Honda CM 185T 1981 Manual Download

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STEERING/FRONT WHEEL/FRONT SUSPENSION

• S T E E R I N G S T E M A S S E M B L Y

Install the steel balls, the cone races, the dust

seal and the steering stem.

NOTE

Grease the steel balls and the ball race.

Tighten the top thread nut  u n t i l sunk
against the  t o p ball race and back off
about 1/8  t u r n .

Check that the stem rotates freely

w i t h o u t play.

PIN SPANNER

Install the top bridge and the f r o n t fork.

NOTE

Align the fork top end w i t h the t o p face

of the fork t o p bridge, as. shown.

Tighten the lower bridge bolts.

TORQUE: 2 . 0 - 2 . 5 kg-m

( 1 4 . 5 - 1 8 . 1 ft-lb.)

FORK B O L T

TOP BRIDGE

Tighten the stem nut.

TORQUE: 6 . 0 - 7 . 0 kg-m ( 4 3 . 4 - 5 0 . 6 ft-lb.)

Tighten the top bridge bolts.

TORQUE: 2 . 0 - 2 . 5 kg-m ( 1 4 . 5 - 1 8 . 1 ft-lb.)

Install the headlight bracket, headlight and

steering handlebar.

Install the f r o n t wheel.

STEERING STEMNUT

WRENCH 30 X 32 mm

EXTENSION BAR

T O R Q U E :

6 . 0 - 7 . 0 kg-m

( 4 3 . 4 - 5 0 . 6 ft-lb.)

Date of Issue: December, 1977

1 1 - 2 3

Summary of Contents for CM 185T 1981

Page 1: ...e 62 Trail 92 mm 3 6 in Front fork oil capacity 125 cc 4 2 oz 98 cc 3 3 oz at draining ENGINE Type Air cooled 4 stroke Cylinder arrangement Parallel twin 20 inclined from vertical Bore and stroke 5 3 x 4 1 mm 2 09 x 1 61 in Displacement 181 cc 11 03cu in Compression ratio 9 0 1 Valve train Chain drive overhead camshaft Maximum horsepower 15 0 BHP 9 500 rpm Maximum torque 1 28 kg m 9 26 ft lb 7 000...

Page 2: ...on Battery and ignition coil Ignition timing F mark 15 B T D C at 1 200 rpm idle Full advance 37 40 B T D C at 3 100 rpm Starting system Motor and kick starter Generator A C generator 0 08 kw 5 000 rpm Battery capacity 6 V 12AH Spark plug Spark plug For cold climate below 5 C 41 F Standard For extended high speed driving ND NGK ND NGK ND NGK U20FS C6H U22FS C7HS U24FB C9H Headlight 25 35W Tail sto...

Page 3: ...Clutch plate warpage 0 0 1 0 0 0039 0 2 0 0079 Clutch spring free length 36 2 1 4252 33 1 1 3031 Cam lift IN 27 695 1 0904 26 6 1 0472 Cam lift EX 27 522 1 0835 26 5 1 0433 Camshaft journal O D 19 967 19 980 0 7861 0 7866 19 92 0 7843 Camshaft bushing I D 20 063 20 083 0 7899 0 7907 20 20 0 7965 Crankshaft runout 0 1 0 0039 Connecting rod small end I D 14 016 14 034 0 5518 0 5525 14 08 0 5543 Conn...

Page 4: ...t rear brake lining thickness 4 0 0 1575 2 0 0 0787 Front fork spring free length 504 6 19 9 495 19 5 Front fork slider I D 31 042 31 104 1 2221 1 2246 31 165 1 2270 Front fork tube O D 30 925 30 950 1 2175 1 2185 30 87 1 2154 Swing arm pivot bushing clearance 0 2 0 3 0 0079 0 0118 0 5 0 0197 Rear shock absorber spring free length 184 1 7 2480 175 6 6 9133 Date of Issue December 1977 HONDA MOTOR C...

Page 5: ... hanger bolt nut 2 10 5 5 7 0 39 8 50 8 Engine hanger bolt nut 7 8 2 0 2 5 14 5 18 1 Rear brake torque link bolt nut 2 8 2 0 2 5 14 5 18 1 Shock absorber nut 4 10 3 0 4 0 21 7 28 9 Foot rest bolt 4 8 2 0 2 5 14 5 18 1 Driven sprocket bolt nut 4 10 5 5 6 5 39 8 47 0 Swing arm pivot bolt nut 1 12 5 0 6 0 36 2 43 4 Torque specifications listed above are important tightening points Others should be to...

Page 6: ...er Valve guide pilot 5 5 Bearing driver 32x35 Bearing driver 42x47 Bearing driver 52x55 Driver pilot 15 Driver pilot 20 Driver pilot 35 Driver handle B Driver handle A Fork seal driver body Driver attachment C Valve spring compressor Float gauge 07702 0010000 07708 0030400 07708 0030100 07716 0020400 07716 0020500 07725 0010101 07733 0020000 07742 0010100 07742 0030100 07742 0030200 07746 0010100 ...

Page 7: ...1 8 Date of Issue December 1977 HONDA MOTOR CO LTD GENERAL INFORMATION W I R I N G D I A G R A M S ...

Page 8: ...GENERAL INFORMATION 1 8 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 9: ...GENERAL INFORMATION WIRING DIAGRAMS 1 8 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 10: ...throttle cable CLUTCH CABLE SPEEDOMETER CABLE CHOKE CABLE WIRE BAND NOTE Clamp wire harness clutch cable and choke cable WIRE BAND NOTE Clamp wire harness choke cable and throttle cable FRONT BRAKE CABLE THROTTLE CABLE CLUTCH CABLE WIRE BANDS NOTE Clamp stop switch wire and starting switch wire Date of Issue December 1977 HONDA MOTOR CO LTD 1 9 ...

Page 11: ... SWITCH WIRE LIGHTING SWITCH WIRE STARTING MOTOR WHITE TAPE NOTE Install the white tape of the wire harness into the center of the clip WIRE BAND NOTE WIRE HARNESS Clamp wire harness choke cable and throttle cable SILICON RECTIFIER IGNITION CO A C GENERATOR WIRES 1 10 Date of Issue December 1977 H O N D A MOTOR CO LTD ...

Page 12: ... MOTOR CABLE NOTE Route above the rear fork installation boss GROMMET NOTE Attach securely to frame ROUTE BETWEEN LEFT SIDE SPACER AND STARTING MOTOR ROUTE THROUGH THE RECESSED PART OF THE LEFT CRANKCASE COVER TURN SIGNAL AND TAILLIGHT WIRES WIRE CORD GROMMET NOTE Date of Issue December 1977 HONDA MOTOR CO LTD 1 11 ...

Page 13: ...f a factory pre set carburetor No adjustments should be made except idle speed with the throttle stop screw This system is separate from the crankcase emission control system CRANKCASE EMISSION CONTROL SYSTEM Blow by gas is returned to the combustion chamber through the breather tube separator and intake pipe CRANKCASE EMISSION CONTROL SYSTEM 1 12 Date of Issue December 1977 HONDA MOTOR CO LTD INT...

Page 14: ...E OWNER HAS PROPER TOOLS AND IS MECHANICALLY QUALIFIED NOTES 1 MORE FREQUENT SERVICE MAY BE REQUIRED WHEN RIDING IN RAIN OR AT FULL THROTTLE 2 MORE FREQUENT SERVICE MAY BE REQUIRED WHEN RIDING IN DUSTY AREAS 3 INITIAL SERVICE PERIOD 200 miles 300 km 4 FOR HIGHER ODOMETER READINGS REPEAT AT THE FREQUENCY INTERVAL ESTABLISHED HERE Date of Issue December 1977 HONDA MOTOR CO LTD 1 13 ENGINE OIL YEAR E...

Page 15: ...MATION LABEL An Emission Control Information Label is located on the CM185T S front frame downtube It contains basic tune up specifications for CM185T s manufactured after December 31 1977 1 14 Date of Issue December 1977 H O N D A MOTOR CO LTD ...

Page 16: ...tion SE Oil pump delivery 4 900 cc 5 000 rpm T O R Q U E V A L U E Oil drain bolt 3 0 5 0 kg m 21 7 36 2 ft lb TROUBLESHOOTING Oil Level Too Low 1 External oil leaks 2 Worn piston rings 3 Worn valve guide or stem seal Oil Contamination 1 Oil not changed often enough 2 Faulty head gasket 3 Worn piston rings Low Oil Pressure 1 Plugged oil pick up screen 2 Oil pump worn 3 External oil leaks 4 Oil lev...

Page 17: ...t engine assembly Start the engine and allow to idle for 2 3 minutes Stop the engine make sure that the oil level is at the upper level mark with the vehicle in an upright position and there are no oil leaks OIL FILTER SCREEN CLEANING Remove the drain plug and drain the oil Remove the kick starter pedal and the right muffler Disconnect the clutch cable from the clutch lever Remove the right crankc...

Page 18: ...LUBRICATION L U B R I C A T I O N P O I N T S 2 3 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 19: ...LUBRICATION LUBRICATION DIAGRAM OIL SCREEN 2 Date of Issue December 1977 HONDA MOTOR CO LTD OIL THROUGH PLATE OIL PUMP DRIVE GEAR OIL THROUGH OlL PUMP ...

Page 20: ...see page 2 2 SPECIFICATIONS ENGINE CHASSIS Spark plug Front brake free play 10 20 mm 3 8 3 4 in Plug gap 0 6 0 7 mm Rear brake free play 2 0 3 0 mm 3 4 1 1 4 in 0 024 0 028 in Drive chain free play 15 25 mm 5 8 1 in Type Clutch free play 10 20 mm 3 8 3 4 in Type Tire pressures For cold climate below 5 C 41 F Standard For extended high speed driving ND NGK ND NGK ND NGK U20FS C6H U22FS C7HS U24FB C...

Page 21: ...tainei and element Wash the element in non flammable or high flash point solvent Allow to dry Soak the element in gear oil SAE 80 90 and squeeze out excess DRY Wash in solvent Squeeze out excess solvent Gear oil SAE 80 90 Squeeze out excess oil install the air cleaner element Install the holder set spring and air cleaner cover Install the left side cover 3 2 Date of Issue December 1977 HONDA MOTOR...

Page 22: ...nt thickness Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped If the spark plug deposits can be removed by sandblasting or wire brushing the spark plug can be reused Inspect the gap with a gauge and adjust by bending the side electrode SPARK PLUG GAP 0 6 0 7 mm 0 024 0 028 in RECOMMENDED REPLACEMENT 0 6 0 7 mm 0 024 0 028 in For cold climate below 5 C 412 ...

