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Honda Activa SCV110 Service Manual Digest Download Page 228

21-1

21. INDEX

21

AIR CLEANER ...........................................................

3-5

AIR CLEANER HOUSING ..........................................

5-3

AIR SCREW ADJUSTMENT .......................................

5-10

ALTERNATOR REMOVAL ...........................................

11-2

ALTERNATOR INSTALLATION ...................................

11-3

BATTERY ..................................................................

3-12

BODY PANEL LOCATIONS ........................................

2-0

BODY COVER ............................................................

2-4

BRAKE LIGHT SWITCH .............................................

3-15

BRAKE SHOES WEAR ..............................................

3-13

CABLE & HARNESS ROUTING ................................

1-13

CAMSHAFT INSTALLATION .......................................

7-20

CAMSHAFT REMOVAL ...............................................

7-19

CARBURETOR DISASSEMBLY/INSPECTION ..........

5-5

CARBURETOR INSTALLATION .................................

5-8

CARBURETOR REMOVAL ........................................

5-4

CHARGING SYSTEM INSPECTION ..........................

15-8

CLUTCH/DRIVEN PULLEY INSTALLATION ..............

9-16

CLUTCH SHOES WEAR ...........................................

3-15

DRIVESHAFT INSTALLATION ....................................

10-7

COMBINATION METER ..............................................

18-5

CRANKCASE BREATHER .........................................

3-6

CRANKCASE/CRANKSHAFT DISASSEMBLY ...........

12-2

CRANKSHAFT INSPECTION ....................................

12-4

CRANKSHAFT/CRANKCASE ASSEMBLY .................

12-5

CYLINDER COMPRESSION .....................................

7-3

CYLINDER HEAD ASSEMBLY ...................................

7-15

CYLINDER HEAD INSTALLATION .............................

8-6

CYLINDER HEAD COVER REMOVAL .......................

8-2

CYLINDER HEAD DISASSEMBLY .............................

7-8

CYLINDER HEAD INSTALLATION .............................

7-16

CYLINDER HEAD REMOVAL .....................................

7-5

CYLINDER INSTALLATION ........................................

8-6

CYLINDER REMOVAL ...............................................

8-2

DRIVE PULLEY REMOVAL ........................................

9-9

DRIVE PULLEY INSTALLATION ................................

9-16

EMISSION CONTROL SYSTEMS ..............................

1-18

ENGINE IDLE SPEED ...............................................

3-10

ENGINE INSTALLATION ............................................

6-4

ENGINE OIL ...............................................................

3-8

ENGINE OIL STRAINER SCREEN ............................

3-10

ENGINE REMOVAL ....................................................

6-2

FINAL DRIVE OIL .......................................................

3-12

FINAL REDUCTION ASSEMBLY ................................

10-7

FINAL REDUCTION DISASSEMBLY .........................

10-3

FLOOR MAT/FLOOR PANEL ......................................

2-5

FRONT CENTER COVER .........................................

2-2

FRONT COVER .........................................................

2-2

FRONT CUSHION ..................................................... 13-20
FRONT WHEEL .........................................................

13-3

FUEL METER/ FUEL UNIT ........................................

18-9

FUEL LINE .................................................................

3-4

FUEL TANK ................................................................

5-11

HEADLIGHT ...............................................................

18-2

HANDLEBAR ............................................................. 13-12
HANDLEBAR COVER ................................................

2-7

HANDLEBAR SWITCHES .........................................

18-8

HEADLIGHT AIM ........................................................

3-15

HORN

.................................................................. 18-11

IGNITION COIL ..........................................................

16-6

IGNITION CONTROL MODULE(ICM) ........................

16-6

IGNITION SYSTEM INSPECTION ..............................

16-3

IGNITION TIMING .......................................................

16-5

INNER COVER ..........................................................

2-6

KICKSTARTER ..........................................................

9-3

LUBRICATION & SEAL POINTS ................................

1-11

MAINTENANCE SCHEDULE .....................................

3-3

MODEL IDENTIFICATION ..........................................

1-2

MUFFLER ..................................................................

2-8

NUTS, BOLTS, FASTENERS .....................................

3-17

OIL PUMP ..................................................................

4-2

PISTON INSTALLATION .............................................

8-5

PISTON REMOVAL ....................................................

8-3

SARI STEP .................................................................

2-9

SIDE STAND ..............................................................

2-10

SECONDARY AIR SUPPLY SYSTEM .........................

3-11

REAR BRAKE ............................................................

14-4

REAR FENDER .........................................................

2-7

REAR WHEEL ...........................................................

14-3

REGULATOR/RECTIFIER ......................................... 15-10
SERVICE INFORMATION

BATTERY/CHARGING SYSTEM .....................

15-1

CRANKCASE/CRANKSHAFT .........................

12-1

CYLINDER HEAD/VALVE ................................

7-1

CYLINDER/PISTON .......................................

8-1

ELECTRIC STARTER .....................................

17-1

ENGINE REMOVAL/INSTALLATION ...............

6-1

FINAL REDUCTION .......................................

10-1

FRAME/BODY PANELS/

EXHAUST SYSTEM ...................................

2-1

FRONT WHEEL/BRAKE/SUSPENSION/

STEERING ................................................

13-1

FUEL SYSTEM ................................................

5-1

IGNITION SYSTEM .........................................

16-1

KICKSTARTER/DRIVE AND

DRIVEN PULLEYS/CLUTCH ....................

9-1

LIGHTS/METERS/SWITCHES ........................

20-2

LUBRICATION SYSTEM .................................

4-1

MAINTENANCE ..............................................

3-2

REAR WHEEL/BRAKE/SUSPENSION ...........

14-1

SERVICE RULES ......................................................

1-1

SHOCK ABSORBER ..................................................

14-7

SPARK PLUG .............................................................

3-6

SPECIFICATIONS ......................................................

1-3

STARTER MOTOR .....................................................

17-3

STARTER PINION ......................................................

9-8

STARTER RELAY SWITCH ........................................

17-6

STEERING HEAD BEARINGS ...................................

3-17

STEERING STEM/FRONT FENDER ......................... 13-15
SUSPENSION ...........................................................

3-16

SYSTEM LOCATION ..................................................

18-0

TAIL/BRAKE LIGHT ....................................................

18-4

TURN SIGNAL LIGHT ................................................

18-3

THROTTLE OPERATION ...........................................

3-4

TOOLS

..................................................................

1-10

TORQUE VALUES .....................................................

1-8

TROUBLESHOOTING

BATTERY/CHARGING SYSTEM .....................

15-1

CRANKCASE/CRANKSHAFT .........................

12-1

CYLINDER HEAD/VALVE ................................

7-1

Summary of Contents for Activa SCV110

Page 1: ......

Page 2: ...HONDA ACTIVA SHOP MANUAL Honda Motor CO Ltd 2009...

Page 3: ...fety equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts an...

Page 4: ...in a variety of forms including Safety Labels on the vehicle Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL...

Page 5: ...de NLGI 2 or equiva lent Example Molykote BR 2 plus manufactured by Dow corning U S A Multi purpose M 2 manufactured by Mitsubishi Oil Japan Replace the part s with new one s before assembly Use recom...

Page 6: ...ly 3 Use only metric tools when servicing this scooter Metric bolts nuts and screws are not interchangeable with English fasteners 4 Install new gaskets O rings cotter pins and lock plates while reass...

