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.'.
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SHOP MANUAL
C70
-15,

' I. .. ' -- '1 '--::.'......: I';:".'-"555? ::- :: -FII35 5'53--'7'3:'-E" . '

 h IIIFBRTMIT SAFETY IIEITIEE
Indicate: H strung nrmiblly nfsrwrr ,I:'.rI-unul mm arias ufe lfmnmm.-u amnnl ms mr.
CRUTIDNI I-'mI1'-n :1 pm:-fbi,1' nf pmwrw-' |'n,r-ur_v ur cq-ulpmrn: -nlarrangir if immwrinn: are nu: aowei
DEIIHECI dtpllnns d1 itidird workshop pruuadmai, safer; prindpiaa, and qnrvncn upgmium Ir |1|ut|nclud||d_
It II |1'l'llll'12I'l'l'I tn nu-tl that this lTE|lL|B.| cnnmlru. some warning: and urinnq qggirrai nml amdu survive ninth-
-Udl W|"l|G|'l cuuld EBUII FEREONIL INJURY ISO rultl bfnnrlll (I |:;r|.|Id during 5 ulhiq qr rgnpfgr 11 |_mgu!q_
F1845! I-1I'1d=B1'lT-Bd III! 17105! '-ImH1i-gi Dquld mt cmrlr 51! oonnlivubl: my: in which ierlnce, wh-&Ih|:r nr_ not
Flm"""""!"'5=l1 1'-W Humtln Ifihl bl ill l B7 U1! pibli hue:-rmu-.1 :|=q\llrIc=i cn each mnoaiuablu way, nur
|:|:I-uld Honda unvasrlmta I|| uunh warn. Anyone udrlg 11-rwlm |iI"DCIl2|\|l'Ii_ or tools, whether or nut re-|:urnrnam:Ie
by HONDA must aan'sFy h-l'I'1'1iE Hlwnughfy lhnt l'lI|l|'lIf plfsunal safety nor ualcla ufelv wlill be iauuardimd |.'|\,r
th I-H11-'|rl.|! methi ur Tu-tllli illiutad.

K
In
 d__-

H-.
cto A
u-\.
.- 1

HUW 'l'[| USE THIS MMIULI.

Frallctw the Mairttertance Shcdulu fgggm
mtmdutiolis to ensure lltat the ye1|i|;||g i5 G EN E RA L IN F DHMATTDN
always in peak operating isnnditit-.-n. Perform-
ing the rst ttt:||~|11rJu||.tr.i maintenance |5 very.- LUBRJCATIDN

=A
impartarit. It cttrnpensatas for the initial wear
that {llIE.1JF5 rlur ing the |:|r-zal-t-in nerFr_'|d_
INS? ECTIDN AND ADJ USTMEN T
Sacti-ans 1 thrttugh 3 annl-,r to the 'l'l||'hQ-|
motorcycle, while sections '11 through 1? FUEL SYSTEM
1'- dc-scribe parts of the muturcycle, grnunea
at:-tsnrriing tn In-r;atinn,
E HG I NE Fl EMDV-it LII |'tlS'|"A L LATIDN
Firirl the section |'D|.l want an this page, then
turn ta tha tabla ui tnnt-ents |:|n page t Qt
that $s't:t|.1n.
CYLINDEH HEADNALVE
ad
d
Must serztinns start with an 5st3mi:||y ur CVLIN DE HIPISTOH
E
system irlustrallari and specificatrnns, torque
values, ganaral instrui:tians_ tools and 'lri':iu|:iFa- ENGHE CLUTCH
shunting far the satttltm The subsequent
D6965 giir dilfilild nrncettttres tor the section. GEARSHIFT LINKAGE
Ii
r"~- ll yau d|:int i-tirtuw the sir:-urtpe of the trciub-|e_
se-e iatttinn 15, THDUE-LESH DUTING. TRANSMISSIDNIDRANKSHAFT

Hater to the adctandum at the hank af the CAM CHAIN TEHSIDNEH

shop manual 1'0! infnrmatign un the IQ-B2
ETD.
F RDNT WHE E LISUSFENSID N _L D-J

F
ALL H-IFDHMATION, ILLUSTRATICINS. DI
HECTIDHS AND SPECIFICATIONS IM- Fl E A Fl WHE E LISUSPENS ION . -I DJ
CLUDED II-I THIS PUBLICATION AFIE
3"" BASED Di-.| THE LATEST Peuuuct rm
FORMATION r1VA|LALE AT THE TIME BATTEHYICHAHGING SYSTEM

HQ
UF APFHUVAL Ftjln PRINTING
HONDA Mt':|T|I:-H C-:1, Lrn. HE5E|=tyE5 IGNITION SYSTEM
/"~. THE HIGHT TD MAKE CHANGES AT ANT
CHASE
S
TIME WIIHDUT Nutice AND WITHDLIT
INCUHHING ANY DHLlt3ATtUN WH.=.T E LEG-TH TC STAR TE H
EVEH. HO PAHT OF TI-H5 PUBLICATION
i MAY HE HEPHDDUDED WITHOUT watt
. TE?-J PEHMFSSIDN. EWITCHES

aae
THDUBLESHDDTIHG
HONDA MDTDH C-U., LTD. _
S-anriaa Publications Office wmms DMBHAM

IF-
'32 ETD ADD E HDU M

_,|-

Dat ttf lssu-is: NOIL, 1951

El HDNDA HIDTDH ELL, LTD.
 I-Ionana.
ctn _h

_.~'--_
MIJIIEL IDENTIFICATION

I It ..._L'
I

.' ;.-f
.' i I.

I J d |- "FE ,._ '-I*_.'-. - - - 3

'_ E
-1|

_i_ ,I *1
III

\ .

.r
we
."'

TI'IB Ifme -}ari.;|I r|t|rrthur is slatpd IJI1 lII'|B I'IDI'I'1'l'it I-III I-II-Ill The Vahictu Identification Humhlr it rm the '5-at-My C-err!" 1".
I]ahI||cI the tide cover. qriurt LnheIon1h&Irarna's left tide.

-1

The e-tqing strriii nurr|I|qr is :It1n1|'J|-ad 0:1 IIIE IDWBF IEI1 crank
\
The :,arb4_[et1;r:t-r i|,'Lur\tiIir:l|nn |1umI'JI!r ts stem-pad on 1ID|:| 0-
--"w

LBJB. the carburetor fume. .1-\

Date uf Issue: May. I935

_'-IHDNDA MD TOH CCI._. LTD.
 ~i%?"%%I . GENERAL INFIIRMATIIIN
. _-_

GENERAL SAFETY I-1 CABLE 3: HARNESS EIULFTING 'IB

SEFIVICE FIULES I-1 MAINTENANCE SCHEDULE I-B
In SPECIFICATIONS I-2 EMISSIDN CCINTFICIL SYSTEM 1-5
TDHDUE VALUES I-4
TCIDLS I-5

.-'_. 1

GENERAL SAFETY
[M
-II Irhr rnginr mmrr be mania; to uin mm wt-mit, math- The -Ivmrm-_y eiercioiyrc contain: .:m.[|"'|.rtI'|':' m-int. -H'[rF:.I
sure the ems Lt itch-tleariiutigd, ,'IIIrti',|' rm-| my engine .IwIi1' :I-'-H. 1-It-in me starting. In me of ccnnttct, Hid:
in II riruwt arm. Ht: en-Jamar ca-n.r-urn: nnismwm I-Imruu_|;Itt[t= wt'.*It mtrcr end -t-uI'I' III deem: If nlarrraijtrre
/"'\,| -nsrbnn monoxide gels. rel: In your tI_t't*.\i.

Eitercihre I: exrrertmhi ammable and is -t'.tt,tI.ItJ.ts'ntr TM bdrfy gcnieretes hydmgm gar which curt -In:
Hnrffr -rtrrmtirt rrlnditiunr. Lin not smoke air III-cw Aigailv rxpfosfm Du nor make nr n.II'u-w untirs or
umexur sparks In your wrists; mes. .spn-rl.-: near Eh Ira.Itrr_t', eqxchlbi i||.=.tI|I|I|: margin; Er.

I-\-

SEIWIIIE IIIILES
a"'*. I
I-Ii" liI'""'-1I"B HUNDA nr HDIIIDA-rec:tmn'ienr-Id! parts ind: Iuhsicents or The-Ir equivalents. Part: that don't meet Hence:
design speuzlficati-ens may tilemege this nntnrsycle.
3- Use the special tcctls designed T1',I|"TI'|Ii pm-|;Iui:t_
3. Use only l"l"lETI'IlI Inn-ls when servicing !I'tI: n-nturcyi:,iu_ Metric Iit-II:, hull, at-tit ntrnws are not Intucluingaable with Engllgh
IEIEI'IErs, TI1: use cf inccrtect taut; e.I'trJ llittlnrrri may der-neqe the n-|amn,:yi;.Iq~_
4. Ins!-all new gaskets, Din|;|s, ccttm pins, I-ucit plates, etc. trmen renssinnialing.
_r"-. E. Wltttn tightening bu-Its at nu-It, begin with the Ierger-iiiamutn or inner he-It first, and Iighlnn ta the specified I;t,||-qua yilugg
itiaqc-nally III 2-3 I-ltrpr-. unless a IIIiI|II-LtI:t ttqslrlcc is specified-
5- CIB9" FWFH I" H0"-Tlmmabi Or high llttsh point scIu'e'nt upcn dis-lsscrnhly. Luhricete any siittlrg ;t.tr|';|m; hefcre reassembly
T. -"i'Il=r rlisscntily, check :tI1 parts Inr prune! Initellettttn en|:I uni-itin-n,

Ff-e

IF-"

Date-at I=.a.ni.~: May, I961] 3 1 _ 1

EHDNDA MDTCIFI C-0.. LTI3.
 I-IlE1lD.l\.|
G ENEFIA L IN FDHMATIDH .-="-"1

SFEIIIFIIIQTIIIIIS
ITEM

DIME N5-1DN5 Dvlrnll llnqth 1.305 rnrn 1T1.1 inl

Dvarull width BB5 mm 120.2 inl
Uvnll heigh: Q95 mm 139.? lnl
Wheelbase 1.180 mm I-43.5 Inl
Sear helgl-11 FED mm 119.9 inl
Fn-utp-sq height 250 mm 110.2 inl
Minlmmn grnur dmruhm I-Ill mm I 5.1 ll
Dry weight B15 kg I IE-4 lb-I "'5-
FRAME Tvul Backhu nu
Fmn: gugpenun, [uni Lldlrq-L inll 55 mm 12.2 In]
Flair iu.q:lminn,1.'ra1.Il| Swlnqirm B0 mm 12.4ln1
Fmn: llre 11:2, presmra 2.25-I I-HF!-'t an kq.*cn'|:125 pxil -*1
Hair tlr-I me, are-saura 2.50-1?-EH 2.5 km cm 140 psil
Fm nl Intuit: Clhll upnmrmi llndlrg in:
HBIF brake Had up-armed Ina-dmg shoe
Furl rlpl cit-,r 11.0 lit H.125 U5 Bil. 0.58 Imp gnlil
Fuel tamrva l.|I0l1Z'|l 0.151 Ill 10,21 Ugai, 0.'tB lrnp gall
B4.
Cairn will
Trail TD mm 12.H lnl

E.NG1NE I Tvu-I
Cyllndar arrarngamant
Air cuulud 4-illll
snqm, lniinad ao1=mm unrtlcul -Fm
Ema mu mccu xHAmML:LM|
Displacement 1'2 um 14.-I uu nu
Curnpruslu n rs: in 8.13:1
Vim lrlln Chum driwqn overland mmmuh
Maximum hu-raapuvm 5.0 B!-|P."1',0I3l rpm
Maximum mrqua 0.55 hq-rn."5_ECKI| rpm
Ull qDIit'||' DJ Iir 1.?4 U5 qr. 0.52 Imp qr} nflur dlmsllmbli
0.0 lit 10._B5 US q1,0.531m|:| qll llf drllr-Frg
LI.Jri-Cllid :1-rtnm Fund |'BI.11.I'E and wet-aumu
_"+
Air ltration F-BIII1
Gqrllrlllr cnmpresnn 12.5 : 0.5 lq.'cm= 11'.I'B 1? pair:
Intake vulva 0|:-um. u arm:
Ginsu 20" man:
25. Ham: I
ll'||'TlI11||t
Exhaust value 0|:-an-5
|:|U'i-I-I 5" ATIJC
Valve clmranaa [Co1d1 IN: 0.05 mm 10.1I.~l2in|\
El." 0.05 mm |U.lIJi'ln1
Enqma weigh: 1B kg 130.? lb?
Id]-I spud 1,500 :1: 100 rpm
/_'-.

GA-FIBLFH ETIDH Garhmnur I'f|'JI Filtun vulva, 14 m1'n10.55 inJ vervrturi L-are
ldcrlllfilz-Hun numb-er 'Br PB32A
'-ET PBIWC
Pllnt screw Initial tting SH page 4-?
Flam hm-I H1? mm [0,-I12 In}
.=.._
- |

|'_I
. II

1-2 * Date M Issue: May, 1_9BU'

Eli-IUNDA MCITDH C1'J., LTD.
 F"-"-.

I-In-_
v
'I=?'I3 _ _
E-EH ERAL INFD FIMATI DH

ITEM

DFINE |"i'-IAIN 1 C1|.rt=h Wu muiti-ptata aummatic nuntrihqai

Tranuniannn 3-spud mnillnt mI!!l'I
Primary rei.i1:|I!tI0r| 4.053
Final raduutiun 1.521
I Gear ratio I 3.???
Gagr ruin ll 1.1122
Gnr ratin-Iii 1 .190
Gmrshi pattern Ln!-r fnul Upft re-tun :-psram H-1-2-3

i ELECTRICAL ignitinn Fiywhaal rmqruam

Paint 98:3
lgnltian liming "F" rrnlrk
F1..liill21l.lIl'lOI
: Stating system
, G-anlratur
""1 Banary I31-Zll[\'
Splfh ping
0.3 - 0.4 n1n1i0.0I2-0.-iII1iniI
15* awn. Sum:
an aruc at 3,1911 rum
Kick nlrtlr ariri mrtlr ninnr
Fiywha-alA.C,g:ar1a|r|tur E7 '|'iI.15_.iII0 mm
B1.I'~11AH-
icmmnal

i
For nu-Id .-Jlmmu Fur vuiendnrl high
bubw 5C, 11F STANDARD -spud D|JIl'l11Dl'l

Qaai ad F65 ' Ha .~a.1'-.=__

u2m=a can uzzrs cm-is umaa ' can
Iu2nFsa lcnsnsi liuzrsn [CHTPHSI |[UL1;4FSH i0RBH5i
_'.Li. .1 |.
"1 Ba-lrk mun ma 0-5 0.1 mm 10.014 0.023 1|-1,1
Fuse aanattv IDA
T.
LIHTS Hndiiqht 1high.I'lnw hnml l5.|'1E|'iI
Tallfunplighl 5.3|"25W 3.-'.'i1'=|=
Turn Bili WW 21c:p aaa 010.113
Speadnmatlr 1.7171 IFFI SAE Nu, 51
Nu-uml India-|u:rr 1-'I"W 1w EAE Nu, 51
Tun _I1Il1I| indicator 11'W 1\=P SAE ND. 51
Hhh balm in|:Iic.at|:|r l.'i'W IE9 $15. E No, 51

1'--1

r""'~

F-ll

n"\-.

E
Data of laturr M31, 1050
EIHDNDH MDTDH EU... LTD.
1-3
 Henna.
GEN E HAL INFO Fl Ml. HUN
1:10 '~$,'
'"-1..
""1

T011002 '1'l|.|.|E
ENGINE
1 tam - - Turquc
'0 .tv Thraaci
ma. [mm 1-
Elm .
1 _
ft-1b <~.
-1- 1
Cylinder 11.11.1111 l:rn'|:r I D 0 1 2 .5
Camshaft spvru-1:1-let 0.5-0.9 -T
Clutch 1:11:11. nut 1 3.0--1.5 -33
Final driwr aurwkat 1.0-1.-I1 -11]
Flywheel 1i 5.5-0.5 -4?
50211 ativlnugr -I -ru-1 :| .h @130-13-U'|m 0.0-1.2 1-.-S- lg;-9
- .1
P-"~.

FRAME _
mm | GW Th-rear! Ternuw
di-a. (mini _' Irg-m H:-ll: "71
' Steering rtam nut | 15.0 0.0 | 43-65
Har1-cilabaraa-rtinq nur. 2.0 - 3.0 H-22
Shearing in-ck 0-G -1.3 1- H
Fmnt axia nut 3.0 - 4.0 22-29
Englnu 11|n|j1|r bu!-1 2.5 3-5 18- 25
Hair axle nut 11.0 1* 5.0 25-BB
Firtai driven sproairut 2.0 - 2-5 1-1--15
Hear braita tr:-rqua link 1.0 2.0 T-14 "'3
Flea-I |hn|:i< abm-rber 2.0 2.0 -2?
F0121 nag 2.0 2.5 1 I

5-wingarm pivot lznh IIIii

_l. 3.0 - 4.0 -29
Frnt mmlrmun nivnt hnit 1.0 2.0 -IE3}:-1.1
Frnt 1u1nen1Furr stunner bull. 2.0 3-0 1:-21
Fnunt 51191:-it absorber upper hair l1.'\l-1 .-Ih -r\.:h-1n.J-|~,}q-.| m mumu u m 2.5 3.5 1a-as
F mnt tu m aignai :!.a',r -III 0.35 - 0.5 2. 5-3.5
.. ...__..-n...-_-- __

TOITII-IE IP-H-|1i\=I1i1=rI= limd lbmw are fur the mun irmnnmnr tigilning 1:1-Dinti. If e tulnua auacicstiun -is nut mire-a, |'u1hw.r
the atlndlrda given beiurw-
"'1
STANDARD TUHDUE "u"ALUE$
.1-1"-\-_.
i Turqua Tnrqul I -.1
ltam - 1'
_ kg-m 11-111 : mm kg-rm 11-111 .|
5 mm halt. rwt 11.115 - a.a -3.:-1 - 4.1 ' 5 mm -mw 0.35 -- 0.5 2.5 3.5
5 mm 1111. "01 0.3 -1.2 0 - 5 Gmm snraw 0.?-1.'l 5- H
5 Tl'lill 0011, I'll-I1 1.5 2.5 13 1B B mm flatge hn|t_ nut 1.0-1.4 7-10
15 mm 01111. T"-I1 3-0 L0 2'2 20 B mm anga belt, nut 14-10 12 -22
12-mm h-nlr. nu: i 5.11 - a.a as - as 10 mm fling: r~.-=11...-1.1 3.0-4.0 22-29

-' '1.

.-1-1.

1-4 1 0-ate of lssua; May. 1900

EHDND-A MDTGH C-0,, LTD.
 GEN EFlA\L IN FUHMET ION
1".
r"'-"K.
'0LS
5PECl.P.L
Tupi Name T-pol l"-in. 'l1"I'r' Flaf. DIIJIJ
-'-*-. 0?5B#-0550000 1 ea, a-9
Valve midi: rlnlr
Flwmeel h-nlclai 02922 12111101] 1 1.1.1, we
1 Dpmmrrnlally available hand rp
wrnacm may ha used.
Bali rat: rrrmuvar 11041?0D1'Il0 1 12-13
_"'_\ M9310-2??-01??-4 1U.5~-. 0n1'r'1
Fin s-p-anrtr. 30 mm 019131;!-uclru 1 12-12,12-10
Value guide driwr med?-1 1301110 1 0-9

COMMON
? Tu-:11 1"-lo. Ref. page
Tupi l'1l-I111: T.m;|| N_ (Pry Alternate Tuul

F lpat lrnlil qluqll 07401-0110300 1 -1-5

"|.I'||1r\1 guide re-rrnwar 07211-2-0010100 1 \l'1!l1H'0-|J1l2lU I'IH'I;W!ll' 0T9-12-32510100 a-9
5.5 mm
Unlwrial huldnr 0l|"'|'2E1-00101111 1 Cl1.11l;1F l"l-lad-Ir [1-T023-01100000 a.:1, aa
Cmnnvarualhr IV ltll
11-1.. adjunlnq wnmrh, D??D3~0UI|11'I1 l:11l B:-19mm ela 1 E a-a
B_:rr__0 mm- hm:-a1r1d wrench
""1 "|"ra1HI lvI!l1Lll-ll 'nwnch. B 02208-0030-1111
U.S.A. nniv, rifnr to
3-5
S,T,11l, No. -117
L,-1:1-pl: nut wrench, (Jam-1.111-ar1:irl B-3
07215-0020202 1
20 11 Ii mm Ii|1'Il10'l!lB
Erlrtrrniln 11 mr 0721541120500 1 5-3

Flptpr puller 02733-00210001 1 1111mmring bolt 013015-350-0'11 1-I1-i

0??-1-0-11110013 Driver 1111111111

rrra4a-a1 1 crane 12-9,13-'1
Bearing driur l'liT\l1llI, A n19-an-aanueuu 13-9
Bauring driver miter. Baring driver attach. 02945-313201 DD 12-9
1--1.. 32 1: 3-5 mm 07711-5-00101011
nremnaatnua.
Earning clrlvar u-utar, 1 Ba-lrinp clrlvrur -ltmch
31' mm 13-'4
07245-1111 0300 |JTii1-5-30011000.
3? 1: -'10 mm
-111 mm
1-. Bearing driver pibt,
err-1a-up-1=u1m 1 12-9
10 mm
Baarinig tlrinmr pi1r.|t, urna-no-10200 1 13--1
12 mrn
B-"ring drlu-ar pilnt, 13-5
IT mm
071-111-011-11:1-inn 1
f'\ lieu [M21011 ablclrb-ar 13-10.13-11
an nrpraarur
111959-32900111 1

Hipplt manner 5. aTr1r1-002112110 1 3-15

-1-5 1 5.1 mm
Vnh mrlaa urea:-arraeaar 6-5. 6-11
.3"-".'\ Valve spring cumpttt erramnruuea 1 1X1I'l'1|I'I'iW|'

Lm;R'nur wrench. 0711641020100 1 5-3, 3-1:1

20 11: 2-'1 mm 1| l .-
{"1
._ _

2
Data pf lsauer May. 1930
@l11"~l1L'lA MCITUR CD., LTD.
1-15
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 HON"-B
_. C70 GENERAL INFORMATION

TH11:1Jl"I'LE mats II'~--17 l ?w_H__ "T'-.

SFEED1JlrlE'l'EF1 maua .- -5- _

rnnm SHAKE mam _ _ I .I I

,'-I -H. I I I-_ "' H _ -_,_

BAHO 1'. .4 - _
. _ . ,_5'.': J2. '._ '-F

F3 REAR I-l.i.|1NE l
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~-..2
l.
-'_F"'-If "I
_=-_'f5I)/
- -- .5.-1'-l
B-l.TI'ER|' _ __-._\"
_-_-, __,___ .1--5*-'~=i_-'_
-'1-W,-r-
P. _i H. "1':-_.|,-:2

."-1' PM
1-""1
9

Datadf Issue: Mn, 1900

an-ruuna MDTDFI up-., 1.11:. 1-7
 HONDA .-
GENERAL INFORMATION [:10 .-\\.,_

IMINTEIIMIBE SGHEIIIILE
P-mnrm 1h: PFIE-F1 llI|l'; INS-F'E1T.'1'l0i"-l in 111: 111.1111:-'5 I1.'h11Ll1:Fal uch scheduled 11m.111'ar1:an1:e p-arind.
INSPECT AND CLEAN, ADJUST, LUBFIICATE, DR REPLACE IF NECESSARY.
. C CLEAN
REPLACE
ADJUST
I-123 LLIBFHCATE
i_ .._, _ . ____

FREDUENCV WHICH EVER CDDMEFER READING INCITE 3,1

(111111 ES I
__ 1= mar Fim1:r
E100 m1 2,5-I'll] rr1'- 5_,l'.l[llIJ 111l 2,500 11'|l ta page
T I-
11,000 llml H.000 l1I.1I 13,000 lI'I1l |12,DUO I";I'I1l
ITEM EVERY
I
FUEL LINES 1 I 1 3'-3
I-
THHDTTLEDPERAHDN 1 I 1 S3
.1.
i 1
CAHBUFIEFDFI IJHDKE l I I 3-1
AIR CLEANER NOTE 1 C = C I-I 3-11-
TEM5 CRANNCASE EIREATHEH NOTE 2
CLEAN E'u"EFl'1" 35
1,2511 rni 12.:1n111<m,1
ED
sa.-111: 1=1.uc __ __ R Fl Fl 3E
VA L-"1' E C I. EAR A NCE I I I 3-0
0U
-CONTACT BREAKER PDINTS I R I 3- F
_ _ ' lGNl_1'l0N_TlIr'llNG I I I 3-B -*-.
REPLACE E-'ER1"'
ENGINE OIL YEAH R
EMSSCINRELAT 1,250 mi 12,1100 11.111 2'2
I-
ENGINE DIL FILTER SCREEN . _I
I-
CAM CHAIN TENSION A A 1- _.-1 :1-a
-I
CARBLIRFTDR lI'-Ii E SPEED I I I 3-10
DRIVE CHAIN 1=. 1. 15111.1.-21111 :gu_m1'111a 1-1-11 -1-1 1
em-ranrr _11-_11;;i111f1=.1-1 1 I 313
1-1-1.
EMS BRAKE SHOE '|'I.'EAFl I 1 113 _

il
B RAKE E-"r..'?1 EM W-_
BRANE LIGHT SWITCH n_ Z1-15
I
HEADLIGHT AIM 1,_ _. ,._ 1 :1-15
1:1.u"rr.1-1 __ _ .,_ 1 |_ i a1e
REanwLATEDT 51.1] E ST AND :-1-115 I
1-
-Ira
'lsu 51-151-151:1:-1 _1, 1. 1, 1. 1,1. :1-11
NUTS, EDI T5. FASTENERS I 1 1 1_ _ 3.111 .1-"1-.

NIDN-I:'1|1S " ' '1"1'H EE LS,-'SP\D1(ES I _ 1 I 1

_i_,_ a-1a
STE EFI_I NG H EAD BEA RINGS
L. 1 , :1-1a
I
SHIDULD BE SERUICED BY AN AUTHORIZED l'iUNIJA DEALER. UNLESS THE CIWNER HAS PFICIFEFI
T1-DDI.5 AND -SERVICE DATA AND IS l".'1ECHA.1-lICALL'I1" CIUALIFIED.
-I-I
IN THE INTEREST DF SAFETY, '1.11'E HECID-I".-1I|IEND THESE ITEMS BE SERVICED DNL-r BY AN AUTl-IFlU-
111251: 1-11:111n'r1 DEALEFI.
NCITE: I. SERVICE MCIHE FREQUENTLY WHEN RIDING IN DUST? AREAS.
2'. SERv.I'ICE MCIFIE FREQUENTLY Wl'lEN FHDING IN RAIN DH AT FULL TH RDTTLE. [I.l.S.A. Di-.lL"1"l
3. FDR HIGHER DDDMEIER READINGS, REPEAT AT THE FREQUENCY INTERVAL ESTABLISHED I-IE-FIE
10
1-B Date pf Issue: May, 105-III
'51-IIDNIIJA MDTCIH 1I.'tI1._ LID.
 Q FRHONDA
r"- CTU GENERAL INFORMATION
-'--
EI|Il5SIl]|'I GIIINTRIIL S'|'STEl|I
The BTU is un I_|i|'}nI!|:1 with |LlI'l- r:a|'l:|i.ireti:w settings and uthar :ws1.I:rris ti: rlduu uarhun monoxide and h\IC|Il'}lZitrh!_.I umiigig |15_

E I H RUST Sr'STE M
Thu lmhilm I?=lT'|i-i5iCl|'I contra! wmarn ll |:i:|mp-used of lean UHLILIIEIIJI se1t|r|g:_ ud nu ni-|.'||u:.:me|1n shuuld be made ermepl lull:
F- spend anljustmiam wllh l|lE |.|l?'lI||!|E ump si:--aw
THE =1-thahsli rmi-ssiun izuntrul svstem is wparata from this urarlkizasa emission acntrul system.
CFIANKCAEE SYSTEM
Tlw Erlgirr-I: il nu I-Iirlrrrl with -: cininrl 1:r=m-kcaan wmm in pruwrrt diicha-rqinq crankcase rmissinns lntrl Th: Itmusuhnru.
..\_ Blow--by qas is raiurmad to the cumbuntinn 'E|1Efll|JE'f !hruuq|| the air cleaner and the caaburutor.

-351' Aiu Cleaner

:7?
.-n
*1"-' -=:::: Fr!-sh Air
-Ii Bligiw-b'yGa.1
|- I
F

__ Transparent
" Tultl

f-3 El DrilIIPh.q 1

INFDHMATIDN LABEL
.-"-\ The Emiigig-n Cuntrul I-|1f|;||'|'|'|utiun Lghil in lnultlhll cl-n IHE :'\\'ll|QAl1lt iifl !|GB.

,r"\

.-"""~

I |_ 1 "II. W11.
H ,. .._

.-1% . K "
J
i

J'-1

"-"el1||::e|I E|T||3ElCII| Cuntrui lnfurmataun

Duh: :11 lame: Mu1|i'_ 1951] 11 1 -9
TJHDI-IDA MDTIJH CD, LTD
 H
:__
_l__ Enis
\HA
R_ Kg J}
L U BR M_H U DN _\_
H
_x
H_H____
E N G W E LU B H m AT m N S STE M
_Y

3
_
II ________
____
AF
___L
_3%
_{___
_ _ ___If
_ __
_ _ ___
~____:_ ____
________

%
___
__Q
__I___:
__

_\_
I_
F1.
_|l
___
_||'
V;
_
_J:
JJ
n %?
F
___m__\__
;HJU!
kx
i
%
_________
______
_ _\Jbl
_

mnq
___v__\_ ?
Ln___ __._+h\\-
%
u_kMyIJ_
1__i

%J
_
_'_h_____Il___
{Rx
A.gm!
__ _

;EJ.
I miw
_ P __

F511

7;
mw _-
WK
TGAVL D
Hm JN
HNE E
CH_CABnmwmWET
Hi m M
HM _ m mm
M ?UEL_MRW M_H|
CDEGl_ CFT HH CHHEA ND H
G DH WW _H M M ___*| CCH AAN GMME
R H A FT KK E
&
q
w_
_

RC THH _E
GA S IL

20 12 ME HM
_mN wm mmBmm
 HONDA
I-I.
Qifij/' C70 2. LUBRIBATIUN
SERVICE INFDHMATIDN 2-I ENGINE OIL FILTER SCREEN
CLEANING 2-2
THUUEILESHDDTING Z-1
CENTHIFUGFIL GIL FILTEFI
-iENGlNE'.?- CLEANING 2-3
ENGINE UIL LEVEL 2--2 OIL PUMP 2-4
ENGINE OIL CHANGE 2-2 ~=-'.'CHA5SlSfI=-
LUBFIIIIATIDN POINTS 2-?

$EIIYIIIE IIIFUIIIIIITIIIII
GENERAL INSTRUCTIONS
Dll firter screen and pil pump inspection and maintnnrloe HM L1! mid! W|ll1EH-I1 FBMUVIHG II"? WEI"!-

SPECI FIEATIDNS
STANDARD I SERVICE LIMIT
|

. Appmrilmntelv 0.6 lllur IELEE U5 i1l II -Ml I-'l|ll';|E'

nal [III wpluw U T Titer [l}.?:I LIE II|[I at Enpin-E assembly
lh

Hewrnmandscl oll HONDA 11-ETFICIKE CHL 5-AE TUW-db pr mulvnlant

Ml senrlce caniilmtlon: SE
Dtblr vim;-:;i1iz: mm; L1: wad when the average temperature In upur riI.1|rI;|
are is wllhin the indicated range.
Hepnmmwndud nil '|'l'5l=UI-|IIHl-

T T T' "' " |

|'\ I

If--. i _ :
.;|;| 1| l|| Ii I l.1I F

.| _ I #-Ill
|_ . _-|. Ill | ll ll _q_|

Tlp n-ieernnpe 0.15 mm |[|=.lJl3Bi1-il D.2{l n1m [H.008 Fnl

Dil pump Bodv DI'BBl'Il'lDlI I111) - 11.15 mm [C|.ClEl~'1 D.DClB -nil D.2lI| mm lD.DDB Inl
r""~. End nlaarenpe I102 [LI]? mm IIILDDI EI.DCl3- inl IJ-I? mm IU-UB5 IFIJ

TIIIIIIBLESHDIITIHB
.""-8- ' Dll level mp low Dil -annmmlnntlun
T. E1-lturn-nluil hanks I. Oil not phinppd pftlrn n:Jll'EIl
2. Worn value pu lde pr seal 1? Heed gnl-iet1'uul't'|i
3, Wprrl B-|:D|'| rlrgs 3. Worn piston ring:
.*I.

Di|IIElIIIIIi$1.-IFI M-=31. I950 I3

f.'IHD.ND.Pi MDTUH Ell, LTD.
 HONDA /.a;t.t@\
Luen ICATIDN CH] _.__
I _

.\-.
(lEI'I[IIlIE>
EIIGIIIE IJII. IIIIEL
Euhlloitt the mptdrwple un_ri!:ht pn Ielrel ground,
Chunk the oil lees-I with the llller D!p.I'(.Iip$lI|;I|t, Du
not screw in the pep Wh|.'n melting miq |;hl5|-t, If the
IBWI it bl-tnv Ihu lmutr lrnntl on the dipstick, Iilltp
Ulit! up-per lwel merit with tl1e fE11'l'L'rrII-'|'|1t'-trl|;|l7d~|{r|"|g|l'|B
oi .

EIIEIIIE l]IL IIIIMIGE

MUTE
I When elmnglng the oil, drelri the peed all hmii BIL FILLEH CA-P.-DIPSTICK Lowsn _____
Th Crrlltlilhu while the engine ls warm Thu I.EvEI. LEV EL '
L ensures ed-mplete end rapid urelnlng.

Flurnoue the pil fillet l1B|Ilu'IIII[HIlCI. __,

Pltloe en oil drain pen ullder the Eng-.|-ii,-, I|'Il:I- reman-

the drain plug. When the all ha been oompletely
tlflllhod. he sure that the drain plug sealing 1,-,-eel-lgr is
In good up-ndition entl Irutell the drain plug.
TORQUE: 2.! 1.5 ltg-m i'l-Ii - I8 H-lbl
Pour the rt-wnmnnrled I-'lII [page 2-1| slowlv lhrouqh
the ell tllser hpte.

CAPACITY: 0,6 llter {'lZl.BE- U3 qt] e'l all dung

_|.
Install the nil filler trap.-clip-stielt. Start the engine
and let it idle 2-3 minutet. Step the engine we
tI'lEl= 1l'\Bt the oil level is ut the upper level rnerlt on
thlt d=pstl|::lt with the m-ptprcyele upright, Cheek
that trt-are ere l"H.l ell leaks PLUG
'-"|_l

EIIIEIIIE llll. FILTER SGIIEEII F HUN T C-C|"-" E H

LOWER FIIGHT
BILIIIIIIB G HAN IICCASE COVE R BOLT _

"CIT? _.
Firm this rnnintennnoe with the engine EIIIU
driinud.

Remove the front covet lower risht mounting bolt,

Remove the ltielt starter pedel end murllur. 5|-l!:Ip-urt . _""~
the motmoytle 'Hili1 is mltohle stand end remove the
Ibiptpsfside stand assembly.
Fliml-E The tight I-;lilllIlI-il5Ii' coves,

__\_

H-Hl'I_EFI PEDAL stamp _

2-2 Ditto of lsstlo: 5-lay, IHHEI

EIHDNDA MCITCIIH C11. LTD.
 LU BHICATIDN

Flerovo untl cleen sh-e pil filler sreen.

lnstell the Di: film,-r screen, right orenltcase pa-sltel
tlnrl cover. ltlelt starter pedal. mufflet and loutptgti
side stend assemble-
Fill the craltltcese with the recommended I=ngInl! tl-II.
Start 1315 mgirie and let it idln for I-3 minutes.
Etnp :!~|e enqina and t:I1El2-It II16 CIII III'tIl=I l-I-liI.II T.I1B
motcm:-,rr:iu u|1r'ighL
Melts sure that there rm: nu oil ieelts

FILTEFI SCREEN

IIEIITIIIFIIEIII. Illl. FILTER BLEIIIIIIIG

Drain the cnglnn t-HI l,l=|-lg! 3-3]-

FIllI'l1lJI'|'E the right crunlti:-else crslrer (page 2-El.

Flsr-noun the lulh I6'lI\'il|', tam and GLIDE! go-var.

CLUTCH LEVEFI

C111-en lhr: trlutch outer cover -entl II1ii-rk! pl the clutch

outer usinp a I:|-trim IInl'.-IIEE cloth.

NOTE
I Du not allow uusr eno dirt to enter the
|:|'||r:rI:hlII1 oll pessegn.
I; '1.'.'=i~1=s=*zr_'r_r'_r~"*":===' ti _l
Install the lzlutoh oultr -trrvel. tram end Ieutlr.
Install th-n r-gm csenltoase oouor. Itioit starter pe-drr-1,
I-nulfler and font pr:gsl'sld: stand esel:-In IJI I-.
Fill the trrnrikcese with the retornmensled engine oll
inane 1?-21.

C LUTl"H DIJTF H

Date uf Issue: May, F950

'EI'H-DNDF-. MlIIl'l'ClFl t'.;E|., LTD
 HONDA ("L3-E%\
LUBHICATI on Qj I ___
- _--.
[Ill PUMP CLEAHFF CDVFR__\__H_H-H-L Q,FFlU'|'\|T CUVEH _ I

REMOVAL . I I I. :5 I ' 1;

50115 Q! -ll
?|-II i'|.| ,_1 Ill .11.-'_ ___ hr .

Th! Bil |'IIll'|IJ- Erl be runwvud with ma angina J

|_ rl'1-ul11|:-e!| In 'll'|n frirn. 1 !.:;'
"I 1
Ra muwna the ml Ur-aln plug and drain the nil fmwn thu
urlginn lnign 2-2]. Flumuw 1.'hq I-#11 crankrme
cover-Image I-1').
Flcmuw thu clutch us-ambly [nag H-21,
" 0--I?" J r I, " i
.i'll'41,|I _

Q: . .-_

MUFFLER KICK STII-HTEH FDCITPEGSISIDE RIGHT CFlANl- ..-..

PEDAL 5-mrm ass"? BABE EEWEFI "
Fl!=rrm'u thu thrau |:||| pump am-.-.-5 an-d nu pur|-'|p_

-5-

SCH E'||"|I".5 ..-...

lN5PEl1TlDl'\l

Flmuuu the |:||| pump h:l|;|'y' |:|;|wr_

."-1

PUMP BUD-"|" GGVEH _

4

2-4 "'- Dutw nl lss|.||:: M-23'. IEHU

DHUNDA MUTDFI C'El._. LTD.
 ;, I-IIJHFIJIL
-1-I-._
BTU LUBFHCATIDN
__|I"""\

Measure use r'n1n| t||3 claaran:-2.

SEHWGE LIMIT: 0.20 mm lD.EHIlB ml
_

F
---R I
//I fir-' D. _~,_';_ll

F ' ""

-._
.<.;.:'*..$./" . . -.-~ J
Q-___-__
1. -_
-..__--___
'
1
_
'\-ll:l"'.

- .- _.-"_
___-___-' __,.-'
--__ Z __-- _.-'
T-_ _
.-I-'l

___."

"'_"-..__h__ i _____.- -___.

.___ _ _ _ ___
.-'-
lkleasuru the |:||.|rr'.l:| i:||:|d\,' clearance
SERVICE LIMIT: I120 n1l'|'| l.0DB lnl

I l D anhhii

|f""~.

_-____Fl_;,.~.1
.I|r

73-__'__- .-

\~'
@;
f
_ - l-' - - -I -.

|:- -:. _-d

_

.__.
.. E

. \I

F"
Measure the !'lJll'Jl and r.".l::nn1nr.u
SERVICE LlMlT: 0.12 r'|1m'lD.DD5inl
-"""'*.

,.v""a

.-'-'~-

.1

Date c|l' l-.-sue: May, IQHJJ

'1 HUI-JD.-5. MDTGFI CD., LTD
2-5
 HONDA. I
LUBRICATIDN cm -I-1

DIEFKSSEMB L"r' ll-lh|E-Fl _HDTDFI EJLITEH FIDTDR

F'lerr1|:|'..'e the drive shaft.

Hcmrtvn thr: inn-er anti uutnr rcture

DRIVE SHAFT

ASS E MB LY

tr-tteil the nuter and inner rnto-re. Align

Invert the drive shaft and align the ftet din the shett
vnth the liat In the inner rctnr. l'he ftete -ahculd
face each ctr-et.

Ir-eteil the pump la-crltl liilJ\i':!r qeeitet end cheer -t

HIJTE __
Meite sure that the |'Jurrl|:t- reutee freely
l wt-tjhtjul handing. _ l

INNER RCITOFI OUTER HUTDH lJF'llu'E SHAFT

ll-JISTALLATICIN
ln!-t.|_|ll lhn ull pump with the! gtqliznl t:n|;le|| 1! altgrtlng
DRIVE SHAFT
the pump drive shah: with the aim in the cam chain
guide aplntlln,
lnetatl the clutch asea-mltlv lnege El-Bi.
In:-tell the riiht cranliww twcr. kir;k_ meter thcrlnl.
muffler and fact negefslde etand eeeemb-iv.
.15-Izlluat the -dluiith [page 3- IE1.
Fill the camkceee with the secemrnenchtl engine nil
(meg 2-1|.

GAS!-'.ET OIL PUMP

2-6 B Dertrt nl lame. May, IQEU

DHDHDH MDTDR C-CI., LTD.
 Hanna.
- ETD LLIBHICATICIN

" <GilliSSlS>
LilBRii3iiTll]ii PIIIIIITS
Use general purpese giease w h i:n nnf specified hare

-""H Jinnl-,-' i:|il er grease ti:i the DlIl'lEl"Hlli'.l'l|1Q suttecite rint

ehciwn here.

CONTROL CAB LE LUBHICATIDN

PEr'lif:ilii:II','_ rIIiii:i::inri<ii;r the thr|;|11_l'g_ from brake
3'-rli:l C l'i-eke cables at their ' upper erictt. Tltu-ruugiiyI
I,-"" I|.|IJ|'i|2eitE Tlte cables and i.hi:lir |;||vi;i-t paint: with i
' Qorniiertlelltr eivaiiehle 1:-al:ila lubricant

ADVANCEFI
OIL FELT CAM THHDTTLE GFIIP
""~

.@ -E
I
/ ~&
StI'i'ii'~iGAFlM I EQQELQUMETER
Pivot BUSHIHES . .-
1
t.ue i=<'ic.t. tit I , I| {'4'
If "'

E Delve CHAIN , i I _,f ' %

l .
.-"

r-;||=t,eii:E (_;_.i._1,|1 II i
I
_ '
Z;-2'
_' .. " CONE RACES
F.--~. -,' ' --- - _
"PI I3-ALL nieces
.
I
l|
I
._ _ I
.
I'
-it ..-
" .._ "

J
,
_, - '__ *' STEEL BELLS

! I .- *'
,'
' I
- - '
~
BFI-MZE ceiii
I 1
' ._1
I
-1-

I-"'\t
i ,1

. I __. __|-'

I-5 r I
. ,I' .'
-"l |i' .1
. Ill If ii

.-'
_. .'
- sine STAND
F PIVOT
ee.-ti-:5 Peeet SPEEDDMETEH
Pivot GEAR
El~i-GIHE

Ll.tiiierif Issue: Mn~|'_ FE]-Bl] ts 2_?

'-EHUNDA MDTCIFI C11, LTD.
 I-Iowan.
cw ~e.~
MEMU

20 Deteeflsseie Mai,-.1530
-IeJHEi-rtirm M{}TUFi EU, LTD.
 %?\I-IONDJL III 2 =
|
s
_,._
C70 Oil ==-EEm ifIlI'l'l= Z2E2 i
q

_,..

SERVICE INFORMATION 3-1 <._DHASSlSl-=-

<_'ENGlNE.1=- DRIVE CHAIN 3-11
_,_
FUEL LINES 3-3 BATTERY 3-13
THRDTTLE DPEHATIDN 3-3 BRAKE SHOE WERR 3-13
CARBURETUR CHOKE 3-4 BRAKE SYSTEM 3-1-Ill
ii-IR CLEANER 3-4 BRAKE LIGHT SWITCH 3-15
FF CRANKCASE BFIEATHEH ILISAi:irtl'i,rI 3-5 HEADLIGHT MM 3-15
SFRHK PLUG 3-5 CLUTCH 3-15

In
VALVE DLEARHNCE 3-5 SIDE STAND 3-16
CDNTPET BREAKER POINTS 3-Tl SUSPENSI ON 3-1?
IGNITIDN TIMING 3-H NUTS. BOLTS, FASTENERS 3-13
SPARK ADVANCER 3-H WHE E LSJSFDK ES 3-13
CAM CHAIN TENSION 3-S STEERING HEAD BEARING 3-13

CARBURETDR IDLE WEED 3-H]

f""~.
CYLINDER CDNIPRESSIDN S--1!}

SEIWIEE II'IFlllIlili\TIUl'l
eemeeet INSTRUCTIONS
n En-glee erl Bee elite 1-1
I Engine nil Hirer sicreen 589 Dti 3-?

