Honda Motorcycle Service Manual

Honda motorcycles and motor scooters and atvs common service manual

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Owner's manual - 131 pages
User manual - 125 pages
Owner's manual - 16 pages

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Table of Contents

- 3
  How to Use This Manual
- 3
  Table of Contents
- 4
  Symbols
- 5
  Abbreviations
- 7
  Carbon Monoxide
- 7
  Gasoline
- 7
  General Information Contents
- 7
  General Safety
- 8
  Hot Components
- 8
  Nitrogen Pressure
- 8
  Used Engine/Transmission Oil
- 9
  Service Rules
- 12
  Fasteners
- 12
  Thread Sizes
- 12
  Types of Threads
- 13
  Hex-head Bolt Strength Markings
- 13
  Width Across Flats
- 14
  "Torx" Bolt
- 15
  CT Bolt
- 16
  Torque Values (Tightening Force)
- 18
  Fastener Loosening
- 19
  Locking
- 22
  Ball Bearing Replacement
- 22
  Removing Ball Bearings
- 23
  Installing Ball Bearings
- 24
  Bearing Remover Compatibility for Wheel Bearing
- 24
  Bearing Remover Compatibility Table
- 24
  Bearing Size
- 24
  Tool Compatibility Chart for Standard Bearings
- 25
  Tool Compatibility Chart
- 27
  Maintenance Contents
- 28
  Fuel Line
- 28
  Fuel Strainer Screen
- 31
  Carburetor Choke
- 29
  Throttle Operation
- 32
  Air Cleaner
- 33
  Crankcase Breather
- 33
  AIRCLEANER HOUSING DRAIN TUBE (Off-road Motorcycles and ATVs)
- 35
  Valve Clearance
  - 30
    Oil Pump and Oil Line
  - 30
    Oil Strainer
- 37
  Engine Oil 2-1
  - 31
    Manual Choke
  - 31
    Starting Enrichment Valve
- 39
  Engine Oil Filter 2-1
  - 32
    Oiled Urethane Foam Element
  - 33
    Paper Element
- 41
  DECARBONIZING (2-Stroke Engine)
- 42
  Carburetor Synchronization
- 45
  Evaporative Emission Control System
- 46
  TRANSMISSION OIL (2-Stroke Engine)
- 43
  Carburetor Idle Speed
- 43
  Radiator Coolant
- 44
  Cooling System
  - 34
    Replacing a Spark Plug
  - 34
    Reusing a Spark Plug
  - 34
    Spark Plug Inspection
  - 37
    4-Stroke, Wet Sump Engines
  - 38
    4-Stroke, Dry Sump Engines
  - 38
    Leak Inspection
  - 38
    Oil Change
  - 40
    Cartridge-Type Paper Filter
  - 40
    Egine Oil Filter Screen
  - 40
    Element-Type Paper Filter
  - 44
    Level Check
  - 45
    Pulse Secondary Air Supply (Pair) System
  - 46
    Transmission Oil Change
  - 47
    Drive Chain Adjustment
  - 48
    Adjustment of Pro-arm Type
  - 49
    Cleaning, Inspection and Lubrication
  - 49
    Inspection of Chain Replacement Period
  - 49
    O-ring Chains
  - 50
    Non O-ring Chain
50
Refer T O the Model Specific Service Manual
50
Components and Systems Found On These
50
Machines.
- 50
  Replacement of Endless Chain
- 50
  Sprockets
- 53
  Drive Belt
- 53
  Drive Chain Slider, Chain Guide, Guide Slider and Rollers
- 54
  Belt Case Air Cleaner
- 54
  Final Drive Oil Level
- 55
  Battery
- 55
  Fluid Level
- 55
  Specific Gravity of Fluid
- 56
  Brake Fluid
- 56
  Condition of Terminal Connections
- 57
  Brake Pad Wear
- 57
  Brake Shoe Wear
- 58
  Brake System
- 58
  Free Play Adjustment
- 58
  Inspection for Air in System
- 59
  Brake Pedal Height Adjustment
- 59
  Hydraulic Brake Type
- 60
  Date of Issue: March, 1995 HONDA MOTOR CO
  - 60
    Drum Brake Type
  - 61
    Brake Light Switches
  - 61
    Headlight Aim
  - 62
    Clutch System
  - 62
    On Centrifugal Clutch
  - 63
    Clutch Fluid Level
  - 63
    Conventional Type
  - 63
    Side Stand
  - 64
    Dual Motion Type
  - 64
    Inspection for Side Stand With Ignition Cut-off Switch
  - 64
    Suspension
  - 66
    Nuts, Bolts, Fasteners
  - 66
    Spark Arrester
  - 67
    Wheels/tires
  - 69
    Steering Head Bearings
