User Manuals: Honda CL90 Motorcycle

Manuals and User Guides for Honda CL90 Motorcycle. We have 1 Honda CL90 Motorcycle manual available for free PDF download: Shop Manual

Honda CL90 Shop Manual (180 pages)

Brand: Honda | Category: Motorcycle | Size: 21 MB

Foreword
2
Contents
3
Features
8
Specifications
9
Product View S90
17
S90 Performance Curves
18
S90 Engine Performance
18
Product View CL 90
19
CL90 Performance Curves
20
CL90 (L) Engine Performance
20
Product View CD90
21
CD90 Performance Curves
22
CD90 Engine Performance
22
Product View C90
23
C90 Performance Curves
24
C90 Engine Performance
24
Product View CT90
25
Posi-Torque (F.no. 000001A and Subsequent)
26
CT90 Performance Curves
26
CT90 Engine Performance
26
Engine
27
Tools Necessary for Disassembly and Reassembly
27
Engine Assembly Diagram S90, CL90, CL90L
29
Engine Description
30
Power Transmission System/Diagram
30
Engine Removal
30
Removing the Drive Chain
30
Disconnecting the Clutch Cable
31
Engine Assembly
31
Removing the Inlet Pipe
31
Engine Installation
32
Setting Direction of Chain Clip
32
Adjusting the Chain
32
Cylinder Head Construction
33
Disassembly (Cylinder Head Block)
33
Squish Area
33
Removing the Starter Assembly/The Rotor
33
Removing the Contract Breaker Assembly
34
Removing the Point Brake/Camshaft
34
Disassembling the Valves
34
Cylinder Head Inspection and Repair
35
Checking/Repairing Cylinder Head Warpage
35
Checking the Valve Guide Diameter
35
Inspect Valve Guide
36
Valve Seat Contact Area
36
Reworking the Valve Seat
36
Valve Mechanism
37
Inspection of Valve Seating
37
Exhaust/Inlet Valve
37
Measuring Valve
37
Outer/Inner Valve Spring
38
Camshaft
39
Camshaft Construction
39
Cam Contour
39
Valve Timing
40
Cam Sprocket Root Diameter
40
Measuring Camshaft Height
40
Cylinder Head Reassembly
41
Rocker Arm/Arm Shaft
41
Assembling the Cylinder Head
41
Torquing Sequence of Cylinder Head
41
Cylinder Construction
42
Connecting the Cam Chain
42
Assembling the Camshaft
42
Installing the Point Base
42
Piston
43
Cylinder Offset
43
Cylinder Disassembly
44
Piston Ring
44
Removing the Cylinder
44
Cylinder Inspection
45
Removing the Piston Pin/Ring
45
Measuring the Cylinder Bore
45
Measuring Piston Skirt Diameter
45
Measuring the Piston Ring Side Clearance with a Thickness Gauge
46
Piston Ring Groove Dimensions Ring and Gap
46
Piston Ring and Gap
46
Cylinder Reassembly
47
Checking Piston Ring Contact
47
Assembling the Piston
47
Cam Chain Tensioner Construction/Detail Diagram
48
Cam Chain Tensioner Disassembly/Inspection/Reassembly
49
Removing the Cam Chain Tensioner
49
Removing the Tensioner Push Rod
49
Component Parts of the Cam Chain Tensioner
49
Construction and Operation of Clutch
50
Clutch Mechanism S90, CL90, CL90L, CD90
50
Clutch Mechanism C90, CT90
51
Clutch Disassembly
52
Component Parts of Clutch S90, CL90, CL90L, CD90
52
Removing the Clutch Outer Cover
52
Clutch Inspection
53
Removing the Clutch Assembly
53
Inspecting the Clutch Spring
53
Clutch Reassembly
54
Friction Disc and Clutch Plater
54
Clutch Outer and Drive Plate or Clutch Plate
54
Clutch Center Guide
54
Flow of Lubricating Oil
55
Oil Pump Construction/Disassembly
56
Gear/Trochold Oil Pump
56
Oil Pump Inspection/Reassembly
57
Gear/Trochoid Type
57
Gear Shift Mechanism Construction
58
Gear Shift Mechanism Disassembly/Inspection/Reassembly
59
Removing the Primary Driven Gear/The Gear Shift Spindle
59
Assembling Shift Drum Stopper
59
Crankshaft Construction/Disassembly/Inspection
60
Removing the Crankshaft
60
Measuring Crankshaft Alignment
60
Crankshaft Reassembly
61
Measuring Axial Clearance
61
Connecting Red
61
Reassembling the Crankcase
61
Transmission Construction
62
Raduction and Torque Ratios
62
Number of Gear Teeth, Indicate CD90
62
Low Gear
62
Second/Third/Top Gear
63
Neutral
64
Transmission Disassembly
65
Removing the Kick Starter Spindle
65
Removing the Gears
65
Removing the Gear Shift Fork
65
Transmission Inspection
66
