Honda Activa SCV110 Service Manual Digest
  1. Manuals
  2. Brands
  3. Honda Manuals
  4. Scooter
  5. Activa SCV110
  6. Service manual digest

Honda Activa SCV110 Service Manual Digest

Hide thumbs
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading

Related Manuals for Honda Activa SCV110

Summary of Contents for Honda Activa SCV110

  • Page 2 HONDA ACTIVA SHOP MANUAL © Honda Motor CO.,Ltd 2009...

  • Page 3: Important Safety Precautions

    Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle.
  • Page 4 AND SPECIFICATIONS INCLUDED IN THIS PUBLICA- TION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF AP- TROUBLESHOOTING PROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY INDEX TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER.
  • Page 5 Example: Molykote ® G-n paste manufactured by Dow Corning, U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
  • Page 6 1-10 SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may cause damage to the scooter. 2. Use the special tools designed for this product to avoid damage and incorrect assembly.

  • Page 7: Model Identification

    GENERAL INFORMATION MODEL IDENTIFICATION FRAME SERIAL NUMBER ENGINE SERIAL NUMBER The frame serial number is stamped on the right side of the The engine serial number is stamped on the lower left side frame body. of the crankcase. CARBURETOR IDENTIFICATION NUMBER COLOR LABEL The carburetor identification number is stamped on the left The color label is pasted in the luggage box under the seat.
  • Page 8 GENERAL INFORMATION SPECIFICATIONS GENERAL ITEM SPECIFICATIONS DIMENSIONS Overall length 1761 mm (69.3 in) Overall width 710 mm (28.0 in) Overall height 1147 mm (45.2 in) Wheelbase 1238 mm (48.7 in) Seat height 765 mm (30.1 in) Ground clearance 153 mm ( 6.0 in) Dry weight 107 kg (236 lbs) Curb weight...
  • Page 9 0.7 liters (0.7 US qt, 0.6 lmp qt) — At disassembly 0.8 liters (0.8 US qt, 0.7 lmp qt) — Honda 4-stroke oil or equivalent motor oil Recommended engine oil API service classification: SJ — Viscosity: SAE 20W-40 Oil pump Rotor tip clearance 0.15 (0.006)
  • Page 10 0.12 liter (0.13 US qt, 0.11 lmp qt) 0.10 liter (0.11 US qt, 0.09 lmp qt) At draining Recommended final reduction oil Honda 4-stroke oil or equivalent motor oil API service classification: SJ Viscosity: SAE 20W-40 Unit: mm (in) CRANKCASE/CRANKSHAFT...
  • Page 11 GENERAL INFORMATION Unit: mm (in) FRONT WHEEL/BRAKE/SUSPENSION/STEERING ITEM STANDARD SERVICE LIMIT Cold tyre pressure Driver only 150 kPa (1.50 kgf/cm , 22 psi) — Driver and passenger 150 kPa (1.50 kgf/cm , 22 psi) — Rim size 10 x 2.15 in —...
  • Page 12 GENERAL INFORMATION BATTERY/CHARGING SYSTEM ITEM SPECIFICATIONS Battery Capacity 12 V – 5 Ah Specific gravity Fully charged Above 1.270 – 1.290 at 20°C/68°F Needs charging Below 1.260 at 20°C/68°F Current leakage 1.0 mA max. Charging rate Normal 0.5 A/5 – 10 h Quick 5 A/0.5 h Regulator/rectifier...
  • Page 13 GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE TORQUE FASTENER TYPE FASTENER TYPE N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft) 5 mm bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9) 6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5) 8 mm bolt and nut 22 (2.2, 16)
  • Page 14 GENERAL INFORMATION FRAME THREAD DIA. TORQUE ITEM QTY. REMARKS (mm) N·m (kgf·m, lbf·ft) FRAME/BODY PANELS/EXHAUST SYSTEM: Muffler protector bolt 14 (1.4, 10) Exhaust pipe protector 14 (1.4, 10) Exhaust pipe/muffler mounting bolt 49 (5.0, 36) ENGINE REMOVAL/INSTALLATION: Air supply hose band screw 3 (0.3, 22) Engine mounting nut (Engine side) 49 (5.0, 36)
  • Page 15 GENERAL INFORMATION TOOLS DESCRIPTION REFERENCE SECTION TOOL NUMBER Float level gauge 070MJ – 001-I110 Clutch center holder 070MB – KPL-I200 Universal holder 070MB – KPL-I100 9, 11 Fly wheel puller 070MC – KPL-I200 Bearing remover weight 070MC – KPL-I300 9, 10 Attachment, 32 x 35 mm 070GD –...
  • Page 16 GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE LOCATION MATERIAL REMARKS Camshaft cam lobes molybdenum oil solution (Mixture of the engine oil and molybdenum grease in a ratio of 1 : 1) Oil pump rotor Engine oil Oil pump driven gear teeth Stem seal fitting surface Cylinder stud bolt threads Camshaft holder nut threads and seating surface...
  • Page 17 GENERAL INFORMATION FRAME LOCATION MATERIAL REMARKS Steering head bearing steel ball and race Multi-purpose grease Front wheel dust seal lip Speedometer gear teeth and sliding surface Do not contaminate the brake Front brake cam pivot and shoe contacting area (Drum) lining surfaces.
  • Page 18 GENERAL INFORMATION CABLE & HARNESS ROUTING SPEEDOMETER CABLE FRONT BRAKE CABLE REAR BRAKE CABLE CAPACITOR DISCHARGE IGNITION (CDI) THROTTLE CABLE STARTER RELAY TURN SIGNAL RELAY BATTERY BATTERY BREATHER TUBE HORN 1-13...
  • Page 19 GENERAL INFORMATION FRONT BRAKE CABLE REAR BRAKE CABLE MAIN FUSE (10 A) THROTTLE CABLE CHOKE CABLE MAIN WIRE HARNESS SPEEDOMETER CABLE BATTERY BREATHER TUBE 1-14...
  • Page 20 GENERAL INFORMATION SPEEDOMETER CABLE FRONT BRAKE CABLE THROTTLE CABLE REAR BRAKE CABLE STARTER RELAY REGULATOR/ RECTIFIER CHOKE CABLE UNIT MAIN WIRE HARNESS 1-15...
  • Page 21 GENERAL INFORMATION THROTTLE CABLE VACUUM TUBE MAIN WIRE HARNESS FUEL LINE REAR BRAKE CABLE CHOKE CABLE OVER FLOW TUBE VACUUM TUBE FUEL LEVEL SENSOR WIRE THROTTLE CABLE CHOKE CABLE FUEL LINE MAIN WIRE HARNESS SPARK PLUG WIRE 1-16...
  • Page 22 GENERAL INFORMATION FUEL LINE THROTTLE CABLE VACUUM TUBE MAIN WIRE HARNESS CHOKE CABLE REAR BRAKE CABLE REAR RIGHT TURN SIGNAL WIRE BRAKE/ TAIL LIGHT WIRE REAR LEFT TURN SIGNAL WIRE 1-17...

  • Page 23: Emission Control Systems

    Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems to reduce carbon monoxide and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent the discharge of crankcase emissions into the atmosphere.
  • Page 24 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR INJECTION SYSTEM) The exhaust emission control system consists of a pulse secondary air injection system which introduces filtered air into the exhaust gases at the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system. This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmiess carbon dioxide and water vapor.
  • Page 25 GENERAL INFORMATION TUFFUP TUBE TUFFUP tube is composed of double tubes which make a liquid room at tread side of the tyre to prevent puncture. The construction is such that when a foreign body, a needle, nail etc. makes a pinhole, keep the air leak to minimum. When the needle makes a pinhole, the liquid will be pushed between the needle and the tube.
  • Page 26 FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS REAR HANDLEBAR FRONT HANDLEBAR COVER SEAT COVER INNER COVER BODY COVER REAR FENDER FRONT COVER FLOOR PANEL UNDER COVER...
  • Page 27 2. FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS INNER COVER SERVICE INFORMATION UNDER COVER TROUBLESHOOTING REAR FENDER FRONT CENTER COVER HANDLEBAR COVER FRONT COVER MUFFLER SEAT MUFFLER PROTECTOR BODY COVER LIFT UP SARI STEP BODY COVER SIDE STAND 2-10 FLOOR MAT/FLOOR PANEL SERVICE INFORMATION GENERAL Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.

  • Page 28: Front Cover

    FRAME/BODY PANELS/EXHAUST SYSTEM FRONT CENTER COVER SCREWS FRONT CENTER COVER REMOVAL/INSTALLATION Remove the screws (4 nos.) and release the front center cover bosses (4 nos.) from mounting grommet. Installation is in the reverse order of removal. Grommets provided with locks, remove front center SCREWS cover carefully.
  • Page 29 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the nuts (2 nos.). Remove the seat. Installation is in the reverse order of removal. NUTS SEAT For removing the hinge seat, remove hinge pin. HINGE SEAT HINGE PIN HELMET HOOKS LUGGAGE BOX ASSEMBLY SCREWS A SCREWS A Open the seat (page 2-2).

  • Page 30: Body Cover

    FRAME/BODY PANELS/EXHAUST SYSTEM Lift up the body cover and stand the rod securely. BODY COVER Do not move the scooter when body cover is lifted up. BODY COVER SEAT CATCH CABLE REMOVAL/INSTALLATION Open the seat (page 2-2). Remove the Bolts (3 nos.) from the luggage box. (page 2-3) Detach the seat catch cable from the seat catch bracket.
  • Page 31 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the following REAR CENTER COVER —Front center cover screw (A) (6 nos.). TAIL/BRAKE LIGHT —Rear center cover screw (B) (4 nos.). —Under cover screw (C) (4 nos.). —Tail/brake light screws (D) (4 nos.). —Stay front body cover bolts (A) (2 nos.). —Rear grip support bolts (B) (4 nos.).