Page 7: ...ial number is stamped on the lower left side of the crankcase The carburetor identification number is stamped on the left side of the carburetor body The color label is pasted in the luggage box under...

Page 8: ...URETOR DRIVE TRAIN ELECTRICAL 1761 mm 69 3 in 710 mm 28 0 in 1147 mm 45 2 in 1238 mm 48 7 in 765 mm 30 1 in 153 mm 6 0 in 107 kg 236 lbs 111 kg 245 lbs 170 kg 375 lbs Under born type steel Bottom link...

Page 9: ...tip clearance Outer rotor to body clearance Pump side clearance Oil pump 0 20 0 008 0 35 0 014 0 12 0 005 LUBRICATION Unit mm in CYLINDER HEAD VALVES Free length ITEM STANDARD SERVICELIMIT Cylinder co...

Page 10: ...t width ITEM STANDARD 18 5 0 73 22 035 22 085 0 8675 0 8695 22 010 22 025 0 8665 0 8671 17 92 18 08 0 705 0 712 125 0 125 2 4 921 4 929 4 0 0 16 108 5 4 27 33 965 33 985 1 3372 1 3380 34 000 34 025 1...

Page 11: ...a 1 50 kgf cm2 22 psi 10 x 2 15 in 130 5 12 SERVICELIMIT 0 20 0 008 2 0 0 08 2 0 0 08 131 5 16 FRONT WHEEL BRAKE SUSPENSION STEERING Unit mm in ITEM STANDARD Cold tyre pressure Rim size Rear wheel rim...

Page 12: ...Bulb Fuse Headlight Tail brake Front turn signal light Rear turn signal light Meter light High beam indicator Turn signal indicator Main fuse 12 V 35 W 12 V 35 W 12 V 5 21 W 12 V 21 W x 2 12 V 21 W x...

Page 13: ...d cover bolt Cylinder head bolt Cam chain tensioner lifter plug Cam sprocket bolt Cylinder head nut Breather separator plate screw Intake shroud attaching screw Exhaust shroud attaching bolt KICKSTART...

Page 14: ...ng nut Front cushion pivot arm cover screw Front cushion pivot arm grease nipple nut Steering stem lock nut REARWHEEL BRAKE SUSPENSION Rear axle nut Rear brake arm bolt Rear wheel hub nut Shock absorb...

Page 15: ...mm Attachment 37 x 40 mm Attachment 42 x 47 mm Attachment 24 x 26 mm Attachment 30 mm I D Pilot 12 mm Pilot 17 mm Pilot 20 mm Bearing remover shaft Bearing remover head 12 mm Remover shaft Adjusting r...

Page 16: ...Drive pulley face nut threads and seating surface Connecting rod big end Connecting rod small end Crankshaft bearing rotating area Timing sprocket teeth of crankshaft Oil pump drive sprocket teeth of...

Page 17: ...r stand pivot Front cushion upper bolt Brake master cylinder push rod contacting area Brake caliper pin boot inner surface Brake caliper pin sliding surface Each dust seal lips Each O ring Front brake...

Page 18: ...ENERAL INFORMATION CABLE HARNESSROUTING SPEEDOMETER CABLE REAR BRAKE CABLE BATTERY BREATHERTUBE BATTERY HORN THROTTLE CABLE FRONT BRAKE CABLE STARTER RELAY CAPACITOR DISCHARGE IGNITION CDI TURN SIGNAL...

Page 19: ...1 14 GENERAL INFORMATION THROTTLE CABLE REAR BRAKE CABLE CHOKE CABLE MAIN FUSE 10A FRONT BRAKE CABLE SPEEDOMETER CABLE BATTERY BREATHER TUBE MAIN WIRE HARNESS...

Page 20: ...1 15 GENERAL INFORMATION SPEEDOMETER CABLE REAR BRAKE CABLE FRONT BRAKE CABLE THROTTLE CABLE STARTER RELAY MAIN WIRE HARNESS CHOKE CABLE REGULATOR RECTIFIER UNIT...

Page 21: ...FORMATION VACUUM TUBE FUEL LINE CHOKE CABLE THROTTLE CABLE FUEL LEVEL SENSOR WIRE MAIN WIRE HARNESS FUEL LINE THROTTLE CABLE SPARK PLUG WIRE CHOKE CABLE VACUUM TUBE MAIN WIRE HARNESS OVER FLOW TUBE RE...

Page 22: ...1 17 GENERAL INFORMATION CHOKE CABLE REAR BRAKE CABLE MAIN WIRE HARNESS FUEL LINE BRAKE TAILLIGHT WIRE REAR LEFT TURN SIGNAL WIRE VACUUM TUBE THROTTLE CABLE REAR RIGHT TURN SIGNAL WIRE...

Page 23: ...in the same way but it is toxic Honda Motor Co Ltd utilizes lean carburetor settings as well as other systems to reduce carbon monoxide and hydrocarbons CRANKCASE EMISSION CONTROL SYSTEM The engine i...

Page 24: ...and carbon monoxide into relatively harmiess carbon dioxide and water vapor This model has the pulse secondary air injection PAIR control valve and PAIR check valve PAIR check valve prevents reverse...

Page 25: ...hold the area where a patch is attached higher than other parts of the tube so that the liquid does not flow over the area Then wipe off the liquid thoroughly and attach the patch firmly or it may ca...

Page 26: ...2 2 FRAME BODY PANELS EXHAUST SYSTEM BODYPANELLOCATIONS 2 0 FRONT HANDLEBAR COVER REAR FENDER REAR HANDLEBAR COVER INNER COVER SEAT FRONT COVER BODY COVER FLOOR PANEL UNDER COVER...

Page 27: ...nd installation of the body panels and exhaust system Always replace the exhaust pipe gasket after removing the exhaust pipe from the engine When installing the exhaust system loosely install the exha...

Page 28: ...e front center cover page 2 2 Remove the bolts 4 nos from the front cover Remove the screws 8 nos from the inner cover side and 2 nos from lower side Remove the front cover Installation is in the reve...

Page 29: ...ggage box hook Remove the luggage box assembly Installation is in the reverse order of removal Always use bit T spanner with screw bit 2 H for removing luggage hook screws REARGRIP Open the seat page...

Page 30: ...from the seat catch bracket Disconnect the rear turn signal light connectors and rear brake tail light connector Release wire from wireband Remove the body cover Installation is in the reverse order o...

Page 31: ...emoval FLOORMAT FLOORPANEL REMOVAL INSTALLATION Liftup the body cover page 2 4 Remove the floor mat Remove the side screws 2 nos Remove the bolts A 3 nos and Remove floor panel left side cover Remove...

Page 32: ...the choke cable Remove the bolt 1 no and inner cover Installation is in the reverse order of removal UNDERCOVER REMOVAL INSTALLATION Remove the floor panel page 2 5 Remove the inner cover page 2 6 Di...

Page 33: ...ve the bolts 3 nos and rear fender Installation is in the reverse order of removal HANDLEBARCOVER REMOVAL INSTALLATION Remove the followings Rearview mirrors Front side screw washer 1 no Rear side scr...