Page 23: ...the adjust ing screw and valve stem VALVE CLEARANCE INTAKE 0 05 mm 0 002 in EXHAUST 0 05 mm 0 002 in Adjust by loosening the lock nut and turn the adjusting screw until there is a slight drag on the feeler gauge Hold adjusting screw and tighten the lock nut Recheck the valve clearance Rotate generator rotor one full turn 360 counterclockwise and align T 1 mark with index mark Piston of other cylin...

Page 24: ...MING NOTE Adjust the contact breaker point gap before this adjustment Using a Continuity Light and Battery Connect one of the lead cables of continuity light to contact breaker terminal and the other end to the positive terminal of bat tery Ground the negative I battery terminal to the frame body Rotate generator rotor counterclockwise and align the F l mark on the spark advance to index mark on t...

Page 25: ...ndex mark on the left crankcase cover Adjust the timing using the same procedures as for the continuity light Reinstall the generator cover IGNITION TIMING ADVANCE Connect a tachometer and stroboscope timing light Raise the engine speed to full 3 100 rpm FULL ADVANCE 3 100 rpm Check that the index mark aligns with the advance marks at 3 100 rpm If the index mark is out of the advance marks check t...

Page 26: ...nt it from turning with the lock nut TENSIONER ARM TENSIONER ASSEMBLY LOCK NUT THROTTLE OPERATION Inspect the throttle cable for deterioration damage or kinks and measure the throttle grip free play at the throttle grip flange THROTTLE GRIP FREE PLAY 2 6 mm 1 8 1 4 in Check for smooth throttle grip rotation from fully closed to fully open in all steering posi tions Adjust or replace as necessary A...

Page 27: ...the clamp hold ing the choke lever fully closed Recheck the choke valve operation CARBURETOR IDLE SPEED NOTE Check the idle speed after all other maintenance items have been performed Support the vehicle in an upright position Warm up the engine Turn the throttle stop screw as required to obtain an idle speed of 1 200 100 rpm NOTE The engine must be warm for accurate idle speed adjustment Stop and...

Page 28: ...edure for the other Watch for compression leakage at the gauge con nection COMPRESSION 12 0 2 kg cm2 170 28 psi ALLOWABLE DIFFERENCE BETWEEN CYLINDERS 4 kg cm 57 psi Low compression can be caused by Valve leakage Improper valve adjustment Blown cylinder head gasket Piston ring wear High compression can be caused by Carbon deposits in the combustion chamber or on piston head Date of Issue December ...

Page 29: ...ghten lock nuts on the both adjusters CLEANING LUBRICATION When the drive chain becomes extremely dirty it should be removed and cleaned prior to lubrication Remove the master link retaining clip with pliers NOTE Do not bend or twist the clip Remove the master link Remove the drive chain Clean the drive chain with non flam mable or height flash point solvent brush and allow to dry Inspect the driv...

Page 30: ...d Adjust the drive chain Page 3 10 BATTERY Remove the right side cover Inspect the battery fluid level When the fluid level nears the lower level refill with distilled water to the upper level NOTE Add only distilled water Tap water will shorten the service life of the battery WARNING The battery electrolyte contains sulpheric acid Protect your eyes skin and cloth ing In case of contact flush thor...

Page 31: ...EE PLAY 1 0 2 0 mm 3 8 3 4 in Major adjustments are performed with the lower adjuster Turn the adjuster to obtain the specified free play Perform minor adjustments with the upper adjuster Loosen the lock nut and turn the adjuster to obtain the specified free play Tighten the lock nut 3 12 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 32: ...ock nut securely B R A K E P E D A L F R E E P L A Y NOTE Adjust the rear brake pedal free play after adjusting brake pedal height Measure free play before the brake starts to engage REAR BRAKE FREE PLAY 2 0 3 0 mm 3 4 1 1 4 in Turn the rear brake adjusting nut if adjusting is necessary Date of Issue December 1977 HONDA MOTOR CO LTD 3 13 ...

Page 33: ...ct the brake and stopper arms for loose connections or damage Check the cotter pin is installed properly STOPLIGHT SWITCH Perform this adjustment after adjusting rear brake pedal free play and height The stoplight should come on when the brake pedal is depressed 20 mm 3 4 in from the standard position Adjust by turning switch adjusting nut 3 14 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 34: ...side of rider NOTE Adjust the headlight beam as specified by local laws and regulations It R i An improperly adjusted headlight may blind oncoming drivers or it may fail to light the road for a safe distance CLUTCH FREE PLAY Measure the clutch free play at the tip of the clutch lever CLUTCH FREE PLAY 10 20mm 3 8 3 4 in Major adjustments are made at the lower adjuster Loosen the lock nut and turn a...

Page 35: ...ar extends to wear line as shown Check the side stand spring for damage and loss of tension and the side stand assembly for freedom of movement NOTE When replacing use a rubber pad with the mark Over 260 lbs ONLY Spring tension is correct if the measure ments fall within 2 3 kg 4 4 6 6 lb when pulling the side stand lower end using a spring scale GOOD NO GOOD 3 16 Date of Issue December 1977 HONDA...

Page 36: ...worn Check the entire suspension assembly to see if it is securely mounted damaged or distorted Check the rear wheel for trueness WHEELS SPOKES TIRE PRESSURE NOTE Tire pressure should be checked when the tires are COLD Check the tires for cuts imbedded nails or other sharp objects Recommended tire pressure and tire size LOAD Cold tire pressures kg cm2 psi Up to 90 kg 200 lbs load Front 1 75 25 Rea...

Page 37: ...wheel off the ground Check that the handlebar rotates freely If the handlebar moves unevenly binds or has vertical movement adjust the steering head bearing by turning the steering head adjusting nut with a pin spanner NUTS BOLTS FASTENERS Retighten the bolts nuts and fasteners related frame at regular intervals shown the Mainte nance Schedule and for the tightening torque refer to Torque Specific...

Page 38: ...t side of the steering The legal vehicle identification number VIN is on the The engine serial number is on the left lower side of the The carburetor identification number is on the right of crankcase the carburetor body Date of Issue December 1977 H O N D A MOTOR CO LTD 3 ...

Page 39: ... work in a well ventilated area and away from sparks or open flames When disassembling fuel system parts note the locations of the O rings Replace them with new ones on re assembly The float bowls have drain plugs that can be removed to drain residual gasoline TOOL Common Tool Float gauge Tool No 07401 0010000 SPECIFICATIONS ITEM DESCRIPTION Venturi dia 22 mm 0 87 in Setting mark PD98A Float level...

Page 40: ...ifold 8 Fuel contaminated 9 Carburetor malfunction Lean Mixture 1 Carburetor fuel jets clogged 2 Fuel cap vent blocked 3 Fuel filter clogged 4 Fuel line kinked or restricted 5 Float valve faulty 6 Float level too low 7 Air vent tube clogged 8 Intake air leak 9 Pilot screw misadjusted Rich Mixture 1 Choke stuck closed 2 Float valve faulty 3 Float level too high 4 Carburetor air jets clogged 5 Pilot...

Page 41: ...sen the screw securing the carburetor band and remove setting nuts Unscrew the carburetor top cap pull the throttle valve out and remove the carburetor CARBURETOR TOP DISASSEMBLY Remove the throttle cable end from the throt tle valve groove while depressing the throttle valve spring Date of Issue December 1977 H O N D A MOTOR CO LTD 4 3 ...

Page 42: ...rt scratch and wear FLOAT FLOAT VALVE AND JETS DISASSEMBLY Remove the carburetor and disassemble the float chamber Pry off the float arm pin with a pair of pliers Remove the float and float valve Inspect the float valve surface for wear or damage NEEDLE CAP PLATE NEEDLE CLIP JET NEEDLE THROTTLE VALVE 4 4 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 43: ...ove the pilot screw Pilot screw adjustment see page 4 8 MAIN JET Blow open all jets and body opening with compressed air NEEDLE JET HOLDER NEEDLE JET PILOT SCREW BODY ASSEMBLY Install the pilot screw the needle jet holder and the main jet NOTE Do not damage the jets at time of as sembly MAIN JET NEEDLE JET HOLDER Date of Issue December 1977 HONDA MOTOR CO LTD 4 5 ...

Page 44: ...4 5 mm 0 57 in THROTTLE VALVE ASSEMBLY Install the jet needle into the throttle valve and clamp it with the needle cap plate NOTE Install the needle cap plate on the lower position of throttle valve completely Install the throttle cable and spring Install the throttle valve FLOAT LEVEL 14 5 mm 0 57 in 4 6 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 45: ...RBURETOR INSTALLATION Carburetor installation is the reverse of the removal NOTE Clamp the choke cable end on the cable setting plate After assembly perform the follow ing adjustments Throttle grip free play See page 3 7 Idle speed adjustment See page 3 8 Date of Issue December 1977 HONDA MOTOR CO LTD 4 7 ...

Page 46: ...position Start the engine and readjust the idle speed if necessary HIGH ALTITUDE ADJUSTMENT The carburetor must be adjusted for high altitude riding 2 000 m 6 500 ft STANDARD SETTING 2 000 m 6 500 ft max HIGH ALTITUDE SETTING 1 500 m 5 000 ft min High altitude carburetor adjustment is done as follows 1 Turn the pilot screw clockwise 1 4 turn from the factory pre set position 2 Start the engine and...

Page 47: ...CARBURETOR 4 ...

Page 48: ... Cylinder head and valves Section 6 Cylinder and piston Section 7 Transmission and crankshaft Section 10 SPECIFICATIONS Engine weight 39 8 kg 87 8 lb at dry Oil capacity 1 5 lit 1 6 U S qt 1 4 lit 1 5 U S qt at draining TORQUES Engine hanger 8 mm bolts 2 0 2 5 kg m 14 5 18 1 ft lb 10 mm bolts 5 5 7 0 kg m 39 8 50 8 ft lb Drain plug 3 0 5 0 kg m 21 7 36 2 ft lb Foot rest bolts 2 0 2 5 kg m 14 5 18 ...

Page 49: ...t side covers Remove the seat and fuel tank Remove the right and left mufflers Disconnect the breather tube and remove the plug cap Remove the starter magnetic switch and the turn signal relay Disconnect the stop switch wires and the bat tery cords Remove the battery 5 2 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 50: ...tor cable at the starting motor Disconnect the coupler of the silicon rectifier and condenser cord Loosen the air cleaner tube band and remove the air cleaner case within air cleaner element Disconnect the A C generator coupler Remove the carburetor See page 4 3 Date of Issue December 1977 H O N D A MOTOR CO LTD 5 3 ...