  • Page 32: Under Cover

    FRAME/BODY PANELS/EXHAUST SYSTEM INNER COVER REMOVAL/INSTALLATION INNER COVER Remove the floor panel (page 2-5). Remove the screws (8 nos.) from the inner side and (2 nos.) from lower side. (page 2-2). Disconnect the choke cable. Remove the bolt (1 no.) and inner cover. Installation is in the reverse order of removal.

  • Page 33: Rear Fender

    FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER BOLTS OVER FLOW TUBE REMOVAL/INSTALLATION Remove the body cover (page 2-4). Disconnect the pulse secondary air injection (PAIR) air cleaner tube. Release fuel pipe and vacuum pipe from rear fender slot. Release the over flow tube from the inside of the rear fender.
  • Page 34 FRAME/BODY PANELS/EXHAUST SYSTEM Disconnect the following: REAR HANDLEBAR COVER — Speedometer connector and wire — Right and left handlebar switch connectors SPEEDOMETER — Speedometer cable AND WIRE Remove the inner side screws (2 nos.), rear side screw/ RIGHT washer (1 no.) and rear handlebar cover. HANDLEBAR SWITCH Installation is in the reverse order of removal.
  • Page 35 FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION GASKET Install the muffler protector and tighten the bolts to specified torque. NUTS TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft) Set the new gasket to the exhaust pipe. Install the muffler and loosly tighten the exhaust pipe joint nuts (2 nos.).

  • Page 36: Side Stand

    FRAME/BODY PANELS/EXHAUST SYSTEM Insert the bolts (2 nos.) and tighten the nuts (2 nos.). Installation is in the reverse order of removal. BOLTS SIDE STAND Lift up the body cover. (page 2-3). Remove the floor mat from the floor panel. Remove the floor panel (page 2-5).
  • Page 37 FRAME/BODY PANELS/EXHAUST SYSTEM Insert the bracket bolts (2 nos.) and tighten the nuts (2 nos.). BOLTS Align the hole of side stand with matching hole in the bracket. ALIGN Insert the bolt (1 no.) side stand pivot and tighten it. (One side of the hole of side stand is threaded in which BOLT the bolt is tightened.)
  • Page 38 3. MAINTENANCE SERVICE INFORMATION DRIVE BELT 3-12 MAINTENANCE SCHEDULE FINAL DRIVE OIL 3-12 FUEL LINE BATTERY 3-12 THROTTLE OPERATION BRAKE SHOES WEAR 3-13 CARBURETOR CHOKE BRAKE SYSTEM 3-13 AIR CLEANER BRAKE LIGHT SWITCH 3-15 CRANKCASE BREATHER HEADLIGHT AIM 3-15 SPARK PLUG CLUTCH SHOES WEAR 3-15 VALVE CLEARANCE...
  • Page 39 Intake 0.16 ± 0.02 mm (0.006 ± 0.001 in) Exhaust 0.16 ± 0.02 mm (0.006 ± 0.001 in) Recommended engine oil Honda 4-stroke oil or equivalent motor oil API service classification: SJ Viscosity: SAE 20W-40 Engine oil capacity At draining 0.7 liter (0.7 US qt, 0.6 Imp qt)

  • Page 40: Maintenance Schedule

    CLUTCH/BRAKE/THROTTLE FREE PLAY Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualified. ** In the interest of safety, we recommended these items be serviced only by an authorized Honda dealer.

  • Page 41: Fuel Line

    MAINTENANCE FUEL LINE FUEL LINE Lift up the body cover (page 2-3). Check the fuel line for deterioration, damage or leakage. Replace the fuel line if necessary. Do not move the scooter when body cover is lifted up. THROTTLE OPERATION Check for any deterioration or damage to the throttle cable.
  • Page 42 MAINTENANCE CARBURETOR CHOKE CHOKE KNOB Check for smooth choke knob operation. Check the choke cable for frayed, kinked or other damage. AIR CLEANER AIR CLEANER AIR CLEANER SCREW B COVER ELEMENT Lift up the body cover (page 2-3). Remove the screws A (6 nos.) and the air cleaner cover. NOTE: If the scooter is used in wet or dusty areas, more frequent inspections are required.

  • Page 43: Crankcase Breather

    MAINTENANCE CRANKCASE BREATHER NOTE: Service more frequently when ridden in rain, at full throttle, or after the scooter is overturned. Service if the deposits level can be seen in the drain tube. Remove the clamp from the crankcase breather drain tube and drain the deposits into a suitable container, then install the clamp securely.

  • Page 44: Valve Clearance

    MAINTENANCE VALVE CLEARANCE CHOKE CABLE NOTE: CLAMP Inspect and adjust the valve clearance when the engine is cold (below 35°C/95°F). Liftup the body cover (page 2-3). Disconnect the crankcase breather tube from the cylinder head cover. Release throttle cable and Choke Cable from the head CRANKCASE cover clamp.

  • Page 45: Engine Oil

    If the oil level is below or near the lower level mark, add the recommended engine oil to the upper level mark. RECOMMENDED ENGINE OIL: Honda 4-stroke oil or equivalent motor oil UPPER API service classification: SJ LEVEL MARK...

  • Page 46: Engine Oil Change

    MAINTENANCE NOTE: OIL VISCOSITIES Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range. Reinstall and tighten the oil filler cap/dipstick securely. ENGINE OIL CHANGE OIL FILLER NOTE: CAP/DIPSTICK Drain the engine oil while the engine is warm.

  • Page 47: Engine Idle Speed

    MAINTENANCE ENGINE OIL STRAINER SCREEN Drain the engine oil. Remove the oil strainer screen cap, spring and oil strainer screen. Clean the oil strainer screen thoroughly. Check the screen for damage and the O-ring for damage or deterioration. Replace the oil strainer screen if necessary. OIL STRAINER SCREEN CAP Install the oil strainer screen, spring and cap.

  • Page 48: Air Cleaner

    MAINTENANCE SECONDARY AIR SUPPLY SYSTEM NOTE: The secondary air supply system introduces filtered air into exhaust gases in the exhaust port. The secondary air PAIR CONTROL VALVE is drawn into the exhaust port whenever there is negative pressure pulse in the exhaust system. This charged PAIR CHECK VALVE secondary air promotes burning of the unburned exhaust gases and changes a considerable amount of...

  • Page 49: Drive Belt

    OIL DRAIN BOLT the check bolt hole up to the bottom edge of the check bolt hole. RECOMMENDED OIL: Honda 4-stroke oil or equivalent motor oil API service classification: SJ Viscosity: SAE 20W-40 OIL CAPACITY: 0.10 liter (0.11 US qt, 0.09 lmp qt) at oil change 0.12 liter (0.13 US qt, 0.11 lmp qt) at disassembly...
  • Page 50 MAINTENANCE After filling, install each filler cap firmly. Charge the battery (Page 15-7). Check the specific gravity (Page 15-7). Install the battery in the reverse order of removal. NOTE: Add only distilled water. Tap water will shorten the service life of the battery. Never apply grease on the battery terminals.
  • Page 51 MAINTENANCE If adjustment is necessary, turn the front brake adjusting ADJUSTING NUT nut. Check the brake cable for kinks or other damage. Check that the brake arm, spring and fasterners are in good condition. while installing Speedometer and brake cable make sure that both are always routed via the given hose-clamps REAR BRAKE...
  • Page 52 MAINTENANCE BRAKE LIGHT SWITCH BRAKE LOCK LEVER The brake light switch at the brake lever cannot be adjusted. If the brake light switch actuation and brake engagement are off, either replace the switch unit or the malfunctioning parts of the system. Check that the brake light comes on when the brake lever is pressed and the front-rear brake engagement begins.
  • Page 53 MAINTENANCE SUSPENSION Loose, worn or damaged suspension parts impair scooter stability and control. Repair or replace any damaged components before riding. Riding a scooter with faulty suspension increases your risk of an accident and possible injury. FRONT Check the action of the front suspension by applying the front brake and compressing the forks several times.
  • Page 54 MAINTENANCE NUTS, BOLTS, FASTENERS Check that all chassis nuts and bolts are tightened to correct torque values (page 1-8). Check that all cotter pin, safety clips, hose clamps and cable stays are in place and properly secured. WHEELS/TYRES NOTE: Tyre pressure should be checked when the tires are COLD.
  • Page 55 LUBRICATION SYSTEM INTAKE ROCKER ARM CRANKSHAFT OIL STRAINER SCREEN OIL PUMP...