Page 34: ...s in the reverse order of removal MUFFLER Remove the exhaust pipe joint nuts 2 nos and muffler mounting bolts 2 nos Remove the muffler and exhaust pipe gasket RIGHT HANDLEBAR SWITCH CONNECTORS REAR HA...

Page 35: ...uffler and loosly tighten the exhaust pipe joint nuts 2 nos Tighten the exhaust pipe joint nuts securely Install and tighten the muffler mounting bolts 2 nos securely TORQUE 49 N m 5 0 kgf m 36 lbf ft...

Page 36: ...e reverse order of removal SIDESTAND Lift up the body cover page 2 3 Remove the floor mat from the floor panel Remove the floor panel page 2 5 Remove the floor under cover page 2 6 BOLT BOLTS Align th...

Page 37: ...ned Tighten the nut with the side stand bolt Align the hole of side stand with matching hole in the bracket NUT SCREW DRIVER SIDE STAND SPRING Fit the side stand spring with the frame and side stand b...

Page 38: ...mes or sparks in the work area or where the gasoline is stored can cause a fire or explosion If the engine must be running to do some work make sure the area is well ventilated Never run the engine in...

Page 39: ...ree play Cold tire pressure Tire size Tire brand SPECIFICATIONS 2 6 mm 1 12 1 4 in NGK CPR7EA 9 CPR7EA 9 0 8 0 9 mm 0 031 0 035 0 16 0 02 mm 0 006 0 001 in 0 16 0 02 mm 0 006 0 001 in Honda 4 stroke o...

Page 40: ...C C C C BATTERY I I I I BRAKE SHOES I I BRAKE LOCK OPERATION I I I I I BRAKE LIGHT SWITCH I I I I I STARTER SWITCH I I I I I HEADLIGHT INDICATOR SWITCH I I I I I CLUTCH SHOES WEAR I I I I HEADLIGHT AD...

Page 41: ...sure that the idle speed does not change If idle speed increases check the throttle grip free play and the throttle cable connection Measure the throttle grip free play at the grip flange THROTTLE GRI...

Page 42: ...r housing Replace the air cleaner element as per maintenance schedule Do not clean with solvent to remove dust and also do not use forced air on it The special oil will be lost and filter becomes dry...

Page 43: ...d to enter the combustion chamber Remove the spark plug Check the insulator for cracks or damage and the electrodes for wear fouling or discoloration If the electrode is corroded with carbon deposits...

Page 44: ...and cylinder head cover Remove the fan page 11 2 Turn the crankshaft clockwise and align the T mark on the flywheel with the index mark on the right crankcase Make sure that the piston is at TDC Top...

Page 45: ...nkcase breather tube to the cylinder head cover Install the removed parts in the reverse order of removal ENGINEOIL ENGINE OIL LEVEL CHECK Place the scooter on its center stand on level ground Start t...

Page 46: ...oil then remove the oil drain bolt After draining the oil completely check that the sealing washer on the drain bolt is in good condition and replace if necessary Install and tighten the drain bolt T...

Page 47: ...ecommended engine oil page 3 8 ENGINEIDLESPEED NOTE Inspect and adjust the idle speed after all other engine adjustments are within specifications The engine must be warm for accurate inspection and a...

Page 48: ...oses are not cracked NOTE If the hoses show any signs of heat damage inspect the PAIR check valve in the PAIR control valve for damage Check the air suction hose between the air filter air chamber and...

Page 49: ...l the transmission case with recommended oil through the check bolt hole up to the bottom edge of the check bolt hole RECOMMENDEDOIL Honda 4 stroke oil or equivalent motor oil API service classificati...

Page 50: ...SWEAR FRONT BRAKE Replace the front brake shoes if the indicator arrow on the brake arm aligns with the reference mark on the brake panel when the front brake is fully applied Refer to page 13 8 for f...

Page 51: ...ment is necessary turn the rear brake adjusting nut Check the brake cable for kinks or other damage Check that the brake arm spring and fasterners are in good condition BRAKE LOCK OPERATION NOTE Check...

Page 52: ...brake lever is pressed and the front rear brake engagement begins HEADLIGHTAIM NOTE Adjust headlight beam as specified by local laws and regulations Support the scooter on its center stand Adjust the...

Page 53: ...e damaged components which cannot be repaired Tighten all nuts and bolts Refer section 13 for fork service Raise the rear wheel off the ground by placing the scooter on its center stand Check for worn...

Page 54: ...29 psi Driver and passenger Front 150 kPa 1 50 kgf cm2 22 psi Rear 250 kPa 2 50 kgf cm2 36 psi Check the tires for cuts embedded nails or other damage Check the front and rear wheels for trueness Che...

Page 55: ...4 2 LUBRICATION SYSTEM 4 0 OIL PUMP OIL STRAINER SCREEN CRANKSHAFT INTAKE ROCKERARM...

Page 56: ...if repeatedly left in contact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis it is still advisable to thoroughly wash your hands with soap a...

Page 57: ...oil pump cover bolts 2 nos 5 mm BOLTS Screw the two 5 mm bolts into the threaded holes in the oil pump cover and pull the cover out of the right crankcase Remove the oil pump gear shaft and gear Remov...

Page 58: ...ar into the oil pump Measure the outer rotor to body clearance SERVICE LIMIT 0 35 mm 0 014 in Measure the rotor tip clearance SERVICE LIMIT 0 20 mm 0 008 in Pull out the oil pump gear Measure the pump...

Page 59: ...pump plate by aligning the holes in the pump plate with the two dowel pins Install and tighten the pump plate attaching screw TORQUE 3 N m 0 3 kgf m 2 2 lbf ft Check that the oil pump rotates smoothly...

Page 60: ...the oil pump cover Coat a new O ring with oil and install it onto the oil pump cover Install the oil pump cover into the right crankcase Install and tighten the oil pump cover bolts 2 nos TORQUE 3 N...

Page 61: ...5 2 FUEL SYSTEM 5 0 12 N m 1 2 kgf m 9 lbf ft...

Page 62: ...f consciousness and lead to death Run the engine in an open area or with an exhaust evacuation system in an enclosed area Bending or twisting the control cables will impair smooth operation and could...

Page 63: ...Fuel contaminated deteriorated Intake air leak Idle speed misadjusted Air screw misadjusted Float level misadjusted Carburetor clogged Compression too low Ignition system faulty section 16 Flooded car...

Page 64: ...Disconnect the engine breather hose from the cylinder head cover BREATHER TUBE AIR CLEANER HOUSING Disconnect the transmission case breather tube from the air cleaner housing Remove the mounting bolt...

Page 65: ...tle valve from the carburetor Remove the throttle cable from the throttle valve while compressing the throttle valve spring Remove the valve plate set and jet needle Check the throttle valve and jet n...

Page 66: ...witch connectors Pull out the float pin and remove the float and float valve Inspect the float valve and seat for wear or damage Replace the float valve if it is damaged If the seat is damaged replace...

Page 67: ...seat air screw seat will get damaged O RING WASHER SLOW JET MAIN JET NEEDLE JET HOLDER NEEDLE JET THROTTLE STOP SCREW O RING AIR SCREW SPRING ASSEMBLY THROTTLE VALVE NEEDLE CLIP RETAINER FLOATVALVE F...

Page 68: ...T HOLDER NEEDLE JET THROTTLE STOP SCREW O RING AIR SCREW SPRING FLOAT LEVELGAUGE O RING Install the float and float valve in the carburetor body then install the float pin through the body and float F...

