Honda C70 1980 Shop Manual Download Page 1

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Summary of Contents for C70 1980

Page 1: ...__ 15 O1 l D A SHOP MANUAL C70 I 1 I 555 FII35 5 53 7 3 E...

Page 2: ...nml amd u survive ninth Udl W l G l cuuld EBUII FEREONIL INJURY ISO rultl b fnnrlll I r Id during 5 ulhi q qr rgnpfgr 11 _mgu q_ F1845 I 1I 1d B1 lT B d III 17105 I mH1i gi Dquld mt cmrlr 51 oonnlivub...

Page 3: ...iatttinn 15 THDUE LESH DUTING Hater to the adctandum at the hank af the shop manual 1 0 infnrmatign un the IQ B2 ETD ALL H IFDHMATION ILLUSTRATICINS DI HECTIDHS AND SPECIFICATIONS IM CLUDED II I THIS...

Page 4: ...I Ill I ahI cI the tide cover The e tqing strriii nurr I qr is It1n1 J ad 0 1 IIIE IDWBF IEI1 crank LBJB The Vahictu Identification Humhlr it rm the 5 at My C err qriurt LnheIon1h Irarna s left tide T...

Page 5: ...m rtI m int H rF I IwIi1 I H 1 It in me starting In me of ccnnttct Hid I Imruu_ Itt t wt It mtrcr end t uI I III deem If nlarrraijtrre rel In your tI_t t i TM bdrf y gcnieretes hydmgm gar which curt I...

Page 6: ...sil E NG1NE I Tvu I Cyllndar arrarngamant Ema mu mc cu Displacement Curnpruslu n rs in Vim lrlln Maximum hu raapuvm Maximum mrqua Ull qDI it LI Jri Cllid 1 rtnm Air ltration Gqrllrlllr cnmpres nn Inta...

Page 7: ...uiti ptata aummatic nuntrihqai 3 spud mnillnt mI l I 4 053 1 521 3 1 1122 1 190 Ln r fnul Up f t re tun psram H 1 2 3 Fiywhaal rmqruam 0 3 0 4 n1n1i0 0I2 0 iII1 iniI 15 awn Sum an aruc at 3 1911 rum K...

Page 8: ...II r h 1 n J q IIIii _l mmmumuuuuuumm III F mnt tu m aignai a r 15 0 0 0 2 0 3 0 0 G 1 3 3 0 4 0 2 5 3 5 11 0 1 5 0 2 0 2 5 1 0 2 0 2 0 2 0 2 0 2 5 3 0 4 0 1 0 2 0 2 0 3 0 2 5 3 5 43 65 H 22 1 H 22 29...

Page 9: ...M21011 ablclrb ar an nrpraarur Hipplt manner 5 1 5 1 5 1 mm Valve spring cumpt t t Lm R nur wrench 20 11 2 1 mm 07401 0110300 07211 2 0010100 0l 2E1 00101111 D D 3 0UI 11 I1 02208 0030 1111 07215 002...

Page 10: ...__ 5 _M _ t__ __ I ___ _ __ _ H H H _F _1 Q E _U_ E T_ __ mm ___ x_ __ _ ___ ___ __H _______ G U K W W _ _ _ M _ __n_ fk _ in1 __ ___ I ___ g ___ i _ __UE Q 2 _____w L L_____ I 7 __I_ c __ _ I I 1 _ I...

Page 11: ...T_11 1 1 ll _ _ f_ _ _ ll 12 l 1 l r__ __ _ J _ H ___ Ill 1 r_ I 1 F H I I l i 1NE 3 5 If F 1 1 1 1 1 _ 1 1 c l 7 111 l 1 2 _____ _ _ _ l j US r Ii I 11 f _ I IGNITION 0011 1 i HI ll ll nIrII l1 r I 1...

Page 12: ...mi 12 1100 11 111 2 2 _ I A 1 _ 1 1 a CARBLIRFTDR lI Ii E SPEED I I I 3 10 EMS anw RELATEDT il I DRIVE CHAIN 1 1 15111 1 21111 g u_m1 1 11a 1 1 11 1 1 1 em ranrr _11 _11 i111f1 1 1 BRAKE SHOE I EAFl...

Page 13: ...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...

Page 14: ...__ u_k 1__iIJ_ My F5 11 _ J _ __ __ _ h mnq n L __ ___ v__ _ _____ _ HJ U i kx n V F _ J J _ J ___ ___m__ _________ __ _ ___ h__ _ ____ Ill _ _ I l F1 _ _ _ Rx ___ A gm J E P _ I __ miw E M E GM KK N...

Page 15: ...verage temperature In upur riI 1 rI ar e is wllhin the indicated range Hepnmmwndud nil l 5l UI IIHl T T T I i _ 1 l Ii I l 1I F _ I Ill _ _ Ill ll ll _q_ Tlp n ieernnpe Dil pump Bodv DI BBl Il lDlI En...

Page 16: ...ain 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...

Page 17: ...G Drain the cnglnn t HI l l lg 3 3 FIllI l1l JI E the right crunlti else crslrer page 2 El Flsr noun the lul h I6 lI il tam and GLIDE go var C111 en lhr trlutch outer cover entl II1ii rk pl the clutch...

Page 18: ...rme cover Image I 1 Flcmuw thu clutch us ambly nag H 21 Fl rrm u thu thrau pump am 5 an d nu pur p_ lN5PEl1TlDl l Fl muuu the pump h l y wr_ 4 _ CLEAHFF CDVFR FFlU T CUVEH __ __H_H H L Q _ I I I I 5 I...

Page 19: ...e SERVICE LIMIT I120 n1l l 0DB lnl Measure the lJ ll Jl and r l nn1nr u SERVICE LlMlT 0 12 r 1m lD DD5inl _ R I fir I D _ _ _ll ll l I l J 1 _ _ _ _ ___ Q ___ __ 1 T _ _ _ __ ___ ___ ___ __ __ Z __ _...

Page 20: ...l wt tjhtjul handing _ l ll JISTALLATICIN ln t _ ll lhn ull pump with the gtqliznl t n le 1 altgrtlng the pump drive shah with the aim in the cam chain guide aplntlln lnetatl the clutch asea mltlv lne...

Page 21: ...I I IJ i 2eitE Tlte cables and i hi lir vi i t paint with i Qorni iertlelltr eivaiiehle 1 al ila lubricant ADVANCEFI CAM OIL FELT THHDTTLE GFIIP E I StI i ii iGAFlM I EQQELQUMETER Pivot BUSHIHES 1 If...

