIAGRAM RECTIFIER A.C. GENERATOR, IGNITION SWITCH Date of Issue: Oct, 1977 © HONDA MOTOR CO., LTD. 99 € HONDA BATTERY CHARGING SYSTEM ered © CHARGING TEST ‘Connect the tester as shown below and run the engine at the fol- lowing speeds: Charging should start (6.8V min.) 1A min (7.2V min) 3.0 min (8.8V min) SPECIFIC GRAVITY OF BATTERY ELECTROLYTE: 1.260-1.280 [at 20°C (68°F)] voltage indicated Do not allow the needle of the meter to swing widely beyond the eedle travel. © STATOR COIL CONTINUITY TEST Pink Yellow White o—}—> ——) ° ‘The coil is normal if there is continuity between circuits (0-0). 100 Date of Issue: Oct., 197 © HONDA MOTOR CO.,LTD. BATTERY CHARGING SYSTEM © RECTIFIER CONTINUITY TEST NOTE Neste (Fee ermine RED/WHITE PINK yettow | GREEN REDMWHITE —_ X x x PINK ° x x YELLOW °

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