Honda C200 1963 Shop Manual Download Page 6 | Manualshive

Page: 6 / 58

Honda C200 1963 Shop Manual Download Page 6

«
...
4
5
6
7
8
...
»

Summary of Contents for C200 1963

Page 1: ......

Page 2: ......

Page 3: ...or technical information This manual is composed of three sections and the third section includes subsections on Construction Operating Principles Disassembling Assembling etc Efforts have been taken...

Page 4: ......

Page 5: ...n of Valves 0 0 0 0 0 0 00 00 0 0 0 00 0 00 0 0 0 00 0 0 00 00 14 Disassembling 0 0 0 0 0 0 0 14 A ssembling 0 0 0 0 0 0 0 0 0 0 0 0 14 CYLINDER PISTON AND PISTON RINGS 0 0 0 16 Construction 0 0 0 0 0...

Page 6: ...00 00 00 00 34 3 7 TRANSMISSION 36 A B c D Construction Operatio 1 Kick Starter Disassembling 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 36 3 0 0 0 0 0 0 0 0 0 0...

Page 7: ...mber is adopted to improve the cooling efficiency of the cy linder head and produce more output with lower fuel consumption 2 The proper speed can be selected easily at all times with the hand operate...

Page 8: ...g Distance m 6 5 at 35 km h Engine Kind of Fuel Gasoline Cooling System and Cycles Air cooled 4 cycle Number of Cylinders and Mounting Angle Single cylinder 10 upward from Ieveii Location of Valves Ov...

Page 9: ...ear Ratios First 2 54 Second 1 61 Third 1 19 Fourth 0 96 Drive Sprocket Ratio 2 67 chain driven Steering Steering Angle 43 left and right Length of Handlebar mm 625 Caster 63 5 Trail mm 75 Wheels and...

Page 10: ...3 4 5 6 7 8 9x OOO r p m Running erformance C 200 8000 Gxr rat v Lo v 25 2 Effective radius of 2nd 6 0 J d II S fire 0 277m 7000 Top 9 5 6000 60 I 0 Q c c t j cc J w 0 c 40t10 40 a 2 a T J 3000 30 0 3...

Page 11: ...0 z 0 0 C 1 I w Q 0 0 0 J C 0 z 0 0 w z _ 0 ij J l 2 I Z 9 MODEl C 200 HONDA 90 9 16 5...

Page 12: ...gh tension cord I Horn button dirmlElr switch Y spiral ori l r Tail lamp r _ _ _ l R spiral on L n 6 0 h Stop V w y tOfrr 1 1 ClJ l T on B u I l c 0 H jj l rl J ail llW F _ Contact breaker Ko Condense...

Page 13: ...pport stand Plastic hammer 14 x 1Omm double head spanner Special Tools Piston ring remover 1Omm T handle socket wrench 14mm T handle socket wrench JNo 2d handle cross head drirver No 3 T handle cross...

Page 14: ...s for Engine Timing gear pullar Valve lifter Drive sprocket holder Clutch holder puller Clutch outer holder 16mm lock nut pin spanner Tappet adjusting socket wrench wrench ring remover Timing gear dri...

Page 15: ...ontrol Matenals are metiCUlously selected and high precision machining is applied under strict quality control to minim1ze friction toss from moving parts A quiet run ning engine also results from thi...

Page 16: ...wound up rnside the chain case 4 Loosen c utch wire and remove it from clutch lever 5 Remove inlet p1 pe from cylinder heod CAUTION When removing from engine be careful not to damage the inlet pipe 0...

Page 17: ..._ ____________3 1 E N G I N E____________ll Fig 3 2 Fig 3 3 Fig 3 4 Disconnecting leads Fig 3 5 Jointing drive chain...

Page 18: ...park p ug fitted Along w ith the cylinder the cylinder hea l and cylinder head cover are mounted on the crankcase at a 10 upward angle B Disassembling 1 Remove 8 mm nut and cap nut a 1d take off cy i...

Page 19: ...EAD 13 8mm Fig 3 7 Butlt in rocker arms Fig 3 8 Combustion chamber 8mm cap nut hexagon nuts f Cylinder head cover 11 x 2 O ring Exhaust push rod Fig 3 6 Fig 3 9 Sequence of lightening nuts for securin...