Page 22: ...I Iowan cw e MEMU 20 Deteeflsseie Mai 1530 Ie JHEi rtirm M TUFi EU LTD...

Page 23: ...3 3 13 SEIWIEE II IFlllIlili TIUl l eemeeet INSTRUCTIONS n En glee erl Bee elite 1 1 I Engine nil Hirer sicreen 589 D ti 3 TDD LS Ccimmen iv W ndiumng wmMh_ B I Q mm g ggmjntm qr mmmpgiqiiy eueliiitil...

Page 24: ...0 etee at 2 900 rpm 1 500 i IUD r irn 12 5 1 i i 5 kgfmi ltttit zi psi 15 25mm I 5i B 1 in 20 il1mmI3 4 1Ii 4iri 2lIi EI l rnm 3 i il T1 iillnJ ___ __ __ Tire sire 2 25 1 ll P R Frqrlt _ L Up tn vehic...

Page 25: ...riot tmoo t Meaiulg thrnttle grip free plav at the throttle grip flange FREE PLAT I 5 i nm I ll 3 1Mii iI Adliuetment can tie r itai Ie itt either end of the thrnitlei ciehle Minor atliustmerrts nrie...

Page 26: ...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 Alli BLEIIIIIEII CIHBI1 the li lEl f l ii 1Ii by tapping It lightly h...

Page 27: ...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 apar...

Page 28: ...te 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 Pvcliust by lou...

Page 29: ...e other hm evidence u l heavy arcing u r are worn tit an angle the paint set thuuld he rnnlltbd Flcitete the crnnlcshaft uounttemiottlcvuitta and malt sure tluit maximum pnint gap is i_3_ _4 mm lD_ElI...

Page 30: ...the ignition tirnintt 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 pl...

Page 31: ...point muar 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...

Page 32: ...NDER 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...

Page 33: ...iile nuts Ind innlll I new cotter pin tonouei steeve NUT 4 0 e o tum tee as mill AXLE nut no E D iiiiii iii lee es ti ll l Tigjiti i the a i3 uetirii nuts Rent iei lc drive l i l3l slack iir ii l I i...

Page 34: ...e liviiirn chain on new strrttcitctl Both chain ii id apvoclte tii mutt hri in goo d condition or the replacement i J1aln or torookets will wear rluldlv NORMAL Luhirl i at e the drive i hiaii NHEUTID...

Page 35: ...tn u uupr r Irv al 1 d uni d itliTBd want Tap matar wll BAFERY HDLUEH PLATE hurtan the 12 mes I ll ul thu ba rlaI I The mmerv dn I rrHy l mnmtru mrjurnr arid Frurmrynur eye skin and r l Eu n In cu we...

Page 36: ...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 free pia v adjuitmant...

Page 37: ...le rnsw l nr1rr iIi w 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 HEADLI...

Page 38: ...tDi F i dlr engauirig _ 1 I 1 1 ADJUSTEH I 1 Sill STMIII Cheek the rubber pad for dewrloretim nr wear Ill ll _ _ l Hrii ece il env imiiiir exceeds tci the were line er i i t IWi NDTE r L ELE 5 i1 59_...

Page 39: ...paired Tightan all nuts end bcittt 713 1 L uhirIoireri the 5i 1Bt l15ii ll i li l l i pi r i1L ____ f 1 _ _ oeeriee ITTINGE HEAR Plan ee 1 iti ir yi liJ un i iupptilt hii raise thE fill wheel eff the...

Page 40: ...mr dserp ohlects Cher it the front end rear wheels for trueneu Meesum the tread depth at the oanter i if the tire Q R lfil rii the tiriu if the tread depth regal the following limit i MINIMUM THEAD l...

Page 41: ...T HONDA Qi cm _ MEMU _ r I I ljlqm nf lame May 1980 35 EIHDNDA MDTCIH 26 LTD_...

Page 42: ...FUEL 5 STEM Hanna Q 3 I cm K 1 0 _ 7j I 5 j O I _ _ T __ 1 _ _ 3 5 I I I I ___ _ _ If I W _ 4_0 no Dnlq 1 lmm M y _ 1BBl _ ETHCINEIA MOTDFE C O LTD E 0 a a...

Page 43: ...mrew n 1 l l u eni 1g TEA 1 26 1 Bn1rnI l l El Il IIIHI T Seepuge L II I i TRIIIIBLESIIIIIITIIIII En pin uranlu but won t run 1 No fuel In tank 2 No fuel to carburetor 3 Ertgi l IICIDGHBI I I i II l F...

Page 44: ...r 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 11I IFII lIr vol re out Hemmle The oarburutor rnc urlti...

Page 45: ...f ll I M JET NEEDLE NEEDLE our FI IIl I MID JETS FLICIAT F LCt T P I l 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...

Page 46: ...buoy om g with camera wed alr 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 iet...

Page 47: ...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 i the throttle valve bottom FLOAT LE...

Page 48: ...I ollre oe ble and on the ca ble clamp Perform the lullmvlrlg Ihepn lld s and arlgualrneltu Throttle operation ll age 3 3 E rI lre lr lr hltI te l tJ ng 3 III CHOKE CABLE I Carburetor Idle soeed loaq...

Page 49: ...w 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...

Page 50: ...above 2 000 I I E 5lIi i I lmtn ll s I535 main let an r i reridiuttlsiie speed RHH u the lri iunetiir irtaln the Iinqme sntl rrrni eve the flout I i1smi er Fliepisce the standard tnsin int with the hi...

Page 51: ...e 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 ltiipr up spilicdeesolrnr or I CI Remove the s eat_ Flrmmie the terew and hnlt tewrinq the fuel link rheii rente re...

Page 52: ...1 Ioeena ENGINE eEMovn _ nstni _At on C10 1 i I Ti 2 5 3 5 he n1 lI1B 1 5 ft lhl 5 O Date pl lawn MW 1QB IEIHUHDA MOTOR CD LTD i _ _...

Page 53: ...Tt It I lE I Ctutch I Gearshift linkage I Di ipomp I Cviinderhceci SPECIFICATIONS Engine tlr r wright Dil eapecit r TUFIGUE VALUES Engine hsnqtw IJDIT5 i nutpeg xid s stsnti arts I I y 1 I i r ri ur...

Page 54: ...ntoue the muffler mounting u1 l and remote e tite muffler assembler Dieoonneot the starter cable Sui port the tent 1 tale up right with a I iIBI ll2i Remove the footpegs tide ttenti sssembiy Linhoolt...

