@ HONDA er SHOP MANUAL TGSOM GyroS 85 -'86IMPORTANT SAFETY NOTICE Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed. CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not followed, NOTE: Gives helpful information. Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Its important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsate. Please understand that those warnings could not cover al conceivable ways in which service, whether or not recommended by Honda ‘might be done or of the possible hazardous consequences of each conceivable way, nor could Handa investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda must satisfy himself chorough. 4y that neither personal safety nor vehicle safety will be jeopardized by the service methed or tools selected.HOW TO USE THIS MANUAL Follow the Maintenance Schedule recommenda: tions to ensure that the vehicle is in peak operat ing condition and the emission levels are within the standards set by the U.S. Environmental Protection Agency. Performing the first schedul: ‘ed maintenance is very important. It com pensates for the initial wear that occurs during the break-in period, Sections 1 through 3 apply to the whole motor scooter, while sections 4 through 18 describe parts of the motor scooter, grouped according to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section Most section start with an assembly or system illustration, service information and trouble: shooting for the section. The subsequent pages give detailed procedures. If you don't know what the source of the trouble is, refer to section 16 Troubleshooting. All information, illustrations, directions 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 reproduced without written permission HONDA MOTOR CO., LTD. Service Publications Office ENGINE CONTENTS GENERAL INFORMATION i LUBRICATION ee MAINTENANCES Ee FUEL SYSTEM Ee ENGINE REMOVAL/INSTALLATION EE CYLINDER HEAD/CYLINDER/PISTON ALTERNATOR CLUTCH/TRANSMISSION CRANKCASE/CRANKSHAFT FRAME COVERS ‘STEERING/FRONT WHEEL/ BRAKE/SUSPENSION REAR WHEEL/BRAKE REAR SHOCK ABSORBER/ ~ SWING JOINT UNIT ELECTRICAL EQUIPMENT WIRING DIAGRAM TROUBLESHOOTING Date of Issue: September, 1985 © HONDA MOTOR CO.,LTD.1. GENERAL INFORMATION GENERAL SAFETY WW SERVICE RULES 1 MODEL IDENTIFICATION 12 SPECIFICATIONS 13 TORQUE VALUES 15 TOOLS CABLE & HARNESS ROUTING 7 NOISE EMISSION CONTROL SYSTEM 1-11 GENERAL SAFETY If the engine must be running 10 do some work, make sure the area is well-ventilated. Never run the engine in @ closed area. The exhaust contains poisonous. carbon ‘monoxide gas. The battery electrolyte contains sulfuric. acid. Protect your eyes, skin and clothing. In case of contact, flush ‘thoroughly: with water and call a doctor if electrolyte gets in your eyes. Gasoline is extremely flammable and is explosive under The battery generates hydrogen gas which can be highly * ‘certain conditions. Do not smoke or allow flames or explosive. Do not smoke or allow flames or sparks near, sparks in your working area the battery, especially while charging tt SERVICE RULES 1, Use genuine HONDA or HONDA.recommended parts and lubricants oF their equivalents, Parts that do not meet HONDA’s design specifications may damage the scooter. 2. Use the special tools designed for this scooter. 3, Use only metric tools when servicing this scooter. Metric bolts, nuts, and serews are not interchangeable with English fasten: cers, The use of incorrect tools and fasteners may damage the scooter 4, Install new gaskets, O-rings, cotter pins, lock plates, etc. when reassembling, 5. When tightening bolts or nuts, begin with larger-diameter or inner bolts first, and tighten to the specified torque diagonally in 2-3 steps, unless particular sequence is specified. 6. Clean parts in non-flammable or high flash point solvent upon disassembly. Lubricate any sliding surfaces before assembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all electric! wires as shown on page 1-7, Calbe and Harness Routing and always keep them away from sharp edges and areas where they might be pinched between moving parts, t-1GENERAL INFORMATION MODEL IDENTIFICATION The vehicle identification number is on the frame tube in front of the floor board, VEHICLE IDENTIFICATION NUMBER. ‘The frame serial number is stamped on the right side of the ‘The carburetor identification number is on the carburetor frame. body. FRAME SERIAL NUMBER CARBURETOR IDENTIFICATION NUMBER The color code label is attached to the fuel tank under the The engine serial number is stamped on theleftside of the seat. When ordering @ color coded part, always specify its engine case, designated color ENGINE SERIAL NUMBER ‘COLOR CODE LABEL t-2GENERAL INFORMATION SPECIFICATIONS Tem SPECIFICATION DIMENSIONS | Overailength 1.710 mm (67.3 in) Overall width {605 mm (23.8 in) Overall height 1010 mm (38.8 in) Whee! base 1,288 mm (50.6 in) Ground clearance 70 mm (2.8 in) Dry weight 64 kg (141.1 1b) FRAME Type Back bone Front suspension, travel Telescopic fork, 65 mm (2.6 in) Fear suspension, travel Unit swing, 60 mm (2.4 in) | Vehicle capacity load 82 kg (180 tb) | Front tire size, pressure 3.00-10-2PR, 150 kPa (1.50 kg/om?, 21 psi) Rear tire size, pressure 4.50-6-2PR, 75 kPa (0.75 kg/cm”, 11 psi) Front brake Internal expanding shoe Rear brake Internal expanding shoe Fuel capacity | 3.20(1.0 Us gal, 0.81 Imp gal Caster angle | 2r Trait 62 mm (2.4 in) | Front fork grease 5 ec (0.17 US 02, 0.18 Imp o2) ENGINE Type Air cooled 2atroke Cylinder arrangement Single cylinder Bore and stroke 41.0374 mm (1.61 x 1.47 in) Displacement | 49.3. em? (3.0cu in} Compression ratio | 6o:1 Transmission oil capacity 210 cc (7.1 US 02, 7.4 Imp oz) Oit tank capacity 1.2it. (1.3 US at, 1.08 Imp at) Lubrication system Lubricated by the fuel ang oil mixture Port timing totake Open Reed valve controlled Close Reed valve controlled Exhaust Open 73.6" BBDC Close 73.5° ABDC ‘Scavenge Open | 53° BBDC Close | 53° ABDC | Engine dry weight 12.0 kg (26.5 1b) Idle speed [1800 = 100 rpm CARBURETOR | Cerburetor type | Piston vaWve Identification number ‘as: PAZIE After'85: PAZIF Air sorew initial setting 2-1/4 turns out Float level 12.2 mm (0.48 in) #3GENERAL INFORMATION Ss ITEM ] SPECIFICATION DRIVETRAIN | Chih ope Automat cig), wet uth Tranaison 2apeed automatic Primary eecton 2636 Gertie 11%: 1822, 2nd 1.000 Fina rcucton sz ELECTRICAL | rtion Candee cpsitvedcharge nition [EDI Stating peter Starting motor Aternator 31/5 000 pm Spark plug nee TaeE ao [ seas [Prensa WaFPRL For cold climate BPR4HSA 7 WI4FPR-L [For extended high sped riding SPREHSA W24FPRL Spark unos 016-017 mm (0024-008 in Ignition timing “F mark 14.5° BTOC Battery capaiy ravaaH |_ Fue capacity 108 LIGHTS Hesdigh Low/High | yav-26r6W Talon 1av-a23v 3782p Tar sor v2 a@ Speedometer ht nv-san 2p Hin bra ncetor rvaww —2ep Turn inl inceator av-aaw___2ep 1-4GENERAL INFORMATION TORQUE VALUES ENGINE Flywheel nut 1 10 35-40 (3.5-4.0, 25-29) (Below 38°C, 95°F), Crankease bolt 5 | 6 8-12 (0.8-1.2, 6-9) {Below 35°C, 95°F) Ratchet plate bolt 3 6 1012 (1.0-1.2, 7-9) (Below 35°C, 95°F) CHASSIS below, STANDARD TORQUE VALUES ‘Torque specifications listed above are for important fasteners, Others should be tightened to the standard torque values listed tem Torque Nim (kg im, fib) | Trem Torque Nim (kgm, fib) Smmboltand nut | 6 mm bolt and nut 8-12 (0.8-1.2, Gmmboltand nut | 18-25 (1.8-25, 10mm bolt and nut | 30-40 (3.0-40, 12mm bolt and nut | 50-60 (5.0-6.0, 45-6 (0.45-06, 3-4) 5 mm screw 6-9) 6 mm screw, SH bolt 13-18) 6 mm flange bolt and nut 1 22-29) Bmm flange bolt and nut | 2: 36-43) | 10mmflange boltandnur | 3! 35-5.0 (035-05, 25-3.6) 7-11 (0.7-1.1, 5-8) }0—14 (1.0-1.4, 7-10) 30 (2.4-3.0, 17-22) 5-45 (3.54.5, 25-32) 1-5GENERAL INFORMATION TOOLS SPECIAL Description [Tool Number Alternate Tool | __Tool Number Ref. Page Universal bearing puller ‘076310010000 | Commercially available 92 in USA Snap ring pliers 07914-3230001 | Commercially avaiaible 11-15, 11.16 in USA Lock nut wrench 07916-1870101 1147,1148 Lock nut wrench 07916-«M10000 14418 Shaft protector 079311870000 92 Crankease puller 07935-G150000 | Crankcase puller 07937-43000 9.2 Bearing remover set, 12 mm 07936—1660001 87 — Bearing remover shaft, 12mm | (07936—1660100) 87 Remover weight (07741-0010201) | Remover weight 07936-3710200 87 Crankcase assembly tool 07965~1480010 94,95 = Collar (07965—1480100) 94,95 ~ Shatt (07965—GM00300) 94,95 ‘Attachment, 28 x 30 mm (079461870100 11410 Rear shock absorber | attachment A | 07967—ca7o101 | 132,133 Rear shock absorber | attachment B | 07967~-GA70200 132, 138 Steering stem driver | 07948-4300101 war Ball race remover | 07948-GA70000 | Not available in U.S.A. naz Hand vacuum pump ASBTX-ON1-XXXXX | US.A. only ST-AH—260-MC7 | 4.5 | (U.S.A. only) Digital multimeter | 074110020000, KS—AHM—32-003 | 144 | [WS oniy) if . COMMON Description Tool Number Alternate Tool Tool Number Ref, Page Float level gauge (07401-0070000 48 Lock nut wrench, 30x 32mm | 07716-0020400 | Commercially available 11:16, 11.18 inUSA | Extension 07716-0020500 | Commercially available | 116,198 in USA Universal holder (07725~-0030000 73,78 Clutch center holder 07724-0050000 | Commercially available 88,95 in USA Flywhee! puller 07733-00100. | Fiywheel puller 07933-0010000 1 ‘Attachment, 24 x 26 mm 07746~-0010700 18 Pilot, 10mm 077460040100 76,1110 Attachment, 32x 35mm 0746-01010 813 Pilot, 18mm 0746-0040300 813 ‘Attachment, 37 x-40.mm 07746-0010200 a4 Pilot, 17: mm 07746-0040400 94 Attachment, 42x 47mm 077460010300 94,1117 Pitot, 20mm 077460040500 | 94 Driver 07749-0010000 76,813 Driver (07746-0020100 | | 76 Bearing remover expander (07746-0050100 | 1140 Bearing remover collet, 10mm | 077460060200 i110 Shock absorber compressor 07958-3290001 | 132,133 1-6GENERAL INFORMATION CABLE & HARNESS ROUTING Note the following when routing eables and wire harnesses: © A loose wire, harness or cable can be a safety hazard, ‘After clamping, check each wire to be sure it is secure. © Do not squeeze wires against the weld or end of a clamp. ‘© Secure wires and wire harnesses to the frame with their Fespective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the Wires or wire harnesses. @ Route harnesses so they are not pulled taut or have ex: cessive slack. © Protect wires and harnesses with electrical tape or tubing f they contact a sharp edge or corner, Clean the attaching surface thoroughly before applying tape. © Do not use wires or harnesses with 2 broken insulator. Repair by wrapping them with protective tape or replace them, © Floute wire harnesses to avoid sharp edges or corners, ‘© Also avoid the projected ends of bolts and screws ‘© Keep wie harnesses away from the exhaust pipes and other hot parts Be sure grommets ae seated in their grooves properly. ‘@ After clamping, check each harness 10 be certain that it is not interfering with any moving or sliding parts. ‘© Wire harnesses routed along the handlebars should not be pulled taut, have excessive slack, be pinched, or interfere with adjacent or surrounding parts in all steering positions. ‘@ After routing, check that the wire harnesses are not twisted or kinked, 41-7GENERAL INFORMATIONGENERAL INFORMATION (1) REAR BRAKE CABLE (2) THROTTLE CABLE (3) FRONT BRAKE CABLE (4) SPEEDOMETER CABLE (19) col UNIT (6) FUEL LINE (2) THROTTLE Te CABLE Clee, (G)FUEL LINE LINE (8) REAR BRAKE CABLES LINE LOCK CABLE (5) PARKING. (9) ENGINE WIRE (10) LEFT REAR LOCK CABLE HARNESS BRAKE CABLE 1-9GENERAL INFORMATION (1) THROTTLE CABLE (2) OIL CONTROL CABLE x : ( (3) FUEL LINE (6) SPARK PLUG WIRE (4) OIL INLET LINE (5) REAR BRAKE CABLE (7) REGULATOR/RECTIFIER (8) BATTERYGENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM (USA ONLY) ‘© The US. Environmental Protection Agency requires manufacturers to certify that Scooter built after January 1, 1983 will comply with applicable noise emission standards for one year or 1,865 miles (3,000 km) after the time of sale to the ult mate purchaser, when operated and maintained according to the instructions provided. Compliance with the terms of the Distributor’s Warranty for the Honda Scooter Noise Emission Control System is necessary in order to keep the noise emission control system in effect. (USA only) TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal oF rendering inoperative by any person, other than for purposes of maintenance, repair, fr replacement, of any deviee or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or, while it is in use; or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: Removal of, or puncturing the muffler, baffles, healder pipes or any other component which conducts exhaust gates. Removal of, or puncturing of any part of the intake system Lack of proper maintenance. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those speci: fied by the manufacturer 1-44LUBRICATION (1) OIL. TANK (3) OIL OUTLET LINE (4) OIL INLET LINE 2-02. LUBRICATION SERVICE INFORMATION 24 OILSTRAINER 24 TROUBLESHOOTING 21 OILTANK O1L PUMP 22 TRANSMISSION OIL OIL LINES/PUMP BLEEDING 23 LUBRICATION POINTS SERVICE INFORMATION GENERAL ‘© The oil pump can be serviced without removing the engine from the frame, ‘© When removing and installing the oil pump do not allow dust or dirt to enter the engine and all ol line, Do not attempt to disassemble the oil pump. ‘© Bleed the oil pump if there is air in the oil inlet line (from the oil tank to the oil pump) or if the oil line has been discon: nected SPECIFICATIONS Engine oil recommendation Honda 2-stroke injector oll or equivalent Engine oil tank capacity 1.2 liters (1.27 US at, 1.06 Imp at) ‘Transmission oil recommendation Use Honda 4-stroke oil or equivalent. API Service Classification: SE or SF f = Viscosity: SAE 10-40 | Other viseosities shown in the chert may be used when the average temperature in your riding area is within the indicated range a ‘Transmission oil capacity 190 ce (6.4 US oz, 6.7 Imp o2) after draining <=E 210 cc (7.1 US 02, 7.4 Imp 02) after disassembly TORQUE VALUE Transmission oil level check bolt 50-60 Nim (5.0-6.0 kg-m, 3643 ft:lb) TROUBLESHOOTING Excessive ongine smoke and/or carbon on spark plug * Pump not properly synchronized (excessive ol Low quality engine cil Overheating * Oil pump not adjusted properly (insufficient oiling). Low quality oil Seized piston * No oil in tank or clogged oil line. + Pump not properly adjusted (insufficient oiling) * Air in il ines, Faulty oil pump. Clogged oil strainer. il not flowing out of tank * Clogged oil tank cap breather hole. + Clogged oil strainer. 2-1LUBRICATION OIL PUMP REMOVAL NOTE Giean the oll pump and its surrounding area throughly before removing the pump. Remove the following parts — engine cover (page 10-5) — air cleaner case (page 4-3). Disconnect the ol inlet line at the oil pump and clamp the end, Disconnect the oil outlet line and the oil pump control cable. Remove the bolts attaching the oil pump set plate Remove the oil pump by pulling it straight up, Remove the O-ring INSPECTION Remove the oll pump and check for — deteriorated O-ring damage to the crankease mating surface. — damage to the pump body. = pump control lever operation. — worn or damaged pump gear = oll leaks. cAUTION + Do not disassemble the oil pump. INSTALLATION Coat a new O-ring with grease and install it into the oil pump. mounting hole Apply molybdenum disulfide grease to the oil pump driven {gear and install the oil pump onto the crankcase. 2-2 (1) PUMP CONTROL LEVER (2) GEAR.LUBRICATION ioc CONTROL CABLE Install the pump set plate and tighton the bolt. samme ae (POIU INLET CINE} Connect the inlet and outlet lines to the oil pump. Connect and adjust the oil control cable (page 36). Bleed air from the oil pump and oil outlet line. OIL LINES/PUMP BLEEDING Remove the air cleaner case (page 43). Fill the oll tank with the recommended oil Place a shop towel around the oil pump. Disconnect the oil inlet line from the oil pump. Fill the oil pump with cil by squirting about 4ce (0.14 US oz) of clean engine oil through the oll pump inlet opening, Fill the oll inlet line with oll and connect it to the oil pump, Disconnect the cll outlet line from the intake pipe, fill it with oil and reconnect to the intake pipe, Install the air cleaner ease (page 4:3). Temporarily install the exhaust muffler Start the engine and allow it idle. Bleed air from the oil pump by loosening the bleed bolt on the oil pump. Ramm Perform this operation in a well ventilared area, + Do not race the engine while bleeding air from she oll pump. Remove the exhaust muffler. Install the engine cover {page 10-6}. 2-3LUBRICATION OIL STRAINER Remove the frame rear cover (page 10-4. Disconnect the oil inlet Tine at the joint and allow the oil to {ain into a clean container Loosen the tube clip and disconnect the oil tube joint under the oll tank, Remove the oil strainer. Clean the oil strainer with compressed air. Install the oil strainer in the reverse order of removal, Fill the oil tank with the recommended oil. Bieed air from the oil pump and oil lines OIL TANK REMOVAL/INSTALLATION Remove the body rear cover (page 10-4) Disconnect the oil inlet line at the joint and drain and cil into ‘a clean container. (2) OIL INLET LINE 2-4LUBRICATION Disconnect the wires from the oil level sensor. - ceeeeaneen Remove the two oil tank mounting bolts and the oil tank W)) CNSUEVEL Sees aa from the frame, Install the oll tank in the reverse order of removal. Bleed air from oil pump and oil lines (page 2:3). TRANSMISSION OIL Place the scooter on the level ground, Remove the oil level check bolt. Remove the drain bolt and drain oll thoroughly. Make sure that the sealing washer on the drain bolt isin good! condition and install the drain bolt. Fill the transmission with the recommended oil (page 2-1) Up to the bottom edge of the oil level check bolt hole. OIL CAPACITY: 190 ce (6.4 US 07, 6.7 Imp 02) after draining 210 ce (7.1 US 07, 7.4 Imp 02) after disassembly Install and tighten the oil level check bolt. TORQUE: 50-60 N'm (5.0-6.0 kg-m, 36-43 fb} Check the transmission case for oil leaks. (1) OIL LEVEL CHECK. BOLT HOLELUBRICATION LUBRICATION POINTS Use general purpose grease when not specified here. ‘Apply oil or grease 10 sliding surfaces not shown here. CONTROL CABLES Periodically, disconnect the throttle and brake cables at their upper ends, Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a light weight oil a (2) PARKING CLOCK LEVER, (1) TRANSMISSION. PIVOT/LINK. (8) BRAKE CAM SHAFT/ WHEEL BEARINGS tan (3) THROTTLE GRIP Over stroke up to 1 mm (0.04 in) is acceptable. However, the alignment mark should never be short of the index mark, otherwise engine damage will occur because of in- sufficient lubrication. ses(2) LOCK NUT (3) ADJUSTER anm. 3 (2) ADJUSTING INDEX MARK BS (3) ALIGNMENT MARK (4) LocKNUT. a Se amr 3-5MAINTENANCE Start the engine and open the throttle slightly above idle speed and make sure that the oil pump control lever starts to move simultaneously as the engine speed incrases. Adjust if necessary by loosening the lock nut and turning the adjusting nut Tighten the lock nut securely after adjustment, NOTE = "If the pump control level is opened excessively, white smoke or hard starting will occur. + If the pump control lever movement is insufficient, piston seizure may result. FUEL FILTER SCREEN Turn the fuel valve OFF. Remove the body centar cover (page 10-4), Remove the fuel cup, O-ring, filter screen, and drain the gasoline into a suitable container * Gasoline is flammable and is explosive under certain con ditions, Do not smoke or allow flames or sparks near the equipment while draining fuel, Wash the cup and filter screen in clean non-flammable or high flash point solvent, Reinstall the screen, aligning the hole in the sereen with the round boss on the fuel valve body. Install anew O-ring into the fuel valve body, Reinstall the fuel cup, making sure the O-ring is in place. Hand tighten the fuel cup and then torque it to specification. TORQUE: 3-5 Nom (0.3-0.5 kgm, 2.2-3.6 ftb) CAUTION. > + Do not overtighten the fuel cup or you wil damage the threads. After installing, turn the fuel valve ON and check that there ae no ol leaks (2) FUEL CUP (3) O-RING FUEL LINE Remove the frame center cover and engine cover (section 10). Replace any parts which show signs of deterioration, damage or leaks, 3-6MAINTENANCE OIL LINE Replace any oil line parts which shows signs of deterioration, damage or leaking. MUFFLER DECARBONIZATION Remove the mutfler (page 10-5) Remove carbon deposits from the inside of the muffler. Install the muffler (page 10:6). me / a (TVOILINLET LINE = (2) OIL OUTLET. LINE i oY ae WHEELS Cee ees iet aL samara Geasteieneniied NOTE A Fea ht 77 Telco ea Tea oe aan TIRE PRESSURE: FRONT 150 kPa (1.5 kg/om?, 21 psi) REAR — 75 kPs (0.75 kg/cm®, 11 psi) TIRE SIZE: FRONT 3,00~10-2R REAR 4.50-6-2PR BRAKES (i) FRONT BRAKE LEVER FRONT BRAKE LEVER FREE PLAY Measure the free play at the end of the lever. FREEPLAY: 10-20 mm (3/8—3/4 in) ron ee (3/8 -3/4 in) r— T ‘Turn the brake adjusting nut to obtain specified free play. . (1) FRONT BRAKE ADJUSTING NUT] 3-7MAINTENANCE REAR BRAKE LEVER FREE PLAY Measure the free play at the end of the lever. FREEPLAY: 10-20 mm (3/8—3/4 in} a LEVER 4. a 10-20 mm (3/8—3/4 in) «@ al ll ‘Adjust the tree play by moving both adjustment nuts an equal amount to allow the specified travel After adjustment, make sure that both rear brake arms have free play. NOTE + If the brake arms have no play, the primary rear brake cable may be stretched. Replace the primary cable and adjust the rear brake cable equalizaer (page 11-8) BRAKE SHOES Replace the brake shoes, if with the correct lever free play, ‘the arrow on the brake arm aligns with the reference mark a" (page 11-12, 12.3). PARKING LOCK LEVER TH PARKING Lock LEVER Measure the free play at the end of the lever FREEPLAY: 10-15 mm (3/8-5/8 in) 10-15 mm. (3/8578 in) 4 3-8MAINTENANCE {f adjustment is necessary, proceed as follows: Remove the head pipe cover (page 10-2). Loosen the lock nut and turn the adjusting nut until obtaining the specified free play Tighten the lock nut securely. Install the head pipe cover (page 10:2) STEERING HEAD BEARINGS NOTE Make sure the cables do nat interfere with the movement of the handlebar. Raise the front wheel off the ground and make sure that the handlebar moves freely. If the handleber moves unevenly, binds or has vertical play, adjust the steering head bearings (page 11-18) If the handlebar still move unevenly, binds or has vertical play after adjustment, inspect the steering head bearings and replace if necessary (page 11-17) SUSPENSION FRONT. ‘Check the action of the front fork by compressing it several times. Check the entire fork assembly for damage. Replace or repair any damaged components, REAR SUSPENSION ‘Check the shock absorber for leakage or damage. Check the suspension operation. Tighten all bolts and nuts to the specified torque values:MAINTENANCE SPARK PLUG Disconnect the spark plug cap and clean and dirt from around the spark plug base Remove and discard the spark plug ‘Measure the new spark plug gap