Page 20: ...also subjected to high temperatures preventing the formation of an oil fllm resulting in wear of tr e guide and valve stem The inlet valve is cooled by the gas air mixture entering the engine but it...

Page 21: ...AD 15 Exhaust Valve rocker Valve rocker arm sha Valve rocker arm shaft end bolt Fig 3 10 Fig 3 1l Rocker arm Heat treated steel Exhaust valve Heat treated steel 1 I Inlet valve fig 3 12 Valve Fig 3 l...

Page 22: ...e stroke causing the piston to slap against the cylinder and allowing oil up into the combustion chamber from the crankcase If the clearance is too small the formation of a lubricating oil film on the...

Page 23: ..._3 3 CYLINDER PISTON AND PISTON RING_________ 17 Cylinder 11 X 2 0 ring __ 7 5rrrn rubber packing J Top rmg Second ring Oil ring Fig 3 15 A Fig 3 15 B Cross section of piston ring Piston pin p o cl p...

Page 24: ...piston rings upside down An improperly fitted ring sometimes scrapes oil up into the combustion chamber instead of down into the crankcase b When fitting a new piston ring first check the clearance i...

Page 25: ...Removing piston ring Oil scraper 11 X 2 0 ring 7 5rrm rlilber packing Piston ring driver Piston Fig 3 18 Filting piston ring Fig 3 20 Checking fit piston ring Fig 3 19 Piston pin N Piston pin clip Fi...

Page 26: ...namo rotor with a dynamo rotor puller as shown in Fig 3 24 CAUTION Take care not to cause a shock to the crankshaft when removing dynamo rotor C Installing 1 Make sure the rotor is not dirty insert a...

Page 27: ..._____________3 4 LEFT CRANKCASE COVER__________ _ 21 dynamo stator L Crankcase cover Primary cord Contact breaker cover Fig 3 22 Fig 3 23 Removing AC dynamo Fig 3 24 Removing dri te sprocket...

Page 28: ...he left crankcase to the transmission main shaft Oil is also pumped through the transmission countershaft to the lower part of the right crankcase and the right crankcase cover From the right crankcas...

Page 29: ...____________ _ 3 4 LEFT CRANKCASE COVER___________23 O il pump Fig 3 27 Passage of lubricant Oil pump Oil Please color the passage with a color pencil etc Fig 3 25...

Page 30: ...utch The Honda 90 clutch is a wet multi plate type As shown in Fig 3 29 and Fig 3 30 the clutch outer case is located beneath the right crankcase cover The clutch is made up of clutch springs drive pl...

Page 31: ...OVER___________25 Drive Clutch center Oil gauge cover outer cover Oil filter plates cross screws Clutch friction Clutch lever Fig 3 28 Fig 3 29 Cross Section of clutch spring cover Clutch lifter Clutc...

Page 32: ...he c amper spring rs mounted as the drive plate cannot be depressed in this case E Assembling 1 Assemble clutch springs drive plate friction discs and clutch plates in clutch outer case and attach ret...

Page 33: ...________27 Oil gauge R Crankcase cover Fig 3 30 B Oil filter provided in clutch outer 16mm lock nut pin spanner holder Fig 3 31 Removing 16 mm lock nut outer cover il filter plates springs driven gear...

Page 34: ...e correct clearance when the dynamo rotor T mark matches the mark on the dynamo stator as in this position the valve lifter rides on the cam bose circle Do not try to adjust tappet clearance when the...

Page 35: ...ER___________29 rig 3 33 Goss view of camshaft assembled Tappet adjusting screw Inlet valve Inlet push rod _ Exhaust valve rocker arm Base circle Fig 3 34 Com Valve lifter Fig 3 35 Illustration of cam...

Page 36: ...t a so drives the oil pump check to see that it couples with the pump properly 3 Attach oil pipe 4 Assemble clutch as described in 3 5 D 5 Adjust topper clearance Refer to 3 9 AI I Shift Mechanism The...

Page 37: ...HT CRANKCASE COVER ___________ Fig 3 36 8 x 161Ml hexagon head bolt Gear shift shift drum Gear shift arm Fig 3 37 Punch marks Gear shift shaft Gear shift return spring Gear change pedal Fig 3 38 Shift...