  - 69
    Toe-in
  - 69
    Wheel Alignment
  - 70
    Camber/caster
  - 71
    Engine Testing Contents
  - 71
    Service Information
  - 71
    Troubleshooting
  - 72
    Compression Testing
  - 73
    4-Stroke Leak-down Test Information
  - 73
    Leak-down Twsting
  - 74
    2-Stroke Pressure/vacuum Leak-down Test Information
  - 75
    Lubrication Contents
  - 75
    Lubrication Service Data
  - 75
    Lubrication Service Information
  - 76
    Lubrication Troubleshooting
  - 77
    4-Stroke Systems
  - 77
    System Description
  - 77
    Typical Oil Flow Pattern
  - 78
    Dry-Sump Type
  - 78
    Four-stroke Engines
  - 78
    General
  - 78
    Wet-Sump Type
  - 79
    Separate Oil Systems
  - 79
    Two-stroke Lubrication Systems
  - 80
    Premixed (Oil in Fuel) Systems
  - 81
    Oil Pump Descriptions
  - 81
    Trochoid Type
  - 82
    Oil Pump Operating Principle
  - 82
    Plunger Type
  - 83
    Oil Pressure Check
  - 83
    Oil Pump Inspection
  - 84
    In-Set Type Oil Pump
  - 84
    Pressure Relief Valve
  - 85
    Oil Pump/oil Line Bleeding
  - 85
    Outlet Line Bleeding
  - 85
    Suction Line, Oil Pump Bleeding
  - 86
    Oil Cooler Inspection
  - 87
    Cooling System Contents
  - 87
    Cooling System Service Information
  - 87
    Cooling System Troubleshooting
  - 88
    Cooling System Descriptions
  - 88
    System Flow Patterns
  - 89
    Cooling Fan
  - 89
    Cooling Fan Switch
  - 89
    Radiator
  - 90
    Radiator Cap
  - 91
    Reserve Tank
  - 91
    Thermostat
  - 91
    Water Pump
  - 92
    Coolant Preparation
  - 92
    Coolant Replacement
  - 93
    Air Bleeding
  - 93
    Coolant Gravity Chart
  - 93
    Coolant System Testing
  - 93
    Hydrometer Test
  - 94
    Mechanical Seal Inspection
  - 94
    Radiator Cap Test
  - 94
    System Pressure Test
  - 95
    Water Pump Replacement
  - 97
    Exhaust System Contents
  - 97
    Exhaust System Service Information
  - 97
    Exhaust System Troubleshooting
  - 98
    Exhaust Pulse Scavenge Effect
  - 98
    Exhaust System Descriptions
  - 99
    Common Exhaust Pipe
  - 101
    Emission Control System Contents
  - 101
    Emission Control System Service Information
  - 101
    Emission Control System Troubleshooting
  - 102
    Crankcase Emission Control System
  - 102
    Emission Control System Descriptions
  - 102
    Source of Emissions
  - 103
    Exhaust Emissio Control System (Pulse Secondary Air Supply System)
  - 104
    Evaporative Emission (EVAP) Control System
  - 104
    Noise Emission Control System
  - 105
    Evaporative Emission Purge Control Valve (EVAP Purge Control Valve)
  - 105
    System Inspection
  - 106
    Evaporative Emmission Carburetor Air Vent Control Valve (EVAP Cav Control Valve)
  - 109
    Emission Control Information Labels
  - 109
    Pulse Secondary Air Injection Check Valve (Pair Check Valve)
  - 111
    Fuel Freshness and Troubleshooting
  - 111
    Fuel System Contets
  - 111
    Fuel System Service Information
  - 112
    Fuel System Troubleshooting
  - 113
    Carburetor
  - 113
    Fuel System Description
  - 113
    Principle of the Vacuum Piston Operated CV Type
  - 113
    Types of Carburetor
  - 114
    Float System
  - 114
    Operation of Systems
  - 114
    Starting System
115
HONDA MOTOR Co.,LTD
- 115
  Slow System (Low Degree of Opening)
116
Date of Issue: March, 1995
- 117
  Accelerator Pump
- 117
  Air Cut-off Valve
  - 116
    Main System (Fully Open)
  - 116
    Main System (Medium Throttle Opening)
  - 117
    Fuel System
  - 117
    Reed Valve Inspection
  - 118
    Fuel Auto Valve
  - 118
    Fuel Auto Valve Inspection