Page 51: ...he left crank case and the rear covers Loosen the foot rest right side setting bolts WARNING Place the frame body on the rigid rack before removing the foot rests Remove the through bolts and remove the foot rests 5 4 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 52: ...remove the master link Remove the drive chain Support the engine with a jack or other ad justable support under the engine Remove the four hanger bolts and front engine bracket Remove two 10 mm hanger bolts on the frame body Date of Issue December 1977 HONDA MOTOR CO LTD 5 5 ...

Page 53: ...el Refer to page 2 2 Perform the following inspections and adjustments Clutch lever free play page 3 15 Drive chain free play page 3 10 TORQUE 8 mm frange bolts 2 0 2 5 kg m 14 5 18 1 ft lb 10 mm frange bolts 5 5 7 0 kg m 39 8 50 8 ft lb NOTE Temporarily install the all bolts on the frame then tighten them securely Install the hanger plates hanger brack et and hanger bolt as shown ENGINE UPPER HAN...

Page 54: ...ENGINE REMOVAL AND INSTALLATION 5 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 55: ...d dowel pins are in place before installing the cylinder head Pour clean engine oil into the oil sinks of the cylinder head to fully lubricate the cam lobes T O O L S Special Tool Valve guide reamer Common Tools Valve guide remover driver Valve guide cutter Valve guide pilot 5 5 Valve spring compressor T O R Q U E S Cylinder head bolts Camshaft holder nuts Cam sprocket bolts Cylinder head cover bo...

Page 56: ...CYLINDER HEAD VALVES SERVICE DATA 6 2 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 57: ...rect valve timing Sticking valve Broken valve spring Weak valve spring Improper valve seating 2 Cylinder head troubles Leaking or damaged head gasket Warped or cracked cylinder head Worn piston ring s and or cylinder Compression Too High over 14 kg cm2 199 psi 1 Excessive carbon deposits on the combustion chamber or piston Excessive Noise 1 Incorrect valve adjustment 2 Sticking valve or broken val...

Page 58: ...due to heat Loosen the cylinder head hold down holts in the sequence shown in steps 2 3 Remove the camshaft holders Pull off the rocker arm shafts after tightening the 5 mm screw into them NOTE Mark each part to insure original as sembly Remove the rocker arms and the rocker arm springs CAMSHAFT HOLDER CAMSHAFT HOLDER ROCKER ARM SPRING ROCKER ARM ROCKER ARM SHAFTS 6 4 Date of Issue December 1977 H...

Page 59: ...t drop the mounting bolts into the cylinder Remove the cam chain from the cam sprocket and place it at the right side of cam sprocket Pull the camshaft out from right side while holding cam sprocket and cam chain NOTE Suspend the cam chain with a piece of wire to prevent it from falling into the cylinder Date of Issue December 1977 HONDA MOTOR CO LTD 6 5 ...

Page 60: ...oring chipping or flat spots I D SERVICE LIMIT 10 1 mm 0 3976 in WEAR OR DAMAGE ROCKER ARM SHAFT INSPECTION Inspect the rocker arm shafts for wear or damage Measure the O D O D SERVICE LIMIT 9 17 mm 0 3610 in CAMSHAFT BUSHING INSPECTION Inspect the camshaft bushing for wear or dam age Measure the I D of the camshaft bushing DAMAGE OR WEAR I D SERVICE LIMIT 20 20 mm 0 7965 in 6 6 Date of Issue Dece...

Page 61: ...reading RUNOUT SERVICE LIMIT 0 05 mm 0 0020 in Inspect the camshaft journal for wear or dam age Measure the O D of camshaft journal O D SERVICE LIMIT 19 92 mm 0 7843 in Inspect each cam lobe for wear or damage Measure the cam lift with the micrometer CAM LIFT SERVICE LIMIT IN 26 6 mm 1 0472 in EX 26 5 mm 1 0433 in Date of Issue December 1977 HONDA MOTOR CO LTD 6 7 ...

Page 62: ...pry only at the cutout of cylinder gasket Remove the cylinder gasket dowel pins and O rings CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters retainers springs and valves NOTE Do not compress the valve springs more than necessary to remove the valve spring cotters Mark all disassembled parts to insure original assembly 6 8 Date of Issue December 1977 H O N D A MOTOR CO LTD ...

Page 63: ...r cracks Check the cylinder head for warpage with a straight edge and a feeler gauge NOTE Measure the cylinder head height CYLINDER HEAD HEIGHT SERVICE LIMIT 72 6 mm 2 8583 in VALVE SPRING FREE LENGTH INSPECTION Measure the free length of the inner and outer valve springs SERVICE LIMITS 0 1 mm 0 0039 in SERVICE LIMITS Inner spring 29 0 mm 1 1417 in Outer spring 35 3 mm 1 3898 in Date of Issue Dece...

Page 64: ... D to obtain the stem to guide clearance VALVE STEM TO GUIDE CLEARANCE SERVICE LIMIT IN 0 08 mm 0 0031 in EX 0 10 mm 0 0039 in VALVE GUIDE REAMER Tool No 07984 0980000 VALVE GUIDE CUTTER 4 NOTE If the stem to guide clearance exceeds the service limit determine if a new guide with standard dimensions would bring the clearance within tolerance If so replace any guides as necessary and ream to fit If...

Page 65: ... 5 mm Install a new oversize valve guide from the top of head NOTE Inspect the valve guide for damage DRIVER AND REMOVER 5 5 mm PILOT 5 5 mm Ream the new guide after installation NOTE Use cutting oil on the reamer during this operation Clean the cylinder head thoroughly to remove any metal particles VALVE GUIDE CUTTER VALVE GUIDE REAMER NO 07984 0980000 Date of Issue December 1977 H O N D A MOTOR ...

Page 66: ...re the valve seat width NOTE The valves cannot be ground If the face is burned or badly worn replace the valve If the seat is too wide too narrow or has low spots the seat must be ground for good sealing A power grinder is recommended NOTE Follow the refacer manufacturer s operat ing instructions FACE RECOMMENDED V A L V E SEAT WIDTH 1 0 mm 0 0394 in VALVE SEAT WIDTH SERVICE LIMIT 1 5 mm 0 0590 in...

Page 67: ...time a stone is removed and re installed on the grinder it must be re faced on the dressing stand IN O D 26 mm 1 024 in EX O D 23 mm 0 906 in Lubricate the pilot bar with a thin coat of oil and firmly insert it into the valve guide Use adequate eye protection when using the valve seat grinder Date of Issue December 1977 HONDA MOTOR CO LTD 6 13 MOVE UP AND DOWN LIGHTLY PILOT BAR A VALVE SEAT GRINDE...

Page 68: ...D SEAT WIDTH BOTTOM CUT Use a 63 5 grinding stone to remove the bottom 1 4 of the old seat Remove the grinder and check the ground area OLD SEAT WIDTH MATERIAL REMOVED FINISH CUT With a 45 finishing stone cut the seat to the proper width NOTE Remove the stone often and inspect the seat for pits 1 0 mm 0 0394 in 6 14 Date of Issue December 1977 H O N D A MOTOR CO LTD ...

Page 69: ...ve face is too low the seat must be raised with a 63 5 grinding stone Refinish the seat to 1 0 mm 0 0394 in width with a 45 finishing stone CONTACT TOO LOW OLD SEAT WIDTH MATERIAL REMOVED WITH 63 5 STONE B O T T O M C U T After grinding the seat apply lapping com pound to valve face and lap the valve lightly CAUTION Do not allow the lapping compound to enter the valve guide After lapping wash any ...

Page 70: ... valve springs with the tightly wound ends facing the cylinder head Install the valve keepers NOTE To prevent loss of tension do not com press the valve spring more than neces sary to install the valve keepers Tap the valve stems gently with a soft hammer to firmly set the keepers CAUTION Support the cylinder head above the work bench surface to prevent possible valve damage CYLINDER HEAD 6 16 Dat...

Page 71: ... gasket Loosen the cam chain tensioner lock nut and pull the tensioner up fully Retighten the lock nut Install the cylinder head Install the cam chain tensioner bolt with O ring Install the intake manifold with O rings NOTE Check that the O rings install the groove of the intake manifold properly Date of Issue December 1977 H O N D A MOTOR CO LTD 6 17 ...

Page 72: ...m shaft holder NOTE Apply a thin coat of oil to the shafts before assembly Install each shaft with the threaded end facing out ROCKER ARM ROCKER ARM SPRING CAMSHAFT HOLDER Slide cam chain and cam sprocket onto the camshaft Turn the rotor and align the T 1 mark to the index mark CAM SPROCKET 6 18 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 73: ...e side and positions it parallel to the cylinder head surface Place the punch marks of the cam sprocket parallel to the cylinder head surface Install the cam chain Tighten one cam sprocket setting bolt Turn the rotor counterclockwise 360 and tighten the other bolt TORQUE 1 7 2 3 kg m 12 3 16 6 ft lb CYLINDER HEAD SURFACE PUNCH MARKS CUTOUT Date of Issue December 1977 H O N D A MOTOR CO LTD 6 19 ...

Page 74: ...E Tighten an X pattern in 2 3 steps 6 20 Date of Issue December 1977 HONDA MOTOR CO LTD NOTE Install the camshaft holder with the F marks to the front Install the dowel pins into the holes in the cylinder head Loosen the adjusting screws fully and install the camshaft holder CYLINDER HEAD VALVES DOWEL PINS ...

Page 75: ...lobes are submerged Adjust valve clearance Pages 3 4 Adjust cam chain tensioner Page 3 7 Inspect the cylinder head cover gasket for damage or deterioration InstalL the head cover and tighten the bolts TORQUE 0 8 1 2 kg m 5 8 8 7 ft lb Date of Issue December 1977 H O N D A MOTOR CO LTD 6 21 ...

Page 76: ...ER HEAD VALVES TORQUE 0 8 1 2 kg m 5 8 8 7 ft lb TORQUE 1 6 2 0 kg m 11 6 14 5 ft lb TORQUE 1 7 2 3 kg m 12 3 16 6 ft lb TORQUE 1 0 1 4 kg m 7 2 10 1 ft lb 6 Date of Issue December 1977 H O N D A MOTOR CO LTD ...