Main/Counter Shaft to Gear Clearance
66
Shift Drum Groove
66
Transmission Reassembly
67
R Mark on the RH Gear Shift Lock
67
Checking the Gear Shift Cam
67
Crankcase Construction
68
Crankcase Disassembly/Inspection/Reassembly
69
Measuring the Crankcase Flatness with a Thickness Gauge
69
Kick Starter Mechanism
69
Kick Starter and Gear Interlock Mechanism
70
Posi-Torque Mechanism Construction
71
Power Transmission in the Posi-Torque Mechanism
71
Earlier Series Rear Sprocket (Prior to CT 90 F)
71
Low Speed Range
71
Posi-Torque Mechanism Disassembly
72
Carburetor Construction
72
High Speed Range
72
Cross-Sectional View of Carburetor
73
Main Jet
74
Choke
74
Air/Needle Jet
75
Carburetor Adjustment
76
Throttle Valve
76
Slow Jar
76
Air Screw
76
Adjustment for High/Intermediate Speed
77
Adjustment for Slow Speed
78
Measurement of Fuel in the Float Chamber
78
CT90 Model from Frame no 000001A
79
Carburetor Setting Table
80
Frame/Tools Necessary for Disassembly and Reassembly
81
Steering Handle Construction
82
Steering Handle Disassembly
83
Removing Brake Adjusting Nut
83
Disconnecting the Clutch Cable/Electrical Leads
83
Removing Throttle Cable from Carburetor
83
Removing Handle Pipe
84
Removing the Top Bridge Plate
84
Removing Brakw and Clutch Cables
84
Removing Throttle Cable
84
Steering Handle Inspection
85
Disconnect Spead and Brake Cable
85
Disconnect Electrical Leads (CT 90)
85
Removing Handle Setting Bolts
85
Steering Handle Reassembly
86
Removing Steering Handle (CD/CT90)
86
Assembling Throttle Grip
86
Clutch Cable Adjuster
86
Steering Stem Construction
87
Adjusting Front Brake
87
Steering Stem Section Diagram
87
Steering Stem Inspection/Reassembly
88
Steel Balls
88
Front Fork Construction
89
Front Cushion Sectional Diagram
89
Front Cushion
89
Front Fork Disassembly
90
Removing Headlight
90
Removing Front Fork Cover
90
Removing Front Wheel/Fender
90
Removing Front Fork Assembly
91
Component Parts of Front Fork
91
Removing Headlight Case
91
Disconnect Front Brake Torque Link
92
Removing Steering Head Top Thread
92
Front Cushion Assembly
93
Front Fork Inspection
94
Front Cushion Spring Table
94
Damping Capacity
94
Dimensions
94
Front Fork Reassembly
95
Fuel Tank Construction/Disassembly
95
Turn off the Fuel Cock
95
Removing Seat Setting Nuts
95
Fuel Tank Inspection
96
Removing Fuel Tank/Cock
96
Removing Tank Side Cover
96
Fuel Tank Reassembly
97
Frame Body Construction/Disassembly
97
Cross-Sectional View of Side Cover Installation
97
Removing Main Ignition Switch
97
Frame Body Inspection/Reassembly
98
Seat Construction/Disassembly
98
Removing Ball Races
98
Removing Seat Mounting Nut
98
Seat Inspection/Reassembly
99
Loose Upper Rear Cushion Cap Nuts
99
Removing Seat Hinge Pin
99
Tool Box
99
Brake System Construction/Disassembly
100
Rear Brake Operation
100
Removing Front Brake Lever
100
Removing Front Brake Cable/Shoes
101
Removing Brake Pedal and Stop Light Springs
102
Removing 3 MM Cottor Pin
102
Removing Rear Brake Rod from Rear Brake Arm
102
Muffler Construction/Disassembly/Inspection/Reassembly
103
Removing Rear Brake Cable
103
Removing Difuser Pipe
103
Air Cleaner Construction/Disassembly
104
Removing Air Cleaner Mounting Bolts
104
Air Cleaner Inspection/Reassembly
105
Removing/Cleaning Air Cleaner
105
Rear Fork and Cushion Damper Construction/Disassembly/Inspection/Reassembly
106
Rear Fork
106
Removing Rear Wheel/Fork
106
Removing Lower Bolt
106
Rear Fork Cushion Damper Construction
107
Sectional View of Rear Cushion
107
Rear Cushion
107
Rear Fork Cushion Damper Disassembly
108
Removing Rear Cushion
108
Disassembling Rear Cushion
108
Component Parts of Rear Cushion
108
Rear Fork Cushion Damper Inspection
109
Manual Operation of Rear Cushion
109
Front Wheel Construction
110
Component Parts of Front Wheel
110
Protective Covering
110
Front Wheel Disassembly
111
Removing Cables/Front Wheel
111
Separate Brake Panel
111
Front Wheel Inspection
112
Disassembling Brake Shoes
112