!""~. TDD LS
Ccimmen
iv-W! ndiumng wmMh_ B I Q mm gggmjntm qr mmmpgiqiiy eueliiitile iii it El mm effitet hex end
wrench
,i"""-. Ugly; qdjuf H
smite lpplte $|:ii|.ni'i:r E, 1.5 at 5.1 mm BITE!-0020200

SPECIFICATIONS
-1' Engine l=-
|{""'~. Ti-vhttiu grip free play: 3-"5 mm ll-"3 " lIl"l' I"I'
5,_pgi-ii; piu;|_ Fiemmneended speri PILIQ l I c"""*dl'" t""p'B
For WM :|i|.mm 5* rd d Fur lptteittilleiiil hlgh
IB-elciw sc, -iri=i ' !iJB'BEI ri="r-e
u r-re Meat HI] ' i~iei=: ND ' NGK
u1n|=5 cisH LlL':?F5 CTHS ue4-FE CHI-I
IF-
IUZDFSFI-L] [ceei-isi iu21'F$H-Li I ici=|rHs1 [1-ii=4F5R-Ll | [CHBHSI |
ping 5,1, Q55 _. 0,1 |'|"i|i'i ii:i.iI.t2-t - 0.0213 irii
I
.|u 'I|"g|-tin qieiarertcez Ci:ilcl- lBe'ii:iw 35.13. S5FJ
lnh|ltie|"EiIil'\8u5t U.LI 1'l1-1'l1- l-D02 I'll

Deteef issue: May, 1930

IDHUNDA MDTDFI CCL, LTD.
=1 3-1
 I-ICIIUDJL '
INSPECTION AND ADJUSTMENT Q1" ~-
-j I _|_
;_-L

Cnntact hrlititnr point gee: 0.3 - 0.4 rrrr'rtlU.Cl1I CD18 lrll

Ignition timing:
ii-min, "F " nurk ts etec
Ftlltiritiit irt 'l,H?B rpm
Full ll'li'l'l'Il..I 30" etee at 2.900 rpm
Idle speed: 1,500 :i: IUD r|:irn
Cell nder eempresele n.' 12.5 1 i:i.5 kgfmi ltttit zi psi]
N C Chlesla I-1'
Drive chain tieeit: 15-25mm I5i'B1 in]
Fl'iIi'lI hnice IE\lEi TFII |;il.|y; 20- il1mmI3.'41Ii'4iri]
Rear brake peclel free play: 2lIiEI.l'rnm[3.i'il-T1,|'iillnJ
Tire:
___. __ __

Frqrlt Re-itr -
Tire sire - 2-25-1?-ll-P R 2.5m 1-een
Up tn vehicle mpacity l:i-acl an ma,
Enid tire pressure ":5 kg am ml 2.5 moi T
Iiiiiit:i-it lei
up ta ee lie teen l :i] ieeq I _1{.e_ igei ' . =?.-.P. <.=:e
TCJFIOUE VALUES
Rear axle iile-eve nut; IJU - ED I'D!-t HS 35 ll:-lI:il
Rear axle nut IJIJ 5.0 I'iilI'! [EB 38 T1-lhl
.1-,

ff.

a-Iq-

."'

_,_

22
3-2 Detecrf Issue May, IQBC
en-iciitieit. MOTOR i:D., t.Ti;i.
 -5.
I-Inn:na.
[u INSFECTICIN AND ADJUSTMENT

(ENGINE)
Flll-1 LINES
Check the fuel lit-es for deterioration. tieirneg or - '
ieeiteige. Replace if necessary

FUEL LINES

THRIITTLE IIFEMTIIIIH
Check for em-ooth thrniile grip it--ll eeeriirle end
I..IIDi'I1l!llII1'. full closing in iiii steering positions.
Check the throttle enhle arid reeieee ll ii it it
tllttrirlrirateri. Itinltetl oir damaged

I.-I.lhrF|:.:'il: the throttle i:ii.tile lpage 2-FJ ii throttle

operation il riot tmoot.

Meaiulg thrnttle grip free plav at the throttle grip

flange.

FREE PLAT: I-5 i'nm'Ill'31Mii'iI'

Adliuetment can tie r'itai:Ie itt either end of the

thrnitlei -ciehle.

Minor atliustmerrts nrie ITIIIIIE -mm Ilte Upper Eti-

|u:iter.

Adjust be loosening the loeit riiit and turrilitg the

adjullige. Tlghleri lIii: lli i|lJ!'..

|'i.lajr.ir etljtutrtte-rtts are ma-tie et the It-rwirr ildlustrrf ori

the carburetor iifter removing the It-ont -cover.

Remove the oerhiirntnr rl-rhbrr C-Bp.

Turn the ailiueoer to ol:it:iin the speciliod frttrr plott-

RecI'iiecit' the throttle operation.

_ I-

D-ate of lseuii: Mei,-, THEN!

@i"lDND.A MDTDR CU. ITD
 Hanna. fife-.
INSPECTION AND ADJUSTMENT
cm KE1; ~
BAIIBIIRETDR BIIIIIIE CAB LE CLAMP
Chh For rrnunrh dtnitn knob operating lrlriilrt-1'1,
The i1I"lOKB Itnoiei rriust move 5i1'!'I-EiD1I'tI"' and guy
w-tare poaitiorieel.

Arllutt ow turriirig ihe lrli;1iri-n adj|_|I_r:i_Eir l1.|_|1 |_|-pt

the rubber t:e|.1_
Pull the rh-eke ltnob all the iivav our intl matte eure
the holte valve la einaeti Irv moving the carhurntm
choice lever.
Adjustment:

Ffrnov the front i'.1r.i-tree lpqgg 5-2|-_

Looseii thr. cable clarnp and pull the i'.'IblE ca-$i|'|g iup
it-I" EH "1! Choke valve is fulli,-' clotted. Pugh the ADJUSTER CHDKE LEVER -_
l'|i-IKE I-"01! I" II'IiII IJB llllr the choice valve 15 t-i,i||-,.-
even he checking for t-em-m |1.'1a._i_r|=l |_-,| D15
tiii-r:It

Install the front cover.

f/' Eterliient are oteervee covert
Alli BLEIIIIIEII . at pr ~,
Rernovri the air cleaner -cover tap nut nntl cover. ._ '- I __
Remove the air cleaner ulament nut and element,
. ---"'-
_f__ L;
I, _
| . -|' ' .--ax
.
I. .L -If_ _I I | _ {E-jrf
.e
. ._,.- I , L I.
ll I ll-In -:5. I!
I ' . I
l' I all

J.
.'I I-'| I {ll CAP NUT
I
| I NUT

ELEMENT *-
CIHBI1 the li"lElf\lii'1Ii by tapping It lightly hp roman
DUEL Blow Iv.-err the remaining duet he app-tying
oernprciaeri .elr from inside the element
REF!-fBB the Elurnerrl II it is eitceialvely ttlriy, turn gr
|'|_-tl. .
ti-iimeged.
Il'IB_B|I the Hmlnr iinicl air cleaner cover.

3.4 F =~ EIEIIE Ell I5!.'i.ia! May, TQELI

$'HDNDA MDTDR CU. LTD
KHONDA
J; [:10 INSPECTION AND emuwmsur

BIMHIBISE BRELTHEII IIISA only!

I BHAHKC-Fl-EE BFIEATHEH
Ha-rnmrq t-he plug hnm the drain tube to drain , --Deana TUBE
deposits.
' 0
lrlstrlll the drain plug. -._\_____

NOTE ax {'
' Snr-ric:-u mrn Treluenth,-' when ridden in rain _-
nr at full throttle, Ur if the dupotil lnunl I-um .-
l he nun In the drnln tube transparent section.
.

"-_;-\_
| I -_

||l
DH-NH PLUG

SPMIK Flllli
Glam mw dlrt frern around the sunk ping hue.
D4a|:e||1ne|:rr ma iperl-r ptuq pep. .6D.?mm - I
IU'.24O.2B|n| f
Harnurve and diird the ipurk plug-
Me-murl: the new tperh plug gap using e wrre-type
feeler gauge.
SPARK PLUG GAP: 0.!-0.? mm {D.f2l-.D1'B irll
Adjust by bending ihe tide eiactrude carefully.
With the plug washer attached, thrubd Th: new spark
plug In by hand tn prevent crussthleadlnq.
Tighten the apart: |:iL|g lnmhur Hi lJ.rh'i wllh u
snark p\Iug~,w|'anch tn compress the plug washer.
G-:mne|:t the spark Mug Clp.

HEBDHHIIENDED BP|l.RlIl'. PLUG:

L '| Clnldian ND!
F Smpnderd ueucm-ls 1t:Ft1'H5!|
rm uzers 1U22FiH-L'|'
For nuld elimlte uni tau tenant
re-1 sc. 5:1 Fl NU UIBFS IUZUF-ER-L1
Fur mar: can in-mar-ml
L
lrlghql-lull rldlnq } unuz-we {LII-I-FER-Li

25:
Due ntiuue: May, 19511
EHUHDA HDTCIH 10.. LTD-
3-5
 rrtsmsc-rrutu mu ADJUSTMENT
I-ICl1\'l'ID.B..
[III]
F-?;.~>~. ~~
.-_-

VALVE |}LEllUiHBE MARK

I
NOTE i __i_
lntpeet and in-dlut-t valve eleatanne whiltr mu
;
uglrhu it mid [below :i5"::. 9-Fri J
Flumtwrr thn manta-ct l:i-reeiter mini mover and value
lilili-1'.iIIiIl cape.

"ne Ih irihhll! wuntercdu-trktvise and align

thn "T" l1|.iF|'l. with the lncln: merit 0|: the left
crankcase uui.rer,

F-lake sure 1110 urttun in nr T.D.C. cm the t!OdIZrlEl-

slun strnite.

IITIJ
_""'.

LUCK. NUT
i'-lit:-ck the valve uleasan-|:i.u by inserting 5 ieeler
gauge helwticn the adjusting ternv and valve tttrm
'i|I'.i. LVE GLE.ltFUlNC.ES
INTAKE: U15 mm [0.DU2 I'll
EXHAUST. D.lJ5 mm [H.002 hill -"-.

FEE LEH GAUGE RDJUSTING 1-.

VALV E ADJUSTING
,_,_

-Pvcliust by louse-ring the Iruzk nut and turning the

niiiustirtg anmii until there is e slight tun; un ttw
feel-er gauge.

Hold the m:iu='ting mew and ght:-n Iha Inrti, nut,

_I-
Henhenk the valve uluurunce.

Install the I-l'iTi1CI hrttel-ter point web and Iraluu

lruncctinn cups.

.3
VALVE M1] LRSTEFI B \-

3-6 =6 Data Of Issue. Meir, T930

r-

I'H{}i'tll2i.\1 HIUTCIR CD, LTD.

 H %;\I-I(J1\lI).Bt
J [III] INSPECTION AND ADJUSTMENT
1-=~
BIINTABT unmet l'l]lllTS _
Ftemuu-| the cuntuet hweeiter pnint never.

Clean the izireel-tar |1IUirr'l turleues with an tile-ctrurll

content |:lrniner tn r|:inCi'n'E any uli film ctr riirl.
1-"""

KT

r'"

If the eunuut turfauu are la-wl hut pr:-,rl4h in r.:-uior

@
or are 5|ighl1'|I |.tit1ed_ file tl-rem lightly.

ll the paints have a nutiuulhie tritnrler nf mm-ll

irurn une surface tu the other, hm evidence u'l
___ ' F ie liqntly
(""1 heavy arcing. u-r are worn tit an angle, the paint set
U 1.0 rnrnute |ililIlIll'l
thuuld he rnnlltbd.
Egon ___\\. SED and cnrreuun

QEJQ
UHSEFIVIEEABLE REPLACE ll wen-i IT. an angle ur int!-,r pitted
1'-\

,r"""\.
Flcitete the crnnlcshaft uounttemiottlcvuitta. and malt!
sure tluit maximum pnint gap is |:|i_3__4 mm
lD_ElI2-13,1116 fnl with a feelnr ll-1'98.

if the point nap lrt irir.-r.i.rrer:t, iueeen the uuntnct

lreelter ntete locking -wrrtw! mitt adjust the point
F Q59-

Tight-rtn the lurking screws and ruuheult the point

Q39-

Inaiiutl the euntect breaker aciint emitrr.

.-""

If-\.

Detauf issue. Mat. IBBD

EIHDNDA MUTGH 00., LTD.
 HONDA 1".
INSPECTION AND ADJUSTIHEHT .-..
.e_

IGNITIIIII TIIIIIHE LIGHT '

i"-IGTE
Puritul lhn eonttitrt breaker point gilp brtliecre I
this iIIZfi'ilI1I'I'lTt inane 3-?f|_

STATIC METHCID

H-Brriovlt th= contact breaker point cotter.

Diiunliri the Bit,"l."|.' breaker IBrmir'\a1wire_

Connect it 1:=orrtir\uit'qr light tn the contact hrearter

termini! wire .ettr'i to the positive it-l tetrninal of it
l'\:ll'|,-' charger! but-tart.-.

Connect the negative Ii-1 better; terminal to an

' i - ' -=1-!!'_;l
I 1 -

it .-at-.
-.

|_
engine ground. BREAK EH WIF-iE *'~.

Hotaiing the hate ptate counterclockwise will

retard the ignition tirnintt.
INDEH MARK
TF1-E !ii|'i'i|'n|t| I5 correct if the light qua-5 nut u-,rt-|.g|1 both
mrarita align

ADJ U STME NT

-F-diust he loosening the twu eentact breaker bate

plate screws anti rtJIB1|1'i|]thl plate.
Fintatinq the ueae pint-n ciockwise will a-dt.-attca the
iq.|1]1'iCii1 timing.
F" MAHH .-".
F1-mating the base plate countarciocitwiee will
retard the -grtiliort tirr||n|],

Tighten the base plate screw and meheek the BASE "'
ignition timing and point gap, P -__ "
aouartee --' t-T-Q3
Disconnect the light and iuttertr.

Connerrt the Bit.-W hr-aaitur terminal wire,

In rteli the contact breaittit point ccruer,

ei1o_

BASE

3-e T
1|-
28 i3ete'-trf issue; May, IBEJ
EHUND-\ HUTDH C'U., LTD.
* 3-. [}][| INSPECTION AND ADJUSTMENT
N -1
.
-_"-.
D"r"NAMlC METHDCI
iWiTH A TIMING L|GHTi
NOTE
Adina: ma contact hriker point gap -licfuns I
mqklng this a|:iiu.1trnu_I_1f-_

..i
|r_\'
Hemm-e the tic-ntact lxaakar paint wwr.

Connect i tachumete-.r and timing light-

Srm ma E-EIFIB and in it idle 2-3 min-urn

1"-
f|'\
,A_d|u=|.t the ldlq id if nacassarv.

IDLE -SPEED: 1,5!!! :l: III] rpm

Aim the rirning light at the timing mark.

u""'-. Thg mlng is; current If thn "F" mask nlipu with T|1,||~G |_]||3l-r1
1h|1 index n'|-BHL
Acljust an. demcrlbad iur thr ilillnt math|:|U. ll "BIB-
airy, INDEX MAFIK
imtill the mntlmi |JD5ni cunm.

SFAIIH RIIIVAIIBEII
Kl

Rumuvu thu uuntuct point muar.

."*'i
Gunnunl. u tlmi-rq light and ta|:h|:l-mater.

Start thu angina.

Hr-ng Enql spec-d In 3,1lJC| rpm Ind =l'1BI=l\ 1l'Ii1 Th"

indml marl: is tletwn-art the iull aclvanci mama.

R|:_i|J' my nju-ancar aasembiy ii IT is ni -ll'lII-

Tluninq prnnnrly. \ 1
lnqull lzhu mnuct bwal=r [J-Dll WWI-

Elili iiiiilll TEilSll]il ADJUSTING '.

;""'* Start the angina nnd ll-.1! il mil!- in

Lanmn Ll-in mm |;|-mun tel-uiciner luck nul: an-cl lmiit

imit.

Thu I.Eh5lDI"li?|' will automatically position its-all TU

1"- prmuglq zhq cnrrelti ulnai-::|n.

If 1-he 1.-.|-min I5 :l.'l l"iCii5'|' rumcwn this mnainner plug.

Gradually acre-w in lhl: inrlqinner odiusting acrnw
until 1h|:r cum chairl :5 rm longer "Biw-
lnstali tin tansinnur plug.
.-I '|'|gh:5r| tha tuniinnnf lnilk l:n:Ht and nut.
.--'
TENSLDNEH PLUG LDGK NUT
F,

l_
Dam u|1"1i5u':: May, IQ-BB
QIHDHDA MCITDH El.'J., LTD.
H 3-9
 FNSPECTIDN mu ADJU5|'l'i'lEi'iIT
HONDA.
[u .-F-.

BQRBURETIIR ll]l.E SPEED

NOTE
' irdperl and -ndiust E-1Eli'iJLl:l.I.1r iijln spit-gt: aimi-
ilii 1:i1|'l|:l' BiE E||"|;||1::1mi!|1t|3r wqhln mg |
cifimliu-n.
' The :i1gli-ii: must he waii-ri in-r i}D;Ll|'I1_'E i :l.li=_-
iriiipa-i:tii:in ant: ailjuslrnitirrt Ten riiiiii-i.it<i:. ti-|'
atop an-i.l gu ti-dint; is siifiiciit-iit.

I?-=1nr'ai:t a tai::hr.ii'r1i_-tier.

Ili'i1n-i-i ii|:i the Eng-Iiie. :hii1 mi: trarimiiiami to "

l\lElJTFi'-ii_. ind lwiltl ihr motorcycle upr-i|j1t

i|"'.5PlIiI un|.i aciluat iilii: sprint-rl witli Iii: thmnln L|Jp

icrmiv, '1l'Il'-lI'EIi.lHl\|'. THROTTLE g? SCREW
'1
IDLE SPEED. i_5i:iu :1i:iiJit>i1i '

CYLINDER BUIIPRESSIIIH _ i:iiii.iiaE

i"il'irm up thii l!f1[Ii|H!i.
Strap thii i?l't|:|iI'l-B Ill!-ii rr:m|.1'-m mt: iparii; pig;-Q.
lnriu-"r The cnmprassinn qaug. -

Pull" the nhnlta liiitlb in. '3

D|Ji:|'| thri thruttiu grip hilly,
Drank the eriginrt with the I[i'TE|' mutur.

l'FE_ _ ________... __ mi
'3rI1"| ll?-B Win: i.intli 111|1 DBUIIH raadirig i|ti:i|ii;
rising, The l'|'li-iIiil'l'H.|I'l'1 reading ii iimglly '
l iEBl3i'lHIIIi within -II-I seconds. I

COMPRESSION PFIESBUHE: 12-5 ii1;tiiii;ii=-iiil -

I171! : 7 Piii ___

Low i:i:ii-npriiuiun can he I:-tlutnd lay."

- lmnrupiar 'i.'i1l|.re ilriiustmtini
' '\."si-iii: lnakaqu __
' Biwirirn -::windai' heaii 1_|-iaiiluii I
Wrnn uiztmii ring i:ii cirlindiar
Hit uni-nprnsaiizii-i cnn hi: aunt! by;
' C1Iii'hrIn i:ia|:ii:mts in Dmiiitll rhiirribar ur on
1+": pistrin c-rrrir-1'-

.i-i,_

3_ 1 0 35 Date of Issue: May, IEIBU

'E.'HDNCI.i5i MUTUH C'U._. LTD.
 Eh HONDA
.~""' C10 INSPECTION AND ADJUSTMENT
.i---
iIili\SS|S>
DRIVE Billil
INSPECTION
F F'l:iii:e the iiehiule on its side Bland and Ihlft ll-E
ttarlsrnieaio-ni itttu neutral. |5-35'|"l

Tuin the -ignition switch OFF.

Hi:i-i-ii:i-.ie the lLil"i\'E' chein inspection h-ole mp.

.i-'*~ Move the lIi!"i'li'I' -ehiiiin up and tlown by hnntl imrl
iiiieasure the amount of :-lat:-in

SLAGK: IE-E mm i5i'B-'1 in]

.I-H Adjust if nuoeeearv

ADJUSTMENT
H-.=.mi;m the rear iiitli; |'iiI'l ootti:-r p-in and loosen tlhu NUT INDEX MARK
||:i,l5 alrirl :ii:|:'|'t: l'|Ul;l.

Turn the iiiiliutiting nuts on both aides en equal

number i;i'|' turn; to obtain the specied oiitain slant.

.|I""I|i.\|i
CAUTION:
lei-'i?T.-.ii.-mriiiii iii: M lmm i
3;I|f1!.;.f;|'g-r meg: with the urrrtr gr1ei'1rm{i'r-W 0-I'll
riorii iiiilirt iii: the :wl.ri.iriirm.
Tighten thir sleew iinio eiiile nuts Ind innlll I new
cotter pin.

ton ouei
steeve NUT: 4.0 - e.o tum tee - as mill
.-H
AXLE nut: no - E.D iiiiii-iii lee - es ti-ll:-l CDTTER PIN AXLE NUT ADJUETIHG NUT

Tigjiti,-,-|-i the a,i3;||uetirii; nuts

Rent-iei:;lc drive ~l!il3l slack iir-ii:l |'I'\ill." wheui iotatlon. LEFT SIDE COVER ELEE-"
i""\i
Check hrnitg pad:-I lr|:i: plat; lIlt.i BCi|1..l51 ii l'li.\l;B!iiilI"li'.
Lulairli:-ate the drive chitin wilh B Emwfiieily
iivilihi-H rlrivr i1i'i:ii|1 iui.|ri:e.l'l! through i-PH iliI!I=-
[E

CLEANING
.-*""'*
Whg-|-| the driiii; iahtiiti hi:.~i:iri-lei EIi'.I'-El'l"lE|'|' dirty, il
5i'li_'.iEi hit rv:|'|1'||;wu11 g|'|i:t i'.|I;\;t'im:i' print In Fl.ll3i'r'ilI'E1il"1
ea followi-
Flt-ii-itrwu the frame lett side cover-
Remove the drive riorocirllrl DIWEF.
Fit:n1i.wi: the two tower chair: r-air: tin-lie as-iii lower
/"' oheiin case.
Flemt:-we the upper ohein oase-
Hemcwe the .-nilq nut i.-.tl|:teI pin end loo:-on the iiiailii-i
hut, eleeire irut and atiiurting nutt- SFHDCKET LCIWEH CUTTER Fihl!
it"- CCNEH CHAIN CASE

Date nit is-.|m:5 Mlitf, iii-U

@HliI'iNDF\ MDTUH Cl'J._ LTD.
 I-ICl1\'lIIJ.H.
ll'il"ECTiDN AND ADJIJSTMENT
urn '~.r_..J .--I-t_
I

Remove thrl rnetter linii ieluinlritt clip and mesh: .1 I \

i|rik_. DFH'u'E EHAIN MASTER LINK II i\5iiHl?-H3 CLIP

HE'l'|'hU'|i'E the drive chain.

Clean the drive ohein iI1 non-flammable cir him -

flesh point atihiant witli iii l|||.l5i'| and iiluw rt ti; dry.
lneoect the i:lrh-it ch'eii1 fer tr,-|ar er d'r|'tqg|_ Hiphgg
anti i=l"-iiin that is iixcimivaitr worn or damaged.

__,r"'
-HI
I

lnipeot the i:i-rniir and driven tpii-ecket teeth for

excessive wear or damage.

Flepieitit ii nccaiaery. IEAH

!!.3lE___ L
Never iiiili a new cirivi: chitin on wot?
sprockets ti-r e liviiirn chain on new strrttcitctl.
DAMAGE 1*
Both chain ii-id apvoclte-tii mutt hri in goo-d
condition, or the replacement i:J1aln or
torookets will wear rluldlv.

NORMAL
"i

---i'1
Luhirl-i:at.e the drive i;hiaii-|, NHEUTIDN OF __ -|-__; |
'*!'TE __ _____ FIDTATICIN . fl ":.'.
i Coiinmercltill nrrrotoi woe drive chain lubricant '-".
iii rocnmmnndad. '---___:

instill the -rirlva chain.

.-.- .-.-'j
l
'_ - 4- - i
.'
'
.I
UTE - a . it lwistea -"
Note the direction of the meetier iii-iii; ttttuii-ting
oil P~ L __ t
.
- "ll!
-I
-

"
F]
. F
-_. '1 -"
LINK

ill-lA'lN
Q. '- ,__
.
".

Install the upper and lnuiicr chain cases. drive RETAINING CLIP '-
sprocket rm-er arid liitt aide oover. I
_r\_
---. I
r5it!]i.ist drive izhiiin ii.liiii:lt lllhrqe 3- I 1 |_

liihlit briw FIF-'l'i|Ili lrire olatr and 3L'i|Ll5IT, ii iteizizsettry. ' '
d_l-

3., 1 2 32 Date of Iiatia: Matt. TQBD

QHDNDH MUTUH [5i:i.. LTD.
 _I\.
1
1%) HONDA
INSPECTION AND ADJUSTMENT

BQTTERY am:-um: CABLE Pusmvs r:.ns|_

Rer-W thtr rlght HUB ucwer
Drs-connect the gr-r:um;| mbiu at w frame
D|sc:nrmH:T thu pusutlw cable at thu buttery tnr
1--.

Flummle the l.1u:1|-ry hold-nr plate

Ham-nun the buttery
Insptt ll":-E hi!-lrry fluid lgvpl
Whrrl thu uuzl level nears uh-_ |uuI.|H' lnl-I'l:|| rqll w|t|-1
dlsflllad, vmar tn u uupr-r Irv-al
1"

-"1-]:|d uni? d|itliTBd want Tap matar wll

-""*. | hurtan the 12-mes I-ll: ul thu barlaI"\I'
BAFERY HDLUEH PLATE

The mmerv dn."IrrHy.l' mnmtru mrjurnr arid

Frurmrynur eye: skin, and r\|l|Eun';.
In cu-we 1|-I rmrmw ush rimrougidv ma
mm and 1-mum-r a dorm If den Iroiyre gen
in your emu.

F
Replace ma ha"ter'y |fsui1at|n1 hqrn qr $ed|mant5
acu.|-mulata on the bntlnm

Li
H" LEVEL LOWER LEVER

BRIHE SIIIIE HEM!

F Hapiace Lhe bruku ah-01:1 I1 lhn anuw nn the
Induntor plaza ahgni wh the mark on lhl
brake panel when the he-at-cu |: nppllcd

f'-.

f""~.

Dataof lama Ma-,~,1HBU 3

F--i-HCIHDA mmun cu urn 13
 H0NnA(,T;Eg=%.'
INSPECTION AND ADJUSTMENT ETD -1-
/,'--
*1.

BRMIE SYSTEM
FRONT BFIAKE LEVER FFIEE PLAY
Hiuuiura Ihq: Irurlr hrukea |::u|:r 11:1: ||lH|1;' Bl 111E [||J Elf
the brak-I: lcwr.

FHEE PLAY: zu-an mm ::m1 11411-1!

l '- 1!-Urn:
1;!-1"'lnl

1. _"1

ll ad]-.utm|.=nt is necessary, turn mu adlultlng nu!

u|'|1*i1 the c:|;|rr|:\C't1'r:E play is obtained.

B215. _ . _ __ ___. _
Make sure the :uT-uut un tin: adiusnng nut is
mum rm 11-m brak irrrl pin nH|,~r making rul .-3
free pia-v adjuitmant. _
I-._",___

HUT -'1

HEAH BRAKE PEDAL FREE PLAY

Chick lh-n hralu pedal free phay. "N

FHE-E F'L.P\"I': Z9-EU mm (EH-1 1M-in}
* I

-'"'--.

_"--|\-ZIK _\.
E ._-1'4"

3__1 4 31 um: lnue: Maw, man

IEEHDNDA moron 10., LTD.
 ' - Hanna.
.---
/_.~ BTU INSPECTION AND AD..iL|'5Tl'l"i ENT

.-I-r-t
r

if atljurtrirerir is r-.u:r:eseary, turn the Bdjuiling hut

until the currnrrt free play is obtain-ed

l-HJTE
.-P
Marita iurr: tHE| r:|Jt-r.n.lt i..li'l the Brliuiilng 1\l.rl l5
seated cln the brake arm |Jlli after milting the
1in;|l free alav adiuttment.

BRAKE LINKAGE
Check the beirk-5 cable, brake ru-ii, brake perhl and
__r-\-
hraite lever for louse connections. tnrcustivn play, ur
|
damage.

Repiam ur rrrplit il Fl-EG'B5i-ilnr.

1'-IL

BRAKE l.lE|iT SHITBH

HRH!-CE LIGI-lT SWITCH ADJUSTING NUT
912.- _.... . . ___.._ i_
Perlurrn this arilusti-nent alter uidlusting brake
. .r?=1=.'=' "r".P-='r -
rldilrxt hhn trait: light iwitth bu that lhrr Ltrlite lnght
will light when the bruit-I pedal I: |:le|:|rnsw|:l nr1rr.iIiw!
.1"""'* i:||ai<e tmgins engagement.

NOTE
' DD l|C|l turn the switch t|r;||;l'|r, .,_
- Thu front brake light 5-witch tic-es not require
n|J||.u'[r|'|i!*t|t.

Adguit by I:umirI;| the swit|:.h acllirstln-g nut.

_ 3
|.f"'\.

HEADLIGHT lllil
.'5\r.l]L|.lt '.ni:r'll|:.!I|1|r !:|I|r lLl'|'|'lI|'i thn |mrt_r'|;.al adiuiting
.--'_"- HITHW.
HORIZONTAL SCREW
|
Turn the lt.l]|.ul.ing 5f:r|:w cluckwiw tn dlnjrt thl
helm up.

P-ll-I51 hlltih-'.|nt||.l|'|' by tuming the hciriztrntil aci-

lur-ting screw.
Tum the Hrllusring rcrrrw clue-lw.n'ne tn direct the
lr beam Iowa-rd the teft aide oi litre rldr-ll,

HOT_E_ _____
I -diwt the headlight beam as epecilted try i
i1:-ual laws anti regulatlnurz.
F-

' .-Ill frprrrph-'r'i'_v rr-n',l'r-tvrtrd l'rau:i''g1'r.r nwmr Mrhd Fl"

trncrrming r.|'nI'r'er:, or Ir nun; ftrri In Ir};-hr the = I

if-I. ruau fur i: mfe rilnu-are _ VERTICAL ADJUSTENG SCREW

D;tl'|.1|1l inure: Mu-,1, 195D

EHCIHDA MOTOR CCL, LTD.
35 3-15
____
INSPECTION me nimusmenir [,']l] @i
' '
.-._

"'1
1
I

BLIJTBH II===-"Le=-r rwr

Stop the engine.

Lciizriien the iidlur-ter lock nut and tum the i:ii.rLi:li

aeliut-'l:er rtlri-eiiiwiee tine turn;::ii:i iint iuri-i excessively. L
5|BWi\-' l!l.lfi1 the ii-iiili-irtcir i:ruiintei'i:lu-clririile and step I
vrlien I'B!liIB1!|2I is-felt_
Frein-1 this pi:rin-t, turn the ed'puirter i:ili:i-i:i;wiee 1i'H to
U4 tum; and tighten ti-i-ii led; nut.
Check ti:i see -that the elutieh I: not slipping and is
iIi'l'-tDi!F|"i" dlr-engauirig. ' 1|

ADJUSTEH I, -1

Sill! STMIII
Cheek the rubber pad for dewrloretim -nr wear, Il l | _ _
Hriiece il' env imiiiir exceeds tci the were line er ' l
i|'i't'.IWi|.

.NDTE
'i'i'i'in repieclng, u-re a rubber 15511 with the - .--1

r~"L'ELE5"i1.59_'l2' 9ii, W _

O -='.'-.

Check the eidir etenci spring I-er image and inn cit
_-.,_i ""1.
teniicin, and the side Fund I58-I'll-lJl'| fur treiidum tit
muiierrientiind bH'iriil|l'lg- .. .
NOTE
l Spring tension it eni-res! if the measurement!
fail -iiiithin 1.5-1.5 ke [13-5.5 ihi Wl'lllI'f -\-

pulling the side stand |D'WI' -end with I :r;I'|l'lg

[Lain
ti Li. ""
'J|'i|i iiq Ib

, _.
r.

SPRING SCALE

3_1 6 35 Dlteul In-ue: rim. ieee

EIHDNDA riiciren GD.-, LTD.
 HONDA
i""" .
@. can INSPECTION AND ADJUSTMENT

siisrtiisiiiii
.52.. .,..i i-i. .r.t~ .. t'*.i7i '.:.'it it-hit rm.-rry =........-......=... I
Loose, worn or uimrmiri-i iurprnnmr purl!
lrnpitlir veiiiioiie .ri*it11iii:ji' anti control.
F
FFlCil-.|T
Check the action of the Front Torin-
Fiepiaur. demeptl cuitipiareents which eanni::1 he
repaired-
.r'*- Tightan all nuts end bcittt

i"""*

. 713-1
L.uhirIoireri the 5i.|1Bt!l15ii'll'i li'll'i pi-'r.i1L

_/'-.
____ f. .1 _ .
-_-

oeeriee ITTINGE
_.-""'~.

HEAR
r"\ Plan; ee |'|1:iti;ir|;yi;:liJ un i: iupptilt hii raise thE fill
wheel eff the ground.
Mow the rear wheel Hizieeirriirl -mih few: in HEB iii .
the ewingeirm huehingis are worn.
Review ii eitonssieelv wtrri-. i
e L _
Chqit the sheieit lteiorlsere for ieaiu or damage.
F- 'l'"i.@'ri:en all rear eueeieneion niitii rind hutlu. -'- '

_.-"-.
Dill: I'll Iniue! Meg, IQBD 3? 3- 1 7
'EIIHCiiNEI'Fi MUTUH C'D._ LTD.

E4
 Hanna. T
iiiisieerrriciiii mo ADJUSTM ENT [:10 ,--.

NUTS, BIILTS. FASTENERS GAUGE

"\-

Ehiitrit I-hei iiii chassis nuts and hiallrt in-1: tiglrtgi-mu 1.;
tlrreret toeque ireluee.
Uhttit Hii utter pins and safety dips.
,_
WHEELS. SPDIEES
more
Fire pressure shoiilcl be cl-ieiriied when tim:'|mJ
COLD.

RECOMMENDED TIRE FHE5$I.lRE AND -

__-

TIRE SIZE:
_|-- -"'
Fru-nt Rear
Tire site 2.25-T?-4PR 2.50-1?-EPFI .--u.

Cu-ld tire Lip in

preesuge uehiidq
imam tfw 1.0 ital 2.9 mi; SPO-HE NIPPLE Ii, 4-5 Ii 5.1|'i\i'!1-
iiae i-cg,
ane ii:-l
Up to
eehuiznn 2.iJi1Eii 21: izai
N | ibilelrl
'""\
Ch-srilt the tires for cuts, imbedded nails, or umr
dserp ohlects.
Cher:-it the front end rear wheels for trueneu,
Meesum the tread depth at the oanter i:if the tire-Q
Rlfilrii the tiriu if the tread depth regal; the
following limit. i

MINIMUM THEAD l.'.IEP'l'I-I: "F-,

FHDNT: 1.5 mml'li"1E in!
HEAR: 1,9 |'|'||1-| 131331;
Fletlghtim the Wl1lIl1'il tpeiltes pmriodieaiitr. -r-.

STEEIIIIIE i'|El[l BEARINGS . - -i -\_

NPTE . I-._,__ i_i In

[ Cheek thlt the ountrnl -eiihlns do not interfere l
with handlebar rotati-i:in. -4-H,

Raise the front wheel off me gr-uunrl,

Ch-i:i::it that the heniiletiar rotates freely.
if ti-ii! handlutnr metres unri-ertitr, binds, or hm
vertical movement, ediust the steering heed betting
be turning the :i.tiIi.tring heed edlurtirig nut (page
12-IHI.
tfjvg
-I
HEAD BEARINGS

3... 1 B 3'5 Date of issue: htay, 1_QEiii

EIHDHDA MUTDH tre-., LTl'.!i.
 /T HONDA
@ Qi) cm
_ MEMU

.-"_'\-.

r"""--

I .|-'-.

.|-I-

ljlqm nf lame: May, 1980 35

EIHDNDA MDTCIH 26., LTD_
 Hanna.
FUEL 5"|"STEM cm K -\
Q; -3,-I
)-
.,.-

If

I /W, ;

I
_ *-._ ==:...
-__.| .*1,0 *~_=~_";-
"--T:--. -. "
-" 1
3|. -5-.
% %%'\
I 'I'
|-I I!
.___?
\_&
_"\-\_

@_;7j/I)
O@
\=5@~j E
-a 0' %
a

4_0 no Dnlq: -:1! lmm: M;|'y'_ 1BBl,'_;

ETHCINEIA MOTDFE C'O., LTD.
,I""*. 4. FUEL SYSTEM
Tm

SERVICE INFORMATION 4-1 THROTTLE VALVE ASSEMBLY -1-5

THDUBLESHCIUTING 4-1 UAFIBUHETDH INSTALLATION 4-6

F-. tmneuneton nemowu -1-2 FUEL STFIAINEFI III--E

THFIDTTLE vnwe DISASSEMBLY 4-2 PILOT SCFIEW 4-T
FLOAT END JETS 4-3 HIGH ALTITUDE ADJUSTMENT 4-8
BAH B UR ETCIH ASSEMBLY I-4 FUEL TENN 4-El
(TN FLOAT LEVEL I-5

SEIWIEE IIIFIIIIIIIITIIIII
r"' GENERAL INSTRUCTIONS
I Use caution when working with gasoline. Always work In I will-vlmllntd mun nrtl um? I-In-I tprili DI Oprl f|il'IHI!-
I- '|".I'h-on dlnsmmhling Iunl Ilfsllrl nl;||'l:_ n-mu lho loonllunu of me D-rlnqa. Fieoluoa them with new onui on rnaisefnbly.
I The float howl has a drain ol-u|] that I:-an be lo-oennod to clrlirl rcslcbunl qnmlirln.
TDD L
Common
Float ga-up UT-I-I11-IHIIEIIEHII

$.lLEI+l\T|D"5 -
.1-"'\ .F."1 __ 11._-
Venmrl die. 14 mm IEIL55 inl hi

_"=.fF'.'!lI.'F?3'il_!"' N 9:- P'B-E211 PEIIIEC

Float level 1Iil.T mm {EH2 inl ii
Maln iet _ ___ IE *3
5-low put #35_ -___
-i-
_
_
Throttle valve #15 .

-.|It needle TEA 1'26

F Thmttla -grip from plw 1"Bn1rnIl.l'ElIl'-IIIHI T
Plim mrew |n|1|.l;|l' u|:eni|1g Seepuge-L II -I-i

(1 TRIIIIBLESIIIIIITIIIII
En-pin: uranlu but won't run Ftnunh HI: Llln milturl
1. No fuel In tank 1. Igniorn mlllunotlun I. Clogged fuel iuti
2. No fuel to carburetor 2. Idle speed innorr-not 2. Faulty out value
3. Ertgil IICIDGHBI 'I\I'i'II"l Full] 3. Carlzurtur rnalfunctloo 3, Float level low
4. No spark at olug 4. Funlconlirnlmrted -I. Fuel up vent |.1lm-.Iu:=!
Ilgnition m-alfunotlonl l|'i|firin| dturlng mobliurnicn Er. Fuel etrainer screw.-n clogged
/" E. Air oleaner clogged
I. lqnltlnn malluncrlon
B. Flestrlotocl fuel line
B. Intake al-r hank 7. Intake olr leak
7'. I-m12Il'|Jl dtoltn opnratlon Bldtllring B. Air 1-unttuhn nlomnd
B. lrnrlropur throttle on-erntlon I. lgoltlnn madfunotlon
2. Carhurntor nt-ulfuottiorl Rich rnhttllrl ,
Hard Illrtlng II llailinq liter nurq 1. Clrnggtd alrleti
1. Improper chain operation "'5' |!"'l"'""'3'I* I'H""*u"I'I 1 Faulty oat veliue
2. lgnilion maliunotion I'll P""l"I|1l| l""|"5""\" 3. Flr;-.111 value tun lugh
3. C-arbu-retor rnalfumtlun 1- Fuel witel" M9986 4. chum mm: closed
4. Fuel oontmuirumd 2- |El"i|5|1" ""|"""|'=""'" 5-. Dirty air odeaner
5. I|1I.BIt1& alr leak
Fl. It-He speed incorrect
F
Date of Issue: May, 195] 41 4- 11
I3!-I.lP-IIII-'5. MDTDFI GU . LTD
 .- .__

HONDA I.--"
FUE L SYSTEM BTU ~.?;E,x,.-
I_

BIIIBIIHIETIIII III-II|Il]\'lll Toe ao|_Ts

|.:rr' |l1e iuel ~.'al'.'e DFF. T
Dr; in rg5i|;I||.:I Iunl Into a oont.a5rIer bv l<=I1=1=|r'r9 11-B
d|||| iCfE"|.'\1.
HBITIIJ-'\'|] thn hml val-II! I'1'|2|J'l'l ITIE tT?ll"IJUh1h-"f-

Inn-n;-r| the choke o-abln clmn H-or-I I-|i5\I~11E4;1 Tl'""

oholu: |:al|Ie.
Loosen the air cleaner cr.I|1n|rrr1i-*9 !ulJB band.
H|5||'m'_;I.|e [h-3 |;||;|I15 5r_';<:urI.||g lI1E |3=&l'IJUI'E|IIIII' ll'l lhlf
irltnh: piou-
Llngergw the ca'rl]|,|rI:T-:.1| t1J|.|- BIILI |JL||| the 11IIFII|'lIr-'
vol-re out.
Hemmle The oarburutor rnc:-urltiug lmlti B1'||:I ear-
I_1|_||'l"?'\t'ZIl. //
CHUKE C-ABLE E-END '

T|'IR|]TTlE IIIILIIE II|5l$5IlIB|.I

Fllrnrrw The arhurl.-1or top and throtllu waive.

_,_

SPRING -
Compress lhe tltronle valve sorlnu. and mm-we 1I'|e ' J
throttlo cabin Itnrn the lltrtltlle '.rBI\|E gro-zwe.

cT\aLE END

4_2 52 Daqnul lsaue. May, 1950

-El HIJND.-5. HIITITDR CU., LTD.
 /' I-Ionrna.
If-\_ ~;.:.j,l cm FUEL SYSTEM

.-Ft--I

TI-FFI-OTTL E VAL q"E NEEDLE CIJF

I'Iarr'oI.'r~ the ncaoln alio Petr-I"-er. I
Fl emoue the iet needle anrl ciip. I
I
lr.5CE|3t the Ihnzrllle value al1r;l jel "IEElIIH' l1:|r rI|rl_ I
I
H"-r-ntchn-r.~ or weer. I

IF
-
I -_
.-.;-gt
-_ . r."
P-
,r"'f l I
M"-" JET NEEDLE
/ |
NEEDLE our
' RETAINER

FLICIAT F LCt:\T P"|I~l

FI.IIl\'I' MID JETS
Remove the float |:I|ernt:ar am-I null |;;-ut the gat pi;-|_
Fh'Imrwa the float and -Ioa: valve.

.r"~

"JP-L

lot:-aot the float vulva and 'iE=El1 For r|roo~aa. nicks or

elepuaita.
Ins-pact the float t'al'.'e ooeration. J I.
I
1+] -"I1-I

1'-\ ir.-" 1'

ft-.I ._'1'J."

. I 1' erg?"
~f- ti
" I '.
I I!
,,_ FI.DP1.T I.-P-.l.".1'E
. FLUPIT

Date of lsaua; Ma-v I I93 D I13 _

'-EHDNDA MDTCIH L'l'U.. LTD. 4-3
 I-Ionana. F--"=-.~ |.L'|-'-

FUEL evetem CTU -\-PI ___

I_ _

..

NEEDLE JET H-OLDEFI MAIN JET Sl.C|'\II' JET

Remove the main jet. needle jet holder and needle
jet. I /
I
The stow air get eannot. be remoued- It is a
ores: t.

Blow nil Iete end buoy omg with camera-wed alr- 1.

.---,

1""-I

NEED L E JET
FLOAT MAIN JET

BARBURETIIII IISSEIIIBLY
Install the |'||:l:|:lI: |et_ needle jet holder and 'lBil'I FET-
Ineiitll the float and line: I-naive ta-getl'|er-
NOTE
r it '\.
Tel-te care not to damage the ieti when
inetalling.

PIN

N Date of Issue" Mev, IBBCI

4-4 IEHDNDA MOTOR CCL. LTD.
 I-:t:::%n.a.
FU E L SYSTEM

FLINT LEVEL
Flemcrve the floltt tillniil
Measure the float level 'n'itI'l the flan! Illa II-Lit
:|;||'|tI|;.'H|1g the Iluat ualve_

FLOAT LEVEL: 10.1 rnrn Ilhti lnl

gplglx the fleet, if lhe Iloat Laval Ia not witirl
lpEGIIIl'.'.B1II0l'I.

FLOAT LEVEL
III '?n'll'll I042 Inl

Cl?-ll-CI1 DUIMIIIIIII

TIIRIITTLE HUIE ISSEIIBLY

Install the olilp on the jet neelrie.
lnmlll the lot nlmlla lnm the throttle valve and
demo It vvlth the rl-eedl-a clip FI'lIiIi"lIl.

NOTE
Install 1-he huadl: ellp retalnul to lt mt: an I
i the throttle valve bottom. I

NEEDLE CLIP

E:ol-npresi the 1:I'lrot:tIa vellra-toting and lnltall the

l:lll'.|Ie lnta the valve.

Date of lame: May, IEIBIJ _ _

!E'HONOA MOTOFI C11. LTD.
 1-Iotstna.
FUEL evetem BTU '-_ _-
1,-
THFIOTTLE 'u'.\!IlI.u'E T
OI-IO-O'v'E
Illllli lI'|u 1|1rr!l|[I|: valve with 1Ifll! lttr-::|t||ef: rnlvtt
oroove all-;|ne-cl wittl the tllrottle stop so-revv.