Page 69: ...or mounting bolts and air cleaner connecting tube band screw Install the fuel tube and drain tube Install the choke cable Connect the throttle switch connectors TORQUE 12 N m 1 2 kgf m 9 lbf ft THROTT...

Page 70: ...E Install the throttle valve into the carburetor body Tighten the carburetor top securely After installation check that there is no fuel leaks Perform the following adjustment Throttle grip free play...

Page 71: ...1 rpm change 1 Turn the air screw until it seats lightly then back it out to the specification given This is an initial setting prior to the final air screw adjustment Remove the O ring from the carbu...

Page 72: ...throttle stop screw 7 Turn the air screw in until the engine speed drops by 50 min 1 rpm FINAL OPENING 4 turns out 8 Readjust the idle speed with the throttle stop screw FUELTANK REMOVAL INSTALLATION...

Page 73: ...in through the air suction hose If the air is not drawn in check the air suction hose for clogging With the engine running gradually apply vaccum to the PAIR control valve vaccum hose Check that the a...

Page 74: ...valve and cover Install and tighten the screws 2 nos securely PAIR CONTROL VALVE REMOVAL INSTALLATION Remove the PAIR check valve page 5 11 Disconnect the vacuum tube from the PAIR control valve COVER...

Page 75: ...6 2 ENGINE REMOVAL INSTALLATION 6 0 49 N m 5 0 kgf m 36 lbf ft...

Page 76: ...removal for servicing Cylinder head valves section 7 Cylinder piston section 8 Crankcase crankshaft section 12 SERVICE INFORMATION 6 1 ENGINE REMOVAL 6 2 ENGINE INSTALLATION 6 4 Engine dry weight ITE...

Page 77: ...re from frame Disconnect the air duct from the frame Remove the rear brake adjusting nut disconnect the brake cable from the brake arm and remove the brake arm joint Remove the brake cable from the cr...

Page 78: ...ngine mounting bracket remove the engine mounting bracket nut and pull out the mounting bolt from the left side Install the engine mounting bracket and mounting bolt Install and tighten the nut TORQUE...

Page 79: ...NGINE MOUNTING NUT UPPER MOUNTING BOLT ADJUSTING NUT BRAKEARM JOINT BRAKE CABLE Install the brake cable to the crank case and cable clamp Install the brake arm joint and connect the brake cable Instal...

Page 80: ...uum tubes and fuel tube in carburetor Connect the air supply hose and tighten the screw TORQUE 3 N m 0 3 kgf m 2 2 lbf ft Install the following Throttle valve page 5 8 Choke cable page 5 5 Spark plug...

Page 81: ...7 2 CYLINDER HEAD VALVES 7 0 4 N m 0 4 kgf m 2 9 lbf ft 7 N m 0 7 kgf m 5 1 lbf ft 0 8 N m 0 08 kgf m 6 lbf ft 18 N m 1 8 kgf m 13 lbf ft 12 N m 1 2 kgf m 9 lbf ft...

Page 82: ...i at 520 min 1 rpm 0 16 0 02 mm 0 006 0 001 in 32 066 32 226 1 2625 1 2688 31 816 31 976 1 2526 1 2589 10 000 10 015 0 3937 0 3943 9 972 9 987 0 3926 0 3932 4 975 4 990 0 1959 0 1945 4 955 4 970 0 195...

Page 83: ...ed Valves Incorrect valve clearance Burned or bent valve Incorrect valve timing Broken valve spring Uneven valve seating Cylinder head Leaking or damaged cylinder head gasket Warped or cracked cylinde...

Page 84: ...pply kick 5 6 times and check the gauge reading Crank the engine until the gauge reading stops rising The maximum reading is usually reached within 4 7 seconds STANDARD 843 kPa 8 6 kgf cm2 122 psi at...

Page 85: ...Install and tighten the screws 3 nos to the specified torque TORQUE 0 8 N m 0 08 kgf m 0 6 lbf ft Install and tighten the bolt 1 no to the specified torque TORQUE 7 N m 0 7 kgf m 5 1 lbf ft Install th...

Page 86: ...mpression stroke The rocker arms should be loose If the rocker arms are tight rotate the crankshaft one turn and realign the T mark with the index mark Remove the cam chain tensioner lifter plug and O...

Page 87: ...om falling into the crankcase Remove the tensioner shaft stopper tool bolts 2 nos tensioner lifter and gasket Remove the nuts 4 nos Remove the bolts 2 nos and cylinder head Remove the cylinder head ga...

Page 88: ...ker arm shaft O D SERVICE LIMIT 9 91 mm 0 390 in Compress the valve springs using the valve spring compressor and remove the valve cotters TOOLS Valve spring compressor 070GE 001 I100 Remove the valve...

Page 89: ...racks Check the cylinder head for warpage with a straight edge and feeler gauge SERVICE LIMIT 0 05 mm 0 002 in Measure the free length of the valve springs SERVICELIMITS 26 8 mm 1 06 in Insert the val...

Page 90: ...eeds the service limits with new guides also replace the valve Inspect and reface the valve seats whenever the valve guide are replaced page 7 12 VALVEGUIDEREPLACEMENT Chill new valve guides in the fr...

Page 91: ...nd reface the valve seat page 7 14 VALVE GUIDE VALVE GUIDE CLIP CYLINDER HEAD VALVE GUIDE REAMER DAMAGED FACE UNEVEN SEAT WIDTH VALVESEATINSPECTION REFACING INSPECTION Clean all intake and exhaust val...

Page 92: ...dth is not within specification reface the valve seat page 8 11 CONTACT TOO LOW OLD SEAT WIDTH 60 32 OLD SEAT WIDTH CONTACT TOO HIGH 45 60 32 VALVE SEAT REFACING Follow the refacer manufacturer s oper...

Page 93: ...1 4 of the existing valve seat material TOOLS Valve seat cutter 24 mm 32 IN 07780 0012900 Valve seat cutter 28 mm 32 EX 070MH 002I120 Valve seat cutter holder 070MH 005I150 45 0 9 1 1 mm 0 035 0 043 i...

Page 94: ...and guide After lapping wash any residual compound off the cylinder head and valve and recheck the seat contact SCREWS BREATHER SEPARATOR PLATE BREATHER SEPARATOR CLEANING Bend up the lock tabs of th...

Page 95: ...ne oil and insert the valves into the cylinder head To avoid damage to the stem seal turn the valve slowly when inserting Install the valve springs with the tightly wound coils facing the cylinder hea...

Page 96: ...the cotters firmly using two hammers as shown Hold one hammer on the valve stem and gently tap in with the other hammer Install the insulator carburettor To prevent loss of tension do not compress th...

Page 97: ...to hold the cam chain tensioner lifter Install the cam chain tensioner lifter and tighten the bolts securely DOWEL PINS Install the cylinder head Suspend the cam chain to keep it from falling into th...

Page 98: ...mark Cover the cam chain opening with a shop towel to prevent from the cam sprocket bolts falling into the crankcase Align the bolt holes in the camshaft and cam sprocket and install the cam sprocket...

Page 99: ...ioner lifter Install the plug with a new O ring and tighten it TORQUE 4 N m 0 4 kgf m 2 9 lbf ft Install the cam chain tensioner hole cap Install the following Spark plug page 3 6 Muffler assembly pag...