using a wire-type feeler gauge, RECOMMENDED SPARK PLUGS: e NGK NO. Standard BPRGHSA | W20FPRL For cold climate BPRAHSA WI4FPRL For extended ieee BPRBHSA | W24FPRL SPARK PLUG GAP: 0.6-0.7 mm (0.024~-0.028 in) Install the spark plug by hand, then tighten with 2 spark plug wrench, Connect the spark plug cap. LIGHTS AND HORN Start the engine and allow it to idle Check all lights and horn for proper operation, HEADLIGHT BEAM ADJUSTMENT Adjust vertically by loosening the headlight case mounting bolts and moving the ease, ‘Adjust horizontally by turning the adjusting screw. (SIDEELECTRODE fy. gy 7) RR JF 2) center ELectRovE (1) HEADLIGHT MlouNTING BOT (2) HORIZONTAL ADJUSTING SCREW 3-10MAINTENANCE IGNITION TIMING NOTE + ‘The Capacitive Discharge Ignition (CDI) system is factory preset and does not require adjustment. i + Use the procedures below to check the CDI function and (4) INDEX MARK ignition timing, (2) "F" MARK Remove the timing hole cap. ‘Connect a tachometer and timing light. Start the engine and allow it to idle. r IDLE SPEED: 1,800 + 100 rpm | Timing is correct if the “F” mark on the flywheel is aligned With the index mark on the left crankcase at idle. If the ignition timing is incorrect, refer to page 14-7. CYLINDER COMPRESSION Warm up the engine. Stop the engine and remove the spark plug Connect a compression gauge to the engine. ‘Open the throttle completely and operate the starter motor for several seconds. NOTE | i Be sure compression does not leak at the gauge connection. Mh SERVICE LIMIT: 800 kPa (8.0 ka/em*, 114 psi) ree avai COMMERCIALLY AVAILABLE ee Low compression ean be caused by: Bown cylinder head gasket + Worn piston ring or cylinder. High compression can be caused by: + Carbon deposits in combustion chamber or on piston head. NUTS, BOLTS, FASTENERS Tighten all bolts, nuts and fasteners to their specified torque values (page 1-5) at regular intervals as shown in the Mainte- nance Schedule. ‘Check that all cotter pins and sefety clips are in place. 3-114-04. FUEL SYSTEM SERVICE INFORMATION TROUBLESHOOTING FUEL TANK AIR CLEANER CASE 41 CARBURETOR 44 a1 REED VALVE 4.10 | 42 AIR SCREW ADJUSTMENT an 43 SERVICE INFORMATION GENERAL © Use caution when working with gasoline. Always work in a well-ventilated area and away from sparks or flames. When disassembling fuel system parts, note the location of the O-rings. Replace them with new ones during assembly. © Bleed air from the oil outlet line whenever itis disconnected. ‘© Route all tubes and cables properly SPECIFICATIONS [ale speed Throttle grip free play TORQUE VALUES Carburetor bolt Fuel strainer cup TOOLS Special Vacuum pump Common Float level gauge TROUBLESHOOTING Engine cranks but won't start No fuel in tank + Too much fuel getting to cylinder. + Clogged air cleaner. Faulty auto bystarter Engine idles roughly, stalls or runs poorly Incorrect idle speed. Rich mixture. Lean mixture + Clogged air cleaner. Leaking intake pipe. + Contaminated fuel Faulty ignition system. Low compression. * Water in fuel strainer cup, 14 mm (0.59 in) "98: PA27E After '85:_PAZ7E 12.2 mm (0.48 in) 2.1/4 turns out 1,800=100"pm 2-6 mm (1/8-1/4 in) 9-12 Nim (0.9-1.2 kom, 6-9 ft-lb} 3-5 Nem (0.3-0.5 kom, 2.2-3.6 ft1b) A937X—041—-XXXXX or ST-AH—260-MCT (U.S.A. only) (07401—0010000 Lean mixture Clogged carburetor fuel jets Clogged fuel cap vent. Clogged fuel filter, Kinked or restricted fue! line + Faulty flost valve. Float level too low. + Clogged air vent tube. Rich mixture + Faulty float valve. + Float level too high. + Clogged carburetor air jets + Disconnected auto bystarter wires. ‘Auto bystarter valve set plate not set property. 4-4FUEL SYSTEM FUEL TANK 7 * Gasoline is extremely flammable and is explosive under cartain conditions. Perform this operation in a well-venti= lated area and do not smoke or allow sparks in the area, FUEL FILTER CLEANING Remove the body center cover (page 10-4), Turn the fuel valve OFF. Disconnect the fuel line at the joint, turn the valve ON and. drain the fuel into a clean container. Reconnect the fuel line to the joint. Disconnect the fuel line from the fuel valve Loosen the fuel valve lock nut and remove the valve and filter Do ail from the tank, . Clean the filter with compressed air. Install the filter and a new Oring onto the valve. Install the valve onto the tank and tighten the lock nut. Do rot over-tighten the lock nut Connect the fuel line to the valve. Fill the tank with gasoline, Turn the valve ON and make sure that there are not leaks. Install the body center cover [page 10-4) FUEL TANK REMOVAL Remove the body center cover (page 104). Remove the seat attaching nuts and the seat from the fuel tank, (2) SEAT 4-2FUEL SYSTEM ‘Turn the fuel valve OFF and disconnect the fuel line from the valve Disconnect the air vent tube from the tank, 5 Remove the four tank mounting bolts and the tank. FUEL TANK INSTALLATION Install the fuel tank in the reverse order of removal Make sure that there are no leaks after instalation. AIR CLEANER CASE (1) wine CONNECTORS @)AI REMOVAL/INSTALLATION Remove the engine cover (page 10-5), Remove the spark plug wire from the plug and clamp. Disconnect the wire connectors above the air cleaner case Remove the air cleaner case mounting bolt and the case. Install the air cleaner case in the reverse order of removal i 3 BR 8FUEL SYSTEM CARBURETOR THROTTLE VALVE DISASSEMBLY Remove the carburetor cover. Remove the carburetor cap and pull out the throttle valve. Disconnect the throttle cable from the throttle valve, Romove the throttle valve spring, carburetor eap and sealing cap from the throttle cable. 4 After ‘85: CAUTION: * The carburetor cap is an integral part of the throttle cable assembly. The cap cannot be separated from the assembly without damaging the cable. (2) THROTTLE VALVE (3) CARBURETOR CAP. Remove the retainer and jet needle from the throttle valve. Check the jet needle and throttle valve for wear or damage and replace if necessary. 2 Z “> Snrerainen 2) NeeDLe cuir | (3) JET NEEDLE (4) THROTTLE VALVE 4-4FUEL SYSTEM CARBURETOR REMOVAL Remove the engine cover (page 10.5) Remove the right rear wheel (page 12-2), Remove the air cleaner case mounting bolt (page 4:3) the air eleaner case away from the carburetor. Remove the twa muttier bracket bolts and the bracket. Remove the two intake pipe cover bolts and the cover. nd pull Disconnect the auto bystarter wires Remove the carburetor eap from the carburetor. ‘Turn the fuel valve OFF and disconnect the fuel line from the carburetor Remove the two carburetor mounting bolts and the carburetor from the intake pipe AUTO BYSTARTER INSPECTION Stop the engine and allow it to coo! for at least 10 minutes RESISATNCE: 10 ohms max. Replace the auto bystarter if it is out of specification or it there is no continuity. Allow the carburetor to coo! for at least 30 minutes and then presturize the enriching circuit. If the passage is blocked, replace the auto bystarter. TOVMUFFUER eRacKeT STO) ATCLERNER ae Weg) Sos (4) INTAKE PIPE COVER Soe (1) FUEL LINE (2) AUTO BYSTARTER WIRES (1) VACUUM/PRESSURE PUMP. AQ37X-041—XXXXX OR PRESSURE PUMP ST—AH-260-MC7 (U.S.A. only) 4-5FUEL SYSTEM Connect a 12V battery between the auito bystarter wires and wait five minutes NOTE + The auto bystarter wires can be connected to the battery terminals without regard to the porality Pressurize the fuel enriching circuit. Replace the auto bystarter if there is not restriction to the pressure applied. (1) VACUUM/PRESSURE PUMP A937X—041—XXXXX OR, PRESSURE PUMP. ST—AH—260-MC7 (U.S.A. only) AUTO BYSTARTER REMOVAL. Remove the two auto bystarter set plate screws, set plate and auto bystarter. (1) SCREWS! Remove the O-ring from the auto bystarter, GV eveTanTen NECOCETBYO SING Chock the auto bystarter needle and valve for wear or damage. Replace the euto bystarter as an assembly, if necessary. (3) BYSTARTER VALVE FLOAT CHAMBER DISASSEMBLY Place a drain pan under the carburetor and loosen the car buretor drain screw to drain the fuel Remove the float chamber screws and chamber from the carburetor. (1) scREWs: (2) FLOAT CHAMBERS) ORAIN SCREW 4-6FUEL SYSTEM Remove the float pin sot screw, float pin, float and float valve. Remove the O-ring. (1) FLOAT, (2)FLOATPIN (3) SCREW (4) O-RING (5) FLOAT VALVE == Inspeet the float valve for grooves and nicks and replace as vave'seat required yield v Turn the air serew inv Until it seats lightly and record the number of turns, Use this as a reference for reinstallation. CAUTION * Damage 10 the air screw seat will occur if the air serew is tightened against the seat Remove the air screw. Remove the throttle stop screw. Remove the main jet and needle jet. (2) THROTTLE STORSCREW f4“ (2) AIR SCREW Blow compressed air through all carburetor body openingsFUEL SYSTEM FG Lier sani ss ste GrreeoiE ser) wan er Ital nade are main Ital he a ae tr gel potion a recorded uring eae inal te vt sop ew (3) THROTTLE STOP SCREW (a) AIR SCREW Install the float valve, float and float pin. Tighten the float pin set serew securely (1) FLOAT (2) FLOAT PIN. (3) SCREW Install @ new float chamber O-ring 5 (4) O-RING FLOAT LEVEL INSPECTION ~~ Remove the O-ring from the earburetor body. Measure the float level as the float lip just contacts the float valve FLOAT LEVEL: 12.2 mm (0.48 in) NOTE The float is not adjustable; if the level is incorrect, it must be replaced, Replace the float if the float level is incorrect. Reinstall the O-ring into the carburetor body groove. (1) FLOAT LeveL GAUGE Check the operation of the float and install the float chamber. 974010010000 AUTO BYSTARTER INSTALLATION Install a new O-ring onto the auto bystarter Install the auto bystarter onto the carburetor. Install the set plate onto the auto bystarter (in the second ‘groowe from the top) and tighten the two screws.FUEL SYSTEM CARBURETOR INSTALLATION (1) FUEL LINE 12) CARBURETOR CAP CAUTION + Do not allow any debris into the carburetor. Be sure the O-ring isin place on the carburetor. Install the heat insulator and carburetor mounting bolts, TORQUE: 9-12.N-m (0.9-1.2 kgm, 7-9 ftib) Install the carburetor eap. xe Connect the fuel line and auto bystarter wires. 44) AUTO BYSTARTER i “gi (80S wines tnstall the air cleaner case (page 43} FCUTGIT Install the intake pipe cover using the two bolts Install the muffler bracket with the two bolts THROTTLE VALVE ASSEMBLY Install the jet needle into the throttle valve and secure it with & the retainer. aa RETAINER (2) NEEDLE CLIP (aysernegoie | LEAN te NOTCH STANDARD 2nd NOTCH cea i THROT Ovatve RICH Sra—4th—Bth NOTCH Install the sealing cap, carburetor cap, throttle valve spring and valve onto the throttle cable. Slide the throttle valve into the carburetor body by aligning its groove with the throttle stop serew. .,. (1) GROOVEFUEL SYSTEM Tighten the carburetor cap, Perform the following adjustments and operations. — throttle cable free play adjustment (page 3-5) air screw adjustment (page 4-11) ~ idle speed adjustment (page 2-5) REED VALVE REMOVAL Remove the carburetor (page 4-5) Remove the Intake pipe by removing the two bolts. Remove the reed valve. 7 acm (1) REED VALVE INSPECTION Check the reed valve for damaged or weak reeds, Check the valve seat for cracks, damage or clearance between the seat and reed. Replace the valve if necessary. CAUTION * Do not disassemble or bend the reed stopper. To do so can cause loss of power and engine damage. If the stopper, reed or valve seat is faulty, replace them as a unit, INSTALLATION The installation sequence is essentially the reverse order of removal (3) REED VALVE SEAT! After installation, check for secondary leaks. 