THFIOTTL E STOP
SC HEW

IIIIIPIBIIIIETIIII IIISTIILUITIIIII
The lrateiletion sequence ls essantlallv the reverse
of rel-noual.
o-.,

I-IOTE
lo __
"\'ii*Bfl -Ittnli-rlg the throttle l|'IIve_ QIFHT-l the
li'lr'nItl: valve l}I'|I|O't'E' with the throttle $!||:|p-
I|CI'LI'|I| .
- Cramp the 1-.l-I-ollre oe-ble and on the ca ble clamp,

Perform the lullmvlrlg Ihepnllds and arlgualrneltu.

- Throttle operation ll:-age 3-3|

.-"I-.
' E&rI':|.lre'lr:lr |:hltI-te l:tJ.ng: 3--III CHOKE CABLE I
' Carburetor Idle soeed -loaqll I3 IIJI

_,.|-|_
Cl-H I-IE FUEL STFIAINEFI
FIIEI. STRMIIEII
Turn the Iuel valve OFF.
Dlalrl the l;iIlL'l.IfI-IIDT hv lrloetrnlng the rirelrl sl:re\v-
Hemove the fuel value, O-ring erltl seralnar.
Clean the strainer
Install Ihr: olmlrver, If]-rirllg Illl Iu|:I valve.

4_6 as Date of Issuer Mav. IHEIU

l'l5.l PIUNDA IJIOTOI-I CO., LTD.
 I-IcE%na.
|I"lI-t F Ll E L SYSTEM

r-L
Ir
Fll.ll'l' SCREW PILDT SCFIEW WITH LIMITEH CAP

HEMUVALi'lN5TALLATlDN
NOTE
The |J=i|DT ecnuw ls lento": on W1 ="r-F 1'Hl
not lg rqrnmlud unrest the oathurttf ll UNIT-
I-~.
_ hau lod- _ L
Remove the carburetor.
Remove the flout chamber-
Torn the pilot screw in ind lawfully mount the
numkpr -;tl turn! hnilur it wea'r_s1ight1~,~.
Hal-to i nut: nf this l|.'| ul-E -11- 1 relererioe when
installing the pilot 5|:-raw.
F
CAUTION:
Darnoge to the pillor screw and roorwlllooetor I
if the pillar ::'NW ts rlglarmed mrbut the marl.
FLOAT Cl-{AME E H
F Hemv i||E lilil-U1 screw \n'lt|'| the lin1:t1|r mp it-
inched-
C.\'\UTlU'N:
I Any fomgole ortnmtlr Jo remote the p1'l=r.|I
| """"" """"" "P ii iT"iFi.@i*.3""""
Inspect thl pilot Ioruw for -I-lint and rnplne ll
neoessarv.
In-rtall tho pilot sum Ind return it to It-1 origlnn-I
potltlon u noted nlutlng re-rn-oval.
F Purfonn pilots-or-aw edluttrnlntif anuw pilot |I:rl=w
limstallecl.
HDTE
DD HUI il'|!-till El iimitpr i;p|;| un | |1q-w pllut
Htruw until aftlr idiustmont ha: been mid:
lie-a helowl.

ADJUSTMENT
NQKTE .
'i=l'|o nilot new it hiztorv pro-sol and no
r-. 5d|u5|;|'r||nl is nEtEl5Bl"|' unlos the pilot scruw
I: replaced,
Tum the pilot suew olooltwise until it teat; llghtlv
and hick it uul to the specification given. Thin I: in
f"~.
Initial setting prior to Th: llnai pilot screw ndiuw
mont-
l|\IlTl.|l|.L DFENING: IBGD I turns out
EH31 2 H2 turn! out
C||.'i:lTiONI _ __ __
|%['!r;q;;|\; ml H31," p|'I|'_rt .\1",|'l|\* i MEI l-\-I11. O\'1l!
F if the pilot screw is riekrencki opmlnir N41 mt.
Warm the |:ng.|.l1E up to operano lnmpermtil.
Stop and go riding for IEI minute: ii s1|llicHirl-T-
Connect u to|:-'l1I:|n'|I=tI=r-
.I'4.|:Iiult 1he IIIHE speed with the lhlottle op www-
|,.v""_ . IULE SPEED: 1,5!!! irpm
Tom the pilot arxew |n or out to obtain the hiuhll
nnglne =pn-url
Ha-adjust the '~|;ll|::pBEI1 to 1,511! i HID r|.-rm, uemg
1"-
the tltrottle stop -so-rew.

Doteof issue: Mn, THBD

IEHOI-IDA MDTUR El.'l.. LTD-
 HONDA [/
FUEL svstem ]l[| /'-~.

LiMiTEH CAP l|"~iST\Li_o'J\TiUN Lli'|iITEFl: CAP

if the |J-iit sore-at ii&5 beeit li:|'_|lei:ir:d_ 3 new limiter
-BB1-I rI1~=ll |-1|r installed utter pliot screw soiluetment it
completed-
After atliustmerit, tzment lhrr limiter eeo over the
Diiu-I !n:tr:w. using LDGTITE FEI #501 or equiunlent.
The limiter |:=ep shouitl Lt: pinned isgeirm 51;; 5t|;|p,
ore.-enring further udiuetment that would e-nrioi-i mi:
fuel mi rtture ilimiter mp position pqri-him |;I|J{;ii;wi55
rt-I1-Btl~::n mti prevents counterclockwise rotetionl.

MUTE
' A pilol strew iimiier cep Inuit be installed. It J
i prevents misseilustment that eoulti |:lLl5e pour
, peiforrmnci: Bod |rlttrt:t|H: emissions.

-|._

HIGH .\i.'i'iTl.|l]E IiI1iliSTllEliT

For suetsined high altitude operation [above 2,000
II'|."E.5lIi i'I|' lmtn-ll s I535 main let an-r.i reridiuttlsiie
speed.
RHH-u! the lriiunetiir irtaln the Iinqme sntl rrrni-eve
the flout I;i1smi:|er-
Fliepisce the standard tnsin int with the high B11irlJEiB
#35 rnsin ist.
Assemble tH|lLi imtsii the oar iJLlr!trJt.
-'\I:i,|l-1:! Idle spurt 1|! 1.500 1 IUD rpm, Lrtinp the
throttle itoo screw

CAi..i_TiC_il'Nr
' Stilt-rn'irrcti' anterior: or eir1!r.w.fe.i' in-war rim: J ET ..-_
T-55!? HI |'-i.Ut?i'-' fh v-iltil riir Irtgii erl't|'irme
mil-bi In .I'rt.'i'i.-r-li5rtri' me'_v reuse elrgirie .|ver.||.rer-
rieg om! oiermrge, For .-ru-rr.e.|'r1eo r:-_|-,\erm'|;i-,1-,1
below I.56'i.1 m |'.?.rh'J-.1 _i"r_.l_ roietto rim !'I.e'.re:l'-
ertl win fr: strrd nsro',|iu'ir mu: speed.

i smneaie High i=|mue= t'|'DtI

. 3 MO rn 1.500 rn (5,000 tri~
i i6.5El ftil max. min.
Main iet man. .u-en #35
' 1981- was
ilctl:-toned 1.5001 l0ETr1=rn -e
he ..=...;;.' ' Faittuqg pt:-not
- oi -_ _-
iupening
i

Date of imm: H-iv. I990

4-B H[IlT\ilIiA MDTDH G-DH LTD.
 HONDA
_,p I
re urn F UE L SYSTEM

Flllil. TANK
Turn ti-is fuel valve to HES.
Loosen the firain 5t:r|-.w uni-l rirmn the fuel thu-r|;|uqh-
ll,-.
ll?
R-:mr.w-=1 the rioht title cover and the il3l|lH",'.
D-.5130:".tiEtttl the iuel i-|1r:: iiti-rn the Fuel t_a,r,l-;_

Du rsrrr -irillrm _fIs'm'; rrr .-'ajl'lIIl"il'4i'f!i:t:4i'ii-' ,pr.tr.ri'i'm'

e
ltiipr up spilicdeesolrnr or I-'"CI'.
1'"-

FUEL
.-""

SEAT
Remove the s-eat_
Flrmmie the terew and hnlt tewrinq] the fuel link.
rheii rente-.re the lusi Tltiit.
Ir-.5.ta|| ihe Fug; tinl-q rn 111-e i'|':\||':il: DH]-El :31 removal.
J{""-. |'t-loin! sure Them: ore |'||.1 Tu|:i leaks.
i3-r:-eel: the uent noiei of the tilier can i-I lJl!tl'-BI;|&-

|"".
Thi-
SCHEW
Q1;
./_'

.="""

Dateo-f Issue: M-:n,-', 1':'-MD

EHUMDA MCITDH 'CE'J., LTD.
4-9
_ _i_
 1-Ioeena.
ENGINE eEMovn|_.'|nstni.|_At|on C10 $1/i ~.
-I Ti

.i.'

.-"""-

.-'-._

.--.._

2.5-3.5 he-n1
lI1B15 ft-lhl

5-O Date-pl lawn; MW, 1QB

IEIHUHDA MOTOR CD., LTD.
 / HONDA :: ::- f" _"'--.
I
.r.
cm EEgm Em =-Fe='z'='i:=: -:
_.\,_

in eestiroe INFORMATION
seems nemowu.
5-1
5-1
K
ENGINE INSTALLATION 5-4

SEIWIIIE ii'iFi]|i|||lT|l||l
GENERAL iNSTRUC.TlDl~i
F The following pa-rt; or component: oil-i1 be !iEt'\'iE1!t1 WI-II1 T.i'tB Bl'li8 initeiiltl iI'l THE Tt-It'IlE-
I Ctutch I .y|||-1;)" I i:'.r|.ri:|ur|:!r.rt
I Gearshift linkage I Pieto-n
I Di-ipomp i .i..gIrnHatnt
I Cviinderhceci I Starter motor
F

SPECIFICATIONS
Engine tlr-|r wright 1B kg i39.? lit]
Dil eapecit-,r I11 lit i{|J,?4 LIE qt, 0.52 Imp qt] et en|;|ins sesemtiy
0.5 lit (0.55 U5 qt, 0.53 Imp qti at chine:

TUFIGUE VALUES
F"
Engine hsnqtw IJDIT5 2.5 -3.5 lug-m he - 2!-1'1-lbi
i'-'nutpeg:."xid-s stsnti arts-I 2.0 -15 leg-rn I14 --19.1:-Iui

'1'"-.

./H"

rm.

Dots of iesue: Mai-,ll=1lJ

IEHt'Iii"-EDP. MDTDH CCL. LTD
5 5-1
_
 HONDA eet.
ENGINE FIEMDVALHNSTALLATIDN [u .-.
_.e

ENGINE REiili]Wti. me ct
Drttin the nnoinn oil.
Heme-tie the tlir oi1te'11n-r etwet err-t1 Irnrtt cmler bend,
Flemotw the front cover.

'-;.;*@*:
PI_I'1}

Frtortt covet: ___

STAHTEH CABLE
LDDIGI1 the ettheust pipe letting nuts
Ftentoue the muffler mounting |'|u1.l and remote.-e tite
muffler assembler-
Dieoonneot the starter cable.

MOUNTING Mute NUTS |""""\

Sui:-port the tent:-|1.:-tale up-right with a IiIBIll2i. 1

Remove the footpegs.-tide ttenti sssembiy.

Linhoolt the brake pedal return ring from rhe
engine hanger butt.

.1--.

FIETUHH SPRING STAND _

ASSEMBL
7___._r.
52
52 Detu of isms: Mere, 1980
'9 HDHDA HDTCIH CCL, LTD.
Fl HONDA
J ENGINE FIEMDVALJIHSTALLATEDN

;"_ Hen-nva the hhh terrsiun win: "mm l|'|E prh Dluq IN
and clamp.
D]5{:|r||1E|;'[ thn |I"il'aH'.I: plpu |rn|I'I IHE :r\l_]|E.

.-a-Hv
ugh
/_
i.

I-

F - n u
HI

ii.-.
w='*.-6 HIGH '|'I.|l|1E
F

AXLE HUT SLEEVE NUT

Rama-'|'! qm mg-t1,~|:r pin and |D'U'l'BI'l HM! Elli! E-l'|d
slwvl-11!-Ill
l_g.35_5|'| {ha |;|ri\1l' Ch-li|'l .ir.||uiI|Q RIG.
q-
Ham-we the iaft aid! 1:01'wr_ nngirll mrodkti C-vr
and Iuwar chain case.
If-\.

|||F"~.
LUWEFI CHAIN
CASE
CUTTER PIN >;.*-*1UT

LINIC HETJHHIHG CLIP _ -.

fa" . . -1' '
Hmmln ihe rn-aster link EE3lfllTl rim ind \"*'=|!-IBF .-Ii-'

link 31 fhi drluc :p1l2|G|iB11.

_.-1""

|
.-F

1""
J-_
.9
55 _
Date of liuar May, 193-CI
QHUHDA MOTOR CCL. LTD.
5-3
 HONDA F
ENGINE HEMDVALIINSTALLATIDH [:'].|] '\%j' .-.
.'-|
RC. GENERATOR
THEE HOSE
|J'i5DlJI1l'1-BCt 'lhE FLC. gE|'1E'r.llu|' nuuplur
Hlrm-I: 1hr: hl'Bi'|LhEl' hose frum Th: faupnritf and
clump.
Rerncml 1hr: two sngirne hangar bnlu and mmm-4; the
englnu.

ENGINE Fl BDLTS __,

ENGINE IHSTALLETIUN
IMI-Bll Thu Ehgll: |1\ lh-0 r-wars: order 0! remove-I. FTFFAINING CLIP

NDTE

"fl-'hBl1 |l'|1bI1lln|1 thl! dfiuu chnlrl rnastlr iink,

main: sum 1-hat the retaining clip open and
@ ""1
Faces um npnmltn uirucninn of nurmal chain
rmnlin-n.
| * Huute the wire: and cabin prpperly ljpggg 1-B1
' ' Flll the crankcase to ma pm-pur leual -with tha
D I Fl ECTICI N D F Fl DTATIEI-M
fanom rwandad oil {page 2-2'].
' Miiusf thrr Izlriw ch-afn tension luaqu 3-1' 1 I.

TOHCIUE VA LUE5:
Flliilllllflldi Itid lnnmhhr: "h"
2.0--2.5 in-m I1-4-18 ft-lhi
Engine hangs hdu:
2.5-3.5 lug-m lI1B25 H-lb! .-"1

_.r~ .

15- 3.5 'kg~rr1

"B-25 H-|bI

5-4 5 Datuoflsuua: h'lau.19BD

n-cur-inn MUTDH :1u.. LTD.
 .d"_-\-

HONna .1 _.
_,-r cw ~;%,J
MEMO

K
1"

J,-.

F-\-

I-_.

-55 ats r|-f Issue: M31), IHHH

EIHD1-IDA MCITDH CD-., LTD
 HONDA
CYLINDER HEADNALVE C70 ___._|
Z

"\

l

,-

_ --
I
r =-

|-

$1
.-H
- |

'\--
In

y..
4!-E-2%
a _ J.

%
Q1;
P" QF r - ""-

I19-1.2k;Bm _
(?Qf1-lb] W
I
"
n Ii
f-@.._;;s
l
Z
.| nu. '1; P_____
XI?
. R _ kjI. |

|
I Q; .
0.9 - 1.2 kg-m
I? - Bit-lb]

1*-'1
K-Q Q? K . ,.-
|

|
.'
_.'l- *- .

.-| _ J

.-""~.

\Fa
.-

I15 - I19 kg-m

' H -- 1 E1-lb!
.1-""1-._

--

-\|

E-0 5 Data |:|f Issue: May. 1930

@'HCIND.I-"| MDTCIH CG, LTD.
 F

.r.-=~
E9f=1B BJIYLINIJER HEI-ID VIII.\IE
SERVICE INFDHIIIIATIDN S-1 VALVE SEAT INSF ECTIDNI
RE FACING E-111]
TRUUBLESHCIDTING B-2

rJ""\.
CYLINIJEFI HEAD REMOVAL
CYLINDER HEAD DISASSEMBLY
H?
B--4
CYLINDER HEAD ASSEMBLY
C"|"I.!NDEFl HEAD INSTALLATION B-13
E--11

VALVE GUIDE REPLACEMENT B--9

SEIIIIIIIE IIIFIIIIIIRTIIIII
("-. GENERAL INSTRUCTIONS
I TI1-'| =0w:1Iun CIJ\'l?|'i rnainlcnancn and In':r-rumlun uf1hr 0'|'IIn|:Iur head, values, I:-in\:l1:|1t il1l'I mcknr lI'lT1i. Them ilrrvicu-i can I10
dune wilih the engine ins1aIIO|:I.
i Clmihuft m1rI r0-01-wr arm Iuhriclrlrrg 0iI is fwd thrnuqh 0II passages. B0 mm tho I-Ii55i.1lll an: nut |:I0g'gnrI.
f""'*.
I During as00n1bI\I, appiy Inn-IyI;u:I0|1um dlsulflda grease '.-0 rha carmha baarlnm :0 prurvlde InItiaI1ul.1rI|:arI0n.

TCICI LS
5|1:0inI Cnmmun
'u'0II.rE Guide FIE&l'|'h!f Q1554-UBBDIIIU '|.||';1]yg uid; |:|5mm.E.,_ 55 mm .;;,u,um-mum m942_32B.|m
WW Bu-'10 Brim 0:002-1100100 Wvv E-W00 5*-I'"lIJFE5|=0-r 00:01-0010000 0| 01051-0200001
TDFIUIJE VALUES
CI.rIInd0r hnad I13 -1.2 kg-m I? E ft-lb}
P. 'E1I'|| -CI'I|1|.r| :'prn|:Ic|:l I15 I15 IHH11 I4 T F1-'|hI

SPECI FICATIUNS
_.'.'.'IIIIf'I?i_II.'?_ _ ..5'EH."""3E LIMIT. _
Cnmpressln-n pressure 10.0 + 0.0 |g.r=m= ms I 1 pm A
Cami"-:|1'1 Cam h-eiqm K IN. 26.1]? mm 'l1:I;1_2lE|_|nI 25.59 mm I'I.CI'I In_I
EX] 6.-1" "~".~_i!."1..i"I -___? _._..___Ei_7-iB'%e":'1r11 'II';.5.I.Ti"1
Dil |:I-earlnc-e 1,010 0.1125 mm IIIUDM IJIIIJID In) CLUE rnrn [D.I'.'.IIJ1' In)
IEII-dc :1I:I|'|-nm "_ 0.004 - 0.035-hm 10.0002 - 5.0014101
r'~ R-:x:I=0r arm shaft 0.1]. 0010- 0.000 mm 10.3020 - 0.3-00:2 am
0.01155 r0'.0Fir-0
R0-cker arm LEI. 10.00010.010mq110.aa:r-0.30431:-I 10.10 mm Iriaa InI__
__
"-"aI'.rn spring Free Iangth Inner 15.1 mm I'D. In] 1's1..r*.-. ~ [DB4 |nI
F I Dr-I'n|r 118.1 mm
_
I1.1T in] 25.9 mm
i
I1.DB|nI
Praluadllennlh lnmrr 2.45 2.75 1952.? mm 2.3 k."2?.? mrn
I511-B1 __G.DE3 Ihi-'D.B5I inI _ I5.D'|" I-I:5_|'EI.B-Q |n:|
[I-IJIIE-'|' 5.55 T.'I'5 IIiQ."2-FI.EI mm EL3 k;|.'2-1.9mm
II-'1-.551 - IT DEG I:IJs."U.SB ir|I (13.53 lb0"IJ.EI8inI
KT. Valvu maids! 'l."aII.ra stam IN. 5.-I155 5.1155 mm 10.1145 41.21152 in) E.-\1=DC| mm I.1"l2B In||
u-mu D.D. Ex 5135- 5.145 mm ID.2IAIII 'Il2'1-'1--I In] 5.1100 mm I.211'BIr||
' va'rIq0|0a" m. 5.400 5.-100 rmn 10.2150 - 0.2150 an: 0.500 mm 10.210510}
LEI. Ex. 5175- 5-I435 "'.' ..I."?'.-?.I_5.5..- "P3159 "*1 5!-'.5F1'9!"_.'1 ..I9;3I55.I"_I-
Srnrn-In-guide I 0010 - 0000 mm 00.0004 -0.001201; 0.0a mrn 10.000 gq|__
cluranua I BL
I
I.-\
E59 "i15_'P_""'L_I"-"'l13.;!.I.I.'?EI.'.'3I I110 mm ICLIJU4 inl
I '\-"aI'.r0 seat wldth 1-0 rnrn ID.EI-II InI _ I.El mm IIIl.'l1E| in)
Cylinder head Wtrppgt -A . -
ELD5 mm IIII.II|l12-in]
F1

51' '
Dana 0| Is.-sue: May, IEIBIIZI
IIEIHCIHIJA MDTDFI I.'2C1._ LTD.
6-1
 HONDA
CYLINDER HEADNALVE CTII
I i _ l 1-

_-

TIIIIIIBIISI-IIIIITIIIE
P0 rforrnence nrc IJI-ems related In the cylinder head can l.l:Ll.tlII'|r he diuanaeed by n |:t.'|l'I|IJl':e:Ir.N'| tie-.1, nr nnice |'Jrul:|In-rn-i which
can he traced to the 1:0-p end with a saundlng red er iI1EfI'||:|:-m'.I|:,
Law Camnretsicn Celrmnrusiun too I-Hgh
1. Valve: 1. Excessive carbon bt.|IId-up an pluten head er urltbusliurl
Incorrect valve adiustrnent r:I'1.eml:-er
Burned or cent uI|': Eula. "DI"
_ gt:-.|;rl'l-:I?I Tulve liilming 1' ltmtkmcr w|___diuumEm
B I1
_ _ no En V W Em u 2. Sticking valve or bra-Itun valve sprint]
2 Clgndur "Md 3. Damaged 0r warn camlh-aft
_ 'lIL;.aaInn|] cnr damagsd head qaattet 4_ Linn Dr mm cam chain
_ amid Dr ache ':""Hd'T mm 5. Warn er damaged cert! chain tanelc-ner
3. C1-' Iihdr and piston {Refer to S-lctinn TI BI Wm, mm zpmck math

_,_

.-"*1

;-_

6_ 2 58 Date cf Issue: Mrw, I530

IE-'IH'DNEIA MIJTDH CI}. LTD.
 Fnorcna.
.|-' CYLINDER HEADIVALVE

.=""
CYLINDER IIEIIII IIEIIIWIIL INDEIII MARK

Hem-zrue the Front mover

[Ji:nur|net':1 the intake pi-pa from the cylinder Mad-
'FI|rr'ri;|;ri.ra the |:ur|'|nr_'I |1|:||'l'l1 CDHEI in-DI TUH1 12I1B
F rzcanlcshaft cnun'tercI0cIn'rir-0 in align the "T" 'lil'Ii
-m1h the I11|;Iex mark.

,r'_\.

1-
FI-
-L
f""'~
'1' MARK

Rqtnnvr the l1'|UI'IIBI'

Rarn-due the Fault plug HP.

Rerneue the cylinder hcn-I-I Ielt aide cover he
removing the through halt from the rlghl !|IIIB.

|p"\. .-A

.
l- _

r""" CYLINDER HEAD

LEFT SIDE COVER

Ramaue the camshaft sprocket-

1"

....nll\
If '-

l".I
,e.
SPFIDCKET

55
IJ-ate'0f Issue: May, IEISD
IIIHDNDJI MOTOR C11, LTD.
6-3
q-_
 HONDA .~"'.T
0v|.|rv0ee HEADNALVE [u J
__:-"

CYLINDER
LODBBII II1: (:1.-lllrder I5 mm bnlt.
Remove the cylinder heed E n'||'|'| halt and r;-,-llndgr
head cover.
Fiarnave the |:r-,rIIn.elet heed.

CYLINDER HEAD CYLINDER ._._

E-mrnBl'JL1' Blnm BOLT

IJCIWE L PINS
Remove the D-rinqi. cvlintlet heed gasket. and rrlnlugl
pins.

_.-_

I .
II

'5'
st
GASKET O-RINGS -I-I.

v..|_ve INSPECTION cams

[IYLINDEII IEIIIII DISIISSEIIBLY
Rnmuvl: the I:-pllndat head right aide eeuer 00.;-I
gasket.
Flume-1|: the valve Inspection cape and D-nnga.

CYLINDER HEAD
FIIGHT SIDE -.',JI]'lJ'EH

ED
6-4 D-110 01 lawn: Mav, T!-Ail]
I-DHDNDA MOTOR 20.. LTD.
 r-.-Eh!-Io1\tn.a.
|
_|.
$5, 010 CTLINDEH HEADIVALVE

I:Imrn HOLT
Sgrgw an E rr|rn Ia::iIl |rr!t: 1'I|E IDEIIZE-I il'|TI 5I13"I'l' i1l'll'I
pull me iha out Qf the I:','II|1rIEr IrEIB.|EI.
FI|.7rr|u'.r1} the r-ackel arma.

'1-I-.

f,|.

ROCKEn AFIM5 ROCKER AFII1-I

F

Remuve lllc camshaft aitgr-lnq the um IOI0e-.1. vvlth

the cvllnder head cutcnts

ra-

CAMSHAFT
'3".

.I"_*- gemmn ._h|_. 1,-.,|\.,-I gpriq] 11u|1'1:cri_ retainers. inrinpt

and valvea.

CAUTION: _ _ ___ ___ _ i

fa pm-ma luvs 0| rvrlsinn. dv Hr IWPIPFFH I!!!
M-_r1.E 55.-;',35 1I[_|}' f.l':||':.I r|er:-es.sa'r_|-' I-r rearmvel
ll/"'.'*~.
| f|Ile'_lEElfI-!I.'I.

Hm-|1|1|\|g\ \|I3|q'E spring 50.01:, shim I.E|.BJ caps and !1El"lI

seals.

.-

VALVE SPRING CO MPFIESSOR

If-.

Date ef Issue: Mav, IEIHO

IEHOHDA MOTOR CO. LTD.
B-5
 I-Iowna./
CYLINDE R HEADIVALVE
cm E13.
_,__

Flam-1:00 r.arb0n deposits from the DIJ|'I|I.Il.'tlI|:|n

chamber.
CIEHH eff the head gaslrart surface-.

NOTE
|_
- Aueid damegirrg the gasket mrtnce.
-Gasket materiel will name c-ff easier if necked
in eelvant.

I-\.

ROCKER ARM INSPECTION

Iraap-a|:.t he r0l:Iter arms fer damage, wear ur clogecl

all helet.
Manure the I.D. of the rueltar lr1'n.
."'HH"'
BTAHDARD1 10.000-1D.1E IH|'II
III.393il'II.H-I-I-3 InI
SERVICE I..I'II'ITi' 10.'IEI HIIH IIIJSB IIII

--._-

""'r
ROCKER ARM SHAFT INSPECTION

lnspa-r:r.tha maker arm ahalt fa-r wear 0r damage.

Measure the ELD. at the rucker an-m rI1:rlt.
STANDARD: H.371!-SSH mm
10.09.20-0.303: ml
SEIWICE LIMIT: 9,91 rnrnII1.2!II12|nl

-\__

6-5 O-ate cf Issue: May, IQIBIJ

e5}-IIOI-IDA MOTOR CO.. LTD.
 "-1;
I-Iomnn.
_;\ IC10 CYLINDER HEADIVALVE
__,..
.4

CAMSHAFT INSPECTION

Using a micrometer. measure the cam Inn-aa.

Ch-|:|:k ldr wur ur r.'Hr|'|B=g|:.
F
STAN DAHD: 25.9? mm H.025 inl
SERVICE LIMIT: 25.55 mm I'I."I1 IIII

A?

1"-

F1

CHMSHAFT DIL CLEARANCE

Mnnum and rrrcmd tha camshaft iuurngl CID-

Measure and rennrd an cams!-um hearing l.lJ. in the
cylinder baud.
'{""'\. Determine the -|:a.m:h|'l1 huurlng oil qlgimngg.
STANDARD: 0.01 0-0115 mm
[IJ.DIIJ3--0.11015 H1]
SERVICE LIMIT: DJD5 l'I1Il1 IIl.IIIlZinI

1""-

f"" VALVE SPFIING FREE LENGTH

INSPECTIUN

H-uaiurg tha lgnglh Q! lhq lnnur and cuter \|'.ihIE-

5-prlhgi
,4--.
ETANDQRDI
lrmur: 25.1 mm {D39 In!
Uuur: 25.1 rr|mI'l.11inI
SERVICE LIMIT:
lnnlr: 23.9 mm [U34 InI
Dutar: 25.9 mm II.l.'IE HI]

I;--.

Date of Issue". Mn-, IBM 53 6- 7

E-HUI-IDA MDTDH CCL, LTD.
CY Ll ND E Fl H EA DFVALVE
I'\'.

-
VA L"u"E STEM--TD-GU I DE CLEA Fi\i"aiCE

lru|.1:|:r nch value for i:|=enr.lln-g, 1.1|.|ming, wmdqqq |J|'

Msurmal iiIE*fl'| wear.
Chuck vnlvn muvnmant in the guitin
Measure and re-::urd path vdluq stum C|,|]_
STAN DAFID:
IN: E.i4555.#B5 mm [H.211-8-0.2-152 ini
EX: 5.1-35-54145 mm ED.21-W-iJ.i14-l in]
SEFIVIBE LIMIT:
IIWEK: E.-40 mm [H.213 ini

.-:.
|

NOTE _ _ ' ___ I

I Fi-Ham tha |pi-cia tn remnue an-,' cm-bun build- \|"|L'|i'E GUIDE HEAMEFI _

up before Ghiing ulnranm. mesa-uasoum I

* K
"-IIBBII-IF! and record ca-ch tr-ltiul guide i.l'.i'. using a
Bfil hula gauge cw inrlida micrumatar.
STli"IDAH D:
IN,|'E}i'.: 5.115--E.-GE mm - {J * -
. . '- Hi -._ _
IU'.Z15B-0.2159 irll
El '\___..-'i_T ___._#:- III .-7-%'._I| L___,__. ll
SEHMIIGE I.'IMiT:
INIEH: 5.50 mm IDJIB5 lni || 1' I -I I
_. 1'. ._ _| '
. ._ -" I __
V
IIQT-I _ _..-'
_. -' =13-1:
_.- -- -I
III...
I
ll

Ulnrrminu the I-tam-t|:|-puida daamnm.

STJUIIDA Fl D:
IN; lJ.IIiIIO.3 mrn ID.IHID4D.iIl1ZIr1i-
1
R.
. $33 ;. .:*fi."-3
_- __ ', . '_| - -. .
EX: Il.D3DIii.UElJ mm IEi'.III12-<D.iII.I1U i|'|i
*3
-EEFIVIGE LIMIT: IN: IJJB-B l'l'lI1'l {II-ini
EX: .'IUmm iII.'DiiHir|-I
r
If the iIEl'\'1-ED-QJICIE BIBIFBFICE B_.K|3HI'di- the wrvim:
lirnill. thllen-min-a it I mm guide with standard
ciimaniiona wuulci bring thu uiuarmcl within
tolerance. If so, replace lira guidas as rhacarr-I-ary and
rm tu Fit-
if the stem-ta-guide uinaranca Eiliiilllldl thn mrvuzu
\_
limits with naw guidaa. rapiana the Inivns arhd
guldus-

~iDTE__
Fiafana ma valve _aaats_ when-uavmr Thu vulva
, guides-Ir: tupimad ipql B-'l1]i.
_-|_

aH-

Bi
6-B Date uf luuei May, IDEIJ
-DHDNDA MGTDH LTD.
 HONDA
1" g CT [I CYLINDER HEADIVFI LVE

'11-.
'H.l.VE EIIIIJE REFLIIIIEIIEIIT VALVE -REi".I'|I'Ju'EFI

Support the cyllndar head and drive the g|.|lcla- out

from n} purl iirih.

MUTE U_ _
F L vmm driving out the u-aha guide. do not I
IIHFl'|I:tQ! Ii'H'.l I'll!-IIIII

1""
VALVE G UIDE DRIVER
D7912-l TCID
Install a new uuanfza vulva quilzln from liw In-P HI
the head.

r'~

F Flpim lhu haw viii! guide altar lnllnlltl-I DH-

VALVE GUIDE FIEAMEFI
NOTE _ mas-maanuou E43
QM

/
1 Uaa milling nil on 11-we reumar dur"'Ia1|1il 0'11"" \ . '
tlnn.
- Flmnu ma rsamc-r wh |I'I5IHTiI"-I Md i9|'"'5"""_l
F :- I.

FInIu|;\5 Iht: vEIl'nE SBBI llllgi 5-Tm. -*"'-- -:_"-- I I "

Illa-an tha cr-,r|i-\d=w mead wumuuhlv tn ru1'*! iv _ L.-=""-..'='.-F X
I-J
- I ' . -- I
I
maul particles _ -. In I
I

_|\.,__
IJ.___. e---1
r-:~_. _'-\_,__
_
."'-'
".| \-.,_
=1-
_F.-IT|_
I'._l

"1".
1'7 ~.__.-
--,1
,-
-.-'-""2I"'-J
..___ _
<1--*~-.:_-._ "'."- ._____P;
.I___ ' ~.-~\
_ _.5 _ {J-"_" ___--I _.\.

I-""'~

Data nf Isaac: May, IQECI

IIIHCINDA MCITUH CU-., LTD.

I
 HONna. K
cirurueee HEADNALVE [:10 -'1-\.
_ _ _i I I

IIIIIVE SEIIT IHSPEBTIUIUIIEFABIHE

Clmdh Ii-nth intake mid m-ch-ans! '-l'IIi'lJB=S- themuqhiv tu
rum-we earhun deposits Apply e light eeatirig 0|
value lapping erampnund 1|; 1_'!I,lI2|'1 vglvu fem, Lap
B-lh '-alum and suat using I rui:|i:|er here or d-ther
hand-lapping tout.

NOTE
Take mere net. lu allow lh: mmpwnd It! enter I
ilirlwm the valve-stem and guide.
ll-lter lapping, wash ciut the itmnpnund enm-
IJIETBW mil apply a edit of engine ail tu the --_\-
waiira flue an-d seat. I

Humova the value and imnact the flee.

CAUTION: .|._
I
The 1i|h'I''.'.l mrmm be I-ruiinii. If mr 1'a'1ve_|"m:'e
Lt r|:.I|:,ei1, P.-r.vr.1 :.:rre1'mI_1r_ .'.Il' er.1rrJ'u'::.'. riise .aea'.|
rmurnp-er_:', rile 1-u:t.|ve muxr he rep&:|rer1'
Inspect the velve se-at. '
I1 the aim in rue wide, tee narr-mu, er has luv: spots.
the wilt mu:-1 be gruum:i- I

more
I Fulluw the refaeer rnenuIu|:turer's -p|:nerat.inq Ii HH , VALVE sen WIDTH .*""
iI'iII"\I-I:IiD|'|5.
r

ff
.

-I

ST-'5-ND-ll-RD: I.Clmm-iD.El-Iini
SERVICE LIIIIITI T.5I'I'|I'I'|
iilEl&ini

--I.

Alter nuttlnq the seat, apply lapping eumpuui-|:l tn PEI. |

the value feee, and lap the value using light pressure.
-lll'l|:r lapping. wish any residual Dl'l'I|IlIJUI'IIi nI'l' the
cylinder heed end value.

T1.

. \-

6_-I U 55 [J-.;|1u I'_lI IQI-{IE M1-,=, 1980

-HONDA MDTCIFI GEL, LTD.
 ft HONnn.
,. Ikj,-' [:11] cvtluuee HEADNALVE
VALVE INi"-IEFI seem.-e 51-em
T BILIHUIER nun tsstmatt calm =.~=-qt; seer seal.
i|t5IaiI ||:t\' iiulv: sI|t'n s:::l:..

Luhrit:-ate E-at-I'i valve i1.||'| '-\'|1J1 rnul'g|-l.trle|1um

|Ii|5-uiEiti|: |3|'I:'.?ISl! :trt|;| int-:|;:r1 the value intlj 1,115 I,|.3|';1|3
taiida.
I _."
III

If II 1
NCITE O
Tu uuuid damage tn the item |.r_ti|I, tut-|1 rhe_i
O.
-.. %I
valve sitv-vlt,| vmen irvsertinp. _ %_,_
I-tililll the valve sprinpt and retainers.
if-'-~.

I l
EPRING OUTER STEM SEAL UALVE
1"
HETP-INEFI SPFIING CAP

lnetell the valve cutters.

CAUTION:
l
TH prr'1'E"JrI |r.rt,I.j.'r1 |i'.i3'.g,_ |;J|'-'_.I ur [r_1m'|r:Ir.,\' {hf
uttivr r,t:Ir1'r|,z.Ir|-urr than nt-ct'.t.tt:'r_t- ru m.trei.| the
re mire t.Tr{.l' err.

VAL '-."E SPRING ceueeesson

1-

1"" Tap the vei't-E !I'.n|11l pltllv with |t I-pit ltanlm-er In

rrnltr seat the valve cutter!-

NOTE _____ ___ _

|_ '5u|-ipurl |l1'e_t:-gilrttler ha-ad abuue the we-ri
bench eurteue to prevent tn-udll-11 viv
I durtlagc.

. '-.

1'

Deteo Elisttttz Hm,-', i!31Bl'J 6? 6'1 1

IZIHUHDA "i'i':IlTDFt Cll, LTD.

._i
 HONDA r"
tI:vurteee nen.erwt|.ve C-III . -.

INDEK MARK
lnutall the ceneqrteft aligning the cam igbui wi1 the
cvlihder heed cuinutq.
Align the camshaft huie with the qliind-qr head I; .
5l'i|:lB:-I l'l'1B-tit 1'1-tr ease tnrrulwfl _aprecJt'at installation.

. -\-
' |

Fl ARM
Apply a thin cu-It of engine pil tci the rucher arm
ti-nifu. . _,_--

lnt-tell the rucl-ter etml and trltnll-I with lite Illfilltl

ands facing cut.
r"'_"\,

l_

CYLINDER HEAD
RIGHT CDVE R -" -
IIil.i{l'|Ii the t:i,'ilntler head tight sidia ctrver using e new
Qltiii.

._"\".

-1.

6_-| 2 5* Deteoflaeue: Me-,-', teen

E-"llUl"-ID.. IIICITITIFI |::0., |.l'u.
-ii
 _r- -g CH] CYLINDER HEAD.-VALVE
.1

_.-.
i
IIYLIIIIJEII IIHII IIISTILLIITIUII eewei Pies
lngtgil is nnw E'fI'IlIIEF heed geeiret end new nil \ I t
uaesage D-rinpe

F
F1
\%\\\\-
- T-In
092';
I
GASKET BRINGS
r'*~

CAP
Install the evllritier heed.
install the cylinder heed ttlvet WI1-ll Th! WOW ft"-1i"iJ
down IEIII !ti!IE'i.

NOTE . '
F Be e-ure to inst-lii 'I.I"iIi sea-'l|il1 Ill'i5Il|"- MP9
WM]-H.-I tap "U5 |u'|-Q] nut nn the cylinder hll
I i=e'r'5e.=.I1?1"- _
Tighten the nuts.
TDFICIUE: 0.9-1.2 irp-In iTE ft-Hal
Tighten tha t;'gt|i|rlI.:i|:r and head El mm bolti-

r"- WASHEFI NUT HEAD E-mm BDLT i3\I'Lll~iEFi

Bmm BOLT

INDEX MARK
(R
Turn the trrehllul-utt eounterclucitwise ant! align the
"T" and lnde:-t marks.
Lumen Ih|t;| mam ti"n'|i|1 [EI"I11I.I-I'll! innit H.111 and
adiusting butt.

If-.

1""-

fl.

em tri irsue: May. ieee 55' 6-13

1111:-|C|r-me. MCITDH ce, tre.
 HONDA
BY L I ND E R H EADIVALVE cm a%;,%
-..b_

__\

INDEX MARK "D" MARK

Pllwr: rhu I:-am chain over mg carruhaf: 1prqq;|r,g1,
aligning the prnnknt n-rruqrk with 1|-19 gylindgr |-mad
Index mark.
Install lhl namihaft lprnckei an mu qmma: ind
tiqhtan ma spruclr.-a1 l,1ul1s._
TEIHDUE: :15-0.9 am 11-1n~|u}

.--1 1

|l1P-tll I-Hi! tvllnchr hind lu ii-da cmral aligning th:

T-lng with tha uvlindar hand nut-uh.

I.-'--.

TANG ..-_-\-_

I2-\-.

111:-tall the muier.

1I=lH|| thu spark plug cap.
Connect the lntaka pipq,
-lillult H19 vmlv CH-1rinl:1: Ipqu 3-Bi.
I .
In-ital the 1:I:rr'ra|::t |:Iu-|nt towr. ___
-Rxlluxit the cam chain tanalun 1p1u_:| 3'-B},
lrmrall thu nal. cuwr.

,_

6-1 4 To Date 1:! |!zn.l: Hay, IQHD

@HDHD-5| MUTDH C11. LTD.
In
 / HONDA
~- _ mu
,_

M-EMU

3? -

'-I-\.
I

,1-'\-.

Ir.-\-

If-_-\-

.--.,_
|

.'I_

[I353 Q? |5iUqI Muqr, '|QHD

Tl
@1|UHDP|. MUTUR CU, LT D.
 1
FIrd Nm
:3
_%lFm"
Jig
_% _H_ Hjlk
_ _ ?_ _ H_ xi
Q
Q
WQW
I?

C
_Y _ EMmH_]_|_ __J__m:_ h_ _ : BL___
____;
_i____|\ _________
p
______
A I_ _|

if \_I__-__II___HHI_ I

T,
EH
_|)_h_x_i
_______H|HW\__
f
1A
A_Qx
If f__
_A
_m__
ii
Q_ ____
____ I|
____
____

_
___ IIIIII

_ ___
_ hp.
_ __
_ |_ |_ _ F
_
TWIHHIL
II

_ ___
I-5__ ll
__L

__

mgmmmm M
A
wm
LTD
 Kyll:-1::E1?=I|rT]n1=|..
.
7. CYLINDER PISTON
SE FIVI GE IN FD H HATI D-N 7-1 PISTON HEIVIDVAL 7-3

TFICILIEILESHDDTING 7-I PISTON INSTALLATICIIII 7-6

CYLINDER HEMDVAL T--I CYLINDER INSTALLATION 'i"B
ll. -I

SERVIBE IIIFIIIIIIIITIIIII
GENERAL INSTRUCTIONS
u C\rIindnr_-|,1i:.tnn malnivananua and lnsn-action can be purfm-ned with tha anaim inita!Iu=I-
IF- -I Canuhaft and rnckar arm lubricating n|'| I: IBIII lI|fHI;I'I1 t-I-II HIIIF UII Flliiiil 3'9 I-"E Th? 955533" 5"" ""'-IT "'3'9!"'-I-

SPECIFICATIONS
IF. "E1 s"r:-mn mo I _ SEFWICE LIMIT
-11.005 -- -u.u1s mm _1_;.a5qa_i:a51u I": _ -I-HIE n_1g|____t_1_.a52 inl
Cylinder I.D'.
Piltun. U I*I.1;:n rinq-to-ring TOP I Mun -11.0-ya-_5=gn_ 10.000-I - u._ua1a i_['1_Il___III.1 2 n'|rn i_J.q!I!\_5_'qL
|;lIl1jUl\ TITIQI QTUIZIIHE lrllt
0.010 D D-45 mm mun-n-1 - n.u01_a In] _ 0.12 mm _IggI15_inl _
n-cl I 1 A-=
|_ _ I H.15--[L351-mm 0.5 mm __It|.I5|? InI
zin P 1 D" FII11-q and nan TOP IU.UlI:I_.DI"I-_II

I 5EClJN_D__|_g.'_l5-Ilmrn IIZIIDE U.I:I'Il'I- InI I15 rmn 'IEI.Di. in]

. __ _ __|1;5_|1__ I t'l.31'J-U.BDmm '|.Ii'1'i - nLi:i:;|}: -A-
fr"-. Plstqm 'D,|II, 45.93 - 47.0? l'|'| rh _II.BE'IJ' I.BR5-II inl -II-6.9-III mm H.847 In)
PI5Il'l pin bore _ 11501 J3. DOB mm 10.5119 El."-51 TI IHI 13.055 mm IEI..itD inI
11I.1|'nrn IEI.52|nI-
._E'1'1=.=."1a12*!:!?!=_"!=t"!*_-F?-_ "+F"?. 1=:9f:?*:!11..!'i?:.5i1i15*=-5"I
Rig,-tg;|_|-_|_t:|i|-| up, _ IIQQI 13 rnrn IIl511GUI'IBI_nI 1293mm ID511 In]

I ..P:-<=~-u=-pm.-=|~@.-1=@==r=n= I"'IE'.@__9-!I!1.'?.""" 1+1.-war-21 - I5-'.1.'E'9..'.'i -'|J,15rr|rn

1?"=~~=~1 <11-"HP-'='~*
IIJ.IJDGinI
I Cvllndar-to-piston clearance DJII5 U-D35 ITII11 IU-Um: - U-5914]" ..I.

4""
'I'II'I]I.IBI.E5IIIIIIT|IIE
Cumpraallnn low
T. Warn wllndar clr niittln FI!'_|'l
Eamasslma imoka
F/_*.
1. Wmn c-pllndar nr plstnn urn;-|
2. I|'n|J'rn|:lIIr lmt-allutl-H at piston rims
3. Scored or a|:.1at|:!'-ad |:.\i1t1:|r| or mrlindr I-\'$I|
Dtrarha-atin-Q
1 Eacas.-r.Iua cub-an huHrI-up nn the nl-H011 ul I'IJLl!lIDIl ahamI'l:Ir will
F- Knncidnq or IIlI'Il'lI'Il1II min
1. Warn piston and tn-'lIndet
9, Ett|.*:E551I'IvE carbon build-up

1"

Date of Issue: May, 1950

IEIHDNDA MCl'l'DH BEL, LTD.
-I!
7-1
 I-ID1\TD1!..(/
E"|"L1NDEFI_iF'|STUN C-III --

IIILINIIEII IIEIIIWAL LLEFI PIN

pr.-1 -.. . 1-

Hem-m.=e the c~,-Iin-.ie|' head [Salmon GI.

