Honda Monkey Z50Jz-1 Manuals

Manuals and User Guides for Honda Monkey Z50Jz-1. We have 1 Honda Monkey Z50Jz-1 manual available for free PDF download: Service Manual

Honda Monkey Z50Jz-1 Service Manual (277 pages)

Brand: Honda | Category: Motorcycle | Size: 44.54 MB

Contents
1
Specifications
3
Maintenance Information
4
Cautions for Operation
4
Specialized Tools
6
Tightening Torque
7
Wiring Diagram
8
Wiring Schematic - Monkey
10
Wiring Schematic - Gorilla
12
Fault Diagnosis
14
Unable to Start of Difficulty Starting
14
Pool Acceleration or Low Power
14
Check, Adjustment
19
Check and Maintenance Method
19
Engine Oil Level Check
23
Engine Oil Replacement
23
Recommended Oil
23
Cleaning the Oil Filter
23
Battery
24
Spark Plug
24
Compression Pressure
24
Ignition Timing Adjustment (with Timing Light)
25
Ignition Timing Adjustment (with Lamp)
25
Checking the Point Clearance
26
Point Replacement
26
Tappet Adjustment
26
Cam Chain Adjustment
27
Carburetor Adjustment
27
Tappet Clearance
27
Throttle Cable Adjustment
27
Clutch Adjustment
28
Idling Adjustment
28
Manual Clutch
28
Automatic Centrifugal Clutch
29
Cleaning the Air Cleaner
30
Front Brake
30
Rear Brake
31
Checking the Stop Lamp Switch
32
Drive Chain
32
Oil Lubrication Flow
33
Cautionary Points During Operating
33
Oil Lubrication Flow Diagram
34
Engine Attachment/Removal
35
Engine Removal
36
Engine Installation
38
Cylinder Head, Valve
39
Maintenance Criteria
40
Cylinder Head Removal
42
Disassembling the Cylinder Head
43
Valve Spring Compressor
44
Checking the Cam Shaft
45
Checking the Cylinder Head
45
Checking the Free Length of the Valve Spring
45
Checking the Valve and Valve Guide
46
Checking the Rocker Arm
47
Checking the Rocker Arm Shaft
47
Valve Guide Replacement
48
Checking and Repairing the Valve Seat
49
Repairing with a Valve Seat Grinder
49
Assembling the Cylinder Head
52
Cylinder Head Attachment
53
Cylinder, Piston
55
Cylinder Removal
58
Checking the Cylinder
58
Piston Removal
59
Checking the Piston, Piston Ring
59
Installing the Piston
61
Cylinder Installation
62
Clutch
63
Removing the Clutch Lifter
65
Removing the Clutch
66
Disassembling the Clutch
67
Checking the Disk
68
Checking the Clutch Plate
68
Checking the Clutch Center and Clutch Center Guide
68
Checking the Clutch Spring
69
Assembling and Fitting the Clutch
69
Oil Pump
71
Removing the Oil Pump
72
Disassembling the Oil Pump
72
Checking the Oil Pump
72
Assembling/Fitting the Oil Pump
73
A.C. Generator, Cam Chain Tensioner
74
Cam Tension Device
77
Crankshaft, Transmission
79
Removing the Drum Stopper and Shift Spindle
82
Removing the Transmission and Crankshaft
83
Checking the Transmission
87
Checking the Gear
87
Checking the Shift Drum
88
Checking the Shift Fork
88
Checking the Crankshaft
89
Assembling the Transmission
90
Assembling the Shift Drum
90
Assembling the Kick Starter
90
Fitting the Crankshaft and Transmission
92
Carburetor
96
Disassembling the Carburetor
98
Disassembly and Assembly of the Carburetor
99
Float Level Check
100
Attaching the Carburetor
100
Steering, Front Wheel, Front Suspension
102
Headlight, Speedometer
103
Removing the Headlight Casing
103
Removing the Speedometer
104
Steering Handle Bars
105
Attaching the Headlight
105
Removing the Steering Handle