Page 55: ...vl 11 Ill l_g 3 5_5 ha ri 1l Ch li l ir uiI Q RIG Ham we the iaft aid 1 01 wr_ nngirll mrodkti C v r and Iuwar chain case If F fa H mmln ihe rn aster link EE3lf llTl rim ind IBF link 31 fhi drluc p1l2...

Page 56: ...uu chnlrl rnastlr iink main sum 1 hat the retaining clip open and 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 leua...

Page 57: ..._ r d _ HONna 1 _ cw J MEMO K 1 f J F I _ r 55 ats r f Issue M31 IHHH EIHD1 IDA MCITDH CD LTD...

Page 58: ...l 4 E 2 y I 0 9 1 2 kg m I Bit lb 1 1 a _ P Q F r I19 1 2k Bm _ I n Ii ll nu P I Qf1 lb W Z r Q1 f K Q 1 Z In J XI 1 _____ _ _ s R Q K _ l _ I15 I19 kg m H 1 E1 lb E 0 5 Data f Issue May 1930 HCIND I...

Page 59: ...m ms I 1 pm A 26 1 mm l1 I 1_2lE _ nI 25 59 mm I I CI I In_I Cami 1 1 Cam h eiqm K IN EX 6 1 _i 1 i I ___ _ _ ___ E i_7 iB e 1r11 II 5 I Ti 1 Dil I earlnc e IEII dc 1I I nm R x I 0r arm shaft 0 1 R0...

Page 60: ...rbon bt IId up an pluten head er u rltbusliurl Incorrect valve adiustrnent r I 1 eml er Burned or cent u I Eula DI _ gt rl l I I Tulve liilming 1 ltmtkmcr w _ __ diuumEm B I1 _ _ no En V W Em u 2 Stic...

Page 61: ...DI TUH1 12I1B rzcanlcshaft cnun tercI0cIn rir 0 in align the T lil Ii m1h the I11 Iex mark Rqtnnvr the l1 UI IIBI Rarn due the Fault plug HP Rerneue the cylinder hcn I I Ielt aide cover he removing th...

Page 62: ...let heed gasket and rrlnlugl pins IYLINDEII IEIIIII DISIISSEIIBLY Rnmuvl the I pllndat head right aide eeuer 00 I gasket Flume 1 the valve Inspection cape and D nnga CYLINDER IJCIWE CYLINDER HEAD CYLI...

Page 63: ...nq the um IOI0e 1 vvlth the cvllnder head cutcnts 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...

Page 64: ...t he r0l Iter arms fer damage wear ur clogecl all helet Manure the I D of the rueltar lr1 n 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 ROCKER ARM...

Page 65: ...urngl 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 IIIlZin...

Page 66: ...e I tam t puida daamnm STJUIIDA Fl D IN lJ II iII O 3 mrn ID IHID4 D iIl1ZIr1i EX Il D3D Iii UElJ mm IEi III12 D iII I1U i i EEFIVIGE LIMIT IN IJJB B l l lI1 l II ini EX IUmm iII DiiHir I If the iIEl...

Page 67: ...aw viii guide altar lnllnlltl I DH VALVE VALVE D7912 l G REi I I J u EFI TCID UIDE DRIVER VALVE GUIDE FIEAMEFI NOTE _ mas maanuou E43 QM 1 Uaa milling nil on 11 we reumar dur Ia1 1il 0 11 tlnn Flmnu m...

Page 68: ...and imnact the flee CAUTION I The 1 i h I l mrmm be I ruiinii If mr 1 a 1 ve_ 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 s...

Page 69: ...npt and retainers 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 mire t Tr l err Tap the vei...

Page 70: ...it 1 1 tr ease tnrrulwfl _aprecJt at installation 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 Illf illtl ands facing cut II il i l Ii...

Page 71: ...EIII ti IE i NOTE Be e ure to inst lii I I iIi sea l il1 Il l 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 iT E ft Hal Tighten tha t gt...

Page 72: ...s _ TEIHDUE 15 0 9 am 11 1n u l1P t ll I Hi tvllnchr hind lu ii da cmral aligning th T lng with tha uvlindar hand nut uh 111 tall the mu ier 1I lH thu spark plug cap Connect the lntaka pipq lillult H1...

Page 73: ...HONDA _ mu _ 3 I I 1 Ir If _ _ I_ M EMU I353 Q 5iUqI Muqr QHD 1 UHDP MUTUR CU LT D Tl...

Page 74: ...Fm Jig 3 BL___ ___ _ _ _i___ _______ __ _ 1 rd I F _ __ IIIIII _IIHHIII _ __ __ _ _ _I _ if f__ If ____ ____ ll _ _ ___ I __ _ ___ 5 _ _ I __ ____ __ L TWIHHIL I I Y C _ ______ __ _____ hp __ Q ii _ _...

Page 75: ...l l pin bore _ 11501 J3 mm 10 5119 El 51 TI IHI _E 1 1 1a12 _ t _ F _ F 1 9f 11 i 5i1i15 5 I Rig tg _ _ _t i up _ IIQQI 13 rnrn IIl511G U I IBI_nI P u pm 1 r n I IE _ _9 I 1 1 1 war 21 I5 1 E 9 i 1 1...

Page 76: ...ho D rir111 qaiI re and Iuw l mu_ CY Ll NDEFI INSPECTIUN Inspect the c Ilmtur burn rnr umar ur Ii m l u I Meat urn thn wlindar D at thraa laueli In III an cl 1 mcia STANDARD 41005 4 u1 s rnrn 1 II5BB...

Page 77: ...we olaarar STAN DAFID 0 0 l I 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 p...

Page 78: ...T 0 15 rnrn I I BMl I 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 _ Ramoua 1 h Iu It r lI I nB IT 3 fI I Measure tI1...

Page 79: ...II1IJ InI PISTON FIING INSTALLATION lr 11 I the pinnn rinqa mm we marilinei hr na 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 sa...

Page 80: ...gap w th the plslitm 1 uI nut_ I iI IIIIIEl I lI ISTll LlII il II II151 ill 1 I E 1 ILl IE I pa l Cl ring and gitiqqt Apolv a thin coat of engine oil to the I 1 1 r ring and cylinder wall I rutail ll...

Page 81: ...ler and 1I _1h1 r ml guide loller pin TORQUE LI 5 l 4 liq rrl IE 5 III It IIII H Loosely install the El mm belt Q ins tell the 1 1 Ii rIer hes 1 Section Bl I 1 Ul _ I In G E F f _ Ir I F Date of Iii...