Flamcr-'a the 6 mm halt
Flumm-u Ihn gun-it: |uII|!-1 pm aru.I guide roller.
Fiammle the cvlind-er.

.T

-I
PI-eirnrwtr tho D-rir111,qaiI-re! and |:Iuw|:l |.mu_

|-"'_"-\.

PINS /1".

CY Ll NDEFI INSPECTIUN
__4|.,_
Inspect the c-,-Ilmtur burn rnr umar ur |:Ii||m:l;|u
Meat-urn thn wlindar |.D. at thraa laueli In III an-cl '1"
mcia.
STANDARD: 41005-4?.u1|s rnrn
|1.II5BB1.B51DInI _ _ _ _
SE HUICE LIMIT: 47.05 mm H.552 InI _.-\.,_

_ _ L _1__ TOP
" ' : ' r- .
'_ ~:--"P!IT' =._':__I__:)--}--...l SEGCIHD
1. 'r|-nan

7H2 I T-I Dal: ul issue: May, IQIBD

'53 HDNDA MDTCIH F-U-, ITD.
 F
-I HONnae.
"" \-M-J L
BTU cv LINDEHIPISTDN

T PISTIIII atunm
|"Eacc I anon lrowai lII crenl-main to I-':r:r1 dirt and
peruout.
Hem-one the piston pm dip with nE|r.IIu nuee piieu.
r-- I'I'I$i I111: pitta-n |'.|in out.
Hemmle the 1.1I1mn_

ii
III-_"'|.

__\ PISTDH PIN c:.1P

ea
_

PIETDNIPISTUN HING INSPECTIUN

hhmurp II'||: piston rI|1g-to-gro-we olaarar.

STAN DAFID! 0.0 'lI.'I'.III~lI-5 n'|n1
III.l}IJDII-*-CI'.III1l- inI
SERVICE LIMIT: 0.12 mm ID.MBInI

-I Remove lha |J-IEEOI1 rin|;|-5..

NCITE _
Do not damage the piston rlnga during re-
rnmrul.

Inlipact tlw pinnn ion riu-n-am: and mranka. rina

gramraa for waar

r-

rw Insert each piston ring into the wllndw. and

maaaure the arid gap.
STANDARD:
TDFISECOND: III.15IJ.35mm
III.lIIl~B.'I!I1#InI
I,-5 OIL: .300.Bn1InI.-12D.D35in]
SERVICE LIMIT:
TOFFEE BOND: 11.5 mm IILBZ in]

If-

Dan; qf lwue: May, I981] T5 7-3

EIHCINDA MCITGFI CD., I-TI-l
_
 HONDA f
GYLINDEHIPISTGN CTII .131

In'|B::aur1.: the piston OD. 10 rnrn IO.-I I-nl above

the aI=:|rt': hdrttum,
STANDARD: 48.88-47.00 mm
l1.a5::|-:.ae:u| InI
-I.
SERVICE LIMIT: 415.50 mm 'II.B|l-Tinl
Cicuiate 131a r_",'I|:1:.Ier-1|:|-|::i:|:|-:m ttieai-1|-||::_
STANDARD: D.|IIE-IHI35 mm
Ill.DIZlIiII.II14 InI
SERVICE LIMIT: 0,15 rnrn I(I.BMl|':I

-L

I|$E.B!I.1rl lhl piemn pin hull I,D.

s'rmoano= 13.002-13.000 mm
II1.511a-11.5121 ml
SERVIIIE LIMIT: 13.055 l'l'I'l'I I'U=-51-I Il'lI

.-""~

_.-

1""'*~.
Ramoua 1.'h:: Iu'It ::r:lI':I|:nB IT-\'3'-fI!"I'.
Measure tI1e connecting rod small and I.D. with I
lrmili hole gauge.
STANDARD: I3-I313.-I13 mm
Io.e1:a-41.515 mi
ae|=w:::e :_m|'r= 111 rm: In.ea:n| '_I.

53:; nation II} for rauieoerrrarvl prnedur. -

Inatall the I01! ermkeuae never. -

.I .I.

_|-._
|

?_4 re ' Date of Issue: May, I950

E-IHDNDA MUTDH C-IJ.. LID.
 :""
J,-_--.
@a":1:5":: CTLINDE FUFISTDN

Mun-sun: the piston pin Cl.D.

STAN DAFID; 1 2_.BB1l-I3MG mm
IILE1 15-15118 InI
SERVICE LIMIT: 11$ mm ID.I5'I"I I'I\I
;""\.

C-almtete the pistorr-to-piston: pl:-I ::Iearan':e_

STANDARD: II.IIEI2-IIIIJIIII mm
IILI-'lI3D'I I'J.EIIlS InI
SERVICE LIMIT: B.IIIT5mm 'II].IIII1IJ- InI

F7

r:
PISTON FIING INSTALLATION
lr|.11;|I| the pinnn rinqa -mm we marilinei hrna He-
% TDP ewe
-After Imtaliatiun, the rings ll1:uLII::I to-'I;IIl gggqyqg. mmg
I'reaI''. .___
(.___ I . [1-o not :1:-_I|:_::_th| rap and sauaind rinqa. OIL mug

"r
1::.<\

-=1""-i==:-
' an: '
f"- . "~. TDP

F" Space the piston ring and gap: 130 degree: HDBFL
Die not ellqn the papa In I115 ll l'II\-I}i-
I
"I
I _
SECOND

SIDE HAIL

._ _.|I|
- SPACER
"1,
mm_gB
J
MOE aloe amt.
f'\.. in l'I'lI1'lD'H III -ii T--_ GAP
_"Ir.I-.___

-
.-' T
~.
____
.'--

r"'* _ __:-

-'-\

Dal:-U:-::|'I luu-a: May, 1956 T? T-5

EIHDNDA HDTDH CCL. LID.

I
 HONDA
GYLINDEHTPISTDN ETD .-~.

PISTIIII lIlSTll.LlII'IIIlI
Anlv moi,-b-danum LIILLLIIIIIII: qr-use to the nonmet-
ing rod email amt.
lrdtali the piston, piston pin and clip.

I-IDTE
' lnetall TJIE platen with lhr: "IN" r:n.;|rIc facing
H1! ir|I;||Io:e ;irIc_
' Do not align the mater: pm clip end gap w|th
the plslitm 1:uI!nut_

.---.

I.iI'|.IIIIIEl-'I lI'ISTll.LlII'il]II
%_
II151-ill 1.I'|E' |1ILl.IE-I pal, Cl-ring and gitiqqt,

.-"'

o-nine PINS Z!-

I

.-I""'\.
Apolv a thin coat of engine oil to the |:|I|1|;1.-r| ring;
and cylinder wall-
I-rutail ll-in cyiinehr, oumprnstinq the piste-11 rings.

~'=.=When
.IE the cylinder is half-e-,: |:Iu'|f|' the_ |,'|i1-fljunl
r-IJLIT-I: '01: tum chain through ti:-a ctrlin-dar.

7-e E Date of Inue: Hay, IQBEI

EJHONDA IIIICITGFI C-D-. I-TD.
" j CYLINDEFHPISTEJN

Install mu :;n.|'n chain QLIILIE rol-ler and 1I|_1h1+:r| ml!

guide loller pin

TORQUE! LI.5'l .4 liq-rrl IE-.5III It-IIII

-"H Loosely: install the El mm belt.

ins-tell the 1:1.-Ii-:rIer hes-1: [Section Bl. Q

'..
I

-"'1
In G Ul|_I E

F-.

-'-~.

f.._.

Ir.

..-I-'

|F'-

Date of Iii-L=lZN Ma:-'. I-'=I3l1 Ti 7_ T

--lii.'i-NBA MUTCIFI E3]-., I TTJ
 HONDA
c|.u'r::|-|_ C70 -F-h

-.9
.-1,

"II:Qllli

3.8 4.5 kg-m

tee-33::-Ia: I Q
.,__ .'l. - ':
E - ---.__.___k
"-_
Q;->0 I
1
"E:-___-_ II _ :21-

._~.

at J, . ______
-:. '\\._ ""'~._"-.
K ._:.l =:~ 1?
3.
-.
"'~.
I-" "-. ~.

:1: I . M
- .. ___ .
-*"~.
-\:\.

@%_
'\._.' H.

r"-T.
f
_t". ;
.-I .

B0
BO Dateof lesue: I|I-egr, 1950
E;1H::||'-Ililn. Motoa 1313.. LTD.
I": 8. CLUTCH
F
' SERVICE IHFDHNIATIDN B I CLUTCH DISASSEMBLY B--3
TRDUBLESHDDTING B-1 CLUTCH ASSEMBLY B-6

F,-.. FIIGHT GFIANKCASE COVER CLUTCH INSTALLATION B-5

HEMDVAL B-2
FI IG HT ERA NKCA-S E IIDVE Fl
C LUTCI-I HEMEWA I. B-2 INSTALLATION B-TI
-L-_:--|

(-. SEIITICE IIIFIIIINITIIIII

GENEFIAL INSTRUCTION
Clutch BElI\'II'I'lI- can be done with the engine In me I1-ama,

rw
TDDLS
Cernlnun
Univareel holder DTTZEQDIDTDI H..A. IN LI.$,.A,, U5! |.'|r|1n1:|11i||!I'y' ivillihla
hand alrap wrench
l_n:;l: not wrenqtt, 20 1: 9-I mrn UTTIB-LKIEDIDD
Exllentiu-n, 1:? in rlrlw 2-: 3 in ITS mm}: ClTI'IEi-IIIEDEDO Commercially available

TDFIDLIE VALUE
F Clutch lock nu: 3.8 - I-.5 Itg-n1 I23 - 33 I1 lhl

SPECIFICATIONS

I
ITE M STANDARD EFI":."ICE LIIIIHT _
_...,

Clutch Spring free length 15-DB rrrl IELSH? inl E3T11'1rn II],E'I inl:
l
_
Dim rh leicneu A
B
I 2.55 - aee rnrn _|o.:oo___::._1o4 : 1_: =e_-~:. .1.-Q: In
3.35 -3.-'I5n1l'n H1135 CI.I3inl ILD mm l[l.12 in]
1"":
_ . Plate warnage DJ" n1rn |iII.El1 inl
I
i
Clutch <:a1'=tIr nui-cia DD-
Drive pear l.D,
anaan - ::n.ae:: rnrn :u.aa:u - u.a:4a inl
2I.'lIl|J 21.021 mrn IIILBQBB 'lIl.H2?B inl '
*5-9 -~11 J:-ta:-I
21.05 nlm Inseam:
I
TIIIIIIBLESIIIIIITIIIC
Clutch lllpi Blunrh cine: not tlkmlleu
1. ND fraa nlav 1. Flat: wamnge
F 2. Diane we-rn
3_ spring Wk Glued: chug! when tllaangqul
1. Lifter rnuchanien liarnmmul

IT"

_P'7"'\.

Data of lasua: Mat-', ISB-D B1 8_i

@'HDI\'-DA l'|ID"l'DFI IZCI-. LTD-

1-A
 HONDA
cu.rn':H ETD LEE,- "
I _

IIIEIIT CIIAIIIICIISE CIIIIER :::t::< sTaeT En PEDAL FHDNT couee

NJ" -
IIIEIIIIIVAL
I I 1'
Drain :l1e ermine oi: thorough-5' 'I _ I. H"
_.- .. . . _,;'=?
_
5:.-ppurt the |n\'Jl1|.|-:'I2'\rI2lE U]IIgI1T with a stand
' L-_.' " _.- .1
Remove III'HI riqht cr:|nl=:;::== rrrrrm Itmgu 1-El. ::- ' '

4 ; 7* it
T I.

.- I

STAND FIIGH T 1-:.,_

ASSEMH I. "t' CDUEH

CLLITIQI-l LIFTER HEMUVAL

ADJUSTING BU LT
F'IE!I1tJt'E 1l'|E Elutth l|'lI::: urIr.I clu1t:l'| odiutting bull

|' "1'

r:LuTI:H LIFTEH .-:~._

CLIITCII IIIEIIIIWIL
llnmv-Mr the rlutch luwr and clutch r:::In.
"~.
Hemoue the elutch -outer co-tar.

1";

L CLLF mu _

2 e2 Date.-of l5:~1.m Muir. IIJBEI

HCINDAuotoe co., LTD.
 HONDA.
..- cm .5...
r"" LOCI-=1 TAB
Etraighta the In-ck vr--1-=1-Hr I-ah. _
{Q},

F D ql Q,

l"\..

LIN IVE HEAL HULDE H

HEHIUHE zhg lcruk nur, was.har and Ir;-ck washnr.
The clutch can nnw ho rumuvud as a -nll.
Hgmqw 11111 rlrivr: gear and r:lu!L:|| GEMEF guide.
*1 |

I, EHTEP-|SiD|'-l LUCK NUT WHENLH.

II] :< 24mm

BLUTBH DISHSSEIIIBLY E ms
fr-E Remove the IE! ring using a 5l:n:wdri'n~ur. S T g
Rumuvn rhu r-IuIh plates, dis-I:-5, I:-nnicrr, drive gear
cuter and rollers. _?

F-.

If-I"I-.

om D1 mun: my, man "3 B_ 3

IEIHDNDA MGTDH [JD-, LTD.
 HONDA.
CLUTCH _ C70 JI -

HEFHDIW ill! |.ll.|[|:h dampm ipringg.

Flaw i w|:||:|d blank under the dr in ptate.
Remove the 5 mm-5-cr'ew.=., |u3|!|'|ir|g II-3 turn: gr i
1Ii'\E |'|'|1||E -|.'|L|5|'||r|g dnwn nn l'h|_: |:|ulf'|;h gutgr,

1-._

CLUTCH SPFHNG INSPECTICIN

Measure I|||: spring mm Inn-qlh,

STANDARD: 25.UB'mlI'| IIJBBT inl
SEHVHZE LIHIT; 23.1 ml'l'l {DB1 In}
_F__/"""-..,____: .-
.- J.
.-
l"__\__L _ J
___. "'-\._H_\_ -' |_.|I-\-.
.-_.
I-C g _
___. _$________-ER

~&_ .. - :1. -
-\-.___ _ _ -\-.

. . H -- .
I
'1 Jr ~._._ |

."""\

CLUTCH DISC INSPECTION

J-H
Heptace ma ulurch diam if lh-5'9 ghnw ,4;-,4 U4
Btclrinq or cilrnulorannn
Maaaura mu din: Ihicknnss.
STANDARD:
DISC A: 2.55 --2.55 mm 1.10D.HN inl
DISC B: 3.35-3.15 mm {.13-.136 lnl
- -.
SEFIVICE |.|n.n|r= nlsc A: 2.3 mm mun mi
DISC B: 3.1! mm 10.12 ini

B-4 " Daiaclflssusz Haw. IQHCI

EHUHIJA MOTOR Gil, LTD.
T BTU CLUTCH
Ir l

Ch-rerti. the [r.'|II|:|5 and plates for exuassiuu w|1ur-

Hanlam if nacau-arv.
Elruck fun -plate warpage on a surfanu plutu using a
f~.:r:~Iur pug!-
,/'_ SERVICE LIMIT: .2mmiD.D1inI

JF-

.|"""

DFIIVE GEAR INSPECTIUN

.-L.
'Bhar.:lr for waar nr damage.
Mtriule the riwe gur |,D,
QTANDAHD: 2-.l.0021.D1 mm
tunes-o.n2t ml
P SERVICE LIMIT! 21.5 nun IDJZE lrll

CLUTCH CENTER GUIDE INSPECTION

rihk ill! WEI! U1 :1-smug:

Manure tha niutd-| cantwar quid: CI-I1
STAH DARE: 2I}.BI|Z'lI|.'B5ll l'IIl'l'l
1.B2lUD..Bl|l3 lI'lI'
senvrcz LIMIT: 20.30111-mI'D-B23 Inl
K"

FT.

Data uf _Iw-":1 Mir, 19311 B5 B-5

IBHQNDA MDTQH CG, LTD.
 HONDA .-5
c|_u'rc|-| BTU " '

BLIITBH ASSEMBLY _ _
Plane thE IL|t|2h sprlnga un lhu drive: plqtr: and inall CLUTCH PLATE A
- |.'|I1r: 1t: the cI|.|t|:h 1:|ut|r.
the drama FRICTION
DHWE GFA_ man B ELIJTEH
PLATE B
''"I____I3ITE serum:
I'l|_=|htur\ the " E"
In 2-5 !1.1:pl in i r;rl:5r;r1;|5q
H'u'"'-EH
I DUTEI|:LuTGr|
|-CENTER
SE
ems
-
.
uettnern. I _ I I L H J
IP15-Til-II the cIut|:h damper -sprtngs. _;I E I 'i'_34;'_, I |' "iii H
tnsteel the rulleht. drive gear outer, <:lt.rt1:h center, Fl
K~:Y-_=.+"'
_ _.;[;-,___|i_, :1. H" -
dim and plate: and secure with the set rlng. ..j| -
~..;.r,
_;; -3~'-G. i|
lt Q "-
~_. .@? ', -,-'_:*""' __.1-

I
IJFINE PLATE
CLUTCH
THING
'/
'|
FRICTION DISC A
|-,_

BLUTBII |NSTlI.l.TI[II'I
PLM N INFIEH E Fl
|FI FIEIII I|"lE' lulh Hunter quid-5 and drive gem
Ihstnll the clutulr asmrr|taIy.
Irl:Il'|II the luck washer, plain H-r-udrn-r ind lqqlq m_||_ I. 1| . __
NOTE
_ .-"''\._
lrrmrll the plain washer wlth thq "tJ|__IT5I|E"
marl: Ia-::i|1g nut. |

.-

LOOK HUT WRENCH, ___

. ED rt 2-Imm
TIQTIIBI1 the luck n_=ut_ ...
TDFIQLIE: 3.Bl-5 kg-m l2B33 fl-lb] _
Band The! lent was-her ml-t,

_.r--

-I ."'

UNIVERSAL HOLDEFI TOH DUE WRENCH

8_6 as Dare of Issue l'~'I-a~,r, IEIBU

'JHt'.JND.. MCITDH t:n., LTD.
 Huntnn
lg; cm CLUTCH
OUTER
lnetall the ciuteh outer cch.'e='.
Irmnlr rhe <:luu:l'\ cam and lever.
Install Uta aring. oil tl'1ru-ugh, eluteh cam spring and
bell retamer.

EL.
CLUTCH LEVEFI CAM

RIGHT BIIIIIIIBISIE BUYER ADJUSTING

IIISTALLATIIIH
lrr51',;||| 11-"1 rzlutdh adjultlg belt end llftut.

CLUTCH LIFTEH

lmmll the D-ring, washer and leek nut

lnetall the riqht clan-linen: wret-
lngtall thg kick itartnr |2|:dl|__ 'I'|;|t:-!;n!Q1.|hLI|!' 5'F.B|'||II
!5emI:|I'-,-', muffler and front cover.
Fill thn qrqnlume tu the proper level Im-| lhl:
|E=t:|2r'1m-|'ldBd= e-'|l Ipam 9-2]-
Adiur-t the |:1|-Itch In-B99 3-IEIH

/ R.
CI-HING WASHER LOOK NUT

Date nf leer: Met-', 1931]

~'HDNDA MOTOR CO.. LTD.
I1 B-7
 H On10D _
G EA H 5H WT L W KAG E __ H

f
_____r
_ _

J
M
A
X /:Hm____
T
____H"_\______._

V
3
_

_ ____U__

XX x
m
__

_ _ __ _ _
mm
J
W
__\
aw
HIINNER___ if
______

%
9w n_ _ _H_HN_I

QI

gHMD HmWA mm Wm_HHE mu

HO
ET D
I"
F
9. GEARSHIFT LINKAGE
SERVICE INFORMATION 9-1 GEARSHIFT LINKAGE
B-2
TROUBLESHOOTING B-1 NSTALLA1-DH
{___
GEARSHIFT LINKAGE REMOVAL 91'

SERIIIIIE IIIFIIRIIIIITIIIH
GENERAL INSTRUCTIONS
r"'_- 1 1 hr; Q33;-g|'||.f|_ gpin-dl|| arid r.m1:r|:rerr arm I:-an he serviced with the engine rrr ri-re tramrr.
I It the shit: tr.rr-kr., drum ar-rl transit-'Iie:ir.:|Ii require serr-'lr:.ing_ ren-rcr-re the engine arid r-eperete thr: -llrnttitril-9.

r-*~
TiI[lI.IBLESIl[I[lTlNI.i
Herd lhiitinu
1 ll-npmc-er clutch ndiuetteltl
IL Shift lurks bent
3, Shltr shaft l:re'P-'t
-1. Shift rlrum =1r-inner beet
Er, Shllr drum earn gruclve I-lee!

P Trnnermrei-en iumpl nut |:|1' gear

1, G-,-.rrr tleqs worn
1 Shin 5.I'1.3I'! hem
3, Shift drurn rrterpnnr urcrkern
-I_ Shit: Irrrit: be-nt

f""-.

fr-I.

F"

F.

.I"''

Drrrerri I|5_|J9I l'rIa'-r, I9-B0

DHOHDR MEIIDH 120., LTD.
R9 9-I
-O
 HONDA r
GEAHSHIFT LINKAGE BTU gr

IIEIIRSIIIFI LIIIIIMIE IIIEIIIIIWIL t=eAee|-||FT PEDAL

DI-Hm the engine ml.
Remeve the gearshift |}3I_

-
r.,__

__,_

R!-nmle the right trranlrtqasrr Queer and rutrrri-| 35- B.

wmhl-r i5E='liur1 Bi.
I H-I]Fl'lO'lr'E' the snap rln-5| end driven gear, I

I .'_-l.r

_--,_|
SNAP RING

_.-Fl-I

Remove the drum stepper arm. ii-Iii

nrrurrr smeeen ARHI

BU
9-2 III-nleui Issue". Mrr~,r_ IRSO
GIHONDA H-DTOR CO., LTO
 HONDA
BTU GEARSHIFT LINKAGE

O R UM P LATE
Remove the drum stunner |iIh'lr: ehll pim-
l-'I.|1I the geerrei-ritt spindle out of thn rrrerriura-2:.

ISHIISIIIFT LIIIIIHBE lIISTi\I.l.i'i'l'lIilI

DRUM
lnstaii Lhrr q.uI|t1I'|III drum pine iI'l'li!I drum rtElDDIlT ' '
Piie.

irretmi the gearshift spindle areemblrr.

GEARGHIFT

OFIUIII STOPPER ARM

Install the drum atnnper arm as shown. "Q11:-:
Tighten the pirrnt heir.

Fietate the gearshift spindle and check the linlrapr

fur am'e-crti-r onemierrr.
Ir-rr51;|| the r:lutr:l'r assembly and right eranitouse
cutter.
Install the qunrshift pedal.

El-ate of Issue: May. IEIBIJ 51 9- 3

EIIHEINDA MOTOR 20., l.T.
 DA
I <_=f=_=
THANSMISSIDHIGRANKSHAFT C70 -I "0...

I
-.

1.0 1.11 kgm

[T - 1{|f"t-lhl

@=' V 5/
is in 1 K-

..-
.-1-"ii ll . in-1 - --I """.
.- ) | Ii ____';-_-q__:___-_5_j:q_
-1.

x_ "!1|-I ,1 ' I -~T--. *1"I

QQ;/*"+
- i |IrI",,d . 1'-H.

2-.

.' "'r--_
n
-=1\\
*3 ' ~'~."..' -"
. ..;~ - 2;-El, .
-r if
.-"-- ' i
E-'
-_1-.- . ' _ r
-
--
.--

-'-'--

4;
_-J
-4'

I.9-J
. $ _
1 U. O 92 um -=-+ IHLIEII Hay. 1550
EIIHDNDA MUTD-H C-0., LTD.
 E U)
,-
I-"
I-IiJ1\I'IlJ.B.
BTU
%
A p Z''l $3
III Z U1
=5 3 EH
II,1
ii -|-ill 1"".
SERVICE INFORMATION 'ID1 TRANSHISSION DISASSEMBL? 1DE

TROUBLESHOOTING II]~1' TRANSMISSION ASSEMBLY ID-9

CHANKGASE SEPARATION ID3 CHAHKCASE ASSEMBLY 1DID

1" IIJ-4
CHAHICSHAFT REMOVAL

SERIIIBE IIIFIIIIIIIIITIIIII
("\ GENERAL INSTRUCTIONS
1 The crnnkcasa must be saparaud to -mrvim 111: maniuhaft -and transmission nnmpnnanu.
I The f-allowing pm-L1 mun be rammed before aamrating H1: crlnl-mesa
Cvlindar head Section B
1" I';'gIl111:l:r and nlstun E:-lIu|1 T
Clutch Suction B
Gngrsh11'1llnIm-ga Sec-than 9
A.C.gnIr1url1:or Slctiun II

TDFICIUE VALUE
Finql d1-Iuu sp-|m:Ia1 I.Cl - 1.4 kg-m IT I-U it-lhI

SPECIFICATIONS
M nm mmnnnu SERVICE LIIIII-T
Tfihsmlislnn Gear LEI, I-II! . 17.013 11043 mm I9-5599 QETIU i|'II _ I7-In ITIITI IU-573 |"'I
1:1 .___|i.______
I 11015-110-1:1mm11115699-:11:-11101111
_._'_ _
I110 rnrn Il1EI?3 In] _
1 - E3 1T.II|1B -- 11.1143 mm 10.65-QB GEE? TU Ir1|| 17.10 mm [CI'.B?3 InI
10.5-E? I111

11
II1III|ImI'l EIT O.D. 15.954- mm IIILBBBB IZLBEQI |n|' 15.55 rnrn
I'M
Cr:I1.|nt:1:I1arH O.1l . 16.965 16.954 mm IIILGHBD H.535? InI 15.95 mm [D.BS? in]
in
Shift drum DD. in
33.E|5 ' -I-_i___33.QG-r1'1.1I11
33.915 mm 11.33615 - 1.3336 In}
_/-\_ sum rm 1.1:. 34.11615: 54.1125 rrlI1l II.3-335- 1.33% I1'_1I a4I1:TT:T1T.i3.lII:
' '51-.1111.-1: pawl Lm 413% 4 11.11-1 n:|m 10.191 u.1E'i}1'| 4.5 mm_1'1:1.'1a 1111
I """"" 111.1111. ass 5.91 mm ID-Z31 0.234 InI an mrn 111.22 1111
C1-anI:1|I1; Connuct-ilng rod big i:m:I T _ 0.6 mm ID-D2 InI
side dgmmm CLID I135 mm IU.GU"l D.D'I-II IHI

f =~ Currnnctirlg rad big end

fadmqian
_ I].l12 mm IIJ - EI.OC|D5 InI U115 111111 lD.IIl2 inl

Flunuut -- 13,10 mm lIO.IIIl in)

Journal hearing A2551 n-1u m'1+1 IU.IJE_I1I Ln]

,..i.._
__ D-In FI IIIIIII UJZE rnrn ID.1DD2in|
P-
1""~
D11; nf Issue: May. 1930' 53 1 o_ 1
BHONOA MOTOR CO" LTD.

Oi _ _ - _
 HONDA |- -=|
TRANSMISSION.-'CRANKSHAFT ""

TIIIIIIBLESHIIEITIIIG
Hard tn ihi
1. |m|:1r|:11-J-=11 -::I1..|'t<:h aijjugrmgnt
2. 5I1IIl* fnri-: hunt
3. Shift iha hem
4. 5I1If'[ drum an-||.'r|.'.1+|1r arm banl

Trlrllmiisinn jumps nut 1:1! qnr

I. G-Ear Irloqsworn
1 Shi shah In-.-n1
3. Slhft drum ltnppar L11 uh:-n
-I. S1'1if1fc1rI-1.: L|-B11!

Exclilivl lllZI~Ill
1. EJ1:!|e.Iii'|'~H crrrnl-cshaftju-ur11al Lu-m-Ing play
1 Excaaslve Gl'Bf:1I|i3|'I|| h1:a|'ir|g play _ ..._

|"'

.1-

-"1.

1| D 2 5" Dateof Issue: 1.131,, 1950

QIIONDA MOTOR GO. LTD.
 ' F\I-ICII\'I'Il.B.
K:-"I11.

,--_ C70 "r1=tAnsm1ss|onI<=FteNK$H~FT

'IIIIAIIIIIJIISE SEPFIRITIUII _ ENE"
Hr,-1mm-1-. lhp cnglmr Ser.'I'.ir.1n HI.
- tamrtt
-Ail
Remove the t:\rIit1|:Ier head ieetion EI-II. _
Homm-1: fhl: l!yI|1'||;I_r.'l' anti piltlt [SHEER T]. l J! e
Hemcrre the clutch I5n'ot1icII1 B].
rm Hgmgue thu ga-ir.$I'1-II! IIHIEBQE [5BD1I~Dl1 9|.
' Remove the irting rnotor I5udi-::r| IBI.
Hem-we the A.C. generator [Section Id-I.
Remove the 1:-ranitsluft one-Ir.
Remove tI1e drive sprocket.

|r""\.

_.,____

1"
CAM CHAIN SHIFT DRUM SHIFT DRUM
RUBBER CAP H-OI T
Remove the elm ohein temioner red lti tili-El.
Ren-||;|-.r|| the ruhher up and 1hiIt drum m-otarrting 5
rnrn bolt. 1- -____
Home-re the crankcase 6- mm eerevm. --.___

("""~ "1:

r1 CAM CHAIN TEN5lONER PUSH ROD

RETAINER
f - Pb, 1|-1; gnqlng wim 11-1|; l|:I1I termitoei-e down- \
Hammva w Quip ring thB|1 |'Elml;l'\I' 1155 |'\E'IIlI|'ll?I' iI"I?I
II.l1:I\t starter I-Brine.

F- I}

f"'-.

Date of iuuet May, teen 95 1 _ 3

ezunowen. motes co, 1.111.
i
 HONna. ./T
TRANSMISSIONFCRAHIILSHAFT ' It

Seperaee the right orenireeee from the Ieit 1:re:1Itr:ae'e.

Remove the dowet pins and gmrkm,
I

_-I-
_-__1|||:1I

- .3

-H1

IIRMIKSIIIIFT IIEIIIIIIHII.
Rome-ve the orani-rehait .1-5.5 _
CFIANKSHAFT INSPECTION
56! the tit-Ihltahaft on I 1t.|n-d or 'u' bioolu.
E-at I diel Indioetur as ehowr1.
/T-_
FIIII-rite the crankshaft two rwoiutinns end reed the I
r1.Irrr.n.1t.
Actual runeut I: 11'?! of Tut-II Ir-dleatnr Reading-
SERVICE LIMIT: 'D.1 mm [D.IIII.'|l InI

mm mm
1BinI II.I2ihI .--.

Measure the I-IIIII eieennoe ut the Itonnoctlng rod bio -""\

end wit a feei-er gauge.
STANDARD: II.'IIII'.35 mm {'iI.'l3Dl\IJ.B1l IrI|I'
SERVICE LIMIT: 0.! mm I152 InI

_"~.

.-

1 O-4 96 Date _r.Il lento: MW, 19%

'QI'ICINI:h'51 IIICITDFI COL, LTD
 HONDA
.:.
C1 U TRANSNIISSIONICFIANKSHAFT

1-
I

II.'IE15=..r|i: The: :Bt:II3I ttlreuzeirfrr at the |.:r::|||r1er|':Ii||g rurl

hig end, at two points In the direction in-dieeted by
the arrowe.
STANDARD: U-0.012 mm IC|LI'.DOI'.IE InI
ii.
,--- SERVICE LIMIT: [I115 mm IIJDJIIE iI'.lI
I I
'-\,__\_\__ .

|r'_'.

.I"'

5pi1'| thejournal trearinq try hund and rlmleoe it If

noisy.
Cheek the 1o..rr'-et heeriou pdey.
$ER'uI'ICE LIMIT: '
AXIAL: e.rrr rrtrn mum-1 1|-.1 .1
5-. e.n.om1.I one mm 1e.un21n1

TIMING SPROCIICET INSTALLATION

1' I I|1s1eII tlnn epru-r:I1ter, ehgnirrg any tooth Ia-ortom 1I'riII'I

the Ituyway-t:H:re nirpi.-I cunlur Iinn.

1"

/T

I.--.

Date of lseue May, '1'.-IIIBI] 57 1 D_5

-E1 HONDA MOTOR CH1, LTD

-,.,i_
 HONDA .5
TR ANEMIEHONICRANKSHAFT -e__ T

TIIIIISMISSIIIII DISASSEHBLY KICK eme-ren SPINDLE centre IIZSHAFT

Rerntr-'1: the erenirehaft and ltieit starter spindle.

Q.

l1.l=- 4.

Remuyn The !!'ilI15I!1-.lIlI_'Il'I nod :I1|!t I.1ru|11 as an "Ir

aseenthly.

."\|

. I _
-_|

..I.__; .1 _lT
.-P.-.

--.

KICK STARTER SPINDLE DISASSEMBLY

SPINDLE --N
Rernoye the snap 1'IIr|;| an-rl r.l|sa:rI.:mI1le l.I\e Itiels |' -'
i*l..l|' IE1 L12|II1|.IIE_
Che-eh the driven r;11r;h|:|!I_ pirai-mi and epiin-die for
exeeeaiye weer.

~-

II Q

I KO
1%
PINIIDN em? ems emizner some ems -

10-6 B8 D3151]! Iosuee: MBY, IQBCI

HONDA MOTOR Cl:-II., LTIJ.
 _/;;\.I-IOBIDA.
J?-
Qi CT" THANSMISSIDNIBHANKSHAFT

..___/
_/"'" TRANSMISSION GEAR OISASEEMBLY C-GUI-ITER<I;IAFT FIRST FEAR SECOND GEAR THIRD. GEAR
|'
Dieareemtie the rrui11ehnr| .1111: eountermeft. |

Inspect eeeh gear for weer or damage-

1*
41., ,1.
rf"-.

'I\Ivt "
MAINSHAFT SECOND GEAR THIRD GEAR

Meaeure eeoh gear's I.D.

STA NOAFID! 'I?'. 'l'E- 'l?,l}rI3 mm
IIJ.IBB5D.B7'ID inl
SERVICE LIMIT: 11.10 mtn IU.B'.I3InI

/*

in

I/H
I|1g@1,||'rp II-l 'O'.D, |;rI 1111: miinillkll ld counter-
ahaft.
KTANO-ARO1
MAINSHAFTI 1E.B3'I=B.B9lI- mm
ID..EBBB'IJ.II|IH1 inl
DOUHTERSHAFT: 1.9i-Ii- 15.581 rnm
1"" [D5550-0.65? |n'I
een1.r1ee LIMIT: 1e.ee r11IIII.BE?InI

I-"'-'-.

I,-.

Date of Issue: Ir'Ie'y, 1950

EIHDHEIA MCITDFI CI1, LTD.
10-?
_
 HONDA E.
TR ANSM I55 ION I'C RAN IILSHAFT cm 11-
_,__

SHIFT DRUM DISASSEMBLY GUIDE PIN CLIP

RBITIDVB I116 QLIIEIB |:|It| dips, pull nut tho guide pir|5
and rernut-1e the 1.1-M1 fqrlqe.

NOTE
Hlerlr. the right and left shift forks to ensure
eorreet assernhfy.

Chisel-: the iluide oin for weer or rlernmge.

GUIDE PIN --IL

-Check the iI'|I'Il Iurlr. ler weer, he-ndIrn;| or other

Amman ..1'2_%_:
Memure the shift forlt LO.
STANDAFI IJ: 34.000-34.1315 mm
11.3:-tee-1 eeee InI
- .|-I-H.~.
SERVICE LIMIT: 311.0? mm H.341 InI

_,,h

-+~._\_
"'-D.

A-ht".

Memun: the shift 'Itj:rIt Ellw I1'!ICIILnE1i5.

ETANDARDI
LEFT; l.HB-llsil mm 'IIJ.IB-1-CI'.I!I5 InI
RIGHT: E.BG5.'5-II mm IIIJ.23'I--D.31'ld InI
SERVICE LIMIT!
LEFT: 4.8 mm IIIJI5 InI
RIEHT15.B l'I'll'I1 {URI irll

I10-e Date of IIEIHI May, I930

HONDAMOTOR CO., LTD.
 T FIANSMI SSI DNHIRA N KS HA FT

Check the shift drum fur wuur ur d:n'n-aw.

MBELITE the sl1|f't drum D-D.
STANDARD: 33.950-aa.e? mm
11.3355-133m nnl
SERWCE LIMIT: 3333 Ir|mH.33BinI

TRMISHISSIUH ASSEMBLY SECDND THIRD

GDUHTERSHAFT Fl FIST GEAR GEAR
Assemble the malnihrft and uuumerlhift qairi and If
secure wi'lh the map ring.

F-lDT'E _
I
Lubncate ear:-h gear_\;-;ih_-Film all aer I \ I X
asnumhly.

L i ~\';~ LO '

SHIFT DRUM ASSEMBLY

/ / 1'~
MP-INSHAFT EECDND GEAR THIRD GEAR

lnrmlr thu 11-n furl-u urn mu mlf-1 drum-

Instill 1M uid: plm art] nmuru wlth the clip. RIGHT SHIFT FUR!
LEFT SHIFT FORK.

r r
|\~ !
9/
I.-" " ___
EHEFT DHLIH

'~ if
;=+=-" '- _'__
A
/ii;-' -_-__-_'-|'r: __

GUIDE PINS

um cf Issue: May. 1950 *1 1 0_ 9

EHUNDA MCITDH CCL, LTD.
 HONDA /----:=\
H.

TH AN5l'|ll$lDNl"CFlAN KSHAFT cm -5%) ~-

.-1_-._.
KICH ETAHTER SPINDLE ASSEMBLY
Amlmlele the Fciclc .sta.rter aw. shmvn. HICK F.Fl'|I4.HT_EFl SFINDLE
NOTE ., S_
P0!-iHUl'lthB Ir|Gt|O|1 lpring in the driven I .1 ,--|.
.-
ret1:hat qrnmre-
FRICTION SPRING
cg: i

-.3; .

KICK. STARTER SNAP HWG I SNAP HMG

FINIDN 51,;-p|5p|
HATCH FT
| .1 I-. |
| .

TRANSMISSION INETP-LLATIDN

|llE!i|| the drum end tran-im-ulnn 1n me left

crank-cane as m assemble-
MAINS-HAFT
NOTE lIDl.ll'lTEFl5H#|l-'l'~\_F """ .
,..r'-
.-

- Alqpt the neutral twitch rotor wlth the J..' J I 3' _Ie.*_
H'Jtr|11wil1:h.
' After lnetlllinq, rntltn the milrreh-all 111 In-ll:
yure that the gear; rntata freely.
twee
|'Ill.
.-' - Il' i kit
_,__ I . "fax"
|._' JP
__ I r U,
"1-A-I :'_
__.___l"lEl.ITFlAL
__1-_ -- '"_,,|.fiI
--
__-_-,-: ' _;______:.
"' 3w1"rcH HCITCIFI
, _.- .-
&._ _ . -'=i=
("17:
F.
-;_l__ I F--.~ meutem.
"":;~ ';___._- - _sw|"rcu
1-:_-__\
-iqt-='.Z'7
" J - " HFIUST wnsl-use
-I L

.1-.,
Instill the tuck l-EH"lI|' spindle in that the frltrtiun
sprlnq mete in the nunhnuu grvcwc.

.-"_"~.q~

EFHIHG ---

1 0-1 0 "lB1l$T@"?5'&''5''.
 I-Iowan
tr
gj TRANSMISS IONICH AH K5 HAF T

F lIRll||lBlSE HSSEHBLY nuwtt PW

lrmtllll 1h|r tranltehett ll the le ttrant-mate.
lrlttall the dowel nuts and gasket-
Plaee the rlghl t':rur|kt:a|e: -:1r|Tt|- 1hB lE11 crankcase end :F'
turn the clanitcase assemble |:wer.
F
lstall and tighten the eratnltceste t-1:r1:'lI'lfI-

If.
l I h

F"

GEM CHAIN SHIFT DRUM EHIFT DRUM

TENSIDNER RUBBER CAP BOLT
lrtetell the uem chair-, tensinn-er and tnrrtiurutr red.
Ir-_1.ull the thlft |'.l|lJrl'l E ltl|l1l| met.-ntlng bolt and
rubber cup. _ ___ Eh
lnal [ha l'lr|.:|l titlu 5|Il|tn-Cltl.
P. TORQUE: 1.1)-1.-\'l l-cg-m [?1Dl't-Fh] --..____
_'I-|_
__\_

CAM CHAIN TE HSIDN E R PUSH HUD

r"""

F.
lnitell the ttielt starter 5p-ring =lr|tl rttlrlcr
. ', , .'
Hunk the 5p| In-t1 end: --n the retelner |]r-ntlvtl and mar _ .| t
the r_tran|-t-:15: |,|r|:|l,EC1'|t':-r1. '-. I J '
I
Install the snap ring. _ |'
I

lnt-telt the A.C. gnrtutall lSe=|:tlon I-ll. ;"- it | | _- KICK STARTER

. . I " ' | %Fl1hlG
/-\-. Install the ftarter mntrrt l$||l:ti=H115lI-
-. Li '.\'
1n5ta|l the geurqhilt llnlteqe I5-eetiun Bl. '
F"I_' . _ at
lnetell the clull-.h [5el.t1|1JI'I Bl-
lnstall the wlinder and pittrm lefrll Fl- -t-.
|n:i:a|| lhn |:\,|'ll1:lEl'1|E1id |Sectlt:|n Bl. :-
'-'iI5'l'1 -

lnsmll the engine (5uI.1li|1rI 51.

F senses L u '
nemtmee "
"
f"~.
i_

Date u-F lseue; Mae, 1950 103

EJHCII-IDA MUTDH Ct}, LTD.
10-11
-1
 HONnn ff
cm
MEMO

-\._

.1-H

.--t,

-F'_-L-

ma Date of Italic: M-Iv. 1!-lBl'J

-D HONDA MUTCIFI C-13.. LTD.
 /'1-ztomnnt
Ft
cm it i I F-EZ 2:Z15Z22---2H52
I,-.
ll

SERVICE INFORMATION 11-1 CAM CHAIN TENSIDNER

1_|_1 PUSH HOD 11-2
TR DUB L EBHOUT I NG
CAM CHAIN TENSIONEFI 11-3
J__

SERVICE IHFIIIIIMTIIJN
G ENE HAL FNETHUCTION
if-.
F
The can |;hai|11;|trt.;i|;|nltl' nl|tI|'.I1m1't rad can he sereibetl with the ungih in the heme-

T|i[ll.lBl.ESllB[lT|llB
F Elm uhlin bltl
1 In-cu-:ru|:l tenelbner eeliuetment
2. Dame-aetl st:-ring
3_ \'1|'|'||'r| ur dan'|agE*d 1-1.It'Ol:|'t|T
-ll. Wern or damaged chain

r-

1""

F-.

FF

.-'
_ _ .___

Date u-f issue: Mme. I931]

TQHUNDA MOTOR CU-, L'|'|l'|.
"5 11-1
ti - _ -
 HDNDA K
CAM CHAIN TENSION EFI
R i_ .3
cto i
.--.
--,_
. |

CHM llllllll TEHSIIIIIER PIISH ll] . _

It .u-| ,3 h
", |.-
_|
..|| _
Drain the e--rg='t||t -;:|i|. | -'32. . :5: |_:_I

|-|-1I='**" T118 |-D-Eh HI-I1 and remul.-e the Ind; 11-|||_ _|'
l.-:3" -tag W-
-r
|4r=rne'-B the inllnq he-It and wu1rt-I,
RENO-rl the adjusting belt, spri-ngi and [en-|-inner '
H.-___
.-"II-rIII. It I-t'=.I.
1:
r
.-'1-""fl(_t"'l:
1. ---,:~,. - I

rt:||.|. i._ Pi" '-"''\-.. :-'#53":

'\--\. '--* -' '_|;.'::"||'
'-_:--.-"":"'
-' .- n
LIST -::I\.:\-i'| ':.;_:-.iH|:_:E-J__. i__
1"-__ .-' lll|
Chil lhn teneic-net md and -,-pm-|g rm 41;.-|_mE_ AD-1 I-:-.; :1 F-F 4 .'__.___-H E - ' ~:
__ - is --=.__--0* >2-
t.~ .-' -._}-' ._
I1 ____I-I _-'.

, L
LUCK BOLT
i
SEALING BO LT LOOK NUT

Install the tuntiuner push |-ml with 1-he tap-er factnvg ' | .__\-E K
' I
_ ll -
' -.. '| ll
Incl: btt-It. I I F I '1-L 1+ |'|'

|
.
Illt
|
I
.
-
|
.;_..
.-._
-._ _ _-
-|__?._H_I|-.\"'\-II
-F
.1 ' "' ": _.
' In xi--9? LQCK f-H
|__ .-_.-.,_ -I,
._|_ .-:_|I J |
':---,-:51: _,. BU L T I
-1 .'..:'- H I" | u- '~'+ _;=' I
T.1" ,1!- '1-L |.'_-;l I.
.-"-Ll
ll
".\-_ _.- . __*-._I LOO K NUT
I
eus net: __.r"
I fl.
I'.I 1;". __.-' - _-
_.-' . _-__- w
____..I" l .-"' '- .__|-I-'._

.-"ff: I

-I K

.--.---

lnttall thn anrlngt.

.-"'_"'t_
Straw adiueting bb!t mm the |:npnlt|:-e
ltll the maliraq Wi-l'i|'lPl and bolt.