  • Page 56: Lubrication System

    0.7 liters (0.7 US qt, 0.6 lmp qt) — At disassembly 0.8 liters (0.8 US qt, 0.7 lmp qt) — Honda 4-stroke oil or equivalent motor oil Recommended engine oil API service classification: SJ — Viscosity: SAE 20W-40 Oil pump Rotor tip clearance 0.15 (0.006)

  • Page 57: Oil Pump

    LUBRICATION SYSTEM OIL PUMP REMOVAL OIL PUMP COVER Drain the engine oil (page 3-9). Remove the alternator assembly (page 11-2). Remove the oil pump cover bolts (2 nos.). BOLTS Screw the two 5 mm bolts into the threaded holes in the oil pump cover and pull the cover out of the right 5 mm BOLTS crankcase.
  • Page 58 LUBRICATION SYSTEM DISASSEMBLY SCREW Remove the dowel pins (2 nos.). Remove the oil pump plate attaching screw (1 no.) and DOWEL PINS pump plate. PUMP PLATE INSPECTION FEELER GAUGE Check oil pump gear for any damage/worn-out teeth. OIL PUPM GEAR Insert the oil pump gear into the oil pump.
  • Page 59 LUBRICATION SYSTEM ASSEMBLY OUTER ROTOR DOWEL PINS INNER ROTOR OIL PUMP GEAR PUMP PLATE PUMP BODY GEAR SHAFT PUMP COVER Install the outer and inner rotors into the pump body. SCREW Install the two dowel pins. Install the pump plate by aligning the holes in the pump plate with the two dowel pins.
  • Page 60 LUBRICATION SYSTEM Install the oil pump gear and gear shaft into the oil pump. OIL PUMP GEAR GEAR SHAFT Apply grease to the oil pump gear shaft hole in the oil pump cover. O-RING Coat a new O-ring with oil and install it onto the oil pump cover.
  • Page 61 FUEL SYSTEM 12 N·m (1.2 kgf·m, 9 lbf·ft)
  • Page 62 5. FUEL SYSTEM SERVICE INFORMATION THROTTLE SWITCH TROUBLESHOOTING AIR SCREW ADJUSTMENT 5-10 AIR CLEANER HOUSING FUEL TANK 5-11 CARBURETOR REMOVAL SECONDARY AIR SUPPLY SYSTEM 5-12 CARBURETOR INSTALLATION SERVICE INFORMATION GENERAL • Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. •...
  • Page 63 FUEL SYSTEM TORQUE VALUES Carburetor mounting bolts 12 N·m (1.2 kgf·m, 9 lbf·ft) TOOL Float level gauge 070MJ – 001-I110 TROUBLESHOOTING Backfiring or misfiring during acceleration Engine won’t start • No fuel in fuel tank • Fuel mixture too lean •...
  • Page 64 FUEL SYSTEM AIR CLEANER HOUSING ENGINE BREATHER HOSE For air cleaner housing cover removal and element SCREW replacement (see page 3-5). REMOVAL Lift up the body cover (page 2-3). Loosen the air cleaner connecting guide band screw. Disconnect the engine breather hose from the cylinder head cover.

  • Page 65: Carburetor Removal

    FUEL SYSTEM CARBURETOR REMOVAL CARBURETOR TOP THROTTLE VALVE Remove the body cover (page 2-4). Loosen the carburetor top. Remove the carburetor top and throttle valve from the THROTTLE VALVE carburetor. Remove the throttle cable from the throttle valve while THROTTLE VALVE SPRING compressing the throttle valve spring.
  • Page 66 FUEL SYSTEM CARBURETOR BODY THROTTLE SWITCH BOLTS CONNECTORS SCREW Gasoline is extremely flammable and explosive under certain conditions. Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion.
  • Page 67 FUEL SYSTEM Remove the following: O-RING NEEDLE JET — Main jet — Needle jet NEEDLE — Needle jet holder — Slow jet HOLDER WASHER — Air screw/Spring/Washer/O-ring — Throttle stop screw/spring MAIN SCREW NOTE: Before removing the pilot screw, record the number of turns until it seats lightly;...

  • Page 68: Float Level Inspection

    FUEL SYSTEM Install the following: O-RING NEEDLE JET — Throttle stop screw/spring — Slow jet NEEDLE — Needle jet holder — Needle jet HOLDER WASHER — Main jet MAIN SCREW Handle all jets with care. They can easily be scored or scratched.

  • Page 69: Carburetor Installation

    FUEL SYSTEM Install the float chamber. SCREWS Install and tighten the screws (2 nos.) securely. FLOAT CHAMBER CARBURETOR INSTALLATION THROTTLE SWITCH BOLTS CONNECTORS CARBURETOR BODY SCREW Install the carburetor body into the insulator and air cleaner connecting tube. Tighten the carburetor mounting bolts and air cleaner connecting tube band screw.
  • Page 70 FUEL SYSTEM Install the throttle valve spring onto the throttle cable. THROTTLE VALVE SPRING Connect the throttle cable to the throttle valve while compressing the throttle spring. THROTTLE CABLE Install the throttle valve into the carburetor body. THROTTLE VALVE Tighten the carburetor top securely. After installation check that there is no fuel leaks.
  • Page 71 FUEL SYSTEM Remove the O-ring from the carburetor body. THROTTLE SWITCH O-RING Throttle switch inspection (see page 16-7). INSTALLATION THROTTLE SWITCH O-RING Install a new O-ring to the carburetor body. Install the throttle switch by aligning the hole of the carburetor with the hole of the throttle switch.

  • Page 72: Fuel Tank

    FUEL SYSTEM Damage to the air screw seat will occur if the pilot screw is tighten against the seat. INITIAL OPENING: 1 7/8 turns out 2. Warm up the engine to operating temperature. Stop and go riding for 10 minutes is sufficient. 3.
  • Page 73 FUEL SYSTEM SECONDARY AIR SUPPLY SYSTEM SYSTEM INSPECTION Start the engine, and warm it up to normal operating temperature, then stop the engine. SCREWS Disconnect the air suction hose from the secondary air cleaner housing. COVER PAIR CONTROL Check the air suction hose port is clean and free carbon VALVE BODY deposits.
  • Page 74 FUEL SYSTEM Inspect the check valve for damage or fatigue. Replace if COVER necessary. CHECK Replace the PAIR check valve if the seat rubber is cracked, VALVE Deteriorated or damaged, or if there is clearance between the reed and seat. Install the PAIR check valve and cover.
  • Page 75 ENGINE REMOVAL/INSTALLATION 49 N·m (5.0 kgf·m, 36 lbf·ft)
  • Page 76 6. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION ENGINE INSTALLATION ENGINE REMOVAL SERVICE INFORMATION GENERAL • The following components can be serviced with the engine installed in the frame: — Oil pump (section 4) — Carburetor (section 5) — Drive and driven pulleys/clutch (section 9) —...

  • Page 77: Engine Removal

    ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL VACUUM TUBE Place the scooter on its center stand and support the frame securely. Drain the engine oil if the crankcase is to be serviced (page 3-9). Remove the body cover (Page 2-4). Remove the following: —...
  • Page 78 ENGINE REMOVAL/INSTALLATION Remove the engine mounting nut and pull out the mounting bolt from the left side. ENGINE MOUNTING NUT Remove rear shock absorber upper mounting bolt (page 14-6). UPPER MOUNTING BOLT Remove the engine from the frame. Support the frame securely to prevent it from turning over.

  • Page 79: Engine Installation

    ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION Route the wires, tubes and cables properly (page 1-16). Install the engine into the frame. Insert the engine mounting bolt from the left side. Install and tighten the nut. TORQUE: 49 N·m (5.0 kgf·m, 36 lbf·ft) ENGINE MOUNTING NUT Install rear shock absorber upper mount bolt (page 14-6).
  • Page 80 ENGINE REMOVAL/INSTALLATION Tighten the screw and connect the air supply hose. Connect the starter motor ground wire from frame. GROUND WIRE AIR SUPPLY HOSE Connect the following. 2P CONNECTOR — Starter motor 2P connector (page 17-3). — Alternator wire connector (page 11-2). —...
  • Page 81 CYLINDER HEAD/VALVES 12 N·m (1.2 kgf·m, 9 lbf·ft) 4 N·m (0.4 kgf·m, 2.9 lbf·ft) 18 N·m (1.8 kgf·m, 13 lbf·ft) 7 N·m (0.7 kgf·m, 5.1 lbf·ft) 0.8 N·m (0.08 kgf·m, 6 lbf·ft)
  • Page 82 7. CYLINDER HEAD/VALVES SERVICE INFORMATION VALVE GUIDE REPLACEMENT TROUBLESHOOTING VALVE SEAT INSPECTION/REFACING 7-10 CYLINDER COMPRESSION CYLINDER HEAD ASSEMBLY 7-15 INTAKE/EXHAUST SHROUDS CYLINDER HEAD INSTALLATION 7-16 CYLINDER HEAD REMOVAL CAMSHAFT REMOVAL 7-19 CYLINDER HEAD DISASSEMBLY CAMSHAFT INSTALLATION 7-20 CYLINDER HEAD INSPECTION SERVICE INFORMATION GENERAL •...
  • Page 83 CYLINDER HEAD/VALVES TOOLS Valve spring compressor 070GE – 001-I100 Valve guide reamer 070MH – 001-I160 Valve guide driver 070ND – 006-I150 Seat cutter, 22 mm (45° IN) 070MH – 003-I150 Seat cutter, 27.5 mm (45° EX) 070MF – 003-I180 Flat cutter, 24 mm (32° IN) 070MH –...

  • Page 84: Cylinder Compression

    CYLINDER HEAD/VALVES CYLINDER COMPRESSION If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. Warm up the engine to normal operating temperature. Stop the engine, Liftup the body cover. COMPRESSION GAUGE Disconnect the spark plug cap and remove the spark plug.
  • Page 85 CYLINDER HEAD/VALVES INTAKE/EXHAUST SHROUDS REMOVAL BOLTS NUTS Remove the bolts (3 nos.), gasket and air supply hose. Remove the following: — Carburator (page 5-4). — Cooling fan cover (page 11-2). — Muffler assembly (page 2-8). Remove the nuts (2 nos.) and insulator. AIR SUPPLY HOSE INSULATOR Remove the screws (3 nos.), bolt (1 no.), intake shroud...

  • Page 86: Cylinder Head Removal

    CYLINDER HEAD/VALVES CYLINDER HEAD REMOVAL CRANKCASE BREATHER PIPE Remove the following: — Engine (page 6-2) — Intake/Exhaust shrouds and seal (page 7-4) — Cooling fan and cover (page 11-2) CYLINDER HEAD COVER — Spark plug (page 3-6) — Muffler assembly (page 2-8) Disconnect crankcase breather pipe from cylinder head BOLTS cover.
  • Page 87 CYLINDER HEAD/VALVES Remove the cam sprocket bolts (2 nos.) while holding CAM CHAIN the crankshaft. Remove the cam sprocket from the camshaft and the cam chain from the sprocket. Suspend the cam chain with a piece of wire to prevent it from falling into the crankcase.