Page 82: ...r _ C70 3 8 4 5 kg m __ l E __ _ ___k _ at J ______ I E ___ _ II _ 21 K _ l 3 _ _ 1 I M ___ _ _ H f _t 1 1 II Qllli tee 33 Ia I Q 9 Q 0 I B0 BO Dateof lesue I I egr 1950 E 1H Ililn Motoa 1313 LTD F h...

Page 83: ...ivillihla hand alrap wrench UTTIB LKIEDIDD ClTI IEi IIIEDEDO Commercially available 3 8 I 5 Itg n1 I23 33 I1 lhl ITE M Clutch Spring free length I STANDARD 15 DB r rrl IELSH inl _ EFI ICE LIIIIHT _ E...

Page 84: ...Itmgu 1 El CLLITIQI l LIFTER HEMUVAL F IE I1tJt E 1l E Elutth l lI urIr I clu1t l odiutting bull CLIITCII IIIEIIIIWIL llnmv Mr the rlutch luwr and clutch r In Hemoue the elutch outer co tar ASSEMH I L...

Page 85: ...hnr The clutch can nnw ho rumuvud as a n ll 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...

Page 86: ...mlI IIJBBT inl SEHVHZE LIHIT 23 1 ml l l DB1 In _F__ ____ J _ ___ _ _ H I _ 1 Jr _ CLUTCH DISC INSPECTION Heptace ma ulurch diam if lh 5 9 ghnw 4 4 U4 Btclrinq or cilrnulorannn Maaaura mu din Ihicknn...

Page 87: ...GEAR INSPECTIUN L Bhar lr for waar nr damage Mtri ule the r iwe gur D QTANDAHD 2 l 0 0 21 D 1 mm tunes o n2t ml P SERVICE LIMIT 21 5 nun IDJZE lrll CLUTCH CENTER GUIDE INSPECTION rih k ill WEI U1 1 s...

Page 88: ...rlng j Q _ __ 1 r _ I CLUTCH IJFINE PLATE THING FRICTION DISC A PLATE B I____I3ITE H u EH DUTEI LuTGr SE E I ems I I I L H J _ Fl 3 Gilt K Y _ _ BLUTBII NSTlI l TI II I FI FIEIII I lE lul h Hunter qui...

Page 89: ...adjultl g belt end llftut 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 qrqnlum...

Page 90: ...W L T W H 5 H A E G _ D 0 _ T ____ H _ ______ _ Hm____ V _ f _____r _ x _ m _ _ X X J M 3 _ __ _ _ __U_ X A __ _ _____ __ _____ if _ J W mm aw __ ___ HI INNER I Q _H_HN _I n____ w 9 D T E mu HE _H Wm...

Page 91: ...um ar rl transit Iie ir I i require serr lr ing_ ren rcr re the engine arid r eperete thr llrnttitri l 9 B 2 ___ r _ r TiI lI IBLESIl I lTlNI i Herd lhiitinu 1 ll npmc er clutch ndiuett eltl IL Shift...

Page 92: ...l Remeve the gearshift 3I_ wmhl r i5E liur1 Bi R nmle the right trranlrtqasrr Queer and r utrrri 35 B I H I Fl lO lr E the snap rln 5 end driven gear I Remove the drum stepper arm r __ SNAP RING ii Ii...

Page 93: ...1I III drum pine iI l li I drum rtElDDIlT Pi ie irretmi the gearshift spindle areemblrr GEARGHIFT OFIUIII STOPPER ARM Install the drum atnnper arm as shown Q11 Tighten the pirrnt heir Fietate the gear...

Page 94: ...AFT C70 I r _ 3 2 El r if i E _1 _ r 1 1 0 1 11 kgm T 1 f t lhl V 5 is in 1 K 1 ii ll in 1 I I i ____ _ q__ ___ _5_j q_ x 1 _ 1 I 1 I T I QQ i IrI d 1 H n 2 4 I 9 J 1 _ J 4 I 0 _ 1 U O 92 um IHLIEII H...

Page 95: ...915 _ _ sum rm 1 1 34 11615 54 1125 11 51 1111 1 pawl Lm 413 4 11 11 1 n m I 111 1111 ass 5 91 mm C1 anI 1 I1 Connuct ilng rod big i m I T _ side dgmmm CLID I135 mm f Currnnctirlg rad big end _ fadm q...

Page 96: ...m 4 5I 1If 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 l llZI Ill 1 EJ 1 e Iii H crrrnl c...

Page 97: ...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 l ti ti...

Page 98: ...t n d or u bioolu E at I diel Indioetur as ehowr1 FIIII rite the crankshaft two rwoiutinns end reed the r1 Irrr n 1t Actual runeut I 11 of Tut II Ir dleatnr Reading SERVICE LIMIT D 1 mm D IIII l InI I...

Page 99: ...I115 mm IIJDJIIE iI lI r _ I 5pi1 thejournal trearinq try hund and rlmleoe it If noisy Cheek the 1o rr et heeriou pdey ii I I __ _ __ ER uI ICE LIMIT AXIAL e rrr rrtrn mum 1 1 1 1 5 e n om1 I one mm...

Page 100: ...he 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 II r an rl r l sa rI mI1le l I e Itiels i l l IE1 L12 II1 I...

Page 101: ...rI3 mm IIJ IBB5 D B7 ID inl SERVICE LIMIT 11 10 mtn IU B I3InI I 1g 1 rp II l O D rI 1111 miinillkll l d counter ahaft KTANO ARO1 MAINSHAFTI 1E B3 I B B9lI mm ID EBBB IJ II IH1 inl DOUHTERSHAFT 1 9i...

Page 102: ...k 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 1eeee InI SERVICE LIMIT 311 0 mm H 341 InI Memun the shift Itj rIt Ellw I1...

Page 103: ...HIRD Lubncate ear h gear_ i h_ Film all a er I I X asnumhly MP INSHAFT EECDND GEAR THIRD GEAR SHIFT DRUM ASSEMBLY GDUHTERSHAFT Fl FIST GEAR GEAR Assemble the malnihrft and uuumerlhift qairi and If I L...

Page 104: ...ntltn the milrreh all 111 In ll yure that the gear rntata freely Instill the tuck l EH lI spindle in that the frltrtiun sprlnq mete in the nunhnuu grvcwc 1 HICK F Fl I4 HT_EFl SFINDLE S_ FRICTION SPRI...