NOTE
I The eeeiing bolt end must hm \'_:|J'I113|3[ T119 J7...
bllurn -:1! the adjusting bolt. | '|

lnetall luck bolt and lock nut. -5., "- -_1_;_=:_-.-5;.-_.: _ ___..--ADJUSTING entt
Ttghien thtt luck nut,
T?
senutue - - ."'
BOLT -_Q
,

" |
|

' we
11-2 Date bf Issue. Hey, IQBII
'@HOND.A. MOTOR C-U.;. LTD.
/___I-IONDA
tfg/=' C11] CAM CHAIN TEHSIDNEH

BAH UIIMII TEIISIUIIER

Remg-re the .A,O. -;]c:|'|r:|.~.|tI.-.-l and llywhe-El [5E|.tIur'-

H|rn\|.w=: '!".:: :.:l.a||.1t.' l:|t;ti|| t|u|dE_

Flernmra the stattur ch-:i=\ ::Ir~11u|!h-H.
F|t:1r||.|'.It: the 51Br1LEl sprockets and nhilm H: e rrn
Re-|1'lu'.|e lhe craltltlhaft CD-.|Br.

CHANPZSHAFT GOV E Fl

. . .. _.._... an-1|-1.-4-1-||-|-|

Fl_e|'|1|:|';n the: teltttlurlel push rc:-cl. i

Renlme the earn than tnlltmuul
C-|tIr;h, 1l"||t ||:|".5|l1l"t!l :'.|.llDt:||!'. fill li-BI DI l$l1Fl'lI1I=|E-

lmtullatie-n It the reverse nf |=:rntnrul.

NOTE _ _
Be sure to Install G-r-up: cm the erankeheft
c'cn--Jr it-rew |'lEl|HFr.

0-nle TEHSIUNEH PUSH nee

[lite Q! |i'5.lJI!. Hay, 1QBO 1? 1 1 _ 3

IEHCINEIA MCI-TOR EIU., LTD.
 HONDA
FHDHT WHEEUSUSFENSIDN BIB -'~
.-:-"l.

Kl -I-bl

l\\-:E?=_-='-""-'=:|-'=t-

e
'1-.r'='"
_ _-5 " - _ -"1

It
6.0 9.0 Item 5
I43 - as ft-lbl 1'

It Y! E-:'E'.il !-*3-

an 3.0 lqrn-. ___

I14 - 22 h:-lhl
._.
I- KT
5
Q '1?
|
$111
, G2 _
B- -G Q
_____...- .

I13 1.3 *5-m _,--"""'HrQ I1

l4 - ID rt-ml
. ' _. -
-...
- _----
ll
___
I .
h I.
gt.
_H F I
'. ,4-7':
__r- 11 . I

II - " I'I.I"_ -_ ' ,7;'.,

J
O

2.-=i._. erF
I

'I.- F-
. -1 | I-51
| m Hd_,
_ ___|_::I_'
J..--"'_ _\

3.0 - 4.11 ltu-m T'

t *
I I
I21 291!-IIJI

'l.D 2.0 kg-m 2.5 3.5 liq-In 2.0 -1D kg-In "'"'h
I'I'1IIt-Ihjl [15-25ft-lbll I1-I-221!-lb}

-T 5.
I

.,||

#_'_

1 2-D 1'3 Date ullnue: Ma-r,'lHlBEl u

@'HUHDA MUTCIFI C11. LTD.
 tarena.
B10 M hi I E5 'II==:2-' E5 11
110"?!
l./

SE R'Il"I OE IN FO RMATI ON
T R OUB LESHOOTI NE
H EAD LI GI-I T
12-1
12-2
12-3
12-3
HANDLEBAFI
FRONT WHEEL
FRONT SHOCK ABSORBER
FRONT FORIUSTEERING STEM
J 1ZE
12

12-12
I2-1E
INST R U ME HTS

SEIIVIIJE IIIFIIIIIMTIIIII
GENERAL INSTRUCTIONS
- A jeelt or clII'|r;||1' mppurt it required to autleert Th: meter:-rein.
~ Flnute all nab-Iee arrd wires ptetrerltr [D396 I-51-

TDU L5
Special
Pln 1|.1ann-er 0190!-0010000
Bail race t|:rnt;wet ITH-IIB-1150000 M5310-1??-01774, U.5.A. Uni;

Ebmmen
Bearlng drhrer handle A DTTJB-IIIIDBEIJ EITQ-45*-51104110
Bearinq driver outer, 31 it 35 mm DTHB-DIJIDICIJ _ ?g5_g3?mm
1 u
Bearing dtluer pilclt, TU mm 01715-0010100
Le-elt nut wrench, 25 rt 30 mm 01110-B33525?
EJ'|'.p11;Ie'_\ |_15_r_ 1_-'1' in driue at 3 In [T5 mm! 071' 16-0620500 cemmemlallv available

TO FIOU E VA LU E5
Sm;-ring ttl.Ell't nut 5.0 9.0 Itq-rn ma -- as H-lhl
Harvdlebar eettlng nut 10 3-I1 IHJ-"1 I14 - 22 rt-rel
Steering Ir:-tilt I15 - I.-3 Ii-II'1 r 4 - ten-lul
Front axle nut 3-D - 4-I1 IIE-l"'I lee - 2e fl.-lbl
Frrrt 51;,.1pttrtli|:|r5pI't'lII1I bult 1.0 1.0 R9-I1! l I-' -11Ilt-ll-11
Frunt :1-.|t|:|a=a|-iun stopper bell 10 3.0 It!-"1 11-: - :2 ft-lb]
Frcl-nt ehclclt rrhr-tlrber upper belt 2.5 - 3-5 F"!-"1 l1e- 2".if1lL'rI

Crete at Iesue: I|Ia\r.1BEl/0 In l I 2-1

EHONDA. MOTOR CO.. LTD.

--
 I-Iontnn. -
F FIOHT WH EE LFBUSFE N5 ION C10 ' /"'1
-J

geelrleetloms
i ii _STAhlDAFI[J ' EERVIOE LIMIT
Wheel bearing play 0.03 mm [D-001 i-11
Frnl wheel runcrut Ht|2I'I|;|I 2.0 mm 10.03 Inl
I
Axial , _;_ mm inl -'1"-. |
Fl-unt umtle l'U-lJLl'I. - i 0.2 mm I-0.01 inl
fI"='I'I1 bfftife rlnlrn I-D: _ 1010- 110.2 mm I-1.32 - I.-'34 in|' .
111 mm I4-I1-inI'
I:l'|21'T'lI IJI'BIi|?.'I|I'|il'lg1I1II|:Ir|'|55.5 3_9 _ .|_ mm [g._'|5q'_ U155 in) g_|].mm wa |n:|
Ftr.\|"rt shtrcit abtttrber !pti|'|_|i1 tree le_r|g'd1 1te.a mm tee: my IE-5.5 mnt [I152 ir|I
_ _EHe-Bn1j1qn__=|1n nlr-Ft! bughina El-I1 ; 13.96 - ta.ae mm [0,E-50 - 0.551 InI 13-55 mm 10.533 Itll . \

; '51-ilipentlun rlrn-I piutrt mullet I.D. _ 14.00 - 14.10 rnm 10.551 H.555 ll'1I' 14.1? l'nrn 10.570 InI G;
Shnelt Icrwer mut buehing D,|:l, I-L95 _ -H53 mm IE|.Il'.I1 - C|_1I1'.2 lll 11.51 mm Inl-
Shcrttit lewet mbunt miter l.lJ. 110:1 _ 11m mm 10.1?! 11.1175 Irtll 12'.4l rnrn 10.11-HE inl I I-\.
g|

TIIIIIIBLESIIIIIITIIIE
Herd |te|rIn|
1- Bilri rn bearing aeliuetinu nut run tight
1 FlLlI1"|\' eteurlntt ITEII1 beer-inns
3. Damaged tteer.I|tr,| Hem bguringi
4. Ineufelent tirtr presaure

Eileen tn eme tide er den net tredt etreiglrt r"""t.

1. Faulnr rlqht er left ahoelt ebeclrbe-.t
2. Bent Irtmt ferlt etm
El. B-a-nt frtt-n1 H1115: whee! lnatall-nu incbrreethr
U Frent wheel wobble
1. Oieterta-cl rim
2. Worn Trent wheel bearing:
3. Faulty tire
4. Axilt nut tightened prupethr
5. 1'r'clrn Irclnt suspenslun m-m I:t|,|5hir|g
E. Laure er bent lpeltes
-'-*.+
Seft luepemlm-|
1. Weak shutit eI:l\le'rbur wring ./ts
Stiff luepemiun
I. Lecil t:I e-reaae In 1-U!pE'l1lI-ilh errn buihirrea

Freni Iuneermnn nmile

1. 'I.'lcrrn t-ulentitm arm bushing:
2'. Damaged rub-uund stepper
3. I.lJIIl'iI? BIT-Erllill -l|!flBI.'.lI'IJB'I' Iagtgeqgfg
4. I-8I1|'~n1 greaaa in msperteien inn h1g1-ring;
5. Lair-It tr! grease in tpeurlemeter gear I|||,|5[l1g

.---\_

1 2- 2 rfu Del: nf _I15|.t:: ley, 1531]

emcrraur. eaten ed- ttcr.
 --'-%_HnNn1-L
.'
/ff C7 U F HUNT WHEE LJSUSPENSIUN
r__
|
HEIIILIHHT
REMOVAL a
F|El"|'|G|'|: the headlight muuntirl-:1 scrum.
D'|su:r.\|'|r|I::|:t thn |\|1.1|d|ig|1t 5'-'|r|: |:|J||r|ECn.H'1 and {E- _--I- " '_
.-"' _ ' .0-'."
i _p
. - ||_ I!
rr-cw-5 tha HEHCH-P'-L
I

1""

JIM
.-"""'

D I SASS E M B L"r";'.\'-'\SS E M B LY
SEALED BEAM FIIETAINING SCFIEW
Ham-we ms hur-mural and \'nr1|I:'-a1ar|iI.rstir\-[iscrnwa
frnm she |=m.
H|'|1|;-Fl: lh-I: clip ,:|':rJ Imalud [mum |.ln|l |E|.zi:rl-Hg
\r:rmr-', and uaele-rJ beam unit
Assembly ls Thr- l'I'-W\?|"ii' ml disasaemulv Aln=r
_r"" as-sun-|ul\,'_ adjun the 'r=aa|:Hiqh: beam {page 3-1.51,

.|"""
r-|o|=uzc|n'rm. VERTICAL
|N5TR|.|H[|"5 ADJUSTING scnew _ADJu5I'|Mt'J scnew
HEMUVAL
F Hnmrwn rm: ||r'.l||.|.||gh1.

F|I:|1'lO'\'E 1he handlelzual m|:~.mt|n!: nu 15.

.-"

Data uf issucri May. 19-BU "1 1 2-3

EHDNDA MCITDFI CU, LTD.
 HONDA
FRONT wusztrsusremsrom Cm /IH.

RHISE 13!! I'li_l.l'Il_II[!tIi| ||3r|1_y.l|: -iDBQ|_';_!|||,g1u|-

5:L'|!i|'|g 5;]-"|'|'||'p,

Diillrwcl thu $1III!E|CIC1lI1ot|.rt:ahl|1.

NOTE
DH not allow the nnulg rt-1;: 19 [an ||-||'q. 1-ha
5IEE'rIr;-g l|H.'1'l.

I-7"-Bl10l""IE'E lhl: =t1u-uni:-mete: and Irtr.It|;.it0r bulb -,1-|||,

DC|l'|l1Et:ttt-rs. --
Ffnm nus the 5pEEdu1:1:r, -

SPEEDUMETEH CABLE SE I IING EFHING

Rum M bum BPEEEFOMETEFI Lll-IT HIGH BEAM INCIIEJATDH

NOTE
If 1 replacement sulb LIt.r|=:1 nqt light, chad;
I1I1E| v-|r'ing '-:Jr t-1 |I'|nrr |;|r qpgn girgutl |_t|' fr
Ink?-I1: cnnnn-:ti'.-nt-. F

INSTALLATION

I Install the spelt-:tc|mete| w|th the lelllrtg. I-|;|r|rt-g.

II1.-!ta'| TI||': rlnredlenpr.

TURN SIGNAL INDICATOR HEUTFIAL IHDICATUR -

_I-.,_\_
~.

_I-I.

1 2-4 In Datanf luua: Ma'|r,19BD

I3 HCINIIIA MCIFDH 30., LTD.
 f HONDA
-1--
~$Y>-Q
' H;,- cm FRONT wHEELmusPEmmum
___

I'|lII|]I.EBlII
REMOVAL
FIBFHC-|'! Ihe Il:.'r..I||g||1'
3 l

L?'ir-crtnn-':ttt the :;:|eed0It1e||:|-'-'r|~-mt.

___ ___ ..-|-
i
_ I I

-I ii

_.-'--. /I! I
FM-r\'r:''|.1 the I-pr-1 i|r'I-l2IIEI\iIl EW.i=II'l r-.1t:|ur|t.-|'|g
1tCFI!'l'l'$.

.r"""

_,-"' TH RUTTLL CABLE END

D15-cu-nnF.-|:1 the TI'l-'|'.IIIIE liib-E term nrl -*|Irt1I:|'.|-I the
rh-nttle gr-p.

_.-

If-.

D:gtt:t|-I I5.1:t||:: Hay, IHHD 11:

z-Human-. moron cc--. nu. 1 2'5
 HONDA
FHDN T WHE E LISUSPENSIDN "'\-.- .
"

H-2-|1|r.w|.' lllr lull I|n||uluI}.:n e.-'1.-|t|.I| ntuulll-ltgt-;|:lewL

l1nn1cv-.'e The "'Ii-'n:|r=-

"'IIr

l-"]|;|I'|'|-',:u,Irt H1r l||'r| r.||_;|||.si5.

Flemu-.-e the left t|r||:l-.

un-mum lh-.-. l'|itr||J|l:E|ul :11 |:|u|1r. rn;| Hutt
Ha|5|1 ';I't-5| h|'mt'I|uk.1:|| u|||JI u||F:I|||'|1|IlI 'I"II'l WIf'lll3 IUlf' lg
-=e-siee. ,_
_-'I'\-
"1

Fle|11tw.-|- 1'|r! 'i.lIH!Eljt'.2I|"l'l-E1Il!I' t-ettirh] in-ring -1r|ri$rJEEEl- " -_ T--n"

r"1r_t1{1'

FI!|1|-:>'-Jr: tI'||.- l"HIH1I=|I}3I 'iFrBI'l'|'lI'Ig.'.

1!; . .
HANDLES-".Fl FHIDUHTING NUT --'-

IHISTALIATIUN
.1-I-t
In':1.1|l 1'I1|t l1:|t gnp.

In':r.aI| the 5DCIEllZIG~Il'l'iIBl -ntn 1"w ha.n|1lnhar with the

:t:t|II=g mrillg.

Clamp 1"-u w--rlrtq harnesses |"t|:- placn. -Ii;

I"|."|r-1 t'|'||1 hnr:-|.I|t1t;u1r nrl >11 I'1'||:ur|t ||r||I I::urI|1e1t|I [HE
ipeuclnmeter cab-e.
II'li1i|II 1ImI|urt1:||t:I::~ur |1'|I::|.|||t||1g |||.|.|,:.

TQHUI.-IE1 LU-3.U HQ-I11 I14-E2 H-"II

it ha.
ihitall the "l'IIl'lO1'i.
{'_ .
l "
1'
I
.1. I-
H Al-iUI.. EBAH MOUNTING NUT _

1 2-6 "II Ltateof Issue: Maw l5i*EllIl

1-?Ill'lLIlhlD.|'t MOT-DH C11, LTD.
 _'_1_

HONDA
- cm FHUNT WHEELISUSPENSIDH

.-'

THFICIITT LE CABLE El"-IIJ

lr|staI' the leh' hancrle her 5'--.'ite'r' rrluutlng -acre--t-5. I
.-5-.t:;.|||,r gt ::.::|.- It: lI||.~ |hru|- ||: gr||-. alitlirlq !l.i|'IF|l'.-I!
Connect the throttle c=1l':-l-_- euzl te t-"-e thre1:'=e gnu.
.-
r

| I

IF
|

___

Jan
Fl ec
F. E55
Ptllgu I ft t;._ .. "|:|||tItt"-I1:||
lG"" . :;w|1t:|'| Idlllj '|-'I|I| t?'--
hn -.t|I||::u- r|g|;r_:*-',r.g|n|1 Il't';i1_JII thrt nw-tljh
1"

F.-'

1|:-|

_I.
F
D UST CO1; E Fl
I- I|1t|:|I.' lI1|; hr_-;||_1l||'r.1 ' I|;|,=q|_
' ' IQ-3-I urIt.I uur|I1tt|:1 tI'.|'
spur.-rle-"121-.1-r -.r.r-I ee.
P-.d|u-.-". |I|rr1l* t' |';||.\-vfr-1|:-j |-_|l3-I. [page 3-El},

t,-5.!
J-

ee
_.F'

,
__.f 1"
,- HUT

Dntcetar I|;.5|_m: |'|'|n\,-_ IQBD

FlHClI'-IIIIFI -"||'ICI?DH CU, LTIJ.
I1
5 T T T 12-?
 HDNDA %\
I370 I 1"-.
F HUNT WH E E LFSUSFENEIDN

''\.

FHUHTIHHHH
nemovet M-
name me lrent wheel off rhn gmuml W plamrq a
lu r.I|:|nr1 hl u|:lt- ut|t:IE|' the enl;|lntr-
F " -_. ._

fr
r
.-'
_.-

' I-

Lut.'m:l1 the st:-as-dumtttnr mbln nut and remtw-B the Q _

inaetlla-mutter eehle.
Fliemnve the front brake atliusling nut itm-1 Elilnlr ' H,
net-,1 1]-H; bruke |;:|I:|Iu tnnm the brake arm. //I

.-l-I-. || I
|

CABLE BRAKE ADJUSTING NUT .-"~.

Remove tree eq-ttnr pin and It:-nn:n the .1:-tlq nut, T

Remove the tmnt axle.
Hen-nun the !.'rnr=-t wheel.

,t'""t

AXLE NUT CD'I'I"EFI FIN

' .1

WHEEL BEARING INSPECTION

.-"'-H
Cheek u\|n||uI lgturlng play by planing the wh-unl in a ' 4

truing mnu and eplnnlnq the wheat by hantt.

FIIrEpIi,(:|j: the bearing-trwitit new on-ea if they Ira nuiw
er have eltlteesiw play. | FLA?
SERVICE ILll'tllT: .D31t'tl'l'l IUJHI1 H11
.~""\

1 2-8 "5 Dleeef Ieeula: Hn\r,19-BI?

@HUNDe'\ HCITCIFI Ell, LTD
 . -- IIQ1II-H
B-ll] FRONT wneeuausretuateal

WHEEL BEAFIING REPLACEMENT

Flamtwa the seal.

Ham-nue the bigrlltgl and 1.'l-i!.I|'rat|': eullar item the
huL|,
K5?-.

9 -
pea} SEAL

MI II I'"""" M """-" I BEARING nrtlveh HANDLE A - lIl?9iH61'lDCllJU

Drift! l thtt right Lltl-ll'|l"tg brat. BE_A|~,G DRtI||rER GU-|'E|:|__ 3;: I 35 mm
Pre-.et'thu diltlnce t:|:|llar lm lalIat|- BEARING DHWEH PILOT, la mm I T DI mm
r--I Hate .
Be lh!FlI!l'l the lzattanca collar Ia I11 petition
. . -
liluru lnlttulllng the Inf! Haring. ___-:-'__'Z_

Dtlue In the left hearing.

Met; E -_ , \
.1 . 'I I I

it
* Drlva thlr blaring! aql-|ll'll'||'. _
1 Drlva the bearing intn ltlttaitlun, l'lII.Il'l' Ii-ll!-! -' --' ' '
\ ehm; I1 [1 fully |g51;||d ind {I111 ll! lilllil I-HI '
is facing nu t
lmtall the 1aal.

I I WHEEL IHSPEUHDN
C:-melt the ri'n'I rur|ut.ll! by planing the wheel in a
tluinq atancli. Spin tha When! rlulllllli and read Th! \
runelut using a tlial indlcetur. r -
l . '
fr" senvtne LIMIT: It 9 _; _
RADIAL nut-luut-= Ln mm tttoe llll 1\ I.
A:-tl.e.L BLINDUT: 2.1! mm ll'.\.l:la inl F, __ _ _ nl

FF
I
Data vi Issue: Maw, I950. 1" 1 2-9
@l+DNDA MUTUH CD LTD.
 HON D
FRONT wneauaueaerusluru CHI I/"2
I-1

AH LE INEPECTIUN

5&1 the axle tn V bInr'.It: and mttrnure the ttrtanut.

The actual runcrut is I."2 t:-f the tntal -nclictater
r-earling,
Ii". I
aenvrce LIMIT: a.: mm lam an .' _"_. '
. ___ d__. fl

/.""* _
xi
I .-'
I-l-

BHAK.-E DRUM I.D. INSPECTION

Measure the hralte drum imicle diameter.

SERVICE LIMIT: III mm MA I-111

___':i,_\__\_

h
_r-

-.;l\
1?
ii

inn.

"'at I"-"I 1 ,
:.\=T"v"-E;
i --/>l
r_

I er-_
BHAKE LINING THICKNE55 INSPECTION

IIIBEUFE Ihl: IJIlI'll.l linlnu thtel-cnes:.. I

#1.
SERVICE LIMIT: 2.0 mm [Elam ll'rI
"___.-;_~_,,.|-_

ti" ' -. .
|l'| f _"f- .1 '-.
.-, .'- I ,-
-- " I |
I | ' I. _|'

ll.

.- I"
.

1 2-10 1 Eheteul Intel. May, TQM

IEIHDNDA ll-IIJTCIH BU-. LTD.
F l;j_,.' 0% FHU-H T WHEELISUSPENSIDN
In BRAKE meter. DISASSEM HI."t"
. SPEEDUMETER GEAH
Herrteve the l:-ralee arm, In-:lit=attIr :=l=|Ir' =IH=!"E1I-lrl'l BRAKE p'9'IIIEI'
wring
' " l SEAL
Flam-mtg the ljlrai-:9 5-hue-s nrrrl I1fiI:N.I1! t:u-n|.. LI:iI_|IFITDI ' j_ I

Ir -' Herr-.nue the sueeclnmeter gaar. - -I-I.-,-_' '

Fltlrhew th-tr wall. II I . I
L_ *- .- .
cill -
5|
I

| I I -_ I I I

_,. t ~
' .. BRAKE cram I"-.lIt
t \ FE-T SE eemte er-lea.sI
ea M-IM seems
BRAKE .l'-IFIM

BRAKE PAN EL ASSEMBLY

Ag:-pl-,' -g*E.:|51L te the -ipeadclmeter [eta-r and llll 1l1I-* T
qaar
lrletall the seel

--' .-'-
SPEEDUNIEFEFI 'I'.IE.I'I.H EEIIIIL

SH-DE eenmes BHAKIE cm-1 -@

Apple grEa5E 1.; The elidmg mrlece elf thn hntlm eanl- ""--.._
lnetirll the brake cam.
Irhl-IBII the hralte eh-rm: and rite! 5lIll'l-l;l-

mramlmnzl-E-Ska l'|'ru'r-res reduw napping

]JDlR.!'I".
Keep greats u rirr ning;

SHAKE SI-IDES

Date of Ii:|.1.||:: May, IQHD

EIHDNDPI MDTDFI I35-I LID-
15
I2-11
 Hanna.
FHDNT wHELrsusPEn|s|ou BTU -'"-"~
"?'\.
BRAKE ARM PU NEH MARKS
I-rsl the felt usal-
lllmlll the wear i1'||:li|:a'm| plate.

EIE___ H
liqn th-B indicator [rlhthe Ir1nr.\r tab wi-I11 the .4 5%,
l.'.!.I!D'L|t {JP this brakn |;|m_

In:-tali the |:||-aka en and rmurn 1|'_Ir|ng,

FDTE
| Julian the r|ur".1:H rurk;
1..
I
Tightr.-n rm: hn1J|:= rm hqn and |-\|_|1_ I

is-'~.,

INSTALLATION
SPEEDUMETE R C15-B LE AXLE NUT
lqstull 11--a hum mane-I b11h-we-n the furk legs.

NOTE
-1.
Mlil !|l.Il'I the ting an {hi |-jihf p;||p|q1';|q|-|
BFITI ll In-Izatad in the qrm-aw at mg huh
- Vi _
:""-1*,
lltnll the a:-ela shaft In-um lhq right aid;
Tighten Ihu me rIur.
TDHDUE: 3.DI.'B ill-I'll '|122B' H-IH
lillf I new cotter pin.
Burma-ct the frunt hraka an-cl Lp=c1|:mmmr.mb|g_;_
-'5L!3|,llJFtT|1Efl'-Dl1'|I lamina ipmgq 3-14}.

BRAKE CABLE Bil,-mi

HUT
1'"-"'
FIIUHT SHIICK ABSIIIIBER
HEMDVAL !.".\

Flemcruu aha frunf. whaui inane 'l2~Bi-

Hu-nu_1u lhn lrunl, 1|-mcl. mwrber and rebuun
i'u:|-pp-ar muuntlng bolts.-:1'n:l rluu,
Fhsmnvu lhu ancl-I: lhnatnrs.

I-It-I"

1 2. 1 2 in Date of Luua: M-av, IQBD -

1HI."JND. MCITDFI C11, LTD-
 m lJ1\I'ID.-5.
BTU FFIDNT WHEELISUSPENSIDN

D'5'55EMBL""' SUSPENSION AFIM EHUCK .A?'S0l=IE5EH

=lmm_;|.-E the Imlmr 1hu|;|r. ubsprber mrnlhrlg bll __T |
and 5|r||ur:||I|:' zhe -sui:-ur=.-iiI:|r' irrr Trf 11118 i|'I=J'-3 ._
absnrhaf. -._ 3-_ '

_.-Ii

|_.
$- ____. 1-,. _-_. 1} -I" _-lI ..\
_||l"

..r"-
_ F?!-'
.

\-,-r.-.-.-
fi
--i-T-wF5.-0-I

Fl-emu-an Wm dust cum and dilamrmhlc the :usbE-

i" F DUST SEAL-5 BUSHING
\ must CAPS

\~ I W
P .. @w@'j
Q6 ' I
ausnuw

.1 GREASE FITTI .
SUSPENSION ARM N-
_i -i- til

EHDCK ABSORBER INSPECTION

FHEE LENGTH
Inspect the sh|:||:|-1 he-r|',' inl nil Ielli-t an -- --;-
M-nz15u[|- |l1|= lreehr.~|1gl+| crf spr|rI|;|-
SERVICE LIMIT: 165-5 mm 16.52 in}

D t Hi: : h1ay,1BHD 121 _ I

EHHTZIDHDAHEADTDH 130., LTD. 1 2 1 3
 J-'I-|
HONDA
FRONT WHEEL.-SUSPENSION ""

SUSPENSION ARM BUSHING NSFEGTIIJN AH FWD... SHOCK LOWER Mmmn.

ERNIE tlw bushing nutilde |.tIume1;qr_

BE FIV ICE LIMIT:
SUSPENSION ARM PIVOT: 1155 mm IlI.533lnI' ..
SHOCK. LOW-EH MDUNT1 11.51 H'll'Il IU.'l-'5? lr|I'
Maas.ur-nth: buuhlrq |1DI|Il' inside dtimsmr. --ii ' _ _ "'-._
ssmncs |.|m~r= "
SUBFENSIDH ARM FIVDT: 14.1-T mm {D510 In] -.3
SHOCK LOWER MOUNT: 11.41 II'lI"rI ID.-489 ITII

1""--..

.-\-.
|

ASSEMB LY
FE
Assemble the suspanason arm! EN
Pggn q.;||;'.". s;|,|5p|rnpi|;:|r| .|'|r||| p|u''[ |2I1.|II ip II'I lhI"Dl.'
plauaa as shown.

I'..-1-.,_

.IP-<.

SUEPENEIDH AH ."""\.
Il'l5I|Il|I the 5lJ5pE|'|i.irJ1| arm In the :|1r.:c;l:. ntasprbgr nnd
Iiqhlb filu I-In-It and nut.

'_-.

SHOCK ABS-DH H-E H -

1 2-14 H Dateuf Iuue: hI.a\r,19BIJ

ezwnouna MDT-DH cu, nu.
 if;;*~,IiDI\l'DJ\.
-""- BTU FFICINT WHEELISUSFENSIUN
-1

P I!"-ISTALL.ATIUN ARM PWQT

1. "' I
lnmnll |-hr: shack EIJ5GI'I2lI}-'$- /K
TORQUE:
LIPPEEFI MOUNT BDLT:
|,."" 2.5-3.5 I1!-t HI!-25 ft-lhI'
SUSPENSION ARM PIVOT HUT:
1.0-2-0 kg-m I71l fl-ll]
|:'|5t51I- thu rI!I.h'.:|u|1d stuppa-rs.
TDRDIJE1 2.3.U hi-rt-I IIIIPZZ it-Ihl

re-.._ REBOUND STDFPEFI BCILT AND NUT

NDTE __ __ _ mi '_
PD|;|1i|;|n thn r|_:!:|nL|1'|lZI stepper ii shown. _]
_|I'

~Ill

neouwu STDPFER
I
1""

F. Instalt the from whmal IDIBII ii-1?I' I

I-.uhr|ci|-tr: rhn suaperlilrl III11 Iwll :- _ %
1' , _.
i I-
.

I sr
'1 "--
|- -iv 3 . gt
In
Y. 1 .- " = 4.
I |. '

P I I, F Ir

I 1 '

1,... amuse FITTINGS-

|:>. r1 .=- Ma .1950 "3 _

EI1AT3|DHD:u:IUTEI?.H LTD. 12 15
 HONDA.
FFIDNT WHEE LISUSPENSIDN C70
FHDNT um-r=|-1 :_:mrE+;4__ . GAHHIEFI
.'
nE=-.1ew~ |_ Q \|\ if
FIEl'r||.:n'|: 1hr.\ F:u|'|dlBba|' {page I2-I:||.

Heme.-"e-the Ila.-|1| '.r.rI1r!nl ipggg 22-Bl.

U
...~.\
4- A

Herrtrwe '-I"-u ehuel-I: aI:-s-:-|'.:-er: Ipqgll 1? III.

Flum eve the .-nvr i-::n.:Iu1.
Flernrrve the f|'|J|1I.1'..-.|r|i1_!|,
FF"
Flem-m'|= I|1r' fr.-mt u|J::|er em-er. I
I
|
I
I
I
I
|
FHDHT FENUEH _._

DiIr.=e|1'1m:t the E'I|uI=.|! c.-|hI|_- ;-t :5-.5 ca. |J|Jrn|L1.'

Flertttlvr Hm cheie k|"_'Iti' ||'t1i:1\ \;-|:r.5I\.r.| and Iernmm
the -"-heke ea IJ|r:.
4'.
REr1||.':-'.r|: the thrntllu. I.|ruIu: .|n-:1 1|;w|=_|E|:||;||'|-'||!|r |:.uhie-;_

I I-H

CHOICE CAB L E

_.d-I-..
FIen1r:wn rhr- ton IJr||Jqc rnn-..|nt|ng belts.

'_-\-.

@>

12-16 " Dame! Issue. Mm,-, 1950

EZIHOF-IDA F.-IDTOFI CEL, LTD.
/nomna
'\_/ C70 FRONT WHEEUSUSPENSIDH

Flame-we the eteeng stnrn nul. Lggqq Nu-y w|{('_;|-|_ 15 3 3|] I|1z|1:
Humm-|_-. -rm: 1u1.| Lxidue. meunn nhd Ila|"IrJ|E'IJB| EXT_I_I'-ISIDN HANDLE AND
Imvareever F

-liI_

Remove the Ieeernng a|:I]u'.itIr-9 nut.

H 1h_ ' R _ 6 ml PIN S1I='Ai'-II-IEH, 36 mm
h;|;neI-rn -1. rv.-I-nl ur ,u1.1per4:e-nelace nn s n n?gm_m1uDL:u
.- ER \l .

H ' x 1_ *-.
e:~Q>l_ '~. r.'='r-._
___:'_:,.':'' A I '.'I-_'

-I. "'1 I ',

|l__I :'| 3| "'

LUWEH CUNE FIACE FIEPLACEMENT

Hem-we the In-.v.-er |:c-ne race, dust eeal and washer.

Inatall a new dart-t l\T.lil'| em] weehur.
DI'l\|H-I B HHW ICI'\\'B'I' CGFIE -IBCE CIIWEI I'.I'l-El IITEIH.
_,_.

1'
II 1
LDWEH cone RACE

D:_th'| 1.1-I Inue: Hay, IQBD 125 _

BHUII-IDA MDTDR ED" LTD. 1 2 1 7
 .-*' .
HONDA
FRONT wueetrsuseerrrsrerrr C70 ~
Ii ' _

er-'~r_|_ FIACE REPLACEMENT ?fg';_P?DF|5;='2:'Q LV M931-I'.|-I I? E-ll 77:1

"
HE!II1iI"|! 1;lf|E =D'.i.iE|' Luirll l|]D!! with lhnr ;|'._:|;|gi.3| 1;gu.|_

_,__

Hrrmtr-'.rri the un|:rrrr hell rac-=- with the errmn tn-nl

NOTE
if the metcmzwele here been rriire-I'Ecl_in en_]
nr:-::irlr:;|'|1, rrstnrnine the-r nrrre nruunrl ilhn steering
; head for -:rar:-Its. _ _ _.-Ii-\.
|

I'Jr-ire the u|IlDEl' I:-ell race Into the iteeririq hrrnd with
the in-r:r:i.~rI 1uc_rls:.
Drive the Inwer bail race inte the steering hencl with
Il|e temr: Iuuls.

;-|-

.--\-.
Apply 3 eee: r.iT Iireerrreg green I:-::| the upper l:|i|-rl rage
Bi-1-d Ir'!r1.ei| Z1 |t|:<:I hallii.
Apple e truer crf hearing green Lu the 1:v-ertmll r.:|r,'.r| r
Ir-
and Inetell E1 nee-I tmtle.
in?-eri the steering item rntr: the steering heed em'.|
irtttuil thr: ripper l3Dl"=H race and beenrrg edluetirng
--.
rrut.

_._

1 2-1 B E Date crf Issue: !i.rIe',r,1Q=B[I

$JI'l-DND.-A MUTUH CU-. LTD.
 HONDA
"

I,-_
K7 _ 0 FRONT WHEE LISUSPENSIDN

T""'" "1" "'J""""= " "' "5 '*""" 1"

upper t:-:rne raee.
BE-rtttt. rtmtrsrtue __
rttrr r=rr~r ETPAHHEII
,
urea:-trereetre
Then, Igqeteut rt 1.-re turn. -I . I/a

.t~
___. Clrech that tneie ti ne we-rertr-el rnrzhremerit rrr-rl that ' ' , , I
' 1h|_r stem |'i:_:-tr.tI'r:: ltre-:!'.','. _ '' _ 1" - - "

' - ' r ".

JP 11'
'| '- ".1.
i:_" . =t- \'I '_ E| II ','- ll "I
__- fr rl ~. r__r| _ I i,_ i-1| ,| |
. -L '-_ .. -.-,= I I

_r"'"

tnttuil lllu handlebar lewtrr -never, mp nr-.r:Igu meunt! |_|'_}t:|{ t-.tt_;|T 'r,|.IHEHCH_ 26 :-t it} rnrn
are-LI tep Itrit-.I;|r.r. HM;
Tightull the eteurrnu stem nut.
TORQUE: H.D-9.0 kl-I11 {il3B'E H-lb]

III-.

In'=1e|II 1+-u tt:|| lr-rrtlge muurtl 12iD|'1t. \" I... 3 I

\ -r
Fluute the up-eeclerrreter, crhnhrr and thrutlle 1-'-1|-lie!
lp-ett I-El.
F-

' lrrstull the Ir-zrnt upper i:.i.wiJr. firm! r-trrrrirr until lrt
I-rtrrdgrr,
lnllll LITE fnlnwtn-g:
' Hunrilubm (tinge ti-El
- Frttint whrrr-I ||,-rqge I2-I2}
__,__ - Headlight [page I? 3i

.-.-.

r:r -:r-fl ;r.r..reetr I-'5' _

eahhenftuhretge Ctl. ttn. 1 2 19
 Hnntnn. |r""_f;e\.|
H EA H WHE E USUSPE NSIDN ."-"I

.- -K

{D Ell kg-tn
129 36 ft-lb]

- _ ___ __ I

.11. . #931 /-
t} --' "-El?-,
I- ___
:''~.
I

It -Zr-. A?-ili -. _.~*" if

:.tr-3.er= F ..i -- I I 1*-_~. I-H

Pm ---" _

.. ' "Ii-'1" '"-.._ '

.-- - P -. _ . - .

A " I//I
.1- ' .t Tr -.
1! I

1-0-2.0 he-in IN-J "-K

li''t-lift-lbl

L.-I r-7',
3.0 4.0 ltg-m
I22 H ft-lh]

_. ,- .,_

1 3-0 m Date er Issue: rttw. teat:

errerreri-. meme ce.. tte.
 @"tti5" it GIJ I mt: $2E5i'=|= =l"'i=5
"-..

[ ju SERVICE IN FORMATION I3--1 DRIVEN FLANGE 13-?

trreuetesuoettrtre 12-2 st-tetzrt rteseneen 12-tn
E REAR wrreet 124 swrrueetem 13.12
l

SEIWIBE INFUIHATIUH
GENERAL INSTRUCTION
I A iitrlt ur ether ttrppurr In reqtrrrecl te supper! the motcrrctrele.

T DU L5
C-emmen _.
Biitlng iI.ItI'.I-Er tun-Idle A U?T4B-IIJIIIIIDD D'?91B-EIIIIDCIIIU
D?B45-DQBENFUU 3? lt1|'I'I
BEBFIW driver IJu[E'l'. 3? rt 4|} rnm
T?'"'" _' urerreenntrocrtr,' 40 n1n'|
Heating rlrluer ptiet, I2 mm U??B-DQ407300
Bill-l'IlIQ driver nllctt, I? rr|r|1 0774518940100
She-t;|-r; trhuuttaer eempreuur 01955-31"9DClI|1

TOFIEILJE VALUES
Ftertr brake l|:t-ftitue lrrllit 1.r:r - 2.r;r rt;--1. t zr - 1-: rt-rtrr
Driveh flu-nga sleeve nut .tr - e.tr Hg-'l t2e _.ee rt-rm
Fleur turtle rt-ut 4.0 -- E.IJ he-m tee - 2e rt-re:
Driven ip.r-zreltee 2.0 - 2.5 kg-m tr-t - rert-rel
Flt!-rtr ihrr-nk aheurher 211 - 3.11 he-m tr-r - 2211-Ital
Swingtr-rnt ptut-u ::r.r:r - 4.11 K9-n'| r22 - 2e rt-rut

SFECIFIEATIUNE
STANDARD serwrce t|r.r'r'T
Ruth iiJlI;UFIlItIJ-1I FL? rrirn 10.01 inl
Wheel t:|e|t:|hg pin- .j_1_-E-. III.D3 mm tlllillii |rr|r
Fiear whnnl runcrut Herein] .
2.0mm Ittee re)

i- tetra rt-.1
Axial ?_I'.ImrI1-
Fler l:rr-Ike ilrurri LD. I 1.5 - 110.2 mm 14.32 4.34 inl lit mm (r.t._t_t'Ir-rlr
Hear brake Iining thieltneet 3.B4.Irnm 10,15-D.'IB|n| 2.0 mm [I105 irll
Fleer struck ulnurher spring free length E-1_9.3 mm In; I 1"ID.5 rnm teen rep I

q'___._ _.__. ...

Date of Issue". Me-,-, IQIED "9 1 3- -g

WHUNDA HDTUR C11. LTD.
 _q_

HEAR WHEELISUSFENSIDN

TRUIIBLESIIUUTIHB
Dsmltlatlun
F. E.rrnt_ tim
Z, Wrfrtn rrerpr r.'rr1IE'r!I IIrE~iFIl'l-I3
3. Lr:-eee er i:rrrrr: epriirrre
4, F;1uI1-|r' titril
E. Lcrcrsa etrla
El, TI-rrr |1-ressur-Er rr'rtJt='Bi3!
3'. Swingerni bushing '-r-rt'rr"-

Suit suspension
1. Weak muck trt:rsr:rrIeer sprlrrgs
2. Shock absorber leehnq

Harri atuperrslun
1. Hem r.lrr.rr:lr ulaenrber
2. Lack of grease irr swirrqarrtl |JLl11'iit=iB H

Strrpenncrn neue
1. Sherri creee binding
2. Lu-use i'ertrrr~=rr
3. i.fr'r.rrn r.r.'tiir'rr]err1'i It.\;I55'r|nrr_:|=

.-"i-.

-i-t

.~i-t.

_|\-_

-|_

3|}
1 3_2 1 Date r:t-f Iieeue: Maw. I950
EIIHDNDA MDTCIFI CD, LTD
 Hanna.
3"" HEAR WHEELISUSPENSIDN

-BRAKE DRIVF CHAIN-

El \'l'|'iE[|. AEIJLISTIING NUT
REMOVAL
HE'S-E [he I!-!|' wln:-1! n1I H1: gruurul Ir; pinning 1|
5-L||.||J|.1-rl L|||J|:|I. undclr lh-;'. mnrnrgynlg

Fiummrlz The :'B3|' brake adgusung nut and G|I~it0||rv:|:1

H19 |Il|3|ICE IE-Ll fr|I||r| ||||: :11 [ue arm. ----in--_|

|JisI:-onnsct the brake torque link it-;.~m 1h: Drukie

panel.
Lnn-sr:"| thn driva c-hi'rI adjuaaing 1'|ul=_

BHAKF BRIWZE TDHUKJE LINK

qur-fa":-r lh|: culhir pin frnm 1h! rnnr mclu nut,

Flu-'r1-:~e the aaucie run and pull 0u1 uzr axle

Hummn tho nlhuql.

J _.-

.. _ 1 \._\""-
\\"q.h_
~:
I-.:| H I _' I .

CUTTER FIN MKLE HUT

AXLE |N5FECTTU'N

5513 '|li'1-'5 33|'!-'4 in "1' *!l|LhG5;S i1|.1 IEIU l|'m :|::.l|'. r\_|r|4;||_1L_ IHI

Tlw actual axle run-::-ul i; |."2 qr TIH Hma| 1

_.-.
lndicatm F|e:uJi|1g:|. J P.-'_.-'

simcz LIMIT: IJ.Z|'nm|lJ.HnI 'qg_'-' if

_' I"; 1

I.{_R
-H

5.?$9,
/ J
___]

D12: ul |5-:-us: |'|kq\|r,1BH-D 13 1 3_3

TEIHDNDA |'|-TUTOR CCL, LTD.
 :-Iomna.
REAR WHEEl.J5USPENSlD1'\| C70 J-

WHEEI. BEARING INSPECTION _ _

llhmgi-c '.r|11|!|_'|| |:e|:::I'|||g |;1la'|.' |.1',' |1 HCZIFIH the whael H 5 PLAY
|;'|_|ir||;| -51;3|'.{1 and spin [||||!j 1h|_: w11r:|:| '.Jl|I' h:|r1|J. -
T-Iepl-ace the bearin-;|1 -with rwl.-v urI=.".- If thr..r n-"I! n-niw '
|:u -LEM: :.~:=.:|'=:-me p-l;1',.- |
SEHVICE LIMIT-. n.n3mmi0.uu1in+ i

I-Q1
__

WHEE L BEARING HEPLACEMENT

BEARING
Hammwg mg |1e,1-'|n[_;'5 -Jn-.1 d|'=1r||||::1: collul l'rur|| THE
|'lL|lJ.
-q

In.

.1"-"\

1,

/'\_
. .-':

_ _.. _ _,__ I .--\._

|-mill; 1|: l.|r:;:|||||='| w|ll'1|_;"|:ase
BEARING DRIVER HANDLE A - ?El493f!1DUD
I1ri\.-0 i"| 1'|'|-:\ I-ght hi:-:|r||1g ||'||. B-E.5|F||NG DH-|"|I'EH UUTEH- 3? - ""3 mm L-|?9i5_CH_Du_D
Pnm: 111: r.t|st.i|l|:e cellar I-:1-J alum. HEuH|N'D DRIVER P-OT 12 mm

more
- Dril,-n kn-: hearing nquarlyr, _.---' _ '-_-_ _ " _
- Drive the bearing into r.I-:\si1in-I"-, rn--h~I1Q =ur= ,-*"'- __.--_-_:'-'-'--' ' _T_:_:-'
lha il -| fully seaaed and mat the seaiu-:t aid" ,._--.,,_._.- ,-
'
|s facing uuf _ .-" __=-:j_ ",I_ - __--'_
L __-4-_.-__. __ __
.-' - '
I | -- *-.-.
_ .___ Q .___, h."' I .-.-_.__
U, ":3.-s'Z_|.._ __
_ _.,_-. _ - _
"'|\_"'-.--"3 _'_7Jv
._ \ _ __.,__ _ _._
"- -~12. - *

-|3_4 131 |].'|11J .1: |::ue |m~,,1sso

HONDA mmor: r:c:., u n.
 / HONDA
s 0 FIEII-Fl WHEELISUSPENSIDN

WHEEL INSPECTION

EIhm:;_ um r.m rUr|L||J|. L1-,| placing the wheel Ln a /,*"' _____"f"-Kl

1:4-u:'|'|;-| 5-yang, Spin fhu wh|:e:| xluwly r'I-Ll 1|!-nil 'l!1& .-"
|-.muu'.us.-nua d|a| indiaatur. 3' __
.= _-,_H H
slzawce LIMIT: * -*.,_ g . ._\
an.nm4_ RIJNDLIT: 2.DI1'|n1'|'U-B|II'l1' 3 _ , _f )
AXIAL Hum: u-r = an mm muainr
. - ~_ 3-H- I\-_,fsi
\ -.-,
.|| .
I i' H
1.-' . .-
.1 I
|
TI
| I| *1 1
'\_ 'x__ -

DNv1F'EFl FIUBBEFI INSPECTION

Heplann l|11e 1|!"-"1pu.l luhlrri If they ME dmi-QB-d DI -1 _

_.-
- .
d-ewri-:\ratu-rt I. ___-

__4 ' I

_..-_='

DAMPER

BRAKE DRUM |.D. INSPECTION

Measure :'='1E brskn drum irlsirlr: dinmrrh

SERVICE LIIMT: I11 rnrn (4.11 inf

.-4"--_ __ E__
__.-;::--'__-_-

' <*"'T H | I .~:i|=!tn. L

'-. .