  - 118
    Fuel Line
    - 119
      Carburetor Disassembly/inspection
    - 119
      Throttle Valve Inspection (CV Type)
    - 119
      Throttle Valve/starting Enrichment Valve Inspection
    - 120
      Starting Enrichment Thermal Valve
    - 121
      Starting Enrichment Thermal Valve Removal
    - 121
      Starting Enrichment Valve (Manual)
    - 121
      Throttle Valve (Piston Valve Type)
    - 122
      Vacuum Piston (CV Type)
    - 123
      Float/jets
  - 124
    Carburetor Assembly
    - 124
      Carburetor Cleaning
    - 125
      Float/jets Assembly
    - 126
      Float Level Inspection
    - 128
      Carburetor Separation/assembly/installation
    - 128
      Pilot (Or Air) Screw Adjustment
    - 128
      Pilot (Or Air) Screw Removal
    - 129
      Limiter Cap Type
    - 129
      Plug Type
    - 130
      Idle Drop Procedure
  - 130
    Pilot (or Air) Screw Adjustment 8-1
    - 130
      Pilot (Or Air) Screw Installation
    - 132
      Air Screw or Pilot Adjustment
    - 132
      Best Idle Procedure
    - 133
      Limiter Cap (Or Plug) Installation
  - 134
    Accelerator Pump Adjustment
  - 134
    High Altitude Adjustment
    - 135
      Cylinder Head Contents
    - 135
      Cylinder Head Service Information
    - 135
      Cylinder Head Troubleshooting
    - 136
      Cylinder Head Construction
    - 136
      Cylinder Head System Description
    - 137
      Valve Train
    - 138
      Example of DOHC With Valve Bucket Type
    - 138
      Example of SOHC-4 Valve System
    - 138
      Valve Lifter Mechanism /Arrangement
    - 139
      Hydraulic Tappets
    - 139
      Hydraulic Tappets Operation
    - 141
      Construction
    - 141
      Decompressor System
    - 141
      Description
    - 141
      Function of Decompressor System
    - 142
      Reverse Decompressor Cam
    - 143
      Camshaft Bearing Inspection
    - 143
      Camshaft Inspection
    - 143
      Camshaft Oil Clearance Inspection
    - 144
      Rocker Arm, Rocker Arm Shaft
    - 145
      Cylinder Head Inspection
    - 145
      Solvent Test
    - 145
      Warpage Inspection
    - 146
      Cylinder Head Disassembly
    - 146
      Valve Springs
    - 146
      Valves
    - 147
      Stem-to-guide Clearance
    - 147
      Valve Guides Inspection
    - 147
      Valve Guides Replacement
    - 147
      When Using a Dial Indicator
    - 148
      Flangeless Type Guides
    - 149
      Valve Guide Reaming
    - 149
      Valve Seats Inspection
    - 150
      Inspect the Valve Seat Face
    - 150
      Valve Seat Refacing
    - 152
      Cylinder Head Assembly
    - 153
      Initial Camshaft Lubrication
    - 155
      Cylinder/piston Contents
    - 155
      Cylinder/piston Service Information
    - 155
      Cylinder/piston Troubleshooting
    - 156
      Cylinder/piston System Description
    - 157
      Piston
    - 157
      Piston Ring
    - 159
      Cylinder
    - 159
      Wear Inspection
    - 160
      Piston/piston Ring Inspection
    - 160
      Piston/piston Ring Removal
    - 162
      Piston Pin Inspection
    - 162
      Piston/piston Ring Installation
    - 162
      Small End Bearing Surface Inspection
    - 163
      Piston Installation
    - 164
      Cylinder Installation
    - 165
      Clutch Contents
    - 165
      Clutch Service Information
    - 165
      Clutch Troubleshooting
    - 166
      Clutch System Descriptions
    - 166
      Wet Multiplate Manual Clutch (Type A: Outer Push Type)
    - 167
      Damper Spring Purpose
    - 167
      Judder Spring Purpose
    - 167
      Type B (Inner Push Type)
    - 168