Page 100: ...page 3 6 Muffler assembly page 2 8 Cam sprocket page 7 6 Remove the camshaft NOTE Do not hammer the cam shaft out as it can damage the camshaft as well as the spring used for decompression mechanism...

Page 101: ...arts of the assembly in solvent and lubricate them with clean engine oil Install the camshaft into the cylinder head by aligning the cam lobes with the cutouts in the holder Install the retainer bolt...

Page 102: ...8 2 CYLINDER PISTON 8 0...

Page 103: ...0 004 0 010 0 20 0 70 0 008 0 028 SERVICE LIMIT 50 10 1 972 0 05 0 002 0 05 0 002 0 05 0 002 49 91 1 966 13 04 0 513 12 96 0 510 0 02 0 001 0 10 0 004 13 05 0 514 1 05 0 041 0 08 0 003 0 45 0 018 I D...

Page 104: ...n X and Y axis Take the maximum reading to determine the cylinder wear SERVICE LIMIT 50 10 mm 1 972 in Calculate the cylinder to piston clearance Refer to page 8 4 for measurement of the piston O D SE...

Page 105: ...SPECTION Inspect the piston rings and replace them if they are damaged Inspect the piston rings for movement by rotating the rings The rings should be able to move in their grooves without catching Pu...

Page 106: ...against the maximum cylinder I D measurement and calculate the cylinder to piston clearance page 8 2 SERVICE LIMIT 0 10 mm 0 004 in Measure piston pin hole I D in an X and Y axis Take the maximum read...

Page 107: ...er first then install the side rails After installing the rings they should rotate freely without sticking Clean any gasket material from the cylinder mating surface of the crankcase When cleaning the...

Page 108: ...YLINDERINSTALLATION Install the dowel pins and a new gasket Apply engine oil to the cylinder wall piston and piston ring outer surfaces Route the cam chain through the cylinder and install the cylinde...

Page 109: ...KICKSTARTER DRIVE AND DRIVEN PULLEYS CLUTCH 9 0 KICKSTARTER DRIVE AND PULLEYS CLUTCH 93 N m 9 3 kgf m 69 lbf ft 49 N m 5 0 kgf m 36 lbf ft...

Page 110: ...0 08 92 2 3 63 33 94 1 336 34 06 1 341 Bushing I D Boss O D Weight roller O D Outer I D Lining thickness Face spring free length Driven face O D Movable driven face I D Movable drive face Clutch Driv...

Page 111: ...KWP 410 Bearing installer Driven face 070NC KWP 410 Clutch spring compressor 070ME KWP 110 TROUBLESHOOTING Engine starts but scooter won t move Worn drive belt Damaged ramp plate Worn or damaged clut...

Page 112: ...Y Raise the lock tabs of the left crankcase cover plate Remove the screws 5 nos and left crankcase cover plate Remove the rear brake cable from the cable holder Loosen the air duct band screw and disc...

Page 113: ...ng the kickstarter pedal mark the pedal and spindle for proper installation position Remove the bolt 1 no and the kickstarter pedal Carefully unhook the return spring from the pin on the crankcase cov...

Page 114: ...eturn spring for weakness or damage bushing for wear or damage SPINDLE COLLAR BUSHING RETURN SPRING driven gear for wear or damage friction spring for weakness or damage starter ratchet teeth of the d...

Page 115: ...arter spindle journal Install the spindle and return spring into the crankcase cover and hook the short end of the spring to the spindle groove Do not hook the long end of the spring Install the washe...

Page 116: ...d friction spring sliding area Turn the kickstarter pedal and hold it Install the driven gear while aligning the friction spring hook with the groove in the crankcase cover and return the pedal to eng...

Page 117: ...able in to the cable holder Connect the air duct to the left crankcase cover and tighten the band screw 1 no securely After installation check that the kickstarter pedal operates properly Install the...

Page 118: ...pinion shaft journal Install the starter pinion into the left crankcase Install the starter pinion holder by aligning its bosses with the grooves in the left crankcase Install the left crankcase cover...

Page 119: ...washer and drive belt from the crankshaft Remove the movable drive face assembly while holding the back of the face ramp plate Remove the following drive face boss ramp plate slide pieces weight rolle...

Page 120: ...the drive face boss for wear or damage Measure the boss O D SERVICE LIMITS 21 98 mm 0 865 in Measure the drive face bushing I D SERVICELIMITS 22 60 mm 0 889 in CLUTCH DRIVENPULLEYREMOVAL Remove the d...

Page 121: ...g inspection refer to page 9 14 Remove the E clips 3 nos and plate Remove the clutch driven pulley assembly and drive belt Set the clutch spring compressor onto the clutch driven pulley aligning the b...

Page 122: ...e Remove the clutch shoe springs and clutch shoes from the clutch drive plate Remove the damper rubbers 3 nos Remove the oil seals and O rings DRIVEN FACE BEARING REPLACEMENT Remove the needle bearing...

Page 123: ...e inside of the driven face with 5 0 5 5 g of grease Apply grease to a new needle bearing Press the needle bearing into the driven face with the markings facing up TOOLS Bearing installer Driven face...

Page 124: ...mm 0 08 in DRIVENFACESPRING Measure the driven face spring free length SERVICE LIMITS 92 2 mm 3 63 in DRIVENFACE Check the driven face for wear or damage Measure the driven face O D SERVICE LIMIT 33...

Page 125: ...ease and install them onto the movable driven face Apply grease to the inside surface the movable driven face Install the movable driven face onto the driven face Apply grease to the guide pins and in...

Page 126: ...spring seat clutch Set the clutch spring compressor over the clutch driven pulley aligning the bosses with the holes in the clutch TOOL Clutch spring compressor 070ME KWP 110 Hold the spring compresso...

Page 127: ...e 9 18 DRIVEPULLEYINSTALLATION Clean any oil and grease from the pulley faces Replace the contaminated drive belt Do not apply grease to the movable drive face and weight rollers Install the weight ro...

Page 128: ...pulley face and washer Apply oil to the drive pulley face nut threads and seating surface and install it Hold the drive pulley face with the special tool and tighten the drive pulley face nut TOOL Clu...

Page 129: ...FINAL REDUCTION 10 2 10 0...

Page 130: ...L REDUCTION DISASSEMBLY 10 3 DRIVESHAFT REMOVAL 10 3 FINAL REDUCTION INSPECTION 10 4 BEARING REPLACEMENT 10 5 DRIVESHAFT INSTALLATION 10 7 FINAL REDUCTION ASSEMBLY 10 7 10 Final reduction oil capacity...

Page 131: ...KPL I510 Bearing remover weight 070MC KPL I300 Crankcase assembly collar 070MF KWP 110 Assembly collar attachment 070MF KWP 120 Crankcase assembly shaft 070MF KWP 130 Attachment 32 x 35 mm 070GD 002 I...

Page 132: ...her tube from the air cleaner housing Remove the bolts 7 nos and the transmission case DRIVESHAFT CASE DRIVEN GEAR PULLER Remove the dowel pins 2 nos and gasket Remove the final shaft Remove the count...

Page 133: ...FINALREDUCTIONINSPECTION Check the left crankcase and transmission cover bearings for wear or damage Check the final shaft for excessive wear damage or signs of seizure Check the counter gear shaft an...