1"
~
Elan: 1:1 I534: Mal,-,1QBO 133
E HUI"-IDA MDTUR CU, LTD.
1 3-5
 Hanna --

FIEAFI I|'IIHEELf5U$PEN$ICIN B70 _--\_

-1.

BRAKE LIHING THICKNEES INSPECTIUN

MI!IJ.lrE li'|u hrahu lining thickneai,

EEHVICE LIMIT: 2.0 mm HLIJB inl - .-

I
. -1-I._

% .1. ___: I ___ \ I _|'

-'

xiii;H Q; I J" E5

1-NI

BRAKE SHOE REPLACEMENT

BFIAKE CAM BHHKE ARM
Remuus the brake arm and Indicator |.1lnt=.
Fiumuw Eh! brake 5i1lIlE'i and brake cam.

,-"'5.

__
INDICA PLATE I

.*"-_
-5-Uni? grim-=: tr: thn iii-:iin|I mrfam oi the brake I:-am.
il1E1.l'I|i ihu brake shoes and shoe .'|{.'II'l|'I5-.

Conlmwirwted .|'m':1i.'r I|'.r||Inp nature stopping

pa aw. ="""H
Heep gru.-me off rile Mk];

. '_'\-
ll

SHOE svmmss same SHOES -'r

13" D-a:a of ism-Ir Miw, IEIBIII

1 3-6 E."HIEINDJ'I. MCITDF: 00., LTD.
 . =-ii I-I(J1\TII.Il.
ii cm HEAR WHEELISUSPENSIDN
PUNCH MA FIIII.'5
Install the telt seal.
lmtnil the wear ir|t'.l:GiIt|r DliI.'B.

NOTE _ _
Align the Indicator plate inntrr tah with "H'-
|_w.r~1~* '-T" =t-."_L1'=#.e.m. J
Install rm trreire an'n.

f-ICITE
' Align the |.|uru:h merits. I

Tighten the hral-re arm belt and nut.

rnercmee r-tare BFIAKIE AHM

INSTA L L ATI ON
BRAKE nee AXLE HUT
Ir-retell the near wheel. '
Ir-Inert the re-er ercle and lrutell the axle nut,
lrrstnll the trreke terqu-e Iihlt end secure it with a
1'-aw c-rnruv pin.
TORQUE: 1.-l!I2, ltg-In IT1iI- ft-lh-I "'I- 1- -..
[I|;||1ng|;r 1_I-1.5 ragr brake red tn tl'I|: tnhr Lrreke l-tI"l'I "
nn-;l |n:_r-!I||il the brake ediuitlrvg |'||Jt.
Lumen the sleeve nut end adjust drive chain slack
lpme 3- I 1 I. Tighten ihe sieeve nut.
TORQUE: ll=.I}5.0 kg-In I29-36 I-blhl
Tiqhte-n the axle nut urrrl ir-stirll a mrw I:-Ihtlnl pm-
TDRCIIJE: 4-0-5.0 It;-In {B-36 ft-Ihl I I
Tighten the |:lr|-re chain erljustinq nuts.
Adjust the rear hrnlie lent 3-iii.

IIRIIIEII FLMIGE LEFT SIDE COVER UPPER CHAIN C-11.55.

eemevnt
Remove the rear wheel {page I3-31.
Hnmrm the left aide :r:2nt|:t, drive sprocket never,
up;-:|r and lewer rlrwe -chain cu!-rrs.

I
J!

_ I
Fl I I I l I E.

DRIVE SFRDIZKET COVER LCIWER CHJIIIN C-REE

Date ef Issue: May. I581] E 1 3- 7

IEIHUNDA MDTCIR CCIE, LTD.
 1-Iontrna.
FIEAFI WHEEUSUEFENSION mu \__;

DFIl"I!'E CHAIN
Fiernoue the |:lrl1.'rr chain.
Rrtnoire the sleeve nut mo IIIIIIeII Ilursqe.
Qt
- It1
1*

Ie,:"

NUT o-I,
I
DRIVEN SPROCKET

' INSPECTION

REDIBEE Ht! sprucltet if worn, bent or I:leI"I1ug::i.

NOTE
ll '.hIe I:lrI'Ir=r| sprocket reI:|uIres rI,I|;|II;II;I|-IIrIq|-I;_ GOOD REPLACE l
5"tII'BT TlIE lIlFi'-1'8 eh-ain and drive sprocket
in-aes-III.
O >< .="\

__,J%__ EL

' REPLACEMENT
_lln.
S-'l1l'It'l'l|l!l'l thn lock piate '|_1tsI. |l.l'1|l my-II,I;II,I-II the
sprocket mouetlhg bolts,
Rt:-In ova the spr-cclret.
lnstslt e new sprocket, loci: otetes and bode,
-l'lQl'ITH'| the bDlt5 incl l:|er|-r.l the rock plate rehg.
against the bolt l1eIIItI_
TORQUE: 2.U2.5 Itg-t'l"l 114-15 ft-lhil

I.

13-B 135 Data cl issue: May, ISBIII

DI-tOI-ILIA MOT-DH CD-,, LTD.
 I-ICI1\'Il'DB.
REAR WHEEUSUSPENSIDN

BEARING _tte.=1Intric
' INSPECTION

Check the IZII'l|IIF\ Flange bearing claw be srtlltninethe

bear-'|tg l:I-,1 hand. He-place the hearing with a new
rtnt; if it -I5 m:|l:i'y 4:|r l'I.:Il |:KEE!I1i\|'e 1llIl'|.

SERVICE LIMIT : D113 rrntt IlI.IIIIt inl

- REPLACEMENT
BEARING DRIVER HANDLE A CITBIIB-3lIIODl][.|
FIIIIt-Inn-II tr-.II Ietel end l.tee.1-ino,
Peck the beating with grit-ttte.
Oritm lrI the bearing sottetew until it seats fulltr.
Install the seal.

BEARING I2lFIl"II'EFl "" }--- matte-aunareu

BEARING DRIVER PILOT. 1? mm

INSTALLATION

Q :3?
Install the drttren tlenge and Ilenge sleeve.

NOTE
in Ally: the Ilttu on the llct:'I'|: v.II.tl~I tr-Ie tII=lII lI'l
the swlngatm.

l|Is1,.:tll tlle lo'lt IIrl'I'e dtalrl tacliurttter atnrl slrurv-rt nut

Install the rear wheel [page I3-Till.
Ir-_ttIt.tl and ndl|.|.-It the drl-II: I:l~rII|It {page J-1 II,
Arllust thc rrrar hmlca [oage 3 14].
lrrstell the upper and lower chain case, I'.IlI"II'E'
i'DrO:El~tt:t cover ttrtd It:l'1 side prover,

SL E EVE NUT

Detect lesutt: Hey, 1950 13? 1 3_9

EIHONIJA MOTOR CO., LTD.
 ___ _._

I-ICIIUILB. r -I1.
_'\_fI"

REAR WHEELFSUSFENSION ctn -I.

SIIIIIIIII ABSIIIIIIEFI
REMOVAL

Rerrtrwt" '-'i"Ie unpe-* trod lower shock absorber mount-

ihe IlI-IE5 Brtti l-tolls, and remove the slturtlc et;qI:IrbIgr-5,

'|_ -I .-II

I-Ii-

-- - I

.I._

DlSASSEI'I'IBL"r"
SHOE K ASSO RB E Fl COM P R ESSO R
Compress 1'1-B spl'l|1g lU.IT erto-tigh to ram-|;rtIo the Incl;
l'ILIl1.

I-IIICII-Bl'l Th-E loclt rhtt ant! remove tho upper" mI5It,r|t_

Dlsui.-;:-ttlrnlaln the unit, ./"Tn

LOCH NUT -.

SPRING FREE LENGTH INSPECTION

_. -I._

Measure the .tnrI|tgI tree length

SERVICE LIMIT: 210.5 n-Int lB.3iiIinI
Inspect zhe shock bode for oil leeks.

*1

lillgtlrm
__,

1 3. 1 0 133 Date of l|:Iut~: Inlay. 1950

i':'HU."IlI.ilI'7l-. NIUTDR CO-., LTD.
K_ C10 HEAR WHEELJSUSPENSIDM

ASSEMBLY

Inmn the s|J=ring with the light mu at lh-c mp. *f'?!-<_a~_..gJmd__

' .| ll Ii"-
____._- nmwen

LDIEK uur 1.5-2.5 kg-m

W
'
:11-1a 1'1-|n| RE
III |
-STCJPPEH RUBBER
LCIWEH M0ur~|T-""'J ' "@.=..,

Agpiy 3l|;||:|ci|'1l agent m1he1|:|ck nut and initall It.

Tighten thzrlnck nut. -i~
|.-":_;-,
-r

'-\-. . .'
*1_
*-
' . .-" .|
u. .-

I J_/ 3| ..
= :'=

swocx ABSORBER '--if

COMPRESSOR H =-

INBTP-LLAT1DN

Tight-an thn shack absorber bull: Irl huts-

TDFIDLIE: i'_.l]_3.D Iii-rn I14-22 H-lb!
'ER1r:-ck shock -lbiurhur upnerltlcun after |nsr.i1lil:io|1.

u r n = Ma JBBG 135 _
@aH::5~:u5:l:|uTc:'n 00.. rru 13 1 1
 HONDA.
HEAR WH E E L.|"5USPEN51DN cm 1
QHMHWM PFVDT HLIT
HEMDVAL

F|1rr11m'r: rhu mufflar ipge E-21.

Ham-wt 111: nmr Whccl {page 13-3|,
HI q,, __.
Home-'5 the dnueu 1lang-e1|:rag!.= 13- 1'1.
Rumrn-n thu shu-ck absorber: (page 13-113].
REMOVE UM! I-_'|1 lntkinq wut and nivut bu-11. Flernnm:
11'"! nvingarm. ":-

'_\

.'-\.

INSPECTION
PWDT BUSHINES
FHSIJEI-I lh PH-I11 bui-H95 and hult Fur axcasaive
VIEIH. Flnplnnr if =|u|:Bn-ar\.r.
DrFUEt|1B bushing; |l'|T:r 1111;: with n iu; hlmmq,

MUTE:
I M3115 ILITI T115-I Eh! 1211.-llhlngi qr1| nu]; |j3|1'|5q.|;|L J r3
1!1lpB\'.'T the 1:.-|'|:|n gultln fur wuar,

PIVOT BDLT :I'\

INSTALLATIUN

Insult mu swlngarm -ltd pl-.rn1 bull,

Install 1hr- rnulflar hrankat aid pivot se|f'1n-ultinq
nl-II.
TORQUE: 2.5-3.5 kg-In 118-25 f1-1h]
1r:Iql| the muck abuurrhnri lung: 13-111.
lrutall the driven flange [pipe 13-BI1. r"-
lstull thn rlzlr wheel [mp 13-7|.
Install The |'r'|u!f|1:r,

'-|

13-12 Da.I'euf |5.5u:: Hay, 1551]

EIHUNDH. MUTDH C-I1, LTD.
 I-Iuntna.
-" A ,1 C70
.1-" MEMO

If

pk

1-'-.

1"-

{...

|""

Dare of Issuer H-Mr, 1933 1'"

QQJHDHD-'1 MDTUR 1:13., |TD.
 HONDA
BATTERYIGHARGIHG SYSTEM ._

LIGHTING SWITCH

1* _.- MAIN FUSE

--
,. _.- _-_

_,'_.
___-I -:-__

.-I I I *"'"E" -
1 Il.- '_| '|
r"""= I//,/
.- t,
.-"- -

.-"_-
' ... 1 11
__/1 -- nm"ren~r
.-"
.-"-
----'
1' 5-
=:""- IGNITION con.
IGNITION
.- _. - ;
Q;' '
,-
__.1' I;
2
.-1:?
A.|:_ GENERATOR
swncn '~ - *-

:_.<_ -
Z I
.-
_ |
:-4::
I*1 I-
___

.1-'f~:-_
.=2!-. ... -
' -gt-~.,=>.
-.' |' -if-.'."-"Ir-'----f=' :1
|;;I.::_ =-;'. -
| H :_, _'. ' __.
II || _'_,l| H -1 |

Ill III? II. II ' '-

.
_
I\.' L

K *:.;~__] F
/4
vi

um HQ

'|4...Q "43 Diteoflssua nm,1nan

@~HoHuA Moron no LTD
 am: Y CHARGING
1
-I-1.
14. svstt /
F.

SE Fl VIC-E INFCIHMATI ON 14- 1 CHARGING SYSTEM 14-4

TFI DUB LESHUCITI N G 14-2 All. GENERATOR 14-5
BATTERY 14-3 RECTI FIEFI 14-S
| a'

SEIWIIIE IIIFIIIIIMTIIIII
GENERAL INSTRUCTIONS
P Buttery 1'-1ui|I lmrul ihnulrl he 1:I|l::1cr.I rkgullrlyr. FIII l|'n1ltd|:tI|led water only.

F ' Quick clmrue the blttenr only m art e.-rm-rgenw. Slm'I'-charging is |.'|rI:fe|rr|':-1:|. Remove the battery Irum the moturcnrula fur
cltarginp. If the battery l'11lJ:1. he chained en the motorcycle, diam-nnect the huttnr -I:ul1|E=-

I1" bum-qt gprtrmna .lI_|n-.fr|-Jp-pr 34:1 |-l.\l|:rJ: mm be hlgilly e,\',|':l'u-,\II-e, u nut maul: or allow nmn or iparkt near the
baeqv, expeefalfy w|I|Fl'e charging '.

- All churning 5g'i1lIl'1l uamrrunlrntt can be tmud nn rhu rutrynld.

TUE! LS
5|-'m1:|nl
Flvvtl Hold W922-1190000, LI.5.A. unw use cummercialw
available hand strut- lrnrlt
K" En-mmnn
Flomr Puller UTF33-E|1'0EH]1 - Fliemevirm halt, 91113-IE-HEB-DUO

TU H D U E V A LU E
Generitur rotor-flywheel hnli 5.5 - 5.5 liq-m :40 _ -11 mul-

SPECIFICATIONS
f-I Bmmn; Bppqelw EV 1 1 AH
Specific qra\rit1,'_ 1.250 - 1-2euI2eB I:BBFl
Bl-|||-ging rate 1.-1 iumzvzma minimum
P.
-151,13. grtnrutur Capacity {DOD rpm I 5,0511 mm
'l"""""'lPll"l '' """ "' ' rte A ll'llI'|. i 2.3 A mu. '
Fte1|1IIE-ar tyne i Slllcnn cllocle I
l
{.___

J;-.

l""'*
Date ul l:;|e: May, I5-Bl] "3 1 4- I
QHDNDA MDTCIFI CU-. LTD-
 I-IONDA I-ft-;';'3.1\~|
BATTE HYICHAHG I HG S vstem CHI /,_,~..
_I

TIIIIIIBLESIIIHITIHB 1

Nu puwer in-v ntrned mt

1- Heed hatterv
LI-M Iluirl level
Luw 2|:|euil'l|; gravity
Charging system Til-||.lr~e
1'. IJ-islcunnactad L1-attuw lT.DII_1I
3. Il.'1Bl|'l Ium: hurngd nu:
-11- Faulty innltic-|| nvltuh
Lmll pnvvlr key tu-med an
1. Wt-.ak hatter-.-'
Ll1l'|'\|'fIuIt.1 |:w,:|
Lu-'- spI.I1:Et: gravity
Charging wttew I;1iIL|r1:
2. Lu-use hatter-,' ennneqiun
Lu-w power engine running _. -=1
'1
1. I:l-nttnrv under|:l'|nr-ged
LD'Wf1L|I|;I Ivel
D119 ur rnq-re in-ggd Q3-llg
2- Chm-ging system f-BIII.|.[|:
Intermittent power
1'. Lee-we Iinttvnr izcrnnecliun
1*. Luuse chargllig :.1;:re|-n. qunntnuun
3- 1-DH-SE !1|rtin|; svstem -EOi|\llE\':IItJ|1
I. Lnnse nunnactiurt qr phu.-1 i;i reuit In lgmI.lr;m '|1'g|T| ."""''~..
Bhnrllnq nuum hiluru
1- I-DDBB. IJI-l<Er|_ or ahurtotl wire or Chltectid-n
9- Rtifvr faulty
3. -'5-_C_ qunerqtuv |'p|.|||'\I'

.\_

.1-"ft,

"H

1-1

14-2 *'" Date u-I lzsuec May, I9-BU

*-EJHDNDA MDTOH C.I.'l._, LTD.
 I-Inntnnt
C70 em-re HWCHAHGING svsrsm

ISHDUNIJ C.|"|ElLE POSITIVE CABLE

HEMUVFIL

I"ir.'n-I'M! thl: -"i-;|ht side ::t:'ver.

Dis-Guritieirl lh-_- gr uu|v.1- |.;||l:il|: ul 1I1r.I If.l1l'I1l:.
Discnnnuct the nos!-titre cable at the batten,-.
HE|1!||Il'.r~:-: 11'|r- I.u|1lrr-r-|r hnlrir_Ir pimp bolt,
Remove the Luntia-|~,-.

1'_-'
PLIRTE

TESTING SPECIFIC GRAVITY

TE:1e|1|:I'| |.z:II w'.!I1 :1 I1'\vrIrq|T|qtt':r ,

SPECIFIC clmwrrv;
:20; e-aFl
__
we-we -fvvWW.__ t Ige
Beimv I-250 1..i |'||:lert:he|ger_t ' J,-'
| .
____
IR-UT E
\
"L -TPHI barterv rnu1.1 be rggttarqgd |r -J ,pm;|f,c TI
Uri-'|I'v it I-1llID'J'v 1.230,
' TI'I SEIGCIEIC |]r|ivi'l',' uariui with '|,|'|g 1:|T|pu|'a- /-
_.r"
\-

\\
Y
luru as ahuwn In the table
. /,1 I \
H9919 II" hattvrv II ml"-Itir:-n is evident cu-
I "1" 517535 5'9-'1-I-'-' "1" DB" DI-E|IE= il Iillud with HYDHDl'l|1I:'TEH ELECTHULYTE l
wrtiment.

The lIMl'.l'| *\"_1-' I.-ml.-i=li~}l.'}ilT1uG-T-'_i

lmrd mmurr W-l'l"II thin, r-vrs er :-i'u-n'u'e;
I-In.r|in'r.rtr.' I"|'u:|'| nalrir I1-til!-I-.l'I11' get prump: I EATi'EFI1" TEMPERATURE vi SPEBIFIIC GRAVITY
rrredfen-I atrermrm. 1:ILI'J'| EH
""4-_
-23.?
.;_-:.-_,-;_-_r--..._'.-.\ _ ._
'%$m$Ej.
I-I---___-E .;___-Ii: --_|:l.::_,1..'l;~ _:;__..__._-;,;-___H__-I-'1']
ll 21-: *~'-'r:_r,-.-T" $31."-':~'=.':;-i-:15331111-.,%::~ii=
- '
l 2l;vIi| I var "*-1 ' >5";-~35 -

ECIGGHAVT"|"
F
I I-1-I1
1 QED =1 7:
...g 1 2:?-
u I-'. -11-:I ti-3:}

SP

4: "~-!l- mcrn zniaul auial q;.IiT

ELECTHDLYTE TEMPEFIATUHE 'C |"'FI

Dates-f Issue: May, ISBD "5

-D HUI-IDA moron t':i:a.. LTD. 14-3
 HONDA
aerrzewtzuaaema svstem C71] - H"-I

.1 _""I. .

BATTERY CHAFIGI NG

Flam-ave tha battery t:ali1:at:-5. "

Cgnnggt 1-itu charger ptrlitilre [+1 tlbl lit.) lh-ll
Q, I 1',
I all
battery p-ositi've'I+I terminal. __-.-.-

__, _
Connturt tho charger I1-|:l5!1I'-'= II ah]-lie I0 IHE
battew negative I-1 terminal.

CHIRFIGING IIUFIYFIEHTE 1.4iT'I\1II1'Illl'liIl'~-

Chargq 111: battery until 5'|JEI,1Il!lI gravity II

1.260-1-2en at 2u+: [El-BFi Ir -1

ea T
- B-r_w are-T:E'}.iT at. '
rap from-eoeh eeI'I'.
- Keep _|'Ivma.: and spark: vwuy from o I
I
.1.-I-.
I
I
'Jta1rgt'rtg.I|orrer_}'.
' 'I"|mv pallwr I.'-IN,"U.F'F or l-Itr it-Ileqmr. not
or eke balmy l'erm|mrI.t.
- Hmvntmur chvqihg 1') the ekvrrvlyte 1950 I991
\ ,
ternpemtmwa exeeedk 45['|.|'I.i':'.F'II. " t It u I | u ll
FIFIIJI II Hill IELIII
1
CAQTIDN: _ ' _ _
Qu:'c.I:-clterigtog tFtrmr.|'d only be drmr In rm I -*_ -" __ ,-
I en1i;!;_gE.:;:*_|.-'_';l1't'v\-ti-|eI1nr.r'g:I_.t.i,' 1': preferred. I

I'M-ter inmililng the battery, coat the tEI'I'I'1lI'I-BII with

oiean gra-eea before oon nuoting the battery nublne -' n EJ9-
n -. - Lela
antmta - I Q; '-L-:'l_=.1_"'
CAUTION!
| Route the breather lube rn lilrrwrl rm Th;
' I
_ -=- ":i'f._;'C
53.3--_ -
_ T" 3--E
'_-.-;-,=-I
urstnr ms amm '|
* 22:12::
1.

_-better? eaunbri 1'

=-Q1.5
a~;q,'~;_
- 'TJ

IIIIIIIBIIIB STSTEII _v""|

I DUTF UT TEST
Winn up 1;I'1|;| eregine 1:|||'It'1r-E 118111115] lQidIl'!Ii.
r""*-.
Check charging witam output with n irultrhller Md I
en'n'net=:|r _ _

HDT_E _ _ b
| Uqa ;| lolly eltarge-cl batearv to chat-k the 1 I _
nhirqlng system -outpuL

TECHNICAL DATA: '

I!
ii!
J

1-I
| -!"""*-
. .-

_rv:A|M svmcl-I _ orv E E.

FUSE
LIGHTING swrrol-| ON [Low beami |_| -
_ INITIAL CHARGING 1,550 rpm mix. .--.._I
_ at 4,000 rpm 119 arnperae min.
AT 3.1300 rpm ' 2.3
_ vo-its max. ~._

|I$

14-4 1'15 Datarof 1|-tub: May. 153311

EIHUHDA MUTDFI C0-I LTD.

j-Pi - -
 1'"
HON
nee
,3 CHI eattaewcnaeomo svsrem
.-""'"
n.c. statnntnn _ -l-\..C. GENEFIATDH CUUPLEH

STATDFI HEMUVIIL '*.

H1:rr|-mm the gear 5hYIl pt;-d,-ti. _ | _.

I:It'I'|t'WI': IIII: |2It|'|l'tt 54.'|l'i'.I|.-II.EI 11tl'|E1.

U|a|::onr'-not 1T|E AC. generator oottoler

FI|!|'|'|m'|'- lhn |o:_:=nl|t|:1 |'t-::||!1! t-,u|'|:r -::|.|ni..1|:| I:|||.1ttil.t.'r ' "PT T
be-ie oiate and spark advanter Ioaoa 15--1-I. j-

_.
Di:-t:nnr:-F:|:1 |It|: rv:u|r||| |wm:h 'J.|l.'u at the :|\'ll|.'Il.

Fler-nova the left t'ar.'-ltcasa cover

IELQ!
I

/
LEFT CHQNKCASE CDVEFI UFIIVE SPHDCKET COVER

F'lnrn-wt: lite twu =tvto- tent-vv!-_ Wite prGliI:IC1IfII' illl

nttttu: Ir-:||1'| 1n|;| I|tf1 ttrnltll.-::nr:e Cover. "'~._~

{___

I-H

STATCIFI CUIL CI:-INTINUTT TEST

{F-H
:-IICITE
'1' I5 I151: I1ECIEESEF'||' 11: |'U."I'ICI"l|'|| TI"'I|I lI'I'lr|'-1| HI? I
mnbn thin !1::.l._

Cheek |1D|'|IIf1uiIu' between the vellow, white, hlauki

'|'|'I'|il:|1 '.|:.;||-I: and -itator grnunrl vv-1h an rtlttnmittet on
I-'-=. the Fl:-t'I scale. Rear-ace the stator if therrr is rm-
mntinuirv.

I(
r

r -.

om of Issue" Mav,1ElE!{l 147

ianorvu.-=1 moron co. |_"ro. 14 5
 HONDA I, .',5==
BATTEH"r'.-CHARGING strstem I270

GENEFIATIDR FIDTDH

' REMOVAL
Use the fl-.-"wheel holeet or ba-nd strep holder and
L|Iu|:I=. LII-_r Iiy-wletel tu meuertl lI|e t:turt1t'ta1l Hum
turning

FIe='n ove the geneiatar iotor bolt.

$5

FLVWHEEL ITBDDDD -.
U.I:-i.|l"II. ill?-lL"r" USE CDI|.1I'v|EH|_At_I_"r'
AVAILABLE BAND STFIAP WFIEHICH

Flam-we the generator auto-.

"\

HCITUR FULLER DFI .-.,

- U.5.A or-1|_\'. HEMDVING BOLT
- INSTALLATION 9l535*3'"
I.
Align the rote! ltaw.-av 1n'lIII'l the key on the eran'lt- I
qhqtr pr-.|-I inrtali the gt:-nenalnr rotor

___
\-

' >3 -|,|-911: _

GENEHQTUH FIUTDFI ._

1 4-6 '3 Ltate of Issue: Mei. 1531]

'33 HUNDIA MDTCIH CCL, LTD.
j
 _"'-'_|\ HDNDB.
."" \.__/' BATEEFIYIGHAHGING SYSTEM

Ir T |[_!'\7|:|'| the [|r:rI.t:r5|t|;ir rn-ttir Itnlt

TCIFI E11-IE1 5.5-8.5 ice-m 110-4? it-lbi

Ira F|_r"i1i'l-lEE|_ HEILDEFI 0353211-1TQtZlJD CIH

IJ.S..\. DNLY CUMMEFICIALLY A1i'AlLAEILE
sratoe INSTALLATION B-NU STRAP "IRENE"
In-trail the stator
|"loi|ir.~ the gnr'er:ttor IF.!-'lGI'i orooorit,-'.

Connect thu IIULJI'.-III 1'-vit|:h load

lretali the iett ci.:iii-tizese c-ova.-, riiive apioeltet oovar
if and qE=||I"iI1II1 oeclal.
Corlhect the gttoerator wire t;r,tu |'lI11l'.
lrtttiil the right i:ti|'|I-c-::I:e cover, rmmegh-n
iliiirt-if:I mid ItIii:_:$ !l'|J|'I'f!l' pt:'|'I.1I

Flli the crankcase with the reoommentieti oil {page

-llrljtiat the -tr-i ti on tirrii-'i|] ipatte 3-Bi.

r"'~

F.

r"'
||l"_"~i

Date t:-I |5$u|.-.1 May, IIIHIJ 1'19 1 4- T

5:'HDI'IDPi. MCITUFI CU , LTD
 HONDA
BATTE RWGHAHGING SYSTEM cm
RECTIFIER HELTIIIFIEH
REMOVAL
H-=mrI'-"H 1""-E Tight iIE|E cnvm,
r':F.\'Fl DYE I?-.2 recl"rlir'r

INSPECTION

'3'-ack 1|1e |'m::51|e| [u- |_-un|inu||-,- i1ntwm':|'| the

term||'|als. Rewrzrzm 1hr; lrrads and nhgck again,
Cr;-n1i-1|:-W sh:-uld amsr m une |'.|irP_q:1i:-11 |1|1l\-
F"h:ulu|:u 1r'-n rnntifler |r there Is |:=on1|nu-Ly" in 1m1|1
dirucllu-":1.

J-I...

\.

1 4-3 15'] Dare of Inue: Mw, 1950

E51!-IUNDA MDTDFI ED. ITFJ.
F-
1" Haw GYLINDEHIFISTDN

MEMCI

|__

F.

, _-\. .
I

F1
.-

r"-

Date of I55-us" Maw, 1580 T51

vi: HONDA MOTOR CU, LTD.
 Hanna
IGNITION S"f'STEM cm ~
.' ,

_u-I-.
I

u,;g_- ~
_
.,+_\--.--,-* __LT;
I-a_>----
I"-**-.'-5-."-| BATTER? __~
I || r || I I I I |
.5",-
,.
_.- #5 |~:m|110n|
.-F.. -0-' \- |" SWITCH _._-- -
_.;.~'= T?-"T. ."~=~=,-..F.
I _ __ - -\_"\-\.
I_1-__
|'-I-_- n-':\_ _:--F _ _ __.-

= -I II 1
-I.
-. J-
I-
I '|'I' || I L ._-2

%_.-;-
|_,_-|. _,_-n. _-_| 'Pr ,_
.___--_"]"
.| _. -__,__

. R I r Tux

--4.-1- -I " J,/"nsc'rsnen

' SILICON ___
_\__-_.\."-

"=_Tr:-l==-_L1-'-:I"| -ll- " I-l

_,_ -.-1'- ..n""'/-F
I
-H"'I'-I. "|L|
,,.- ""'-I _ _ ____\<1T_____4' R | .'_"\'
,'_,.__IGHlTlCIN
E
'2' " COIL
-_ /____:RI:
RF, " hu."-av .I 31.;
i
.- --. _.
.-""- E--J--'.'l_:,_' -2:4;
T-I'M
'- .' - "IQ. ., | ".-II: - -'_ |
. "
- -
I.
.-' | I- I. III". .1, III I E-._ I.-u In I "I I -I I r-. II-I I -II: -_ PC" HTS
5" . w |_ I
I
ii - ' '
..;-: _ _ " _=
Q1
'.
I E . ?I_#3
.' -*
;
-
* - * I l * * ~
\I "_
f
I
_ _'- ' '_
_
F-1
"-=H=='. :
|\-I
.__.-*- .1
IQ: '
I , _"- mruumssn
r"\
\I J|
,.-

F."
I-
J.-I-
ll.
--1;.

I
A.-C. GENE H ATDFI

III
SPARK
PLUG

ENGINE ETD? e"'\|,

.III.G. GEHERIITDH IGNITION SWITCH SWITCH

nar-||1'|u:u
mu. ET---5_
. . I 'l| RECTIFIER

I ;
- I/E
Ci 5 I I I =__/ BJITTEFW -P-H

SFHFIIII PLU G-I

i.-- $3 e
FIIIIIIEIII I
0--it ,"_~
I

..|..
GDHDENSEFI POINTE-

15-0 H USED-I Issue May IQSIIF -= . .

'1'-HONDA MCITCIFI Ell, LTD.
 /' HONDA
I
,-
@J can i5.IGNITIIIN SYSTEM
fI''-.

SE RV ICE IN FDFIIIIIIII-TI ON I5-1 CONTACT BFIEAIIIEFI POINTS 15-3

TROUBLESHOOTING 15-1 SPARK AEIVANOEH 15-4
IGNITION CO-I L 15-2
I'll-F -- _I

SERVICE IIIFIIRIIIIITIIJII
GENERAL INSTRUCTION
K,-I. Fur apari-: plug informatinn, ass pagn 3-5.

TCIHCIUE VALUE
Spark a-dyaitcei GL9 FR Hg-H1 [II Q ft-IIJI
{-
SPECIFICATIONS [ I I Canada MuI:iul
Eparl: pi ug Standard u22|=a iU1'S'FSFi-L]
ND Fm unici nlirnptu i:|:Ir,\w EDD H11 FI- LFQOFS iu2uFsH-L1
, F5. aitizn-cIarI-I'IEI'I-sip-aiad riI:Iinq-_ U U211 FE ;ua4i=sH-L1
I _ _ i _':-;L_EIQIr]_______ __ ETHS ICHTHSI
| NGK For pnhci climate: bi!-lnw EEC I\I1:'FI can ~'caa|-rs]
F I r;;;';;.1;.;;..;;; rl'a|H"LI$;r]T|Ei1'1} can rcaansl
Sp-aria plug pap I 0.6 - 0-1 mm 10.024 - u-u2a mi
Igniti-pn timing . P" "'2'. L5. ETD?
E.~".9.*_%"~" =" BT92-2-1v9:.a_m
E-on-ciianaar capacity . I?iN_..__.____i
Cnrtuci hr:-aic-ar pain: gap 13.3 -- 0.: mm i|:r.lJI2 - 0.016 inl '

Ft TIIIIIIBLESIIIIIITIIIII
Eriuinu wank: but will not nan: Enna mm but rum puuriy
1. Enginu atnp lwitch OFF I. ignition primary circuit
1, Nu mark at |:|1u|;| - Faint; rIirt'y qr I~|:|L|I|!\'.I
f"r - incnrract point gap
3. Improper igniti-an timing
No lparir. at plug Faulty ignitinn mi!
Faulty mndemar
1. Enpina atop s-witth OFF
I, Fnirits EH11 ciptltiiig
L|:u:ra=a' pr i:|-arir wire
Irrtarmittenl shnrt circuit
3. Pu-ints burnu-ci, wet fuuiud u-r riirty
(-1 -II. Nu primary Eurtbltl lu pr:-inl: and coils 2. Ignitinn n:c0nr.iary l=i':l-Ill
Fmity piim
Lc-uau I:r~' hruirun wlra
- Fguily high remiun wire
Fauity lqnitiun switch
5. Pl-up fr.\ui:|I 3- improper ignition timing
B. Fa-uity plug wira Timing Illll incnrrecl
1, Coil yr-aaic or inap-aratiira 1_ Cn|'|1riIugaII|.I'.rnru:E1 ILllI"y'
{-1.
B, Faulty nuridunsur

F
Data 1::-I It-sun; Hay, IIJBU
EHDNDH MOTOR CU- LTD.
'5 15-1
 HONDA .-5
.-' '\-.

BATTEHWCHAHGIHG system CTI] ."

;-"

IIIIIITIIIII IIIIIL
F tar -.1--i
REMOVAL _ ' |.
'
_
I-1-
, |
T '
I ' a
ITE-Ii"|Gv|'B I?-E right an-LI II.-1| ilrln qmyurs.
Firniuim 1!-1: I=~attI:'r1.- and 51&|IIEl rainy switch.
DI-iI;i.1l'iI1lII'3TII1E"'|'i|'iIi! I!3LI:1.
T'IE"--Hi"-= l|1i= r-ii by rc'rnu+'in[; the atta-rzhrr-g nur
rum HIT? mrt .irJ@

_-l--
--_ -ll?! __4

IGNITION EICIIL p.1T,.\(;H||q-5 NUT

CONTINUITT TEST

C-I'IlH;I"i I'U|' cunr-nuiry as |.I"lu'n'|1.

THE DDII I5 good II lI1c'r-cl is -:,:|;'.nti|1|_|ir_'y'_
5E'30NE'~HI= 1'-E5--9-35 H3 PRIMARY" 1.35-1.a51:
..-= -
t_. .--HT -
-wt- , "T: I
-x

E. 5;; I I
'
FILM. I E _
L'__ J. -
L I
NI
' _i
FI R I Continuity H _-; '|__D|] q , y
-w

PERFORMANCE TEST
_?__
PE'|'I|I|i'|'|| iII|e 3-|.1|::-Ir1: sniuiic t-n$1 yr-1'I'| 3 |:i_',iI| tugige-|'_ '
PRIMER? ELEUTFICIDE
SERVICE LIMIT: B mm I1.-'4 IIII min. |

~.i?=.-11 <
IT I"'i';\III.I-W the CD-I lmmlr rnr|n||i'51:mr1~.'r"1 |r|51:n_|c-
Iiunt. I .-._

E mm |
m.24 my SPAR

SECONDARY EL ECTFIODE I

1 5- 2 15" Data ':|F isms: May, IEIBICI

El HONDA M-iJ'l'EI|T t:i1._ LT|'J,
I
:"' "
%.g) cm IGNITION SMSTEM

F BIIIITAIIT BIIEIIIIEII FIIIIITS , #11::

REMOVAL

Hem-oue the zoom! I:|E'|-IIIEIF point emu:-r

illlli
Dir.;;nrmer:1 the point win: lead.
Flumnun 1I'|n c.or|t_a-ct breaker usslemiliy. If

For CI,l"-1|IC[ hre:oI<Ef points impaction, sen page 3-?

NOTE _ i It
K- I IIIREOIITBIEI-EII-"'1'.lqJ|'lI'||'CIEF\'EOl1-"1'-I?-II"-IF'iI[l5I-'l? '
-e:In.u|1 u-'1|iE| CIII ID IT.

CONDENSER CAPACITY TEST

Remoir-a thn rzcurrinnsei 1|o-m the hit-sr plate. ' _

Olerrharge the ooneinmer In grouncling itn tlirmirlki I"-*'_'-.
. . . -- F._1
iH3|I'lE-I I115 (IHl.'iII'|- '

4"
Ii-F|ea5u|r,| rhn condenser eapalsity with a iehter.
CAPACITY: u.a2-on #F T
E -1 _
ii -1 in |.IuE oi spuoificqtirsir, iepiaee ihe crmricher. 1-I-_ ___ __ _
" |t_Q|

F 4
P'H.

POINT REPLACEMENT
F.
SFITING SCI-IEW5
Fiemoye -:hn prylni setting screws -1n=l bolt.
Fiepiacr. the contact p-I:|in[,

NOTE i i F
Du not formt 1:; 1|'I!1IHII the bekoiite wwhers I
rt; insulte the |t:IIml.IBI15'lIrr"|3E!'II!r'B[ClI' torrnin-'-I
F '?|'|;|-'rr1 [|-r|;u,_|n|:I.

Install contact breaker assembly in the reverse order

qt rem-ouai
Adjust the 1;In|r|I gap an-|:i ignition =imiI1|;|- K il
fr.

r'

Date of issue: I-Iay, IEIBI3 T55 _ 1 5_ 3

.271 HONDA MOTOR CO., LTD.
 HONDA FI
IGNITION system I:-III Itisj -'.

SPARK tnwrmzen
For alzivancer function nest, sue page 3-9. - ,- _.-
Removl the Irontact point cover or|tI' contact hreaI:- I
er aelsrlm-I:|Iy. . /
- r
Check the ipflg for |'C|Bs or run-slon and aduartcru - .' .-._|
Iii" ADI E'HlI'B5-$i~'E' weer if the aciuanser Iaits rr.i ramrn. .
Firzplase if I'iE|1'5s.Itry. - B

- |
,1--.

""h-.|

_.-|.
|

ADVANCE FI Fl EP LACEM E NT

Hsrrlcm: the holt by hoiding ms satacur.

Remove the s|:i'.~'a|1cer.
-'3.

--.; er
K...

.""!\

Irt-stall thu nrivar-met", aligning the llot with II||: i / .--'-,

Ffywhuni DIn_ ~ '
Inetaii the s|:Itpl1|.'r onti tighten the Lm-It, .-
TOHBI-1E= n.e-1.2 ii-TI1 IT9 met
.1 '\.
-.

"t
-1.

-|5_4 '5 Eietaofissua: May.1DB

enemas Mcttnn so, LTD.
 ff&ii" IB..ELECTRI[i STARTER
.r"'"
,.___ i _

SERVICE INFORMATION ta-1 steinten neuiv 1s_s '

TFIOLIB LESHOOTING ta-1 stisnten ctutsi-ironiye
1 -s
.-"F STARTER moron ts: CHAIN B ii

SEIWIIIE IIIFIIIIIIIMIIJII
GENEFIAL INSTRUCTION
I.-M. The ;1q|-151 |-|'||'_'|~|;m can he rgrr-ii;;ur-,u;| with tho r:|ngInI! in the items.

SPECIFICATIONS
|TEg.1 Standard SurI.i'it:e Limit

.|. I--1:1.".-2| i"l'|D[DI' flush spring tension _ *1-I-l\I.'I Q I14-I CIII HOD q I1i].E ozi
. .. ..._

Hiusii sengrit 12 mm II].-47 ir-ii T mm I0. I5 l"I

_ . .. . .___._ -1

Strtrt.-ttr i:iu1i:lt rir.ur.-n tor-octtet O.D. 37-900 It .-IE2! -ni 35.75 rnm IT.='i-Iii I1;

ruse ILIA
nee-OP"-D-neo0"'
IGNITION SWITCH
BLACK
F. I :-
|'I'l Tl-
"'7 STARTER
_-
- .. L _L _I_ FIELAY
.-.
5T.n.i=rTEFl MOTDH I
_ :- -= YELLDwmED LIOHT GHEEN.~'hED
"~. .r"
at- IIIIII,, |::Iil-
5

'IIIIIIOI
Z
-. '\'i
IOI
l

Ir.-

' '*~-* -vi

.5 {C}; sit "TEF' SWITCH NEUTRAL
ruitrer-w 5"""TF"'
fr _ ~.___ ___

TIIIIIIBLESIIIIIITIIIE
Sta-rtnr motor will not turn Surur motor turm arriigirio :I-uiuly
1. Battery i:i.sehsn;|ei:5 1. Low oottary specific gravity
2. Iiiuin lute burned nut 2. Excessive re-sistanm -Il'I i:ir|:r.rit
-II, Firuity starter relay 3. Binding in stutter motor
5. Faulty starter switch Starter moeur uni-is, but eriigii-in doe: not turn
H, F:.u.iIly ni:utreI :wlIrLIt I. Faulty starter niutch
Ti. Loose or etisoonnetrted wire or cable I, Fllliy strlttet mntnr grutrs
IF, B, Faulty sIIIrti:r mttar 3. Faulty startar I1I"I.EIIl and sprockets
Starter motor and engine to ms, but engine don not start
1. Faulty rgrilli-on system
I"-

Date of issue" May, Iiilil-IJ 15? 1 6-1

is-Horton MEITUH CD, LTO
 I-'1'-._-_. "E?-ix,

ELECTRIC stninten [III] P-

STAIITEII BIIITIIII
nemoyst

H'.|.|!t ra rgnrnorr switch OFF, reniirre r.Iu- __-

ililrrirtitl rt--ipilfilr r-tIi'1i-r .'.|.r r.i'|r frame before
.i.e.n'r'r.'1iItg the rrurrer mrirrtr.

FI:rt|'_tii'r:- lItr.' Ir.~.'1 i;ri|n I:|;.35r_i qi;t\.'|_tr,

FIBFI1-D't'E II'IE' hlitrre-| LI|.i.'i.- !.LI"IICI'I.I':'II snap ring_

5P-MP RING stsnren caste -..,

DI:-w:r:I1r|r:1.'.1 the starter sable at the starter motor.
I1ElIl'|IZt-'1'! II'iE II'||t'1t'-: st.-|rt|:r m|:|1||| n1t_:iur=!':ng bolts

R.1I'l1O'1II the starter I".TO]'I'Jl

HEAR COVER ARMATUHE 5HiM'5 FRONT BRACKET O-FII?-I-G

If It.-1,.

Ci
ii

"*_~s|~isi= HINO
PLANETARY ..,
---"-_'_ GEAH

-i~-_sn.irnien .--,

SHIMS I

l% a\se.itarr~.|e
snusn
EPHING

U-RING BRUSH YDKE O-FIINO set 's1=n|ns

1 6- 2 H Date of Issue: Iriay, IQBEI

E'Hi.IINL"J.i"i IIHIIITUFI CO . I T[I|_
 1-Ionirrm.
KT-\ ELECTRIC STARTER

BFILISH INSPECTION B1;_|_-_,i| Br__|5,i.| r.;p|1|r-45

FIE-moi-9 t+|r;i ;.i:.-uiirr motor i:-see screws and ii==:i

rrovei.
In5pi:t:t IIii: 1JIl.i5I'l-E5 and li"ilI-iii-i.iFD IIIrI I-'lI'I-l!I| |l'=""Th-

SERVICE LIMIT: -it mm I018 in]

Iiierr-iuri+ orush sprinit tension with ii ti-iri-Q BBBIE
senyiitze LIMIT: anu gIlII.G ozl

COMMUTATOR INSPECTION
COMMUTATOR
Rf:-tn uyc II to iiir iil-BILHIL

FIUTE . .___
FI|:i:pri;I tl'iii Ini;i.i1it;iii IIFILI i'ii.I1IJEI OT ihiI'n5.

irispi:-st II'|n- commutator hats for Ol5IIOIOl'i1l-i1li'I.

Bars i.l seraiurecl iri pairs inrliriaie grounded arniiirlur:
coils.