Page 77: ...t of round 0 05 mm 0 0020 in Taper 0 05 mm 0 0020 in War page Max 0 05 mm 0 0020 in 0 1 mm 0 0004 in Pistons piston rings and piston pins Piston skirt O D 52 960 52 990 mm 2 0850 2 0862 in 52 86 mm 2 0811 in Piston pin bore 14 002 14 008 mm 0 5513 0 5515 in 14 05 mm 0 5531 in Piston pin O D 13 994 14 000 mm 0 5509 0 5512 in 13 98 mm 0 5504 in Piston ring side clearance Top second 0 015 0 045 mm 0 ...

Page 78: ... deposits on pistons Excessive Smoke 1 Worn cylinder and piston rings 2 Improperly installed piston rings 3 Damaged piston or cylinder Engine Overheating 1 Excessive carbon deposits on piston or combustion chamber Piston Slap 1 Worn cylinder and piston 2 Excessive carbon deposits 7 2 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 79: ...and pin into the crankcase Remove the tensioner lock nut washer and O ring Remove the tensioner base Remove the cylinder Remove the gasket and dowel pins Clean the base face of the cylinder with the scraper NOTE Gasket will come off easier if soaked in solvent Avoid damaging the gasket surface Date of Issue December 1977 H O N D A MOTOR CO LTD 7 3 ...

Page 80: ...m 0 0020 in SERVICE LIMIT 53 1 mm 2 0905 in Inspect the base of the cylinder for warpage NOTE SERVICE LIMIT 0 1 mm 0 0039 in PISTON REMOVAL Remove the piston pin clip with the pliers NOTE Be careful when removing clips to keep them from dropping into the crankcase Press the piston pin out of the piston NOTE Mark the pistons to indicate the cylinder positions 7 4 Date of Issue December 1977 HONDA M...

Page 81: ...r Insert each piston ring into the cylinder with the piston and inspect the end gap in the cyl inder to a point 10 mm 0 4 in from bottom Date of Issue December 1977 HONDA MOTOR CO LTD 7 5 CLEARANCE SERVICE LIMIT 0 12 mm 0 0048 in CYLINDER PISTON PISTON PISTON RING INSPECTION Inspect the piston ring to groove clearance END GAP SERVICE LIMIT 0 5 mm 0 0197 in PISTON RING ...

Page 82: ...clearance SERVICE LIMIT 0 01 mm 0 04 in Measure the piston pin hole I D Measure piston pin bore I D in two directions at right angle to each other Inspect the connecting rod small end I D 7 6 Date of Issue December 1977 HONDA MOTOR CO LTD O D SERVICE LIMIT 52 86 mm 2 0811 in CYLINDER PISTON 10 mm 0 4 in KD SERVICE LIMIT 14 05 mm 0 5531 in ...

Page 83: ...e measurements at several points TOP AND SECOND RING THICKNESS SERVICE LIMIT 1 12 mm 0 0441 in P I S T O N R I N G I N S T A L L A T I O N Instai the piston rings NOTE Avoid piston and piston ring damage during installation All rings should be installed with the markings facing up After installation the rings should be free to rotate in the grooves Clean the ring grooves before install ing the pis...

Page 84: ...all the spacer first and then the rails NOTE After installing each ring on the piston turn the rings by hand to check for smooth movement When installing a new ring check that it fits smoothly into the ring groove and does not bind 7 8 Date of Issue December 1977 HONDA MOTOR CO LTD OIL RING TOP RING SECOND RING SIDE RAIL SPACER SIDE RAIL 2 0 3 0 mm 0 79 1 18 in ...

Page 85: ... Install the pistons in their original locations Use new piston pin clips when assembling NOTE Install with the piston pin clip end gap turned away from the cutout of the piston CYLINDER INSTALLATION Install the dowel pins and the gasket GASKET PISTON PIN CLIP CLIP END GAP Date of Issue December 1977 H O N D A MOTOR CO LTD 7 9 CUTOUT ...

Page 86: ...oner base and slide the O ring over the tensioner adjusting bolt Install the plain washer and lock nut Install the tensioner on the tensioner base with the pin and clips NOTE Do not drop the pin or d i p into the crank case Pull the cam chain tensioner al tighten the lock nut securely the way and AM CHAIN ENSIONER BOLT 7 10 Date of Issue December 1977 HONDA MOTOR CO LTD Install the dowel pins O ri...

Page 87: ...7 Date of Issue December 1977 HONDA MOTOR CO LTD CYLINDER PISTON ...

Page 88: ... Tool No 07923 1070001 SERVICE DATA ITEMS STANDARD SERVICE LIMIT Clutch Clutch lever free play Clutch spring free length Clutch disc thickness Clutch plate warpage 10 20 mm 3 8 3 4in 36 2 mm 1 4252 in 3 0 mm 0 1181 in 0 0 1 mm 0 0 0039 in 33 1 mm 1 3031 in 2 6 mm 0 1024 in 0 2 mm 0 0079 in Oil pump Rotor tip clearance Rotor to cover clearance Rotor to body clearance 0 15 mm 0 0059 in 0 01 0 07 mm ...

Page 89: ...damaged Clutch Operation Feels Rough 1 Outer drum slots rough Hard Shifting 1 Stopper plate bent or worn 2 Improper clutch adjustment Gear Shift Pedal Won t Return 1 Return spring broken 2 Shift spindle interferring with crankcase or cover Jumps Out Of Gear 1 Stopper arm spring broken or weak Low Oil Pressure 1 Plugged oil filter screen 2 Oil pump rotors worn 3 External oil leaks 4 Oil level low H...

Page 90: ...emove the right crankcase cover by removing the screws CLUTCH Install the clutch holder on the lifter plate and into kick spindle and remove the 14 mm lock nut Remove the pin lock washer and oil pump drive gear Remove the four lifter plate setting bolts the lifter plate and the four clutch springs NOTE Loosen the bolts in an X pattern in two or more steps Date of Issue December 1977 HONDA MOTOR CO...

Page 91: ...ct the clutch spring free length Pry off the 20 mm circlip Remove the clutch center friction disc plates clutch plates and clutch pressure plate CLUTCH CENTER FRICTION DISC CLUTCH PLATE CLUTCH PRESSURE PLATE 8 4 Date of Issue December 1977 HONDA MOTOR CO LTD SERVICE LIMIT 33 1 mm 1 3031 in ...

Page 92: ...colored or worn Measure each friction disc thickness SERVICE LIMIT 2 6 mm 0 1024 in C L U T C H P L A T E I N S P E C T I O N Check the plates for warpage on a surface plate and with a feeler gauge Remove the splined washer on the clutch outer Remove the drive gear SERVICE LIMIT 0 2 mm 0 0079 in Date of Issue December 1977 H O N D A MOTOR CO LTD 8 5 ...

Page 93: ...d the clutch outer Install the splined washer NOTE Note the direction of the splined washer Assemble the pressure plate the friction discs and the clutch center NOTE Lubricate new clutch discs with thin oil before assembling Install them in the clutch outer NOTE Install the clutch assy while holding the pressure plate and clutch center and tuYning it 8 6 Date of Issue December 1977 HONDA MOTOR CO ...

Page 94: ... NOTE Tighten the bolts in two or more steps and in cross pattern Install the clutch drive gear and oil pump drive gear Install the lock washer and pin NOTE Install the washer with the word OUT SIDE facing the right side Tighten the 14 mm lock nut TORQUE 4 5 6 0 kg m 32 5 43 4 ft lb Date of Issue December 1977 HONDA MOTOR CO LTD 8 7 ...

Page 95: ...CLUTCH OIL PUMP GEAR SHIFT KICK STARTER 8 8 Date of Issue December 1977 HONDA MOTOR CO LTD OIL PUMP NOTE Clean the oil filter screen at time of disassembly ...

Page 96: ...clockwise until the cut out of the oil pump gear aligns with the mounting screws Remove the three screws and remove the oil pump OIL PUMP DISASSEMBLY Remove the oil pump cover OIL PUMP COVER OIL PUMP INSPECTION Measure the rotor tip clearance Date of Issue December 1977 H O N D A MOTOR CO LTD 8 9 SERVICE LIMIT 0 2 mm 0 0079 in ...

Page 97: ...ce Measure the rotor to cover clearance SERVICE LIMIT 0 25 mm 0 0098 in SERVICE LIMIT 0 12 mm 0 0048 in Remove the rotors Remove the gear cover and the pump gear and pull the rotor shaft out PUMP GEAR 8 10 Date of Issue December 1977 HONDA MOTOR CO LTD ROTOR SHAFT GEAR COVER ...

Page 98: ...p gear cutout with the rotor shaft cutout Install the gear cover Install the inner and outer rotors NOTE Align the inner rotor cutout with the rotor shaft cutout INNER ROTOR Install the gasket and cover Check for smooth operation O I L P U M P I N S T A L L A T I O N Install the new O ring correctly and instal the oil pump Date of Issue December 1977 HONDA MOTOR CO LTD 8 11 ...

Page 99: ...Remove the gear shift pedal and the stopper arm Remove the stopper plate and the shift dium pins Remove the gear shift spindle NOTE Check the each part for wear or damage 8 12 Date of Issue December 1977 HONDA MOTOR CO LTD STOPPER ARM SPRING DRUM STOPPER ARM STOPPER PLATE GEAR SHIFT SPINDLE ...

Page 100: ...und the return spring pin Install the stopper arm NOTE Install the spring as shown After installing check stopper arm oper ation Install the stopper plate NOTE Insert pin into hole of the stopper Tighten the stopper plate setting bolt NOTE I After reassembly check for operation Date of Issue December 1977 H O N D A MOTOR CO LTD 8 13 ...

Page 101: ...e 18 mm circlip and disassemble the ratchet spring and the drive ratchet DRIVE RATCHET K I C K S T A R T E R P I N I O N I N S P E C T I O N Measure the kick starter pinion I D I D SERVICE LIMIT 18 07 mm 0 7114 in 8 14 CLUTCH OIL PUMP GEAR SHIFT KICK STARTER KICK STARTER Pull the kick starter spring out and remove the kick starter ...

Page 102: ...s Insert the circlip in the groove of the spindle Assemble the guide plate the collar and the return spring on the spindle K I C K S T A R T E R I N S T A L L A T I O N Install the kick starter NOTE Set the guide plate in the groove on the right crank case SERVICE LIMIT 17 93 mm 0 7059 in RETURN SPRING COLLAR ALIGN PUNCH MARKS GUIDE PLATE RATCHET CIRCLIP Date of Issue December 1977 H O N D A MOTOR...