  • Page 88: Cylinder Head Disassembly

    CYLINDER HEAD/VALVES CYLINDER HEAD DISASSEMBLY ROCKER ARM Screw a 6 mm screw into the threaded hole in the rocker arm shaft and pull the shaft out of the camshaft holder. Remove the rocker arm. Remove the other rocker arm shaft and rocker arm. Remove the insulator carburator.

  • Page 89: Cylinder Head Inspection

    CYLINDER HEAD/VALVES CYLINDER HEAD INSPECTION Remove the carbon deposits from the combustion chamber and clean off the head gasket surfaces. Check the spark plug hole and valve areas of the combustion chamber for cracks. COMBUSTION CHAMBER Check the cylinder head for warpage with a straight edge and feeler gauge.
  • Page 90 CYLINDER HEAD/VALVES Ream the valve guide to remove any carbon buildup be- VALVE GUIDE REAMER fore measuring the guide. Insert the reamer from the combustion chamber side of the head and always rotate the reamer clockwise. TOOL: Valve guide reamer 070MH –...
  • Page 91 CYLINDER HEAD/VALVES NOTE: VALVE GUIDE CYLINDER HEAD Install the valve guide while measuring the valve guide height from the cylinder head. SPECIFIED HEIGHT: IN/EX: 9.7 – 9.9 mm (0.382 – 0.389 in) Let the cylinder head cool to room temperature. VALVE GUIDE CLIP Ream the new valve guides.
  • Page 92 CYLINDER HEAD/VALVES • Contact area (too high or too low area): — reface the valve seat TOO LOW TOO HIGH Inspect the width of valve seat. The valve seat contact should be within the specified width and even all around the circumference. STANDARD: 1.0 mm (0.04 in) SERVICE LIMIT: 1.5 mm (0.06 in)
  • Page 93 CYLINDER HEAD/VALVES Using a 45° cutter, remove any roughness or irregulari- ROUGHNESS ties from the seat. TOOLS: Valve seat cutter, 22 mm (45° IN) 070MH – 003I150 Valve seat cutter, 27.5 mm (45° EX) 070MF – 003I180 Valve seat cutter holder 070MH –...
  • Page 94 CYLINDER HEAD/VALVES After cutting the seat, apply lapping compound to the valve face, and lap the valve using light pressure. • Excessive lapping pressure may deform or damage the seat. • Change the angle of lapping tool frequently to prevent uneven seat wear.
  • Page 95 CYLINDER HEAD/VALVES ASSEMBLY CYLINDER HEAD VALVE COTTERS SPRING RETAINER VALVE SPRING STEM SEAL SPRING SEAT VALVE GUIDE VALVE GUIDE CLIP INTAKE VALVE EXHAUST VALVE Blow through the oil passage in the cylinder head with compressed air. Install the spring seats and new stem seals. STEM SEAL VALVE Lubricate the valve stems with clean engine oil and...
  • Page 96 CYLINDER HEAD/VALVES CYLINDER HEAD ASSEMBLY Compress the valve springs and install the valve cotters. TOOL: Valve spring compressor 070GE – 001-I100 To prevent loss of tension, do not compress the valve springs more than necessary to install the cotters. VALVE SPRING COMPRESSOR Support the cylinder head so that the valve heads will not contact anything that causes damage.

  • Page 97: Cylinder Head Installation

    CYLINDER HEAD/VALVES CYLINDER HEAD INSTALLATION GASKET Install the cam chain guide so that its bosses are placed in the grooves in the cylinder. Install the dowel pins and a new gasket. DOWEL PINS Install the cylinder head. Suspend the cam chain to keep it from falling into the BOLTS cylinder.
  • Page 98 CYLINDER HEAD/VALVES Align the timing mark (index line) on the cam sprocket with the top surface of the cylinder head. CAM CHAIN Install the cam chain onto the cam sprocket, then install the cam sprocket onto the camshaft. Make sure that the timing mark (index line) aligns with the top surface and the “T”...
  • Page 99 CYLINDER HEAD/VALVES Install and tighten the cylinder head cover bolts. BOLTS TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Remove the stopper tool from the tensioner lifter. STOPPER TOOL Install the plug with a new O-ring and tighten it. LIFTER PLUG TORQUE: 4 N·m (0.4 kgf·m, 2.9 lbf·ft) Install the cam chain tensioner hole cap.
  • Page 100 CYLINDER HEAD/VALVES CAM SHAFT REMOVAL CYLINDER HEAD COVER Remove the following: — Engine (page 6-2) — Intake/Exhaust shrouds and seal (page 7-4) INTAKE SHROUD — Cooling fan and cover (page 11-2) — Spark plug (page 3-6) — Muffler assembly (page 2-8) —...

  • Page 101: Camshaft Installation

    CYLINDER HEAD/VALVES INSPECTION Check each cam lobe for wear, scratches or scoring. Measure the cam lobe height. SERVICE LIMITS: Intake: 32.041 mm (1.2615 in) Exhaust: 31.791 mm (1.2516 in) Turn the outer race of each camshaft bearing with your finger. The bearing should turn smoothly and quietly.
  • Page 102 CYLINDER/PISTON...
  • Page 103 8. CYLINDER/PISTON SERVICE INFORMATION PISTON REMOVAL TROUBLESHOOTING PISTON INSTALLATION CYLINDER REMOVAL CYLINDER INSTALLATION SERVICE INFORMATION GENERAL • To service the cylinder and piston, the engine must be removed from the frame. • Take care not to damage the cylinder wall and piston. •...
  • Page 104 CYLINDER/PISTON CYLINDER REMOVAL CYLINDER Remove the following: — Cylinder head (page 7-5). — Cam chain guide. — Cam chain tensioner (page 7-5). Check the cam chain guide and cam chain tensioner for excessive wear or damage, replace them if necessary. Be careful not to damage the sliding surface of the piston and cylinder.

  • Page 105: Piston Removal

    CYLINDER/PISTON Check the top of the cylinder for warpage with a straight edge and feeler gauge. SERVICE LIMIT: 0.05 mm (0.002 in) PISTON REMOVAL PISTON PIN Place a clean shop towel over the crankcase to prevent the clip from falling into the crankcase. Remove the piston pin clips with the pliers.
  • Page 106 CYLINDER/PISTON Insert each piston ring into the bottom of the cylinder squarely using the piston. Measure the ring end gap. PISTON RING SERVICE LIMITS: Top: 0.45 mm (0.018 in) Second: 0.45 mm (0.018 in) Measure the piston O.D. 90° to the piston pin hole and at point 10 mm (0.4 in) from bottom of the piston skirt.

  • Page 107: Piston Installation

    CYLINDER/PISTON PISTON INSTALLATION PISTON RING Carefully install the piston rings into the piston ring grooves with the markings facing up. • Do not damage the piston ring by spreading the ends too far. • Do not confuse the top and second rings. •...