105
Removal of the Steering Handle Bar (Gorilla)
106
Installation of the Handle Bar
106
Front Wheel
107
Front Fork, Steering System
108
Rear Wheel, Rear Suspension
114
Rear Cushion, Rear Fork
116
Rear Fork Pivot Bolt
117
Tail Light, Rear Carrier
118
Removing the Indicator Stay
118
Removing the Rear Carrier
118
Electrical Devices
119
Battery Removal
121
Relative Density Check
121
Charging System
122
Battery Charging
122
Charging Efficiency Test
122
Ignition System
123
Stator Coil Conductivity Test
123
Rectifier Conductivity Test
123
Condenser Capacity Inspection
123
Switch Inspection
124
Ignition Coil Conductivity Test
124
Main Switch
124
Indicator Switch
125
Horn Switch
125
Lighting Switch
125
Stop Switch
126
Horn Inspection
126
Monkey Z50JF - 7 Supplementary Version
127
Table of Contents
127
Specification Sheet
128
Maintenance Standards
129
Specialist Tools
132
Common Tools
132
Valve Cutter
132
Wiring Schematic
134
Attaching the L. Side Cover
139
Removing the Handle Bars
143
Attaching the Handle Bars
144
Electrical System
145
Regulator/Rectifier
146
Monkey Z50JM (Monkey Baha) Addendum
147
Inspection, Maintenance Method
157
Checking Ignition Timing
159
Lighting Device
159
Headlight (Head Lamp)
159
Detaching/Attaching the Engine
160
Seat Removal
161
Seat Fitting
161
Rear Fender/Side Cover
161
Removing the Cam Shaft
163
Checking the Cam Shaft Bearing
164
Fitting the Cam Shaft
164
Clutch, Gear Shift Linkage
166
Removing the Gear Shift Linkage
171
Checking the Gear Shift Linkage
172
Fitting the Gear Shift Linkage
173
Fitting the Clutch
174
AC Generator, Cam Chain Tensioner
178
Removing the Cam Chain Tensioner Push Rod
179
Checking the Cam Chain Tensioner Push Rod
179
Fitting the Cam Chain Tensioner Push Rod
179
Steering, Front Wheel
180
Handle Removal
181
Handle Fitting
184
Handle Grip Rubber Replacement
185
Headlight Removal
191
Headlight Fitting
192
Meter Removal
192
Meter Fitting
193
Steering Stem Fitting
194
Spark Plug Does Not Spark
202
Electrical System Layout
204
Battery Leak Test
205
Checking the Charging Status of the Battery
206
AC Generator (Charging Coil)
206
AC Regulator Removal
207
AC Regulator Fitting
207
AC Regulator Check
207
DC Power Supply
207
DC Power Supply Check
208
Checking the Ignition Device
208
Ignition Coil Primary Voltage
208
Exciter Coil
209
Pulse Generator
210
System Circuit Check
210
Ignition Coil Check
211
Ignition Coil Removal/Fitting
212
Exciter Coil Check
212
Pulse Generator Check
213
Pulse Generator Removal/Fitting of the CDI Unit
213
Headlight Globe Replacement
213
Neutral Pilot Lamp/Indicator Pilot Lamp
214
Meter Illumination Lamp
214
Tail/Stop Light
215
Indicator Globe
215
Resister Check
216
Resistere Removal/Fitting
216
Monkey Z50JN Addendum
217
Z50R P Addendum
230
Z50JN (Monkey Baha) Addendum
238
Z50JP Addendum
240
Z50Jp (Monkey BAHA) Addendum
242
Z50RW Addendum
244
Z50R (W) Frame No. AB02-1500001 or Later
245
Gorilla Z50J (W)-6 Addendum
246
Z50J[Y] Addendum
252
Toxic Gas Emission Prevention System
261
Blow-By Gaseous Reduction Device
261
Z50J2 Addendum
269
Z50J4 Addendum
271

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Honda Monkey Z50Jz-1 Service Manual (277 pages)

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