Page 103: ...CRANKCASE COVER INSTALLATION Install the dowel pins and gasket RIGHT CRANKCASE SPRING Install the right crankcase cover Connect the clutch cable Install the kick starter pedal and right muffler Refill the engine with the recommended oil and check for level See page 2 2 Start the engine and check clutch operation 8 16 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 104: ...8 Date of Issue December 1977 HONDA MOTOR CO LTD CLUTCH OIL PUMP GEAR SHIFT KICK STARTER TORQUE 4 5 6 0 kg m 32 5 43 4 ft lb ...

Page 105: ...ON 9 12 SERVICE INFORMATION WORKING PRACTICE This section covers removal installation and servicing of the contact breaker A C generator starter clutch and starter motor with the left crankcase cover removed All these operations can be accomplished with the engine in the frame TOOLS Special Tool Clutch outer holder Common Tools Rotor puller Universal holder TORQUE Rotor bolt Tool No 07923 1070001 ...

Page 106: ... But Runs Poorly 1 Worn spark plug or breaker points 2 Incorrect point gap 3 Improper ignition timing 4 Faulty advance mechanism Starter Motor Will Not Turns 1 Loose or disconnected wire or cable 2 Faulty starter motor Starter Motor Turns Engine Slowly 1 Binding in starter motor drive chain or drive sprocket Starter Motor Turns But Engine Does Not Turn 1 Faulty starter clutch 2 Faulty starter moto...

Page 107: ...ker point attaching screws Remove the oil felt attaching screw C O N T A C T B R E A K E R P O I N T I N S P E C T I O N Inspect the contact point surface for wear or pitting NOTE Clean with point file or grind stone if the point surface is dirty Replace badly worn or pitted points CONTACT POINT BASE PLATE OIL FELT GOOD CORRECT REPLACE Date of Issue December 1977 HONDA MOTOR CO LTD 9 3 ...

Page 108: ...ly perform point gap and igni tion timing inspection and adjustment See page 3 5 DRIVE SPROCKET REMOVAL Remove the left crankcase rear cover Remove the chain clip master link Remove the drive chain Remove the flexing plate and drive sprocket D R I V E S P R O C K E T I N S T A L L A T I O N The installation sequence is essentially the re verse of removal 9 4 Date of Issue December 1977 H O N D A M...

Page 109: ...r cover Remove the point cover Disconnect the A C generator coupler Remove the left crankcase cover Remove the stator coil STATOR COIL INSPECTION Try the stator coil continuity test There should be continuity between the three lead wires pink white white yellow yellow pink of the stator coil Date of Issue December 1977 HONDA MOTOR CO LTD 9 5 ...

Page 110: ...ound S T A T O R COIL INSTALLATION NOTE Route each wire between cover and stator A C GENERATOR ROTOR REMOVAL Drain the engine oil and remove the right crankcase cover See page 8 3 Block the clutch to prevent it from turning with a clutch outer holder and remove the rotor bolt Remove the spark advancer 9 6 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 111: ...Date of Issue December 1977 HONDA MOTOR CO LTD 9 7 ROTOR PLATE SPRING CAP STARTING CLUTCH OUTER ROLLER ...

Page 112: ...g caps and the roller springs NOTE Check all parts for wear damage or de formation Remove the three clutch outer attaching screws with a shock driver Remove the starter clutch outer and side plate Check the starter clutch outer for wear STARTER CLUTCH 9 8 Date of Issue December 1977 HONDA MOTOR CO LTD WFAR SHOCK DRIVER ...

Page 113: ...y Insert the springs spring caps and rollers into the starter clutch outer Check the starter clutch for smooth operation DOWEL PIN STARTER CLUTCH OUTER STARTING MOTOR REMOVAL Remove the left crankcase cover See page 9 5 Remove the rotor See page 9 5 Remove the starting sprocket setting plate Remove the starting sprocket starter motor sprocket and starter chain Remove the left side spacer SIDE PLAT...

Page 114: ... dam age Disconnect the starter cable Remove the starter motor S T A R T I N G M O T O R D I S A S S E M B L Y A S S E M B L Y Refer to section 16 STARTING MOTOR INSTALLATION Install the left side spacer NOTE Install the knock pins and gasket at the time of assembly For cable routing refer to page 1 11 9 10 Date of Issue December 1977 HONDA MOTOR CO LTD DAMAGE WEAR ...

Page 115: ...ime Install the sprocket setting plate NOTE Note the direction of sprockets Turn the crankshaft counterclockwise and check sprocket for smooth oper ation Route and connect the starter cable A C GENERATOR INSTALLATION Install the rotor NOTE Align the knock pin with the groove of rotor Do not fall the starting clutch rollers Date of Issue December 1977 HONDA MOTOR CO LTD 9 11 CRANKCASE ...

Page 116: ...n tightening the bolt hold the clutch lifter plate with a clutch holder Install the right crankcase cover kick pedal and right muffler Fill with the engine oil See page 2 2 After assembly perform clutch adjustment LEFT CRANKCASE COVER INSTALLATION Install the left crankcase cover left crankcase rear cover gear shift pedal and left muffler 9 12 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 117: ...A C GENERATOR STARTER MOTOR TORQUE 4 5 5 0 kg m 32 5 36 2 ft lb ...

Page 118: ...NE REMOVAL Section 5 CYLINDER HEAD REMOVAL Section 6 CYLINDER Section 7 CLUTCH OIL PUMP GEARSHIFT LINKAGE Section 8 A C GENERATOR STARTER MOTOR Section 9 TOOLS Special Tools Bearing driver Driver handle Common Tools Bearing driver 32x35 Bearing driver 42x47 Bearing driver 52x55 Driver pilot 15 Driver pilot 20 Driver pilot 35 Driver handle A TORQUES Crankshaft bolts and nut Crankcase bolts Tool No ...

Page 119: ...Connecting rod big end radial clearance 0 1 0 4 mm 0 0039 0 0158 in 0 004 0 012 mm 0 0002 0 0005 in 0 1 mm 0 0039 in 0 6 mm 0 0236 in 0 05 mm 0 0020 in TROUBLESHOOTING Hard Shifting 1 Shift forks bent 2 Shift fork guide shaft bent Jumps Out Of Gear 1 Gear dogs worn 2 Shift shaft bent 3 Shift forks bent or damaged Crankshaft Noise 1 Connecting rod big end bearing worn 2 Connecting rod bent 3 Cranks...

Page 120: ...crankcase up wards and remove the 6 mm screws Place the engine with the right crankcase uo wardsand remove the setting bolts Remove the right crankcase B A L L B E A R I N G I N S P E C T I O N Replace the main shaft bearing if it is noisy Date of Issue December 1977 HONDA MOTOR CO LTD 10 3 ...

Page 121: ...h hands SHIFT FORK GUIDE SHAFT G E A R S H I F T F O R K G E A R S H I F T G U I D E S H A F T I N S P E C T I O N Inspect the shift forks and replace if broken or worn Measure each shift fork I D I D SERVICE LIMIT 12 05 mm 0 4744 in WEAR OR DAMAGE Check each shift fork end thickness END THICKNESS SERVICE LIMIT 4 70 mm 0 1850 in 10 4 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 122: ...t right angle to each other SERVICE LIMIT 11 96 mm 0 4709 in Check the gearshift drum for wear or dam age TRANSMISSION DISASSEMBLY Disassemble the transmission gears and inspect each gear for wear or damage Replace if broken or worn Date of Issue December 1977 HONDA MOTOR CO LTD 10 5 ...

Page 123: ...HONDA MOTOR CO LTD CRANKSHAFT REMOVAL Remove the crankshaft after unscrewing the five setting bolts and nut Pry off the lock pin and remove the plain washer Remove the tensioner arm Set the crank weight balancer to the position shown and remove the cam chain ...

Page 124: ... the radial clearance at two different points across from each other as shown Measure runouts at points shown Actual bend is 1 2 of Total Indicator Reading SERVICE LIMIT 0 6 mm 10 0236 in SERVICE LIMIT 0 05 mm 0 0020 in jUIrn SERVICE LIMIT 0 1 mm 0 0039 in LEFT RIGHT Date of Issue December 1977 H O N D A MOTOR CO LTD 10 7 ...

Page 125: ...C R A N K C A S E D I S A S S E M B L Y Remove the oil seal Remove the oil through plate by removing three screws Remove the crankshaft bearing BALL BEARING INSTALLATION L E F T C R A N K C A S E Install the ball bearing with a bearing driver 10 8 Date of Issue December 1977 HONDA MOTOR CO LTD AXIAL PLAY PLAY RADIAL REPLACE REPLACE ...

Page 126: ...he end of the crankcase as tha willblock up the oil passage in the shaft Install the O ring and the oil through plate Tighten the screws NOTE Apply locking agent to the screws R I G H T C R A N K C A S E Install the bearing with a bearing driver Date of Issue December 1977 H O N D A MOTOR CO LTD 10 9 ...

Page 127: ...ncer Install the cam chain tensioner arm with the slippery surface facing the chain NOTE Install with the A mark facing the cylinder head Slide the crankshaft into the left crankcase aligning the stud on the case with the hole in the bearing holder as shown Tighten the nut and five bolts TORQUE 1 0 1 4 kg m 7 2 10 1 ft lb CRANK WEIGHT BALANCER CAM CHAIN CAM CHAIN GUIDE NSERTION PART BEARING HOLDER...

Page 128: ...le the mainshaft and the countershaft shown above NOTE After assembly check each gear for smooth operation Install the circlips into the groove completely Slide the mainshaft and countershaft into the left crankcase NOTE Install the mainshaft and countershaft at the same time Hold the thrust washers with fingers during operation Date of Issue December 1977 H O N D A MOTOR CO LTD 10 11 ...

Page 129: ...all with the right fork facing the mark up and center fork facing the mark down Insert the shift guide shaft into the left crank case through the holes in the shift forks NOTE After assembly inspect each gear for smooth operation by rotating the main s h 8 f t 10 12 Date of Issue December 1977 HONDA MOTOR CO LTD NEUTRAL SWITCH ROTOR NEUTRAL SWITCH CENTER SHIFT FORK SHIFT DRUM RIGHT SHIFT FORKS SHI...

Page 130: ...e gasket correctly Install the right crankcase on the left crank case NOTE When installing do not dislodge the gasket Tighten the oolts TORQUE 1 0 1 4 kg m 7 2 10 1 ft lb Place the engine with the left crankcase up and screw in the 6 mm screws Date of Issue December 1977 H O N D A MOTOR CO LTD 10 13 ...