      One-way Clutch System (Type C: Inner Push Type With Back Torque Limiter Mechanism)
    - 169
      Operation
    - 169
      Power Flow Diagram
    - 170
      Type D (Crankshaft Mounted)
    - 171
      Type A: Shift Clitch Combined
    - 171
      Wet Multiplate Centrifugal Clutch
    - 172
      Gear Shift Lifter
    - 173
      Operation Principals
    - 173
      Type B: Separated Shift Clutch
    - 174
      Clutch Inspection
    - 174
      Clutch Lifter Disassembly/inspection
    - 175
      Clutch Removal/disassembly
    - 179
      Clutch Outer
    - 179
      Clutch Outer Guide, Needle Bearing
    - 179
      Lifter Plate Bearing
    - 180
      Clutch Disc
    - 180
      Lifter Push Rod
    - 180
      Lutch Center
    - 180
      Lutch Plate
    - 181
      Clutch Spring
    - 181
      Mainshaft
    - 181
      Udder Spring, Spring Seat
    - 182
      One-way Clutch
    - 182
      Primary Drive Gear
    - 183
      Clutch Center Guide, Collar
    - 183
      Clutch Reassembly
    - 183
      Crankshaft
    - 190
      Clutch Lifter Reassembly
    - 191
      Fluid Replacement
    - 191
      Hydraulic Clutch System Service
    - 192
      Clatch Master Cylinder Removal/disassembly
    - 193
      Clatch Master Cylinder Inspection
    - 194
      Clatch Master Cylinder Assembly/installation
    - 195
      Clutch Slave Cylinder
    - 195
      Clutch Slave Cylinder Assembly
    - 197
      V-matic Belt Drive System Service Information
    - 198
      V-matic Belt Drive System Description
    - 199
      Drive Pulley Operation
    - 200
      Driven Pulley/centrifugal Dry Clutch
    - 201
      Drive Belt Inspection
    - 201
      Drive Belt Installation
    - 201
      Drive Belt Removal
    - 202
      Drive Pulley Removal
    - 203
      Drive Pulley Disassembly
    - 203
      Drive Pulley Inspection
    - 203
      Dry Type
    - 203
      Wet Type
    - 204
      Drive Pulley Assembly/installation
    - 205
      Drive Pulley Face Installation
    - 206
      Clutch/driven Pulley Disassembly
    - 207
      Clutch Outer Inspection
    - 207
      Clutch Shoe Inspection
    - 207
      Driven Pulley Inspection
    - 207
      Driven Pulley Spring Inspection
    - 208
      Clutch Shoe Replacement
    - 208
      Driven Face Bearing Inspection
    - 209
      Driven Face Bearing Replacement
    - 210
      Clutch/driven Pulley Assembly
    - 213
      Transmission Contents
    - 213
      Transmission Service Information
    - 213
      Transmission Troubleshooting
    - 214
      Gearshift Mechanism
    - 214
      Transmission System Description
    - 215
      Planetary Gear Type
    - 216
      Shift Finish
    - 216
      Shift Return
    - 216
      Shift Start
    - 217
      Constant Mesh Transmission
    - 218
      Bushings Cheking
    - 218
      Gears Checking
    - 218
      Transmission Disassembly
    - 218
      Transmission Inspection
    - 219
      Shift Drum Checking
    - 219
      Shift Fork Checking
    - 219
      Shift Fork Shaft Checking
    - 219
      Transmission Assembly
    - 221
      Crankcase/crankshaft Contents
    - 221
      Crankcase/crankshaft Service Information
    - 221
      Crankcase/crankshaft Troubleshooting
    - 222
      Crankcase/crankshaft System Descriptions
  - 223
    Crankshaft Inspection
  - 223
    Crankshaft Main Bearing
    - 223
      Radial Clearance (Assembly-type Crankshaft Only)
    - 223
      Side Clearance
  - 224
    Crankcaseicrankshaft
    - 225
      Main Bearing Selection
    - 226
      Crankcase/crankshaft Removal
    - 227
      Main Beraing Installation
  - 228
    Connecting Rod Bearings