NOTE _ _ __ _____ ______________________

I Do i1-sit use i.-mary cloth or rant! pair! Ian Eli! _
IIIIJ|11FI'lLlIi'II.I.I'I

CI'|r_st;It I'I1|' i:i1intiriui|y LiieL'.r.i'Ei:rI piliri OT i2f'i'ii'i"iLHi'iOI

hers, and !oritii.'e-en commutator hurl iiml im-niiitur
theft-
Cerrimutator hat pain: Continuity
.it.i-rniir.urii to 1IieI1: No contlnuiw

Date of lseiis: Miiy. IQIECI I 6 3

-f.-HONDA MOTOR CO., LTI'.'i.
 .; .;._.|'

ELECTRIC smmen C70 I-

._.-

EIHUSH WIRE INSPECTION

CHEER Iu| rur|t|n|_,||1;5r f:'|:|-|'11 1_h|g- |_;1|_1|u h-"1-|||-|3| 1;|;| "Lg

IJILHII-8'! I-rITI'I I1IEII'; W IE Jud l|.11hn momr |:-ass;
RI=|'.I-E-llr the I:lh.ri1"| |.\-I-r|, |I n; w|rg |g bq-<;|lu|r|_ Q1 |f |1 |5
she-rte-.1 Tr: ch-P motur :33-59
Bahia tamulnml to m-umr can Nu uontlnuhy
Dhhln turrmnul to brulh Euntlnully

ASSEKIIHLWIIINSTALLATIUN

-'5-swmu 1'11: starter motor

AI||;|n mu LE5-'.-! nulnh with 1hn IJl'lJiI'| h|:|I|:I|2-| pm

5-

Ins:-all II!-B hear ccwer lIIgn|ng :11 51-or wo:_h the Izlrush
SLUT
I
Ins-t.aII the 5..a|te-r mcnur by ruwxrilnq the re-maul

Data of Issue Ma"-,-', IBBIZI

EHDI-ID-. MOTOR (IE1. LTD.
 /HONDA
F GTO ELECTRIC smnren

STARTER REI.lf
If

SIAFIIEFII H.-|:LA"r"

I N SP ECT I U N

U-:=:;:-r|::;-z I"1I! 5!.'.|rI|:*. nu'|'1r_'I| !h.|'IuI'- WIIII III-e: igm |c:-I1

ON.
The OUII I5 II-.mn;1I I we >L.=|1e- Id-lay m'IIr:2Ir_I|v.Iu

3'"-

.r~-
4!_'\..
I-7D|'I"-'.'.'I2II LIII uII|1'|lnE|r:' Iu [||.": |I||r:|:| rcII;w r'n.|1'rh
I'.':dL1lc- Inrn1-n;|l~..
'1|:|n|1=-ct i Ei'-4' Dl'.IE-I -,-' r.u 1|-Ir; Illlfh win: Ir;-.1111-;.
TH: :.-'|.'\'I||:I1 I. |1r:-'rn.:I II II1n||:|'I l1lIlI1|'IfllJI1l|'.

.-*""

.-'~\
STIIIIITER [:LI.|TBI'|f'I]RIl'E EIIHIII
HEMDUAL
5"" SNAP HING CI-IAIN GUIDE
Ffnmuulr Ih-Q AL. Qarml at-Jr rntur I5-artiun I41.
FIIE-'1'1I:m:- The star:-an I:-hmu g|.,|-|.Ir: =r|c:I pm-|:=4:Iu|.
FI.n-'r|-'.1\1I.- IIII: :|;:-r|:r|::II.r:1 5-1:11-n-;| |'|Ia11||.

Flumuue the 5|!-EIIII ri-'1-;|.

FIErI"|u\' IIII: 11B|Ir.'I |:hni|| .1|1rl :|'Ir|I|:I1:1s..
If-I-I

I-'I'.

l
PTIUTEL-TDFI SEWING PL ATE

Daze or Ir.:ue: May, IQEIII

$1 HUI-IDA HIUTDP Gil, LTD.
 .-i

Homnnf I '-.- I"

ELECTRIC srnnten CHI . _E/*1 d

.\\
STA RTE FI C LIJTC H D I SASSEM I3 LY

HEN-lEl'JB II?! TI"lI'E' S-EI'E"|'l"5.

PIl'|'l'I=l'I'I|'-EI thn zlartur ~3I||tI;r: r.Iu'I9r.

Harncwa 1ha ralle-rs, nlungers a|1|:I sprm-gt.

STAFITEFI CLUTCH INSPECTION

II1:-|:IIJr:'.' 1I'Ii I|:|II=Iri fur imuuth u-perivnn.
CIIECII III: rt!-III.-r': Itlr I::\Ir;r::::Iva wunr,

.-.
I.

.II\._

Impact the drive and cirsuen spruckuti and chain fur

#Il:ljI$$II|l ||'I|'II|' lflr HKHIF.

I|1~:a:|LIn: the unue -sp-rI:Ir:|-=.et U.IJ'.

SERVICE LIMIT: 35.71-mm I1.1HI?InI

In

jg. -|---

STAHTEH CLUTCH ASSEMBLY

.-"""II
lnrtall thi rtartur r:JutI::h uutrr.

NQITE
Eta!-H: the arid 01 nnlrh 11:-rmv against Ihngruuvn
In thr clutch -:I-u'tl:\_r.__
.-*1-.,_
Irtstpll thu BDFIFIIIIB. |:|lurI-|1u-rs and ruIIur:-I

INSTIALLATIUN
-_
.-.,_
Rawrn mu rumcwal |:|rn|;~!:r.1|.I|'\:.

r'1

{S-6 152 D-.1n_-u'I Iisue-: Ma-,1, I981]

-DHCINDA MOTOR CCL, LT I1-
 {HONDA
F.
oi, cm IISWITCHES
SERVICE INFORMATION 1?I HANDLEHAFI SWITCHEE 11-3
BRAKE SWITCHES 17-2 IGNITION SWITCH 1?--'-I
f NEUTRAL SWITCH 1 Tr - 2

SERVICE IIIFIIRIIIITIIIII
GENE HAL INSTRUCTIONS
_J" - Sq|Tru wimi I'I.l|.'t* dliforent colorant IJIII1EI!- around them near the o-onn-uctnr Tings: wit no-rirletld ID G-II1E-I '-'-Iirb wI'Iit-I'I
oorresn-ond with thn Ia-and uoinr.
' All |'.III:'|:II|t pIog1 IIB\'B Iooitiiig tabs that must be rolauiod bcfuru tllsconnclirlg. IHII ml-ll! DH -iIll5II1I!"J'~\'I'IE I'B'I1-'I'I'll'IIEtFl'lD-
- Thu fnllu-wing |;:;\II;|r curt qru un:I.I 1'IIruI.IgI"|uut 1I'|ii n!1:t|I:|I1 and IZIII the Wirig dimrnm IHIIBIIIJI1 IBI.
.p- B Blue G Gwen LG LIgl1tGr1HIn W White
Bi; - a|q-=I= Gr - G-Iv D mnun r - I-lI'Im'r
Hr - Brown LB l_n'|IBluI H Hnl
- To IECIIBIB an Elgctriual fa|Iurn_ ch;-ca 1h: wntirioity o-I the electrical oath throuqh thn part. A oontim-|i11|-' check uurl
u|unII'|-' be mad! wi'J'It|ut removing Lhu pan from the mowrcvclu. Simply dim!-linen the wire! and connect B wnfivlw
tI.1ji|! cur 'ItI|IIi-I;lI'iIl\I'I'I.1!I,I:|' In |II! tE'1'I'Ii_I! CIT III'DIlI'IB|IIII:I2II'Ii
~ A ngntinu-tlf I-i;51'ur i5 usniul |.\'h:r| izhmzking Lu find out whether orr not thorn is an uluotrical crmnecliri I-IE!-':HE W-"II
points. Au ohmmatar is l1BBI2IBIII to munsuria the roiistermu of II circuit, Ii: when mute rs a specific mil resiutlnui iI'I'1\=II'-HI.
nr Ir-|!|.|:n |1hE|,.1I|'-1] for high ronlataiiira I!n.|lBI.I by corroded connections-

1"

.="''-

r'

r"~-.

Dato of Issue-'_ May _ _ II63___

-soiior-ion MUTIZIFI I::o., LTD 1 7'1
 .-' '--.

HONDA. if
SWITCHES C70 .- '-

.- -._

BIIIIKE SWITCHES FRONT BRAKE SWITCH E|i""r' LEAD

FRONT BRAKE SWITCH
FI=_-ni-owe the I1-satlli-ght.
I.II5I;Q|1i_tI;Ij l'I|c Ct,-Y _1||tI Bit iieatti oi me front brake
twitch.
Clmizk fur i:uniIno.|-,- with mi: imnt brake app-Iiacl.
Eraka applied: Continuity
Bash not amaliciii: No continuity
I'Ic|:ilai:c II!-E switm I1 -Wee-aasarv.

1-_ w
BI: I.E-"IO _,_\_l

REAR BRAKE SWITCH

BRAKE SWITCH
Fem-we rh: r-gm sicia cover.
Disconnect LI'H.l G.-"F oI||'.I Bk Ic|.i.|d1 [If 1h; Igai hrukg
wiritch.
'3I'lE~E|I1'r rintinuitv with the ioar built: uppiiq-i;i,
Brain lppliad: Continuity
Brlitl not opp-Iinlt No corrtinuitlf , ".
Rlucc thc =iw'i1ch ii ricccssarah E3?

Bl LEAD G.""|" LEAD P.

NEIITRAL SWITCH
HE
IIEIITIIIIL SIUITIIII
FI:I1i|::Ni: thc IEII Li|:Ii: l:_:11u:|' ;|r|-|:I angina 5p|'g[.Ii:g1_
co-rot.
Ilhirck it-rr swilch tnr coctintiitv hctwccn the switch
turm-nol Iw-re romou-ed} and gr-oun-ii -mih I_hc
H.
I1l.EiI1SIi|-iiinn In rii:|.irrr|I qrirl with thn h'3n5411i55-I011 ||1
any goat.
Ih I'lIl!IuIIHI|I Cwrlmity
In gait! Nu uominultlg
Rec-i=v=:i= lI1r' l"'tllII.I'UI wirI1':I'l if necessary.
'-.

_-.1,-"'
F

1 7-2 H Don: oi Imm: May, IEISII

IE.-HIJNEIPI MOTOR ISO" LTD.
 /"T HONDA
{I'-'\
K _=_j GTII SWITCHES
Ji-"It

HIIIIIILEBIIII SWITCHES H EADL IGH1 H I -LO SWITCH

The |1I||_'II|II1I1' -::Ii|:.t|=-I i'.|'|':tt!"|G'5 *II'l3"I-- EUI" 5IEII'l=I'-I

I"|:irI|, enigino atop, lt=1'1cII' I1!-1-I!-I I36 I"ItI-='"I 35 3"
os-'ic'11hl',r-
. I-I
\._ I
_i-. I3."-r |||_||t-,- 1ni;:~. I-:1: ihe co-rri-|:|nr-itnlrl f-II the - e-
I-|.:n:in.-Imr cios:-or switchon i1=IIoW'

I:Il.'1"|lllil! tho hm|r:IIi5h1-

t',Qmin||-ty shot;-Ir] e:-mt hntwi-c|'I TIRE CHIC" '=I'-I!
ynryg gin i!:|i:?'i |.th.B|'I.

Ii-"'-

r TURN SIGNAL SWITCH HDFIN BUTTON

HEADLIGHT HI-LOW SWITCH

I-loadiighl Hi- Loni Switch
HI; Bu: I I_ __Hl I |::| Ln-
|".i'I|DDLE INI1 Ii"toBtnI"|' IHI ' E.-C:
L-D: "I" toI||'
CJi--CII~ --C5
p.l,'__
IL" . -
K |l;qlurootI-a ti -1-"I1 ' W

TURN SIGNAL SWITCH Turn Signal Sn'Itl=Il

LE FT: O to GI -I IR W ..L_
QFF: No continuity LEFT | _ _-_t- _--I
FIIGI-IT: LB to Gr _'dF'i'= _ _ __
|"""'.
RIGHT E3 "-ii-1'
_ Co-Ior coda LB GI 0 _

Flu

HORN BUTTON
Hum Bi-mun
LG tn I3 with button dlprnnd.
No continuity with button r1iIhlld-
I iii E i
N
F.

T
. .
i Color Codi I
1-
I
LG C

F.

,-t.
IE5
Date o-I Issue: May, I950
QIHUNUA "-IICITDH 130., LTD.
1 7-3
 HONDA
SWITCHES I-.%,xI
-_ _I_

STARTER BUTTON EN
NE ET-BF swircii
FIR to LGIFI with button denrnstcd.
No continuity with button released.

Starter Hutton
* I T ..'
FiI"e'
.-05- = Qi-
Ccint @955 wn u:I.Fi=i Y
-F

ENGINE STOP SWITCH

RUN: No co-ntinuity
CIFF; Bit.'\'i' to STARTER BUTTEIN -.
Engine Stop Switch

o|=F _ IfT.Ii-I-:i:1' _
nuiiii '
tin" .-.___?~
Ioiorcocie N BItNt' I G
_.iI-I-I.
.

-\_

IIIIIITIIIII SIIIITBII
COUPLER ""\
FIltl1"I.Il.lE tlic II'I.1I'llt1|'.>'-E1 E-"II'.I |.IiIii:|r||i|!c| Ihn r:|1|i|"|lci

Chock thc I:onti-'=|.i.|-,-' oi ii.-rmin.-ii-i ir-. 1IIFr irlitinn

5'.f|'II'|:I"| '-tiiI|: |:.it|||_1|r_ir

I OFF: HIti'\|'|IIJi:i-G
ON: Bltto-R

. , .2
____

___ st anti to _ _.-It.

grr i
'19.
_E2oIot ondn' B-It
Q -~H. Bttlt Q

Rcplece Ii"'|B switch Ii itc-::|='t5;|ry

IG NITICI N SW ITC H _,_

1 7-4 we Onto r.-I italic: May. ISBEI

-D HONDA MUT-EIFI C11. LTD.
 _,-r I-.

IBIRIJUBLESHIIIITINE
|"rI_I-L

ENGINE '|'iIlLL NOT START OR DIFFICULT SHIFTIN-G 1 B-5

IS HARD TO START 13-2 ENGINE NOISE 1 B-5
ENGINE LACICS POWER 1B3 MOTORCYCLE POLLS TO
._-
ONE SIDE 13-?
POOR PERFORMANCE AT IDLE
AND LOW SPEED IB--4 FAULTY FRONT Si REAR
POOR HIGH SPEED SHOCK AEISORBEFIS 18-?
PERFORMANCE I3-Ii FAULTY BRAKE IEIi'
Ir"- SMOKING EXHAUST 13-5 IS-T
ELONGATED DRIVE CHAIN
FAULTY CLUTCH 'I3S

if-.

I-"'"

.-.
I

IF

I.-.

_/F

IF

Date of Issue: May, IHSIII IE? 1 8 1

HONDAMOTOR CO.. LTO.
 r"' =-i
tnoueteseoorrnro CTR --,
-'-t
EIIGIIIE I'Ill.I. IIIIT STIIIIT III! IS IIIIIIII Tl] START
PCISSIB LE CAU SE
I. CIIE|'.h. If Iu|:I rtt3[,I'|1J5 FUEL DOES NOT REACH A-p Err'i|:Ity' Iul tank
tattmmtqr CARBURETOR Clogged htel line ICIE-t'M=:ttt1 fuel tank 5;.
carhu reto-r
Clogged htul yelyn
F IJE L H EACHES Clogged Iuel tenit oep breeriinr hniri
CAR BU R I-TTOR

I
1'. Remove toerlt t:-lug Gr ten WEAK OR NO SPARK in Faulty ot fouled plug
tnerlt Fouled, burnt nr pitted cttntoet
brceitor It-ointt
II|i';'t'Jrit!-t'.'I. hrukqr putnt gap
Faulty condenser
Brolterl or thnttecl hiqh tent-ton wire '-t
Open or ehorteo ignition coil
Faulty iQtiItIIJl'l st-yi1:i;h
GOOD SPARK Irlcormct ionition timing

I
Ci. Tcet cyi Inder- comore-inn
TORMAL CO III P R ESSION
LOW COI-IPRESSION-i-e- Er-nine our tzrm-itienl
Nu unlyc clearance
"-I"-alirc rtucit open
Worn cylinder St oieton I"i|1g5_ -I
.-'"-
Blown cylinder hr.-.er:I gleitet
Flaw Irl -t:ylinr.Iirr he-ed
Incorrect yeltre timing

1'
-II. Start elnqi rte ENGINE Fines, trot??- Choke irelrie open
ooes r-rot st.-ant Ct_ltI.'Iun!l.ttr pilot egmw Qipen
Air ieeiirro t'I\rou|;h- ItttaItti tht|'nIfr,'.iI|:i'
ENGINE STARTS Incorrect Ignition ti mitrig
I .'-""\.
I
S. Remove ioerlt plug WET FLUGHA b Fiooiclecl corboretor
DRY PLUG
Cerhrtrrrttr-r choke excessively
closed
-"~.
Thtottl! relive crceetiireiy open

S. 5Hi'l engine with ettoite

clototl ""\

I-I_I-L

1 B-2 In Crete of Imtez Iiiiey; IEISII

'13- HONDA M-TOR tICI., LTIII.
m
 [I THDUBLESHDDTING

l;""" .
EIIEIIIE LMIIIS Pl]'IIElI -
POSSIB LE CAUSE

1_ Halter '.ryI'tr:,rI5 r.rH gt|.rur'ir.I H WHEELS DO NOT SPIN __ __e- II] Dragging his-rlrr
spin FREELY III Faulty wh-eel bearing
I3I Osertightened drive chain
.-" WHEELS SPIN FREEL"i"

2, Check tire pressure INCORRECT TIRE F'RESSLIREi'- [III Puncturecl tire

III Faulty tire velvrr
TORMAL PRESSURE
|,..-.

3, Rapidly accelerate from DOES NOT ACCELERATE WITH -e- III $II|:!|pi.i'i If!IuII'l-
low no tr:-con-rl ENGINE SPEED RAISED IEI Worn or unrvcn -|.Iut1IIi Iltclritih

|.i"""\. ACi.'!EI.EFIATES

I
it, Rev up gr-eduelly ENGINE FEED DOES NOTA1-III Carburetor dhoite closed
INCREASE IE] Cogeecl air ulcan-it
rzti Ciogge-ti Iuel line
I-ti Clogged fuel l.|nIt up breather hole
ENGINE SPEED IBI Clogqetl muffler
INCREASES

1"" 5 Chuck ignition timing INDIIJFIFIECT tir.t:rioA- III Incorrect ignition timing
rti Ignition malfunction
CORRECT TIMING

E, Chectt yeiye clearance INCORRECT VALVEO III Incorrect yelye cleerenoe

CLEARANCE III Worn value mt
CORRECT VALVE
CLEARANCE
I-"_"~ I
T. Test cylinder compression LOSS OF COMFRESSIONih I-II \.r"e-Iue ttuclt open
III Worn cylinder Si piston rings
no RIIIAL cow-neserort I5] Btown cylinder heed oritlrer
K-P.-.
I-ti lncdsrect yelye timing
I
B, Ohecit carburetor for C-ARBURETOR -CLOGGED C-erburenor iets cloqgetl
clogging
CA RSIJ R ETO R NOT
TLOGG ED
F
5, Fierrrrwe sperrtr. plug PLUG FOULEO DH F poled plug
orscotoneo III Incorrect hcet rirnglt Dll-L9
PLLIG HUT FDULED
Tin III-ISCOLOHED
(W.

Date of ltsuc: May, IEHIII 169. -1 B-3

-El HONDA MOTOR CO., LTD.
 1-t:r:;E%t:us. .-Pi

I I-
TROUBLESHOOTING
1
it

Chncir oil layrrl and condition OIL DIFIT"r' on LEVEL- A in Lenrel too low or high
incorrnecr is] Co-nur|'nineter'i t:|iI
ODRFIECT ENGINE OIL
LEVEL

Remove cylrnder heed cover
and ctr-scit ItJI:rrit*.etit;in
SLIFFICIENTLK
LLIBFIICATED
INSUFFICIENTLY _ E... 11] Cboygnd oil has-sage
LUBHICATED ni Poor nil pump deiivery
i3I Low oil preeeure

Check If engine oyerheen. ENGINE oyeenerne --A In E1-rtcsrsivit carbon in combustion

chamber rq_|

IIII lnooi-rec-I I'LrcI

ENGINE DOES NOT rel Sfrppino clutcin
TUE R H EAT ill Mntrure too Ietrrr

Rapidly ictnrlerate or run er encrne r:nocrts-_- III Worn psston or cylinder

hich speeds IEI Mixture too ieqn
I3] Incorrect IUII
ENGINE OOES NOT I-ti Excessive certr-on in combustion
KNOCK- chamber
i"5i Advanced ignition timing

FIIIIII FEIIRIIIIIAIIEE AT lIl.E AIIII LIIII SPEED ..E.._;,.-ME CAUSE

Checlt Ignition timing Sr rncorrnecr TIMING e A iii Incorrect rirning l:IjiIi;trn'tt1
yeiye clearance ctennnnce i.'.ti In-correct uelye claerenoe
CORRECT TIMING A .--s,_
CLEARANCE

Check. carburetor oiior rnooenectur no.ius"reo - in Mixture too Iuen

screw srI;l,iI-rttnltnt rzi Mitrrtee ton rich "E
CORHECTLT ADJUSTED

I
Checi-t for err leeks me tear-zei in In Faulty iarburltor Qrrtltl
ctr Carburetor not securely tightened -"d"\.\l

iai F.-rulry Intelrc pipe qrninn

ND AIR r_Erti<5 to Deterio-rated D-ring

I
Remoye resent plug Er wane on irrrennrrren-ri..r1i Faulty or fouled plug
rut spark WARN [El Fouled, rough. or pitted breaker
point sl-Irftlcl
GOOD EPAFIFI [SI Condenser shorted
I-II Faulty ignition coil
-._
It

18-4 In D-stool ltauu: l'Ir1ay,TSE9[l

QOHONOA MOTOR LTD.
 1-Iowan.
F cm THUUB LESHDDTING

FE.

Fllllll HIGH SPEED FEIIFIIIIIIIAIIBE 55ELE "55

'l_ [Ih||1;l-Q ignic-n timing B1 INCDHHEUF TIMING 31-i 1- lll Inna-rract timin-3 II-ll!-lFIII'1ET1l
valw cluarancl CLEARANCE lIl' lr||:lj:|l'fE'I value claaranca

CDHHEET TIMING E
I.-I-m
'1ILEAFl ANCE

1 Dlsuonmct lunr ti-ltlr at FIEETHIETED FUEL FLD'l'|I' a- ill Emmy luai tank
carhuratnr and check For l2l Clqggtl furl 'rul1a
crng-gmg l3l -ljluggmgl furl 1..-mt cm braallier llDlE'
F-
UNRESTRICTED FUEL
FLOW
i
3, Chuck; .p:lli|tu1'_fl|nl h'alIm_ CLUGEED l1] Clqggd jel
r"" E: narburamr jet For cluqplnq ll] Clogged fuul Ii-ltr
I3] Ciclgg-ed lual ualw
NUT CLDGGED

T
4 Huplmu |:arl;.|L|r!t|:|: mnin |u1
{EDNDITIDN IMPROVED
CDNDITIDN AGGHA'u'ATEDiI- [ll J91 sizu IIDCI small
[El ll mncllricm llI'I|JfrJ\FBl2l with small lIt!
all Cluggud air cllur
bl Chn-he nut opened fully

K
E, Chuck v4|lu&1imin-g l-NC-U-HHECT ii lill incorrect ualw timing idil-I$tl'I'1E1

CORRECT

l Faulty value snrlnn

B, Chggk vulva |:|-n|1g*[5|'15i|;|-n WORN DH BHDKEN SPRING-it ill

SFHING TENSION
CORRECT
1"-.
Slillillllll EXHAUST PDESIB LE CAUSE
F. i Hun m0|::'rll'.'y'lI:lE a In-nq BLACK Ski-Gil-E EMITTEU iv ill \|i'n|'r| |:','|i|1l',l:r Bl pih ring:
distzmm at hlqli weed lil -Dil lavll ton high
'l3l Pi;-run. ring: lncn-rm-:t.l\-' installud
lil Fault- raimn cw cl-llnder
THIN EIl(l"lA|-..l5T EMITTED l5] Flam in cylinder hnad

F,-.
2. Flururn thrule grlpl qul-cklv WHlT'E SNIUKE EHIl'TElIli1I- lll Worn lntal:-n ualvn lrulrln nr him
[2] Deusriurared vulva guide D-ring

ND WHITE BJDKE
EMITTED

I-'1-. T
3. Hun motoruvulu a lung WHITE SHI-DICE EMlT'l'ED-lI- I1? Wum exhaust valve gnlidu S: rtuf
rll-;1nn|:=e ul lnw spa-ad ll-ill E;+m|.|-51 v5l'n: guide lnen-rractllf aaatud
131 Worn exhaust valw strrri I-Bil
l""" uncumnen EXHAUST

Data of ls:-ms: MW, 1530

'3-HDNDA MDTUH CD- LTD.
In
1B-5
 Hanna. _
"rnuuetesuoetme C70 z-",1 1"-1.
\-

"=-.
|illllT'f BLUTIIII
PU5-SIB LE CAUSE

T. Preperlv ecllusr clutch CLUTCH 5|_|PPmt3 i -lg. 11; wqik ggumh -pf|n.n
{Ell Wr.'|H| ur ill!-tnrted clutch plate gr
frlctitrn dist:
J

BlFlilBl.I.T Si'llF'i'lliE
PUSSIH L E CEUSE

DIFFICULT sH|rr|r1ei- in Bremen geqr ehilr qrrtl 5|!lr|n||'

ill Hrrritltn shift furl:
E3} 5luqgirri1 movement of ehiit drum E
fork .-I-\.
I
Hi Bruit-tm shifting gear rlrcltrutiun
[5] Shift arm pawl tli.u:=ennet.1ed ir4:|'|
shift drum

FED-M. NUT |iiETUHHEDiI- [I] Br-niten shift return tlflg

TD NEUTRAL ii] Ehiil Bhrit lrrtlrfurrinq with tare tr-r
cmiur

GEARS .ll..Ilr.IlPlNG GUT OF -in H! Bent shifting near or we-rn $i1r-H lurk
POSITION iii Br-lr-H ur weirir-entrl shift rlrurrr
stopper spnnu.
1"

Eliiiilii IIUISE
PCi35l B L E CA USE

VALVE Hli in Eartseslv-rl valve clearance

Hi Warn valve
PISTON -SLAP Worn nrunn He cvl-rrtler
Ertcleilvr CBFl'lD11 in nnmhurrien
chamber
[Bi Worn piston pin 81-rrtmneetinq re-cl
smell end
"N
CAM CHAIN r~|u:sE?-_- rrl Worn eemehelt hearing
I21 Wurn camshaft spmuitat teeth
[3] Exeeselveiv elongated drive chain

CLUTCH cunrrieiiw 111 Excessive clearance between clutch .-I-_'I-Ll

pine Er r:l|.rt|:h uuter
12] Wlaltnnntl -clutch damp-er eprin-ii

NDIST D-FH\I'E 5 DHiVEH-er Hi Wtrtn or deteriorated tlriuen gear

GEARS deq:-er
ii-?l Wr gear teem
.'_'|,_

11$!
13-6 Date ul iuu-e." Mae, 195111
'?HUND-5. MEITDH CD, LTD.
 I lgeeumna
F ETI] TROUBLESHOOTING

F l|lIIT0lIII'IBLE PIILLS Ti] IIIIE SIIIIE FOSSIB LE CAUSE

DIFFICULT STEEHIHG uni iii Dwrtigh1eru=ti steering head tore

eutn DIRECTIONS threetl nut
(Ii-\-
iii Brn-I-ten tteerrng rteel halls
i3i Bent steering Ir!!!"
WHEEL wr:lee1_es E-P ii] Eneeatrve uiiuv in wh-uni hearing
ll! Bmrrl. wheel rim
I3] Loose nzle-ire:
Ill Ere-E'l5l'|II ti-lav in Iw-l'|gnrl' Divi
if-I. huglttg
[El Frgrrr-I: l:|en1
IEI Drive ehiin acliusreu urwquellv
.u.Ilun:e|:i

ll;I"\.
MOTORCYCLE FULLSE III Unhelanult frqnr E rear shtr-r:i~.
TO ONE SIDE aI!iHJlI'JII"i
III Fr-gm it r|'-!-it wheel: nut alignncl
I31 Hem fr-:|nt I'|:|rl~; ur wringm

lilII.lI.T'f FRIJIIT I: IIEMI Si-IIIIIII HBSIIIIBEIIS FOESIH LE CAUSE

SOFT FIlDEi m III Weak !|Ill'lT|5

Iii Excessive lead
F |-met: FHIJE Cir lri Feultv ire-l frlt
III Fgultv rear sfhntllr iIIJ"llIlfI-IE!

NOISE IN SHOCK ABSOFIEEHE ill Faulrv stopper ruh-her

[El Faulty rqir |I'|l,1riCI=! lib!-DTIJIFF

FlI.iLTI' BIIIIIE PCIISSIB LE CAU SE

r"_"-
INEFFECTWE ADJUSTER E-h II} '|'l|l|}|'n brgl-tn lining, brelte shoe cum
qr in-rate tzem

.-I-5| SOUEAKING -ii I- III Worn brake lining

III Fnreign particles cm hri-ti lining
I31 Finugh brake |:ir|rrI1 1hr:-e ttantaetmg
lat:
ill Ihlurn imrltu |'.r-1|1E| huihinq

INEFFECTIVE BFIAKE Er III Fault-,r Irent brake table

iii E-riltrr shun pprtiallv contacted
I3l Mud ur water in hr-rlirl
HI Dii er grI:r|1E on brake lining
IEI were nrelee lining

ELIIII GHED IIIIIIIE Bllllil POSSIBLE CAUSE

iii Inutrrrerzt etljuitmums

III Hut lubringtetl guflileientlv ent:-ugh
.---1 I3! Wnm mrodrets

Date nf issue: l|-ltlv, I-HBO "3 _

E:-HONDA MOTOR CCL, LTD. 7
@522
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_|__ \_ _
 2D. B2 ADDENDUM
.""-
INTRODUCTION CONTENTS

TI'I|s aII1;IencI1.Irn CO'I'II..E.lIl'lS rnfurmauun Iur IIIH IHB2 I. GENERAL INFORMATION . . . . . . . . . . . 20-2
___ _ CTIII. Raf-er tr: the base shop manual for sewice
infurr11aliI.III nu-I. included In this addendum, 7. LUBRICATION . . . . . . . . . . . . . . . . . . . . 20-5

3. INSPECTION AND ADJUETHENT . . . . . EU-5

ALL INFORMATION, ILLUSTRATIONS, |J|I=IEc.- lI.FUEL5I'STEM...-...... . . . . . . . . . H20-R

--~ TIONS ANIJ SPECIFICATIONB INCLUDED IN Tl-IIB
PUBLICATION ARE BASEDON THE LATEST PROD 5. CYLINDER HEADNALVE . . . . . . . . . . 2041
UCT INFORMATION AMIAILABLE AT TI-IE TIME OF
AFPFI-IIIIIAI. Fun PRINTING. HONDA MOTOR 10..
LTD. RESERVES THE RIGHT TO MAKE CHANGES Ii. CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . 2!]-I2
-""_' AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANT OBLIGATION WHATEVER. T. TRANSMISSION . . . . . . . . . . . . . . . . . . 2!]-I4
NO PART OF THIS PUBLICATION MAY B-E FIE-
R. CAM CHAIN TENSIONEFI . . . . . . . . . . . 2!}-14
|FROOUOED WITHOUT WRITTEN

HONDA MOTOR 60., LTD. R. FRONT WHEELI'5IJSPEN$lON . . . . . . . 2!]-1?

Surwricl PuI:IIiu'I:In-I1: Office
I'D. HEAR WHEELISIJSPENSION . . . . . . . . 20-1?
.---.
I1. BATTERTICHARGING STSTEM . . . . . EU-TB

I2. IGNITION SYSTEM . . . . _ . . _ . . . . . . . . 2!]-22

I3. ELECTRIC STAFITEFI . . . . . . . . . . . . . . QC-EB

14. TECHNICAL FEATU RES . . . . . . . . . . . 2U-ET

,-._ I5. TROUBLESHOOTING . . . . . . . . . . . . . . 2U-23

I6. WIRING DIAGRAM . . . . . . . . . . . . . . .. 21]-3T

. ""\-

-\

r'_'\

|F'_\

-t _ _

Dane bf |;;u=: Nu-.-__19a1 "'9 2o_-I

ii-I-IONDA MOTOR CO-,LTO.
 HONDA -
'82 ADDENO UM ETD .---\_

I.I.
I

I. IIEIIEIIIII. IIIFDRIATIIIII
SFEBIFIBITIIIIIS
ITEM
DIMENSIONS OIIBFBII IB'ICI'I L mm I719 inI
Dvrull '|IIl'II.'Il!I'I Bilmm (26.0 InI
Ouirall height 1,010 mrn (39.8 InI
Minrrnurn qrI:IunI;I tlgu-rant: 150mm I{5.5in1
.-' '!q_
_ EII_v wa_qht E2kgIIB.IIII:I-I
FRAME Fmnt 1I.I1pIImiI:|rI, tnlvnl Bntlum link BB mm [23 InI
Rear u.|apem.IuI1, trnuel Swingiarm 51 mm IE'.:I- InI
Caster angle E33|II_' |' '-
TI'dIII 1-'5 rnrn I195 InI
ENGINE M-an-:|munI torque I16 kg-m I-II.3\I II-Il:].I'E,EIII1 rprn
OH qplnhr IJ.-E Iltun IIILB5 U5 III. 0.71 Imp I:|tr after disasawmbly
IntiIc| valve O-pa-In 'I'.I5 ETDC
Cline: I15" ABDE:
ltI.U5mmIiIt
E III!-nu IT vulva ODBWI 22.5 BBDC
Chases 2.5" ATDC
Englma welght 20 I-cu [=1-4.1 IIIII
.=-5} I
CAFI BU R ETION Curt. |I:I-unLiI|I:.atInn nunmer PEIEA
ELECTRICAL I|;|1iII:|n CDI
F uI| Ildulnip 23.5 BTDC ut 3.100 rpm
I3a|1urau:|r FI~,m.~I-I:-I A.C. gBr|EIlI-Ur EIIWIEIIDIJ rpm
EIITIIT cauanitv IEV-EAH
Spud: plug
Standard u22I=sI=I:-u INIIII. cams INGKI
Fm mid CIIITIIII III-IDW 5C [lIFI uzursn-u II-IDI. cnaus INGKI
For extendud hlgh speed r1I:Iin:g uznrsn-u INDI. =:HI='IHs INGKI
LIGHTS Headlight [high.I'|-aw beam] 1'5|'?1'EW *""I
Turn slqml 3332 ED EAE ND. IDT3
SIJBBEIOIWBTBT 15'!
NI:u1rIII Indicrrur 3.'IW SAE No. 158 "H
Turn slqnal Indrnamr 3.-I'lII 5-PIE Nu. I53
High bum IIICIEDIIIUF ZN

"""-.

-HI

20_2 '3" Onlacrflssuui M=~.,1m?.1

-EIHONOA MOTOR COL, LTD,
 HONDA
f
I-H
% CT II 112 ADDENDUM
{T-'\.

TDIIIIIIE IIALIIES
ENGINE

Turque
U, Thread
'11" I r,I'|l. Irrmll kg-m ft-IIJ
,_

Elem-shaft sprocket 5 D-7' I-I 5-H

F'.|'|i| I;IrL'I,IrI 1prI:\CIe-E1 B I-I-15 B-I1
r CI.'I'I.I
12-15
5-H
'I.I'iI~.'u- .:|I;lj1.|$l1rII;1GrBIAI 5
OII drim ho-It II 2-III'~-2.5 15-IB
Fuul IIII.Ul' I5DIl -1-|yq|lIJi,\.1 ._ I].IJ3-IJ.D5 0.2-0.-I
I-_.-.

F FI RIM E

I _ I Torque
I
Thread -
It" GI din. Imml In;-rn It-1I:I

TOP bridge eiue I.IuII: I 2.5-3.5 13-25

5ue1-mg lock 0.8-1.2 B-9
I"-II , Engine hunger I:-all 2.0-3.0 15-22
Hear ixle 5IEE| r1U'I I 3-5-4.5 I3-33
Rear brake tn-r1:|ue IInI\I mmmmm 1.5-2.5 I T-18
Ree: .II1I:II::II ebs1:IrI:I-er 1U 2.5-3.5 I8--25
Swlngerm ni-m1. hr:-I' TD as-3.5 13-25
Fmnt epspeneran pw I:It hull 5 2-0-15 I 1EIIB
Frcmt |I'II:II:Ic absorber upper IJCIII R l\.Ih3-IFhI\-JH-'|I"\-17*-'| e en-2.5 ' 1EIEI

I mots
SPECIAL
f _"'I
I_ Tug Mm-|'|| TCIDI HO . CI'l'I' FIef- WW
I FI|,rwI'1 eel I'1CIIOIl' U-7915~I5I34mII:ID I 2'13-EIII
'l|"iI|'IIrII Id'|II!ILBI* D'I'HIIB-GB-II@CO I LID-B
_ H Flutgr puligr IIIII'5-II-3"-ZIIIIIIIIII 1 I EC-1'0
__

r"'"~ I
Pu

um er I15!-re: raw. Ieer II" 20 .. 3

r HON CIA MOTOR CO-, LTD.

I--
 I-I-LI
B2 ADDE NDLIM

_"'-.

BIBLE MID IIIIIIIESS IIDIITIIID

.33 -
.-
'\\\ FRONT eenrce CABLE /
_'|'-Q __ |;;'Z:1:;_
L I II I --I -*'_'J'_I::._;-:"__~....'_
-I T: _ -.
___'__I II I
I
-I I
H. '-. '
._\ . ..: . _,..- __ __,,,J H _ -I-H
A F It

15!; CHEIKECABLE
.-"_"H

THROTTLE CABLE
I__\_
EFEEDCIIIETEFI CABLE

I
I

,-".-
.-
_,-"-:-I-FT-:::I'_:-.I\I.__--,-E .-"
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II TI'"'~"TTl-E .' ,.I_-' -'THROTTLE mete
mlueenuess -_ pr;-I " , ""-E .@' .' II__ '|.:_H
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I. -1'.__i.- I H. I I I .. In
NI III ~ 1 I JII1 .-
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IIIAIH HARNESS
'.' -= __-
"\
'-;_ __ J - - F~r'_.' II II-*1:-.
LII 2: III-RI A..C. GEN EFIATOFI
AFINESS
~- -ix. -I.1.. -_' ...'.el1?T'R- _.
3:-=-
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EIHONDA urcrrue ccI.. rm.
 II-I"-I B2 ADDENDUM

r"'\ IIIIIIITEIIIIIIDE SDIIEDIILE

pl rfm-m ht p|qE-1:g|gE 1|'-,I5pETI In I11; IJIII-he-I'=_I'IIIenueI at e-euh ir;l1I':-dule-d Irte-ntenancr: partied-

I; |,|-Igzpclf and Gleam. II'IId[II|II1., Luhriurtn 0-1 Renlee-e If neea-Ir-0rrI'.
'. Clean
: Repleue
Adju
f;l'1l.'} Lu hrleete
: H Eu EHCY
'|'IlHICHE'II"ER ODOMETER READING II-IOTE Ell
COMES
EV E H Y FIRST :In... In? ' ">1; .3;-I /
ITEM
"'l'.__!' 5Q90
,__,
M: Jr
.-' DHhr I
"5iq;b:I 5'1-IE
3-3
I
I.
__ ' FUEL LINES
S _I_=_I._I_I'iLI_.jrI'1.rII|~I*eI=r C I."II l ['21 _20-0
EM " THROTTLE OPERATION
I; .| 00
-C ' caeeunetoe CHOKE . - .
EC-B
2 _?'
OT
E " AIRCL.EAI'~IE_FI _ NOTE III n I-I 5:0
NOTE [2]
CL emu even Y 35
ELPIT
C Fl AN IIICASE B R EATI-IE R 1___;0 rni 12.000 kn-II T
R S-FA FI If. PLUG Ia ' R R -.2013
N I _ I ________ ?_ I 10-B
_ '. var. v E r.:-I_E__I~T_.
A .'_]E _!
FIEPLAC E EV ERY 2-E. IDE-
SSO
.. ENGINE OIL YEAR R 1,200 mi I2,000_IIII-II
EIIII ' I: I 2-2 I
I THII
' ENGINE
_

IIIR l"II'
OIL

BFI_T_'_l'E R"\"
-
FILTER
CAREIURETOR IDLE SPEE D
N
_-I'I'I
BC SEEN

III0II'rH
I

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..
I -.- _
3-ID
I3 U. _
I0-10
F

' I 335' '

'
D
TE
III
I I _R_R_IIIII'I'.E SHO E WE -"IR
I BRAEE 's~I*5'rerII
0H.rIr.:E |_|iiI'I-T? SWITCH
A I 3-H
0557:.
EL HEADLIGHT AIIII Y _
3-IE
EI-IE
~"'I NR CLUTCH
3-IE
SIDE STAND _. ..-

__
SSO ' 5u5PEI\I?sIDIII _I. l_|'., I.L '
I,L. en
NLIT5. ROLT5. FASTENEIIIC _ I I__ _ I 3-H3
|-it-J

N-EM " 'I'I|'HEEL_5I"5PQlf.E5 _ I I I_ 3-IE

e_.rfeI=_I=Ir~I&' HEAD 0_e5e IN [3 ' I ' 3-IE
I00 . ._
I-P

I Shuum hi Em |cB,d U... an Iu "1 |-3-I155 |-[mg]; 553;-_ I;|-IE5; the gu.Ir||r I1. pruprer Hili 'III:I BBIVIDIJ date lI1I;I I1 l'I'1EI5I'liI'lIlII"I"
queIifier:I.
H In II-M |,-,m";; n,f;q{I;1;I;_ M |1=|g;|r|-|r|15I|'1d'1_'hI:ia item: he 0erIIiI:ed r:InI\,r by en eumurized Honda drrnler.
F".
NOTES: [II Rewrite rrrure frequently when rirllng III-11'-P5-Ir HIRI-
rgt Min |-mm ffq|_|g-1'! when riding n-I rem I-:Ir'et full throtIr IU.5.-"I. mI'I'I-
qap |=I;II hiqhar I:IdI:-Inerer readings. rennet it the frImIIIr"='r ilrlrl Biiblhhd I'W"=

.-.. I
|J;I;I_II:I'IIw.Ie: Nu-u.,1-BB1 1
EIFHONOA MOTOR CU... LTD.
 ___1

HONDA I
'32 ADDENDUM |:'m

2. LLIBRIBATIUN
BIL IIEBBIIIIEIIDITIIIIIIS
5:-Fl-L L-.'!_'l|.'h' -1|} .'-"I1'|"J -"H1

U51: HUNUJ1 I1-STHUKE IIJIL or uquwal9n1_

API SERVICE CLF-SSIFFCATIDNI SE r.Ir SF S -1E 1l'J'J'L' 41]
'b"|5CO5|TI"'
SHE IEIW I1-U
!'5.IT1l'.1II}|'J -L1-El
Dthar '|'Is|:'.c|:-ities sh-zrwn |l'l 111: |:I-mr: rn.1-,.- |',||:
u5E-ll w|||:rI !h*_' uuerag: H:rrI|'_|n-raturu In I,':\q_.|r
rid-nI;| -1-rrr=| -L within the In-::lI-|:a.Iud wflgv. 20 CI 20 40 EIIJ BO 'lE|CI F
I I- I I I I I I
-In 0 ID 20 an :0 L

3. INSPEIITIUII Illlll ADJUSTMENT

HIEL STRLIIIER
_l
'I_
Tum ihe {u:| nruiuq DFF

.\E:=
Lnosnn thu Izarh-ur:I1'<:Ir drain screw a-n|.1 drain
THE fL|u| lru-Jrl Ihe c:arbI.|r|:tnr ir-u ,1 iu|13bl|9
cuntainur. AxI--...:_':-"I
_ _|A~\ Ir?I |' I 1
|l|'l|",""r /"J

15 ""11"-F"'~""G Gal-ulina n ammable nnci in

J-===;;:_ 1-.. - ._ I |_I_ ,,J__
- :__:- _ -_\_,.
upluulve undnr curtain |:n|'||:li1i1:||1|. Du nnl
imulsl ur allow IITlB'I ur rpariu near ihe ,F_.-.:_'e*
:qu'||:I|r'Ian1: 'l\'hl]E drllnin-Q lunl.
r.
P-I
Ham-we the fuel Iiltar bah and uuli nut I!h|:
fuel Illlzr and D-rings.
D-RINGS
Walh the fuel fill!-I In Ciearl rlnn-llamrnnhhe or ;""-I-_._ J .---...-
high I!-1-sh T-l:l|nt ml-runt

HI.-lI1Lta|I the luul h||.|:1' Ind ncw O ring img

"~FuEL FILTER
tho funl uahm. Hand ti|;l'11an I?-a fuel iter halt
making sure the new D-rmq: aw in |:|laI:a:
Thcrr Iurqun tn wucificatiun; .I-\

"runnue; 0.3-0.5 kn-n1 I2--1 H:-I|:|J ---FUEL FILTER BOLT

Altar installinq, turn the fuel uaalva I.'JI'-.| Ind

"Ii
chuck Ilh-a1 thurn am nu iuei Iaaki-.

I.