Page 134: ...ver shaft 15 mm 070MC KPL I510 Drive shaft bearing Bearing remover head 17 mm 070MC KPL I520 Bearing remover shaft 15 mm 070MC KPL I510 Apply engine oil to new bearing rotating areas Drive new bearing...

Page 135: ...ver shaft 12 mm 070MC KPL I410 Apply engine oil to new bearing rotating areas Drive new bearings into the transmission case TOOLS Driveshaft bearing Driver 070GD 001 I100 Attachment 37 x 40 mm 070GD 0...

Page 136: ...70MF KWP 120 Crankcase assembly shaft 070MF KWP 130 Coat the circumference and lip of a new oil seal with engine oil Install the oil seal into the left crankcase until the depth from the crankcase end...

Page 137: ...int page 14 4 Fill the transmission case with the recommended oil page 3 8 RECOMMENDEDOIL Honda 4 stroke oil or equivalent motor oil API service classification SJ Viscosity SAE 20W40 OILCAPACITY 0 10...

Page 138: ...11 2 ALTERNATOR 11 0 6 N m 0 6 kgf m 43 lbf ft 39 N m 4 0 kgf m 29 lbf ft 0 8 N m 0 08 kgf m 0 6 lbf ft...

Page 139: ...heel and the cooling fan These parts can be removed with the engine installed in the frame Refer to section 15 for alternator stator inspection TORQUE VALUES Fan cover bolt 0 8 N m 0 08 kgf m 0 6 lbf...

Page 140: ...FLYWHEEL NUT Remove the two screws 2 nos bolts 2 nos and the cooling fan cover Remove the bolts 3 nos and cooling fan Hold the flywheel with the universal holder and remove the flywheel nut 1 no TOOL...

Page 141: ...ator stator ALTERNATORINSTALLATION Install the stator and tighten the bolts C 2 nos Install the wire clamp and tighten the bolt A 1 no Install the grommet into the right crankcase Install the ignition...

Page 142: ...l holder and tighten the nut TOOL Universal holder 070MB KPL I100 TORQUE 39 N m 4 0 kgf m 29 lbf ft Install the cooling fan and tighten the bolts 3 nos NOTE Bolts other than actual can damaged the sta...

Page 143: ...12 2 CRANKCASE CRANKSHAFT 10 N m 1 0 kgf m 7 lbf ft 12 0...

Page 144: ...ul not to damage the crankcase mating surfaces when separating and assembling the crankcase halves The crankcase oil seals must be replaced with new ones when assembling the crankcase halves SPECIFICA...

Page 145: ...ate from the left crankcase Remove the cam chain tensioner pivot bolt and cam chain tensioner Remove the crankcase bolts 8 nos Place the crankcase with the left crankcase down and remove the right cra...

Page 146: ...s Clean off crankcase mating surface Remove the crankshaft from the left crankcase Remove the cam chain Remove the oil seal from the left crankcase Remove the oil seal from the right crankcase CRANKSH...

Page 147: ...04 mm 0 002 in Set the crankshaft on V blocks and read the runout using dial indicators Actual runout is 1 2 of total indicator read ing SERVICE LIMIT 0 1 mm 0 04 in BEARING INSPECTION Turn the beari...

Page 148: ...hain into the left crankcase Install the crankshaft into the left crankcase through the cam chain being careful not to damage the oil seal lip Note the connecting rod location when installing the cran...

Page 149: ...ghten the pivot bolt TORQUE 10 N m 1 0 kgf m 7 lbf ft Install the oil seal stopper plate and tighten bolts 2 nos Hook the center stand return spring to the stand and spring pin Install the following c...

Page 150: ...13 2 FRONT WHEEL BRAKE SUSPENSION STEERING 59 N m 6 0 kgf m 43 lbf ft 4 N m 0 4 kgf m 2 9 lbf ft 49 N m 5 0 kgf m 36 lbf ft 68 N m 6 9 kgf m 50 lbf ft 13 0...

Page 151: ...T WHEEL 13 3 FRONT BRAKE 13 8 HANDLEBAR 13 12 STEERING STEM FRONT FENDER 13 15 FRONT CUSHION 13 20 13 TORQUE VALUES Handlebar post pinch nut 49 N m 5 0 kgf m 36 lbf ft U nut Front axle nut 59 N m 6 0...

Page 152: ...TROUBLESHOOTING Hard steering Steering top cone race too tight Worn or damaged steering bearings Worn or damaged steering bearing races Bent steering stem Insufficient tire pressure Steers to one side...

Page 153: ...rm joint BRAKE PANEL COLLAR Push the tab and disconnect the speedometer cable Loosen the front axle nut Support the frame securely and raise the front wheel off the ground Remove the axle nut axle and...

Page 154: ...Remove the distance collar and drive out the other bearing TOOLS Bearing remover head 12 mm 070GD 005 I130 Bearing remover shaft 070GD 005 I100 Replace the wheel bearings in pairs Remove the nuts 4 n...

Page 155: ...g SERVICELIMITS Radial 2 0 mm 0 08 in Axial 2 0 mm 0 08 in WHEELBEARING Turn the inner race of each bearing with your finger The bearings should turn smoothly and quietly Also check that the bearing o...

Page 156: ...is fully seated Install the distance collar Drive in a new right bearing squarely with the sealed side facing up until it is fully seated Do not allow the bearings to tilt while driving them in TOOLS...

Page 157: ...STALLATION Install the brake panel assembly Install the front wheel between the fork legs by aligning the brake panel groove with the boss of the left fork leg Apply thin coat of grease to the front a...

Page 158: ...shoe reduces stopping power Discard contaminated shoes and clean a contaminated drum with a high quality brake degreasing agent Inhaled asbestos fibers have been found to cause respiratory disease an...

Page 159: ...ensure that they are reinstalled on their original position Remove the brake arm nut and bolt 1 no Unhook the return spring from the brake arm Remove the indicator return spring and brake cam FELT SE...

Page 160: ...into the brake panel Apply grease to a new dust seal lip and install it into the brake panel BRAKE CAM SPRING DUST SEAL BRAKE PANEL FELT SEAL 10 N m 1 0 kgf m 7 lbf ft INDICATOR RETURN SPRING BRAKE CA...

Page 161: ...ke cam aligning the punch marks on the arm and cam Install the brake arm bolt and nut and tighten the nut TORQUE 10 N m 1 0 kgf m 7 lbf ft Apply grease to the brake cam and the anchor pin Contaminated...

Page 162: ...de Disconnect the throttle cable and remove front brake lever bracket throttle housing of lower side Remove the bolt 1 no and rear brake lever bracket Remove the handlebar post pinch nut 1 no and bolt...

Page 163: ...a collar from right side Install and tighten the handlebar post pinch nut TORQUE 49 N m 5 0 kgf m 36 lbf ft If the handlebar grips were removed apply Honda Bond A or its equivalent to the inside surf...

Page 164: ...with the hole in the handlebar Install the front brake lever bracket throttle housing of upper side and tighten the bolt 1 no Install the rear brake lever bracket and align the locating pin with the h...

Page 165: ...ck nut wrench 070MA KPL I200 Remove the top cone race TOOL Lock nut wrench 45 5 mm 070MA KPL I100 Support the steering stem Remove the upper steel balls 26 from the steering head Be careful not to loo...