Page 105: ...cup _ ln a l ha l lr l titlu 5 Il tn Clt l TORQUE 1 1 1 l l cg m 1Dl t Fh ____ _ I _ __ _ ___ Eh CAM CHAIN TE HSIDN lnitell the ttielt starter 5p ring lr tl rtt lrlcr Hunk the 5p In t1 end n the rete...

Page 106: ...HONnnff cm MEMO _ 1 H t F _ L ma Date of Italic M Iv 1 lBl J D HONDA MUTCIFI C 13 LTD...

Page 107: ...AIN TENSIONEFI 11 3 SERVICE IHFIIIIIMTIIJN G ENE HAL FNETHUCTION 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 Elm uhlin bltl 1 In cu r...

Page 108: ...LING BO LT 32 5 _ _I II rIII It i__ 1 __ 53 I t I r 1 1 _ _ n l i LOOK NUT __ E K ll _ I I F I 1 L 1 _ _ Illt I _ _ _ __ _H_ I II I ll l 3 tag W 1 f l _t l I _ In xi 9 LQCK f H F 1 _ _ _ _ I _ _ _ I J...

Page 109: ...d 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 l i BI DI l...

Page 110: ...In Ite _ Kl I bl I _ 1 It Y E E il 3 G Q B 5 G2 _ _____ _ ll I I 111 6 0 9 0 Item 5 I43 as ft lbl 1 _ Hr _ ___ Q II I I I _ _ I gt h I _H F I F 11 J Hd_ _ _ __ _ _ I_ _ F er __r 4 7 I O 7 1 I 51 t 2...

Page 111: ...A DTTJB IIIIDBEIJ EITQ 45 51104110 Bearinq driver outer 31 it 35 mm DTHB DIJIDICIJ _ g 5_g3 mm Bearing dtluer pilclt TU mm 01715 0010100 Le elt nut wrench 25 rt 30 mm 01110 B33525 EJ p11 I e _ _15_r_...

Page 112: ...1 11 1175 Irtll 11 51 mm Inl 12 4l rnrn 10 11 HE inl I TIIIIIIBLESIIIIIITIIIE Herd te rIn 1 Bi l ri rn bearing aeliuetinu nut run tight 1 FlLlI1 eteurlntt ITEII1 beer inns 3 Damaged tteer I tr Hem bg...

Page 113: ...SS E M B L r SS E M B LY 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 disasaem...

Page 114: ...l I 7 Bl10l IE E lhl t1u uni mete and Irtr It it0r bulb 1 DC l l1Et ttt rs Ffnm nus the 5pEEdu 1 1 r SPEEDUMETEH CABLE SE I IING EFHING Rum M bum BPEEEFOMETEFI Ll l IT HIGH BEAM INCIIEJATDH NOTE If 1...

Page 115: ...___ _ I I FIBFHC Ihe Il r I g 1 l L ir crtnn ttt the eed0It1e r mt i I I FM r r 1 the I pr 1 i r I l2IIEI iIl EW i II l r 1t ur t g 1 tCFI l l TH RUTTLL CABLE END D15 cu nnF 1 the TI l I IIIE liib E t...

Page 116: ...t1 1 FI 1 Jr tI l HIH1I I 3I iFrBI l lI I g IHISTALIATIUN 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 I r...

Page 117: ...THFICIITT LE CABLE El IIJ I r I IF ___ Jan FlecE55 F ft lG tItt I1 w 1t Idlllj I I t 1 Ptllgu I t _ hn t I u r g r_ r g n 1 Il t i1_JII thrt nw tljh F _I IQ 3 I urIt I uur I1tt 1 tI I I 1t I lI1 hr_ _...

Page 118: ...1 tlq nut Remove the tmnt axle Hen nun the rnr t wheel WHEEL BEARING INSPECTION Cheek u n uI lgturlng play by planing the wh unl in a truing mnu and eplnnlnq the wheat by hantt FIIrEpIi j the bearing...

Page 119: ...r Ia I11 petition li luru lnlttulllng the Inf Haring ___ __ Z_ Dtlue In the left hearing I I I Met E _ it Drlva thlr blaring aql ll ll _ 1 Drlva the bearing intn ltlttaitlun l lII Il l Ii ll ehm I1 1...

Page 120: ...an _ _ ___ d__ fl I 1 _ xi I BHAK E DRUM I D INSPECTION Measure the hralte drum imicle diameter SERVICE LIMIT III mm MA I 111 h ___ i _ __ _ _r l 1 ii inn I I 1 at T v E r_ i l I BHAKE LINING THICKNE5...

Page 121: ...il l 5 I I _ I I I BRAKE cram l It 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 l l ll 1l1I T qaar lrletall the seel SPEEDUNIE...

Page 122: ...In Izatad in the qrm aw at mg huh Vi _ l ltnll the a ela shaft In um lhq right aid Tighten Ihu me rIu r TDHDUE 3 D I B ill I ll 12 2B H IH l il lf I new cotter pin Burma ct the frunt hraka an cl Lp c1...

Page 123: ..._ _ r r i w f i T F5 0 I F _ ____ 1 _ _ _ Ii 1 I _ lI _ l Fl emu an Wm dust cum and dilamrmhlc the usbE i F DUST SEAL 5 BUSHING must CAPS I W P w j I Q6 ausnuw 1 GREASE FITTI SUSPENSION ARM N _i i ti...

Page 124: ...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 rn...

Page 125: ...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 ne ouwu STDPFER 1 F I...

Page 126: ...nvr i n Iu1 Flernrrve the f J 1I 1 r i1_ Flem m I 1r fr mt u J er em er 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 REr1 r t...

Page 127: ...ut 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...

Page 128: ...he 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...

Page 129: ...nttuil lllu handlebar lewtrr never mp nr r Igu meunt _ _ t t tt_ T r I HEHCH_ 26 t it rnrn are LI tep Itrit I r r HM Tightull the eteurrnu stem nut TORQUE H D 9 0 kl I11 il3 B E H lb III In 1e II 1 u...

Page 130: ...129 36 ft lb _ ___ __ I 11 931 I t El ___ It Zr A ili _ if tr 3 er F i I I 1 _ Pm _ Ii 1 _ P _ A I I 1 t Tr 1 0 2 0 he in IN J K li t lift lbl L I 3 0 4 0 ltg m I22 H ft lh I 1 1 3 0 m Date er Issue...

