Honda 65 Series Manuals

Manuals and User Guides for Honda 65 Series. We have 1 Honda 65 Series manual available for free PDF download: Shop Manual

Honda 65 Series Shop Manual

Honda 65 Series Shop Manual (128 pages)

Brand: Honda | Category: Motorcycle | Size: 45.57 MB

Table of Contents

Table of Contents
4
Engine Features
9
Features
9
Overhead Camhaft (OHC)
9
Frame (C50, C50M, C65, C65M)
11
Frame (S50, S65)
13
2 Special Tools

14
- Engine View
  16
3 Engine

17
- Engine Description
  18
- Engine Removal
  18
- Power Transmission System
  18
- Engine Installation
  19
- Engine Mounting Bolts View
  19
- Installing Direction of Joint Link
  19
- Temporary Installation View
  19
- Lubrication System
  20
- Oil Pump Disassembly
  20
- Oil Pump Principle
  20
- Cylinder Head Design
  21
- 4 Camshaft
  
  25
  - Inlet Valve, Values Are for C50, C50M, S50 - Table
    25
  - Outer Valve Spring Table
    25
  - Inner Valve Spring Table
    25
  - Valve Timing Diagram
    26
  - Camshaft Construction (Oil Passage)
    26
  - Cam Contour
    26
  - Cylinder Disassembly
    27
  - Camshaft Inspection
    27
  - Cam Sprocket Teeth Base Contour
    27
  - Cylinder Cross Section
    27
- 6 Piston
  
  28
  - Cylinder Inspection
    28
  - Cylinder Reassembly
    28
  - Cylinder Dimensions
    28
- 7 Piston Ring
  
  29
- 8 Valve Operating Mechanism
  
  32
  - Valve Operating Mechanism Disassembly
    32
  - Valve Operating Mechanism Inspection
    32
  - Arrow Marking on Piston Head View
    32
  - Cam Chain Tensioner
    33
  - Valve Operating Mechanism Reassembly
    33
  - Removing the Valve Rocker Arm
    33
  - Removing Valve Cotter
    33
  - Cam Chain Tensioner Disassembly
    34
  - Cam Chain Tensioner Inspection
    34
  - Cam Chain Tensioner Reassembly
    34
  - Right Crankcase Cover
    34
  - Clutch
    35
  - Right Crankcase Cover Disassembly
    35
  - Right Crankcase Cover Reassembly
    35
  - Clutch Assembly and Oil Passage Diagram (S50, S65)
    35
  - Clutch Disassembly
    36
  - Clutch Inspection
    36
  - Clutch Center Guide Diagram
    36
  - Primary Drive Gear Diagram
    36
  - Clutch Reassembly
    37
  - Crankcase
    37
  - Breather
    37
  - R & L Crankcase View
    37
  - Crankshaft Disassembly
    38
  - Breather Functional Diagram
    38
  - Crankshaft Inspection
    39
  - Measuring Crankshaft Alignment
    39
  - Measuring Axial Clearances
    39
  - Timing Sprocket Teeth Root Contour
    39
  - Transmission
    40
  - Gearing Arrangement for C50, C50M, C65, C65M
    40
  - Crankshaft Reassembly
    40
  - Assemblying R Crankcase
    40
  - Transmission Disassembly
    41
  - Transmission Inspection
    41
  - Counter Shaft Dimension Diagram
    41
  - Clearance between Counter Shaft and Counter Shaft Third Gear
    41
  - Kickstarter
    42
  - Shift Fork Diagram
    42
  - Thrust Washer Diagram (C50, C50M, C65, C65M)
    42
  - Kickstarter Disassembly
    43
  - Kickstarter Inspection
    43
  - Kickstarter Reassembly
    43
  - Component Parts of Kickstarter View
    43
  - Carburetor (C50, C50M, C65, C65M)
    44
  - Carburetor Sectional Diagram
    44
  - Air System
    45
  - Fuel System
    45
  - Main System
    45
  - Carburetor Cross Sectional Diagram
    45
  - Float Chamber
    46
  - Choke (Starting)
    46
  - Function of the Respective Components
    47
  - Main Jet
    47
  - Air Jet
    47
  - Needle Jet
    47
  - Jet Needle
    48
  - Throttle Valve
    48
  - Slow Jet
    48
  - Adjusting the Carburetor
    49
  - High Speed Adjustment
    49
  - Adjusting the Intermediate Speed
    49
  - Air Screw
    49
  - Adjusting the Slow Speed
    50
  - Adjusting the Idle
    50
  - Carburetor (S50, S65) Diagram
    51
  - Air Flow
    51
  - Fuel Flow
    51
  - Float Chamber (S50 and S65)
    52
  - Choke (Starting System)
    53
  - Adjusting the Fuel Level
    53
    