4-10FUEL SYSTEM AIR SCREW ADJUSTMENT NOTE The engine must be warm for accurate air serew adjust: ment If the engine misses or runs erratically, proceed a8 follows: Screw in the air screw until it lightly seats, then turn it out as specified. AIR SCREW OPENING: 2.1/4 turns out CAUTION ‘Damage to the air screw seat will occur if the air screw is tightened against the seat Reset idle speed with the throttle stop serew. IDLE SPEED: 1,800 + 100 rpm Make sure that the engine dose not miss or run erratically by lightly snapping the throttle. If necessary, turn the air serew 1/4 turn (maximum) in either direction to find the best performance If the engine can not be adjusted within 1/4 turns, refer to Troubleshooting, POOR PERFORMANCE AT LGW AND. IDLE SPEEDS (page 16:3) 4-11ENGINE REMOVAL/INSTALLATION 5-05. ENGINE REMOVAL/INSTALLATION Es = ——— SERVICE INFORMATION 51 ENGINE INSTALLATION 53 | ENGINE REMOVAL, 52 SERVICE INFORMATION GENERAL © The engine must be removed to service the crankshaft, sPeciFicaTions = Engine weight 12 kg (26.5 1b) TORQUE VALUES Engine mounting bolts 24-30 Nom (2.4~3.0 kgm, 17-22 frb) Roar axle nut (85-80 Nim (6.58.0 kgm, 48-58 ft-lb) 5-4ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Remove the engine cover (page 10-5). Remove the body center cover (page 10-4), Place jacks or other supports under the swing joint and both sides of the frame, Remove both rear wheels with the hubs (page 12-2) Disconnect the ground cable from the battery negative termi ral. Disconnect the engine harness connectors from the main harness Make sure that the parking lock lever is released and dis ‘connect the parking lock rod by removing the nur. Disconnect the right and left rear brake cables from the brake Disconnect the oil control eable from the oil pump and cable holder Remove the carburetor cap. Remove the air cleaner case (page 4-3). 5-2ENGINE REMOVAL/INSTALLATION Turn the fuel valve OFF and disconnect the fuel line at the joint. BPO) Fer Line iqiont Te Disconnect the oil inlet line at the joint and drain the oil into a clean container. Remove the three engine mounting nuts and the engine from the swing joint, Remove the two dowel pins from the swing joint. ENGINE INSTALLATION Installation sequence is essentially the reverse order of re: moval TORQUE: ENGINE MOUNTING BOLTS: 24-30 Nom (2.4~3.0 kgm, 17~22 ft-lb) REAR AXLE NUTS: (65-80 Nim (6.5. kgm, 48-58 fb) Perform the following inspections and adjustment after installation wire and cable routing (page 1-7). throttle grip free play adjustment (page 35). cil control cable adjustment (page 3-5) oil pump and line bleeding (page 2:3) rear brake adjustment (page 3:8) parking lock adjustment (page 3.8)6. CYLINDER HEAD/CYLINDER/ PISTON SERVICE INFORMATION 61 CYLINDER/PISTON REMOVAL 63 TROUBLESHOOTING 61 PISTON/CYLINDER INSTALLATION 6-6 CYLINDER HEAD REMOVAL 62 CYLINDER HEAD INSTALLATION 68 SERVICE INFORMATION GENERAL ‘© Allcylinder head, cylinder and piston service can be done with the engine installed in the frame. ‘© Before disassembly, clean the engine to prevent dirt and dust from entering the cylinder and crankcase. ‘© Remove all gasket material from the mating surfaces of the cylinder head, cylinder and crankcase. ©. Use caution when disassembling and assembling the cylinder head, cylinder and piston to avoid damaging them. ‘© Clean all disassembled parts thoroughly before inspection. Coat all sliding surfaces with clean 2-stroke injector oil before assembly. SPECIFICATIONS ITEM STANDARD mm (in) | SERVICE LIMIT mm (in) “Cylinder head warpage = 0,70 (0.004) ‘ 441,000—47,020 (1,6142-1.6750) 47,050 (1.6161) Pision O.D, (4 mm from bottom of piston skirt) | 40.955~40.970 (1.6124—1.6130) 40,900 (1.6102), Cylinder to-iston clearance a 0.035~0,050 (0,0013-0.0019) | _0.10 (0.008) Piston pin hole 1.D. 10.002—10.008 (0,3938—0.3940) 10.025 (0.3947) | Piston pin O.D. |__ 9.994—10.000 (0.3935-0.3937) 9.980 (0.3929) | Piston-to piston pin clearance 0,0020,074 (0.0001=0,0006) | __0.030 (0.0012) | Piston ring end gap (top, second) 0,100.25 (0.004-0.01) 0.50 (0.02) TORQUE VALUE Cylinder head bolt TROUBLESHOOTING Compression to low, hard starting or poor performance at low spood * Leaking cylinder head gasket. Loose spark plus. Worn, stuck or broken piston rings. + Worn or damaged eylinder and piston. Faulty reed valve, ‘Compression too high, overheating or knocking Excessive carbon build-up in cylinder head or on top of piston. 8-12.Nm (0.8-1.2 kgm, 6-9 tb) Abnormal noise-piston + Worn eylinder and piston. + Worn piston pin or piston pin hole. * Worn connecting rod small end bearing, Abnormal noise + Worn, stuck or broken piston rings. Worn or damaged eylinder 6-1CYLINDER HEAD/CYLINDER/PISTON CYLINDER HEAD REMOVAL Remove the engine cover (page 10-5). Remove the right rear viheel (page 12-2 Remove the muffler bracket by removing the two bolts. Remove the intake pipe cover by removing the two bolts Remove the spark plug cap. Remove the two nuts attaching the spark plug guard and the guard, Remove the cylinder head shroud by removing the bolt, Remove the four eylinder head bolts and the cVlinder head. NOTE + Loosen the bolts in a crisscross pattern in 2 or 3 steps: Remove the cylinder head gasket 6-2 SUV CVONDER HEAD TF” » (2) 80LTs bs " (4) SPARK PLUG «80Lt “) GuanD (GTEYLINDER HEAD |B nurs (2) BOLTS, (5) PLUG CAPCYLINDER HEAD/CYLINDER/PISTON COMBUSTION CHAMBER DECARBONIZING Remove the carbon deposits from the combustion chamber, and the piston head, Clean the head gasket surface. e , CAUTION geet ae ae ed et ms! CYLINDER HEAD WARPAGE INSPECTION ‘Check the cylinder head for warpage with a straight edge and a feeler gauge along the lines indicated. SERVICE LIMIT: 0.10 mm (0,004 in) CYLINDER/ PISTON REMOVAL Remove the cylinder head (page 6-2). Remove the left rear wheel (page 12-2) Remove the exhaust pipe joint nuts, mounting bolt and the pipe, Remove the cylinder being careful not to damage the piston. CAUTION Do not pry between the cylinder and crankcase or strike the fins. Place a shop towel into the crankease around the connecting rod.CYLINDER HEAD/CYLINDER/PISTON Remove the piston pin clip with needle nose pliers Press the piston pin out of the piston, NOTE * Do not damage or seratch the piston. + Donot apply side force to the connecting rod, Do not let the clip fall into the crankcase. Remove the piston rings NOTE * Spread each piston ring and remove it by lifting it up at a point just opposite the gap. CYLINDER/PISTON INSPECTION Check the cylinder and piston for wear or damage. Ciean carbon deposits from the exhaust port area, CAUTION ‘Do not scratch or score the eylinder liner Inspect the eylinder bore for wear at three levels in the X and Y directions. Use the largest measurement to determine the amount of eylinder wear. SERVICE LIMIT: 41,050 mm (1.6161 in) (1) PISTON PIN TS (2) PISTON PIN CLIP (2) SECOND (1) TOF RiNG| RING 3) EXPANDER 6-4CYLINDER HEAD/CYLINDER/PISTON CAUTION The cylinder is identified with either a “A” or no mark in the location shown. When the eylinder is replaced, use @ new cylinder with the same mark as the old one, Measure the piston O.D. at a point 4 mm from the bottom of the skirt SERVICE LIMIT: 40,900 mm (1.6102 in) Calculate the piston-to-cylinder clearance SERVICE LIMIT: 0.10 mm (0.004 in} Measure the piston pin hole 1.0. SERVICE LIMIT: 10.025 mm (0.3947 in) Measure the piston pin 0.0. SERVICE LIMIT: 9,980 mm (0.3929 in) Calculate the piston-to-piston pin clearance ‘SERVICE LIMIT: 0,030 mm (0.0012 in) PISTON RING INSPECTION ‘Set each piston ring squarely into the eylinder 30 mm (1-1/4 in) from the bottom using the piston and measure the end gap with a feeler gauge. SERVICE LIMIT: 0.50 mm (0.019: TIMARKAORNO MARKCYLINDER HEAD/CYLINDER/PISTON CONNECTING ROD INSPECTION Install the bearing and piston pin in the connecting rod smelt ‘end and check for excessive play. PISTON/CYLINDER INSTALLATION Clean the piston ring grooves. Lubricate the piston rings and piston ring grooves with clean 2stroke oil Install the piston rings on the piston, with the marks facing up. NOTE ‘After instalation, check that the rings move freely in the ing grooves: + The top ring is @ keystone ring and is not interchangeable | with the square second ring (1) PISTON (2) TOP RING Check the fit of each ring in the ring groove by pressing the fing into the groove to make sure that it is flush with the piston at several points around the ring. ‘A ring that will not compress means that the ring groove is dirty and should be cleaned or that the wrong ring is in the sroove. Coat the needle bearing and piston pin with 2-stroke oil Install the needle beating at the connecting rod, and install the piston with the “EX” mark facing the exhaust side. Install new piston pin clips. 6-6 (1) TOP RING (2) SECOND RING (3) EXPANDER (1) PISTON PIN | (2) PISTON PIN CLIP (3) “EX” MARKCYLINDER HEAD/CYLINDER/PISTON Remove all gasket material from the cylinder and erankcase mating surfaces, Install a new cylinder gasket onto the cylinder. Be sure the ring end gaps are aligned with the piston ring locating pins in the ring grooves. caution ‘Be sure the rings do not rotate in the their grooves over the locating pins 10 prevent ring breakage and piston and cylinder damage Lubricate the piston and cylinder with 2stroke oil, compress the rings and slide the cylinder onto the piston. CAUTION + Avoid damaging the sliding surface of the piston. (1) CYLINDER GASKET! WRIA) PISTON RING LOCATING PINS - ih "a 6-7CYLINDER HEAD/CYLINDER/PISTON Install the following: = cylinder head. — exhaust pipe using the mounting bolt and two joint nuts. — left rear wheel (page 12:3) — engine cover (page 10-5), CYLINDER HEAD INSTALLATION Install a new cylinder head gasket. Install the cylinder head. Install and tighten the four cylinder head bolts in a erisserass pattern, in 2 to 3 stops, TORQUE: 8-12 Nem (0.8-1.2 kg-m, 6-9 ftlb) Install the following = cylinder head shroud with the bol. — spark plug guard and tighten the two nuts. = spark plug and cap. Install the following: ~ intake pipe cover using the two bolts, — muffler bracket with the two bolts, — right rear whee! (page 12-3) ~ engine cover (page 10:5), Perform the following inspections: — compression test (page 3-11). — check for abnormal engine noise, — check for eylinder air leaks. (4) JOINT NUT ov (4) SPARK PLUG GUARD (3) BOLT (5) PLUG CaP INTAKE PIPE COVER, a. “ee * i Tigres 6-8MEMOALTERNATOR (1) LEFT-HAND THREADS 7-0 lass KE WE7. ALTERNATOR i. SERVICE INFORMATION 7] ALTERNATOR INSTALLATION 75 LEFT CRANKCASE REMOVAL 72 LEFT CRANKCASE COVER ASSEMBLY 7-6 LEFT CRANKCASE COVER LEFT CRANKCASE COVER DISASSEMBLY 7-2 INSTALLATION 7 ALTERNATOR REMOVAL 73 SERVICE INFORMATION i GENERAL re ‘© Dornot remove the pulse generator from the stator bate © See Chapter 14 for alternator inspection, TORQUE VALUE Flywheel nut 35-40 Nom (3.5~4.0 kgm, 25-29 feb) TOOLS Common Flywheel puller 07733-0010000 or 079330010000 Universal holder 07725-0030000 Driver 07749-0010000 Attachment, 24 x 26 mm 07460010700 Pilot, 10 mm 07746-0040100 Driver 07746-02010 7-1ALTERNATOR LEFT CRANKCASE REMOVAL Remove the following: — engine cover (page 10.5). sear wheels (page 12-2) cylinder head shroud (page 6-2) and exhaust pipe (page 6-3). ~ left rear brake cable from the brake arm, = air intake duct Remove the left crankcase cover bolts and the cover. LEFT CRANKCASE COVER DISASSEMBLY For ease of disassembly, temporarily reinstall the left crank: ‘case cover onto the rear wheel and remove the final shaft nut and bearing cap. NOTE: +The nut has lefthand threads Remove the snap ring. 7-2ALTERNATOR Heat the crankcase cover around the bearing. CAUTION + Wear gloves 10 protect your hands when handling the heated cover. Thread the nut onto the final drive shaft just enough to cover the end of the shatt, and carefully drive the shaft and bearing ‘out of the crankcase cover using a plastic hammer. Flemove the inner bearing ALTERNATOR REMOVAL Remove the following left crankease cover (page 7-2), = cooling fan bolts and the fan. — two dowel pins, Hold the flywheel with the universal holder and remove the flywheel nut. (NUT y (2) UNIVERSAL HOLDER, “___.97725~-0030000 7-3ALTERNATOR Remove the flywheel with the puller Disconnect the auto bystarter, resistor and ignition coil wire connectors, Disconnect the wire from the starter motor. Disconnect the ground wire oy removing the starter motor ‘mounting bolt Remove the body center cover (page 10-4), Disconnect the engine harness connectors, Remove the stator mounting bolts and the stator NOTE * Do not try to remove the pulse generator from the stator base, +_Be careful not to damage the stator coils. 