Page 131: ...TORQUE 1 0 1 4 kg m 7 2 10 1 ft lb 10 Date of Issue December 1977 HONDA MOTOR CO LTD TRANSMISSION CRANKSHAFT TORQUE 1 0 1 4 kg m 7 2 10 1 ft lb TORQUE 1 0 1 4 kg m 7 2 10 1 ft lb ...

Page 132: ...before removing it S P E C I F I C A T I O N Front fork oil capacity 125 cc 4 2 oz 98 cc 3 3 oz at draining T O O L S Special Tools 6 mm Allen wrench Ball race driver Common Tools Pin spanner Steering stem wrench 30x32 Extension bar Bearing driver 42x47 Driver handle A Driver pilot 15 Fork seal driver body Driver attachment C Tool No 07917 3230000 Tool No 07944 1150001 Tool No 07702 0010000 Tool N...

Page 133: ...g m 18 1 21 7 ft lb 1 8 2 3 kg m 13 0 16 7 ft lb S E R V I C E D A T A 11 2 Date of Issue December 1977 HONDA MOTOR CO LTD ITEMS STANDARD SERVICE LIMIT Axle shaft bend 0 2 mm 0 0079 in Wheel rim runout Radial Axial 2 0 mm 0 0787 in 2 0 mm 0 0787 in Brake lining thickness 4 0 mm 0 1575 in 2 0 mm 0 0787 in Brake drum I D 140 0 mm 5 5118 in 141 0 mm 5 5512 in Front fork Spring free length TubeO D Sli...

Page 134: ...ne Side or Does Not Track Straight 1 Bent fork 2 Bent axle 3 Forks installed in triple crown incorrectly 4 Wheel installed incorrectly Hard Front Suspension 1 Incorrect weight fluid in front forks 2 Clogged fork hydraulic passages 3 Fork sliders binding on fork legs Soft Front Suspension 1 Incorrect weight fluid in front forks 2 Too much clearance inside forks 3 Broken fork spring s Suspension Noi...

Page 135: ...A D L I G H T C A S E Run each wire through the holes of headlight case The wire and breather harnesses should be passed through lower hole Connect the wires color to color and set each coupler into the holder in the headlight case as shown H E A D L I G H T C A S E I N S T A L L A T I O N Align the lines on the headlight case with the punch marks on the headlight brackets NOTE After assembly insp...

Page 136: ...f the speedometer I G N I T I O N S W I T C H R E M O V A L Remove the headlight and pull off the ignition switch coupler Pull off the handlebar holder cover Remove the handlebar holder lift the handle bar and remove the ignition switch M E T E R B U L B R E P L A C E M E N T Remove the speedometer and pull out the socket for each bulb Replace the bulbs Install the speedometer Date of Issue Decemb...

Page 137: ...ch with the front brake cable and throttle cable TURN SIGNAL HORN AND DIMMER SWITCH Remove the two screws at the lighting and horn switch Remove the wire harness band Remove the switch and the clutch cable Remove the handlebar holder cover and the handlebar holder Pull up the handlebar STARTER AND ENGINE STOP SWITCH 11 6 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 138: ... first Grease the sliding face of throttle grip Install the throttle grip and the starter switch NOTE Align the slit of the starter switch hous ing with punch mark on the handlebar Tighten the forward screw first Install the turn signal and horn switch NOTE Align the slit of the switch housing with punch mark on the handlebar Tighten the forward screw first TORQUE 2 0 2 5 kg m 114 5 18 9 ft lb HAN...

Page 139: ...ble Remove the adjusting nut and the brake arm pin and disconnect the brake cable Pry off the cotter pin and remove the axle nut Pull the axle shaft out and remove the front wheel F R O N T A X L E R U N O U T Set the axle in Vblocks rotate and measure the runout Actual runout is 1 2 of Total Indicator Reading TIR 11 8 Date of Issue December 1977 HONDA MOTOR CO LTD SERVICE LIMIT 0 2 mm 0 0079 in ...

Page 140: ...play PLAY A X I A L REPLACE PLAY RADIAL REPLACE WHEEL RIM RUNOUT Check rim runout on a trueing stand Spin the wheel by hand and read the runout using a dial indicator RADIAL SERVICE LIMIT 2 0 mm 0 0787 in AXIAL SERVICE LIMIT 2 0 mm 0 0787 in FRONT BRAKE DRUM I D Remove the brake panel from the front wheel Inspect the brake drum I D I D SERVICE LIMIT 141 0 mm 5 5512 in Date of Issue December 1977 H...

Page 141: ...a bearing driver NOTE Do not allow the bearing to tilt while driving Install the bearing with the sealed end facing the outside WARNING Avoid getting grease on the inside face of the brake drum Grease the inside of the dust seal Install the dust seal and the collar on right side of front wheel hub BEARING DRIVER 42x47 DRIVER HANDLE A DRIVER PILOT 15 11 10 Date of Issue December 1977 HONDA MOTOR CO...

Page 142: ...ide Tighten the axle nut and install the cotter pin Spread the cotter pin ends as shown TORQUE 4 0 5 0 kg m 28 9 36 2 ft lb Install the speedometer cable Install the front brake cable through the brake arm and adjust the brake Check the brake lever free play and inspect the speedometer operation Date of Issue December 1977 HONDA MOTOR CO LTD 11 11 ...

Page 143: ...f brake linings B R A K E S H O E S R E P L A C E M E N T Remove the brake arm Pry off the cotter pin and remove the washer Remove the brake shoe return springs Replace the brake shoes as a set FRONT BRAKE PANEL COTTER PIN SERVICE LIMIT 2 0 mm 0 0787 in BRAKE SHOES BRAKE ARM RETURN SPRING 11 12 Date of Issue December 1977 HONDA MOTOR CO LTD BRAKE CAM INDICATOR PLATE BRAKE ARM RETURN SPRING ...

Page 144: ... shown WARNING A void getting grease on the brake lining COTTER PIN WASHER Install the dust seal and the indicator pla te on brake cam NOTE Align the cutouts INDICATOR PLATE BRAKE CAM CUTOUTS Install the return spring and brake arm Tighten the brake arm bolt and nut NOTE Align the punch marks Date of Issue December 1977 H O N D A MOTOR CO LTD 11 13 BRAKE CAM BRAKE ARM 0 8 1 2 kg m 5 8 8 6 ft lb TO...

Page 145: ...e front wheel See page 11 8 Remove the front fender Loosen the bolts on the fork top and bottom bridges NOTE Slightly loosening the fork bolt while it is installed in the stem makes disassembly easier Pull down while turning the fork tube 11 14 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 146: ... Remove the fork bolt Remove the fork spring FORK SPRING FORK BOLT F R O N T F O R K S P R I N G F R E E L E N G T H Inspect the fork spring free length SERVICE LIMIT 495 mm 19 5 in Drain the ATF from fork by pumping it up and down Date of Issue December 1977 H O N D A MOTOR CO LTD 11 15 ...

Page 147: ...piece 6 mm ALLEN WRENCH NO 07917 3230000 F O R K T U B E A N D P I S T O N I N S P E C T I O N Check the fork tube and the piston for wear Set the fork tube in V blocks and check run out with a dial indicator Divide total indicator reading by 2 to deter mine actual runout SERVICE LIMIT 0 2 mm 0 0079 in 11 16 Date of Issue December 1977 HONDA MOTOR CO LTD SEAT PIPE OIL LOCK PIECE FORK TUBE ...

Page 148: ...m to top O D SERVICE LIMIT 30 87 mm 1 2154 in Remove the dust seal and pry off the set ring with the snap ring pliers Remove the oil seal NOTE Use care when removing the oil seal not to damage the fork slider with a screw driver OIL SEAL Date of Issue December 1977 HONDA MOTOR CO LTD 11 17 SET RING OIL SEAL ...

Page 149: ...lider for wear or damage Measure the slider I D I D SERVICE LIMIT 31 165 mm 1 2270 in F R O N T F O R K A S S E M B L Y Before assembly wash the parts in solvent and wipe them off completely FORK BOLT 11 18 Date of Issue December 1977 HONDA MOTOR CO LTD FORK TUBE OIL LOCK PIECE SET RING OIL SEAL FORK SLIDER SOCKET BOLT ...

Page 150: ...et bolt ALLEN WRENCH NO 07917 3230000 Install the oil seal in the top of the slider NOTE Apply ATF to the oil seal and install it with the fork seal driver Fork seal is seated when the groove in the slider is visible at the top of the seal FORK SEAL DRIVER BODY DRIVER ATTACHMENT C GROOVE OIL SEAL Install the snap ring into the groove of the fork slider with snap ring pliers Fill the forks with goo...

Page 151: ...RING F R O N T F O R K I N S T A L L A T I O N Install the front fork into the top bridge NOTE Align front fork top end with top sur face of fork bridge Tighten the top bridge and bottom bridge bolts TORQUE 2 0 2 5 kg m 14 5 18 1 ft lb Install the front fender and the front wheel 11 20 Date of Issue December 1977 HONDA MOTOR CO LTD FORK BOLT ...

Page 152: ...OP BRIDGE REMOVAL Remove the steering handlebar See page 11 6 Remove the headlight and headlight case Remove the headlight bracket Remove the stem nut Loosen the fork top bridge bolts and remove the top bridge Date of Issue December 1977 HONDA MOTOR CO LTD 11 21 ...

Page 153: ...nd ball bearings Remove the steering stem PIN SPANNER STEERING STEM STEEL BALLS 21 pes BOTTOM BALL RACE STEEL BALLS 21 pes TOP BALL RACE BALL RACE REMOVAL Drive the ball race out with the ball race driver BALL RACE DRIVING Drive the ball race into the steering head pipe with the ball race driver REMOVAL BALL RACE DRIVER NO 07944 1150001 DRIVING 11 22 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 154: ...tall the top bridge and the front fork NOTE Align the fork top end with the top face of the fork top bridge as shown Tighten the lower bridge bolts TORQUE 2 0 2 5 kg m 14 5 18 1 ft lb FORK BOLT TOP BRIDGE Tighten the stem nut TORQUE 6 0 7 0 kg m 43 4 50 6 ft lb Tighten the top bridge bolts TORQUE 2 0 2 5 kg m 14 5 18 1 ft lb Install the headlight bracket headlight and steering handlebar Install th...

Page 155: ... December 1977 HONDA MOTOR CO LTD 11 TORQUE 2 0 2 5 kg m 14 5 18 1 ft lb TORQUE 4 0 5 0 kg m 28 9 36 2 ft lb TORQUE 2 5 3 0 kg m 18 1 21 7 ft lb TORQUE 2 0 2 5 kg m 14 5 18 1 ft lb TORQUE 6 0 7 0 kg m 43 4 50 6 ft lb TORQUE 2 0 2 5 kg m 14 5 18 1 ft lb ...