    Fuel Level Gauge Diagram
    53
    
    Carburetor Setting Table
    54
    
    Frame
    55
  - Handle
    55
    
    Steering Handle Disassembly
    55
    
    Steering Handle Inspection
    55
    
    Steering Handle Reassembly
    56
    
    Front Fork Disassembly
    56
    
    Front Fork Inspection
    56
    
    Front Fork Reassembly
    56
  - DI Sassembly
    56
    
    Frame
    56
    
    Front Cushion Diagram
    57
  - Front Cushion Construction
    57
    
    Front Cushion Disassembly
    57
    
    Staking the Pivot Dust Seal Cap
    57
    
    Rear Cushion Diagram
    58
    
    Front Cushion Inspection
    58
    
    Front Cushion Reassembly
    58
    
    Characteristic of Front Cushion Spring Diagram
    58
    
    Front Wheel Disassembly
    59
    
    Front Wheel Cross Section Diagram
    59
    
    Removing Front Brake Shoe
    59
    
    Removing Speedometer Gear
    59
    
    Front Wheel Inspection
    60
    
    Front Wheel Reassembly
    60
    
    Measuring Wheel Runout Diagram
    60
    
    Measuring Brake Drum Diameter
    60
    
    Rear Wheel Cross Section Diagram
    61
    
    Tire Air Pressure
    61
    
    Installed Angle of Valve Stem View
    61
    
    Installing 6202 R Ball Bearing by Driving
    61
    
    Rear Wheel Construction
    62
    
    Rear Wheel Disassembly
    62
    
    Rear Wheel Inspection
    62
    
    Measuring Brake Lining
    62
    
    Rear Brake Disassembly
    63
    
    Rear Brake Inspection
    63
    
    Rear Brake Reassembly
    63
    
    Measuring Brake Pivot Pipe Diameter
    63
    
    Rear Fork Disassembly
    64
    
    Rear Fork Inspection
    64
    
    Play in the Break Pedal
    64
    
    Measuring Pivot Rubber Bushing
    64
    
    Drive Chain Disassembly
    65
    
    Drive Chain Inspection
    65
    
    Rear Fork Reassembly
    65
    
    Air Cleaner
    66
    
    Air Flow through Air Cleaner Diagram
    66
    
    Drive Chain Reassembly
    66
    
    Chain Adjuster Mark View
    66
    
    Frame Body
    67
    
    Air Cleaner Construction
    67
    
    Air Cleaner Disassembly
    67
    
    Air Cleaner Inspection
    67
    
    Muffler and Exhaust Pipe
    68
    
    Frame Body and Electrical Equipment Installation Diagram
    68
    
    Muffler Cross Section and Gas Flow Diagram (C50, C50M, C65, C65M)
    68
    
    Muffler Cross Section and Gas Flow Diagram (S50, S65)
    69
    
    Electrical System
    70
    
    Starting System - C50M, C65M
    70
    
    Starter Characteristics
    70
    
    Starting Circuit Diagram
    70
    
    Use of the Starter
    71
    
    Starter Troubleshooting and Repair
    71
    
    Starter Performance Chart
    71
    
    Starter Wiring
    71
    
    Charging System
    72
    
    A.C. Generator
    72
    
    Ignition Coil Spark Characteristic C50M, C65M
    72
    
    A.C. Generator Performance Chart (C50M, C65M)
    72
    
    Flywheel, A.C. Generator and Ignition Coil
    73
    
    A.C. Generator (for C50M, C65M)
    73
    
    Table of Specifications and Performance
    73
    
    Inspecting Sparkling Performance
    74
    
    Testing Spark Plug Firing
    74
    
    Testing Ignition Coil
    74
    
    Measuring Resistance
    74
  - Spark Plug Adjustment
    74
    
    Spark Advancer
    75
    
    Flywheel Generator Troubleshooting
    75
    
    Battery View
    76
    
    Battery Construction
    76
    
    Inspecting the Spark Advancer
    76
    
    Spark Advance Performance Chart
    76
    
    Battery: Instruction on Use and Servicing
    77
    
    Procedure for Changing Rates
    77
    
    Specific Gravity and Residual Capacity Chart
    77
    
    Electrolyte Level Indicator View
    77
    
    Battery: Servicing During Use
    78
    
    Battery Charging Procedure
    78
    
    Battery Troubleshooting and Preventative Maintenance
    78
    
    Battery Troubleshooting and Corrective Action
    79
    
    Spark Plug Application
    80
    
    Heat Range of the Spark Plug
    80
    
    Construction of Spark Plug - Diagram
    80
    
    Heat Range of Spark Plug - Diagram
    80
    
    Spark Plug Reach