Page 38: ...e diagram fig 3 41 The shift mechanism con be removed K Assembling 1 Assemble gear shift shaft in the reverse procedure from that described in 3 5 J 3 CAUTION When assembling check the movement of the...

Page 39: ..._3 5 RIGHT CRANKCASE COVER___________33 Fig 3 40 Removing gear shift spindle Fig 3 41 Checking the motions of three points after assembling gear shift spindle Primary driven gear ring Gear shift spind...

Page 40: ...ft shaft as described in 3 5 J 3 Remove dynamo stator and rotor as described 3 4 B 4 Place the crankcase with the left side down and separate the two sides by removing the 6 mm phillips screws ioining...

Page 41: ..._ __________3 6 CRANKSHAFT AND CONNEKTING ROD_________ 3 5 Fig 3 42 double head spanner Fig 3 43 Remov1ng tim ng gear Fig 3 44 Driving tining gear into position...

Page 42: ...freely and by action of the gear shift mechanism different pairs of gears are bound to the driven shaft obtaining different reduction ratios The Honda 90 utilizes a 4 speed constant mesh transmission...

Page 43: ...______________3 7 TRANSMISSION _____________37 Driven gear Driving gear A Reduction Rat1o s B Torque Rat1o A the numder of teeth B the number of teeth A Fig 3 45 Fig 3 47 Low Fig 3 46...

Page 44: ...ain shaft third gear is engaged with the countershaft third gear power transferred to the main shaft by the primary driven gear is transmitted by the main shaft third gear to the countershaft third ge...

Page 45: ..._____________3 7 TRANSMISSION ____________39 Fig 3 48 Second Fig 3 49 Third Fig 3 50 Top Fig 3 51 Neutral...

Page 46: ...t crankcase remove 6 mm phillips screws and remove drive sprocket as described in 3 4 D The main shaft countershaft and gear shift drum can be removed in one unit 4 Flatten the shift fork pin lock was...

Page 47: ...tchet guide spring Fig 3 52 Fig 3 53 Main shaft second gear Main shaft third gear Transmission countershaft I Cam gear Kick starter pinion_ I I ___ Primary driven gear Kick starter spindle __ c shaft...

Page 48: ...ed in the right crankcase and the oil pump and neu tral switch contact in the left crankcase C Assembling l P ace crankshaft assembly in left crankcase CAUTION New gaskets must be used each time the e...

Page 49: ...43 3 8 CRANKCASE _____________ Fig 3 56...

Page 50: ...ith tappet adjusting wrench and tappet lock wrench and adjust the clearance with the adjusting screw CAUTION The adjustment may be changed when tightening the adjusting nut so recheck the tappet clear...

Page 51: ...____________3 9 INSPECTIONS AND ADJUSTMENTS__________45 fig 3 58 Fig 3 59...

Page 52: ...too large Duration of ignition becomes too short and sparking func tion for high speeds is lowered Contact points must be replaced when the gop is Jess than 0 2 mm or more than 0 5 mm 6 Correct igniti...

Page 53: ...____________3 9 INSPECTIONS AND ADJUSTMENTS ___________47 Point file Fig 3 6 1 A Contact point file and oilstone Fig 3 62 Measuring ignition timing Fig 3 61 B Polishing contact point Fig 3 63...

Page 54: ...by the action of the screw spline on the CLUTCH CENTER GUIDE 1221 m the direction of arrow A The clutch is engaged and the engine crankshaft IS rotated Once started the engme turns at a low RPM the ce...

Page 55: ...lutch weight stopper ring 8 Clutch weight 19 lutch spring 17 Clutch damper spring 16 5 X 8mm phillips screw 14 Camplate l5 Clute outer 18 _ Clutch ever 13 Gear shifting spindle 12 Q kg m I Q I c l Clu...

Page 56: ...EVER I13 and the CAM PLATE I15 in the direction of arrow C and the clutch is disengaged The clutch can be disengaged by either upward or downward movement of the clutch lever as indicated by arrow D T...

Page 57: ...MEMO...

Page 58: ...The SEISI Press Tokyo Japan...

Reviews:

No comments

Brands by name

0 1 2 3 4 5 6 7 8 9 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

Popular brands

Load more brands