  • Page 108: Cylinder Installation

    CYLINDER/PISTON Apply engine oil to the piston pin outer surface. “IN” MARK PISTON PIN Install the piston with the “IN” mark toward the intake side and insert the piston pin through the piston and connecting rod. Install new piston pin clips into the grooves of the piston PISTON PIN pin hole.
  • Page 109 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH KICKSTARTER/DRIVE AND PULLEYS/CLUTCH 93 N·m (9.3 kgf·m, 69 lbf·ft) 49 N·m (5.0 kgf·m, 36 lbf·ft)
  • Page 110 9. KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH SERVICE INFORMATION CLUTCH/DRIVEN PULLEY REMOVAL 9-11 TROUBLESHOOTING CLUTCH/DRIVEN PULLEY KICKSTARTER INSTALLATION 9-16 STARTER PINION DRIVE PULLEY INSTALLATION 9-18 DRIVE PULLEY REMOVAL SERVICE INFORMATION GENERAL Never operate the starter motor with the left crankcase cover removed. •...
  • Page 111 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH TOOLS Clutch center holder 070MB – KPL-I200 Universal holder 070MB – KPL-I100 Socket wrench, 39 x 41 mm 070MA – KPL-I300 Bearing driver 070MD – KPL-I100 Bearing remover (Driven face) 070MC – KWP-410 Bearing installer (Driven face) 070NC –...
  • Page 112 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH KICKSTARTER PILLION STEP COVER LEFT CRANKCASE COVER REMOVAL SCREWS Remove the left floor side cover (page 2-5). Open the screws (2 nos.) and remove pillion step cover. Remove the rear brake cable from the cable holder. BOLTS Loosen the air duct band screw and disconnect the air LEFT CRANKCASE COVER...
  • Page 113 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH Remove the kickstarter driven gear while turning the KICKSTARTER DRIVEN GEAR kickstarter pedal. Remove the thrust washer. FRICTION SPRING THRUST WASHER Before removing the kickstarter pedal, mark the pedal BOLT KICKSTARTER PEDAL and spindle for proper installation position. Remove the bolt (1 no.) and the kickstarter pedal.
  • Page 114 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH INSPECTION SPINDLE Inspect the following: COLLAR — spindle for wear or damage — gear teeth for wear or damage — return spring for weakness or damage — bushing for wear or damage RETURN SPRING BUSHING — driven gear for wear or damage FRICTION SPRING DRIVEN GEAR —...
  • Page 115 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH ASSEMBLY KICKSTARTER PEDAL RETURN SPRING BUSHING COLLAR SPINDLE COVER PLATE SNAP RING DRIVEN GEAR FRICTION SPRING Install the bushing and collar into the left crankcase cover. COLLAR BUSHING Apply grease (0.1 – 0.3 g) to the kickstarter spindle journal.
  • Page 116 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH Install the kickstarter pedal in its original position as BOLT KICKSTARTER PEDAL marked during removal and tighten the bolt (1 no.). TORQUE: 29 N·m (3.0 kgf·m,22 lbf·ft) MARK Install the thrust washer onto the crankcase cover. THRUST WASHER Apply grease (0.2 –...
  • Page 117 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH LEFT CRANKCASE COVER DOWEL PIN INSTALLATION Install the dowel pins (2 nos.) and apply liquid gasket. GASKET Install the left crankcase cover and cable holder, and BOLTS tighten the bolts (8 nos.) in a crisscross pattern in 2 or 3 LEFT CRANKCASE COVER steps.
  • Page 118 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH INSPECTION Check that the starter pinion operates smoothly. Check the pinion gear teeth and shaft for wear or damage. Check the starter driven gear teeth of the drive pulley face for wear of damage. INSTALLATION Apply grease (0.1 – 0.3 g) to the starter pinion shaft journal.
  • Page 119 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH Remove the washer and drive pulley face fin and drive DRIVE PULLEY FACE face. WASHER Remove the washer and drive belt from the crankshaft. DRIVE BELT WASHER Remove the movable drive face assembly while holding the back of the face (ramp plate). MOVABLE DRIVE FACE Remove the following: SLIDE PIECES...
  • Page 120 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH INSPECTION WEIGHT ROLLER Check each roller for wear or damage. Measure the weight roller O.D. SERVICE LIMIT: 17.40 mm (0.670 in) DRIVE FACE BOSS Check the drive face boss for wear or damage. Measure the boss O.D. SERVICE LIMITS: 21.98 mm (0.865 in) Measure the drive face bushing I.D.
  • Page 121 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH Remove the clutch/driven pulley assembly and drive belt. CLUTCH/DRIVEN PULLEY ASSEMBLY DRIVE BELT Set the clutch spring compressor onto the clutch/driven CLUTCH/DRIVEN pulley, aligning the bosses with the holes in the clutch. PULLEY TOOL: Clutch spring compressor 070ME –...
  • Page 122 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH Remove the clutch shoe springs and clutch shoes from PLATE DRIVE PLATE the clutch drive plate. Remove the damper rubbers (3 nos.). Remove the seal collar. MOVABLE DRIVEN FACE Pull out the guide roller pins (3 nos.). Remove the moveable driven face from the driven face.
  • Page 123 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH Remove the snap ring and drive the ball bearing out of the driven face. SNAP RING/BALL BEARING Pack new ball bearing cavities with grease. Drive the ball bearing into the driven face with the sealed side facing down. TOOL: Bearing Driver 070MD –...
  • Page 124 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH CLUTCH SHOE LINING Check the clutch shoe for wear or damage. Measure the thickness of each shoe. SERVICE LIMIT: 2.0 mm (0.08 in) DRIVEN FACE SPRING Measure the driven face spring free length. SERVICE LIMITS: 92.2 mm (3.63 in) DRIVEN FACE Check the driven face for wear or damage.
  • Page 125 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH CLUTCH/DRIVEN PULLEY INSTALLATION Clean any oil and grease from the pulley faces and clutch outer. Replace the contaminated clutch shoes. DRIVEN FACE NEEDLE BEARING MOVABLE DRIVEN FACE OIL SEAL O-RINGS SNAP RING SEAL COLLAR BALL BEARING DRIVEN FACE SPRING E-CLIP SPRING SEAT...
  • Page 126 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH Install the seal collar. SEAL COLLAR Install the damper rubbers onto the clutch drive plate. CLUTCH SHOE DAMPER RUBBER Install the clutch shoe springs onto the shoes. Install the clutch shoes and springs onto the drive plate. Install the plate and secure them with E-clips.
  • Page 127 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH Install the drive belt and clutch/driven pulley assembly. CLUTCH/DRIVEN PULLEY ASSEMBLY DRIVE BELT Install the clutch outer and nut. CLUTCH OUTER NUT Hold the clutch outer with the special tool and tighten the UNIVERSAL HOLDER clutch outer nut. TOOL: Universal holder 070MB –...
  • Page 128 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH Install the movable drive face assembly onto the MOVABLE DRIVE FACE ASSEMBLY crankshaft while holding the ramp plate. Install the drive belt onto the drive face boss. Install the drive pulley face and washer. DRIVE PULLEY FACE WASHER Apply oil to the drive pulley face nut threads and seating DRIVE PULLEY FACE NUT...
  • Page 129 FINAL REDUCTION 10-2 10-0...
  • Page 130 At disassembly 0.12 liter (0.13 US qt, 0.11 lmp qt) 0.10 liter (0.11 US qt, 0.09 lmp qt) At draining Honda 4-stroke oil or equivalent motor oil Recommended final reduction oil API service classification: SJ Viscosity: SAE 20W-40 TORQUE VALUES Final reduction oil level check bolt 13 N·m (1.3 kgf·m, 9 lbf·ft)
  • Page 131 FINAL REDUCTION TOOLS Case/driven gear puller 070MC – KPL-I1001 Bearing remover set, 12 mm — Bearing remover head, 12 mm 070MC – KPL-I400 — Bearing remover shaft, 12 mm 070MC – KPL-I410 — Bearing remover weight 070MC – KPL-I300 Bearing remover set, 15 mm —...
  • Page 132 FINAL REDUCTION FINAL REDUCTION DISASSEMBLY TRANSMISSION CASE Drain the final reduction oil (page 3-9). Remove the following: — rear wheel (page 14-2) — rear brake adjusting nut and brake arm joint (page 14-3) — Left crankcase cover (page 9-3) — Clutch/driven pulley (page 9-11) Disconnect the final reduction breather tube from the air cleaner housing.
  • Page 133 FINAL REDUCTION Remove the driveshaft oil seal. OIL SEAL FINAL REDUCTION INSPECTION Check the left crankcase and transmission cover bearings for wear or damage. Check the final shaft for excessive wear, damage or signs of seizure. Check the counter gear shaft and counter gear for excessive wear, damage or signs of seizure.

  • Page 134: Bearing Replacement

    FINAL REDUCTION BEARING REPLACEMENT BEARING REMOVER LEFT CRANKCASE Remove the final shaft bearing, counter gear shaft bearing and drive shaft bearing using the special tools. BEARING REMOVER SHAFT Be careful not to damage the left crankcase and transmission case mating surfaces. BEARING REMOVER WEIGHT TOOLS:...
  • Page 135 FINAL REDUCTION TRANSMISSION CASE OIL SEAL Remove the final shaft oil seal from the transmission case. Remove the final shaft bearing from the transmission case. FINAL SHAFT BEARING Remove the driveshaft bearing and counter gear shaft BEARING REMOVER bearing using the special tools. BEARING TOOLS: REMOVR...
  • Page 136 FINAL REDUCTION DRIVESHAFT INSTALLATION ASSEMBLY COLLAR ATTACHMENT Install the driveshaft into the transmission cover. Position the assembly collar against the driveshaft bearing inner race. Thread the assembly shaft onto the driveshaft. Hold the shaft and draw the driveshaft into the bearing inner race by turning the nut.
  • Page 137 Fill the transmission case with the recommended oil (page 3-8). BOLTS RECOMMENDED OIL: Honda 4-stroke oil or equivalent motor oil API service classification: SJ Viscosity: SAE 20W40 OIL CAPACITY: 0.10 liter (0.11 US qt, 0.09 lmp qt) at oil change 0.12 liter (0.13 US qt, 0.11 lmp qt) at disassembly...
  • Page 138 ALTERNATOR 39 N·m (4.0 kgf·m, 29 lbf·ft) 6 N·m (0.6 kgf·m, 43 lbf·ft) 0.8 N·m (0.08 kgf·m, 0.6 lbf·ft) 11-2 11-0...
  • Page 139 11. ALTERNATOR SERVICE INFORMATION 11-1 ALTERNATOR INSTALLATION 11-3 ALTERNATOR REMOVAL 11-2 SERVICE INFORMATION GENERAL • Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present. • This section covers service of the alternator stator, flywheel and the cooling fan. These parts can be removed with the engine installed in the frame.
  • Page 140 ALTERNATOR ALTERNATOR REMOVAL LIGHTING COIL LINE CONNECTOR Liftup the body cover (Page 2-4). WIRE BAND Disconnect the alternator wire connectors. PULSER COIL CONNECTOR EXCITER COIL LINE CONNECTOR Remove the two screws (2 nos.), bolts (2 nos.) and the cooling fan cover. SCREWS FAN COVER BOLT...
  • Page 141 ALTERNATOR Remove the flywheel with the flywheel puller. FLYWHEEL TOOL: Flywheel puller 070MC – KPL-I200 Remove the woodruff key from the crankshaft. FLYWHEEL PULLER Remove the bolt A (1 no.), wire clamp and grommet from the crankcase. BOLT A / GROMMET Remove the bolts B (2 nos.) holder and ignition pulse STARTER...
  • Page 142 ALTERNATOR Clean any oil or grease from the tapered portion of the FLYWHEEL NUT crankshaft and the tapered hole in the flywheel. Install the flywheel on the crankshaft by aligning its groove with the woodruff key. Install the flywheel nut (1 no.). Hold the flywheel with the universal holder and tighten the nut.
  • Page 143 CRANKCASE/CRANKSHAFT 10 N·m (1.0 kgf·m, 7 lbf·ft) 12-2 12-0...
  • Page 144 12. CRANKCASE/CRANKSHAFT SERVICE INFORMATION 12-1 CRANKSHAFT INSPECTION 12-4 TROUBLESHOOTING 12-1 CRANKSHAFT/CRANKCASE ASSEMBLY 12-5 CRANKCASE/CRANKSHAFT DISASSEMBLY 12-2 SERVICE INFORMATION GENERAL • This section covers the crankcase separation to service the crankshaft. • The engine must be removed from the frame to separate the crankcase. •...
  • Page 145 CRANKCASE/CRANKSHAFT CRANKCASE/CRANKSHAFT DISASSEMBLY Remove the parts required for crankcase separation (page 12-1). Remove the center stand return spring. RETURN SPRING Remove the cotter pin, washer, center stand pivot bolt COTTER PIN/WASHER and center stand. PIVOT BOLT CENTER STAND Remove bolts (2 nos.) and oil seal stopper plate from the CAM CHAIN left crankcase.
  • Page 146 CRANKCASE/CRANKSHAFT Remove dowel pins. Clean off crankcase mating surface. DOWEL PINS Remove the crankshaft from the left crankcase. CRANKSHAFT Remove the cam chain. CAM CHAIN Remove the oil seal from the left crankcase. OIL SEAL Remove the oil seal from the right crankcase. OIL SEAL 12-3...
  • Page 147 CRANKCASE/CRANKSHAFT CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance with a feeler gauge. SERVICE LIMIT: 0.55 mm (0.022 in) Measure the connecting rod big end radial clearance. SERVICE LIMIT: 0.04 mm (0.002 in) Set the crankshaft on V-blocks and read the runout using dial indicators.
  • Page 148 CRANKCASE/CRANKSHAFT CRANKSHAFT/CRANKCASE ASSEMBLY OIL SEAL Clean the insides of the crankcases. Check the crankcases for cracks or other faults. Coat the lip and circumference of a new oil seal with engine oil. Install the oil seal into the right crankcase so that the depth from the inside of the case is 0 –...
  • Page 149 CRANKCASE/CRANKSHAFT Place the right crankcase over the crankshaft and on the left crankcase, being careful not to damage the oil seal BOLTS lip. Install the crankcase bolts (8 nos.) and tighten them in a crisscross pattern in 2 or 3 steps and specified torque. TORQUE: 13 N·m (1.3 kgf·m, 9 lbf·ft) Check that the crankshaft turns smoothly.
  • Page 150 FRONT WHEEL/BRAKE/SUSPENSION/STEERING 49 N·m (5.0 kgf·m, 36 lbf·ft) 68 N·m (6.9 kgf·m, 50 lbf·ft) 4 N·m (0.4 kgf·m, 2.9 lbf·ft) 59 N·m (6.0 kgf·m, 43 lbf·ft) 13-2 13-0...
  • Page 151 13. FRONT WHEEL/BRAKE/SUSPENSION/STEERING SERVICE INFORMATION 13-1 HANDLEBAR 13-12 TROUBLESHOOTING 13-2 STEERING STEM/FRONT FENDER 13-15 FRONT WHEEL 13-3 FRONT CUSHION 13-20 FRONT BRAKE 13-8 SERVICE INFORMATION GENERAL • Riding on damaged rims impairs safe operation of the scooter. • When servicing the front wheel, fork or steering stem, support the scooter. •...
  • Page 152 FRONT WHEEL/BRAKE/SUSPENSION/STEERING TOOLS Bearing remover head, 12 mm 070MD – 005-I130 Bearing remover shaft 070GD – 005-I100 Driver 070GD – 001-I100 Attachment, 32 x 35 mm 070GD – 002-I140 Pilot, 12 mm 070GD – 004-I130 Lock nut wrench 45.5 mm 070MA –...