Page 166: ...the front fender inner side BEARING RACE REPLACEMENT BOTTOMCONERACE Remove the bottom cone race and dust seal from the steering stem Install the a new dust seal onto the steering stem Press a new bot...

Page 167: ...001 I120 Remover weight 070MC KPL I300 Drive the bottom ball race out of the steering head using the special tool TOOLS Adjusting remover head 070GC 001 I110 Remover shaft 070GC 001 I120 Remover weig...

Page 168: ...ERING ASSEMBLY DUST SEAL BOTTOM CONE RACE STEEL BALL BOTTOM BALL RACE TOP BALL RACE STEEL BALL TOP CONE RACE STEM LOCK NUT Install the front fender and tighten the bolts 2 nos securely Install and tig...

Page 169: ...the lock nut wrench use a deflecting beam type torque wrench 10 inches long The lock nut wrench increases the torque wrench s leverage so the torque wrench reading will be less than the torque actual...

Page 170: ...TORQUE 68 N m 7 0 kgf m 51 lbf ft Make sure that the steering stem moves smoothly without play or binding Install the following Handlebar page 13 12 Front wheel page 13 3 NOTE Check for both sideways...

Page 171: ...3 kgf m 24 lbf ft 26 N m 2 6 kgf m 19 17 lbf ft PIVOTARM INSPECTION Visually inspect the shock absorber for oil leaks or other faults INSPECTION Check the pivot arm for wear or damage If you fill up...

Page 172: ...ten the bolt 1 no to specified torque TORQUE 32 N m 3 3 kgf m 24 lbf ft Install the pivot arm and tighten the nut 1 no to specified torque TORQUE 26 N m 2 6 kgf m 19 17 lbf ft Install the following St...

Page 173: ...14 2 REAR WHEEL BRAKE SUSPENSION 14 0 39 N m 4 0 kgf m 29 lbf ft 22 N m 2 2 kgf m 16 lbf ft 118 N m 12 0 kgf m 87 lbf ft...

Page 174: ...rts of the tube so that the liquid does not flow over the area Then wipe off the liquid thoroughly and attach a patch firmly or it may cause air leak TUFFUP tube cannot always prevent tire puncture Al...

Page 175: ...OK bolt replace with a new one Rear wheel hub nut 49 N m 5 0 kgf m 36 lbf ft Apply oil to the threads and seating surface Shock absorber upper mounting bolt 39 N m 3 9 kgf m 28 76 lbf ft Shock absorbe...

Page 176: ...nut washer and the rear wheel Check the rotating direction mark on the tire Remove the nuts 4 nos and wheel hub INSPECTION Check the wheel rim runout using a dial indicator Actual runout is 1 2 the to...

Page 177: ...loosely in the hub INSTALLATION Install the wheel hub on the wheel and tighten the nuts 4 nos to the specified torque TORQUE 49 N m 4 9 kgf m 36 14 lbf ft Install the rear wheel and washer Apply oil t...

Page 178: ...AKE SHOES BOLT ARM CAM RETURN SPRING ARM PIN BRAKE CABLE ADJUSTING NUT ASSEMBLY BRAKEARM BRAKE CABLE BRAKE CAM ADJUSTING NUT BOLT BRAKE ARM SHOE SPRING BRAKE SHOE DUST SEAL Remove the adjusting nut br...

Page 179: ...no TORQUE 10 N m 1 0 kgf m 7 lbf ft Install the return spring Install the brake arm joint brake cable and brake adjust ing nut page 3 14 Apply grease to the brake cam and anchor pin Install the shoe...

Page 180: ...r and lower mounting bolts 2 nos TORQUE Upper 39 N m 3 9 kgf m 28 76 lbf ft Lower 22 N m 2 2 kgf m 16 lbf ft Install the body covers page 2 4 UPPER MOUNTING BOLT LOWER MOUNTING BOLT SHOCKABSORBER REMO...

Page 181: ...14 8 REAR WHEEL BRAKE SUSPENSION MEMO...

Page 182: ...15 2 BATTERY CHARGING SYSTEM SYSTEMDIAGRAM ALTERNATOR LIGHTING SWITCH REGULATOR RECTIFIER DIMMER SWITCH BATTERY 15 0 EARTHING CABLE SEC00 15 pmd 2 17 2010 1 40 PM 2...

Page 183: ...d store it in a cool dry space For maximum service life charge the stored battery every two weeks For a battery remaining in a stored scooter disconnect the negative battery cable from the battery ter...

Page 184: ...orming Filling a new battery with electrolyte will produce some voltage but in order to achieve its maximum performance always charge the battery Also the battery life is lengthened when it is initial...

Page 185: ...BATTERYVOLTAGE MEASUREDCHARGINGVOLTAGE 15 5 V at 5 000 min 1 rpm Correct Incorrect Correct Correct Incorrect 1 Remove the battery page 15 6 Check the battery condition using the recom mended battery t...

Page 186: ...Incorrect Check the regulator rectifier connector voltage and resistance page 15 10 From page 15 3 Correct Faulty regulator rectifier Open circuit in related wire Loose or poor contacts of related te...

Page 187: ...tor rectifier and alternator connector Yellow terminals Incorrect Incorrect Faulty regulator rectifier Poorly connected connector Too high Correct Check the continuity between Green wire terminal of t...

Page 188: ...the terminals with petrolium jelly Reinstall the removed parts Connect the positive terminal first and then the negative cable INSPECTION Check for cracked or broken case or plates Check the plates fo...

Page 189: ...0 007 per 10 C change in temperature Be sure to con sider this when taking measurements Reading of the hydrometer s fluid level should be taken horizontally BATTERY CHARGING Remove the battery page 15...

Page 190: ...ry Using exces sive current or extending the charging time may damage the battery Charging current Charging time Quick 5 A 0 5 hour Normal 0 5 A 5 10 hours CHARGINGSYSTEMINSPECTION CHARGING VOLTAGE IN...

Page 191: ...ting temperature Stop the engine and connect the multimeter as shown NEGATIVE CABLE HEADLIGHT 3P CONNECTOR LIGHTINGOUTPUT Open the front handle bar cover page 2 7 Do not remove headlight assy Connect...

Page 192: ...his test Lift up the body cover page 2 3 Disconnect the alternator 2P connector page 11 2 Check the resistance between following terminals STANDARD Charging coil White Green Ground Lighting coil Yello...

Page 193: ...e Charging coil line Lighting coil line Ground line Specification Battery voltage should register 0 2 1 0 at 20 C 68 F 0 1 0 8 at 20 C 68 F Continuity should exist Terminal Red and ground White and gr...

Page 194: ...16 2 IGNITION SYSTEM SYSTEMDIAGRAM IGNITION CONTROL MODULE ICM IGNITION SWITCH SPARK PLUG IGNITION PULSE GENERATOR IGNITION COIL 16 0 EARTHING CABLE...

Page 195: ...ately charged A weak battery may be unable to turn the starter motor quickly enough or adequate ignition current may not be supplied Use spark plug of the correct heat range Using spark plug with an i...

Page 196: ...il secondary current ampere 2 Faulty ignition coil 1 Multimeter impedance is too low below 10 M DCV 2 Cranking speed is too low Operating force of the kickstarter is weak 3 The sampling timing of the...