Page 156: ...xle nut Swingarm pivot bolt Rear brake torque link nut Shock absorber nut Driven sprocket nut Brake cam bolt S E R V I C E D A T A Tool No 07959 3290001 Tool No 07967 1150100 Tool No 07746 0010300 Tool No 07749 0010000 Tool No 07746 0040300 4 0 5 0 kg m 28 9 36 2 ft lb 5 0 6 0 kg m 36 2 43 4 ft lb 2 0 2 5 kg m 14 5 18 1 ft lb 3 0 4 0 kg m 21 7 28 9 ft lb 5 5 6 5 kg m 39 8 47 0 ft lb 0 8 1 2 kg m 5...

Page 157: ...ken rear spring s 2 Faulty rear shock s Hard Rear Suspension 1 Faulty rear shock s Suspension Noise 1 Incorrect torque an axle 2 Faulty rear shocks or springs 3 Broken spring s 4 Bent rear fork Faulty Brake 1 Incorrect adjustment of pedal 2 Brake lining worn 3 Brake lining surface dirty 4 Brake cam worn 5 Incorrectly fitted brake arm serrations 6 Faulty brake wear indicator 12 2 Date of Issue Dece...

Page 158: ...e nut Remove the drive chain Remove the axle nut and pull the axle shaft out Remove the rear wheel R E A R A X L E R U N O U T Set the axle in V blocks and measure the run out by rotating the axle Divide total indicator reading by 2 to determine actual runout R E A R W H E E L B E A R I N G I N S P E C T I O N Turn the rear wheel by hand to check for condition Replace the bearing if it is noisy or...

Page 159: ... the right bearing first WARNING Be careful to keep grease off the brake drum NOTE Drive the bearing squarely not allow ing it to tilt Install the bearing with the sealed end facing the outside SERVICE LIMITS RADIAL 2 0 mm 0 0787 in AXIAL 2 0 mm 0 0787 in WHEEL TORQUE 5 5 6 5 kg m 39 8 47 0 ft lb WHEEL BEARING WHEEL BEARING DRIVEN SPROCKET DRIVER HANDLE A BEARING DRIVER 42x47 DRIVER PILOT 15 Date ...

Page 160: ... chain and sprocket if they show excessive wear or damage DAMPER BUSHING INSPECTION Inspect the damper bushing for wear or dam age Date of Issue December 1977 H O N D A MOTOR CO LTD 12 5 REAR WHEEL REAR SUSPENSION REAR SPROCKET DISASSEMBLY DAMPER BUSHING DRIVEN SPROCKET SNAP RING FIXING BOLT GOOD NOT GOOD ...

Page 161: ...et groove properly Grease the left side of rear wheel hub and inside of the driven sprocket Install the sprocket and snap ring NOTE Install with the cutout of the snap ring facing the sprocket Tighten the four nuts FIXING BOLT FINAL DRIVEN SPROCKET SNAP RING TORQUE 5 5 6 5 kg m 39 8 47 0 ft lb Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 162: ...e brake rod and brake stopper arm Adjust the drive chain See page 3 10 NOTE Align the index marks of the adjusters with the same side scales on the swing arm Tighten the axle nut TORQUE 4 0 5 0 kg m 28 9 36 2 ft lb Install a new cotter pin into the axle nut and stopper arm nut and spread the ends NOTE Lubricate drive chain if necessary Adjust the rear brake See page 3 13 I D SERVICE LIMIT 131 0 mm...

Page 163: ...R A K E SHOES R E A R B R A K E L I N I N G T H I C K N E S S Measure the rear brake lining thickness SERVICE LIMIT 2 0 mm 0 0787 in B R A K E S H O E S R E P L A C E M E N T Pry off the cotter pin and remove the washer Remove the brake shoe springs Replace the brake shoes C O T T E R PIN B R A K E SHOES 12 8 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 164: ...on the brake linings Install the indicator plate onto the brake cam NOTE Align the cutouts of brake cam and indicator plate Install the brake arm on the brake cam NOTE Align the punches marks of brake cam and the arm Tighten the brake cam bolt and nut WASHER COTTER PIN WEAR INDICATOR BRAKE CAM CUTOUTS Date of Issue December 1977 HONDA MOTOR CO LTD 12 9 REAR WHEEL REAR SUSPENSION PUNCH MARKS BRAKE ...

Page 165: ...er and lower bolts REAR SHOCK ABSORBER DISASSEMBLY Compress the rear shock absorber with the spring compressor and spring holder Hold the lock nut with a spanner and remove the upper holder SPRING COMPRESSOR NO 0 7 9 5 9 3 2 9 0 0 0 1 UPPER H O L D E R LOCK N U T SPRING H O L D E R NO 0 7 9 6 7 1 1 5 0 1 0 0 REAR D A M P E R 12 10 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 166: ...entially the re verse of disassembly NOTE Apply locking agent to the lock nut at time of assembly HOLDER ATTACHMENT NO 07967 1150100 REAR SHOCK COMPRESSOR NO 07959 3290001 S H O C K A B S O R B E R I N S T A L L A T I O N Install the rear shock absorbers with the upper and lower bolts TORQUE 3 0 4 0 kg m 21 7 28 9 ft lb Check the operation after installing the rear shock absorbers Date of Issue De...

Page 167: ...e pivot bolt and pull the swingarm out S W I N G A R M D I S A S S E M B L Y A S S E M B L Y NOTE Drive the bushings into place with a soft mallet or use a block to avoid damaging it S W I N G A R M B U S H I N G I N S P E C T I O N Measure the O D of collars and I D of bushing and inspect the pivot to bushing clearance BUSHING SWING ARM SERVICE LIMIT 0 5 mm 0 0197 in 12 12 Date of Issue December ...

Page 168: ...2 7 Install the shock absorbers Install the left and right mufflers REAR BRAKE PEDAL BRAKE PEDAL REMOVAL Disconnect the brake rod and remove the stop light switch spring Remove the cotter pin and washer and remove the brake pedal NOTE Note the location of the stoplight switch spring After installing the brake pedal adjust the free play See page 3 13 Date of Issue December 1977 HONDA MOTOR CO LTD 1...

Page 169: ...REAR WHEEL REAR SUSPENSION 12 Date of Issue December 1977 H O N D A MOTOR CO LTD ...

Page 170: ... the fuel valve FILTER SCREEN Clean the filter with compressed air GASKET After installing check or leaks LOCK NUT AIR CLEANER Remove the seat Cleaning the air cleaner element See page 3 2 Inspect the starter magnetic switch See page 16 6 Inspect the condenser See page 15 5 FUEL TUBE Check for wear or cracking STARTER MAGNETIC SWITCH TURN SIGNAL RELAY AIR CLEANER SET SPRING CONDENSER SILICON RECTI...

Page 171: ...EAR FENDER REAR FENDER REMOVAL Remove the seat Remove the rear fender Separate the rear fender A and fender B R E A R F E N D E R I N S T A L L A T I O N NOTE Install fender B into the groove of fender A 13 2 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 172: ...FUEL TANK AIR CLEANER REAR FENDER CRANKCASE BREATHER CRANKCASE BREATHER Rout the breather tubes as shown Date of Issue December 1977 H O N D A MOTOR CO LTD 13 3 ...

Page 173: ...ove the battery from the motorcycle for charging whenever possible If battery must be charged on the motorcycle disconnect the battery cables Keep fire or sparks away from a charging battery because it produces hydrogen All charging system components can be tested on the motorcycle S P E C I F I C A T I O N S Battery Capacity Specific gravity normal charge Charging rate 6V 12 ampere hours 1 260 1 ...

Page 174: ...Charging system failure 2 Loose connection Low Power Engine Running 1 Weak battery a Low battery electrolyte level b One or more dead cells 2 Charging system failure Intermittent Power 1 Loose battery connection 2 Loose charging system connection 3 Loose starting system connection 4 Loose connection or short circuit in ignition system 5 Loose connection or short circuit in lighting system Charging...

Page 175: ...n eyes or clothing Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of wa ter or milk Follow with milk of magnesia beaten egg or vegetable oil Call phy sician immediately Eyes Flush with water and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes away Ventilate when clwrging or using in enclosed space Always shield eyes when working near ...

Page 176: ...f rapid charging must be performed use care to prevent a temperature rise above 45 C IJ3 F After installation apply grease on the termi nals CHARGING SYSTEM CHARGING TEST Perform the test after warming up the engine NOTE Gradually raise the rpm while watching the voltage Do not raise the voltage rapidly BATTERY SPECIFIC GRAVITY 1 260 1 280 20 C 68 F CHARGING STARTING SPEED 2 200 rpm 3 3 Amp Min at...

Page 177: ...tinuity through the rectifier with a volt ohmmeter or continuity tester NOTE Perform the rectifier inspection noting the polarity of the tester Do not test with a megger High voltage damages the diodes LIGHT GREEN RED WIRE NEUTRAL SWITCH PINK WHITE BLUE WIRE LEFT AND RIGHT IGNITION COILS YELLOW Continuity should exist according to the fol lowing table When and are exchanged there should be no cont...

Page 178: ...GHT A C GENERATOR SILICON RECTIFIER A C GENERATOR G GREEN Y YELLOW W WHITE P PINK R RED B r BROWN B BLUE TO IGNITION SWITCH HEADLIGHT INSTRUMENT LIGHT 14 Date of Issue December 1977 HONDA MOTOR CO LTD IGNITION SWITCH BATTERY BATTERY SILICON RECTIFIER TAILLIGH ...

Page 179: ...d before diagnosing troubles in the ignition system SPECIFICATIONS Spark plug type Plug gap Contact breaker points point gap Condenser capacity Ignition advance F mark initial Max advance From F to max advance for cold climate below 5 C 41 F standard for extended high speed driving ND NGK ND NGK ND NGK U20FS C6H U22FS C7HS U24FB C9H 0 6 0 7 mm 0 024 0 028 in 0 3 0 4 mm 0 012 0 016 in 0 25 10 uF 15...

Page 180: ...rect Ignition Timing Incorrect 1 Inconect breaker point gap 2 Faulty spark advancer Engine Starts but Runs Poorly 1 Ignition primary circuit a Points dirty or fouled b Incorrect point gap c Weak or defective coil d Faulty capacitor e Loose or bare wire f Intermittent short circuit in a switch 2 Ignition secondary circuit a Plugs fouled or worn b Faulty or crossed plug wires 3 Ignition timing a Imp...