t o

r c

l e

I C

Table of Contents

- 3
  How to Use This Manual
- 3
  Table of Contents
- 4
  Symbols
- 5
  Abbreviations
- 7
  Carbon Monoxide
- 7
  Gasoline
- 7
  General Information Contents
- 7
  General Safety
- 8
  Hot Components
- 8
  Nitrogen Pressure
- 8
  Used Engine/Transmission Oil
- 9
  Service Rules
- 12
  Fasteners
- 12
  Thread Sizes
- 12
  Types of Threads
- 13
  Hex-head Bolt Strength Markings
- 13
  Width Across Flats
- 14
  "Torx" Bolt
- 15
  CT Bolt
- 16
  Torque Values (Tightening Force)
- 18
  Fastener Loosening
- 19
  Locking
- 22
  Ball Bearing Replacement
- 22
  Removing Ball Bearings
- 23
  Installing Ball Bearings
- 24
  Bearing Remover Compatibility for Wheel Bearing
- 24
  Bearing Remover Compatibility Table
- 24
  Bearing Size
- 24
  Tool Compatibility Chart for Standard Bearings
- 25
  Tool Compatibility Chart
- 27
  Maintenance Contents
- 28
  Fuel Line
- 28
  Fuel Strainer Screen
- 31
  Carburetor Choke
- 29
  Throttle Operation
- 32
  Air Cleaner
- 33
  Crankcase Breather
- 33
  AIRCLEANER HOUSING DRAIN TUBE (Off-road Motorcycles and ATVs)
- 35
  Valve Clearance
  - 30
    Oil Pump and Oil Line
  - 30
    Oil Strainer
- 37
  Engine Oil 2-1
  - 31
    Manual Choke
  - 31
    Starting Enrichment Valve
- 39
  Engine Oil Filter 2-1
  - 32
    Oiled Urethane Foam Element
  - 33
    Paper Element
- 41
  DECARBONIZING (2-Stroke Engine)
- 42
  Carburetor Synchronization
- 45
  Evaporative Emission Control System
- 46
  TRANSMISSION OIL (2-Stroke Engine)
- 43
  Carburetor Idle Speed
- 43
  Radiator Coolant
- 44
  Cooling System
  - 34
    Replacing a Spark Plug
  - 34
    Reusing a Spark Plug
  - 34
    Spark Plug Inspection
  - 37
    4-Stroke, Wet Sump Engines
  - 38
    4-Stroke, Dry Sump Engines
  - 38
    Leak Inspection
  - 38
    Oil Change
  - 40
    Cartridge-Type Paper Filter
  - 40
    Egine Oil Filter Screen
  - 40
    Element-Type Paper Filter
  - 44
    Level Check
  - 45
    Pulse Secondary Air Supply (Pair) System
  - 46
    Transmission Oil Change
  - 47
    Drive Chain Adjustment
  - 48
    Adjustment of Pro-arm Type
  - 49
    Cleaning, Inspection and Lubrication
  - 49
    Inspection of Chain Replacement Period
  - 49
    O-ring Chains
  - 50
    Non O-ring Chain
50
Refer T O the Model Specific Service Manual
50
Components and Systems Found On These
50
Machines.
- 50
  Replacement of Endless Chain
- 50
  Sprockets
- 53
  Drive Belt
- 53
  Drive Chain Slider, Chain Guide, Guide Slider and Rollers
- 54
  Belt Case Air Cleaner
- 54
  Final Drive Oil Level
- 55
  Battery
- 55
  Fluid Level
- 55
  Specific Gravity of Fluid
- 56
  Brake Fluid
- 56
  Condition of Terminal Connections
- 57
  Brake Pad Wear
- 57
  Brake Shoe Wear
- 58
  Brake System
- 58
  Free Play Adjustment
- 58
  Inspection for Air in System
- 59
  Brake Pedal Height Adjustment
- 59
  Hydraulic Brake Type
- 60
  Date of Issue: March, 1995 HONDA MOTOR CO
  - 60
    Drum Brake Type
  - 61
    Brake Light Switches
  - 61
    Headlight Aim
  - 62
    Clutch System
  - 62
    On Centrifugal Clutch
  - 63
    Clutch Fluid Level
  - 63
    Conventional Type
  - 63
    Side Stand
  - 64
    Dual Motion Type
  - 64
    Inspection for Side Stand With Ignition Cut-off Switch
  - 64
    Suspension
  - 66
    Nuts, Bolts, Fasteners
  - 66
    Spark Arrester
  - 67
    Wheels/tires
  - 69
    Steering Head Bearings
  - 69
    Toe-in
  - 69
    Wheel Alignment
  - 70
    Camber/caster
  - 71
    Engine Testing Contents
  - 71
    Service Information
  - 71
    Troubleshooting
  - 72
    Compression Testing
  - 73
    4-Stroke Leak-down Test Information
  - 73