Page 197: ...onnections before this inspection Poor connected connectors can cause incorrect read ings Check that the cylinder compression is normal and check that the spark plug is installed correctly in the cyli...

Page 198: ...coil peak voltage PEAK VOLTAGE 100 V minimum To avoid possible electrical shock during voltage mea surements do not touch test probe metal parts If the peak voltage measured at the ICM connector is a...

Page 199: ...ank the engine with the kickstarter and read the peak voltage PEAK VOLTAGE 0 7 V minimum If the peak voltage measured at the ICM connector is abnormal disconnect the ignition pulse generator connector...

Page 200: ...E ICM REMOVAL INSTALLATION Remove the front center cover page 2 2 Remove the ignition control module ICM from the battery stay disconnect the connectors and remove the ICM Install the ICM in the rever...

Page 201: ...ectors of the throttle switch Check for continuity between the Yellow Blue and Blue Green wire connectors with the throttle position while operating the throttle grip Fully open no continuity Fully cl...

Page 202: ...17 2 ELECTRIC STARTER 17 0 STARTER RELAY SWITCH FUSE 10 A REAR BRAKE LIGHT SWITCH STARTER SWITCH FRONT BRAKE LIGHT SWITCH SYSTEMDIAGRAM EARTHING CABLE STARTER...

Page 203: ...w chart page 17 2 A weak battery may be unable to turn the starter motor quickly enough or supply adequate ignition current If the current is kept flowing through the starter motor to turn it while th...

Page 204: ...h and check for a Click sound from the starter relay switch Cleck the starter relay voltage page 17 7 Normal Check the starter relay switch operation page 17 7 Normal Loose or poor ignition control mo...

Page 205: ...the starter motor terminal Remove the screw 1 no and disconnect the starter motor wire from the starter motor Remove the mounting bolts 2 nos ground wire and the starter motor from the crankcase Remov...

Page 206: ...discoloration Bars discolored in pairs indicate shorted coils Do not use emery or sand paper on the commutator Check for continuity between pairs of commutator bars There should be continuity Check f...

Page 207: ...R CASE ARMATURE SPRINGS GASKET O RING BRACKET Install the springs into the brush holders Push and hold the brushes into the brush holders and insert the armature into the front bracket Be careful not...

Page 208: ...s INSTALLATION Install a new gasket onto the starter motor Install the starter motor into the crankcase Install the ground wire and mounting bolts 2 nos and tighten the bolts securely Connect the star...

Page 209: ...ctor page 16 6 Measure the following between the wire terminals of the wire harness side connectors with the ignition switch ON Y R R W W G R Y R Bl R G Bu Y Bl Y W G Bl W Bl NO WIRE NO WIRE Starter r...

Page 210: ...2 LIGHTS METERS SWITCHES 18 0 SYSTEMLOCATION FRONT BRAKE LIGHT SWITCH TURN SIGNAL RELAY HORN SWITCH DIMMER SWITCH TURN SIGNAL LIGHT SWITCH LIGHTING SWITCH STARTER SWITCH IGNITION SWITCH EARTHING CABL...

Page 211: ...ic connectors have locking tabs that must be released before disconnecting and must be aligned when reconnect ing To isolate an electrical failure check the continuity of the electrical path through t...

Page 212: ...the reverse order of removal Install the dust cover with its TOP mark facing up BULB DUST COVER HEAD LIGHT ASSEMBLY ADJUSTING BOLT WASHER REMOVAL INSTALLATION Remove the handlebar front cover page 2...

Page 213: ...ont turn signal bulb holder by turning counterclockwise Remove bulb by pressing in and turning counter clock wise and replace it with a new one Installation is in the reverse order of removal FRONTTUR...

Page 214: ...ulb by pressing in and turning counter clock wise and replace it with a new one Installation is in the reverse order of removal TAIL BRAKELIGHT BULB REPLACEMENT Insert hand from bodycover rear side ab...

Page 215: ...lace it with a new one REMOVAL Remove the rear handlebar cover Remove the screws 2 nos and combination meter DISASSEMBLY Unhook the retaining tabs 4 nos and remove the front panel from the rear panel...

Page 216: ...reverse order of removal Connect the terminals and install the sockets are according to the color codes indicated on the lower case Route the meter harness as shown in the illustration INSTALLATION I...

Page 217: ...on Continuity should exist between the color coded wires as follows IGNITION SWITCH REMOVAL INSTALLATION Remove the inner cover page 2 6 Remove the front cover page 2 2 Disconnect the ignition switch...

Page 218: ...lebar switch connector Continuity should exist between the color coded wire ter minals as follows RIGHT HANDLEBAR SWITCHES STARTER SWITCH LIGHTINGSWITCH LEFT HANDLEBAR SWITCHES TURNSIGNALSWITCH DIMMER...

Page 219: ...heck the following Remove the combination meter page 18 5 Connect the combination meter 6P connector and black wire connector Check for open circuit in yellow white between the meter and fuel level se...

Page 220: ...ly replace the fuel level sensor FUEL UNIT INSTALLATION Check that the base packing is in good condition replace if necessary Install the fuel unit holder plate onto the unit Install the fuel unit and...

Page 221: ...nction Loose connectors If above items all normal check the following Remove the front center cover page 2 2 Disconnect the connector from the relay 1 Short the black and gray terminals of the turn si...

Page 222: ...19 1 19 WIRINGDIAGRAM 19...

Page 223: ...19 2 MEMO...

Page 224: ...inder piston and piston rings Valve stuck open Improper valve timing Leaking cylinder head gasket Loose spark plug Low compression Reaching carburetor Not reaching carburetor 1 Check the fuel flow to...

Page 225: ...rburetor not serviced frequently enough Plug not serviced frequently enough Use of plug with improper heat range Lean fuel mixture section 5 Wrong type of fuel Excessive carbon build up in combustion...

Page 226: ...Check carburetor air screw adjustment Good spark 3 Perform spark test Weak or intermittent spark Abnormal Loose carburetor and or intake pipe Damaged carburetor insulator Deteriorated intake pipe O r...

Page 227: ...ignition control module ICM Clogged 2 Check carburetor for clogging Normal 5 Check choke valve Abnormal Choke valve open or broken 6 Check valve spring Weak Faulty valve spring Incorrect POORHANDLING...

Page 228: ...13 3 FUEL METER FUEL UNIT 18 9 FUEL LINE 3 4 FUEL TANK 5 11 HEADLIGHT 18 2 HANDLEBAR 13 12 HANDLEBAR COVER 2 7 HANDLEBAR SWITCHES 18 8 HEADLIGHTAIM 3 15 HORN 18 11 IGNITION COIL 16 6 IGNITION CONTROL...

Page 229: ...EL SYSTEM 5 1 IGNITION SYSTEM 16 1 KICKSTARTER DRIVEAND DRIVEN PULLEYS CLUTCH 9 1 LUBRICATION SYSTEM 4 1 POOR PERFORMANCE AT HIGH SPEED 20 4 POOR PERFORMANCEAT LOWAND IDOL SPEEDS 20 3 POOR HANDLING 20...

Page 230: ...Published by Honda Motorcycle Scooter India Pvt Ltd BOP200902900 Printed in India Honda Motor Co Ltd 2009 62KPLN2...

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