Page 131: ...u SFECIFIEATIUNE U T4B IIJIIIIIDD D 91B EIIIIDCIIIU D B45 DQBENFUU 3 l t1 I I T _ urerreenntrocrtr 40 n1n U B DQ407300 0774518940100 01955 31 9DClI 1 1 r r 2 r r rt 1 t zr 1 rt rtrr tr e tr Hg l t2e _...

Page 132: ...r rr r tJt 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 JL...

Page 133: ...adjuaaing 1 ul _ 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 AXLE N5FECTTU N 5513 li 1 5 33 4 in 1 l LhG5 S i1 1 IEIU l m l r _ r 4 _1L_...

Page 134: ...THE lL lJ q In 1 _ _ _ _ _ _ __ I BEARING DRIVER HANDLE A El493f 1D UD I1ri 0 i 1 I ght hi r 1g B E 5 F NG DH I EH UUTEH 3 3 mm L 9i5_C H_Du_D Pnm 111 r t st i l e cellar I 1 J alum HE u H N D DRIVER...

Page 135: ..._ I 1 1 _ x__ _ g _ an nm4_ RIJNDLIT 2 DI1 n1 U B II l1 3 _ _f u r an mm muainr 3 _ H I fsi I i H 1 1 I TI DNv1F EFl FIUBBEFI INSPECTION Heplann l 11e 1 1pu l luhlrri If they ME d mi QB d DI d ewri r...

Page 136: ...KE CAM BHHKE ARM Remuus the brake arm and Indicator 1lnt Fiumuw Eh brake 5i1lIlE i and brake cam INDICA PLATE 5 Uni grim tr thn iii iin I mrfam oi the brake I am il1E1 l I i ihu brake shoes and shoe I...

Page 137: ...ltg In IT 1iI 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...

Page 138: ...8 eh ain and drive sprocket in aes III NOTE REPLACEMENT 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...

Page 139: ...sottetew until it seats fulltr Install the seal BEARING I2lFIl II EFl BEARING DRIVER PILOT 1 mm INSTALLATION Install the drttren NOTE tlenge and Ilenge sleeve in Ally the Ilttu on the llct I v II tl...

Page 140: ...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 SPRING FREE LENGTH INSPECTION Measure the tnrI tgI tree...

Page 141: ...STCJPPEH RUBBER III LCIWEH M0ur T J i Agpiy 3l ci 1l agent m1he1 ck nut and initall It Tighten thzrlnck nut _ r u 1_ I J_ 3 swocx ABSORBER if COMPRESSOR H INBTP LLAT1DN Tight an thn shack absorber bul...

Page 142: ...if u Bn ar r DrFUEt 1B bushing l T r 1111 with n iu hlmm q MUTE I M3115 ILITI T115 I Eh 1211 llhlngi qr1 nu j3 1 5q L J 1 1lpB T the 1 n gultln fur wuar INSTALLATIUN Insult mu swlngarm ltd pl rn1 bul...

Page 143: ...I Iuntna A 1 C70 1 MEMO If pk F 1 1 I Dare of Issuer H Mr 1933 1 QQJHDHD 1 MDTUR 1 13 TD...

Page 144: ..._ _ __ 1 I l _ I I I E _ 5 _ IGNITION r ___ I 2 I 1 I t 1 11 nm ren r __ 1 IGNITION con A _ GENERATOR Q 1 __ 1 swncn _ _ _ Z I 4 1 f _ 2 gt if Ir f 1 I _ H _ _ __ II _ _ l H 1 Ill III II II I L I 1 I...

Page 145: ...prtrmna 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 ba eqv expeefalfy w I Fl e charging All churning 5 g i1lIl 1 l uamrrunlrntt can be tmud nn rhu r...

Page 146: ...g wttew I 1iIL r1 2 Lu use hatter ennneqiun Lu w power engine running 1 I l nttnrv under l nr ged LD Wf1L I I I vel D119 ur rnq re in ggd Q3 llg 2 Chm ging system f BIII Intermittent power 1 Lee we Ii...

Page 147: ...ahuwn In the table H9919 II hattvrv II ml Itir n is evident cu I TI I SEIGCIEIC r ivi l uariui with g 1 T pu a 1 I I 1 517535 5 9 1 I 1 DB DI E IE il Iillud with HYDHDl l 1I TEH ELECTHULYTE l wrtiment...

Page 148: ...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 tE I I I 1lI I BII with oiean gra eea before oon nu...

Page 149: ...v u r wm h J l u at the ll Il j IELQ Fler nova the left t ar ltcasa cover LEFT CHQNKCASE CDVEFI UFIIVE SPHDCKET COVER F lnrn wt lite twu tvto tent vv _ Wite prGliI IC1IfII il ll nttttu Ir 1 1 n I tf1...

Page 150: ...neiatar 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 9...

Page 151: ...i r the gnr er ttor IF lGI i orooorit Connect thu I IULJI III 1 vit h load lretali the iett ci iii tizese c ova riiive apioeltet oovar if and qE I iI1I I 1 oeclal Corlhect the gttoerator wire t r tu...

Page 152: ...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 1 r n rnntifler r there Is on1 nu...

Page 153: ...1 F __ F _ I F F1 F r F Haw GYLINDEHIFISTDN MEMCI Date of I55 us Maw 1580 T51 vi HONDA MOTOR CU LTD...

Page 154: ...__ n _ _ F _ _ __ I I 1 I I I L _ 2 _ I _ R I RF _ ____ RI i I 31 2 E hu av ___ r Tux SILICON n F I l 4 1 I J nsc rsnen I _ _ __IGHlTlCIN COIL _ 1 ll III III G GEHERIITDH __ l_ _ 2 4 IQ I I III 1 III...

Page 155: ...a rs can rcaansl I 0 6 0 1 mm 10 024 u u2a mi U211 FE P 2 L5 ETD E 9 _ BT92 2 1v9 a_m I i N_ __ ____i 13 3 0 mm i r lJI2 0 016 inl TIIIIIIBLESIIIIIITIIIII Eriuinu wank but will not nan 1 Enginu atnp l...

Page 156: ...ITT 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 H I 1 E5 9 35 H3 PRIMARY 1 35 1 a51 t_ wt HT T I E 5 I I I L __ J L I _ i E _ NI FI R I Continu...

Page 157: ...the ooneinmer In grouncling itn tlirmirlki I _ F _1 iH3 I lE I I115 IHl iII Ii F ea5u r rhn condenser eapalsity with a iehter T CAPACITY u a2 on F E 1 _ ii 1 in IuE oi spuoificqtirsir iepiaee ihe crm...