20-6 _ 1 mm Uf|1!L|BI I'-h:w_,19B1

@ HUNDFI Moran I:n.,1_Tc>.
 H
11"- B2 ADDENDUM

-1

BIIIBIIRETUR UHUKE
C2-|':_-It Inr etlncicitri I:|1.'JI<.B lever ntmrntlnlt
the Ievu-' shuulci szair wlwrs pnsitiunnd Mr-vn
the -',hr;-|c.I- |l!'||'' all thi: way lu .I'I-2 let: arid
n-.aiua aura ihe I:-7'-|:II-Ia -waive is closed by" rn-Iwinu
the chnlm law-::r at thi: I.-.;;rl1._re1o|.
|\!5U_'|,_|$TME.NT
Tl::I'I-nu-:1 Jne if-Dl'I1 CDHEI.

l_un-mm l'r.I.- -::|hlI: -:l..1|n|1 ||'1|.] |.lu|l the CEIIJIE

uusi-I9 up 4.451 unr-I the cnciku val.-'1: II !uIh,r
6|-,j5|d Hutightnn tl-II: I:iB|1'I|1. f'a'|<:-vi: the 1:lIr.|lI:E-
I!'||'lH irl 1l'u'=' 'n'-3'3, 10 I'|I|'-I I'I1'I1' bl! Il.II'I" 1I|'II-I
;h giqg -,-3'--,1-5 is; f|_||--,- l_'lfl|_!"'i by c?i"u:I::kaI'|g fur 1 -17
"'|rn I'I-IE I-B -ul |:.=I.|Ie slaci.
EHDKE LEVER CHOKE
l|I'|1u!| ll|r.-: lr|'.|."-K C1I:".'r'.'|

llll IILEIIIER
AIR E CAISE BHEA TU BE
Tum the Itan-:tI-2-I:I-at all thn v'-aw tn the r-gr!

|'_O5.I'_.l|'l Th: \i::rr:',un .Itl1|c:h|r|g lhr: \.'t|!|II-Erl-IIT|I'I|]

cum: and uraathur tubu and tiituunnuct th
tu|;||:-1

II
FI.-.|-nu-.--= the :|;t|:w!. attaching the an I:='u-annl
ca-5e_ P\,,lI out, :hn inst: wirth the nlr Iiieaiter
ll-l1"l'l|!|'1|.

CONNECTING

AIH CASE
=19-.11 305- tha r_|ir -:|e|:|n||| :i-E'r'I&|11I.

Iflieait zha element in taut-I-nr,I -I |iI5I'1'-T|'v TU R

||J|:Iili|'I d|.|1t1, |':llI:>'|.'-|'3I.".'B1-' -E|I'1\r I'BII1itIl'\1] dl-I11 UM
appl,-iIIg GC|I'|'l|Ill'I3F-.iE-1] qt: trmri :I':a I!-54lZ|'EI -J!
1i'.r' I-||i!|'l'lIHl1.

R;-;p|,;;|; 1|-1,; blgmant -F II; E: ||1:1:r|saiv|:l\| rlirlv

Ir:-rn or damagur!

||151;;|I| 1;hr~ |'.t|":l|'I'lE'II| uI|C1 t:\C|I'h"|EIZ.'I 'I"'IlI I1I'll"4!I'-I

ing 'l.ulJE.
_,__
|n5ta|| ti"-I: air cleanrr case.

Cnrlnmzii the breather tube

ELEMENT

1815
Dan: 01 |:t!:UBI |'\|U-'.. 1931
20-?
-TEIHDHDA MUTUH CCL, LTD-
 HONDA /_
B2 ADD E NDLIM
crn
WINE CLEARANCE I-IDLE

NOTES:
I inspect and adjust valve clearance witrle Ill:
-engine is euitl lbeluw 35-"-"C. BEEF].
I ltt-eta the lne.e1lur| ul' the "T" mark.

Tu cheek the ualye clearance, tempyg thg

rltltahnlt. tlrninq marit hole and value mspec
titan cups.

I"-l|ri2ljlJ5l' tlurn-tr: IT n:r_'.955.a;'y train ualya ad-

iultnt IIITBIIIB-G B-HBDIII II:-ee page 3-E-I.

HE sure in relmtall th GED!

___4,-.1
CHAN HSHAF T

IGNITION Tllllllli
LIGHT
IIIDTE The C-;|pIiI2l1'lI|B Dlseh-arge Ignrtlnn 1-,-1
lII'l'I- I! f3I:.l10|'y are-set an-rl r;ann1;|t big gdju 5ted_
Tu inspect the f|.|nr:tic|n nf Llt: CD1 mumpu
reentr-. ignition timing tn!-pecun prqgdtlf-l
are r,||1.-en hern-
Fllnvnye the timing h-ale eeu. "x
Cenneezr II tlehnmr:-tar anti tmting lnghl
Start the engine and Hlw ir m Idle |1,5[l]
rpati. Cheek the ign-riqn tirnine.
Timing it-eurrect if the -nder-r mark alight with
the "F" mark at -tl!=.
II the ignltiu-I1 tim-inn ie incorrect, erreclt lhn
CEJI unit, e.-Inter coil end nuiaq gq|-|;|m|;Ir_ and
"BI-tl Faulty parts. Flrrfer tI:| page 20-22 Igni-
tlun S-\.|'5tern.
-'-.
BITTER?
GAPS UPPER --at
HEIPUHE the right arr-rle cnyzr
Inspect the battery llu.-cl layer
Wihrn the fluid near: the luun.-r I:y:!_ lnumn
TIIB bl! and tape:-I the battery bracket fur
unease to the battery.
HEI'l'lU'-fl- thtr battery filler cam-.
--~.
Carefully acid distilled wat-er Ir; the |4|:||:Iur iatrvei
rntrir using a small syringe nr plastic fur-In-qt.
NOTE Acid only distilled water. Tap water
will em:-rtan the service Ir-in nf the battery.
The battery aIh:r=tn:Il'|rlI tinn-
teim mlturla aeitt. Protect your Wu. sltln. Q I
and clutina.
In cue n-I II:nnta|r:t_ ulh thoroughly with
mm: and eenur.-t 1 damn: il electrolyte am
In '|'GL|t -I1.-ii.

20-3 '3 Denenflsauai N0-'-,1QB_l

emewna MGTDH 00., ttn.
 E, egg) C?" eeaneeneum

Hep-In-::e the battery it euifati-an at sediment!

hlue lI.'_!l;lJ|'I"|1JIlI1'lH.I12lIl the brill-::||n.

CAUTION: When r:hedtlr||| the battery lilac

trulytl lei ut ltllllng distilled ureter, nuke
T nure ihe breather tuba in ea-nneratad tn the EMITIIIN INSERT THE BITT
hetllry hrnaiar r:n.|'I:Il:1 -ell:-aw as shown. BRERTHEN TUBE
SEEURELY UN
5l_IT_5"l'

I.-

II. FIIEL SYSTEM

| l
SPEEIFICATIUNS

y--ml [care Identification nu. I PBIEA

Below I 500 m Above 2.000 m _
I.-lain |et (5,000 fri IE-.500 Itl
-HTS u tar Gig-av
Throttle yalya 4 3.0 '
I
, J-at nn::r.lIe DA.-Ur _ _ _ .
-- -- ~i- 1,";-F
I4
.-" J-
aha .

-I eaea~. -HELFCJ
' ._ _ - _ an I.-_-

' -".-.---.\
_5.- _' .

If

K - -;.

. at QI%%i%%
3"

e E5
n]
@
/
_ . _____n.ua-u.na kg-n'|
I
--. re.2-0.1 rnal

em of Issue: 'I~Il=._ teat "'7 T 2 O_ 9

IE HONDA MDTDH Cll. LTD.
 HONDA Ia
'e2 ADDENDUM [III] -5'

Hllil-I lLTlTI.|lJE
'|i'.Il1er- lrle vehicle =1 to big operated |;r_Ji|lir1u
uur-li.i mntrr E,-[I00 meters ll:i_iiDiIl It!l'!1| the
carburetor mus! be .'I|J_||.H]:|"|.I to i-l'l!IlI'D'|E' di ivo-
ill-ill W end -Ii-r-r-'ie5e eiilteuiit 'llflliL'Sl'|',I|'l"|

I. FIE'r|"i|2|'|E HIE r_'z-rrI1i..rrr1i;Iir

2. FII.?IT'-lJ'ii'B H19 lI'ElllJlJ!l1|Ill 1li;tiat_ [h3|||'_,3|;|_

3. lIl!II'4.'l'i'i'- tl'I-I! # T5 ma ll |El iiI'll.l iirnall 1+-ie

-1* T2 ntaiit jer
4i Filr:-lisaiir-ii-iiii and 'l'lH.iIl iliii i:iirt.ii.iri;-rm
5. 'I.'il'atll'- i.i|.i the ier|nr- tn operating 1ierr|r,:iura-
lute ISIZOI1 id Q0 driving I||r t|_:n rri.irti|_|t_g5
is eutIir_~ieii|.fi
B i5'i.d['\J!-I '.II-E Idle .rp~e:r:r_l lu 1,%l]i_' IDD mir-
wllh the ll-rnittln stop soi"ew.
WDTE. Iitiri atl||.|strnnn1 |Til,|!I IJE 'l'lJLIl: a!
l|I|]l1 IIIIITUGIJ =0 'E'l'IiJY1! |.:-||.I|||:i' high altitude
Cl'ClE:l'I.ll'Jll.

7 iI\IC1'ill 1.Fil! '\4"I!PII;=r: Emrrsinn Crtntrri-! I|l-

loiinr-iJii Lliirilntii label as sihriwi-i.

I-ICITE Du |ll.H attach 11"-is iaggi t|_| ,|ii-,- |i;;r1

that Bari be easily removed lrn.-ri 1iii- uiii-iiigile,

"t""""""n""""'3 Continuous oparariun at In

lltlludl lumr than 5,Dl2IiIJ Ieet ll,5-00 mereral
with the carburetor adp-rt-iirl for hruli altitude: E -1--:i
may earn: the engine to Idle rciugliily and slell
and could muse angina diiirri-rig-Ii Item oner-
heating. When the vehicle ie to be operated
'- *-":I_::ii
raziritilriuiriuliy below 5,000 feel H.500
rr1atareI_ reinstall the I 75 rnein iet and adjust
l.I'nr idle lpned to 1,500 1100 r|1il1|i.

HE =i-HI: to mrltii there adiustriteiiiii I1! I|']lll|'i|,I1'I-

2;; *
lg-
r-"'
1-.,

tullle.
-_____ _ u
i-'=i-r El

-I 0 Dull of lame l-Ioir. 1501

20 e:-uuuoit Iiiiotoe co LTt:i
 HONDA.
C70 '32 ADD E H DUM

5. CYLINDER HEAD/MLVE
EPEUFFEA1 HZIHS
- STANDARD SERVICE LIMIT
|
.-F-it.

Ca m mt I ct". mum z1_.g-g5__ mm

' |1.1t:t|: mt ggts mm _t_1_.t_re rm
IE.'U?Etl'!l'|'l[1.l]'2BBiI1P 15.59111!" [1.UH'|I'I'l|

ETUHIIER HEM] IPIIJ-EEK M|l\Hl'-Z "O"

|" -
HEMDV AL

Hesnnua the front I:-uvtlr

I.-PH. Dimnnnect the mtaltlt rltnr Truth Ih cvlinder

head.

Htlmcwv the murtlur an-|:I the up-ark pluu cap.

Hgrncmu Thn |,'.'|,r|i|'|-Eh-:1 ht-!:r|.'| ||!f'l titll Cm!!!

Hm-nave lh: crttrtkitaft can -Ind H-Irrt I11!

ctanitlhnfl |;.-uunmml-nckwtse to ilttl the "O"
mark on the GiI1'li|'lI|l lnrnli-ET with I'M Idh
3""-. rn-urlt.
CAHBHA FT
Humutu: thu nzamthah anruttkst.

Remuuu thn t;'\rl-'ntl|&<r I12-ad lpaqe 5-11-'l

IN DE! MAR K
|N5TF\L|..|TiUN

lr|:ta=l the wlirtdut hunt! atsmtl-hltr {P6913 E-131

J,-_\. Hlmgvq the narrr qhuln Lemlu-rter Duih TDCI

-1r.|at1u 2'5-I-III.

Turn tha crankthatt cu-unmrcltt-ltwll ind

aiiqn 1hr: "T" -1-utrlt wtth the mdntt mttri .,_-

.<
I

Ptm,-tr the cam chain outtr tht: tiun-uhatt sprock-

et, a||I||I'lll'l the tptuckst "D" marl-t with 111!
cylinder h-aatl lndmt marit-

lnstall 111: t:i|m$hB mrumtnt on In-2 camshah .

-- 4
F-. and tlrtten the inrncltt-t bolts.
_ II _---1- _

TGIFICLUE: DJ1.1 kt:-m |5B ft-thin

tn-,-ml ti-|= rlemlintnq r:|nm'e-d parts {pa-gt: 5-

H1-_
r""-
-*-*-

1- -1
I B!
Ditlufltauui N ., 1581 -
-D HONDA MDTUSH CO.,LTD. -I 1
 HONDA _
B2 ADD-E NIJUM cm _/ H
B.BLTGH

I
ITEM 1 STAN D AHD SERVICE LIMIT
Clutch gpri-ng tr N lanqm I 15-I mrrl [I175 in} I15 mm 10.39 in]

Q
t it II
%~
.. -J G I T" ' _ -.
E! . _ __|'I :1 _.
., . '

git -.; *' L "x

3.5-4.5 ittrm
tan-as mar

_____ _ __L I -'== 1.

- I-1. ____:r__r___:_ ._ In Q ' . _ _.
.E H
-.
~-__ _.--j"T-
wt: " It
I'll
. 'I:||
.--I-
|l
t ._\ I I u '-.5 'III ||
k'I ' ,- |
._L .

Q _ -. .-'
| | ' __-"I I
I
" . -,

I 1"-t |

-\-t

20-12 1@* D ataoflsauw: r~|-:v.,1sta1 u

@:~ur.;n~mA mntun t:|::., |_'r|:+.
 HONDA
P-"h_
/i C70 B2 It DDEN DU M

|r""-.
CLUTCH WEIGHT IJFIWEFLATE
NIJTE: For disassemble and lnitt-eI:tit:|rI =-H: | |CLUTCH
page B-3. I WEI HT

ASSEMBLY
,.|-i-.__
lr\.t.taII the -::|utc|| weights on me eluteh Gll'|
plate at iI|O'|\'I1

Install thl: |-.tL||.t .-lug and the eiutc-h springs.

STOP FI I HG

C LUTCH DU TE Fl
1|-11taII therdriue pkatu in the clutch outer Md I (1
tighturl the mre-.n: in 2-3 new in a crlesttrose J,"
iJIIern- _ if.

|./"1
Install the eluteh damper spring:

@)
.
-J
DAMPER SPRING
scnew

en GEAR CLUTCH csrrren

I|1:.tt1II the dl'I'|'E' gear e-utsr and |:lult:Il :I:r1lBt

I-ICITE: Airtyt the grown in the tlulh DENIM

with the b-trues ti-n the drive utter.

I|'1$l_3_II the clutch pl-ates and tlitl"-5 IMI IEC1-IIE

r, with the set ring.

r"-
._\\

-!

Date t1-I i55|.tE3 N0'.r., 1951 191 -

EHDNDA MDTDFI Gil. LTD. 1 3
 Hanna,-5'1
e2 ADDENDUM C10 /I_.-..

T. TIIIIIISIIIISSIIIII
5F'ECIF ICATIUII-IE
I
__ ITEM rIr~IeAHD seevice LIMIT _
|5h'nttorIt |.t:. IH-.UT5T.'I-lI.ILl:lmmII.3-415-1I-I425-trti 3'-1I.1rr|n11l,I3-IH-ir|I

B. IIIIII BIIIIII TEIISIIIIIIEII

IE rnn1BLT

_ ITEM ETANUMU 5 e|_?'|'-|'?'E I PK

IT I M _I
Sr.Ir|nt| Ire! Ie-|t',|tI\ 2|-II -'r'.m I13 |r'.| 1'1 i'|.F| '
I'3.II In]
-- ._||
'Fu|I'r|:|t:ID.IJ. Itsee-Izneemtt-H11_gqm"-.
, ID.-1?1B--H.172-rnl Itrrr.-nu ml
PIISI-I IIIIII
eerttewtl.
Dfiillfl the Engine \;|i|
H
FIE-rIII=I'-II! the sealing he-It, was-tIrer, t-urmnner
eurlnu nn|:I push red.

Remeue tI1e E rnrn belt and sealing washer,

INEPECTIUN P-U5" HUD

Check the pttih red for wear er damage, anti

meaeure me CIJIJ. ,,._\I

STANDARD: 1 I.9B512.UCIO mm
IU.4?TBO.1IT|'2II i|1I
SERVICE LIMIT: 11.91 I"l"|I'I"l IU.4iI'lJ in) A

Measure the sprint; free iength.

ETAIIIDARDI B3 mm I33 ||'||

SERVICE LIMIT: T? ITIITI I3.IIIinI

FIa|:|Ieee either part It it: rr:eay.tm|'nt;|r|t dtje-5 J-Kl

net fail within the limit.

TENSIDHEH SPRING

_I|

_ "95 Datecrf Issue; r~|=w-,.'|ee1 _

20 14 enemtm MDTCIH t:c:., LTD.
_
 -H $2)
HONDA.
c]'[] 112 ADDENDUM

JFK

CHANIILSHA FT CCIVEH

R E MDVAL

Renteve the tenelnner nI..I1~I=I rud [pine 29- IAI-

If"-\-

' Ftemeue the A.C. genereter nn-d Ilvwhll

IPIBI I'D-IEI.
Fiemove the starter chain and mrocltets Ieege
1&5-II.

F Ftnmaue the ttrlniuthult c.|:w-ur ant! the I:IirI'I

chain teneiner.

Cite-t:It the tenunner S-FIrUCIt|:1 ler wear or

_-~ damage.

TEIISIIIIEI/I'II$I'I IIIII]
D-RING HJLT AM
INSTALLATION
lnltali the earn chain tenslunhr

||-malt 1|-|| D-rings un the i:renItehiIt I:-Itwet

.-"-3 1|;-few I-tulee end e-mler.

Inetell the t:enItehe'It cetrttt anti Lighten it

with two ecre-we.

CHAIN GUIDE
truteil the tterter chain and seIreIi:Itet_t.

tnttell the flwmeel end A.C. generator IPIIIQI:

I'D-THI.

.--;
|I

8/_\.

Egg: 1:|f lnue: I-iI:w., IQBI 153 _

IEIHDHDA IHIUTUH CU.tLTCl.
A i _ A -
 Hanna.
B2 ADDENDUM
cm ,,~-
PUSH FIDD-
PUSH FIDIJ SPHIIIIG 1,!
IFIEIHII 'III"IB IIIUSII I't'.t\Il.I_ 5|:|nrt_r,t_ |,i,|'5hEe ttgi 5|;Iq!I'|'||'|
I:It:I|t.

NCITE: MIIIIII sure tI|E pueh rtt-t:l '|';eih,Itt| i5 free

Irnrn rlutt before ||l5'lt|tIIa1Itjt-n

t /
- A",I'-'1' _
' 'I'73't .15r;.
' - .'_t:I|.,

WASHER SEALING BDLT --I.

E rnrn EDLT I-IDLE

Ttarqtte the tealinq belt

TDl'-IEIIUE: 2.0--2.5 l-cg-in (TB tB1t-lhi

FIII the titer-ltI:-alae with the retrurnrnettctett tel

Ittaea 2D--'Ii- """'t
PIIII-Ir EIIIBI1 engine oil through 1I'|: 5 mm belt
ltttle ur=tIl nit flew: nut nl the hole.

lnttali the B It I8 I-1m lrttlt and seal-rig wmthn-r

NDTE, I..lu.- the prunnr length Ltulr A In-|'||]|

hell mmr interfere with lI'Hl truth re-cl.

.-I-'-.

t--II-Ml

-...

2o_1 6 1" Date ttt Ittttet rttttttt, 1-aet

Q HONDA MEIITDFI CCL. LTD.
 _ . -Jet I-Icutirnat
"-1.

tr"-'-, %7 [I1 I] B2 ttttteetteutn

I 9. tnntr vrnttt/susrtnstnn

E11? -'"_
1' e??? r
_ _

(-- e.e-en kfrn _______,,_ ABLE

I11-3-H-5 ft-Ibl

F
111-3.0 kg-In
I"_22 H'IhI '
e f
"II"
t I-t
NOTE: Flemcwe the dtelte cable
heItl:ItIt IttI tllltlettnlct the nl:|I|
IrtItt the ti-IHIIIII lever to 1'I|'I'llII'l'l
the Ieft hltulleblr ltulteh.
- e
t.t.-ttt... 3
I1 II-1I'2-ft-IIII . {Z1
,I5-ggI;e=t-tttt~-
15-15 Ittrm -. | . _ I --..-,;,I.-;l-;-.--"-'-.- :-
rta-25 rt-ntl - "_'| ' ''
I- tI.e-t.2tt "
I '= . .-
. _ E 1- ,lit
' . -I I

FQE: "_.- _ "

__,.--- I-. -. t'....._;..|_ _
F. I
. . III
._ I . _ - _'- - _

at ' _ It I ' an-2.5 mug;

H,-' - _" '-I IIHIB It-lh!
=-"=-=-I
1_D_2_5 ku_m___,_.---"""'
=\A
-G "
I ,
t__52$?
Fglgi-\;..
:_
SFHIIIIG FREE LENGTH:
I73-4 rnttt IEJ3 InI
SERVICE LIMIT:
II.
3
jw
-;I _ I. .t _
I I - 5 - an-es Itg-In
If -|- ' ' I'lII1B I1:-lbI
9' I

F .""I' 'I
"| %:.,tIt.._ ~ 10-It.tI Itg-tn
III
I,t
|
I. -
-L
" I22-29 it-lb]

$
(*1.

III. IIEIIII IIIIEEI./SIISFEIISIIIII

SPECI FIDAT IDI"Il'S

ITEM _ STANDARD serwitze LIMIT

Sheek eheurber II|J=Iet| free Ienttlh -229.1 mm [9 D2 ttt; 1215 mm teed In]

um ttt Itttutt rtmt, teat 15 _

-ZZIHDHDA MDTUH CCL. LTD. 1 7
"B2 ADDENDUM ..~..

11. BAITEIII/BIIAIIBIIIB ststtrt _

SPECIF ICATIDNS

B-ttltertr II.-e|=ItI:lttr _T EAI-I

__|:_|e-cie g1Iev||' I210-1.290 IIUDG IB-FF]
_DtIttIng_rem I.-II ampere: maximum

-III_"3II-- HEAIJLIGHTSWITGH
. - - I///' I
BATTEFIY -
t
~ - - ' .
- .,'---.5 ______-'
,=-'iY_-1..
-._
:3-""-t.,___L____l_| FU_.E___,..
.-- "_"'-t
_ . - |

-It , . ,- Lt t, t ._ 4
I | '
..
'- ' tI tI It - .t - .
_ _ ____.-.J-
_ "- :?_-____,_:____.. - [ sttrcette -- -
RECTIFIER "
-I-ii

_
Qjghit.
Iq " '-"!."'~I.-._ t|| ' we\-
.-
\E'Ii&
t J__
ItI5.
'?* "*-1-1.-.t~-e:'
.,_ u_ L_ I i
.l
_FL
_ _t-".______
1-t. ___ _
__
ll 1

_' 5 --
|t_ . .

1"-_-_
-..,,_
.I'll
_-
-!I
-I . -
.

til tit-1-.5
;t--L._?_

.__;fj. .L___ _.
" .

LC- GENE FIATDFI

.I"'9"t

_.-f

/..-;' - .
r _ Ln:
Ht. I -
"'~I._ -- -'

e.tI-e_.e It!-III I I ' __ /"*~..

I22-zemei " _ __.._ _- _;;r -_ __._.- .5-*-'
___

'-::-.:,l;t-l__l

-.| 4-1
1

_ 195
\ Deteef lease: r~.|tttt_, teat
A
20 18 eheuue HIJTDFI CD.-.LTD.
 ,6 I-II)1\TD..Ht
r-- [:10 'ee ADDENDUM

D-B. LC. GEIIIEFIAT-DH GDUFLEFI

INSPECT I GIN

FIerUit'E' the item e-i:II-Ier-

."-I"-
t' Diseein neet the A-..I;. gnrierater counter
Mttatturq the reeismnee between the termi-
rials.

RESISTANCE:
fr" White-Green: til 3- -0.5 I?-IIIIrI:I
't"e|li:iinGreen: El-.2-B-6 Dhm:

Fteeilaee the eta-tnr IIlt1.BI'I'|II|I'ItI IP ehlf I'Bitl-

grtttie tt ntit withtn reriee.
t-"-\.

I"IEI|IEI'It'AL

Hem-ihre the frent curet-

Remove the gearshift pedal iirIt:l the drive

tttreeitut ecwer

;'"- GEAHSHIFT PEDAL LEFT GHAHKCASE

I_':t:I-tree

Dllettrineet the A.-C. eeheretur enupler.

Dieceitneet the neutral switch lead Ireim the

=wltI:h terminal illEI remove the left i:te.nl:-
ease eetier.
I-t
If " FIItrI'I-I;IItIIt the wire nreteeter.

.t HIRE LEAD

Dete til Ieeuit: I~tleiti., I931 197 _

IEHDNDA MDTDH E.Il,_ LTD. 1 9
 _____

HONDA. 5"
112 muzuuum [g J,-

STA SCREWS
F|E1Cr|'|: [wC| lllui I|.'r|:w: :|n|_1 stator frnrrl the
|I-H C|'i||'||:iil? CUYBT.

LEFT

Um the fil,-wheel l1|L||rJ|:r nr n hand mug huldgr

and mrur-u 'rh|| fh-who-el tn |'.-raw!"-1 mu wank
shaft from :|.||n|r|g.

Humane the genenum rn1.q|' nu1_

.--t

FLYWHEEL HDLDEH Ii-L

D?L'5-G84-UDOU bind strip hnlde-r

.-'--,_
nmcwu the -utor

_,_~_

H DTU H
DT'H3-3-4-BDIUDOD

195 L'lal:-:;|1|1:u:: Ncr-'_ 198'] _

-EFHCIHD-I1 MDTDR CD., LTD.
F? _ _
 F HONDA
If
tlklfyl
ctll B2 ADDENDUM

fr--1.

F YWH EE L HDLDE F-

Align tha rl:-tor kuvv-at-' with thlr kv lJr~ T|lE'

cnmkstlart and lrutall the gnneratur rI::-tur

Tghtqerl 1E tt-l.|t ."lLlt.

F
T-DRDUE: 3.0-3.8 kg-ltl 122-213 ft lbil

I'-

WIRE FHIJTEIITUH STATDH

Irlstnll the BIHSCH an me left crankcase cnuuf
wlth the 5lJHJ'WI

Rn-my th-u |]|;l'||t|'tl.ltH leads |:sru:-u=|-,r an-cl install

1|-tr: -me prnmctur
fr-

Ll: -
Fl-

C.|:l|'l"\l11' 1l-"tn l1:lllrq| swltch lal-L| lIl.'| I|lE W-l"IG|'l

ll:-rl1l-mill

Install the left crankcase cull nr, tlliur: sl1r<>lr1l-H1

l_IlfIl|'-HT and HBlL|"lif'lI ldll.

F1.
I2-:l."-l'lla~l:'t the -glaneritur wirr l:c=ul;:lt:r

|n:1,.l|'.| ll-la rrunr |!t2n.'E'l

r__

El-ateuf mu-: |'~ll:rr.,19El1 1 2{]- 21

EIHDNDA MU-TDR cu, um,
 'a2 ADD ENDUM ___

12. IGIIITIBN SYSTEM

l_ l - ,_ ,4. _

| | __. \-
| I I l-*=- |'-. _
I .-IE-*?1"\_ -
_. \L I: . '
*1
'f3='-l._____J. J __________-" ,._----<51? _"-.___.

-3 ll-1 _ , I __________. --
|l_ _ .
ll
|| |'
CDILIHIT
I . . ,.
,- IGNIT [DH EDI
iilir I|_-ill
I _''-,__-_.I,
,{T.t _"' i _

._ Eh ..

'5' ' '-.'L---':' l' L lift. K '. _ ' __.- -

..
~. hi
I.
I I 4;; L-TL-.1-:- it

l
_
:1;-'1?
'?"""
_ -.
.
. a.
7"if
,=,l =--gift
_
I |_|'
I
\
-a.-1{E,-l -T
f= F "'
'=:'
| . _'___-"l"__
_
,
I __--_
_,.
___ _
__ -
_.-
| ""'l-I.

"W
_,-l-'
I-
_n~,I I \- I 5' -.I|

l>;<3 '-.'_'_'_-H
*----:_- _-
l ix?
-.

-._..-1;? y___,
SPAFIK PLUG

""1
ll..C. GE HE H ATDR

_-'-~
IGl'lIIIT1DN SWITCH E1 GITER CD1 L

i _ ._ '| G .-F-._
SPARK ii cu 1 - I "-

.1
lGl'|l'TlH
I T T
lTlTI fJ. 4I CDIL
-:
FULE-E
GENERATOR -: -3

.-

20-22 Dal: of Isms-'. I-Ill:lv,, 1961

-DHDHDA MCITDH C11, LTD-

?-i ' ii -
 /T HONDA
C70 '32 AD DEN DUM

EPE CIFIEATIDNS
i

5;:-stilt: plug Standard __ _ L.l22FS_ll_LlE~lDl, stuns ll-ll3l<.

For mm climate ennw she |41F I uzlzlesll-I.l lgltll. CHE-HS ltjleltl
For E1: randeel high weed riding u2-tl=sl=l-u ltlnl. I3l'li:IHS It-ll3tu
Spark plug gill Cl.ED.]' m rr lEI.EiI~'-1- 43.028 tn I

lqnltimt tinting F tI1a_:|rlc 'l5'_J_B_]-ES;-Bil lditei

Fnlt ltdtlanult I'll?" B1iJCt'3,1DU rrlnl

TIlllllBLESl'lllilT|llI'i
Nu Snlult at Pine Engine S-tim but Hun: Fuel-I~|r
1. Englnll !-lIlZt|II iv-"itch lIlFF" 1, Ignlt-urt lJf|l'l'lily cirliu-l:
2. Pnnrw gnnnected, broken or shct-r:al:l w-res Fauittr igrlllltfl CD-l

Hem-een AC g-nnerutur and Il]I'l1l:ifl'1l -CD|| Lease or be-rn win.-

- Bntweert CD-I unit and or-glll lt-r SWiliEl'I - fmzlre fJ\.|l!E' qan-eruter
Between CD1 nnit and ignition mil 2- E-euullclul-I l:-irl:t.lit
- Between lgl'llIllCll'l CD" Ind illlug .|'3\C gen-t:r.:|'lul fllulllr
Between ptllee gerterator and CD! uml - CDI unit fellin-
3. Fi-.=l',-V tQl'll[:-l.l1'|C|III| Faulty pulse l]I!lrt!1:l1.L|I'
4, Fnul1qI -EDI unit Fuulhr 5-lltilrllt FltTl.'irlr_'t|-
-E|_ AC g[ll'l::'|ttl:l-P l|lLlilI\l
-B, F.-mltt; pulae earl-erater

lEl'ilTl[lll BIJIL
HEMUVAL
F||'I'|\'.l\|E the |Jti[tH!"|'

?-lt:*1'ttJtlt: t|'lE |Il|1Tt9'l|' l1l'.l:|l

I I
Date clflesua: NmI.,l'Ell H"
'E'I-IUNEIA MCJTEI-Fl CD..LTD.
 B2 ADDENDUM HI
|_

Iii

IGPHTIIJH COIL NUT

Flemeue the lett sitle eager.

Flertletre the relay hex .ITI{.'.t-l:hlt"|g |'lul'_:|-t1.d' halt,

Human-e the relay bet:

Hemetle the igltltlttll cull mount-ng nut incl

remttee the iqrliticln nail.

FIE LAY
-t

lH5PECT|UN - - 1

Measure the [E5-l51llCE ul :1-tu pl'lTl'|iI'\|' nnn til ll R l

sect:-nder; znll, ll |t' |' all I i 'l

PHIMRHT: U 2-5 3 DlIr1" F Ill I liI_

ll
5ECO'|ll|DlFl't"l 3.11---11.2 K l:lltl-l -___ Qt, ___,

1 I '
r- t -| - ~' | '-la _
REDIBGE !-:FEI' Cll I1 11 rel:-stance ring; nu: ' _ r_ .-"'"-\
fa|Iw;i't.n-hr_' range, - __h - --
" I

F l | '-I J
..

e Cl
' I

PRIMARY
ll I
'-J
SECONDARY
-*-I

Blll lJl'l|T
i
FIEMDVAL

Herntwn the batterq-and battery hex.

Hmr-P-re the CDI unit.

""-.

20-24 M lth! D1 Eeiutl: New-., I981

@ HUHIIIA MDTCIFI ECL, LTD.

__-
 F!
I "'i:1u B2 ADDENDUM

F" INSPECTION "SK EXT

C-heelt the uelntinulttr nf the EDI utl-It termi-
net;

Hepteee the CDI unit if the readings are not

within the llrrlltsi I|"ll]Wh in the table.
/T"
NOTES:
I The CDI unit It fuIIt,- transirttlrized.
1' Fer ee-curate testlltg, it it neleeseety te uee
e ntecilled elnlttrll: teeter. Use elf en Irn-
nrntter te-ster may give false readings.
f" I Use a SAHWA ELECTRIC TESTER IF,-N
CITBUB-UDZEIDIJDI at KCIINA ELECTRIC
tester: ITH-5H]- '
_.l-"-

_ mm,+ Fruh-I aw ettt I IGH SANWA It. K ohm:

- KCIWFI. at ILIIIII Dltrrte
sw I -=~= DICI

LIL!
EXT 01-20
F
| PC 4EI- IUD 2'IJB-IIIEII t_lJ

I
E I-51] Ill - Z0 .'.l5'I] L '\

I |;r;| DI! l:I,'l

__\_

-.1
I

ff-. EIBITEII IIOI|.,/PULSE GEIIElIlTI]ll

INSPECTION J5.

l"" Ffltmteele ihe frunt t;t;rt.'tt-r.

Die:-eltltect the A12. generettsr emu cnuprel

Measure the ettc-ter eeil res-lst.a-nee between

LI'lt: I.'l'IBCIlI:'l'lllI wlte l|:rrlt|r"-BI and the gntmntl.
l("=.
EKCITER CDEL RESISTANCE:
I5lJi'DG Ohm

f-Iurte1.lrt- the pulse genenlter ecl-il resistance

between the Ll-il,lE_|I"|\i's:tl: intl lI't|l g't;|etn wit:
(_ terminals.

PULSE GEHEHH-TU-Fl HESISTIIHCE

ED 'IT{'I htrl

Date er! leave: I931

\'Il|:|'l-IDIIYII. MCITDFI CD., LTD.
20 25
 HONDA
112 ADDENDUM --_

I3. ELEBTRIB STARTER

STARTER IIIIITIIR
REMOVAL T

Renteu-e the mrter tlrive serecltet .t.nat.t ti-up

lpage 1EI-RI

Dleecnneet the stertnr cabal: et the mtl-tor

terminal. I
I

Flemnue t.ne starter nt-eter meunt-ltq IJ1.'l='I11i an-d

remllt: the meter-
stenten cent: ___

.-Pea

I-"-L

.--,

_ 5'4 D tenll e: Nttth, leer

20 26 eaneeeiuunten ecl..LTtt.
_ _ _i __ Ti
 HONDA
' B] I] ea leettelteust
l>

It. rtcutlctt rtttutts I

The autprrlatle ehalrl ttlnslttne-r epneitl: pf it push rod, a pne-tleett valve and rt tettsipner sprlnp. The push red pesititetl is maln-
llilrtd by B lrtl-It-'l-trlt Inteunt cl-I r-em thltirr-sttlittshttel eil in the ts-il chamber. The amount elf ell present is determined by e
sore hine-cl action of the value anl:I the tattsiener spn ng.

When the tensiiener spring putltas the red up to I"E'IIHZlllB eltein sleek, the erle-wet; wet-t-e eperte ertel ttlluwu r.til t:t.ll.It:t:|.t:l:I in the
reel ID flew mm the all chernher.

WI'ltH'l BIIIEH IH1"l!-IHI1 11.!!!-I Id r-all: th= 1-1|-lsh l-tad dmtln, preswre from the elll In the t:h-aml:l-er ferret the traltle t:Iesel:I sl:l the
rttnitien uf the red is rtteintain=al:l.

TE"5l"EFl--_ ' . -. _ tettslurten

nel.l.en ' ;j@._ K AH
. _ .- - '-,1 .

1. _h_ .......
ti
- ' PUSH net:

ea I *"*'
. . DNE-Wlt"l' VRLVE
" I E :_:1"'
.____-I-____\l_
5- _ _
-l-I. _ _ __
. _~
__
i
.-.; elt cnenteea
:3

G mm EDLT E F
N-
+5
4';
-q-.
W-Y
_ 1;- ._-__'___
I-.-t=I3'.3:'E-Ii

-TENSIDNER SPRING
SEALING BDLT
'1. I

ll \|

E-i'&P..
-.

.l"-LT"
_t
I ll I _ -

.-v'=\": 53' I

it--_...j;
Dett ef lame: hIolr,, IE8] _
El HONDA HDTD-R CD- LTD-
 I-ICIIl!\iTIJ.!\..="'
"rs: ADDENDUM [:10 J;-..
__\_

I5. TRIIIIBLESIIIIIITIIIS
i

EIIEIIIE IIIIIES IIIIT STIIRT [IR I5 IIIRII TI] START

Pri:il;r=al:r!e Cause

I. Cheek -f ftl-ltl is glrltlrtg In NCIT GETTING I'D - hlci fuel in fuel ta-nit
i:etI:iiuret.ei C-RITHUHETUR Cl-:i-ggetl lust tube er luiil f-lter
Clogged I'Ir:iat '-talee
GEITINGTD CARBURFTCR Clogged fuel tettl-:. i:iii|:i
hreether tube
ll.

J. Tnr sperlt test 'ii".IE-RR IJFI NU SPARK it-P Faulty tpitrlc |.l-ug
Fouled spark plug
GUDD SPARK. Faults; CDI un=|
Brerften er shorted high tension .-""1
wire
Faulty AC generator
Elrrllltrt tlrir thrtrted ignitirgt-n cull
Faulty pulse generator
Fr.el.'ll"I'5r drlrnrs-r:|.-et.I, brnliteth t:rr
shertetl wires

El. Test i:i,-llntlei ite-rnpreesinn LD'ri't' CDMPRESSIDN -er Fm-llttl reeelll starter
Value clearance teiu small
COMPRESSION I'iI-DFIIIIAL 'ri'|ltle stuck epen
tl'|'l:irn cylinder amt t.'ilst-i:iri rings
-'*~.
Damaged rztrllnder head gasket
Sell-Bl'.I value
Impreprtr iraltie timing

'1. 5ti'l"II IJ'|i' Il2lI.Ir2ni'li'Iltg nt:rn'naI trtgrteng EHGINE FIRES BUT-in Choke excessively tit:-en
pre-eeuru SOC-IN STOPS Cerbureter pile-1: scisi-u excess-
rirulv closed
ENGINE DDESNDT FIRE A-r leaking pest carburetttir
lnsulatqr
J_i,|
Imprrrlper lttniti-en timing [EDI
rrnit err ptrlse gettereter fault-gl

5. Rernetie snarl: plug WET PLUG - Crtrhureteir fliaicitled

Carbureter i:I'li:il:e E'il(ll"ESlI'lEI'f ='-~.
Dir cl-used
Thrpttle rial-ire erteiessi-.ieItr eipen

6. Start with eltelte appil-ieict

.1,

EIIEIIIE LIIIIIS POWER

I

Preibaible Cause

1. Raise wheels eff greiuruel aiiitt spin WHEEL DOES NOT SPIHL-r Elrelte draggire;
by hand FREELY Wetn rt-r damaged wheel bearing __,_
Wheel be-eelng needs lulzitliretiitii
WHEE L SPINS F REE LY DI'I'|'l! ehain ttr-l:ri tight
Rear axle nut exeesthielti
tlgltteti-etl

20-2B 2 Date elf Isaue: I'~[psi'., 1981

EIHGNDA MUTDR CD., LTD.

_
 A HClE:I_;I"]DA
B2 ADDENDUM

{-1.
2. ljhaclt tim D-lB'55LlFI.= with Hr: [pogo FREE-BU FIE TDD LBW E-1- Punt.-mrutl lir:
Fl;-u|l:'5r tin: vulvn
PRESSURE NORMAL

r____| 2. Tiiv Fll|;Ji|'.i acoolemtioo from low to ENGINE S-FEED noes not?-* Clutch lpplrq
aeooncl CHANGE WHEN CLLFl'IIH I5 Mom clutch disolnlate
HELEn5ED Warned clutch rJlsI.:-"r-ill!!!
ENGINE SPEED LDWEFIED WHEN
CLUTCH [S RELEASED

4. |_igl-|1l,r lr_'ElBl'S1;E anoma ENGlHE SPEED NOT lNl'.IFIEA.SED#- E.-orl:|urP.~tur make-clmod

|f""". 5-UFFIBIEHTLY Clogged air ole-anar
ENGINE SPEED INCREASED Hemictant fuel fl-ow
Clu-ggod full tank hroittint tuba
lo-goat! muffler

f'-*- 5. C?i1la1:l: ignition I!-rrnhg |m:oHHEo1'-_-- Faulty CDI unit

Faulty pulse generator
CDHHEGT Faulty ionitioo Idvinoor

+1 Ciwock --nun |:lnnn|n:u- iHEREm lmproom ualv: a-diusimont

'|."|'um valve squat
CFHHEGT

1. Ta-:1 cylinthlr cuntprln ul-Ing I 1-on Low -ii-_.-. Valve stool: open
nnmpraaslon pauqa Worn c~,-1m|:le|' and piston rings
r ."\lDFllMAL
Lea-king h-oatl yulcot
In-iprmee ualvu llming

ljiiack carhutltnr lcr clo-gglng BLDGGED C-arhumtor nu! servlcod fru-

qu-|'|t|'qr B|1|.'||JQl'|
HGT CLOGEED

Fri.-more spark nlug FDLILEDDH DISGULDHED ou- Plug not aorvlcocl frnquontlv
enough
NUT FUULED CIR DISC-ULCJFIEEJ Um oi n-mg with lmpropor hnat

F l
H]. Fcemuma oil larval oaugo and chock DIL LEVEL IHUUFIFIECT-Ep-
ranp

-ll level loo hlgh

|;|-ll l|:vu| Di! lauol too low
C-rltlklrt -all
l'.L*l'JFl'RECT

11. Homo-vo ovlldor hood cow-r -inl-1 ''AL"|"E THMN NOT Clo-ggad oi! passaqa
mapert lu hrleation LUBHIGETED PHDFEHLY Cl-ragged all cm-nml nrlflre

V ALVE TH AJN Ll-JB H l ~.TE

F P'+HClPEFlL"|"

Che-cl: if oI1g|ou- ovnrhonts oi.-EH:-|E.r:rE|::-E- E.:tE5\i:-1'9 oath-on l:|ul-|:l-uo in

combustion chamho-r
not DVEHHFATEU Use of |mpr|:||-oar quallw -of
fuol
(___ Clutch Llioniru
Fiml-pir mi:-:ILlrE tun :2-an

Data of mull: Noun, H351

'2 HONDA HDTQH 50., LTD-
=" 2o-29
 I-Iomna. "D
' ADD EN DUM cm ~_-1 -~
|-|.\_

13. Floaolarata or run at high speed
ENGINE DUES HGT KNDCK
ENGINE Bil-IOCIICS E |l] Warn piston amt! r.:'fl|r|rJr.'r
121 Fuel-a-Ir mixture too lean
13! Ur: of improper grade of luoi
Hi Excessive carbon build-up ln
rturrlhualrurr clrarnber
5? Ignition timing loo advanoocl
[Faulry EDI urlil: or 3|'l'|'n-|::1|'|-

Pflllll PEIFUIPIIHUE IT LBW lliiii IDLE SPEED

Probable E-auae _
1
Check i-an-lfi-on timing and valve IHCUH HE l:T____i,, lll lrrltlrooor valva claara-nos
clearance |2l improper rgnltion timing
{Faulty SDI unit -or eoarlr ad-
CE+l'Fl HECT eanoerl
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Chaolr oirbumtor 1ai1ol: screw lN%HHECT-Eh |II| Fuel-arr mncturo too lean
ocllrultrnent iii Fuel-air Il:'|i:|ll{l..H'B loo ri|:h
C-Cl-Fl Fl ECT
f
Chock if air iiiEBi\Ill1Q beet LEAKJNG (H Deterioraied |l"|:.Ll|a|!|.'1r {I--rirq]
carburetor -l|:Lllo1l:|r iii Loos: narburrrtrrr
H EJT LE Ali HG

Tw ilaril rm wear: on :uTEr=rm|TrEu'ri- ill Famw, carbon or wet fouled /_\_

SPARK eperlr plug
GCIIDD EPA Ff l-C [El Flulhl CDI unit
[El All generator faulty-
l'l Faolry ignirr-on coil
l5l Faulty oulla alzllraneel

Fllllli PEHFUIIIMHBE AT HIGH SPEEDS

Probable Cause
Chitk igoilio-I1 tlrning and lralaa INCORRECT ill Improper valve claerarroe M'-
claarenoe liil Faulllr EDI unit
l3l Faulty nurse generator
C0 H Fl ECT HI For-llI'l1 arllranrrrrr
l
Dlaoonnocr fuel oube at eerburelor FUEL F1_El-I RE5TF|t[__TE|:|
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lll Lack of fuel ll'l tenlc '

i2'l Cloggci fucl lino
FUEL FLOWS FFlEEL"r' 131 Clogged fuel tank .l:lr:la|!l'lu|' lhn
iii-J Elggori fool ireluo
Hornoae carburetor and check lul CLUGGEU E ill Clean
clogged jel: .---..
N illT BLDG GED

Check valve tlrrrrng ||'-JCUH HEIJT iii, ill GJH1 wroulrat not Inetallocl
Waverly
Cliilil Fl ECT

I5. Chok valllo spring tension WEAK I 1 I Faulw spring

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