Removing Tire
112
Measuring Wheel Runout/Bend of Axle
112
Front Wheel Reassembly
113
Measuring Brake Lining
113
Seating Tube
113
Valve in Line
113
Rear Wheel Construction
114
Component Parts of Rear Wheel
114
Rear Wheel Disassembly
115
Disconnecting Drive Chain
115
Removing Rear Wheel/Sprocket
115
Rear Wheel Inspection
116
Component Parts of Final Driven Flange
116
Removing Final Driven Sprocket
116
Installing Rim Band
116
Rear Wheel Reassembly
117
Assembling Tire
117
Replacing Ball Bearing
117
Chain Clip Direction
118
Periodic Adjustment
119
Maintenance Inspection
119
Engine Adjustment
119
Measuring Cylinder Compression
119
Tappet Adjustment
120
Aligning to the T Timing Mark
120
Adjsuting Tappet Clearance
120
Breaker Point Servicing and Gap Adjustment
121
Locking the Adjusting Nut
121
Adjusting the Point Clearance
121
Ignition Timing Adjustment
122
Adjusting the Ignition Timing Advance
122
Spark Plug Adjustment/Clener
123
Measuring Spark Gap
123
Fuel Supply System
124
Fuel Strainer Clening
124
Oil Filter Screen Cleaning
124
Fuel Cock Lever
124
Air Cleaner Servicing
125
Removing Oil Filter Screen
125
Removing Air Cleaner
125
Cleaning Air Cleaner Element
125
Clutch Adjustment
126
Adjusting Clutch Cable
126
Carburetor Cleaning and Adjustment
127
Adjusting the Carburetor
127
Idling Speed Setting Table
127
Parts Not Requiring Periodic Oil Change or Lubrication
128
Engine Oil Change
128
Removing Drain Bolt
128
Oil Level Gauge
128
Drive Chain Adjustment
129
Grease Gun
129
Inspecting Drive Chain Tension
129
Adjusting the Drive Chain
129
Brake Adjustment
130
Free Play of Brake Lever/Pedal
130
Adjusting Front Brake Lever
130
Muffler Cleaning
131
Spoke Torquing
131
Adjusting Rear Brake
131
Removing Diffuser Pipe
131
Battery Inspection
132
Meassuring Voltage of Battery
132
Battery Electrolyte Level
132
Drive Chain Service
133
Measuring Specific Gravity
133
Operating Instructings for Service Tester, Type ST 4 B 4
134
Security Inspection of Parts
138
Torquing Points on Left/Right Side (CL90, CL90L)
138
Torquing Points on Left/Right Side (CD90, CT90)
139
Torquing Points on Left/Right Side (C90)
140
Periodic Inspection and Servicing
141
Daily Inspection Points on Left/Right Side (S90)
141
Daily Inspection
142
Periodic Inspection
143
Trouble Shooting
144
Main Engine Trouble
144
Carburetor Trouble
146
Condenser Test Method
146
Measuring Condenser Capacity
146
Engine Noise
147
Adjusting the Idling
147
Steering System
148
Clutch System
148
Gear Change System
149
Suspension
149
Brake System
149
Drive Chain
150
S90 General Export Type Wiring Diagram
151
S90 USA Export Type Wiring Diagram
152
CL90 General Export Type Wiring Diagram
153
CL90, CL90L USA Export Type Wiring Diagram
154
CD90 USA Export Type Wiring Diagram
155
C90 USA Export Type Wiring Diagram
156
CT90 USA Export Type Wiring Diagram
157
CT90 (from F no 000001A) USA Export Type Wiring Diagram
158
Supplement to S90ZK1
159
Cam Chain Tensioner
159
Kick Starter
160
Carburetor
160
Front Shock Absorber (Front Fork)
160
Rear Shock Absorber (Rear Cushion)
161
Wheel Axle Nut
161
Maintenance Schedule
162
Supplement to S90ZK Wiring Diagram
163
Supplement to S90ZKT Specifications
164
Supplement to CT90K2-K6
165
Comparison of CT90K2-K3 to CT90
165
Air Cleaner Maintenance
165
Steering Handlebar Clamp
166
CT90K3 Wheel Axle
166
Comparison of CT90K4 to CT90K3
167
Right Crankcase Cover
168
Fuel Sub Tank
168
Comparison of CT90K5 to CT90K4
169
Supplement to CT90K2-K6 Wiring Diagram
171
Supplement to CT90K2-K6 Specifications
172
Comparison of CT90K6
173
Turn Signal, Horn and Dimmer Switch
174
Throttle Grip Inspection/Adjustment/Disassembly
174
Side Stand Inspection
175
Rubber Block Replacement
175
Supplement to CT90K8 (77)
177
Supplement to CT90K8 (77) Wiring Diagram
178
Supplement to CT90K8 (77) Specifications
179

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Honda CL90 Shop Manual (180 pages)

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