    Leak-down Twsting
  - 74
    2-Stroke Pressure/vacuum Leak-down Test Information
  - 75
    Lubrication Contents
  - 75
    Lubrication Service Data
  - 75
    Lubrication Service Information
  - 76
    Lubrication Troubleshooting
  - 77
    4-Stroke Systems
  - 77
    System Description
  - 77
    Typical Oil Flow Pattern
  - 78
    Dry-Sump Type
  - 78
    Four-stroke Engines
  - 78
    General
  - 78
    Wet-Sump Type
  - 79
    Separate Oil Systems
  - 79
    Two-stroke Lubrication Systems
  - 80
    Premixed (Oil in Fuel) Systems
  - 81
    Oil Pump Descriptions
  - 81
    Trochoid Type
  - 82
    Oil Pump Operating Principle
  - 82
    Plunger Type
  - 83
    Oil Pressure Check
  - 83
    Oil Pump Inspection
  - 84
    In-Set Type Oil Pump
  - 84
    Pressure Relief Valve
  - 85
    Oil Pump/oil Line Bleeding
  - 85
    Outlet Line Bleeding
  - 85
    Suction Line, Oil Pump Bleeding
  - 86
    Oil Cooler Inspection
  - 87
    Cooling System Contents
  - 87
    Cooling System Service Information
  - 87
    Cooling System Troubleshooting
  - 88
    Cooling System Descriptions
  - 88
    System Flow Patterns
  - 89
    Cooling Fan
  - 89
    Cooling Fan Switch
  - 89
    Radiator
  - 90
    Radiator Cap
  - 91
    Reserve Tank
  - 91
    Thermostat
  - 91
    Water Pump
  - 92
    Coolant Preparation
  - 92
    Coolant Replacement
  - 93
    Air Bleeding
  - 93
    Coolant Gravity Chart
  - 93
    Coolant System Testing
  - 93
    Hydrometer Test
  - 94
    Mechanical Seal Inspection
  - 94
    Radiator Cap Test
  - 94
    System Pressure Test
  - 95
    Water Pump Replacement
  - 97
    Exhaust System Contents
  - 97
    Exhaust System Service Information
  - 97
    Exhaust System Troubleshooting
  - 98
    Exhaust Pulse Scavenge Effect
  - 98
    Exhaust System Descriptions
  - 99
    Common Exhaust Pipe
  - 101
    Emission Control System Contents
  - 101
    Emission Control System Service Information
  - 101
    Emission Control System Troubleshooting
  - 102
    Crankcase Emission Control System
  - 102
    Emission Control System Descriptions
  - 102
    Source of Emissions
  - 103
    Exhaust Emissio Control System (Pulse Secondary Air Supply System)
  - 104
    Evaporative Emission (EVAP) Control System
  - 104
    Noise Emission Control System
  - 105
    Evaporative Emission Purge Control Valve (EVAP Purge Control Valve)
  - 105
    System Inspection
  - 106
    Evaporative Emmission Carburetor Air Vent Control Valve (EVAP Cav Control Valve)
  - 109
    Emission Control Information Labels
  - 109
    Pulse Secondary Air Injection Check Valve (Pair Check Valve)
  - 111
    Fuel Freshness and Troubleshooting
  - 111
    Fuel System Contets
  - 111
    Fuel System Service Information
  - 112
    Fuel System Troubleshooting
  - 113
    Carburetor
  - 113
    Fuel System Description
  - 113
    Principle of the Vacuum Piston Operated CV Type
  - 113
    Types of Carburetor
  - 114
    Float System
  - 114
    Operation of Systems
  - 114
    Starting System
115
HONDA MOTOR Co.,LTD
- 115
  Slow System (Low Degree of Opening)
116
Date of Issue: March, 1995
- 117
  Accelerator Pump
- 117
  Air Cut-off Valve
  - 116
    Main System (Fully Open)
  - 116
    Main System (Medium Throttle Opening)
  - 117
    Fuel System
  - 117
    Reed Valve Inspection
  - 118
    Fuel Auto Valve
  - 118
    Fuel Auto Valve Inspection
  - 118
    Fuel Line
    - 119
      Carburetor Disassembly/inspection
    - 119
      Throttle Valve Inspection (CV Type)
    - 119
      Throttle Valve/starting Enrichment Valve Inspection
    - 120
      Starting Enrichment Thermal Valve
    - 121