Page 181: ...t Remove the fuel tank Disconnect the wire Remove the coil I G N I T I O N C O I L I N S P E C T I O N 3 point spark test The coil is satisfactory if the spark jumps across the gap greater than 6 mm 0 24 in Date of Issue December 1977 HONDA MOTOR CO LTD 15 3 SPARK DISTANCE AT LEAST 6 mm 0 24 in ...

Page 182: ...ack white wires SECONDARY COIL CONTINUITY TEST There should be continuity between secondary wires C O N D E N S E R CONDENSER REMOVAL Remove the seat Disconnect the condenser wire from the con nector Remove the condenser Condenser may be located under the gas tank on right side of bike 1 5 4 Date of Issue December 1977 HONDA MOTOR CO LTD BLUE WIRE BLACK WHITE WIRE SECONDARY WIRES ...

Page 183: ...GNITION SYSTEM CONDENSER INSPECTION Measure the capacity after shorting the con denser Measure the condenser capacity BLUE WIRE Date of Issue December 1977 HONDA MOTOR CO LTD 15 5 SHORTING THE CONDENSER ...

Page 184: ...NGINE STOP SWITCH SPARKPLUG CONTACT BREAKER IGNITION COIL IGNITION SWITCH SPARKPLUGS CONDENSER CONTACT BREAKER W WHITE B K BLACK B BLUE R RED 15 Date of Issue December 1977 HONDA MOTOR CO LTD ENGINE STOP SWITCH BATTERY ...

Page 185: ...tion 9 While servicing the starter motor the main switch must be kept O F F SPECIFICATIONS Starter Motor Type Drive Rated Output Reduction ratio 6V gear reduction electric motor Chain to crank shaft 0 25 kw 6 44 Load Voltage 4 2V Amperage 120A Torque minimum sprocket shaft Min 0 55 kg m RPM minimum sprocket shaft Min 400 rpm Brush length Service limit Locked 2 8V Max 300A 1 5 kg m 12 2 12 4 mm 0 4...

Page 186: ...ttery 2 Excessive resistance in circuit 3 Binding in starter motor drive chain or drive system Starter Motor Turns But Engine Does Not Turn Failure in 1 Drive chain or sprockets 2 Drive shaft or starter clutch 3 Starter motor planetary gears 4 A C Generator drive gears Starter Motor and Engine Turn But Engine Does Not Start 1 Ignition circuit problems 2 Engine problems Engine Kicks Back on Startin...

Page 187: ...starter motor case screws and the rear cover Loosen the brush terminal screws Remove the brushes from the holder plate CARBON BRUSH THRUST WASHER BRUSH HOLDER PLATE REAR COVER BRUSH B R U S H I N S P E C T I O N Measure the carbon brush length SERVICE LIMIT 7 0 mm 0 2756 in Date of Issue December 1977 HONDA MOTOR CO LTD 16 3 ...

Page 188: ...two or more bars are discolored replace the commutator NOTE Do not use emery or sand paper on the commutator A R M A T U R E C O I L C O N T I N U I T Y T E S T There should be continuity between the sepa rate commutators A R M A T U R E C O I L I N S U L A T I O N T E S T There may be no continuity between com mutators and the shaft 16 4 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 189: ...l to brush wire Continuity B R U S H S P R I N G I N S T A L L A T I O N Attach the spi ing edge into the groove of brush holder insert the driver into the inside of spring and coil it up fully Install the spring on the brush holder plate by finger pressure as shown Install the rear cover and align the index marks on the case and rear cover Tighten the stator cover bolts Date of Issue December 197...

Page 190: ...w Red wire to Black wire Yellow Red wire to Black wire Continuity S W I T C H O P E R A T I O N T E S T Connect 6 vo t source across primary leads and check for continuity between terminals There should be continuity between the termi nals BLACK 16 6 Date of Issue December 1977 H O N D A MOTOR CO LTD ...

Page 191: ...STARTER MOTOR IGNITION STARTER MOTOR BK BLACK R RED Y YELLOW 16 Date of Issue December 1977 HONDA MOTOR CO LTD ELECTRIC STARTER SYSTEM ...

Page 192: ...lectrical failure check the continuity of the electrical path through the part A continuity check can usually be made without removing the part from the motorcycle by simply disconnecting the wires and connecting a continuity tester or volt ohmmeter to the terminals or connections A continuity tester is useful when checking to find out whether or not there is an electrical connection between the t...

Page 193: ...rned ON 1 Battery dead or disconnected 2 Ignition switch disconnected from harness 3 Faulty ignition switch 4 Faulty main fuse 20 amp 5 Wiring faulty loose or broken All Lights Come on but Dimly When Ignition Switch Is Turned ON 1 Battery low 2 Wiring or switch has excessive resistance Headlight Beams Do Not Shift When HI LO Switch Is Operated 1 Beam filament burned out 2 Faulty dimmer switch 3 Fa...

Page 194: ...upler white coupler There should be continuity as indicated by 0 0 in the table TURN SIGNAL SWITCH Disconnect the winker switch coupler red coupler There should be continuity as indicated by 0 0 in the table BROWN BROWN WHITE BLUE LIGHT BLUE Date of Issue December 1977 H O N D A MOTOR CO LTD 17 3 ...

Page 195: ...re should be continuity as indicated by 0 0 when the horn button is pushed DIMMER SWITCH Disconnect the dimmer switch coupler red coupler and wire connectors blue white wire and white wire There should be continuity as indicated by 0 0 in the table 17 4 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 196: ...pler There should be continuity as indicated by 0 0 in the table ENGINE STOP SWITCH Disconnect the engine stop switch coupler black coupler There should be continuity as indicated by 0 0 in the table BLACK BLACK WHITE YELLOW RED Date of Issue December 1977 HONDA MOTOR CO LTD 17 5 ...

Page 197: ...the lever is pulled REAR STOP LIGHT SWITCH Operate the switch to check for continuity There should be continuity with the brake lever is pulled HORN Test the horn sound by applying 6 volt battery directly If sound is small adjust the horn sound by turning the adjusting screw 17 6 Date of Issue December 1977 HONDA MOTOR CO LTD ...

Page 198: ...17 Date of Issue December 1977 H O N D A MOTOR CO LTD SWITCHES LIGHTS HORN ...

Page 199: ...OW SPEED POOR HIGH SPEED PERFORMANCE SMOKING EXHAUST FAULTY CLUTCH DIFFICULT SHIFTING ENGINE NOISE MOTORCYCLE PULLS TO ONE SIDE FAULTY FRONT REAR SHOCK ABSORBERS FAULTY BRAKE ELONGATED DRIVE CHAIN 18 2 18 3 18 4 18 5 18 5 18 6 18 6 18 7 18 7 18 8 18 8 18 8 Date of Issue December 1977 HONDA MOTOR CO LTD 18 1 1 8 ...

Page 200: ... or shorted high tension cordfi 6 Open or shorted ignition coil 7 Faulty ignition switch 8 Incorrect ignition timing 3 Test cylinder compression LOW COMPRESSION NORMAL COMPRESSION 4 Start engine ENGINE FIRES BUT DOES NOT START ENGINE FIRES 5 Remove spark plug DRY PLUG 6 Start engine with choke closed WET PLUG D Engine not cranked 2 No valve clearance 3 Valve stuck open 4 Worn cylinder piston rings...

Page 201: ...ir cleaner 3 Clogged fuel line 4 Clogged fuel tank cap breather hole 5 Clogged muffler 5 Check ignition timing CORRECT TIMING INCORRECT TIMING 1 Incorrect ignition timing 2 Ignition malfunction 6 Check valve clearance CORRECT VALVE CLEARANCE 7 Test cylinder compression NORMAL COMPRESSION INCORRECT VALVE CLEARANCE LOSS OF COMPRESSION 1 Incorrect valve clearance 2 Worn valve seat 1 Valve stuck open ...

Page 202: ...ixture too lean 3 Incorrect fuel 4 Excessive carbon in combustion chamber 5 Ignition timing too early POOR PERFORMANCE AT IDLE AND LOW SPEED Possible Cause 1 Check ignition timing valve clearance INCORRECT TIMING CLEARANCE 1 Incorrect timing adjustment 2 Ificorrect valve clearance CORRECT TIMING CLEARANCE 2 Check carburetor pilot screw adjustment INCORRECTLY ADJUSTED 1 Mixture too lean 2 Mixture t...

Page 203: ...d fuel tank cap breather hole 1 Clogged jet 2 Clogged fuel filter 3 Clogged fuel valve 1 Jet size too small 2 If condition improved with small jet a Clogged air cleaner b Choke not opened fully 1 Incorrect valve timing adjustment 6 Check valve spring tension WORN OR BROKEN SPRING 1 Faulty valve spring SPRING TENSION CORRECT SMOKING EXHAUST Possible Cause 1 Run motorcycle a long distance at high sp...

Page 204: ...MOTORCYCLE TENDS TO CREEP WITH CLUTCH DISENGAGED 1 Distorted clutch plate or friction disc 2 Uneven clutch spring tension DIFFICULT SHIFTING Possible Cause DIFFICULT SHIFTING 1 Broken gear shift arm spring 2 Broken shift fork 3 Sluggish movement of shift drum fork 4 Broken shifting gear protrusion 5 Shift fork pawl disconnected from shift drum PEDAL NOT RETURNED TO NEUTRAL 1 Broken shift spindle r...

Page 205: ...late cover 1 Worn or deteriorated driven gear damper 2 Worn gear teeth MOTORCYCLE PULLS TO ONE SIDE Possible Cause DIFFICULT STEERING IN BOTH DIRECTIONS WHEEL WOBBLES MOTORCYCLE PULLS TO ONE SIDE 1 Overtightened steering head top thread nut 2 Broken steering steel balls 3 Bent steering stem 1 Excessive play in wheel bearing 2 Distorted wheel rim 3 Loose spokes 4 Excessive play in rear fork pivot b...

Page 206: ...absorber FAULTY BRAKE Possible Cause INEFFECTIVE ADJUSTER SQUEAKING INEFFECTIVE BRAKE 1 Worn brake lining brake shoe cam or brake cam 1 Worn brake lining 2 Foreign particles on brake lining 3 Rough brake drum shoe contacting face 4 Worn brake panel bushing 1 Faulty front brake cable 2 Brake shoe partially contacted 3 Mud or water in brake 4 Oil or grease on brake lining 5 Worn brake lining ELONGAT...

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Honda CM 185T 1981, Manual

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