  • Page 153: Front Wheel

    FRONT WHEEL/BRAKE/SUSPENSION/STEERING FRONT WHEEL BRAKE ARM JOINT SCREW REMOVAL Support the scooter on its center stand. Remove the screw (1 no.) and front fork cover. Remove the front brake adjusting nut, brake cable, brake arm joint. ADJUSTING NUT FRONT FORK COVER Push the tab and disconnect the speedometer cable.
  • Page 154 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Remove the dust seal from the right side of wheel. DUST SEAL Insert the bearing remover head into the bearing. From the opposite side install the bearing remover shaft and drive the bearing out of the wheel. Remove the distance collar and drive out the other bearing.
  • Page 155 FRONT WHEEL/BRAKE/SUSPENSION/STEERING WHEEL RIM Check the rim runout by placing the wheel in a truing stand. Spin the wheel slowly and read the runout using a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in) WHEEL BEARING Turn the inner race of each bearing with your finger.
  • Page 156 FRONT WHEEL/BRAKE/SUSPENSION/STEERING ASSEMBLY WHEEL HUB BEARING COLLAR BEARING 49 N·m (4.9 kgf·m, 36.14 lbf·ft) DISTANCE COLLAR DUST SEAL Install the front wheel hub and tighten the nuts to NUTS specified torque. TORQUE: 49 N·m (4.9 kgf·m, 36.14 lbf·ft) Pack all bearing cavities with grease. WHEEL HUB Never reinstall an old bearing, once a bearing has been removed, the bearing must be replaced with a...
  • Page 157 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Apply grease to a new dust seal lip and install it. COLLAR Install the collar from right side of wheel hub. DUST SEAL Install the brake panel from left side of wheel. BRAKE PANEL INSTALLATION Install the brake panel assembly. BOSS/GROOVE Install the front wheel between the fork legs by aligning the brake panel groove with the boss of the left fork leg.
  • Page 158 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the brake arm joint into the brake arm. BRAKE ARM JOINT Install the brake cable through the brake panel and to the brake arm. SCREW Install the brake adjusting nut. Adjust the front brake lever free play (page 3-13). Install the front fork cover and tighten the screw (1 no.) to specified torque.
  • Page 159 FRONT WHEEL/BRAKE/SUSPENSION/STEERING BRAKE SHOES Remove the brake shoes and springs. • Replace the brake shoes as a set. • Mark the brake shoes to ensure that they are reinstalled on their original position. SPRING Remove the brake arm nut and bolt (1 no.). BRAKE ARM Unhook the return spring from the brake arm.
  • Page 160 FRONT WHEEL/BRAKE/SUSPENSION/STEERING ASSEMBLY SPRING DUST SEAL BRAKE PANEL FELT SEAL BRAKE SHOE 10 N·m (1.0 kgf·m, 7 lbf·ft) SPEEDOMETER DRIVE GEAR RETURN SPRING INDICATOR BRAKE CAM Apply grease to the felt seal and install it into the brake FELT SEAL panel.
  • Page 161 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the return spring, inserting its end into the hole in INDICATOR the brake panel. Install the wear indicator plate on the brake cam, aligning its wide tooth with the cam’s wide groove. ALIGN RETURN SPRING Install the brake arm onto the brake cam, aligning the ALIGN BRAKE ARM punch marks on the arm and cam.
  • Page 162 FRONT WHEEL/BRAKE/SUSPENSION/STEERING HANDLEBAR BOLT REMOVAL Remove the handlebar cover (page 2-7). Remove the bolt (1 no.) and front brake lever bracket/throttle housing of upper side. FRONT BRAKE LEVER BRACKET/ THROTTLE HOUSING Disconnect the throttle cable and remove front brake FRONT BRAKE LEVER lever bracket/throttle housing of lower side.
  • Page 163 Install and tighten the handlebar post pinch nut. TORQUE: 49 N·m (5.0 kgf·m, 36 lbf·ft) If the handlebar grips were removed, apply Honda Bond HANDLEBAR GRIP THROTTLE GRIP A or its equivalent to the inside surface of the grips and to the clean surface of the left handlebar and throttle pipe.
  • Page 164 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the front brake lever bracket/throttle housing of lower THROTTLE CABLE side and align the locating pin with the hole in the handlebar. ALIGN Install the front brake lever bracket/throttle housing of upper side and tighten the bolt (1 no.). BOLT FRONT BRAKE LEVER BRACKET/ THROTTLE HOUSING...
  • Page 165 FRONT WHEEL/BRAKE/SUSPENSION/STEERING STEERING STEM/FRONT FENDER REMOVAL Remove the following: — Front wheel (page 13-3) — Handlebar (page 13-12) Remove the steering stem lock nut. TOOL: STEM LOCK NUT Lock nut wrench 070MA – KPL-I200 LOCK NUT WRENCH Remove the top cone race. TOOL: Lock nut wrench 45.5 mm 070MA –...
  • Page 166 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Remove the bolt (1 no.) from the front fender. BOLT Remove the bolts (2 nos.) from the front fender inner side. BOLTS BEARING RACE REPLACEMENT BOTTOM CONE RACE BOTTOM CONE RACE Remove the bottom cone race and dust seal from the steering stem.
  • Page 167 FRONT WHEEL/BRAKE/SUSPENSION/STEERING BALL RACE REMOVER WEIGHT Drive the top ball race out of the steering head using the special tool. ADJUSTING REMOVER HEAD TOOLS: Adjusting remover head 070GC – 001-I110 Remover shaft 070GC – 001-I120 Remover weight 070MC – KPL-I300 REMOVER SHAFT TOP BALL RACE...
  • Page 168 FRONT WHEEL/BRAKE/SUSPENSION/STEERING ASSEMBLY STEM LOCK NUT TOP CONE RACE STEEL BALL TOP BALL RACE BOTTOM BALL RACE STEEL BALL BOTTOM CONE RACE DUST SEAL Install the front fender and tighten the bolts (2 nos.) securely. BOLTS Install and tighten the bolt (1 no.) securely. BOLT 13-18...
  • Page 169 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Apply grease to the bottom steel balls (19) and install it onto the steering stem. Be careful not to loose the steel balls. STEEL BALLS Apply grease to the upper steel balls (26), and install it onto the steering stem. STEEL BALL Tighten the steering top cone race fully by hand.
  • Page 170 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the steering stem lock nut to the steering stem. STEM LOCK NUT Tighten the steering stem lock nut to the specified torque. TOOL: Lock nut wrench 070MA – KPL-I200 TORQUE: 68 N·m (7.0 kgf·m, 51 lbf·ft) Make sure that the steering stem moves smoothly without play or binding.
  • Page 171 FRONT WHEEL/BRAKE/SUSPENSION/STEERING INSPECTION SHOCK ABSORBER Visually inspect the shock absorber for oil leaks or other faults. INSPECTION PIVOT ARM Check the pivot arm for wear or damage. If you fill up the pivot with grease, loosen the grease nut and do it. TORQUE: 4 N·m (0.4 kgf·m, 2.9 lbf·ft) GREASE NUT INSTALLATION...
  • Page 172 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the front cushion and tighten the bolt (1 no.) to specified torque. BOLT TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft) CUSHION Install the pivot arm and tighten the nut (1 no.) to specified torque. PIVOT ARM TORQUE: 26 N·m (2.6 kgf·m, 19.17 lbf·ft) Install the following: —...
  • Page 173 REAR WHEEL/BRAKE/SUSPENSION 39 N·m (4.0 kgf·m, 29 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 118 N·m (12.0 kgf·m, 87 lbf·ft) 14-2 14-0...
  • Page 174 • After the rear wheel installation, check the brake operation by applying the brake lever. • Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points. • Refer to the brake system information (page 14-3). •...
  • Page 175 A contaminated brake drum or lining reduces stopping power. Discard contaminated linings and clean a contaminated drum with a high quality brake degreasing agent. • Always check the brake operation before riding the scooter. • Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points. SPECIFICATIONS Unit: mm (in)