      Starting Enrichment Thermal Valve Removal
    - 121
      Starting Enrichment Valve (Manual)
    - 121
      Throttle Valve (Piston Valve Type)
    - 122
      Vacuum Piston (CV Type)
    - 123
      Float/jets
  - 124
    Carburetor Assembly
    - 124
      Carburetor Cleaning
    - 125
      Float/jets Assembly
    - 126
      Float Level Inspection
    - 128
      Carburetor Separation/assembly/installation
    - 128
      Pilot (Or Air) Screw Adjustment
    - 128
      Pilot (Or Air) Screw Removal
    - 129
      Limiter Cap Type
    - 129
      Plug Type
    - 130
      Idle Drop Procedure
  - 130
    Pilot (or Air) Screw Adjustment 8-1
    - 130
      Pilot (Or Air) Screw Installation
    - 132
      Air Screw or Pilot Adjustment
    - 132
      Best Idle Procedure
    - 133
      Limiter Cap (Or Plug) Installation
  - 134
    Accelerator Pump Adjustment
  - 134
    High Altitude Adjustment
    - 135
      Cylinder Head Contents
    - 135
      Cylinder Head Service Information
    - 135
      Cylinder Head Troubleshooting
    - 136
      Cylinder Head Construction
    - 136
      Cylinder Head System Description
    - 137
      Valve Train
    - 138
      Example of DOHC With Valve Bucket Type
    - 138
      Example of SOHC-4 Valve System
    - 138
      Valve Lifter Mechanism /Arrangement
    - 139
      Hydraulic Tappets
    - 139
      Hydraulic Tappets Operation
    - 141
      Construction
    - 141
      Decompressor System
    - 141
      Description
    - 141
      Function of Decompressor System
    - 142
      Reverse Decompressor Cam
    - 143
      Camshaft Bearing Inspection
    - 143
      Camshaft Inspection
    - 143
      Camshaft Oil Clearance Inspection
    - 144
      Rocker Arm, Rocker Arm Shaft
    - 145
      Cylinder Head Inspection
    - 145
      Solvent Test
    - 145
      Warpage Inspection
    - 146
      Cylinder Head Disassembly
    - 146
      Valve Springs
    - 146
      Valves
    - 147
      Stem-to-guide Clearance
    - 147
      Valve Guides Inspection
    - 147
      Valve Guides Replacement
    - 147
      When Using a Dial Indicator
    - 148
      Flangeless Type Guides
    - 149
      Valve Guide Reaming
    - 149
      Valve Seats Inspection
    - 150
      Inspect the Valve Seat Face
    - 150
      Valve Seat Refacing
    - 152
      Cylinder Head Assembly
    - 153
      Initial Camshaft Lubrication
    - 155
      Cylinder/piston Contents
    - 155
      Cylinder/piston Service Information
    - 155
      Cylinder/piston Troubleshooting
    - 156
      Cylinder/piston System Description
    - 157
      Piston
    - 157
      Piston Ring
    - 159
      Cylinder
    - 159
      Wear Inspection
    - 160
      Piston/piston Ring Inspection
    - 160
      Piston/piston Ring Removal
    - 162
      Piston Pin Inspection
    - 162
      Piston/piston Ring Installation
    - 162
      Small End Bearing Surface Inspection
    - 163
      Piston Installation
    - 164
      Cylinder Installation
    - 165
      Clutch Contents
    - 165
      Clutch Service Information
    - 165
      Clutch Troubleshooting
    - 166
      Clutch System Descriptions
    - 166
      Wet Multiplate Manual Clutch (Type A: Outer Push Type)
    - 167
      Damper Spring Purpose
    - 167
      Judder Spring Purpose
    - 167
      Type B (Inner Push Type)
    - 168
      One-way Clutch System (Type C: Inner Push Type With Back Torque Limiter Mechanism)
    - 169
      Operation
    - 169
      Power Flow Diagram
    - 170
      Type D (Crankshaft Mounted)
    - 171
      Type A: Shift Clitch Combined
    - 171