    81
    
    Spark Plug Electrode Diagram
    81
    
    Sooty Plug View
    81
    
    Overheated Plug View
    81
    
    Turn Signal Lamp Installation
    82
    
    Flasher Relay View
    82
    
    Flashing Circuit Diagram
    82
    
    Main Spark Plug Troubleshooting and Corrective Action
    82
    
    Headlight Trouble and Corrective Action
    83
    
    Horn
    83
    
    Flashing Trouble and Corrective Action
    83
    
    Turn Signal Lamp Spring Contact Holder View
    83
    
    Selenium Rectifier
    84
    
    Battery Installation
    84
    
    Fuse View
    84
    
    Adjusting the Horn - Illustration
    84
    
    Selenium Rectifier Installation and Handling
    85
    
    Damages to Selenium Wafer
    85
    
    Selenium Rectifier Installation Instruction
    85
    
    Connecting the Test Leads
    85
    
    Speedometer
    86
    
    Inspecting the Selenium Rectifier
    86
    
    Periodic Adjustment
    87
    
    Maintenance Inspection
    87
    
    Engine Adjustment - Measuring Compression
    87
    
    Tappet Adjustment
    87
    
    Ignition Timing Adjustment
    88
    
    Valve Clearance
    88
    
    Alignment of the "F" Timing Mark
    89
    
    User of Service Tester
    89
    
    Checking the Operation of the Spark Advancer with a Tachometer
    89
    
    Filing Breaker Point Contact - Illustration
    89
    
    Contact Points
    90
    
    Spark Plug Adjustments
    90
    
    Insufficient Breaker Point Gap
    90
    
    Excessive Beraker Point Gap
    90
  - Fuel Supply System
    91
  - Fuel Strainer Cleaning
    91
    
    Fuel Cock Lever View
    91
    
    Fuel Tank Cap Cross Section
    91
    
    Oil Filter Screen Cleaning
    92
    
    Fuel Flow through the Fuel Cock Diagram
    92
  - Air Cleaner Cleaning
    93
    
    Clutch Adjustment (S50, S65)
    93
    
    Lever Play (S50, S65)
    93
    
    Removing Air Cleaner Cover
    93
  - Carburetor Cleaning and Adjustment
    94
    
    Idle Adjustment
    94
    
    Lubricating
    95
    
    Parts Not Requiring Periodic Oil Change or Lubrication
    95
    
    Engine Oil Change
    95
    
    Oil Level Gauge View
    95
    
    Drive Chain Adjustment
    96
  - Greasing
    96
  - Oil Brand and Grade
    96
  - Lubrication
    96
  - Front Brake Adjustment
    97
  - Rear Brake Adjustment
    97
  - Muffler Cleaning
    98
  - Spoke Torquing
    98
    
    Battery Inspection
    98
    
    Electrolyte Level
    98
    
    Security Inspection of Parts (C50, C50M, C65, C65M)
    99
    
    Damaged and Dirty Battery Cable Connector
    99
    
    Specific Gravity
    99
    
    Torquing Points on Left Side
    99
    
    Security Inspection of Parts (S50, S65)
    100
    
    Torquing Points on Right Side
    100
  - Periodic Inspection and Servicing
    101
    
    Daily Inspection
    101
    
    Periodic Inspection
    103
    
    Troubleshooting
    104
    
    Main Engine Trouble
    104
    
    Condenser Test Method
    105
    
    Condenser Measurement
    105
    
    Carburetor Cross Section Diagram
    106
    
    Adjusting the Idling
    107
    
    Carburetor Cross Section View
    108
    
    Engine Noise
    109
    
    Steering Stem Troubleshooting
    109
  - Trouble Shooting
    109
    
    Clutch System
    110
    
    Gear Change System
    110
    
    Suspensions Troubleshooting
    111
    
    Brake System Troubleshooting
    111
    
    Drive Chain Troubleshooting
    111
    
    Specifications
    112
    
    Engine Performance (C 50)
    116
    
    Running Performance (C 50)
    116
    
    Engine Performance (C 65)
    117
    
    Running Performance (C 65)
    117
    
    Engine Performance (C 65M)
    118
    
    Running Performance (C 65M)
    118
    
    Engine Performance (S 50)
    119
    
    Running Performance (S 50)
    119
    
    Engine Performance (S 65)
    120
    
    Running Performance (S 65)
    120
    
    Dimensional Drawing
    121
    
    Wiring Diagram (C50, C65)
    123
    
    Wiring Diagram (C50M, C65M)
    124
    
    Wiring Diagram (S50, S65)
    125

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