7-4 y (1) FLYWHEEL PULLER 077330010000 or 078330010000,ALTERNATOR ALTERNATOR INSTALLATION Install the stator onto the crankcase aligning its wire grommet with the groove in the crankcase Tighten the two stator mounting bolts Connect the engine wire harness connectors to the main harness Connect the ground wire using the starter motor mounting bolt. Connect the starter wire to the starter motor NOTE + Route the wites properly (page 1-7). Install the woodruff key in the keyway in the crankshaft NOTE Clean the tapered hole in the flywheel of any burrs and dirt Install the flywheel onto the erankshaft aligning its keyway with the woodruff key on the crankshaft. Hold the flywheel with the universal holder and tighten the ‘flywheel nut. TORQUE: 3540 N-m (3.5~4.0 kgm, 25-29 ftb) (2) STARTER MOTOR? Wine Ti) BOLTS: x< ~ (1) UNIVERSAL HOLDER, 07725-00300 | 7-5ALTERNATOR Install the cooling fan onto the flywheel using the two bolts mat ee ercdotns ran LEFT CRANKCASE COVER ASSEMBLY ae a Drive a new inner bearing into the lett crankcase cover. (2) ATTACHMENT, 24 x 26 mm 077460010700 PILOT, 10mm _07746~0040100 Insta the final shatt. Drive a new outer bearing over the final shaft. (1) FINAL SHAFT (2) DRIVER 077460020100 Install the snap ring in the groove in the left erankease cover. 7-6ALTERNATOR ‘Temporarily install the left crankcase cover onto the rear em GUNOTILEFERAND THREADS) Install the bearing cap and tighten the final shaft nut. NOTE: +The final shaft nut has lafthand threads, LEFT CRANKCASE COVER INSTALLATION Install the two dowel pins onto the crankcase. Install the left erankease cover onto the crankcase and tighten the cover bolts. Install the following ~ ir intake duct. left rear brake cable ‘exhaust pipe and cylinder head shround (page 6 8). rear wheels (page 12-3). engine cover (page 10:5). Adjust the rear brake (page 3.8). ' (2) LEFT REAR BRAKE CABLE 7-7CLUTCH/TRANSMISSION \ we 2 TILER HARD HHneADaT hy Ss 50-60.'Nm (6.0-6.0 kam, 36-43 feb)8. CLUTCH/ TRANSMISSION SERVICE INFORMATION TROUBLESHOOTING RIGHT CRANKCASE COVER REMOVAL RIGHT CRANKCASE COVER DISASSEMBLY LOW CLUTCH/DRIVE PLATE REMOVAL PARKING ARM REMOVAL OIL PUMP GEAR REMOVAL 81 STARTER PINION REMOVAL 8:10 82 STARTER PINION INSTALLATION 8-11 OIL PUMP GEAR INSTALLATION a1 83 PARKING ARM INSTALLATION 812 LOW CLUTCH/DRIVE PLATE a4 INSTALLATION 813 RIGHT CRANKCASE COVER 88 ASSEMBLY 813 a RIGHT CRANKCASE COVER 810 INSTALLATION 8.15 SERVICE INFORMATION GENERAL © Al clutch/transmission service can be done with the engine installed, SPECIFICATIONS [___S1ANARD nn SERVIGE LINIT mm Tal Specitied oil ‘Transmission oil capacity TORQUE VALUES it level check bolt Low drive plate nut Ratchet guide plate bott Bearing remover set, 12mm. Common Clutch center holder Driver Attachment, 32 x 35 mm Pilot, 15 mm Clutch outer 1D 7.00-110.20 (4.331-4.538) 1105 (435) Singer te LD 23.00. 2.03 (0806-0807) 231 (0391) Gitch Inn hikes 18 (008) “10 (0.08) | Ghtch sri tee length ges 182) 305 (150) Setond dutch | Clutch lining hikes 1.5 (0.06) 1.0 004) ‘atch sre oe eth 185 (0.7) 205 (081) Chueh outer 1D 76,00-76.10 (2 282-2.006) 7.2 (3.00) Second drive ples 1D 22.88-22.98 (0808 -0.905) 22.80 10.88) Honda 4-stroke oll ‘SAE 10W-40 or equivalent 190 oc (6.4 US oz, 6.7 Imp 02) after draining 210 cc {7.1 US 02, 7.4 Imp 02) after disassembly 50-60 Nem (5.0-6.0 kav, 36—83 ft-lb) 38-42 Nem (3.8-4.2 kg-m, 27-31 feb) 10-12 Nim (1.0-1.2 kom, 7-9 ftib) 07936-1650001 —}— Bearing remover, 12mm 078361660100 Romaver weight 077410010201 or 97936—3710200 077240050000 or commercially available in U.S.A. 07749-0010000 (07746-0010100 (07746-0040300 8-1CLUTCH/TRANSMISSION TROUBLESHOOTING Engine starts, but scooter won't move + Worn clutch lining + Worn clutch outer Damaged eluten, + Damaged or seized gear. Abnormal noise ‘Worn or seized gear. Worn bearing Oil leaks + Oil level too high. Worn or damaged oil seal 8-2CLUTCH/TRANSMISSION RIGHT CRANKCASE COVER REMOVAL Drain the transmission oil (page 2-5. Remove the engine cover (page 10-5). Place jacks or supports under the engine and right and left sides of the frame. Remove the right rear wheel (page 12-2), Remove the two mutfler bracket mounting bolts and the bracket. Ramove the intake pipe cover by removing the two bolts. Disonnect the Fight rear brake cable from the brake arm and right erankease cover. Release the parking lock lever. Remove the right erankcase cover bolts and the cover. Remove the dowel pins and gasket. (1) RIGHT CRANKCASE COVER™ a 8-3CLUTCH/TRANSMISSION RIGHT CRANKCASE COVER DISASSEMBLY Ti) NEEDLE BEARING) SNAP RING] Remove the snap ring and needle bearing from the final shaft. Remove the snap ring, washer and second clutch assembly Remove the primary drive gear and thrust washer. (2) THRUST WASHER Bend down the lock washer tabs and remove the three bolts, ni plain washers, lock washers and ratchet plate. aaa (2) BOLTS/PLAIN AND LOCK WASHERS 8-4CLUTCH/TRANSMISSION Remove the thrust washer and primary driven gear. 7 Remove the final drive gear shaft and thrust washer. Remove the final driven gear and shat. (2) FINAL SHAFT 9 Remove the snap ring and bearing from the right crankcase (1) SNAP RING. Remove the oil selCLUTCH/TRANSMISSION RIGHT CRANKCASE COVER INSPECTION Check the bearing bores in the right crankease cover for wear (or damage. GEAR/GEARSHAFT INSPECTION (1) PRIMARY DRIVE GEAR Check each gear and shaft for wear or damage, epics nea 2 (2) FINAL DRIVE GEAR (1) PRIMARY DRIVEN GEAR (2) FINAL DRIVEN GEAR SECOND CLUTCH INSPECTION Measure the clutch lining thickness, ‘SERVICE LIMIT: 1.0 mm (0.04 in) 8-6CLUTCH/TRANSMISSION Remove the E-clips, washers, clutch shoes and springs. Check the clutch shoe springs for damage. Measure the cluch shoe spring frae length. SERVICE LIMIT: 20.5 mm (0.81 in) LOW CLUTCH OUTER INSPECTION Check the clutch outer for wear or damage. Measure the I.D. of the eluteh outer. SERVICE LIMIT: 110.50 mm (4.35 in) ‘Check the needle bearings for wear or damage and replace if necessary, Remove the needle bearings using the speical tools. Press new needle bearings into the low clutch outer as shown. |+——(1) FREE LENGTH (1) NEEDLE BEARING (1) BEARING REMOVER, 12mm 07936—1660100 (2) REMOVER WEIGHT 977410010201 OF 079363710200 0.51.0 mm F (6.02-0.04 in) | 31-3.6mm (0.12-0.14 in) 8-7CLUTCH/TRANSMISSION (Check the ratchet pawls and springs for wear or damage Measure the sun gear plate |.D. SERVICE LIMIT: 23.1 mm (0.91 in) a (1) RATCHET PAWL ‘Measure the 0.0. of the second drive plate. SERVICE LIMIT: 22.80 mm (0.898 in) Check the pranetary gear for wear or damage and replace if necessary. LOW CLUTCH/DRIVE PLATE REMOVAL Remove the right crankcase cover (page 8-3) Hold the drive plate with a holder and remove the nut. (GV CLOTEH CENTER HOLDER 677240050000 OR COMMERCIALLY AVAILABLE INUS.A. NOTE ~The nut has lefthand threa Remove the low clutch/drive plate (2) NUT, (LEFT-HAND THREADS) LOWCLUTCH)) > DRIVE PLATE 8-8CLUTCH/TRANSMISSION LOW CLUTCH INSPECTION Measute the clutch lining thickness SERVICE LIMIT: 1.0 mm (0.04 in} Inspect the elutch springs for wear or damage. Remove the E-clips, washers, and clutch shoes. Measure each clutch shoe spring free length. SERVICE LIMIT: 39.5 mm (1.56 in) Replace any worn or damaged parts, SECOND CLUTCH OUTER INSPECTION Check the second clutch outer for wear or damage. Measure the 1.0, SERVICE LIMIT: 76.2 mm (3,00 in) PARKING ARM REMOVAL Remove the right crankcase cover (page 8:3). Unhook the spring and remove the parking arm assembly and arm shaft Remove the left rear wheel (page 12-2) Remove the nut and parking arm from the left end of the parking shaft. Remove the parking shaft from the crankcase (1) CLUTCH SPRING (2) WASHER @ECLIPCLUTCH/TRANSMISSION PARKING ARM/SHAFT INSPECTION (1) PARKING SHAFT (2) PARKING ARM Inspect the parking arm, shafts and spring for wear or damage. ASSEMBLY (3) SPRING (4) ARM SHAFT OIL PUMP GEAR REMOVAL (1) OL PUMP DRIVE GEAR] Remove the following: — clutch (page 88). = oll pump drive gear. ~ parking arm assembly (page 8-9) WW oi FONE ~ holder plate bolt and the plate * DRIVEN GEAR = oil pump driven gear. STARTER PINION REMOVAL Femove the following S — clutch (page 8:8). = = starter pinion 8-10CLUTCH/TRANSMISSION STARTER PINION INSPECTION Check that the starter pinion rotates only in one direction, {Also check that the gear returns freely. ‘) y \ ya STARTER PINION INSTALLATION Install the starter pinion onto the crankcase (STARTER PINTO A S OIL PUMP GEAR INSTALLATION ‘Apply grease to the oil pump drive gear and journal. Install the oll pump driven gear into the crankcase. Install the gear holder plate with the bolt Install the parking arm assembly (page 8-12). (2) PARKING ARM, ASSEMBLY 8-11CLUTCH/TRANSMISSION Install the oll pump drive gear onto the crankshaft PARKING ARM INSTALLATION Install the parking shaft into the crankcase Install the arm onto the left end of the parking shaft and tighten the nut Install the left rear wheel (page 12:3) ace Install the perking arm assembly and shaft. (SHAFT (1) PARKING ARM ASSEMBLY 8-12CLUTCH/TRANSMISSION LOW CLUTCH/DRIVE PLATE INSTALLATION (1) cuutcx ceNTeR HOLDER 07728 60800000 01 COMMERCIALLY AVAILABLE IN USA Install the low clutch/drive plate onto the crankshatt Hold the drive plate with @ holder and tighten the nut, TORQUE: 38-42 Nem (3.8-4.2 kg-m, 27-31 ftlb) NOTE ~~ *_The nuthas lefthand threads: RIGHT CRANKCASE COVER ASSEMBLY Install @ new oil seal onto the right crankcase cover. Drive a new beating into the right crankcase cover antl pi (2) ATTACHMENT, 32 x 35 mm 077460010100 PILOT, 15 mm_07746-0040300 Install the snap ring. (SNAP RINGCLUTCH/TRANSMISSION Instllthe final shaft and final ceiver gear onto the right GE RCOIVENTGEAR crankcase cover ’ So Install the thrust washer and final dive gear shaft ioRMACAEE Install the primary driven gear and thrust wosher onto the GEAR SHArT drive gear shaft, NOTE Face the dshead end of the thrust washo in Install the ratchet plate using new lock washers, the plain washers and bolts. Tighten the bolts in the sequence shown, TORQUE: 10-12 Nem (1.0-1.2 kgm, 7-9 fb) Bend the lock washer tabs up against the bolt heads. Make sure that the primary driven gear rotates smoothly. Install the sun gear plate, thrust washer and primary drive gear conto the second drive plate Install the thrust washer onto the final shat. (2) THRUST WASHER. 