      Wet Multiplate Centrifugal Clutch
    - 172
      Gear Shift Lifter
    - 173
      Operation Principals
    - 173
      Type B: Separated Shift Clutch
    - 174
      Clutch Inspection
    - 174
      Clutch Lifter Disassembly/inspection
    - 175
      Clutch Removal/disassembly
    - 179
      Clutch Outer
    - 179
      Clutch Outer Guide, Needle Bearing
    - 179
      Lifter Plate Bearing
    - 180
      Clutch Disc
    - 180
      Lifter Push Rod
    - 180
      Lutch Center
    - 180
      Lutch Plate
    - 181
      Clutch Spring
    - 181
      Mainshaft
    - 181
      Udder Spring, Spring Seat
    - 182
      One-way Clutch
    - 182
      Primary Drive Gear
    - 183
      Clutch Center Guide, Collar
    - 183
      Clutch Reassembly
    - 183
      Crankshaft
    - 190
      Clutch Lifter Reassembly
    - 191
      Fluid Replacement
    - 191
      Hydraulic Clutch System Service
    - 192
      Clatch Master Cylinder Removal/disassembly
    - 193
      Clatch Master Cylinder Inspection
    - 194
      Clatch Master Cylinder Assembly/installation
    - 195
      Clutch Slave Cylinder
    - 195
      Clutch Slave Cylinder Assembly
    - 197
      V-matic Belt Drive System Service Information
    - 198
      V-matic Belt Drive System Description
    - 199
      Drive Pulley Operation
    - 200
      Driven Pulley/centrifugal Dry Clutch
    - 201
      Drive Belt Inspection
    - 201
      Drive Belt Installation
    - 201
      Drive Belt Removal
    - 202
      Drive Pulley Removal
    - 203
      Drive Pulley Disassembly
    - 203
      Drive Pulley Inspection
    - 203
      Dry Type
    - 203
      Wet Type
    - 204
      Drive Pulley Assembly/installation
    - 205
      Drive Pulley Face Installation
    - 206
      Clutch/driven Pulley Disassembly
    - 207
      Clutch Outer Inspection
    - 207
      Clutch Shoe Inspection
    - 207
      Driven Pulley Inspection
    - 207
      Driven Pulley Spring Inspection
    - 208
      Clutch Shoe Replacement
    - 208
      Driven Face Bearing Inspection
    - 209
      Driven Face Bearing Replacement
    - 210
      Clutch/driven Pulley Assembly
    - 213
      Transmission Contents
    - 213
      Transmission Service Information
    - 213
      Transmission Troubleshooting
    - 214
      Gearshift Mechanism
    - 214
      Transmission System Description
    - 215
      Planetary Gear Type
    - 216
      Shift Finish
    - 216
      Shift Return
    - 216
      Shift Start
    - 217
      Constant Mesh Transmission
    - 218
      Bushings Cheking
    - 218
      Gears Checking
    - 218
      Transmission Disassembly
    - 218
      Transmission Inspection
    - 219
      Shift Drum Checking
    - 219
      Shift Fork Checking
    - 219
      Shift Fork Shaft Checking
    - 219
      Transmission Assembly
    - 221
      Crankcase/crankshaft Contents
    - 221
      Crankcase/crankshaft Service Information
    - 221
      Crankcase/crankshaft Troubleshooting
    - 222
      Crankcase/crankshaft System Descriptions
  - 223
    Crankshaft Inspection
  - 223
    Crankshaft Main Bearing
    - 223
      Radial Clearance (Assembly-type Crankshaft Only)
    - 223
      Side Clearance
  - 224
    Crankcaseicrankshaft
    - 225
      Main Bearing Selection
    - 226
      Crankcase/crankshaft Removal
    - 227
      Main Beraing Installation
  - 228
    Connecting Rod Bearings

Troubleshooting

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Quick Links

50 Refer T O the Model Specific Service Manual

50 Components and Systems Found On These

50 Machines.

115 HONDA MOTOR Co.,LTD

116 Date of Issue: March, 1995