  • Page 176: Rear Wheel

    REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL REMOVAL Place the scooter on its center stand. Remove the muffler (page 2-8). Remove the axle nut, washer and the rear wheel. AXLE NUT/WASHER Check the rotating direction mark on the tire. ROTATING DIRECTION MARK Remove the nuts (4 nos.) and wheel hub. NUTS WHEEL HUB INSPECTION...
  • Page 177 REAR WHEEL/BRAKE/SUSPENSION WHEEL BEARING 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.
  • Page 178 REAR WHEEL/BRAKE/SUSPENSION DISASSEMBLY • Replace the brake shoes as a set. • Mark the brake shoes to ensure that they are reinstalled on their original position. Remove the brake shoes and springs. SPRINGS BRAKE SHOES Remove the adjusting nut, brake cable and brake arm joint from the brake arm.
  • Page 179 REAR WHEEL/BRAKE/SUSPENSION Apply grease to a new dust seal lip and install it into the brake panel (transmission case). Apply grease to the brake cam sliding surface and install it into the brake panel. BRAKE CAM Install the brake arm onto the brake cam, aligning the PUNCH MARKS punch marks on the arm and cam.

  • Page 180: Shock Absorber

    REAR WHEEL/BRAKE/SUSPENSION SHOCK ABSORBER UPPER MOUNTING BOLT REMOVAL Place the scooter on its center stand. Remove the body covers (page 2-4). Remove the upper and lower mounting bolts (2 nos.) , and the shock absorber. LOWER MOUNTING BOLT INSPECTION SHOCK ABSORBER Visually inspect the shock absorber for oil leaks or other faults.
  • Page 181 REAR WHEEL/BRAKE/SUSPENSION MEMO 14-8...
  • Page 182 BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM LIGHTING SWITCH DIMMER SWITCH REGULATOR/ RECTIFIER BATTERY EARTHING CABLE ALTERNATOR 15-2 15-0 SEC00-15.pmd 2/17/2010, 1:40 PM...
  • Page 183 15. BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM 15-0 CHARGING SYSTEM INSPECTION 15-8 SERVICE INFORMATION 15-1 ALTERNATOR INSPECTION 15-10 TROUBLESHOOTING 15-3 REGULATOR/RECTIFIER 15-10 BATTERY 15-6 SERVICE INFORMATION GENERAL • The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging.
  • Page 184 BATTERY/CHARGING SYSTEM • The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every two weeks to prevent sulfation from forming. • Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance, always charge the battery.
  • Page 185 BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK Incorrect • Faulty battery 1. Remove the battery (page 15-6). Check the battery condition using the recom- mended battery tester. RECOMMENDED BATTERY TESTER: BM-210-AH or BM-210 BATTERY MATE or equivalent Correct Incorrect 2.
  • Page 186 BATTERY/CHARGING SYSTEM (From page 15-3) Check the regulator/rectifier connector voltage and Incorrect • Open circuit in related wire • Loose or poor contacts of related terminal resistance (page 15-10). • Shorted wire harness Correct • Faulty regulator/rectifier 15-4...
  • Page 187 BATTERY/CHARGING SYSTEM LIGHTING CIRCUIT FAULTY Before starting the troubleshooting, check for burnt bulb of the headlight, tail light, and meter illumination light, and make sure the bulb wattage is specified. Too low or Measure the regulated voltage of the lighting sys- Check the alternator lighting coil resistance (page tem (page 15-9).
  • Page 188 BATTERY/CHARGING SYSTEM BATTERY REMOVAL Remove the following: COVER — Front center cover (page 2-2) — Ignition control module connector (page 16-6) COVER STAY POSITIVE Remove the bolt cover stay and cover. CABLE Remove the battery breather tube from the battery. Disconnect the negative cable connector first and then the positive cable connector, and then remove the battery.

  • Page 189: Battery Charging

    BATTERY/CHARGING SYSTEM SPECIFIC GRAVITY The battery electrolyte contains sulfuric acid. Avoid contact with skin, eyes or clothing. The specific gravity must be checked with a hydrometer. Test each cell by drawing electrolyte into the hydrometer. SPECIFIC GRAVITY: Fully charged: 1.270 – 1.290 at 20°C/68°F Needs charging: Below 1.260 at 20°C/68°F •...

  • Page 190: Charging System Inspection

    BATTERY/CHARGING SYSTEM Normal Quick Charging 0.5 A current Charging time 5 – 10 hours 0.5 hour • The battery gives off explosive gases; keep sparks, flames, and cigarettes away. Provide adequate ven- tilation when charging. • Turn power ON/OFF at the charger, not at the battery terminal.
  • Page 191 BATTERY/CHARGING SYSTEM CHARGING OUTPUT: Warm up the engine to normal operating temperature. Stop the engine, and connect the multimeter as shown. • To prevent short, make absolutely certain which are the positive and negative terminals or cable. • Do not disconnect the battery or any cable in the charging system without first switching off the igni- tion switch.
  • Page 192 BATTERY/CHARGING SYSTEM • When measuring current using a tester, set it to a high range, and then bring the range down to an appropri- ate level. Current flow higher than the range selected may blow out the fuse in the tester. •...
  • Page 193 BATTERY/CHARGING SYSTEM Item Terminal Specification Battery Red (+) and Battery voltage charging line ground (–) should register 0.2 – 1.0 Ω Charging coil White and line ground (at 20°C/68°F) 0.1 – 0.8 Ω Lighting coil Yellow and line ground (at 20°C/68°F) Ground line Green and Continuity...
  • Page 194 IGNITION SYSTEM SYSTEM DIAGRAM IGNITION COIL IGNITION CONTROL IGNITION SWITCH MODULE (ICM) EARTHING CABLE SPARK PLUG IGNITION PULSE GENERATOR 16-2 16-0...
  • Page 195 16. IGNITION SYSTEM SYSTEM DIAGRAM 16-0 IGNITION TIMING 16-6 SERVICE INFORMATION 16-1 IGNITION COIL 16-6 TROUBLESHOOTING 16-2 IGNITION CONTROL MODULE (ICM) 16-6 IGNITION SYSTEM INSPECTION 16-3 THROTTLE SWITCH 16-7 SERVICE INFORMATION GENERAL • Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present.
  • Page 196 IGNITION SYSTEM TROUBLESHOOTING • Inspect the following before diagnosing the system. — Faulty spark plug — Loose spark plug cap or spark plug wire connections — Water got into the spark plug cap (Leaking the ignition coil secondary voltage) • If there is no spark at cylinder, temporarily exchange the ignition coil with the other good one and perform the spark test. If there is spark, the exchanged ignition coil is faulty.
  • Page 197 IGNITION SYSTEM IGNITION SYSTEM INSPECTION DIGITAL MULTIMETER • If not spark jumps at the plug, check all connections for loose or poor contact before measuring each peak voltage. • Use a commercially available digital multimeter (im- pedance 10 MΩ/DCV minimum). •...
  • Page 198 IGNITION SYSTEM EXCITER COIL PEAK VOLTAGE Remove the front center cover (page 2-2). ICM 9P CONNECTOR Disconnect the ignition control module (ICM) 10P connectors (page 16-6). Connect the Imrie tester or peak voltage adaptor (+) probe to the exciter coil (Black/Red) wire terminal of the 10P connector, and the (–) probe to the body ground.
  • Page 199 IGNITION SYSTEM IGNITION PULSE GENERATOR PEAK ICM 10P CONNECTOR VOLTAGE Check that the cylinder compression is normal and the spark plug is installed correctly in the cylinder head. Disconnect the ignition control module (ICM) connector (page 16-6). Connect the peak voltage adaptor probes to the ignition pulse generator wire and ground wire terminals of the wire harness side connector.

  • Page 200: Ignition Timing

    IGNITION SYSTEM IGNITION TIMING SCREWS When the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
  • Page 201 IGNITION SYSTEM THROTTLE SWITCH THROTTLE SWITCH BOLTS CONNECTORS SYSTEM INSPECTION SCREW Lift up the body cover (page 2-3). Disconnect the Yellow/Blue and Blue/Green wire connectors of the throttle switch. FUEL TUBE CHOKE CABLE Check for continuity between the Yellow/Blue and Blue/ Green wire connectors with the throttle position while operating the throttle grip.
  • Page 202 ELECTRIC STARTER SYSTEM DIAGRAM FRONT BRAKE LIGHT SWITCH REAR BRAKE LIGHT SWITCH STARTER SWITCH FUSE 10 A EARTHING CABLE STARTER RELAY SWITCH STARTER 17-2 17-0...
  • Page 203 17. ELECTRIC STARTER SYSTEM DIAGRAM 17-0 STARTER MOTOR 17-3 SERVICE INFORMATION 17-1 STARTER RELAY 17-6 TROUBLESHOOTING 17-2 SERVICE INFORMATION GENERAL Always turn the ignition switch OFF bofore servicing the starter motor. The motor could suddenly start, causing serious injury. • The starter motor can be serviced with the engine installed in the frame. •...
  • Page 204 ELECTRIC STARTER TROUBLESHOOTING Starter motor will not turn • Check for a blown main fuse (10 A) • Check that the battery is fully charged and in good condition. With the ignition switch ON and the brake lever Connect the starter motor terminal directly to the Clicks squeezed (or pedal depressed), push the starter battery positive terminal.