Page 158: ...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 1ce...

Page 159: ...Iii I1 ruse ILIA nee OP D neo 0 IGNITION SWITCH BLACK F I I l Tl 7 STARTER _ _L _I_ FIELAY L 5T n i rTEFl MOTDH I _ YELLDwmED LIOHT GHEEN hED r IIIIIOI I atIIIIII Iil i IOI l 5 Z NEUTRAL TIIIIIIBLESII...

Page 160: ...litrre LI i i LI IICI I I II snap ring_ DI w r I1r r 1 1 the starter sable at the starter motor I1ElI l 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 5P MP RING...

Page 161: ...E ___ FI i pri I tl iii Ini i i1it iii IIFILI i ii I 1IJEI 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 _...

Page 162: ...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 swm u 1 11 starter motor AI n mu LE5 nulnh with...

Page 163: ...ct i Ei 4 D l IE I r u 1 Ir Il llf h win Ir 1111 TH I I1 I 1r rn I II II1n I l1lIlI1 IfllJI1l STIIIIITER LI TBI f I RI l E EIIHIII HEMDUAL Ffnmuulr Ih Q AL Qarml at Jr rntur I5 artiun I41 FIIE 1 1I m...

Page 164: ...r Itlr I Ir r Iva wunr 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 jg STAHTEH CLUTCH ASSEMBLY...

Page 165: ...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...

Page 166: ...h Igai hrukg wiritch 3I lE E I1 r ri ntinuitv with the ioar built uppiiq i i Brain lppliad Continuity Brlitl not opp Iinlt No corrtinuitlf R lucc thc iw i1ch ii ricccssarah E3 Bl LEAD G LEAD NEIITRAL...

Page 167: ...th B I HEADLIGHT HI LOW SWITCH HI Bu I i I DDLE INI1 Ii toBtn I L D I toI TURN SIGNAL SWITCH LE FT O to GI QFF No continuity FIIGI IT LB to Gr HORN BUTTON LG tn I3 with button dlprnnd No continuity wi...

Page 168: ...ch o F _ IfT Ii I i 1 _ nuiiii tin ___ I oiorcocie N BItNt I G IIIIIITIIIII SIIIITBII FIltl1 I Il lE tlic II I 1I llt1 E1 E II I IiIi i r i c Ihn r 1 i lci Chock thc I onti i oi ii rmin ii i ir 1 I IF...

Page 169: ...NCE AT IDLE AND LOW SPEED POOR HIGH SPEED PERFORMANCE SMOKING EXHAUST FAULTY CLUTCH Date of Issue May IHSIII IE 1 8 1 HONDA MOTOR CO LTO 13 2 1B 3 IB 4 I3 Ii 13 5 I3 S DIFFICULT SHIFTIN G ENGINE NOISE...

Page 170: ...ged htul yelyn Clogged Iuel tenit oep breeriinr hniri Faulty ot fouled plug Fouled burnt nr pitted cttntoet brceitor It ointt II i t Jri t t I hru kqr putnt gap Faulty condenser t Brolterl or thnttecl...

Page 171: ...LERATE WITH e III ENGINE SPEED RAISED IEI ENGINE FEED DOES NOTA1 III INCREASE IE rzti I ti IBI INDIIJFIFIECT tir t rioA III rti INCORRECT VALVEO III CLEARANCE III LOSS OF COMFRESSIONih I II III I5 I t...

Page 172: ...ennnnce i ti rnooenectur no ius reo in rzi me tear zei in In ctr iai to wane on irrrennrrren ri r1i WARN El SI I II Lenrel too low or high Co nur nineter i t iI Cboygnd oil has sage Poor nil pump deii...

Page 173: ...THIN EIl l lA l5T EMITTED l5 2 Flururn thru le grlpl qul cklv WHlT E SNIUKE EHI l TElIli1I lll 2 ND WHITE BJDKE EMITTED T 3 Hun motoruvulu a lung WHITE SHI DICE EMlT l ED l I I1 rll 1nn e ul lnw spa...

Page 174: ...n tlfl g Ehiil Bhrit lrrtlrfurrinq with tare tr r cmiur Bent shifting near or we rn i1r H lurk Br lr H ur weirir entrl shift rlrurrr stopper spnnu PCi35l B L E CA USE VALVE H l i in Hi PISTON SLAP Bi...

Page 175: ...r it wheel nut alignncl Hem fr nt I rl ur wring m FOESIH LE CAUSE SOFT FIlDE i m III Iii met FHIJE Cir lri III NOISE IN SHOCK ABSOFIEEHE ill El Weak Ill lT 5 Excessive lead Feultv ire l f rlt Fgultv r...

Page 176: ...___ r 8_m_m E ___ __ UH_N I I W VD_ WWIUAT _ I I w n N EI ELJHTQ W WU P __ _H D IL H WWA _ _ __ 0 I O D _HT_T_ _ _ _ _ _ __ _ ___ Yw W K I I ll I aF N _m D_Jm _ _ WU V _ I _ wv_q__M _ _s_ v 5 5 ___un_...

Page 177: ...OTICE AND WITHOUT INCURRING ANT OBLIGATION WHATEVER NO PART OF THIS PUBLICATION MAY B E FIE F ROOUOED WITHOUT WRITTEN HONDA MOTOR 60 LTD Surwricl PuI IIiu I In I1 Office CONTENTS I GENERAL INFORMATION...

Page 178: ...n IJ E Iltun IIILB5 U5 III 0 71 Imp I t r after disasawmbly I I5 ETDC I15 ABDE 22 5 BBDC 2 5 ATDC 20 I cu 1 4 1 IIIII lt I U5mmIiIt CAFI BU R ETION Curt I I unLiI I atInn nunmer PEIEA ELECTRICAL I 1iI...

Page 179: ...ne hunger I all Hear ixle 5IEE r1U I Rear brake tn r1 ue IInI I Ree II1I II II ebs1 IrI I er Swlngerm ni m1 hr I Fmnt epspeneran pw I It hull Frcmt I II II Ic absorber upper IJCIII R Torque I Thread I...

Page 180: ...1 I i__ _ g_ I II TI TTl E I_ THROTTLE mete mlueenuess _ pr E I__ I _ __ I I _H II I I I I l I I I I I In NI III 1 I JII1 IIIAIH HARNESS II _ _ I 1 i _ _ I H I __ __ F r II 1 LII L _ 4 1 _ L_i_If J A...