8-14CLUTCH/TRANSMISSION Install the following: = second eluteh assembly onto the final shaft. (> = thrust washer and a new snap ring. = needle besring and a new snap ring Apply grease to the needle bearing RIGHT CRANKCASE COVER INSTALLATION Install the two dowel pins and a new gasket. Apply grease to the crankshaft bore, a Install the right crankcase cover and tighten the bolts in a crisscross pattern in 2 to 3 steps. . = i (1) RIGHT CRANKCASE x i: Connect the right rear brake cable to the brake arm. (1) RIGHT REAR BRAKE CABLECLUTCH/TRANSMISSION Install the intake pipe cover with the two bolts TTINTAKE PIPE COVER Install the mutter bracket using the two bolts Fill the transmission with the recommended oil (page 2.5), Install the right rear wheel (page 12-3). Install the engine cover (page 10-5). Adjust the rear brake (page 3-8). Adjust the parking lock (page 3:8). 8-16MEMO9-09. CRANKCASE/ CRANKSHAFT SERVICE INFORMATION TROUBLESHOOTING CRANKCASE SEPARATION CRANKSHAFT REMOVAL 94 CRANKSHAFT INSPECTION 93 a1 CRANKSHAFT INSTALLATION 94 92 CRANKCASE ASSEMBLY 95 92 SERVICE INFORMATION GENERAL ‘© This section covers erankcase separation to service the crankshaft. ‘© The following parts must be removed before separating the crankcase Engine + Carburetor Oi! pump reed valve Starter motor + Alternator + Cylinder head and cylinder + Clutch SPECIFICATIONS Ire ‘Connecting rod big end side clearance Connecting rod big end radial clearance Crankshaft runout TOOLS Special Crankshaft assembly tool Universal bearing puller Shaft protector Crankcase puller Common Driver ‘Attachment, 42 x 47 mm Pilot, 20 mm Attachment, 37 x 40 mm Pilot, 17 mm Clutch center holder TROUBLESHOOTING Abnormal engine noise + Worn main journal bearing. + Worn crank pin bearing + Worn transmission bearing. Section 5 Seetion 4 Seetion 2 Section 4 Section 14 Section 7 Seetion 6 Section 8 STANDARD mm {in} SERVICE LIMIT mm (in) | = 0.8 (0.02) | 0.04 (0.002) 0.18 (0.006) 07965~1480010—— Collar 07631-01000 L- ghatt 07931-18700 (07935~GJ50000 (Not available in U.S.A.) or 079374300000 (07965-1480100 (07965-GMo0300 07749-0010000 07746-0010300 (07746 -0040600 (07746-0010200 (07746-0040400 077240050000 9-4CRANKCASE/CRANKSHAFT CRANKCASE SEPARATION Romove the breather tube from the erankoase, Remove the crankcase assembly bolts, Remove the right crankcase from the left crankoase NOTE + Use the crankcase puller if difficulty is encountered in separating the crankeases, CRANKSHAFT REMOVAL Drive out the crankshaft from the left erankease using a plastic hammer. Remove the left crankshaft bearing from the crankshaft. NOTE + Do not rouse the old bearing 9-2 B=) oneatien Tuse x 5 ig(1) CRANKCASE PULLER 07935-61500 (NOT AVAILABLE IN U.S.A) OR 079374300000 =. (1) UNIVERSAL BEARING PULLER 076310010000 OR COMMERCIALLY AVAILABLE IN U.S.A, (2) SHAFT PROTECTOR 07931 1870000CRANKCASE/CRANKSHAFT Remove the oil seals from the both crankcase. (1) OIL SEALS, : (2) LEFT CRANKCASE. Say eee CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance with a feeler gauge. ‘SERVICE LIMIT: 0.5 mm (0.02 in) Measure the connecting rod big end radial clearance at two points in the X and Y directions. SERVICE LIMIT: 0.04 mm (0.002 in) nd Set the crankshaft on a stand or V-blocks and read runout Using a dial gauge. SERVICE LIMIT: 0.15 mm (0.006 in) 58mm (23 in) 9-3CRANKCASE/CRANKSHAFT Spin the crankshaft bearing by hand and check for play, The bearing must be replaced if it is noisy or has excessive play. CRANKSHAFT INSTALLATION Wash the crankcase and crankshaft in solvent and blow dry with compressed air. Check for eracks or other faults NOTE + Appiy clean 2-stroke injector oil to all moving and sliding faces of the crankcase. + Remove all gasket material from the erankease mating sur faces. Dress any roughness or irregularities with an oil stone. Drive a new journal bearing into the right and left crankcase halves. TooLs: LEFT CRANKCASE (1) DRIVER (07749-0010000 (2) ATTACHMENT. 37 x 40mm 077460010200 PILOT, 17 mm (07746-0040400 RIGHT CRANKCASE (1) ORIVER 07749-0010000 (2) ATTACHMENT, 42 x 47mm 07746-01030 PILOT, 20mm (07746-0040500 Install a new oil seal onto the left erankease Install the erankshaft into the left crankcase, NOTE If assembly is difficult, use the erankease assembly tool as shown, Do not use @ press or drive the crankshaft into the case + Lubricate the journal bearing and connecting rod big end with Honda 2-stroke oil or equivalent. (1) AXIALPLAY (2) RADIAL PLAY ie ~ (1) CRANKCASE ASSEMBLY TOOL| 07965—1480010 9-4CRANKCASE/CRANKSHAFT Install the oil sea! into the left crankcase using the special tool as shown. CRANKCASE ASSEMBLY Install the two dowel pins end a new gasket. ‘Assembly the crankcase halves, NOTE ae a + To draw the erankshaft into the right crankcase, tempo- rarily install the oil pump drive gear and eluteh, and thread the low drive plate nut onto the crankshaft (the nut has lefehand threads), Install and tighten the five crankcase attaching bolts in a criss cross pattern. After assembling, check that the crankshaft rotates freely without binding Install the crankcase breather tube. Reinstall all removed parts and mount the engine in the frame. (1) CRANKCASE ASSEMBLY TOOL 07965-1480010 Me baa [4.5mm (2)01L SEAL] (0.18 in) 1 (1) CLUTCH CENTER HOLDER 077240080000 OR COMMERCIALLY AVAILABLE IN U.S.A. @ C ; ae” “Si et10. FRAME COVERS SS SERVICE INFORMATION 10-1 BODY CENTER COVER 10-4 FRONT COVER/HEAD PIPE COVERS/ REAR COVER 104 FLOOR BOARE: an ENGINE COVER 105 SERVICE INFORMATION GENERAL ‘© Align the tabs on the covers properly with the grooves when installing, © Take care that the wires are not cought when installing the covers. 10-1FRAME COVERS FRONT COVER/HEAD PIPE COVERS/ (1) HEAD PIPE UPPER COVER J (2) FRONT COVER FLOOR BOARD REMOVAL Remove the headlight (page 14-5) and disconnect the oil level warning light wires in the headlight case. Remove the two bolts attaching the front and head pipe covers and remove the front eave: Turn the ignition switch OFF, release the parking lock lever and remove the head pipe upper cover Raise the parking lock lever up and remove the head pipe lower cover Remove the floor board by removing the two bolts, INSTALLATION ‘Align the tabs on the floor board with the groove in the center plate Tighten the two floor board bolts Align the tabs on the head pipe lower cover with the groove in the floor board and install the cover (2) TABS AND GROOVES, 10-2FRAME COVERS ‘Align the holes in the head pipe lower cover with the bosses on the frame as shown, Release the parking lock lever and install the head pipe upper ‘cover, then raise the parking lock lever. ‘Align the hole in the head pipe upper cover with the bosses on the frame as shown Install the front cover aligning its holes with the bosses: Install and tighten the two bolts. Connect the oil level werning light wires to the wire harness and install the headlight. M7) HOLE AND BOSS: a | WyFRAME COVERS BODY CENTER COVER SI REMOVAL ‘Turn the fuel valve OFF. Remove the screw attaching the fuel valve knob and the knob. Remove the canter plate by removing the two bolts Remove the two screws and two bolts attaching the body center cover to the frame and the cover. INSTALLATION Install the body center cover in the reverse order of removal, REAR COVER REMOVAL Raise the seat and remove the document compartment. Remove the four rear carrier attaching bolts, carrier, four collars and rear cov ayneavcom — GHIOETSICOLLAAS 10-4FRAME COVERS Disconnect the tai/brake light coupler. Remove the rear cover by removing the two nuts and bolts. INSTALLATION Install the rear cover in the reverse order of removal. (3) TAIL/BRAKE LIGHT COUPLER, ENGINE COVER MT MUFFLER REMOVAL, Remove the two muffler mounting nuts Remove the two muffler joint nuts and the muffler from the ‘exhaust pipe. Remove the four engine cover bolts and remove the cover. INSTALLATION Install the engine cover in the reverse order of removal. NOTE + Make sure that the exhaust muffler joint gasket is in good, condition before installing the muffler. (2, ENGINE COVER 10-5STEERING/FRONT WHEEL/BRAKE/SUSPENSION 60-80 Nem (6.0-8.0 kom, 43-88 fb) 40-50 Nem (4.0-5.0 kom, 29-36 ft-lb) 5-13 Nim (051.3 kgm, 36-9 feb) 40-50 Nim (4.0-5.0 kom, 29-36 f-Ib) 11-011. STEERING/FRONT WHEEL/BRAKE/ SUSPENSION SERVICE INFORMATION TROUBLESHOOTING HANDLEBAR, PARKING LOCK THROTTLE CABLE W4 REAR BRAKE CABLE 7 112 FRONT WHEEL 19 113 FRONT BRAKE W411 115 FRONT SUSPENSION 1114 116 STEERING 11.16 SERVICE INFORMATION GENERAL '© Brake dust contains asbestos which can be harmful to your health. © Do not use compressed sir to clean brake drums or brake panels. Use @ vacuum with a sea collector. Wear'a protective face mask and throughly wash your hands when finished. SPECIFICATIONS I Tem STANDARO mm (A) SEAVIGE LIMIT mm Ua Raintree 5 021001) [Rim runout: Radial = 2.0 (0.08) | ae aoe Front foci rat F 121.8 (4.80) 7170 (461) [Front brake drum 1D 180.0 (3.15) 80.5.(3.17) [| Front brake lining thickness 3.5 (0.14) 1.5 (0.06) TORQUE VALUES Handlebar lower holder nut Brake adjuster bolt lock nut Front axle nut Front brake arm bolt Steeringstem lock nut Fork bridge bolt Steering stem nut TOOLS Special Lock nut wrench Lock nut wrench Snap ring pliers Attachment, 28 x 30 mm Ball race remover Steering stem driver Common Extension Lock nut wrench, 30 x 32 mm Attachment, 42 x47 mm Pilot, 10 mm Bearing remover shaft Bearing remover head, 10 mm Driver 40-50 N-m (4.0-6.0 kgm, 29-36 fib) 3.5-6 Nom (0.35-0.5 kgm, 25-36 ft-lb) 40-50 N-m (4.0-5.0 kgm, 29-36 feb) 4-7 Nem (0.4-0.7 kgm, 3-5 feb) 5-13 Nim (0.5-1.3 kgm, 3.6-9 ft1b) 40-80 Nim (4.06.0 kgm, 29-36 ftlb) 60-80 N-m (6.0-8.0 kgm, 43-58 ft-lb) 07916~1870101 (07916~-kM10000 07914—3230001 (07946-1870100 (07946—-GA70000 (Not available in U.S.A.) 07946~4300101 077160020500. 07716-0020400- 07746-0010300 07746-0040100 077460050100 07746-0050200 07749-0010000 =} or commercially available in U.S.A. 7151STEERING/FRONT WHEEL/BRAKE/SUSPENSION. SSF TROUBLESHOOTING Hard steering Parking lock lever is engaged, but swing lock is not ‘Steering top cone race/nut too tight. appli Damaged steering balls and races. + Cable not adjusted property Insufficient tire pressure, + Swing lock pawl damaged, Swing lock pawl linkage damaged, Steers to one side or does not track straight Bent front fork. Parking lever returned with ignition switch in LOCK. Bend front axle or spoke plate, + Deformed or damaged lever stopper + Twisted or damaged parking lever shaft Parking lever not locked + Worn or damaged parking lever shaft-to-stopper faces, Cable not adjusted propery. Damaged or elongated cable. Front wheel wobbling Damaged engine side parking return spring, + Bent rim, ‘Axle not tightened properly, Parking lever does not return or is stiff + Bent spoke plate. Insufficient cable play + Excessive wheel bearing play. * Damaged parking lever spring, + Faulty or unevenly aworn tire. Cable Erving disungaged from swing lock lever Soft suspension ‘Swing mechanism is locked, but parking lock lever isnot Weak fork springs. ‘engaged + Improperly adjusted cable. Front suspension noise + Swing-to-parking lock rod disconnected, Slider binding. * Parking lock arm paw! damaged ar chipped + Loose front fork fasteners Parking disc teeth damaged or chipped. 1152‘STEERING/FRONT WHEEL/BRAKE/SUSPENSION HANDLEBAR (1) ine BANOS \ REMOVAL Remove the handlebar switch wire bands. Remove the two left handlebar switeh housing serews and Gy SCREWS remove the left handlebar switch housing with the rear brake zm lever bracket, Remove the two right handlebar switch housing screws and remove the right handleber switeh housing with the front brake lever bracket Disconnect the throttle cable from the throttle grip and slide It off the handlebar. 