  • Page 205: Starter Motor

    ELECTRIC STARTER STARTER MOTOR DUST COVER/SCREW REMOVAL Always turn the ignition switch OFF before servicing BOLTS the starter motor. The motor could suddenly start, causing serious injury. Lift up the body cover (page 2-3). Slide the dust cover off the starter motor terminal. STARTER MOTOR Remove the screw (1 no.) and disconnect the starter motor wire from the starter motor.
  • Page 206 ELECTRIC STARTER Inspect the commutator bars of armature for ARMATURE COIL discoloration. Bars discolored in pairs indicate shorted coils. Do not use emery or sand paper on the commutator. COMMUTATOR BAR Check for continuity between pairs of commutator bars. There should be continuity. Check for continuity between each commutator bar and the armature shaft.
  • Page 207 ELECTRIC STARTER ASSEMBLY BOLT SPRINGS ARMATURE BRACKET MOTOR CASE GASKET O-RING Install the springs into the brush holders. SPRINGS Push and hold the brushes into the brush holders, and insert the armature into the front bracket. Be careful not to damage the brush and armature. 17-5...

  • Page 208: Starter Relay

    ELECTRIC STARTER Install the gasket onto the front bracket. GASKET Install the armature into the motor case while holding the armature tightly to keep the magnet from pulling the armature against the case. The coil may be damaged if the magnet pulls the MOTOR CASE armature against the case.
  • Page 209 ELECTRIC STARTER STARTER RELAY VOLTAGE Measure the voltage between the yellow/red wire terminal (+) and ground (–). If battery voltage appears when the starter switch is pushed with the ignition switch ON, the power source circuit is normal. Connect the starter relay switch connector. GROUND LINE AND RELATED CIRCUITS Disconnect the ignition control module (ICM) connector (page 16-6).
  • Page 210 LIGHTS/METERS/SWITCHES SYSTEM LOCATION TURN SIGNAL LIGHTING SWITCH LIGHT SWITCH DIMMER SWITCH FRONT BRAKE LIGHT SWITCH STARTER SWITCH IGNITION SWITCH HORN SWITCH EARTHING CABLE TURN SIGNAL RELAY 18-2 18-0...
  • Page 211 18. LIGHTS/METERS/SWITCHES SYSTEM LOCATION 18-0 IGNITION SWITCH 18-7 SERVICE INFORMATION 18-1 HANDLEBAR SWITCHES 18-8 HEADLIGHT 18-2 BRAKE LIGHT SWITCH 18-9 TURN SIGNAL LIGHT 18-3 FUEL METER/FUEL UNIT 18-9 TAIL/BRAKE LIGHT 18-4 TURN SIGNAL RELAY 18-11 COMBINATION METER 18-5 HORN 18-11 SERVICE INFORMATION GENERAL •...
  • Page 212 LIGHTS/METERS/SWITCHES HEADLIGHT BULB REPLACEMENT Remove the front handlebar cover (page 2-7). Remove the headlight bulb dust cover. Remove the headlight blub while pressing down the locking pin. Install a new bulb in the reverse order of removal. Install the dust cover with its "TOP" mark facing up. BULB RETAINER DUST COVER...
  • Page 213 LIGHTS/METERS/SWITCHES TURN SIGNAL LIGHT FRONT TURN SIGNAL LIGHT BULB REPLACEMENT Remove the handlebar front cover (page 2-7). Remove front turn signal bulb holder by turning counterclockwise. Remove bulb by pressing in and turning counter clock wise and replace it with a new one. Installation is in the reverse order of removal.
  • Page 214 LIGHTS/METERS/SWITCHES REAR TURN SIGNAL LIGHT BULB REPLACEMENT Insert hand from bodycover rear side, above rear fender BULB area and remove rear turn signal bulb holder by turning counterclockwise. Remove rear turn signal bulb by pressing in and turning counter clock wise and replace it with a new one. Installation is in the reverse order of removal.

  • Page 215: Combination Meter

    LIGHTS/METERS/SWITCHES COMBINATION METER BULB BULB REPLACEMENT Remove the handlebar front cover (page 2-7). Remove the handlebar rear cover (page 2-7). Pull the indicator and meter bulb socket out of the combination meter. Remove the bulb by pressing in and turning counter clock wise and replace it with a new one.
  • Page 216 LIGHTS/METERS/SWITCHES ASSEMBLY SPEEDOMETER FRONT PANEL METER HARNESS REAR PANEL Assemble the combination meter in the reverse order of removal. • Connect the terminals and install the sockets are according to the color codes indicated on the lower case. • Route the meter harness as shown in the illustration. INSTALLATION Install the combination meter in the reverse order of removal.

  • Page 217: Ignition Switch

    LIGHTS/METERS/SWITCHES IGNITION SWITCH INSPECTION Remove the inner cover (page 2-6). IGNITION SWITCH 3P CONNECTOR Disconnect the ignition switch 3P and 1P connector. Check for continuity between the wire terminals of the ignition switch connector in each switch position. Continuity should exist between the color coded wires as IGNITION SWITCH follows: 1P CONNECTOR...

  • Page 218: Handlebar Switches

    LIGHTS/METERS/SWITCHES HANDLEBAR SWITCHES RIGHT SIDE: Remove the front handlebar cover (page 2-7). Disconnect the handlebar switch connectors. Check the continuity between the wire terminals of the handlebar switch connector. Continuity should exist between the color coded wire ter- minals as follows: RIGHT HANDLEBAR SWITCHES STARTER SWITCH C o l o u r...
  • Page 219 LIGHTS/METERS/SWITCHES BRAKE LIGHT SWITCH Remove the front handlebar cover (page 2-7). Disconnect the brake light switch connector and check for continuity between the switch terminals. There should be continuity with the brake lever applied, and there should be no continuity with the brake lever is released.
  • Page 220 LIGHTS/METERS/SWITCHES Turn the ignition switch “ON”. FUEL UNIT Move the fuel unit float up and down and make sure that the fuel meter needle moves smoothly. FLOAT UP: Needle in “FULL” FLOAT DOWN: Needle in “EMPTY” If the system inspection is OK but fuel meter needle does not move properly, replace the fuel level sensor.
  • Page 221 LIGHTS/METERS/SWITCHES TURN SIGNAL RELAY TURN SIGNAL RELAY 2P CONNECTOR INSPECTION Check the following: — Battery condition — Burned out bulb or non-specified wattage — Burned fuse — Ignition switch and turn signal switch function — Loose connectors JUMPER WIRE If above items all normal. check the following: Remove the front center cover (page 2-2).
  • Page 222 19. WIRING DIAGRAM 19-1...
  • Page 223 MEMO 19-2...
  • Page 224 20. TROUBLESHOOTING POOR PERFORMANCE AT LOW AND ENGINE DOES NOT START OR IS IDLE SPEEDS 20-3 HARD TO START 20-1 POOR PERFORMANCE AT HIGH ENGINE LACKS POWER 20-2 SPEED 20-4 POOR HANDLING 20-4 ENGINE DOES NOT START OR IS HARD TO START Possible cause Not reaching •...
  • Page 225 TROUBLESHOOTING ENGINE LACKS POWER Possible cause 1. Raise rear wheel off ground and Engine speed does not • Clogged air cleaner accelerate lightly increase sufficiently • Restricted fuel flow • Clogged fuel tank cap breather hole • Clogged muffler Engine speed increase 2.
  • Page 226 TROUBLESHOOTING POOR PERFORMANCE AT LOW AND IDLE SPEEDS Possible cause 1. Check carburetor air screw Incorrect • See section 5 adjustment Correct 2. Check if air is leaking past intake Leaking • Loose carburetor and/or intake pipe pipe • Damaged carburetor insulator •...
  • Page 227 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED Possible cause 1. Check fuel flow from fuel tank Fuel flow restricted • Clogged fuel stainer • Clogged fuel tube/vaccum tube Fuel flows enough 2. Check carburetor for clogging Clogged • Carburetor not serviced frequently enough Normal 3.
  • Page 228 21. INDEX AIR CLEANER ............IGNITION CONTROL MODULE(ICM) ......16-6 AIR CLEANER HOUSING .......... IGNITION SYSTEM INSPECTION ......16-3 AIR SCREW ADJUSTMENT ........5-10 IGNITION TIMING ............16-5 ALTERNATOR REMOVAL ........... 11-2 INNER COVER ............ALTERNATOR INSTALLATION ........11-3 KICKSTARTER ............BATTERY ..............
  • Page 229 INDEX CYLINDER/PISTON ........ELECTRIC STARTER ........17-1 ENGINE DOES NOT START OR IS HARD TO START ......20-1 ENGINE LACKS POWER ....... 20-2 FINAL REDUCTION ........10-1 FRAME/BODY PANELS/EXHAUST SYSTEM ............ FRONT WHEEL/BRAKE/SUSPENSION/ STEERING ..........13-1 FUEL SYSTEM ..........IGNITION SYSTEM ......... 16-1 KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH ....
  • Page 230 Published by Honda Motorcycle & Scooter India (Pvt.) Ltd. © Honda Motor Co.,Ltd. 2009 BOP200902900 62KPLN2 Printed in India...

Table of Contents