Page 181: ...1 200 mi I2 000_IIII II I I 2 2 _ _ I I I CAREIURETOR IDLE SPEED I I _ 3 ID I I IIIR l II N E I El I3 U F THII BFI_T_ _l E R III0I I rH I Lweexiwm I _ I _ I0 10 I F _R_R_IIIII I E SHO E WE IR D I 335...

Page 182: ...ear ihe qu I r Ian1 l hl E drllnin Q lunl Ham we the fuel Iiltar bah and uuli nut I h fuel Illlzr and D rings Walh the fuel fill I In Ciearl rlnn llamrnnhhe or high I 1 sh T l l nt ml runt HI lI1Lta I...

Page 183: ...ll r lr K C1I r llll IILEIIIER 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 FI nu the t w...

Page 184: ...i 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 Fa...

Page 185: ...breather tuba in ea nneratad tn the hetllry hrna iar r n I Il 1 ell aw as shown I II FIIEL SYSTEM SPEEIFICATIUNS EMITIIIN l INSERT THE BITT BRERTHEN TUBE SEEURELY UN 5l_IT_5 l Below I 500 m Above 2 00...

Page 186: ...stop soi ew WDTE Iitiri atl strnnn1 Til I IJE l lJLIl a l I l1 IIIIITUGIJ 0 E l I iJY1 I i high altitude Cl ClE l I ll Jll 7 iI IC1 i l l 1 F il 4 I PII r Emrrsinn Crtntrri I l loiin r iJi i Lliirilnt...

Page 187: ...nrnl i ET with I M I d h rn urlt Humutu thu nzamthah anruttkst Remuuu thn t rl nt l r I12 ad lpaqe 5 11 l N5TF L TiUN lr ta l the wlirtdut hunt atsmtl hltr P6913 E 131 Hlmgvq the narrr qhuln Lemlu rte...

Page 188: ...rm tan as mar _ ____ _ __L I 1 E H It AHD SERVICE LIMIT N lanqm I 15 I mrrl I175 in I15 mm 10 39 in it Q t I I J G I T _ E _ 1 _ 3 5 4 5 it __ I I 1 ____ r__r___ _ _ In Q _ _ __ _ j T wt I ll I t _ I...

Page 189: ...UTCH 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 iJ IIern _ if J DAMPER SPRING Install the eluteh damper spring scnew en GEAR CLUTCH c...

Page 190: ...l PIISI I IIIIII eerttewtl Dfiillfl the Engine i FIE rI II 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 ptti...

Page 191: ...tenein er Cite t It the tenunner S FIrUCIt 1 ler wear or _ damage TEIISIIIIEI I II I I IIIII INSTALLATION D RING HJLT AM lnltali the earn chain tenslunhr malt 1 D rings un the i renItehi It I Itwet 3...

Page 192: ...titer ltI alae with the retrurnrnettctett tel Ittaea 2D Ii 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...

Page 193: ...I l rta 25 rt ntl _ tI e t 2tt E I I _ 1 lit I I FQE _ _ _ _ t _ _ F I 111 3 0 kg In t 52 F glgi II 3 jw _ I at __ It I an 2 5 mug H _ I IIH IB It lh I A I SFHIIIIG FREE LENGTH G I73 4 rnttt IEJ3 InI...

Page 194: ...____l_ FU _ E___ _ t __u__L_ I 1 1 t e _ _ _____ ___ l i FL ____ __ _ ____ t Qjghit ItI5 I ll _ tit 1 5 E Ii _ Lt t I It t _4 I I It t t t _ _ ____ J _ sttrcette RECTIFIER I ii Iq I _ _ t t J__ we ll...

Page 195: ...eta tnr IIlt1 BI I II I ItI IP e hlf I Bit l 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 LEF...

Page 196: ...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_ nmcwu the utor STA LEFT FLYWHEEL HDLDEH SCREWS D L 5 G84 UDOU bind strip h...

Page 197: ...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 Ll C l l l1 1 1l tn l1 lllrq swltch lal L lIl I l...

Page 198: ..._ I __ __ _ _ _ I _ l _n I I _ f F I I 5 I 1 _ l 3 _ _ _ H y___ _ _ SPAFIK PLUG ll C GE HE H ATDR IGl lIIIT1DN SWITCH E1 lix GITER CD1 L SPARK cu I i _ _ G 1 1 lGl l Tl H CDIL T T T GENERATOR I FULE E...

Page 199: ...Between ptllee gerterator and CD uml 3 Fi l V tQl ll l l1 C III 4 Fnul1 qI EDI unit 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 ttJt...

Page 200: ...tu pl lTl iI nnn til ll R l sect nder znll ll t all I i l F Ill I ll PHIMRHT U 2 5 3 Dl Ir1 fa Iw i t n hr_ range __h 5ECO ll DlFl t l 3 11 11 2 K l lltl l ___ Qt ___ 1 I REDIBGE F EI C ll I1 11 rel s...

Page 201: ...H SK EXT Fruh I _ mm aw ettt I IGH sw I DICI EXT 01 20 LIL PC 4EI IUD 2 IJ B IIIEII I E I 51 Ill Z0 l 5 I t_lJ L EIBITEII IIOI PULSE GEIIElIlTI ll J5 INSPECTION Ffltmteele ihe frunt t t rt tt r Die el...

Page 202: ...he 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 rem llt the meter stenten cent ___...

Page 203: ...I IHZlllB 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 preswr...

Page 204: ...i hreether tube Faulty tpitrlc l ug Fouled spark plug Faults CDI un Brerften er shorted high tension wire Faulty AC generator Elrrlllt rt tlrir thrtrted ignitirgt n cull Faulty pulse generator Fr el...

Page 205: ...OT lNl IFIEA SED 5 UFFIBIEHTLY m oHHEo1 _ iHE R Em 1 on Low ii _ BLDGGED FDLILEDDH DISGULDHED ou DIL LEVEL IHUUFIFIECT Ep AL E THMN NOT LUBHIGETED PHDFEHLY oi EH E r rE E Punt mrutl lir Fl u l 5r tin...

Page 206: ...E AT HIGH SPEEDS WEAK _ 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 adv...

Page 207: ...3 _ 1I J r _ _ UH K _ _ Q _ _ _ Q__ _ _ m _ 1 E M A R G M D G m m W Rm 1 N E avg S__ kW _ ma a ___E HE _ A iI N I mm II I HM I Q F_ _ 23 _ C 15 55_ __ E l_w__5__ G __ ____m ___U ___ gm WEE ___ A magma...

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Honda C70 1980, Shop Manual

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