11-3STEERING/FRONT WHEEL/BRAKE/SUSPENSION Remove the four handlebar holder attaching bolts and the handlebar. INSTALLATION Install the handlebar onto the lower holder, then install the Upper holders with their punch marks facing the forward. Align the punch mark on the handlebar with the top edge of the lower holder Tighten the upper holder bolts NOTE Tighten the forward bolts fist, then the rear bolts ‘Apply Honda Bond A, Honda Hand Grip Cement (U.S.A. only) or an equivalent to the inside surface of the grips and to the clean surface of the left handlebar and throttle pipe. Wait 3-5 minutes and install the grips. Rotate the grips for even application of the adhesive. Nort + Allow the adhesive to dry for an hour before using Slide the throttle grip onto the handlebar. Connect the throttle cable to the throt Arease to the cable end. rip and apply Install the right handlebar switch housing, eligning the punch mark on the handlebar with the switch housing matting surface. Tighten the forward serew first, then tighten the rear screw. (PUNCH MARK 11-4STEERING/FRONT WHEEL/BRAKE/SUSPENSION Install the lett handlebar switeh housing, aligning the punch mark on the handlebar with the switch housing matting surface Tighten the forward switch housing screw first, then, tighten the rear screw. (1) PUNCH MARK Install the handlebar switch wire bands. (4) WIRE BANDS Fi or ‘Adjust the throttle grip free play (page 3-5) and brake lever free play [page 2-7). PARKING LOCK LEVER REMOVAL/INSTALLATION Remove the head pipe covers and floor board (page 10-2). ‘Support the scooter by placing the floor jack or other adjust: ‘able support under the frame. Move the parking lever down and loosen the Jock, adjusting ‘nuts, and disconnect the parking cable. Remove the two nuts and parking lever Install the parking lever in the reverse order of removal and (2) ADJUSTING NUT (3) NUTS) adjust the parking lever free play (page 3-8) CABLE REPLACEMENT Remove the floor board, engine and body center covers {section 10} Support the scooter by placing the floor jack or other adjust able support under the frame. Loosen the lock, adjusting nuts and disconnect the parking ceable from the cable guide and parking lever. (3), FLOOR BOARDIEM 2) ADJUSTING NUT, 11-5STEERING/FRONT WHEEL/BRAKE/SUSPENSION Remove the cotter pin and washer, and disconnect the parking cable from the swing lock arm, Replace the parking cable with a new one if required and install in the reverse order or removal NOTE Route the wire and cable securely as shown on page 1-7. Use a new cotter pin when reinstalling the cable, THROTTLE CABLE PRIMARY CABLE REPLACEMENT Remove the two right handleber switch housing sorews and separate the switch housing Disconnect the throttle cable from the throttle arp. Remove the engine cover (page 10-5}. Pull the cable junction box out, remove the screw and open the cover. Remove the joint plate and disconnect the primary eable from the junction box. Replace the primary cable with a new one if required and install the cable in the reverse order of removal NOTE * Route and clamp the wires and cables securely as shown on page 1.7 ‘Adjust the throttle grip free play (page 3.5), 11:26STEERING/FRONT WHEEL/BRAKE/SUSPENSION SECONDARY CABLE REPLACEMENT Remove the engine cover (page 10-5) and disconnect the primary cable from the junction box (page 116). Disconnect the throttle cable from the carburetor top (page 44) Disconnect the oil control cable from the oil control lever (page 2-2). Remove the secondary cable from the junction box. Replace the cables with new ones if required and instal in the reverse order of removal TSECONDRAY Tales t NOTE + Route and clamp the cables securely as shown on page 1-7. t the throttle grip free play and oil control cable (page 35) REAR BRAKE CABLE PRIMARY CABLE REPLACEMENT Remove the brake lever pivat bolt, nut and brake lever and dis: connect the brake cable from the lever. Remove the body center cover (page 10-4) Remove the equalizer box cover and disconnect the primary brake cable from the equalizer plate, Replace the brake cable with a new one if required and install in the reverse order of removal NOTE = Route and clamp the cable securely as show on page 1-7 ‘Adjust the rear brake lever free play. SECONDARY CABLE REPLACEMENT Remove both rear wheels with the wheel hub attached (page 122) Remove the rear brake cables from the brake arms. (REAR RAKE GABLE 2) 9RAKE ARM 11-7STEERING/FRONT WHEEL/BRAKE/SUSPENSION Remove the body center cover (page 10:4). Remove the equalizer box cover and disconnect the secondary secon CNLES cables from the equelizer plete oe Replace the secondary cable with new ones if required and instal in the reverse order of removal NOTE Fouts and clamp the eables securely ax shown on page 1-7 > REAR BRAKE ADJUSTMENT NOTE > Adjust the rear brake when the cables have been replaced ‘or the rear brake ean not be adjusted with the adjusters. Remove the body center cover (page 10-4) and the equalizer box cover. Loosen the lock nut and turn the primary cable adjusting bolt Turn the roar brake adjusters until the brake shoes just touch the brake drum. Make sure that the clearance betwoon the cable flange and the ‘cable stopper is zero, then turn the primary cable adjusting bolt counterclockwise until the brake lever free play is zero, then turn it 2 more times counterclockwise. [ircase stances) 2) ADJUSTING BOLT? Tighten the lock nut TORQUE: 35-5 Nom (0.35-0.5 kgm, 25-36 ftb) Loosen both rear brake adjusters equally so that the rear brake lever free play is 10-20 mm (3/8-3/4 in}. Apply rear brake and make sure that the clearance between the secondary cable flange and cable stopper is equal If they are not equal, adjust them by turning the rear brake adjuster Install the equalizer box cover and body center cover, (2) CABLE STOPPERS. 1158STEERING/FRONT WHEEL/BRAKE/SUSPENSION FRONT WHEEL (1) SPEEDOMETER YY, REMOVAL, Disconnect the front brake cable and speedometer cable. Raise the front wheel off the ground by placing a floor jack for other adjustable support under the frame Remove the axle nut and pull out the front axle, Remove the front wheel INSPECTION © AXLE SHAFT ‘Set the axle shaft in V blocks and measure the runout. ‘The actual runout is 1/2 of the total indicator reading, ‘SERVICE LIMIT: 0.2 mm (0.01 in) © WHEEL RIM Place the wheel in a truing stand. Spin the wheel by hand and measure the rim runout using @ dial indicator. SERVICE LIMIT: RADIAL: 2.0 mm (0.08 in) AXIAL: 2.0 mm (0.08 in) © BEARING INSPECTION Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not turn smoothly, quietly, or if they fit loosely in the hub. NOTE: Foplace hub bearings in pairs For replacement of bearings, see page 11-10.STEERING/FRONT WHEEL/BRAKE/SUSPENSION DISASSEMBLY Remove the side collar and oil sea, Insert bearing remover head into the bearing. From the opposite side install the bearing remover shaft and ‘rive the bearing out of the whee! Remove the distance collar and drive out the other bearing, ASSEMBLY Pack grease into the bearing cavities, Drive in the right bearing into the wheel securely with its Sealed side facing out until it seats. Install the distance collar and drive in the left bearing with its sealed side facing out until it seats NOTE Do not allow the ings to tilt while driving them in. CAUTION + Once the bearings are removed, the bearings must be re- laced with new ones. Install @ new oil seal on the wheel Install the side collar. ik (2) OL SEAL (1) SIDE COLLAR bl r h (2) O1'SEAL (1) BEARING REMOVER SHAFT 077460050100 (EQUIVALENT COMMERCIALLY AVAILABLE INUSA) c. (2) BEARING REMOVER HEAD, 10 mm : 07746—-0050200 (EQUIVALENT COMMERCIALLY AVAILABLE IN U.S.A.) SS) Driver 07749-0010000 - (2) ATTACHMENT, 28 x 30 mm 07946-1870100) PILOT, 10 mm 677460040100 (1) SIDE COLLAR 1110STEERING/FRONT WHEEL/BRAKE/SUSPENSION INSTALLATION (1) GROOVE Position the front wheal between the fork legs, aligning the brake panel groove with the stopper on the fork. Insert the axle shaft through the wheel hub from the right side (2) STOPPER} Install and tighten the axle nut. TORQUE: 40-50 Nom (4.0-5.0 kg-m, 29-36 ft1b) (TV AXLE NUT Connect the front brake eble and speedometer cable. Seonbreknrbie andapeionetnerty (1) SPEEDOMETER CABLE uy ‘Ajust the front brake free play. @) ERONT BRAKE CABLE FRONT BRAKE Remove the front wheel (page 11-9) and brake panel from the front wheel INSPECTION f © BRAKE DRUM ‘Meature the brake drum I.D. SERVICE LIMIT: 80.5 mm (3.17 in)STEERING/FRONT WHEEL/BRAKE/SUSPENSION © BRAKE LINING ‘Measure the brake lining thickness SERVICE LIMIT: 1.5 mm (0,06 in) Ee ee as * Contaminated brake linings reduce stopping power. Keep grease off the linings + Brake dust contains asbestos which can be harmful to your health. Do not use compressed air to clean brake parts. Use ‘@ vacuum with a sealed dust collector. Wear a protective face mask and wash your hands wien JSinished. DISASSEMBLY Remove the brake shoe spring and brake shoes Remove the brake arm bolt, brake arm, wear indicator plate, return spring and brake cam, Remove the oil seal and speedometer drive gear. 11-12 (1) SHOE SPRING (2) BRAKE SHOES (i) onl seAL (3) SPEEDOMETER DRIVE GEAR (2) BRAKE CAM ~~ (4) BRAKE ARM.STEERING/FRONT WHEEL/BRAKE/SUSPENSION ASSEMBLY 4-7Nm (0.4-0.7 kom, 3-5 felb) Lubricate the speedometer drive gear with grease and install ‘the drive gear in the brake panel ue (1) SPEEDOMETER DRIVE GEAR Insta he (VOICSEAL GPBRAKE CA ‘Apply grease to the brake cam and anchor pin, and insert the bbrake cam in the brake panel mm ‘Contaminated brake linings reduce stopping power. + Keep grease off the brake linings. + Wipe any excess grease off the brake cam,STEERING/FRONT WHEEL/BRAKE/SUSPENSION Apply oil to the felt seal and install to the brake panel, Install the brake arm return spring. Install the wear indicator plate aligning the wide tooth on the plate with the wide groove in the brake cam. Install the brake arm aligning the punch mark on the brake arm with the index line on the brake eam. Install and tighten the brake arm bolt; TORQUE: 4~7 Nom (0.40.7 kgm, 3-5 ftlb) Install the brake shoes and shoe spring. Ce * Contaminated brake linings reduce stopping power. Keep grease off the brake linings. Pace the brake panel in the front whee! Install the front wheel (page 19-11) and adjust the front brake free play (page 3-7) FRONT SUSPENSION REMOVAL, Remove the front wheel (page 11-8). Remove the front fender by removing the four bolts. 11-14 (3) FELTSEAL (4) RETURN SPRING. (1) INDEX MARK & (2) PUNCH MARK. (1) SHOE SPRING (3) BRAKE ARM. (2) BRAKE SHOESSTEERING/FRONT WHEEL/BRAKE/SUSPENSION Slide the boot down the fork leg (i) 8007 (2) SNAP RING roliaameatccrague™ i ee ‘i Rie ie dil x (3) SNAP RING PLIERS 079143230001 (EQUIVALENT COMMERCIALLY AVAILABLE INUS.A.) INSPECTION (1) FRONT SHOCK ROD Inspect for wear or damage and replace if necessary. . arin ante Measure the spring free length SERVICE LIMIT: 117.0 mm (461 in) ANY INSTALLATION ‘Apply grease to the front shock sliding surfaces. 11-15STEERING/FRONT WHEEL/BRAKE/SUSPENSION Install the spring, stopper rubber and front shock rod in the fork pipe and secure with the snap ring NOTE Install the snap ring with its radiused edge facing up and be Certain the snap ring is seated firmly in the groove. Slide the boot up onto the fork pip Install the front fender using the four bolts. Install the front wheel (page 11-11) STEERING REMOVAL Remove the following: ~ front wheel (page 11.9). — right and left front suspension (page 11-14). — front cover and head pipe covers (page 10-2). handlebar (page 11-3). = headlight (page 14-15). ~ speedometer cable and grommet from the head pipe. Disconnect the horn wire connector, and remove the horn and front turn signal Remove the steering stern nut. Remove the two bolts attaching the fork bridge. “TI) SNAP RING PLIERS 07914—3230001 (EQUIVALENT COMMERCIALLY AVAILABLE INUS.A) a q\ 4 e \(2) SNAP RING (3) BOOT (2) GROMMET si (1) EXTENSION 07716-0020500 (EQUIVALENT COMMERCIALLY | AVAILABLE IN U.S.A.) o (2) LOCK NUT WRENCH, 30x 32 mm 07716—0020400 (EQUIVALENT COMMERCIALLY AVAILABLE INUS.A) EI-16STEERING/FRONT WHEEL/BRAKE/SUSPENSION Hold the top cone race and remove the steering stem lock nut. Hold the front fork and remove the top cone race and front fork NOTE + The steel balls are loose in the races, and can be easily cropped or lost BALL RACE INSPECTION Inspect the top and bottom ball races for wear or damge, and replace if necessary BALL RACE REPLACEMENT Drive both ball races out of the steering head using a ball race remover or a suitable punch. Drive the top and bottom ball races into the steering head Using an attachment and driver. NOTE Do not tit oF damage the races while driving them in BOTTOM CONE RACE INSPECTION Inspect the bottom cone race for wear or damage and replace if necessary BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race using a chisel and discard it Place @ new bottom cone race on the stem. Drive the new cone race on using steering stem driver 07946— 4300101, (1) Lock NUT WRENCH 07916—1870101 (2) LOCK NUT WRENCH o7916-KM410000__ xX (1) BALL RACE REMOVER 07946-GA70000 (NOT AVAILABLE INUS.A) EPP cd) oniveR 07740-0010000 ~~ (2) ATTACHMENT, 42 x47 mm 077480010300 (i) BOTTOM CONE RACE 14-17STEERING/FRONT WHEEL/BRAKE/SUSPENSION INSTALLATION ‘Apply enough grease onto both races to retain the stee! balls and install 26 balls onto each race. Apply grease to the bottom cone races and install the fork into the heed pipe being careful not to drop the steel balls. ‘Apply grease to the top cone race and screw in the race until snug against the top ball race, then back it out 1/8 turn, ‘Tum the steoring stom lock-to-lock 4-6 times to seat the bearings and check that the steering stem rotates smoothly ‘and that there is no vertical play. Hold the top cone race and tighten the steering stem lock nut. TORQUE: 5~13 Nim (0.5—1.3 kgm, 3.6-9 ftlb) Install the fork bridge and fork bridge mouting bolts, Tighten the fork bridge mounting bolts, TORQUE: 40-60 N-m (4,0-6.0 kgm, 29-36 feb) Install and tighten the steering ste nut TORQUE: 60-80 N-m (6,0-8.0 kgm, 43-58 feb) Insert the speadomerer cable into the steering stem and install the eable grommet. Install the following: = handlebar (page 11-4) = horn, horn, wires and front turn signal stay. = headlight (page 14-16). = front cover and head pipe covers (page 10-2), — front suspension (page 11-15), = front wheel (page 11-11). (1) TOP CONE RAGE (2) FRONT FORK ~~ (1) LOCK NUT WRENCH 079161870101 (2) LOCK NUT WRENCH. 07916-10000, (2) FORK BRIDGE MOUNTING BOLTS eA: (1) LOCK NUT WRENCH, 30 x 32 mm 07716-0020400 (EQUIVALENT COMMERCIALLY AVAILABLE IN U.S.A.) [(2) SPEEDOMETER CABLE tt-18MEMO.REAR WHEEL/BRAKE (2.4-3.0 kom, 17-22 fib) 45-50 Nm (4.5-5.0 kom, 32-36 feb) 65-80 Nm (6.5-8.0 kom, 48-58 ft-b) 12-012. REAR WHEEL/BRAKE SERVICE INFORMATION 124 REAR WHEEL 122 TROUBLESHOOTING 124 REAR BRAKE 124 SERVICE INFORMATION GENERAL, ‘¢ Brake dust contains asbestos which can be harmful to your health, Do not use compressud air to clean brake drums or brake panels. Use a vacuum with a sealed duct collector. Wear 8 protective face mask and thoroughly wash your hands when finished. SPECIFICATIONS Te STANDARD mm Gn) SERVIGE Lin mmf Rear wheel rim runout | 2.0 (0.08) fer brake drum 1D. 800-802 (18-3.16) ansisi) Pan a a tok 35 (014 | 1.5 (0.00) TORQUE VALUES oe aie 65-80 Nm (65-80 kom, 46-5618) Appl i Few heal ub bat $5.50 Nim (5-50 kgm, 92-96 fib) Apply ol cartel oe 24-30Nim (24-20 kgm, 17-22 Rb) Rear brake arm bolt 4-7 Nim (0.4-0.7 kgm, 3-5 ft lb) zz TROUBLESHOOTING Rear wheel wobbling Bent rim, Faulty or unevenly worn tres + Axle nut improperly tightened. Poor brake performance + Brake not adjusted properly Contaminated brake shoes. Worn brake shoes, Worn brake shoes at cam contacting area, Worn brake cam. Worn brake drum, Improper engagement between brake arm and camshaft serrations, 1221REAR WHEEL/BRAKE REAR WHEEL REMOVAL Support the scooter by placing the floor jack or other adjust: able support under the swing joint Apply rear brake, Without the whee! hub attached Remove the three rear wheel hub bolts and remove the rear wheel With the wheel hub attached Remove the wheel cap and rear axle nut, then remove the rear whee! with the wheel hub, INSPECTION Remove the rear wheel with the whee! hub, Check the wheel rim runout using a dial indicator as shown. SERVICE LIMIT: RADIAL: 2.0 mm (0.08 in) AXIAL: 2.0 mm (0.08 in) Measure the rear brake drum 1D, SERVICE LIMIT: 80.5 mm (3.17 in) 12:2 Ti) BOLTS,REAR WHEEL/BRAKE REAR BRAKE DRUM REPLACEMENT Remove the three rear wheel hub bolts and remove the wheel hub from the wheel Ti) WHEEL HUB BOLTS Install @ new wheel hub onto the rear wheel and tighten the rear wheel hub bolts, NOTE + Apply oll to the bolts threaded portion, TORQUE: 45-50 Nem (4.5-5.0 kom, 32~36 ftib) DISASSEMBLY/ASSEMBLY Remove the rear wheel rim bolts and separate the wheel rim. ASSEMBLY Install the rear wheel and tighten the whee! rim bolts, TORQUE: 24-30 Nem (2.4~3.0 kgm, 17-22 ftlb) 24-30 Nem Oy 17-22 frtb) © 45-50 Nem (4.5-5.0 kom, 32-36 ft-lb) 65-80 Nem (6.5-8.0kgm, 48-58 1b) INSTALLATION Without the wheel hub attached Install the rear wheel, apply oil to the bolt’s threaded portion sand tighten, TORQUE: 45-50 Nem (4.5-6.0 kg-m, 32-36 ft1b) With the whee! hub attached Install the rear whee! Apply oil to the axle nut threaded portion and tighten, ‘washer under the right axle nut, ‘TORQUE: 65-80 N-m (6.5-8.0 kam, 48-58 feb)REAR WHEEL/BRAKE REAR BRAKE INSPECTION Remove the rear wheels with the wheel hub sttached (page 122) Measure the brake lining thickness SERVICE LIMIT: 1.5 mm (0.06 in) off the brake linings. Wipe off any excess Replace the shoes if they are worn beyond the service limit. DISASSEMBLY Remave the rear brake cable from the brake arm. Remove the brake shoes, shoe spring, brake arm spring. Remove the brake arm bolt, brake arm, wear indicator plate, lt seal and brake cam, 4-7 Nm (0.4-0.7 kgm, 3-5 feb) 12-4REAR WHEEL/BRAKE ‘Apply grease to the brake cam and anchor pin. Install the brake cam: ‘Apply oil to the felt seal and install it over the brake cam. Install the wear indicator plate aligning the wide tooth of the plate with the wide groove on the brake cam. Install the brake arm onto the brake cam, aligning the wide tooth of the brake arm with the wide groove of the brake cam and tighten the brake arm bolt, TORQUE: 47 N-m (0.4-0.7 kgm, 3-5 feb) (2) 80LT, Install the brake arm spring, Install the brake shoes and shoe spring, Connect the brake cables. Install the rear wheel (page 12-3) and dajust the rear brakes (page 3:8), 12-5REAR SHOCK ABSORBER/SWING JOINT UNIT 7 e 10-14 Nm t a “A1.0=1.4 Kom, 710 Feb) 24-30 Nem (24-30 kom 17-22 fb) S Boe em, a @ \ = MIG aaena ° a o-4skam, © (30-4.5kgm, 40-55 N-m SZ i foretn, & wan : @ 13-0 & ~ geeten J & es13. REAR SHOCK ABSORBER/SWING JOINT UNIT SERVICE INFORMATION 13-4 REAR SHOCK ABSORBER: 132 TROUBLESHOOTING 13-1 SWING JOINT UNIT 13-4 SERVICE INFORMATION GENERAL ‘© The compression rubbers are made of natural rubber and will detriorate if they come in contact with oil or grease. SPECIFICATION i Tew STANDARO mm (in) [SERVICE LIMIT mm Grd] [iar 6 aberba oring a ath 03.6 (4.08) 1005 96) TORQUE VALUES Rear shock absorber: mounting bolt 30-45 Nom (3.0-4.5 kgm, 22-32 feb) lower joint lock nut 30-45 N-m (3.04.5 kgm, 22-32 ft-lb) Apply locking agent Swing joint: joint shaft pivot bolt 40-55 Nim (4.0-5.5 kgm, 29-40 feb) shaft aut 55-65 Nim (5.5-6.5 kg-m, 40-48 feb) Unit case bole; 8 mm 24-30 Nom (2.43.0 kg-m, 1722 fib) 8mm 10-14 Nim (1.0-1.4 kgm, 7—10 feb) ‘Swing lock arm A bolt 4-7 Nem (0.4-0.7 kgm, 3-5 ft1b) TOOLS Special Rear shock abosrber attachment A 07967-GA70101 Rear shock absorber attachment 8 07967—GA70200 Common Fear shock absorber compressor 07959-3200001 TROUBLESHOOTING Refer to page 16-5 for parking/swing lock troubleshooting, Soft suspension * Weak shock absorber spring. * Damper oil leaking, Hard suspension + Bent damper unit, Suspension * Shock absorber spring binding + Damaged stopper rubber. 13-1REAR SHOCK ABSORBER/SWING JOINT UNIT REAR SHOCK ABSORBER REMOVAL Fomove the body center cover (page 10-8) Support the scooter by placing a floor jack or other adjustable support under the frame. Remove the rear shock absorber upper and lower mounting bolts and the shock absorber DISASSEMBLY Install the shock absorber compressor as shown and compress the shock absorber Loosen the damper lock nut, and remove the lower joint and lock nut Disassemble the rear shock absorber, NOTE Do not damage the damper sliding surface INSPECTION Measure the rear shock absorber spring free length, SERVICE LIMIT: 100.5 mm (3.96 in} Inspect the damper for damage and replace if necessary. (2) REAR SHOCK Sean ABSORBER BBS) LOWER MOUNTING BOLT (1) REAR SHOCK ABSORBER ATTACHMENT & (07967-GA70200 (2) REAR SHOCK ABSORBER ATTACHMENT A 07967-GA70101 a (3) REAR SHOCK ABSORBER COMPRESSOR’ 07959-3200001 (1) DAMPER LOCK NUT (2) LOWER JOINT 13-2REAR SHOCK ABSORBER/SWING JOINT UNIT ASSEMBLY 30-45 Nem (3.0-4.5 kam, 22-32 fb) (1) Apply a locking agent Install the shock absorber spring with the closely wound cot! toward the top. Compress the shock absorber with the compressor and attach: ments as shown, Extend the damper rod fully and apply a locking agent to the ‘threaded portion of the dampor rod, Install the lock nut and lower joint and tighten the lock nut. TORQUE: 30-45 Nem (3.0-4.5 kg-m, 22-32 feb) 30-054m Bos stem, 22-32 ft-lb} @ susNm BD 0-48 kam, 22-32 11D) (1) REAR SHOCK ABSORBER ATTACHMENT 8 07967-GA70200 (2) REAR SHOCK ABSORBER ATTACHMENT A = _07987-Gaz0101 (3) REAR SHOCK A8SORBER ‘COMPRESSOR ¥ 07959-3290001 ON(1) DAMPER LOCK NUT (2) LOWER JOINT 13-3REAR SHOCK ABSORBER/SWING JOINT UNIT INSTALLATION Install the rear shock absorber in the reverse order of removal and tighten both mounting bolts TORQUE: 30-45 Nim (3.0-45 kg-m, 22-32 ft-lb) After installing the rear shock abosrber, check for operation. SWING JOINT UNIT REMOVAL, Remove the engine (section 6). Release the cables from the cable clamps. ‘Turn the fuel valve OFF and disconnect the fuel line from the tube joint. Disconnect the oil inlet line from the tube joint. Remove the cotter pin, plain washer and disconnect the park- ing cable. Remove the rear shock absorber lower mounting bolt. TUPPER MOUNTING BOLT ABSORBER (1) CLAMPS re . nal () LOWER MOUNTING BOLT (2) FUEL TINE = 13-4REAR SHOCK ABSORBER/SWING JOINT UNIT Remove the swing joint shaft lower pivot bolt and swing joint i 1) SWING JOINT UNIT Bicrrivor sours Remove the upper pivot bolt and remove the swing joint link from the frame, (3) SWING JOINT LINK INSPECTION (1) STOPPER RUBBERS Inspect the swing joint link rubber bushings and stopper rubbers for wear or damage. ‘Cheek the joint link for eracks or damage. (2) RUBBER BUSHINGS DISASSEMBLY (i) SWING LOCK ARMA Remove the bolt and swing lock arm A. f Pooh NOTE Align the splits before removing the arm. Remove the seven case bolts